Miller SWINGARC DIGITAL-2 12 AND 16 User manual

March 1982 FORM: OM-1523C Effective With Serial No. JB558742 MODEL SWINGARC DIGITAL - 2 12 SWINGARC DIGITAL - 2 16 WNERS ANUAL MILLER ELECTRIC MFG. CO. 718 S. BOUNDS ST. P.O. Bax 1079 APPLETON, WI 54912 USA NWSA CODE NO. 4579 PRINTED IN U.S.A. ax .. afd oo LIMITED WARRANTY EFFECTIVE: JUNE 1, 1979 This warranty supersedes all previous MILLER warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY - Subject to the terms and conditions hereof, Miller Electric Mfg. Co., Appleton, Wisconsin warrants to its Distributor/ Dealer that all new and unused Equipment furnished by Miller is free from defect in workmanship and material as of the time and place of delivery by Miller. No warranty is made by Miller with respect to engines, trade accessories or other items manufactured by others. Such engines, trade accessories and other items are sold subject to the warranties of their respective manufacturers, If any . All engines are warranted by their manufacturer for one year from date of original purchase, Except as specified below, Miller's warranty does not apply to components having normal useful life of less than one (1) year, such as spot weider tips, relay and contactor poinis, MILLERMATIC paris that come in contact with the welding wire:including nozzles and nozzle insulators where failure does not result from defect in workmanship or materiel. Miller shall be required to honor warranty claims on warranted Equipment in the event of failure resulting from a defect within the following periods from the date of delivery of Equip- ment to the original user: 1. Arc welders, power sources and components .. 1 year 2. Origrnal main power rectifiers ...... 3 years (labor - 1 year only) 3. Allweiding guns and feeder/guns ............ 90 days 4. All other Millermatic Feeders. ............_ .... 1 year 5. Replacement or repair parts, exclusive of labor . 60 days 6. Batteries. ..... a 6 months provided that Miiler is notified in writing within thirty (30) days of the date of such failure. er TPS At o TO As a matter of general policy only, Miller may honor claims submitted by the original user within the foregoing periods. In the case of Miller's breach of warranty or any other duty with respect to the quality of any goods, the exclusive remedies therefore shall be, at Miller's option (1) repair or (2) replacement or, where authorized in writing by Miller in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Miller service station or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at Customer's risk and expense. Upon receipt of notice of apparent defect or failure, Miller shall instruct the clai- mant on the warranty ciaim procedures to be followed. ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTA- TION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER 15 EX- CLUDED AND DISCLAIMED BY MILLER. EXCEPT AS EXPRESSLY PROVIDED BY MILLER IN WRITING, MILLER PRODUCTS ARE INTENDED FOR ULTIMATE PURCHASE BY COMMERCIAL/INDUSTRIAL USERS AND FOR OPERATION BY PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT AND NOT FOR CONSUMERS OR CONSUMER USE. MILLER" WARRANTIES DO NOT EXTEND TO, AND NO RESELLER iS AUTHORIZED TO EXTEND MILLER'S WARRANTIES TO, ANY CONSUMER. SLE DL RIDE NA IZ NX Я ft = yr A =" = ra NE. STI mer ri y Sd ene ль ERRATA SHEET | January17,1984 FORM: OM-15234 After this manual was printed, refinements in equipment design occurred. This sheet lists exceptions to data appearing later in this manual. | BENET YOR Delete references to wing nuts for drive rofl pressure adjustment and replace with round knurled knobs. Also, the gun/feeder adapter securing knobs (item 16, Figure 3-4) are replaced with 7T-bar style securing devices. AMENDMENT TO SECTION 6 - MAINTENANCE Add the following WARNING to Section 6-2. CLEANING OF DRIVE ROLLS HIGH ROTATIONAL SPEED may cause damage to drive rolls, e Do not allow drive rolls to rotate at high speed if compressed air is used for cleaning the drive roll assembly. Add Section 6 - 5. DRIVE SHAFT INSPECTION AND MAINTENANCE Drive shaft cleaning and inspection should be performed on a periodic basis, depending on the type and conditions of service. Inspect the drive shafts for free movement by rotating the drive gears in the direction of wire travel. If either drive gear does not turn freely, clean the drive shafts and clutch assembiies in the large spur drive gear and repack ‘with a good quality gear grease. Use the procedure outlined below to remove the drive shafts. Where operating condi- ‘tions are severe, more frequent inspections should be made. 1. Retract wire past drive housings. 2. Disconnect welding guns. 3. Remove drive gears in both drive roll housings 4, Remove motor gear guard. 5. Remove right drive roll housing. 6 Remove drive shafts and large spur drive gear. » SOLVENTS CONTAINING PHENOL OR FORMIC ACID can damage plastic q gears. e Do not use solvents containing phenol or formic acid. 7. Clean drive shafts; dry thoroughly; and grease. 8. Reinstail drive shafts in spur drive gears and drive roil housing and secure housing to mounting bracket. Do not tighten mounting boits. 9. Reinstall drive gears on drive shafts. Check for proper alignment of drive roll housing on drive shaft by rotating drive gears in the direction of wire travel. If the drive gear does not turn freely, adjust the position of the drive roil housing until the drive shaft is allowed free movement. Tighten mounting belts and recheck for the movement, 10. Reinstall motor gear cover. 11. Reconnect welding guns and rethread welding wire. 12. Resume operation. AMENDMENT TO SECTION 7 - TROUBLESHOOTING gELGE9Ar NYL ZYZ8Sdar ‘ом ¡EMOS YHM 8390J)43 SIEPOIN 104 WIEIBEIQ поло) *| - £ eanbyy fi Fos OE + =a {a а Ty ASAL nial gasms OL = —— ANC Day Oh AS t Diagram ircui Amend Figure 7 - 1. 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Em > Trlr JADE THON JO NN @ i SMIYANHAS LIE 1131 MM — - # TL © fon Lau} Lis ZE ps ref fe mad ee 9 ; ye i . 8 + ÿ 1 ta Tec | | 1 © nta, 33, 4 ovErUNE VOYENDAD ! v E) Dra LH HU 149 € à £ © ' — — — AU» FI œil 5 e fs as Da 1698 y ¡E ег ss 27 ASTI ef al - ve À | — “E -— ; ® i | зам J HORS SE ea dad tr 315 L471] С > Ind es 3rd A MD TA Ka E AC Ma INIDAOL 1334539 MITA un баЭсо ® “H, JUNSYIFI LH. 4dA39$3 LÉ. LiOd HOMO ©) se 143 OL 13345 93H MAMA UNS der 530 0A VV D je | 81 1 - OHIMHAY MOLOW - Md) O08. Iv Sed Jaw :1 Ta - * NT Фе нон + * or Tm HIER orm OM-1523C Page 3 item Or Dia. Part Replaced Pg No. Mkgs. No. With Description Quantity Pg4 R7,3 074 127 073 562 POTENTIOMETER, carbon 1 turn 2 watt 10Kohm........ 2 Pg6 VR1 082 722 Deleted (Eff w/JD699139) 146 GS1,2 053 894 087 260 VALVE, 115 volts ac 2 way 1/41PS 1/8 orifice .......... 1 Pg8 R58,62,65,66 : 71,72,76,90 035884 035 884 RESISTOR (aty chg)......... PS RS 8 R77 052 142 RESISTOR, carbon film 0.25 watt 120K ohm ........... 1 Pg8 63,64 031 694 044 602 CAPACITOR, poly fim 0.47 uf400 voltsde ............ 2 Pg8 T50 036 143 085 399 TRANSFORMER, pulse .......................... ven 1 092 648 RESISTOR, carbon film0.25 wattzeroohm ............ 13 262 053 841 093664 СЕАВ, зриг..................... Penoranecarredecea. 1 092 865 KEY, 1/B8Bx1/8x3/4 .....rrem.esorccrarvorooadacon. 1 KEY, 1/8x1/8x3/4 BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS. OM-1523C Page 4 Section No. Page No. SECTION 1 - SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE 1-1. Introduction . o.oo. eee eae 1 1-2. GeneralPrecautions ........... iii Я 1-3. ArcWelding ett es 7 1-4. Standards Bookletindex............_.recceereessvererrre e 10 SECTION 2 - INTRODUCTION 2-1. General..................... ee a aa a a ee aan 6 12 2-2. Receiving-Handiing.......... RAA rn PS 12 2-3. Description..............eeeecredceredeceederenceroroacanc ee 12 2-4. Safety.........22202 0024 4e ae ee a de a eee a ea a ae aaa 12 SECTION 3 - INSTALLATION 3-1. Location And Assembly cities 12 3-2. DriveMotor .................. . resccierecacevremnmererecem. 14 3-3. Installation Of Wire Support «o.oo iti ities 14 3-4, Reinstallation Of Hub Assembly ..............._......00es00ve0. 14 3-5. Installation Of Wire Reel... o.oo eee eens, 14 3-6. Drive Roll And Wire Installation............e._e..eeoeosrsesoeoore 14 3-7. Water Control Kit (Optional) Connections ............._—.—._—.—.esves 16 3-8. Welding Gun Connections ............._.eeeeercoa0rerrec e 16 3-9. Shielding Gas Connections ..............o__._.eeeccevvere core, 17 3-10. Boom Adjustments ............. e .oeerrrrea.zrerierenzerace= 17 3-11. Motor Control Connection ............._esre.cee.sriecererere.. 17 3-12. Gun Trigger Connections ..............eeeeeeccecereererreze. 17 3-13. Weld Cable Connection ......... courte. 18 3-14. 115Volts/Contactor Control Connections .............eeeeerec.. 18 3-15. Installation Of Spool-Type Wire..................”. rereereceo. 18 3-16. Installation Of Reei-Type Wire................eo_mecrecocororvr. 18 3-17. Adjustment Of Hub Tension ....................ee0erereerea.. 18 3-18. Wire Guide Pulley Adjustments...............—...0eme.0meerras 19 3-19. Welding Wire Threading ............o rre... 0ersrr recono. 19 SECTION 4 - FUNCTION OF CONTROLS 4-1. Power Switch ....... eae 20 4-2, Wire Speed Controls... aa 20 4-3. Remote Control Receptacles And Switches ..................... 20 4-4. PurgeButlons ........ eee 20 4-5, InchSwitches ee RR RL RN eae G 20 4-6. Inches Per Minute Meter ......... iii 20 4-7. Reset Circuit Breaker .............e_eemvecadaroerer eee, 20 4-8. Burnback Controls ............_e.eavrreriarerarerereccoxm anar. 20 SECTION 5 - SEQUENCE OF OPERATION 5-1. Gas Metal-Arc Welding (GMAW) ..... anecoconrarreana rr ronca 20 5-2. Shutting Down .........oocrr.eexvrrerereene conan reana ne 21 SECTION 6 - MAINTENANCE 6 - 1. inspection And Upkeep ..................00 0... 00srasaraeee. 21 6-2. Cleaning Of Drive Rols.................... rerreraceaar ene. 21 6-3. Fuse ....... 0 rrrerorare cananea ennneeracanme ne nene nan 21 6-4. Brush inspection & Вер!асетет® ............... 2..5... ванн... 21 SECTION 7 - TROUBLESHOOTING SECTION 1 - SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE SECTION 1 - REGLES DE SECURITE POUR LE FONCTIONNEMENT DU POSTE DE SOUDAGE A L'ARC 1-1. INTRODUCTION - We learn by experience. Learning safety through personal experience, like a ‘child touching a hot stove is harmfut, wasteful, and un- wise. Let the experience of others teach you. Safe practices developed from experience in the use of welding and cutting are described in this manual. Research, development, and field experience have evolved reliable equipment and safe installation, operation, and servicing practices. Accidents occur when equipment is improperly used or maintained. The reason for the safe practices may not always be given. Some are based on common sense, others may require technical volumes to explain. It is wiser to follow the rules, Read and understand these safe practices before attempting to install, operate, or service the equipment. Comply with these procedures as applicable to the particular equipment used and their instruction manuals, for personal safety and for the safety of others. Failure to observe these safe practices may cause serious injury or death. When safety becomes a habit, the equipment can be used with confidence. These safe practices are divided into two Sections: 1 - General Precautions, common to arc welding and cutting; and 2 - Arc Welding {and Cutting} (only). Reference standards: Published Standards on safety are | also available for additional and more complete procedures than those given in this manual. They are listed in the Standards Index in this manual. ANSI 249.1 is the - most complete. The National Electrical Code, Occupational Safety and Health Administration, local industrial codes, and local inspection requirements also provide a basis for equipment installation, use, and service. 1-2. GENERAL PRECAUTIONS A. Burn Prevention Wear protective clothing - leather (or asbestos) gauntlet gloves, hat, and high safety-toe shoes. Button shirt collar and pocket flaps, and wear cufftess trousers to avoid entry of sparks and slag. Wear helmet with safety goggles or glasses with side shields underneath, appropriate filter ienses or plates “(protected by clear cover glass). This is a MUST for welding or cutting, (and chipping) to protect the eyes from radiant energy and flying metal. Replace cover glass when broken, pitted, or spattered. See 1-3A.2. Avoid oily or greasy clothing. A spark may ignite them. Hot metal such as electrode stubs and workpieces should never be handled without gloves. 1-1. INTRODUCTION - Contrairement a Гарргеп- tissage de la vie, I'apprentissage de la sécurité par ex- périence personnelle, comme l'enfant qui touche un poêle chaud, est dangereux, imprudent et inutile. Instruisez-vous donc de l'expérience d'autrui. Des méthodes de sécurité issues de l'expérience du soudage et du coupage sont décrites dans le manuel. La recherche, le progrès et l'expérience dans ce domaine ont développé un matériel fiable et des méthodes de: sécurité pour l'installation, le fonctionnement et l’entretien. Des accidents se produisent lorsque le matériel est inadéquatement utilisé ou entretenu. La raison de ces méthodes de sécurité peut ne pas être toujours donnée. Certaines sont fondées sur le sens commun, d'autres demanderont à être expliquées par des livres techniques. Il est plus sage de suivre les règles. Lisez et comprenez ces méthodes de sécurité avant d'essayer d'installer, de faire fonctionner ou de réparer l'appareil. Pour votre sécurité personnelle et celle d'autrui, conformez-vous à ces règles et aux manuels d'instructions. Manquer d'observer ces méthodes de sécurité pourrait entrainer des biessures graves ou même la mort. Quand la sécurité devient une habitude, le matériel peut alors être utilisé en toute confiance. Ces méthodes de sécurité sont divisées en deux sections: 1 - Précautions générales, communes au soudage et au coupage à l’arc, et 2 - Soudage à l'arc (et coupage) (uniquement). Normes de référence: Des publications des normes américaines de sécurité sont aussi à votre disposition pour d'autres modes opératoires plus complets que ceux du présent manuel. Elles sont données dans l’In- dex des Normes de ces règles de sécurité. ANSI Z49-1 est la plus complete. Les codes de l’'ACNOR, les codes provinciaux et municipaux donnent aussi les exigences pour une installation, une utilisation et un entretien sûrs. 1-2. PRÉCAUTIONS GÉNÉRALES À. Prévention des brûlures Portez des vêtements de protection, des gants à crispin en cuir (ou amiante), un casque et des chaussures de sécurité. Boutonnez le col de votre chemise et les pattes de vos poches, et portez des pantalons sans revers pour éviter que des étincelles et du laitier ne s'y introduisent. Portez un masque avec lunettes de sécurité ou avec écrans laté-raux de protection, des lunettes filtrantes ou des couvre-lentilles (protégés par un verre clair). Pour le soudage ou le coupage (et le burinage), il est OBLIGATOIRE de protéger ses yeux contre l'énergie de rayonnement et les éclats de metal, Remplacez le verre protecteur lorsqu'il est brisé, piqué ou quit a recu des projections. Voir 1.3A.2. Évitez de porter des habits imprégnés d'huile ou de graisse. Une étincelle pourrait les enflammer. Ne manipulez jamais sans gants un métal chaud tel que des chutes d'électrode et des pièces à souder. OM-1523 Page 1 Medical first aid and eye treatment. First aid facilities and a qualified first aid person should be available for each shift unless medical facilities are close by for im- - mediate treatment of flash burns of the eyes and skin burns. _ Ear plugs should be worn when working on overhead or in a confined space. A hard hat should be worn when others work overhead. Flammable hair preparations should not be used by persons intending to weld or cut. B. Toxic Fume Prevention Adequate ventilation. Severe discomfort, illness or death can result from fumes, vapors, heat, or oxygen enrichment or depletion that welding {or cutting) may produce. Prevent them with adequate ventilation as described in ANSI Standard 249.1 listed 1 in Standards index. NEVER ventilate with oxygen. Lead -, cadmium -, zinc -, mercury -, and beryllium - bearing and similar materials, when welded (or cut} may produce harmful concentrations of toxic fumes. Ade- quate local exhaust ventilation must be used, or each person in the area as well as the operator must wear an air-supplied respirator. For beryllium, both must be us- ad. Metals coated with or containing materials that emit toxic fumes should not be heated unless coating is removed from the work surface, the area is well ven- tilated, or the operator wears an air-supplied respirator. Work in a confined space only while it is being ven- tilated and, if necessary, while wearing an air-supplied respirator. Gas leaks in a confined space should be avoided. Leaked gas in large quantities can change oxygen concentration dangerously. Do not bring gas cylinders into a confined space. Leaving confined space, shut OFF gas supply at source to prevent possible accumulation of gases in the space if downstream valves have been accidently opened or left open. Check to be sure that the space is safe before re-entering it. Vapors from chlorinated solvents can be decomposed by the heat of the arc {or flame) to form PHOSGENE, a highly toxic gas, and other lung and eye irritating products. The ultraviolet (radiant} energy of the arc can also decompose trichloroethylene and per- chloroethylene vapors to form phosgene. DO NOT WELD or cut where solvent vapors can be drawn into the welding or cutting atmosphere or where the radiant energy can penetrate to atmospheres containing even minute amounts of trichloroethylene or per- chioroethylene. C. Fire and Explosion Prevention Causes of fire and explosion are: combustibles reached by the arc, flame, fiying sparks, hot slag or heated Page 2 Premiers soins et traitement des yeux: Tout atelier devrait avoir à sa disposition un poste de premiers soins ainsi qu’une personne compétente, á moins qu'ur, service médical ne soit à proximité pour soigner immédiate- ment les brûlures des yeux et de la peau. Portez des bouche-oreilles lorsque vous travaillez au plafond ou dans un espace restreint. Portez un casque lorsque d'autres personnes travailient au plafond. Les personnes devant souder ou couper ne doivent pas employer des préparations inflammables pour leurs cheveux. B. Prévention des gax toxiques Ventilation adéquate: Les gaz, les vapeurs, la chaleur, un enrichissement ou UN manque d'oxygène peuvent entraîner un malaise, une maladie ou même la mort. Remédiez-y par la ventilation décrite dans la Norme AN- S| Z49.1 paragraphe 1 de l'Index des Normes. NE ven- tilez JAMAIS à l'oxygène. En soudant ou en coupant, les plomb, cadmium, zinc, mercure et béryllium ou autres matériaux semblables peuvent créer des concentrations nocives de gaz toxiques. On doit avoir recours à une ventilation aspirante adéquate du locai, ou alors toute personne sur les lieux, de même que le soudeur, doit porter un masque à adduction d'air. On doit employer les deux pour le béryllium. Les métaux enrobés ou composés de matériaux émet- tant des gaz toxiques ne doivent pas être chauffés à moins que l'enrobage ne soit ôté de la surface à travailler, que le local ne soit bien ventilé, ou que le soudeur ne porte un masque à adduction d'air. Ne travaillez dans un espace restreint que s'il est bien ventilé et, si nécessaire, portez un masque à adduction d'air. On doit éviter les fuites de gaz dans un espace restreint. Les fuites de gaz en grande quantité peuvent transformer dangereusement la concentration d'ox- ygène. N'amenez pas de bouteilles de gaz dans un espace restreint. | En guittant un espace restreint, FERMEZ le robinet d'alimentation de gaz de la boutéille. Ains: on pourra rentrer en toute sécurité dans la pièce, même si les robinets “avai” ont été ouverts par accident, ou si on les a laissés ouverts. Les vapeurs de dissolvants chiorés peuvent étre décom- posées par la chaleur de l’arc (ou de la flamme) et former du PHOSGÈNE, gaz très toxique, et d'autres produits irritant les poumons et les yeux. L'énergie ultra-violette de l'arc peut aussi décomposer les vapeurs de trichloroéthyléne et de perchioroéthylène pour former du phosgéne. NE SOUDEZ PAS ou ne coupez pas dans des endroits ou les vapeurs de dissolvants peuvent étre attirées dans l' atmosphere de soudage ou de coupage et où l'énergie de rayonnement peut pénétrer dans des atmosphères contenant des quantités même minuscules de trichloroéthylene ou de per- chioroéthylène. C. Prévention des incendies et des explosions Les causes d'incendie et d’expiosion sont les combustibles atteints par l'arc, la flamme, les étincelles, le laitier chaud ou les matériaux chauffés, le mauvais material: misuse of compressed gases and cylinders; and short circuits. Y -— BE AWARE THAT flying sparks or falling siag Can pass through cracks, along pipes, through windows or doors, and through wall or floor openings, out of sight of the goggled operator. Sparks and slag can fly 35 feet. To prevent fires and explosion: Keep equipment clean and operable, free of oii, grease, and (in electrical parts) of metallic particles that can cause short circuits. | If combustibles are in area, do NOT weld or cut. Move the work if practicable, to an area free of combustibles. Avoid paint spray rooms, dip tanks, storage areas, ven- tilators. If the work cannot be moved, move combustibles at least 35 feet away out of reach of sparks and heat; or protect against ignition with suitable and snug-fitting, fire-resistant covers or shields. Walls touching combustibles on opposite sides shouid not be welded on (or cut}. Walls, ceilings, and floor near work should be protected by heat-resistant covers or shields. Fire watcher must be standing by with suitable fire ex- tinguishing equipment during and for some time after welding or cutting if: a. appreciable combustibles (including building construction} are within 35 feet b. appreciable combustibles are further than 35 feet but can be ignited by sparks c. openings {concealed or visible} in floors or walls within 35 feet may expose combustibles to sparks d. combustibles adjacent to walls, ceilings, roofs, or metal partitions can be ignited by radiant or conducted heat. Hot work permit should be obtained before operation to gnsure supervisor's approval that adequate precautions have been taken. After work is done, check that area is free of sparks, glowing embers, and flames. An empty container that held combustibles, or that can produce flammabie or toxic vapors when heated, must never be welded on or cut, unless container has first been cleaned as described in AWS Standard A6.0, listed 3 in Standards index. This includes; a thorough steam or caustic cieaning (or a solvent or water washing, depending on the combustible’s solubility) followed by purging and tnerting with nitrogen or carbon dioxide, and using protective equipment as recommended in AB.0. Waterfilling just below working level may substitute for inerting. A container with unknown contents should be cleaned {see paragraph above). Do NOT depend on sense of smell or sight to determine if it is safe to weld or cut. emploi des gaz comprimés et des bouteilles ainsi que les courts-circuits. Sachez que les éclats d’étincelles ou la chute du jaitier peuvent s'infiltrer dans les fissures, le long des tuyauteries, par les fenétres et les portes et par les couvertures des murs ou du sol, sans que le soudeur portant des lunettes ne les voie. Les étinceiles et les scories peuvent voler jusqu'à 35 pieds. Pour prévenir les incendies et les explosions: Veillez à ce que votre appareil soit propre et en état de marche, dénué d'huile et de graisse, et de particules de métal sur les pièces électriques qui pourraient entraîner des courts-circuits. | Si des combustibles se trouvent à proximité, ne soudez pas, ne coupez pas. Si possible, déplacez votre travail loin des combustibles. Evitez les ateliers de peinture au pistolet, ies cuves d'immersion, les entrepôts, les ven- tilateurs. Si cela n’est pas possible, placez les combustibles à au moins 35 pieds des étincelles et de la chaleur et protégez-les des étincelles avec des couvertures ou des écrans protecteurs adéquats, bien ajustés et ignifugés. On ne doit pas souder (ou couper) ie côté opposé des murs touchant les combustibles. Les murs, plafonds et planchers proches du travail doivent être protégés par des couvertures ou écrans protecteurs ignifugés. Un surveillant doit se tenir à proximité avec un matériel de lutte contre l'incendie adéquat, pendant et quelque temps après le soudage ou le coupage si: a. Des quantités appréciables de combustibles {y compris une construction en chantier) se trouvent à moins de 35 pieds. b. Des quantités appréciables de combustibles sont à plus de 35 pieds mais peuvent être enflammées par des étincelles. c. Des ouvertures (cachées ou visibles) sur les planchers ou les murs á moins de 35 pieds peuvent exposer des combustibles aux — étincelles. d. Les combustibles adjacents aux murs, plafonds, toits ou cloisons metalliques peuvent étre enflammés par une chaleur rayon- nante ou transmise. Avant de commencer, avisez le contremaitre pour qu'il s'assure que les précautions adéquates soient prises. Une fois le travail terminé, vérifiez qu’il n'y ait pas d’étincelles, de cendres ardentes ou de flammes dans le local. On ne doit jamais souder ni couper sur un récipient ayant contenu des combustibles, ou pouvant produire des vapeurs inflammables ou toxiques à la chauffe, à moins que le récipient n’ait été lavé au préalable, comme décrit dans la Norme AWS A6.0, figurant au paragraphe 3 de I'Index des Normes. Cela comprend: un nettoyage à fond à la vapeur ou au caustique (ou un lavage avec dissolvant ou eau selon la solubilité du combustibie) suivi d’une purge et d'une in- jection d'azote ou de gaz carbonique, en utilisant un équipement de protection comme recommandé dans l'A6-0. L’atmosphère inerte peut être remplacée par un niveau d'eau arrivant au-dessous du travail à effectuer. Vous devez laver un récipient dont la nature de contenu est inconnue (voir paragraphe ci-dessus}. NE vous fiez PAS a l'odorat ou á la vue pour dire si l'on peut le souder ou le couper en toute sécurité. OM-1523 Page 3 Hollow castings or containers must be vented before ~ welding or cutting. They can explode. Explosive atmospheres. Never weld or cut where the air may contain flammable dust, gas, or liquid vapors (such as gasoline). D. Compressed Gas Equipment Standard precautions. Comply with precautions in this manual, and those detailed in CGA Standard P-1, PRECAUTIONS FOR SAFE HANDLING OF COM- PRESSED GASES IN CYLINDERS, listed 6 in Stan- dards index. 1. Pressure Regulators Regulator relief valve is designed to protect only the regulator from overpressure; it is not intended to protect any downstream equipment. Provide such protection with one or more relief devices. Never connect a regulator to a cylinder containing gas other than that for which the regulator was designed. Remove faulty regulator from service immediately for repair (first close cylinder valve). The following symp- toms indicate a faulty regulator: Leaks - if gas leaks externally. Excessive Creep - if delivery pressure continues to rise with downstream vaive closed. Faulty Gauge - if gauge pointer does not move off stop pin when pressurized, nor returns to stop pin after pressure release. Repair. Do NOT attempt repair. Send faulty regulators for repair to manufacturer's designated repair center, where special techniques and tools are used by trained personnel. 2. Cylinders Cylinders must be handled carefully to prevent leaks and damage to their walls, valves, or safety devices: Avoid electrical circuit contact with cylinders including third rails, electrical wires, or welding circuits. They can produce short circuit arcs that may lead to a serious accident. {See 1-3C.) ICC or DOT marking must be on each cylinder. It is an assurance of safety when the cylinder is properly handled. ; Identifying gas content. Use only cylinders with name of gas marked on them; do not rely on color to identify gas content. Notify supplier if unmarked. NEVER DEFACE or alter name, number, or other markings on a cylinder. It is illegal and hazardous. Page 4 Vous devez pratiquer un évent sur les pièces Ou réci- pients creux avant de les souder ou couper: ils peuvent exploser, Atmospheres explosives: Ne soudez ni ne coupez jamais dans des lieux où l’air peut contenir des poussières, gaz ou vapeurs liquides inflammables (tels que l'essence). | D. Gaz comprimé Précautions générales: Suivez les précautions de Ce manuel, et celles décrites à la Norme CGA P-1 (Précau- tions de sécurité pour la manipulation de gaz comprimés en bouteilles), paragraphe 6 de l'index des Normes. 1. Détendeurs de pression La soupape de sûreté d'un détendeur est destinée à pro- téger seulement le détendeur de la surpression. Elle n'a pas pour but de protéger les boyaux et le chalumeau: on protège ceux-ci par des soupapes de retenue conçues spécialement pour cette fonction. Ne montez jamais un détendeur sur une bouteille contenant un gaz différent de celui pour lequel le détendeur a été conçu. Enlevez immédiatement un détendeur défectueux pour le faire réparer (d'abord, fermez le robinet de la bouteille}. Les symptômes suivants dénotent la défec- tuosité du détendeur: Fuites - si le gaz fuit extérieurement. Ascension excessive - si la pression de débit continue à monter, le robinet du chalumeau étant fermé. — Manomètre défectueux - si l'aiguille du manomètre ne s'écarte pas de la goupille de butée lors de la mise en pression, ou ne revient pas sur la goupille après l'échap- pement de la pression. Réparation. N'ESSAYEZ PÂS de réparer vous-mêmes. Envoyez iles détendeurs défectueux à réparer aux ateliers de réparation agréés du fabricant, où des techniques et des outils spéciaux sont utilisés par un personnel formé. 2. Bouteilles Les bouteilles doivent être manipulées avec soin pour prévenir les. fuites ou dégâts à leurs parois, robinets ou systèmes de sûreté. Evitez qu’un circuit électrique soit en contact avec les bouteilles, y compris les rails de contact, les fils électriques ou les circuits de soudage. Cela pourrait créer des arcs courts-circuits pouvant entraîner des accidents graves {Voir 1.3C.). Chaque bouteille doit porter les inscriptions ICC ou DOT. C'est un gage de sécurité pourvu que la bouteille solt bien manipulée. Identification du gaz: N'utilisez que les bouteilles indi- quant ia nature du gaz; ne vous fiez pas a ia couleur pour reconnaitre ia nature du gaz. Adressez-vous a votre fournisseur si cela n'est pas indiqué. N’EFFÂCEZ ou ne modifiez JAMAIS les noms, numéros ou autres indications sur une bouteille. Cela est illégal et dangereux. Emptiss: Keep valves closed, replace caps securely; mark MT; keep them separate from FULLS and return promptly. Prohibited use. Never use a cylinder or its contents for other than its intended use, NEVER as a support or roller. | Locate or secure cylinders so they cannot be knocked over. Passageways and work areas. Keep cylinders ciear of areas where they may be struck. Transporting cylinders. With a crane, use a secure support such as a platform or cradle. Do NOT lift cylinders off the ground by their valves or caps, or by chains, slings, or magnets. Do NOT expose cylinders to excessive heat, sparks, slag, and flame, etc. that may cause rupture. Do not allow contents to exceed 130°F. Cool with water spray where such exposure exists. | Protect cylinders particularly valves from bumps, falls, falling objects, and weather. Replace caps securely when moving cylinders. Stuck valve. Do NOT use a hammer or wrench to open a cylinder valve that can not be opened by hand. Notify your supplier. Mixing gases. Never try to mix any gases in a cylinder. Never refill any cylinder. Cylinder fittings should never be modified or exchang- ed. 3. Hose Prohibited use. Never use hose other than that designed for the specified gas. A general hose identification rule is: red for fuel gas, green for oxygen, and black for inert gases. Use ferrules or clamps designed for the hose (not or- dinary wire or other substitute) as a binding to connect hoses to fittings. No copper tubing splices. Use only standard brass fittings to splice hose. Avoid long runs to prevent kinks and abuse. Suspend hose off ground to keep it from being run over, stepped on, or otherwise damaged. Coil excess hose to prevent kinks and tangles. Protect hose from damage by sharp edges, and by sparks, stag, and open flame. Examine hose regularly for leaks, wear, and loose connections. Immerse pressured hose in water; bubbles indicate leaks. Repair leaky or worn hose by cutting area out and splic- ing (1-2D3). Do NOT use tape. Vides: Maintenez les robinets fermés, replacez bien les chapeaux; inscrivez “Vides”; séparez-les des Pleines et retournez-les rapidement. Emploi interdit: N'utilisez une bouteille ou son contenu que pour ce à quoi elle est destinée, mais JAMAIS comme support ou rouleau. Placez les bouteilles pour qu'elles ne tombent pas. Lors- qu'un détendeur (et un boyau) est monté sur elles, - placez les ou attachez-les debout. Passages et lieux de travail. Enlevez les bouteilles d'un endroit où l’on pourrait les frapper. Transport des bouteilles. Âvec une grue, utilisez un support fiable tel qu’une plate-forme ou un cadre. NE SOULEVEZ PAS des bouteilles du sol par leur robinet ou chapeau, ou avec des chaînes, élingues ou aimants. N'EXPOSEZ PAS les bouteilles à une chaleur excessive, aux étincelles, au laitier et aux flammes, etc., pouvant causer leur rupture. Le contenant ne doit jamais dépasser 55°C. Refroidissez en puivérisant de l'eau si nécessaire. Protégez les bouteilles et particulièrement les soupapes contre les chocs, les chutes, les chutes d'objets et la température. Remettez bien les chapeaux lorsque vous déplacez les bouteilles. Robinet coincé. N'UTILISEZ PAS un marteau ou une clé métallique pour ouvrir un robinet de bouteille que l'on ne peut pas ouvrir à la main. Avisez votre fournisseur. Mélange de gaz. N'essayez jamais de mélanger des gaz dans une bouteille. Ne rechargez jamais une bouteille. Les éléments de la bouteille ne doivent jamais être modifiés ou remplacés. 3. Boyau Utilisation interdite. N'utilisez jamais un boyau autre que celui approprié au gaz indiqué. La règle générale d'identification est: rouge pour les gaz combustibles, vert pour l'oxygène, et noir pour les gaz inertes. Utilisez des bagues ou colliers appropriés au boyau (et non du fil ordinaire ou autre substitution) pour brancher les boyaux à l’appareillage. N'utilisez pas des raccords en cuivre. N'utilisez que des accessoires standard en laiton pour raccorder un boyau. Utilisez une petite longueur de boyau. Cela évitera les noeuds et l'usure prématurée. Suspendez le boyau au- dessus du sol pour éviter qu'il ne soit écrasé, piétiné ou endommagé. Enroulez le surplus de boyau pour éviter les noeuds et emmêlements. Evitez que le boyau ne soit endommagé par des tranchants, étincelles, laitier et flamme nue. Vérifiez régulièrement les fuites, l'usure et les rac- cordements lâches. Plongez le boyau sous pression dans de l’eau: ies bulles indiqueront les fuites. Réparation. Coupez la partie percée ou usée, et rac- cordez (1-2D3). N'UTILISEZ JAMAIS de ruban adhésif. OM-1523 Page 5 + 4. Proper Connections Clean cylinder valve outlet of impurities that may clog - ~ orifices and damage seats before connecting regulator. Except for hydrogen, crack valve momentarily, pointing ‘outlet away from people and sources of ignition. Wipe with a clean lintless cloth. Match regulator to cylinder. Before connecting, check that the regulator label and cylinder marking agree, and that the regulator inlet and cylinder outlet match. NEVER CONNECT a regulator designed for a particular gas or gases to a cylinder containing any other gas. Tighten connections. When assembling threaded connections, clean and smooth seats where necessary. Tighten. If connection leaks, disassemble, clean, and retighten using properly fitting wrench. Adapters. Use a CGA adapter (available from your supplier) between cylinder and regulator, if one is required. Use two wrenches to tighten adapter marked RIGHT and LEFT HAND threads. Regulator outlet (or hose) connections may be iden- tified by right hand threads for oxygen and ieft hand threads (with grooved hex on nut or shank) for fuel gas. 5. Pressurizing Steps: Drain regulator of residual gas through suitable vent before opening cylinder (or manifold valve) by turning adjusting screw in (clockwise). Draining prevents excessive compression heat at high pressure seat by allowing seat to open on pressurization. Leave adjusting screw engaged slightly on single-stage regulators, Stand to side of regulator while opening cylinder valve. Open cylinder valve slowly so that regulator pressure in- creases slowly. When gauge is pressurized (gauge reaches regulator maximum) leave cylinder valve in following position: For oxygen, and inert gases, open fully to seal stem against possible leak. For fuel gas, open to less than one turn to permit quick emergency shutoff. Use pressure charts {available from your supplier) for safe and efficient, recommended pressure settings on regulators. Check for leaks on first pressurization and regularly there-after. Brush with soap solution (capfui of Ivory Liquid* or equivalent per gallon of water). Bubbles indicate leak. Clean off soapy water after test; dried soap is combustible. E. User Responsibilities Remove leaky or defective equipment from service immediately for repair. See User Responsibility statement In equipment manual. *Trademark of Proctor & Gamble Page 6 4, Branchements corrects Avant de brancher le détendeur, nettoyez la sortie du robinet de la bouteille des impuretés qui peuvent obstruer les orifices et endommager les sièges. Sauf pour l'hydrogène, ouvrez momentanément le robinet, en éloignant la sortie des personnes et des sources in- flammabies. Essuyez avec un tissu propre et non graisseux. Appareillez le détendeur à la bouteille. Avant de brancher, vérifiez que la marque du détendeur et la description de la bouteille concordent, et que l’orifice d'entrée du détendeur et l’orifice de sortie de la bouteille aillent ensemble. NE BRANCHEZ JAMAIS un détendeur conçu pour un gaz spécial (ou des gaz spéciaux) à une bouteille contenant d'autres gaz. Serrez les branchements. Lorsque vous assemblez des branchements filetés, nettoyez et polissez les sièges où c’est nécessaire. Serrez. Si les branchements perdent, démontez-les, nettoyez et resserez avec une clef adé- quate. Adaptateurs. Placez, si besoin est, un adaptateur CGA {en vente chez votre fournisseur} entre la bouteille et le détendeur. Avec deux clefs, serrez l'adaptateur fileté À DROITE et À GAUCHE. On peut reconnaître les branchements de sortie du détendeur (ou boyau) à l’aide du filetage à droite pour l'oxygène et à gauche (identifié par un écrou cannelé) pour les gaz combustibles. 5. Démarches de mise en pression Purgez le détendeur de résidu de gaz avant d'ouvrir la bouteille (ou le robinet de canalisation) en serrant la vis de réglage (dans ie sens des aiguilles d’une montre). Cette opération permet au siège de haute pression de s'ouvrir à la mise en pression, supprimant ainsi toute surchauffe de compression. Maintenez la vis de réglage des détendeurs à simple détente légèrement engagée. Avant d'ouvrir le robinet de la bouteille, assurez-vous que les boyaux sont branchés et que les soupapes aval sont fermées. | Tenez-vous latéralement au détendeur en ouvrant le robinet de la bouteille. Ouvrez-le lentement pour que la pression du détendeur monte progressivement. Lorsque le manomètre est mis sous pression (indique le maximum) le robinet de la bouteille de gaz inerte ou d’ox- ygêne devra être ouvert à fond pour assurer l'étanchéité et celui de la bouteille de gaz combustible ouvert de moins d'un tour pour pouvoir le refermer rapidement en cas d'urgence. Référez-vous aux tableaux de pression (distribués par votre fournisseur) pour un réglage recommandé de pression sûr et efficace sur les détendeurs. Vérifiez les fuites à la première mise en pression puis régulièrement, brossez avec une solution savonneuse (un bouchon d'Ivory Liquid* ou semblable par gallon d’eau). Les bulles indiquent une fuite. Enlevez l’eau savonneuse après examen; le savon sec est inflammable. Е. Responsabilités de l'usager Ótez immédiatement les parties percées ou défec- tueuses. Voir les Responsabilités de l'Usager du manuel de l’appareil. *Marque de Commerce de Proctor & Gamble F. Leaving Equipment Unattended Close gas supply at source and drain gas. G. Rope Staging-Support Rope staging-support should not be used for welding or cutting operation; rope may burn. 1-3. ARC WELDING - Comply with precautions in 1-1, 1-2, and this section. Arc Welding, properly done, Is a safe process, but a careless operator invites trouble, The equipment carries high cyrrents at significant voltages. The arc is very bright and hot. Sparks fly, fumes rise, ultraviolet and infrared energy radiates, weldments are hot, and compressed gases may be used. The wise operator avoids unnecessary risks and pro- tects himself and others from accidents. Precautions are described here and in standards referenced in index. A. Burn Protection Comply with precautions in 1-2. The welding arc is intense and visibly bright. lts radiation can damage eyes, penetrate lightweight clothing, reflect from light-colored surfaces, and burn the skin and eyes. Skin burns resemble acute sunburn, those from gas-shielded arcs are more severe and painful. DONT GET BURNED; COMPLY WITH PRECAU- TIONS. 1. Protective Clothing Wear long-sleeve clothing (particularly for gas-shielded arc) in addition to gloves, hat, and shoes (1-2A). As necessary, use additional protective clothing such as leather jacket or sleeves, flame-proof apron, and fire- resistant leggings. Avoid outergarments of untreated cotton. Bare skin protection, Wear dark, substantial clothing. Button collar to protect chest and neck and button pockets to prevent entry of sparks. 2. Eye and Head Protection Protect eyes from exposure to arc. NEVER look at an electric arc without protection. Welding helmet or shield containing a filter plate shade no. 12 or denser must be used when welding. Place over face before striking arc. Protect filter plate with a clear cover plate. Cracked or broken helmet or shield should NOT be worn; radiation can pass through to cause burns. Cracked, broken, or loose filter plates must be replaced IMMEDIATELY. Replace clear cover plate when broken, pitted, or spattered. F. Appareil laissé sans surveillance Fermez l'alimentation de gaz á la source et purgez. G. Liens et supports temporaires Pour vos travaux de soudage ou de coupage, nutilisez pas de la corde comme soutien, elle est inflammable. 1-3. SOUDAGE A L'ARC - Conformez-vous aux précautions des paragraphes 1.1 et 1.2 de cette section. Le soudage а l'arc bien exécuté est súr, mais un soudeur négligent est un danger. Le poste de soudage transporte des courants élevés sous de fortes tensions. L'arc est trés vif et chaud. Les étincelles volent, les vapeurs montent, l'énergie ultra-violette et infrarouge rayonnent, les soudures sont chaudes, et des gaz com- primés peuvent être utilisés. Le soudeur prudent évite les risques inutiles, se protège et protège autrui contre les accidents. Les précautions sont décrites ici et dans les normes données dans l‘Index. A. Protection contre les brúlures Conformez-vous aux précautions du paragraphe 1.2. L'arc de soudage est intense et visiblement vif. Son rayonnement peut blesser les yeux, traverser les habits légers, se réfléchir sur les surfaces claires, et brûler la peau et les yeux. Les brûlures de la peau ressemblent à un gros coup de soleil. Celles d'arcs sous gaz protecteur sont plus graves et plus douloureuses. NE VOUS BRULEZ PAS - SUIVEZ LES PRECAUTIONS. 1. Vétements de protection Portez des vétements a manches longues (surtout pour l'arc en atmosphère inerte) avec gants, masque et chaussures (1.2A.). Si nécessaire portez en plus une veste ou des manches en cuir, un tablier et des guêtres ignifugés. De préférence ne portez pas de vêtements en coton non traité. Protection de la peau. Portez des vêtements épais foncés. Boutonnez le col pour protéger la poitrine et le cou, et boutonnez les poches pour. prévenir l'infiltration d'étincelles. 2. Protection des yeux et de la téte Évitez que vos yeux soient exposés à l‘arc. NE regardez JAMAIS un arc électrique sans protection. Lorsque vous soudez, portez un écran ou masque avec verre filtrant teinté N° 12 ou plus fonce. Mettez-le sur le visage avant d'amorcer l'arc. Protégez le verre filtrant d'un couvre-verre clair. NE PORTEZ PAS un masque fendu ou brisé; le rayonnement peut s'infiltrer et causer des brúlures. Les verres filtrants fendus, brisés ou láches doivent étre remplacés IMMEDIATEMENT, Remplacez un couvre- verre brisé, piqué ou taché par des projections. OM-1523 Page 7 Flash goggles with side shields MUST be worn under the helmet to give some protection to the eyes should the helmet not be lowered over the face before an arc is struck. Looking at an arc momentarily with unprotected eyes (particularly a high intensity gas-shielded arc) can cause a retinal burn that may leave a permanent dark area in the field of vision. 3, Protection of Nearby Personnel Enclosed welding area, For production welding, a Separate room or enclosed bay is best. In open areas, | surround the operation with low-reflective, non- combustible screens or panels. Allow for free air circula- tion, particularly at fioor level. Viewing the weld. Provide face shields for all persons who will be looking directly at the weld. Others working in area. See that all persons are wearing flash goggles. Before starting to weld, make sure that screen flaps or bay doors are closed. B. Toxic Fume Prevention Comply with precautions in 1-2B. Generator engine exhaust must be vented to the outside air. Carbon monoxide can kill. C. Fire and Explosion Prevention Comply with precautions in 1-2C. Equipment's rated capacity. Do not overload arc welding equipment. it may overheat cables and cause a fire. Loose cable connections may overheat or flash and cause a fire. Never strike an arc on a cylinder or other pressure vessel. It creates a brittle area that can cause a violent rupture or lead to such a rupture later under rough handling. D. Compressed Gas Equipment Comply with precautions in 1-2D. E. Shock Prevention Exposed hot conductors or other bare metal in the welding circuit, or in ungrounded, electrically-HOT equipment can fatally shock a person whose body becomes a conductor, DO NOT STAND, SIT, LIE, LEAN ON, OR TOUCH a wet surface when welding, without suitable protection. | Раде 8 Vous devez portez des tunettes a écrans latéraux sous ie masque pour protéger les yeux dans le cas ol le masgue ne serait pas abaissé sur le visage avant l'amorcage de l’arc. Regarder momentanément un arc sans protection (principalement un arc en atmosphère inerte à haute in- tensité) peut brûler la rétine et laisser Un point sombre permanent dans le champ de vision. 3. Protection du personnel à proximité Local de soudage ferme. Pour le soudage de production, il vaut mieux utiliser une salle séparée ou une baie fermée. Dans les locaux ouverts, entourez les travaux d'écrans ou panneaux peu réfléchissants et ininflam- mables. Laissez l'air circuler fibrement, particulièrement au niveau du sol. Donnez des masques aux personnes qui regarderont directement la soudure. Autres personnes travaillant sur les lieux. Veillez à ce que toutes les personnes portent les lunettes de protection, Avant d'attaquer la soudure, assurez-vous que les rebords d'écran ou les portes soient fermés. B. Prévention des gaz toxiques Suivez les précautions du paragraphe 1.2B. L'échappe- ment du moteur de la génératrice doit être ventilé à l’air extérieur. L'oxyde de carbone peut tuer. C. Prévention des incendies et des explosions Suivez les précautions 1.2C. Puissance nominale de l'appareil. Ne surchargez pas le poste de soudage à l'arc. Cela peut surchauffer les câbles et causer un incendie. Les branchements lâches de câble peuvent surchauffer ou faire des étinceiles et causer un incendie. N’amorcez jamais un arc sur une bouteille ou autre réci- pient sous pression. Cela créerait un point de rupture entraînant à plus ou moins longue échéance explosion du réservoir. D. Gaz comprimé Suivez les précautions 1.2D. E. Prévention des décharges électriques Des conducteurs chargés ou métal nu incorporés au circuit de soudage ou à un appareil chargé sans mise à la terre peuvent donner une décharge fatale à la personne dont ie corps devient conducteur. NE SOUDEZ PAS DEBOUT, ASSIS, COUCHE, PENCHE sur une surface humide ni en contact avec une telle surface sans protection appropriée. To protect agatnst shock: Keep body and clothing dry. Never work in damp area without adequate insulation against electrical shock. Stay on a dry duckboard, or rubber mat when damp- ness or sweat can not be avoided. Sweat, sea water, or moisture between body and an electrically HOT part - or grounded metal - reduces the body surface electrical resistance, enabling dangerous and possibl lethal currents to flow through the body. | 1. Grounding the Equipment When installing, connect the frames of each unit such as welding power source, control, work tabie, and water circulator to the buiiding ground. Conductors must be adequate to carry ground currents safely. Equipment made electrically HOT by stray current may shock, possibly fatally. Do NOT GROUND to electrical conduit, or to a pipe carrying ANY gas or a flammable ti- quid such as oil or fuel. Three-phase connection. Check phase requirements of equipment before installing. If only 3-phase power is available, connect single-phase equipment to only two wires of the 3-phase line. Do NOT connect the equipment ground lead to the third (live) wire, or the equipment will become electrically HOT - a dangerous condition that can shock, possibly fatally. Before welding, check ground for continuity. Be sure conductors are touching bare metal of equipment frames at connections. If a line cord with a ground lead is provided with the equipment for connection to a switchbox, connect the ground lead to the grounded switchbox. If a three- prong plug is added for connection to a grounded mating receptacle, the ground lead must be connected to the ground prong only. If the line cord comes with a three-prong plug, connect to a grounded mating receptacle. Never remove the ground prong from a plug, or use a plug with a broken off ground prong. 2. Electrode Holders Fully insulated electrode holders should be used. Do NOT use holders with protruding screws. 3. Connectors Fully insulated lock-type connectors should be used to join welding cable lengths. 4. Cables Frequently inspect cables for wear, cracks and damage. IMMEDIATELY REPLACE those with excessively worn or damaged insulation to avoid possibly - lethal shock from bared cable. Cables with damaged areas may be taped to give resistance equivalent to original cable. Keep cable dry, free of oil and grease, and protected from hot metal and sparks. Pour vous protéger contre les décharges électriques, maintenez votre corps et vétements secs. Ne travaillez jamais dans un endroit humide sans isolation adéquate contre les décharges électriques. Lorsque vous ne pouvez éviter l'humidité ou la sueur, placez-vous sur un caillebotis sec ou un tapis en caoutchouc. La sueur, l'eau de mer, ou l'humidité entre le corps et une pièce CHARGÉE, ou une pièce de métal à la masse, réduisent la résistance électrique de la surface du corps, permet- tant l'entrée de courants dangereux, voire mortels. 1. Mise à la terre de l'appareil À l'installation, branchez les châssis de chaque élément (source de courant, commande, établi et circuit d’eau) à la terre. Les conducteurs doivent pouvoir conduire les courants telluriques en toute sécurité. L'appareil chargé par les courants vagabonds peut donner une décharge risquant d’être mortelle. NE BRANCHEZ PAS VOTRE PRISE DE TERRE à une conduite électrique, ou à un tuyau de gaz ou de liquide inflammable tel que l'huile ou un combustible. Connexion triphasée. Avant l'installation vérifiez la phase nécessaire à l’appareil. Si seul le triphasé est disponible, ne branchez l'appareil monophasé qu'à deux des fils de la ligne triphasée. NE BRANCHEZ PAS le conducteur de terre de l'appareil au troisième fil (sous tension}, autrement l’appareil serait chargé: condition dangereuse pouvant donner une décharge fatale. Avant le soudage, Vérifiez si la prise de terre est uniforme. En branchant, assurez-vous que les conducteurs touchent le métal nu du châssis de l'appareil. Lorsqu‘un appareil doit être alimenté a partir d'un cof- fret d'alimentation, le conducteur de terre doit étre relié a celui-ci. Si vous avez en plus une fiche á trois broches pour la terre, ne branchez le conducteur de terre qu'á la broche de terre. Si le cordon d'alimentation a une fiche à trois broches, reliez-le à une prise femelle tripolaire reliée à la terre. N'enlevez jamais la broche de terre d'une fiche ou n’utilisez jamais une fiche dont la broche de terre serait brisée. 2. Pince-électrodes Utilisez des pince-électrodes bien isolées. N'UTILISEZ PAS des pince-électrodes avec vis saillantes. 3. Connecteurs Utilisez des connecteurs à verrouillage bien isolés pour assembler de longs câbles. 4, (Cables Vérifiez fréquemment l'usure, les fissures et l'altération des cables. REMPLACEZ IMMEDIATEMENT ceux dont l'isolation serait trop usée ou altérée pour prévenir les décharges mortelles provoquées par un câble dénudé. Vous pouvez enrouler les parties endommagées de ruban adhésif en épaisseur suffisante pour donner une résistance de câble neuf. Maintenez les câbles secs, dépourvus d'huile et de graisse et mettez-les à l'abri du métal chaud et des étincelles. OM-1523 Page 9 5. Terminals And Other Exposed Parts. Terminals and other exposed parts of electrical units should have insulating covers secured before operation. 6. Electrode Wire Electrode wire becomes electrically HOT when the power switch of gas metal-arc welding equipment is ON and welding gun trigger is pressed. Keep hands and body clear of wire and other HOT parts. | 7. Safety Devices Safety devices such as interlocks and circuit breakers should not be disconnected or shunted out. Before installation, inspection, or service, of equipment, shut OFF all power and remove line fuses (or lock or red-tag switches) to prevent accidental turning ON of power. Disconnect ali cables from welding power source, and pull all 115 volts line-cord plugs. Do not open power circuit or change polarity while welding. Hf, in an emergency, it must be disconnected, guard against shock burns, or flash from switch arcing. Leaving equipment unattended. Always shut OFF and disconnect all power to equipment. Power disconnect switch must be available near the welding power source. 1-4. STANDARDS BOOKLET INDEX - For more information, refer to the following standards or their latest revisions and comply as applicable: 1. ANSI Standard 249.1, SAFETY IN WELDING AND CUTTING obtainable from the American ее Society, 2501 NW 7th St., Miami, FL 125. 2. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING obtainabie from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402. 3. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, obtainable from the U.S. Govern- ment Printing Office, Washington, D.C. 20402. 4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION obtainable from the American National Standards institute, 1430 Broadway, New York, NY 10018. 5. ANSI Standard 241.1, STANDARD FOR MEN'S SAFETY -TOE FOOTWEAR obtainable from the American National Standards Institute, 1430 Broadway, New York, NY 10018 Page 10 5. Têtes de câbles et autres parties dénudées Avant la mise en marche, les têtes de câbles et autres parties dénudées d’un appareil électrique doivent être munies de leurs couvrefils isolants. 6. Fils-électrodes Le fil-électrode est chargé lorsque lorsque l'interrupteur d'alimentation du poste à souder au MIG est sur MAR- CHE et que l'on appuie sur la gâchette du pistolet. Evitez que les mains et le corps soient en contact avec ie fil et autres éléments chargés. 7. Dispositif de sécurité Le dispositif de sécurité-verrouillage et coupe-circuit ne doit pas être débranché ou déshunté. Avant l’installation, l'inspection ou la réparation de l'appareil, mettez l'alimentation sur ARRET et enlevez les fusibles généraux {ou verrouillez les interrupteurs) pour éviter une remise en MARCHE accidentelle. Débran- chez tous les câbles de la source de courant ainsi que les prises des cordons d'alimentation en 115 volts. Lors du soudage, n’ouvrez pas le circuit d'alimentation et ne changez pas la polarité. S'il est débranché au cours d'une urgence, faites attention aux brûlures de décharge ou aux jaillissements d'étincetles. Appareil laissé sans surveillance. Mettez toujours sur ARKRET et débranchez l'appareil. L‘interrupteur d'arrêt doit toujours se trouver a prox- imité de la source de courant. 1-4. INDEX DES NORMES -Pour plus de renseignements, référez-vous aux normes de l'ACNOR ou aux normes américaines suivantes: 1. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING distribué par l'American Welding Society, 2501 N.W. 7th Street, Miami, FL 33125 2. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING distribué par le Superintendent of Documents, U.S. Government Printing Office, Washington D.C. 20402 3. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, distribué par U.S. Government Printing Office, Washington, D.C. 20402, 4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION distribué par I' American National Standards Institute, 1430 Broadway, New York, NY 10018. 5. ANSI Standard 2741.1, STANDARD FOR MEN'S SAFETY - TOE FOOTWEAR distribué par l'addresse donnee en 4. Ee —————— — 10. 11. 12. 13. 14. 15. ANSI Standard 249.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PRO- CESSES obtainable from the American National Standards Institute, 1430 Broadway, New York, NY 10018. AWS Standard: A6.0, WELDING AND CUT- TING CONTAINERS WHICH HAVE HELD COM- BUSTIBLES obtainable from the American Welding Society, 2501 NW 7th Street, Miami, FL 33125. NFPA Standard 51, OXYGEN - FUEL GAS SYSTEMS FOR WELDING AND CUTTING obtainable from the National Fire Protection Association, 470 Atlantic Avenue, Boston, MA 02210. NFPA Standard 70-1978, NATIONAL ELEC- TRICAL CODE obtainable from the National Fire Protection Association, 470 Atlantic Avenue, Boston, MA 02210. NFPA Standard 518, CUTTING AND WELDING PROCESSES obtainable from the National Fire Protection Association, 470 Atlantic Avenue, Boston, MA 02210. CGA Pamphlet P-1, SAFE HANDLING OF COM- PRESSED GASES IN CYLINDERS obtainable from the Compressed Gas Association, 500 Fifth Avenue, New York, NY 10036. CSA Standard W117.2, CODE FOR SAFETY IN WELDING AND CUTTING obtainable from the Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association, 1900 Arch Street, Philadelphia, PA 19103. American Welding Society Standard AWSF4.1 “Recommended Safe Practices for the Prepara- tion for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances”, obtainable from the American Welding Society, 2501 NW 7th Street, Miami, FL 33125. ANSI Standard Z88.2 “Practice for Respiratory Protection’ obtainable from the American Na- tional Standards Institute, 1430 Broadway, New York, NY 10018. 10. 11. 12. 13. 14. 15. ANS! Standard 249.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PRO- CESSES distribué par l’addresse donnee en 4. AWS Standard A6.0, WELDING AND CUT- TING CONTAINERS WHICH HAVE COM- BUSTIBLES distribué par l’addresse donnee en 1. NFPA Standard 51, OXYGEN - FUEL GAS SYSTEMS FOR WELDING AND CUTTING distribué par la National Fire Protection Associa- tion, 470 Atlantic Avenue, Boston, MA 02210 NFPA Standard 70-1978, NATIONAL ELEC- TRICAL CODE distribué par l’addresse donnée en 8 | NFPA Standard 51B, CUTTING AND WELDING PROCESSES distribué par l'addresse donnée en 8 CGA Pamphlet P-1, SAFE HANDLING OF COM- PRESSED GASES IN CYLINDERS distribue par la Compressed Gas Association, 500 Fifth Avenue, New York, NY 10036. CSA Standard W117.2, CODE FOR SAFETY IN WELDING AND CUTTING distribué par la Cana- dian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY distribué par la National Welding Supply Association, 1900 Arch Street Philadelphia, PA 19103. American Welding Societe Standard AWSF4.1 “Recommended Safe Practices for the Prepara- tion for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances”, distribué par l'American Welding Societe, 2501 NW 7th Street, Miami, FL 33125. ANSI Standard Z88.2 “Practice For Respiratory Protection” distribué par "American National Standards Institute, 1430 Broadway, New York, NY 10018. OM-1523 Page 11 SECTION 2 - INTRODUCTION em TT Model Dual 12 | Dual 16 Speed Range 50-780 I.P.M. (1.27-19.8 т) Boom Length 12 ft. (3.7 m) | 16 ft. (4.9 m) Swing 360° Vertical Lift Horizontal To 60° Above Maximum Height (W/4 Ft Post) At Full Lift Of Boom 17 ft. (5.2 m) 21 ft. (6.4 m) Counterbalance Compression Spring Is Designed To Balance boom At Any Angle. Pressure Adjustment Is Angle Or To Limit The Vertical Lift At 40°, 50°, or 60°. Ship Net Ship Weight (Pounds) 210 Ibs. 330 Ibs. | 275 Ibs. 415 ibs. (95 kg) (150 kg) | (125 kg} (188 kg) 2 - 1. GENERAL - This manual has been prepared especially for use in familiarizing personnel with the design, Installation, operation, maintenance, and troubleshooting of this equipment. All information presented herein should be given careful consideration to assure optimum performance of this equipment. 2-2. RECEIVING-HANDLING - Prior to installing . this equipment, clean all packing material from around the unit and carefully inspect for any damage that may have occurred during shipment. Any claims for loss or damage that may have occurred in transit must be filed by the purchaser with the carrier. A copy of the bill of lading will be furnished by the manufacturer on re- quest if occasion to file claim arises. When requesting information concerning this equipment, it is essential that Model Description and Serial (or Style) Numbers of the equipment be supplied. 2 - 3. DESCRIPTION - This unit is a boom mounted digital wire control/feeder, The control/feeder is of the constant wire feed speed type which feeds wire alter- nately from two welding guns. lt is designed to be used in conjunction with T or 2 constant potential welding power source. The boom is a patented design allowing both vertical lift and swing. Cables are routed through the boom from the feeder control to the wire drive assembly. == SECTION 3 - 3-1. LOCATION AND ASSEMBLY (Figure 3-1) A. Location A suitable location for this unit will allow room for the boom toc swing horizontally in the desired arc, and to pivot upward to the desired angle. Proper placement will aiso provide sufficient clearance from obstruction at Page 12 The control/feeder is a heavy duty wire feeding unit which maintains constant wire feed speed regardless of line or load variations. It contains all the controls and equipment needed to supply welding wire and shielding gas to the welding guns. 2 - 4. SAFETY - Before the equipment is put into operation, the safety section at the front of this manual should be read completely. This will help avoid possible injury due to misuse or improper welding applications. The following definitions apply to CAUTION, IMPOR- TANT, and NOTE blocks found throughout this manual: [Ue Under this heading, installation, operating, and maintenance procedures or practices will be found that if not carefully followed may create a hazard to personnel. LE Under this heading, operating, and maintenance procedures or practices will be found that if not carefully followed may result in damage to equipment, VI XW Under this heading, explanatory statements will be found that need special emphasis to obtain the most efficient operation of the equipment. INSTALLATION messes tsa the wire support end of the unit when the boom swings. The structure to which the unit is being installed should he of sufficient construction to support the weight of the unit when the boom is in the horiziontal position. B. Assembly 1. Existing Support {Customer Supplied) Mo EDEN /n selecting the pipe used to support the unit the model utilizing a 12 foot boom requires a 2-1/2 inch diameter, Schedule 40 pipe (wall thickness of .203 inches). The model with a 16 foot boom requires a 5 inch diameter, Schedule 40 pipe (wall thickness of .258 inches). a. Uncrate and remove all packing material from the unit. b. Mount pipe post (14) to the desired struc- С T8-081 753 Figure 3-1, Base And Boom Assembly The structure to which the pipe post is mounted must be of sufficient construction to support the weight of the unit when the boom is in the horizontal position. c. Proceed to Subsection B2, Steps c through К. 2. Post Support {Optional) a. Uncrate and remove all packing material from the unit. b. Mount post support (14) to the desired structure. The structure to which the post support is mounted must be of sufficient construction to support the weight of the unit when the boom is in the horizontal position. | с. Remove yoke pin {1}, nut (10), washers (96 17) and bolt (18) from the yoke (3) and swivel plates (16). Do not remove safety collar (11) until instructed to do so. The swivel base (8) contains high pressure springs to counter balance the weight at the weld head. d. Place bearing (13) on top of post (14) and insert swivel (8) into post (14). e. Place the boom base plate (19) in between the hwo swivel plates. f. Slide washer (17) onto boit (18) and insert bolt (18) through hole (15). Slide washer (9) onto bolt (18) and install nut (10) onto bolt (18). Tighten nut (10); then back off nut (10) 1/2 turn. g. Insert pin (1) through yoke (3), hole (2), and install cotter pin {4) through pin (1). h. Connect the welding guns to the drive assembly as instructed in the Owner's Manual for the desired welding guns. i. Grasp bar {20) and pull boom down slightly. The boom should be pulled down only far enough to remove the pressure which is ap- plied to the safety collar (11). | J. Remove the safety collar {11} and retain for future adjustments. k. The boom should now balance in any position from horizontal to 60 degrees above horizontal. If the boom does not balance properly, proceed to Section 3-10. The post support (14) is provided with a fitting for lubricating the swivel periodically, to prevent premature wear and to ease turning during operation. Excessive greasing of support fitting is not required or recommended. 3. Base Support (Optional) ei // an optional base support was purchased with the unit, mounting holes are provided for fastening the base support to the floor. When an optional base support is used, the base must be securely mounted to the floor. As a minimum, 1/2” dia., S.A.E. grade 5 bolts, with adequate corrosion protection should be used to secure the base. If the unit is to be mounted in an extremely damp environment, mounting bolts made of a non-corrosive material with a strength equivalent to S.A.E. grade 5 steel should be used. a. Uncrate and remove all packing material from the unit. b. Fasten base support to the floor. OM-1523 Page 13 c. Complete Steps c through k, Subsection B2. BAISE The base support is provided with a fitting for ubricating the swivel periodically, to prevent premature wear and to ease turning during operation. Excessive greasing of support fitting is not required or recommended, | | 4. Swingpak Base (Optional) a. Uncrate and remove all packing material from the Swingpak base. | ELA ARV NBR The installation of the welding power source onto the Swingpak base should precede mounting of the Swingarc unit in order to prevent tipping of the frame under the weight of the boom. b. Uncrate and remove all packing material from the Swingarc unit. c. Complete Steps c through k, Subsection B2. _ for lubricating the swivel periodically, to prevent premature wear and to ease turning during operation. Excessive greasing of support fitting is not required or recommended. 3-2. DRIVE MOTOR - The drive motor is provided with a vent screw which must be removed prior to the operation of the control/feeder. The vent screw can be removed through the hole provided in the motor shroud (see Figure 3-6). 3-1) 1. Remove the securing screws (5) and lock washers (6) from the swivel base (8) 2. Lift the wire support {7) in place over the holes in the swivel! base (8). | 3. Insert securing screws (5) with lock washers {6) and tighten. 3-4, REINSTALLATION OF HUB ASSEMBLY {Figure 3-2) - If it should become necessary to replace part or all of the hub assembly(s), reinstall the new hub assembly(s) as follows: 1. Slide the following iterns onto the spindie support shaft {1} in order given: Fiber Washer (2) Flat Washer (3) Hub (4) Flat Washer (b) Fiber Washer (6) Keyed Washer (7) Spring (8) Flat Washer (3) то топора 2. Rotate hex nut (10) onto support shaft (1). Hex | nut should be rotated only until g slight drag is felt while turning hub (4). Page 14 DVI 7he Swingpak base is provided with a fitting | 3 ~ 3. INSTALLATION OF WIRE SUPPORT (Figure TB-081 754 Figure 3-2. Wire Support And Hub Assembly 3. Depress the two spring loaded stops (11) on the retaining ring (12) and slide the retaining ring (12) into proper position on the hub (4). Release the two stops (11). 3-5. INSTALLATION OF WIRE REEL (Optional) (Figure 3-3) - The following procedures for the installation of the wire reels are applicable to the left and/or right sides. | Figure 3-3. Reel Installation TB-081755 1. Remove the retaining ring 14). 2. Slide the wire reel (1) onto the hub (5). Rotate the wire reel (1) until the hub guide pin (6) is seated in the reel (1). 3. Replace the retaining ring (4). 3-6. DRIVE ROLL AND WIRE GUIDE INSTALLA- TION (Figures 3-4 & 3-5) - Upon intitial installation, or as a result of changes in wire size and type, it is necessary to install the required drive rolis and wire guides. BTA) BE Base selection of drive rolls upon the following recommended usages: 1. V-Groove rolis for hard wire. 2. U-Groove rolls for soft and soft shelled cored wires. 3. U-Cog rolls for extremely soft shelled wires (usually hard surfacing types). 4. Split V-Knurled rolls for hard shelled cored wires (self-shielding and CQO2 shielded types). 5. Drive roll types may be mixed to suit particular requirements (example: V-knurled roll in combination with U-groovel. Having selected the appropriate drive rolls and wire guides proceed to the installation instructions for the type of drive roll to be used. A. Drive Roll Installation (Figures 3-4 € 3-5) 1. Loosen pressure adjustment wing nut {item 2, Figure 3-4) and pivot it free of cover. 2. Pivot gear cover (4) away to expose pressure gear. 3. Loosen and remove the three securing screws (7 E 12) on each gear (5 & 9). 4. For one piece drive rolls (8 & 13): Slide a drive roll onto the drive gear (9) and pressure gear (5) with holes aligned and secure with screws (7 & 12). For split drive rolls (6 & 10}: Align holes on each side of split drive rolls, insert a securing screw (7 & 12) and slide a drive roll onto the drive gear (9) and pressure gear (5) with screw in line with one of the threaded holes. Insert remaining screws (7 & 12) and tighten. 18 19 18-081 810-A 9 13 12 12 Figure 3-4. Drive Rolls Installation Wikis One-piece drive rolls (8 & 13) are of the double usage type. When the grooves become worn, reverse each drive roll, locating the unused groove in position to feed the wire. Split drive rolls (6 & 10) are of the double usage type. When the knurled groove of the drive roll becomes worn, the split halves may be reversed so that the unused edges will now provide a new knurled groove. DOI 70 ensure proper gripping action of U-Cog drive rolls, both rolls should be installed showing slots on the side or both should show the side without slots. Also, it is necessary to line up the blunted teeth on the pressure gear roll directly over the spaces between the teeth on the drive gear roll as illustrated in Figure 3-5. Da Drive Gear U-Cog Roi! - 2 IN Pressure Gear A U-Cog Roll » Slotted Side of U-Cog Roll TA-081 756 Figure 3-5. U-Cog Drive Rolis Installation B. Inlet Wire Guide (Figure 3-4) 1. For .030 in.-5/64 in. (.8-2.0 mm) wire. a. insertliner (18) into inlet wire guide (17) and secure with setscrew. b. Loosen the inlet wire guide securing screw (3). DIE Wire guides should be installed so that the tip of the guide is as close to the drive roll as possible without touching. c. Insert guide assembly into drive assembly. Secure by tightening screw (3). 2. For 3/32 in.-1/8 in. (.094-3.2 mm) wire. a. Separate anti-wear guide and inlet wire guide. b. Insert anti-wear guide (19) into inlet wire guide (1) and secure with setscrew. c. Loosen the iniet wire guide securing screw (3). Dei Wire guides should be installed so that the tip of the guide is as close to the drive roll as possible without touching. d. Insert guide assembly into drive assembly. Secure by tightening screw (3). OM-1523 Page 15 Des d30 Behind the drive gear are spring washers. To obtain proper alignment of the drive roll on the drive gear with the wire guides rotate the drive gear securing bolt (11) thereby moving the drive roll in or out to the desired position, The drive roll on the pressure gear will locate itself on the wire when the gear cover is replaced and the gears mesh together. 3 - 7. WATER CONNECTIONS (Optional) ELUM ENEE: /f 2 recirculating coolant system is used, do not make connections from the coolant pump to the water valve but rather connect directly to the gun water hoses. Failure to comply may result in damage to the coolant pump and/or gun. A. Installation Of Water Hoses Water coolant is supplied to either one gun or both guns utilizing one water solenoid and the same input, output, and return hoses. The solenoid is energized when the POWER switch is placed in the ON position. Route the hose through the handles on the control/ feeder base and ensure that the hose does not in- terfere with wire feed. Connect a hose from the water supply to the Water input fitting at the rear of the control. This fitting has a left-hand thread. When water is required for one gun only, connect the adapter to the appropriate weld terminal on the drive assembly and connect the water return hose to this adapter. If water is required for both guns, connect the return hose “Y” assembly to an adapter at each weld terminal. Route the water out hose to a proper disposal. 8. Electrical Reconnection Of Water Solenoid The control is shipped connected to supply water when the POWER switch is in the ON position. The water solencid circultry can be modified to supply water when the appropriate gun trigger is depressed. 1. Shut unit down and disconnect from line voltage. dor ANANISIV'BR Placing the POWER switch in the OFF position does not remove power from all of the control's internal circuitry. Completely terminate all electrical power to the controf by removing the 115 volts ac plug from its power supply, and ensure that “machinery lockout procedures” have been emploved on the welding power source's input line (see Instruction Manual on welding power source) before attempting any inspection or work inside the unit. 2. Remove control box wrapper. 3. Locate terminal strip 17 on baffle in control. 4. Right Side Only: To supply water on the right side when the Right Gun trigger is depressed, move lead No. 6 from terminal A on terminal strip 1T to termina! C. Page 16 Left Side Only: To supply water on the left side when the Left Gun Trigger is depressed, move lead No. 6 from terminal A on terminal strip 1T to terminal E. Either Side: To supply water on either side when the appropriate gun trigger is depressed, move lead No. 6 from terminal A on terminal strip 1T to terminal K. | 5. Replace wrapper. 3 - 8. WELDING GUN CONNECTIONS A. Outlet Wire Guides (Figure 3-4) We The outlet guide is provided as part of each gun assembly. | 1. Loosen the outlet guide adjustable knobís) (16). . Tod IB Wire guides should be installed so that the tip of the guide is as close to the drive roll as possible without touching. 2. insert the gun/feeder adapterís) (14) from the guns) which includes the installed outlet guide(s), into the drive assembly opposite the respective inlet wire guide(s) (1) as illustrated in Figure 3-4. 3. Tighten the outlet guide adjustable knobs (16). B. Weld Cables (Figure 3-6) Two holes are provided in the drive assembly for connecting the boom weid cables and the corresponding gun weld cables (see Figure 3-6). Connect the Left Gun weld cable (if so equipped) to the boom weld cable on the left side of the drive assembly and the Right Gun weld cable (if so equipped) to the boom weld cable on the right side of the drive assembly using the supplied hardware. Boom Weld Cables Vent Screw Access Hole Gun Weld integral Gas Cable Fitting Figure 3-6. Gun Weld Cable Connections ТА-081 811 C. Shielding Gas The shielding gas hose from each gun is to be connected to the appropriate gas hose which extends out of the motor end of the boom. Connect the gas hose from the Left Gun to the hose labeled LEFT GAS and the gas hose from the Right Gun to the other gas hose. Integral gas input fittings are provided on the drive assembly for guns utilizing this type of connection (see Figure 3-6). If the gas hoses which extend out of the motor end of the boom are provided with fittings, cut the fittings off and push the hoses onto the appropriate barbed fittings on the drive assembly. See the appropriate welding gun Owner's Manual for instructions on making this connection. D. Gun Trigger Two four-contact receptacles extend out of the motor end of the boom for connecting the gun trigger plugs to the control. Connect the Left Gun to the gun trigger receptacle labeled LEFT TRIGGER, and the Right Gun to the other gun trigger receptacle by inserting the plugs fully into the receptacles and rotating the locking rings. FAL [VI When one welding power source is utilized, both electrode wires will be electrically energized when either gun trigger is depressed. E. Water (If Applicable) If water coolant is required for one gun only, connect the gun water input hose to the water output hose at the motor end of the boom, (If water is required for both guns, the water output hose from the control divides at the motor end of the boom to accept connections from both gun water input hoses). Connect the water return hose from the gun to the adapter at the appropriate weld terminal on the drive assembly. Reducing bushings are provided to accept 5/8-18 L.H. fittings. If the reducing bushings are removed, 7/8-14 L.H. fittings can be accomodated. 3-9. SHIELDING GAS CONNECTIONS - A divided-hose assembly is supplied with the unit for mak- Ing connections to the Shielding Gas input fittings at the rear of the control from one shielding gas source. These fittings have a right-hand thread. If a different shielding gas is required for each welding gun, a separate hose can be connected from each shielding gas source to the appropriate input fitting at the control. | The gas hoses, routed through the boom, connect to the appropriate Shielding Gas output fittings at the front of the control. 3-10. BOOM ADJUSTMENTS (Figure 3-7) A. Weight Lift Adjustment Ensure that during all adjustment procedures, full threads on the adjustment rod are maintained through the yoke. If full threads are not maintained, the hoom may suddenly drop down and cause injury to personnel or damage to equipment. - Adjustment Rod TA-081 757 Figure 3-7. Boom Adjustments The amount of weight which the boom can retract into the upright position when released can be varied by adjusting the jam nut and adjustment rod located at the base of the boom. If heavier guns are installed on the end of the boom thereby making it necessary to increase the amount of weight that the boom can lift, loosen the jam nut and rotate the adjustment rod so that adjustment rod threads into the yoke. When the proper adjustment is obtained, tighten the jam nut against the base of the yoke. If lighter guns are used with the Swingarc, rotate the adjustment rod so that the adjustment rod threads out of the yoke. B. Locking Knob By rotating the Locking knob, located on the side of the swivei plate, in a clockwise direction, the boom may be held in any desired position. Rotating the Locking Knob in a counterclockwise direction will permit the boom to free travel. Changing the position of the Locking Knob to the other threaded holes provided along the side of the swivel plate, limits the lift of the boom to 50 degrees or 40 degrees respectively during free travel. 3-11. MOTOR CONTROL CONNECTION (Figure 3-8) - A receptacle is provided for connecting the motor control plug to the control. Align keyways and insert the plug from the control end of the boom into the receptacle and rotate the plug threaded collar clockwise as far as possible. 3-12. GUN TRIGGER CONNECTIONS (Figure 4-1) - Two receptacles, labeled TRIGGER, are provided on the front panel of the control for making gun trigger control connections. The gun trigger control cables extend out of the control end of the boom. Insert the gun trigger control plug, labeled LEFT TRIGGER, into the gun trigger control receptacie on the Left contro! and the other gun trigger control plug into the receptacle on the Right control and rotate the threaded collars clockwise. OM-1523 Page 17 3-13. WELD CABLE CONNECTION - Two weld cables extend out of the control end of the boom for making secondary connections to the welding power source(s}. The end of each weld cable is equipped with a terminal for a 1/2 in. (13 mm) stud. Connect weld cables to the desired POSITIVE or NEGATIVE output terminal on the appliable welding power source. _. a Left 115 Volts/ DVC Switching : Relay Receptacle Contactor Control Receptacie | © 2 Y Motor Control — Receptacie Right Contactor Control Receptacle Gas Input Fitting TA-046 105 Figure 3-8. Rear Panel Connections Wide /f one welding power source is used, connect the weld cables from the control/feeder to the welding power source POSITIVE or NEGATIVE output terminals as desired. 3-14. 115 VOLTS/CONTACTOR CONTROL CON- NECTIONS {Figure 3-8) A. Using One Welding Power Source The contactor control circuitry in this control/feeder is connected to operate both guns from one welding power source, Align keyways and insert the 115 volts/contactor control piug into the Left 115 Volts/Contactor Control receptacie and rotate the threaded collar clockwise. In- sert the 115 volts power plug into the 115 volts ac receptacle on the welding power source and rotate clockwise. Insert contactor control plug into the welding power source contactor control receptacle and rotate clockwise. Store the remaining contactor control cable. EULER Both electrode wires will be electrically energized when either gun switch is closed. B. Using Two Welding Power Sources Through minor modification, the contactor control circuitry of the control/feeder can be adapted to operate two welding power sources, that is, the left gun trigger governing contactor control to one welding power source and the right gun trigger governing contactor control to the other. Two cables are supplied for making the appropriate connections. RELA IVE Placing the POWER switch in the OFF position does not remove power from all of the control's Page 18 internal circuitry. Completely terminate all electrical power to the control by removing the 115 volts ac plug from its power supply, and ensure that “machinery lockout procedures” have been employed on the welding power source's input line (see Instruction Manual on welding power source) before attempting any inspection or work inside the unit, 1. Remove the wrapper from the control box on the control/feeder. 2. Locate terminal strip 1T on the bottom panel of the control. 3. Disconnect lead No. 39 from terminal K on terminal strip 1T and reconnect it to terminal E. 4. Replace wrapper. Align keyways and insert the contactor control piug into the Right Contactor Control receptacie and rotate the threaded collar clockwise. Insert contactor plug into the right welding power source contactor control receptacle and rotate clockwise. 6. Align keyways and insert the 115 volts/contactor control plug into the Left 115 Volts/Contactor Control receptacle and rotate threaded collar clockwise. Insert the 115 volts power plug into the 115 volts ac receptacle on the welding power source and rotate clockwise. Insert contactor control plug into the welding power source contactor control receptacle and rotate clockwise. 3-15. INSTALLATION OF SPOOL-TYPE WIRE (Figure 3-2) 1. Remove the retaining ring (12). 2. Slide the spool of wire onto the hub (4) so that the wire will feed off the top of the spool. The spool turns in a clockwise direction. 3. Rotate the spool until the hoie in the spool aligns with the pin in the hub (4). Slide the spool onto the hub until it seats against the back flange of the hub. 4. Replace the retaining ring (12). 3-16. INSTALLATION OF REEL-TYPE WIRE (Figure 3-3) 1. Loosen the four wing nuts (3) on the fingers (2) of the wire reel (1). | 2. Pull the four fingers (2) out until they can be rotated toward the center of the reel (1). 3. Install the wire onto the reel {1} over the four fingers (2). Ensure that the wire feeds off the top of the reel (1). The reel (1) turns in a clockwise direction. 4. Rotate the four fingers {2) back to their proper position. Tighten the four wing nuts (3). 3-17. ADJUSTMENT OF HUB TENSION (Figure 3-2) - Check the hub tension by slowly pulling the wire toward the feed roll. The wire should unwind freely, but = the hub tension should be sufficient to keep the wire taut and prevent backlash when the wire feeding ceases. If adjustment is required, loosen or tighten the hex nut (10} on the end of the spindle support shaft (1) accordingly. 3-18. WIRE GUIDE PULLEY AD- JUSTMENTS - The boom is shipped with the wire guide pulleys positioned in the upper sets of holes for running small diameter wires (0.030-1/16 in.) Move the pulley(s) to the lower set{s) of holes for running large diameter wires (3/32-1/8 in.) or if the inlet wire guide or the wire guide tube is wearing excessively. 3-19. WELDING WIRE THREADING SALE Prior to threading the welding wire through the gun, ensure that weld power is not available at the weld head. 1. Install the wire (reel-type or spool-type) as instructed in Section 3-15 or 3-16 on the desired side. 2. Cut off any portion of the free end of the wire which is not straight. Ensure that the cut end is free from rough surfaces to permit proper feeding. 3. Route the wire through the wire guide tube on | the side of the boom, over the wire pulley, and to the drive assembly. 4. Loosen the wing nut on the drive roll pressure adjustment, pivot the pressure adjustment free of the cover, and pivot the pressure gear assembly away until it is in an open position. 5. Feed the wire through the inlet wire guide, past the drive rolls, and on into the outlet wire guide. Feed approximately 4 inches (102 mm) of wire into the outlet wire guide. If when the gear cover is closed, the U-Cog drive rolls are not aligned properly (see Section 3-6), pivot the gear cover away from the drive gear and rotate the pressure gear one tooth. 6. Pivot the gear cover closed making sure the teeth on the pressure gear mesh with the teeth on the drive gear. The welding wire must also be in the grooves of the drive rolls. 7. Pivot the pressure adjustment wing nut until the washer on the pressure adjustment is seated on top of the gear cover. 8. Turn the pressure adjustment wing nut in a clockwise direction until the drive rolls are tight against the welding wire. Do not overtighten. Further adjustment to attain desired clamping pressure can be made after the welding power source and the control/feeder are put into operation. 9. Draw the gun cable out straight. 10. Repeat Steps 1-9 on the opposite side. 11. Energize the welding power source. 12. Place the control POWER switch in the ON position. 13. Depress the Left JOG switch. This will run the welding wire through the Left Gun without placing weld current on the wire. Release the Left INCH switch when welding wire extends approximately one inch out of the gun tip. 14. Depress the Right JOG switch until welding wire extends approximately one inch out of the Right Gun tip. Weld current will not be present on the wire, wena SECTION 4 - FUNCTION OF CONTROLS "N Inches Per Left Purge Button Minute Meter Right Purge Button Right Jog Switch Left Jog Switch — т X Left Wire Speed Right Wire Speed Control Control =. A Left Pilot ————— — Light Fuse чё | — Right Pilot Light Aa I, Circuit Breaker Left Ramote .———— Control Switch Power Switch — Right Remote Left Remote Control Receptacie Control Switch Right Remote Control Receptacle Gas Fitting ee Left Trigger Right Receptacle Trigger Receptacle Gas Fitting ТА-046 154 Figure 4-1. Control Components OM-1523 Page 19 4-1. POWER SWITCH (Figure 4-1) - Placing the POWER switch on the control in the ON position wili apply 115 volts ac to the unit and thereby place it in an operational condition, ready to feed wire and permit shieiding gas to flow from either gun, Placing the POWER switch in the OFF position will shut the control/feeder down. Le AN EIN Placing the POWER switch in the OFF position does not remove power from all of the controf's internal circuitry. Completely terminate all electrical power to the control by removing the 115 volts ac plug from its power supply, and ensure that “machinery lockout procedures” have been employed on the welding power source's input line (see Instruction Manual on welding power source) before attempting any inspection or work insde the unit. 4-2. WIRE SPEED CONTROLS (Figure 4-1) - The ten turn WIRE SPEED controls provide the means of determining the rate at which welding wire is fed into the weld. Rotating the Left WIRE SPEED control in a clockwise direction will increase the rate at which wire is fed from the Left Gun. Rotating the Right WIRE SPEED control in a clockwise direction will increase the rate at which wire is fed from the Right Gun. 4 - 3. REMOTE CONTROL RECEPTACLES AND SWITCHES (Figure 4-1) - The Remote Control receptacles and switches are provided for use in conjunction with certain optional controls. When an optional control is connected across a Remote Control receptacle, the corresponding switch must be in the REMOTE position. If no optional controls are utilized, the Remote Control switches must be in the STANDARD position. 4 - 4. PURGE BUTTONS (Figure 4-1) - The PURGE buttons are momentary contact switches. The Left PURGE button will energize the Left Gas Solenoid and purge the shielding gas line of the Left Gun. The Right PURGE button will energize the Right Gas Solenoid and purge the shielding gas line of the Right Gun. The PURGE buttons also allow the shielding gas regulator(s) to be adjusted without energizing the welding circuit. 5-1. GAS METAL-ARC WELDING (GMAW) 1. Make all necessary connections as instructed in Section 3 of this manual. 2. Rotate the Right WIRE SPEED control until the desired setting is displayed on the inches Per Minute meter. 3. Momentarily depress the Left JOG switch. Rotate the Left WIRE SPEED control until the desired setting is displayed on the inches Per Minute meter. 4, If a remote control is to be used on either or both sides, make connection to the appropriate Remote Control receptacle(s) and place the corresponding Remote Control switch(s} in the REMOTE position. If no remote controls are used, place both Remote Control switches in the STANDARD position. Page 20 4-5. JOG SWITCHES (Figure 4-1) - The JOG switches are spring loaded toggle switches. When ac- tivated, either switch completes the circuit to the motor without having to depress the corresponding gun trigger switch. The Left JOG switch advances the Left wire at the Left WIRE SPEED control setting and the Right JOG switch advances the right wire at the Right WIRE SPEED control setting, without energizing the welding circuits or the corresponding shielding gas valves. 4-6. INCHES PER MINUTE METER (Figure 4-1) This meter displays the wire speed in inches per minute. When the control is turned on, the meter displays the wire speed set by the Right WIRE SPEED control. If it is necessary to set the Left WIRE SPEED, actuate the Left INCH switch momentarily. The meter will then display the setting of the Left WIRE SPEED control. During welding the meter displays actual wire speed as set by the WIRE SPEED control for the gun in use. 4 - 7. RESET CIRCUIT BREAKER (Figure 4-1) - A circuit breaker, located on the upper portion of the control front panel, provides protection to the feeder motor. In the event the motor should be placed in an overload condition, the breaker would trip and suspend all output. Should this breaker trip, the RESET button would have to be manually depressed in order to reset the circuit breaker. 4 - 8. BURNBACK CONTROLS (Optional) - The burnback circuitries in this control provide a means of keeping the welding wires from sticking to the workpiece after the corresponding gun switches are released. The Left BURNBACK control keeps weld current present on the left welding wire and the Right BURNBACK control keeps weld current present on the right welding wire from 0 to 15 cycles after the corresponding wire has stopped feeding. This delay action permits the welding wires to burn back to a point where they neither stick to the workpiece nor the contact tubes. If welding wire sticks to the contact tube, decrease the BURNBACK control setting. If welding wire sticks to the workpiece, increase the BURNBACK control setting. | SECTIONS - SEQUENCE OF OPERATION_— us 5. Place the POWER switch on the control in the ON position. Prior to welding, it is imperative that proper protective clothing {welding coat and gloves} and eye protection (glasses and welding helmet] be put on. Failure to comply may result in serious or permanent bodily damage. 6. Energize the welding power source(s). 7. Turn on the shielding gas at the source(s). 8. Depress the PURGE buttons for one minute. 9. Hold the tip of the desired gun approximately 1/2 inch (13 mm) from the workpiece. 10. Depress the trigger on the gun handle. Gas will start to flow and wire will start to feed if drive roll pressure is properly adjusted to prevent slippage. If wire slippage is noticed, tighten the drive roll pressure adjustment wing nut 1/2 turn clockwise. Repeat until slippage stops. Do not overtighten wing nut. The welding wire and all metal parts in contact with it are energized while welding. Do not touch the welding wire or any metal part making contact with it. Ds SECTION 6 - Nerd Periodically inspect the labels on this unit for legibility. All precautionary labels must be maintained in a clearly readable state and replaced when necessary. See the Parts List for part number of precautionary labels, 6 - 1. INSPECTION AND UPKEEP - Usage and shop conditions will determine the frequency and type of maintenance. Inspect equipment as follows: 1. Make sure welding power source is shut down. 2. Inspect gun for broken areas, cracks and loose parts: tighten, repair, and replace as required. 3. Carefully remove any weld spatter or foreign matter which may accumulate around the nozzle orifice. Use a hardwood stick, never a metal tool. 4. Repair or replace, as required, all hose and cable; give particular attention to frayed and cracked in- suiation and areas where it enters equipment, 5. Remove grease and grime from components; moisture from electrical parts and cable. 6. Blow out the gun wire guide liner with compressed air when changing wire. This will remove any metal chips and dirt that may have accumulated. 6 - 2. CLEANING OF DRIVE ROLLS - Occasionally it will become necessary to clean the wire groove on the drive rolls. This cleaning operation can be performed with a wire brush. To clean the wire grooves it will be necessary to first remove the drive roll(s) {see Section 3-6 for removal and installation instructions). MISA Failure to properly maintain the drive rolls can result in a build-up of wire particles which will decrease the efficiency of the wire feeding operation. 6 - 3. FUSE (Figure 4-1} - The control is protected from damage due to an internal short or excessive overload by fuse F1. Should F1 open, the control would be completely inoperative. 6-4. BRUSH INSPECTION & REPLACEMENT (Figures 6-1 & 6-2) 1. Shut unit and associated equipment off. 5-2. SHUTTING DOWN 1. Turn off the shielding gas at the source(s). 2. Place the POWER switch on the control in the OFF position. 3. Turn off all associated equipment. If welding is performed in a confined area, failure to turn off the shielding gas supply could result in a build-up of gas fumes, thereby endangering personnel reentering the welding area. MAINTENANCE mana mm Placing the POWER switch in the OFF position does not remove power from all of the control's internal circuitry. Completely terminate all electrical power to the control by removing the 115 volts ac plug from its power supply, and ensure that “machinery Jockout procedures” have been employed on the welding power source's input line (see Instruction Manual on welding power source) before attempting any inspection or work inside the unit, 2. Open brush cap by sliding screwdriver under catch and lifting. Remove brush cap. Spring Bracket Brush Pigtail TA-046 226 Figure 6-1. View Of Spring Assembly And Brush When Brush Cap Is Opened 3. Grasp spring retaining bracket with long-nose pliers. 4. Push spring retaining bracket in lightly and move towards brush. This should release the spring assembly and it can be removed. Pull brush out using brush pigtail. If replacement is necessary (brushes are less than 1/4 in. (6.4 mm) in length) disconnect the brush pigtail from the brush box tab and remove brush. 7. Connect new brush pigtail to brush box tab. l.ong-Nose Pliers Spring Assembly a Brush р Brush Box Brush Box Tab NOTE: Spring — assembly hooks here. Figure 6-2. View Of Spring Assembly And Brush From Armature End Of Motor TA-046 226 OM-1523 Page 21 8. Route pigtail through slot in brush box. Ensure that the pigtail will not come into contact with a metal surface. 9. Insert brush into brush box. Ensure that the low end of the bevel on the top of the brush is towards the spring. 10. Using long-nose pliers insert spring assembly beside brush sliding the spring retaining bracket along the brush box wall. The spring retaining bracket hooks on the brush box wall as illustrated in Figure 6-2. 11. If the spring retaining bracket is in place, it will lie flat against the brush box wail when the pliers are released. 12. Ensure that the spring is in the proper position as illustrated in Figure 6-1. 13. Replace and latch the brush cap. 14. Reconnect power to ali equipment and resume operation. Ts SECTION 7 - TROUBLESHOOTI NGC A CCC Hazardous voltages are present on the internal circuitry of this unit as long as power is connected. Disconnect power before attempting any inspection or work on the inside of the unit Troubleshooting of internal circuitry should be performed by qualified personnel only. The following chart is designed to diagnose and provide remedies for some of the troubles that may develop in this unit. It is assumed that proper installation has been made, ac- cording to Section 3 of this manual, and that the unit has been functioning properly until this trouble developed. Page 22 Use this chart in conjunction with the circuit diagram while performing troubleshooting procedures. If the trouble is not remedied after performing these procedures, the nearest Factory Authorized Service Sta- tion should be contacted. In all cases of equipment malfunction, the manufacturers recommendations should be strictly followed. Wire drive motor repairs should be limited to brush replacement (see Section 6-4). Attemp- ting further repairs may result in personnal injury in addition to motor damage. Warranty is void if the motor is tampered with. For further repair and replacement information contact the Factory Service Department. Ensure that all connections to the control and welding power source are secure and that all switches are in the proper position for the welding application before beginning troubleshooting procedures. TROUBLE PROBABLE CAUSE SUGGESTED CHECK AND/OR REMEDY Depressing gun switch will not energize control/ feeder. Electrode wire is not energized, and shielding gas does not flow. POWER switch in wrong position or defective. Place switch to ON position. Replace defective POWER switch. 115 volts open. input fuse Fi *Replace fuse F1. 115 volts ac input plug is not secure in receptacle. Insert plug fully into 115 vac receptacie and rotate plug 1/2 turn clockwise. Plug from gun trigger 1s not secure in gun trigger control cable. Insert plug fully into gun trigger control cable and rotate locking ring. Plug from gun trigger control cable is not secure in TRIGGER receptacle. Insert plug fully into TRIGGER receptacle and rotate locking ring. | Circuit breaker CB1 tripped. Manually reset circuit breaker by depressing the button on the front panel of the control labeled RESET. | Wire feeds, shielding gas flows, but electrode wire is not energized. 115 vac/Contactor Control plug is not secure in contactor receptacle on welding power source. insert plug fully into receptacle and rotate plug 1/2 turn clockwise. | Contactor Control cable leads not secure on contactor plug terminals. Secure leads to plug terminals. Defect in welding power source. See TROUBLESHOOTING Section in welding power source instruction manual. Wire feeds erratically. Pressure on drive rolls is in- sufficient. Rotate pressure adjustment wing nuts clockwise in 1/4 turn increments until wire slippage stops. Drive roll is too large for wire size being used. Change to proper size drive roll. See Section 3-6. Worn drive roll, Replace drive roll. See Section 3-6. Dirt in drive roll. Clean drive roll as instructed in Section 6-2. “it it becomes necessary to replace any fuse in the control/feeder, ensure that a fuse of the proper rating, type, and size is used. OM-1523 Page 23 Weißer NH 1-7 eInBIJ P 3 Ur ASE i CIA IL ANO HAY LANE 9/0 £80-9 "ON WeIBerg 119.19 08 y 1 1838} [5 обв A EL Pe 55 a #57 | [594] a ATI" e = roe AD E— — ADE SHA т E 39 | a Lo AHH WY Y siga | al “| 1 ose но FF Eu : | 8" $ og] es | “aa | 95 42 ar wo Lg ÉS 1 + | 2 e Pones ! Lal gig $F s 1 Teri |< v { ip &s ria IHD P Ela a 7 aA ae on a a A Y HONI-f- = Lo. — —т ATRO 3.0834 LH ILC IY L430 HoT | AS ct MINO DEVOMIAAS 5 25) 19H 62H | IT DNAS | в i r TT a ar он I бела ола L314 140d | WF A #76 > | | LM EEE | | $2 55 db db dd qu 1 ! ACFE Fb BE ZU PE 50/0 мн & | | Er 6 9 HOLOF > am >> | © 220 ¡E RA, E 3015 1431 ' | OtON3106 SYS I | ra — ANO | | — | + 4 1015 LADY 155 TY ONIS | I 7H QIONZ105 5v9 cos zen E HIDDIHL A E | о 1 Gaos | US L J 8? | | y Biota | — = — — I a lr | Sm | | NS | \ OLI bota y € NTF zu I I ev eV ZV a e отн rou dl SY 2 EV Y | «a | ee YY Y YY Y e © + 1 1 < GI e | * * 5d i H— — 1081507 HÔLITLNOS 1431 | | @ TIFYLSNI OL 994594 “гг ЗАСЛ УМО аО NN © SHIVENHNS AHÔIMT 1431 x Р © ar | | 5 br 3 / xHVENENS 137 та OL . ® AZ e ` Аб Id ПД © | | 4 rues > & IW, ACA EL 1334534 HLI | „Но зн пбУЗи сн. L433 LM. NC МОЧИ OL 19345348 HLM SAIYNSYIAV S397 110A TY ; , — NI“ 0 >> > OMINNAD HOLONI-dl 09€ 1Y SWEO4 IAvaA Ty Page 24 March 1982 FORM: OM-1523C Effective With Serial No. JB558742 . Ajquiassy VIEN - v ainbi4 | ‘Alquiasse siy) ul papnjoul 8-201 gv0-GL а 6514-19 syued 10 3S1 syed ul ‘op wal) 99g, q b14 | e LS, \ Ih " TT ) ——— 97 67 A rl == E Za | LA E wr E \ |) OM-1523 Page 1 ~ Quantity _ Item Dia. Factory _ __Model No. Mkgs. Part No. Description ___ 12 | 16 Figure À Main Assembly 1 046 174 CORD, contactor (consisting of).............2200 00000 aa 000100 1 1 2 079 531 CLAMP, cable. ............ ii 1 1 3 PLG3 079 878 . HOUSING PLUG & PINS (consistingof) .. .................... 1 1 4 079535 .. TERMINAL, male 1 pin ..........e eee rex esereeeeeeaeereA. 4 4 5 049 455 , CORD, portable No, 18 2C (order by ft.) .............. e... 10 ft. 10 ft. 6 PLG11 039 635 . CONNECTOR BODY, twistlock 2P2W 20 amp 250 volts ........ 1 1 7 081 964 CORD, control - interconnecting (consisting of} ................. 1 1 8 PLG12 039 635 . CONNECTOR BODY, twistlock 2P2W 20 amp 250 volts ........ 1 1 9 PLG17 039 687 .CAP, twistiock - grounded 2P3W, 5 amp 277 volts ............. 1 1 10 604 571 .CORD, portable No. 18 4C (order by ft.) ..........—.—.—.—_mrecen. 10 ft. 10ft. 11 079531 CLAMP, cable ..... eee 1 1 12 PLG1 048 284 . HOUSING PLUG & SOCKETS (consisting of) ................. 1 1 13 079534 .. TERMINAL, female 1 socket ...................... 00... ".. 4 4 14 049 455 . CORD, portable No. 18 2C (order by ft.) ..............—.—... ….. 2ft. 2 ft. 15 080 418 HOSE ASSEMBLY, gas {consistingof) ........................ 1 1 16 056 851 . FITTING, hose - brass barbed nipple 3/16 TBG ................ 3 3 17 010606 .FITTING, hose-brassnuth/8-16.............. cco, 3 3 18 056 108 . FITTING, hose - brass ferrule 0.425 ID x23/32 ............... 6 6 19 604 550 . HOSE, neoprene No. 1 x3/16 1D (order by ft.)............ e. 041. 11, 20 073 433 . FITTING, brass - barbed male 3/16 TBG x 1/4 NPT ........... 2 2 21 044 858 . FITTING, pipe Y short 1/8 NPT x1/4NPT ................ Ca 1 1 22 073 432 . FITTING, barbed - male 3/16 TEG x 1/8 NPT ................ 1 1 23 051 297 ADAPTER oo ee eee 1 1 24 047 684 CORD, trigger - left 16 ft. (consistingof) ...................... 1 24 047 685 CORD, trigger - left 20 ft. iconsistingof) ...................... 1 25 049 012 CORD, trigger - right 16 ft. (consistingof) .........—.—.—..e.-._c_e_. 1 25 048 618 CORD, trigger - right 20 ft. (consisting of) ................—.—.—... 1 26 PLG2 079 878 . HOUSING PLUG & PINS (consistingof} ..................... 1 1 079 535 .. TERMINAL, male 1 pin een | 4 4 27 079531 .CLAMP, cable ...........e.eonoeoeccrreoecranareererer econo. 2 2 28 605 156 .CORD, portableNo. 18 4C ......... iii, 16 ft. 20 ft. 29 PLG 14,15 080328 .RECEPTACLE W/SOCKETS, free - hanging (consisting of) ..... 1 1 30 079 534 ..TERMINAL, female 1 [email protected] 2 2 31 003 160 HOSE, gas - left 15 ft. (consisting of) ............reee=eee=eee.. 1 31 | 003 159 HOSE, gas - left 19 ft. (consisting of) ...............e.e..—..... 1 32 079 202 HOSE, gas - right 15 ft, {consistingof} .. ...................... 1 32 079 204 HOSE, gas - right 19 ft. {(consistingof) . . ...................... 1 33 056 851 . FITTING, hose - brass barbed nipple 3/16 TBG ............... 1 1 34 010 606 . FITTING, hose-brassnut5/8-18 RH ....................... 1 1 35 056 108 . FITTING, hose - brass ferrule 0.475 ID x 23/32 ............... 1 1 36 604 550 . HOSE, neoprene No. 1 x0.187 ID (order by ft.) ............... 16 ft. 19ft. 37 079 196 . FITTING, brass - barbed female 3/16 TBGx1/4 NPT .......... 1 1 38 010 604 . FITTING, hose - brass bushing 1/4 NPT x5/8-18 RH .......... 1 1 39 046 757 CONTROL BOX (See Fig. B Page 6)..............ee.erereavro 1 1 40 083 687 CORD, motor 15 ft. (consisting of) .............-re-e-veeraena 1 40 083 693 CORD, motor 19 ft. (consisting Of)..............iívrreseererees 1 41 079739 .CLAMP, cable ...............o eccerececeerrerererreccen.. 1 1 42 PLG7 047 636 . HOUSING PLUG & PINS (consistingof} ..................... i 1 43 079 535 .. TERMINAL, male 1 pin ............._e_e.eeeerenneaaaeon 14 14 44 073 179 .CORD, portable No. 16 6/C (order by ft.).................... 15 ft. 19 ft. 45 PLG8 071 892 .RECEPTACLEW/SOCKETS (consistingof) .................. 1 1 079535 .. TERMINAL, male ...... ... iii 0 14 14 OM-1523 Page 2 Quantity item Dia. Factory Model No. Mkgs. Part No. Description 12 j 16 Figure A Main Assembly 46 079 706 CLAMP, cable .............._eeeeecccev.uzavo re dea. enmana 1 1 47 080 415 CABLE, weld 27 ft. left (consistingof} ........................ 1 47 080 940 CABLE, weld 30 ft. left (consisting of) ....................—.—.—.. 1 48 078 992 CABLE, weld 24 ft. right (consistingof). . ............... ee 1 48 078 993 CABLE, weld 28 ft. right (consistingof)....................... 1 49 077 455 . TERMINAL, ringtongue 1/2No.3/Owire ................... 1 1 50 600 323 . CABLE, weld - copper No. 3 (order by ft.) .................... 20 ft 24 ft. bi 600 742 . TERMINAL, ring tongue 3/8 stud No. 3/Owire............... В | 1 52 Figure C BOOM (See Page 10) ..............eereerevcorporearenrenenoo 1 1 53 1079 591 BASE, 4ft.or ........._e_eeeeeeoaiiacoeoroaarecaaaamavn 1 53 1079 214 BASE, Bt... eee, 1 53 1078 264 BASE, 411. OF Li tree, 1 53 1079 216 BASE, Officer ii ii i ieee er tr aa 1 54 1075 390 POST, support - boom 4 ft. (consisting of) or .......... enano 1 54 1079 215 POST, 6 ft. w/o base support - boom (consisting of)............ 1 54 1075 078 POST, support - boom 4 ft. {consistingofjor .................. 1 54 1079 217 POST, 6 ft. w/0 base support - boom (consisting of)..........…. 1 55 080 157 . FITTING, grease 1/8NPT ... 121.111 aa a aa Lea a ea a aa a a aa a ee 0 1 1 56 080 408 GEAR, spur - steel 33 tooth 1/2 bore keyed ................... 1 1 57 080 412 GUARD, motor - gear.........._._.eeerorercocor0evrerroecena 1 1 58 080 419 SPACER, steel 1 OD x 17/32 1D x 1/4 thick ...........—.....—... 1 1 59 080 416 INSULATOR, housing .............eeeereonorcresacoomeseno 1 1 60 072 010 BUSHING, 0.316 IDx7/16x13/16x3/16 ................... 4 4 61 Figure D WIRE DRIVE & GEARS {See Page 12) (consistingof) ........... 2 2 62 079 633 . FITTING, hose - brass barbed nipple 3/16 TBG ............... 1 1 63 080 409 SHAFT, drive - clutch...........oeo.eeocersoer:ttiea a mie... 2 2 64 080 404 GEAR, spur- drive. ...........oeeceeeecmorrnvereeea amaron. 1 1 65 080 411 GUARD, drive - gear..........o _eeeceeoeervedieaererereanoa 1 1 66 010 910 WASHER, fiat -steel SAE 3/8 ............ iii... 4 4 67 602 213 WASHER, lock - steel split 3/8 ..................e—— reseca. 4 4 68 601 965 SCREW, cap-steelhexhd3/8-16x1........................ 2 2 69 601 872 NUT, steel - hex full 3/8-16 .............cec._..—..eeoneseonneo. 1 1 70 080 417 INSULATOR, housing .........eeeeeceneazarognaraceneacao 1 1 71 056 068 KEY, steel 1/8x1/8x1/2........1000 04 ea a ea aa a ea Lan ee nan 1 1 72 047 5563 MOTOR ASSEMBLY (consistingof} ................ count... 1 1 73 080 802 . MOTOR, gear 1/8 hp 115 volts d¢ 2000 rpm {consisting of}. . ... 1 1 080283 ..COVER, brush. ....... cco ieee. 2 2 080 282 ..SPRING, brush ....... ccc ieee cine à 2 2 *080 281 .. BRUSH i a a a ne ea a aan ae en 2 2 74 049 033 .SPACER, housing -tachometer .........02211 2001211 a anne 2 2 75 049 032 .CLAMP, strain - relief ............_o.eeororccceraacoaoreooa 1 1 76 081 627 -, CIRCUIT CARD ASSEMBLY, tach (consisting of) ............. 1 1 OCT 081 711 .. OPTO COUPLER, transistor - transmissive .................. 1 1 Q2 037 200 .. TRANSISTOR, 200MA 40 volts NPN .................— e... 1 1 RS 032 420 ..RESISTOR, carbon. 5watt820chm...................... 1 1 R9,11 039 333 ..RESISTOR, carbon film 0.25 watt 18K ohm................. 2 2 R10 039 328 ..RESISTOR, carbon fiim0.25 watt 1500ohm................ 1 1 77 049 029 . HOUSING, tachometer-feedback ................ cou... 1 1 78 049 031 . SHAFT, extension - armature ........222242000000 000 a ana 12200 1 1 79 045 766 .OPTICAL ENCODER DISC .............. ...0000m0earecie.. 1 1 80 049 030 . COVER, housing - tachometerfeedback ..................... | 1 1 31 081 630 .CORD, motor 17 inch ...............a e. ed0ararerea recae. 1 1 Page 3 Quantity Item Dia. Factory Model No. _ Mkgs. __ Part No. | Description 12 | 16 Figure A Main Assembiy 82 079 739 .CLAMP, cable ...............eoeeecoecerecrrecaaoorieoa 1 1 83 PLG9 047 636 .RECEPTACLE & PINS (consisting of) ...........——_—eeeeeeen.. 1 1 079 535 .. TERMINAL, male ..........oee.eeececarorareorerrerco... 14 14 *Recommended Spare Parts. tParts For Optional Equipment. BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. Quantity Dia. Factory Model Mkgs. Part No. Description 12 16 Parts For Optional Equipment 047 945 BURNBACK CONTROL, left side (consisting of) ..............—._..om-.rr.e.... 1 1 046 023 BURNBACK CONTROL, right side {(consistingof) ............................ 1 1 047 980 . TIMER, delay 20 mil sec/20 sec ................... iit a a eee a ea a ae nee à 1 1 R7,9 074 127 . POTENTIOMETER, Tturn2watt 10Kohm ARE 1 1 024 366 . KNOB, pointer ...........eeeeoeeecenearveaaoaveceaanrrracaonvrerecxaer. 1 1 079 589 WATER CONTROL KIT, one side (consisting of) ................eem erre... .. 1 081 052 WATER CONTROL KIT, one side {(сопя Ипа о?) ..... 2..2... к.кв кк квкккккы 1 080 100 WATER CONTROL KIT, both sides (consisting of) ........................... 1 081 054 WATER CONTROLKIT, both sides (consistingof) ........................... 1 WS1 035 601 . VALVE, 2 way 1/4 IPS port 1/8 orifice (consisting of) (or) ................... 1 1 +033 050 . . COIL, 115 volts ac (Singer Controls).. RR 1 1 WS1 053 894 . VALVE, 2 way 1/4 IPS port 1/8 orifice (consisting of) . ...................... 1 1 + 053 964 ..COIL, 115 volts ac (Eemco) .................... 0... narecanronearoro 1 1 010 295 . FITTING, hose - brasselbowmale 1/4 NPT xb/8-18LH..................... 2 2 010 190 . FITTING, pipe - galvanized nipple L1/4 NPT _..... iii. 1 1 602 934 . FITTING, pipe - galvanized coupling 1/4 NPT... ....... iii. 1 1 056 296 . TUBING, plastic No. 4 ............eeesreccrrvccacrrroroorereracerone nee 1 1 010 141 . CLAMP, nylon 1/4 clampdia ........... iia aaa ean 1 1 010 378 . GROMMET, rubber9/16 ID x3/4mountinghole............c.c 0 iii. 1 1 + +079 773 . ADAPTER, terminal -water/electrode ......... ....... iia, 1 1 + +008 657 . FITTING, hose - brass bushingreduceb5/8-18LH......... cc... o.oo... 1 1 000 571 HOSE, water TO ft. ... oe ee eee eines 1 1 000 570 . HOSE, water 16 ft. (kit for one side).......1200000 044400 0 0 4 a a a a 0 ea a ee ee 6 1 000 572 . HOSE, water 19 ft. (kit for one side). ...................e.rreerd0crerereme. 1 080 499 . HOSE, water 12 ft. (kit for both sides) .................e-—...erresvvarecen 1 081 501 . HOSE, water 19 ft. (kit for both sides) ................eeexerereanerar e 1 000 573 . HOSE, water 25 ft. (kit for one side). ....................reeea0caxnmarrrece. 1 000 569 . HOSE, water 29 ft. (kitfor one side). ...............00c-6-686eesemereoacarena 1 080 500 . HOSE, water 25 ft. (kit for both sides) ................._—..es.emaceecoarv—.. 1 081 502 . HOSE, water 29 ft. (kitforbothsides) ............ co iii... 1 048 471 TOOL, extraction - pinamp ...............—...eecrcu.uircrrrreooecanrievane. 1 1 045 503 LOCKING COVER .. RER лк кв кк a 0 0 1 1 + When ordering coils be sure to provide manufacturers name. + + When using kit for both sides the quantity is 2 reg'd. for these items. BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. OM-1523 Page 4 xog [9U09 - g 94n614 801 970-aL ELL ELL ® > o 07 9L Sel veL 221 221 121 LEL OEL 6CL SEL 72) ДИ 9LL GLL LLL sal 991 091 6SL Раде 5 item Dia. Factory №. Mkgs. Part No. Description Quantity Figure B 046 757 Control Box (See Fig. A Page 2 Item 38) 111 1047 101 WRAPPER.............oeoewrrcrrecoreseciaceaererevreconacoriereconee— 1 047 497 LABEL, general precautionary ........._——r—ecesmsrrrrtcererrorrrecccon. 1 112 R45 603 856 POTENTIOMETER, WW slotted shaft 10 turn 2 watt 10K ohm ............... 2 113 51 011 233 SWITCH, toggle SPDT 10 amp 250 volts ac ........e..eeeescrrenreccemne 1. 114 CB1 011 991 CIRCUIT BREAKER, 1 pole 1.5 amp 250 volts .........e..eeeerearresrenn.. 1 115 080 148 SOCKET, relay 11 pin ........._._..0.00.-.ee00aurroetiraroennenerrecracen. 3 116 027 811 CONNECTOR, 14 pin ..............eeesmrecaamerrerrerrerorerecacen er. 1 117 079 844 SPRING, holddown - relay ............eeeeeesoeoecenverooramenreraaveme 1 118 CR3 081 797 RELAY, enclosed - 24 volts ac 4APDT..............__—rrrrecvresrererocane. 1 119 CR1,2,6 080388 RELAY, enclosed - 24 volts ac 3PDT........222202200 000 0e aa 0 ea sea a cena ne 3 120 R3 079 497 RESISTOR, WW fixed 2b watt2000o0hm......... ccc iit 1 121 R1 030 661 RESISTOR, WW fixed2bwatt10ohm......... cian 1 122 601 219 LINK, jumper -terminalblock20amp ........... cc iii ities 4 123 REC] 048 283 RECEPTACLE W/PINS {consisting of)... ......... i iii. 1 079 535 TERMINAL, male 1 pin... iit ieee ee a a aa aa 0 eee 06 4 RCZ, 124 33,13 048 282 RECEPTACLE W/SOCKETS (consisting of) ........e.._......eerveenecerv о 3 079 534 . TERMINAL, female 1 socket ...........oeeeecororvervroena ra recuecen e 4 048 144 TERMINAL, male 1 pin plug - keying (used withRC3) ...................... 2 125 047 100 PANEL, mounting - receptaciles............._——_—e_s_resccrrorrerrecee are 1 126 RC4,10 056 266 CONNECTOR, female 6 contact 7.5amp..........—r—eceeeeeseervecorerer.. 2 127 079 683 HEAT SINK, resistor..........._eeoreooramaaorearecarnoronrvrecoro nera. 1 128 604 311 GROMMET, rubber 1/4ID x3/8mountinghole ............... cova... 1 129 010 193 TUBING, steel 3/8 OD x 18 ga wall x 1/4 .............—e—.—_—_—.—errrcereormen ve. 6 130 010 199 TUBING, steel 0.275 ID x 0.048 wall x 1 ............e.e.-rrerrsreenvecreace. 2 131 030 949 HEAT SINK, rectifier............eeressroaacaaeareooenrrrrracarora ron. 1 132 056 170 SHIELD, wire - feeder .............o..receeoreri va reeneerereecmere ae aa 1 133 R2 030 941 RESISTOR, WW fixed 100 watt 5ohm.........—.—__eooonorreraanenreranee. 1 134 026 837 INSULATOR, terminal - nylon ............—e—e—eresrrecnnororrecarere raro 3 135 CR4 034 841 RELAY, 24volts aC DP DT ii 4 a 44e eee a a a a a a ee a a ae 1 136 RC18 054 116 CONNECTOR, female 4 contact 10 amp. ...........eeeo.erecireooreneece. 1 137 SR1 035 914 RECTIFIER, integrated 30 amp 400 volts. ..............e..e..e0eneconeorena 1 VR1 082 722 VARISTOR,0.6watt 178 vols... .. oie ist eee eee 1 138 НС 047 637 HOUSING RECEPTACLE & SOCKETS (consistingof) ..................... 1 079534 . TERMINAL, female 1 socket ............eoeeresenerececacereranarerero 14 139 — 047 123 STAND-OFF, No. 4-40 x2-5/8 ............ee0e.serervereríecacer nee. 4 140 071 642 CIRCUIT CARD, motor speed (See Fig. В1 Раде 8}. ....................... 1 141 RC5 073730 CONNECTOR, edge 22 pin ............._...ee.sservrsvrooravoreer eva a nro 1 142 C1 031 692 CAPACITOR, electrolytic 750 uf 200 volts de. ...........e.__..eee.reoraaom 1 143 006 426 BRACKET, mounting - capacCitOr. iii ieee. 1 144 PLGA4,10 056 2656 CONNECTOR, male 6 contact 10 amp 730 ВМЗ . ...... iinet, 2 145 010 296 FITTING, hose - brass male 1/4 NPT x5/18-18RH............. coo... 4 146 GS1,2 035 601 VALVE, 115 volts ac 2way 1/4 IPS 1/8 orifice or (consisting of). ............. 2 +033 050! . COIL, valve 115 volts (Singer Controls) ...............——__..e00siírireao. 1 146 6GS1,2 053894 VALVE, 115 volts ac2 way 1/4 1PS 1/8 orifice (consisting of) ................ 2 +053 964 .COIL, valve 115 volts iEemco) .........._..eeeoñeoeecenarreeooooarecade a 1 147 079 573 FITTING, pipe - galvanized nipple L 1/4 NPTx6 .............—5smvecuxrme.. 2 148 046 754 BRACKET, mounting - gas/water ...........Ñ.c_eeee.eeeeo0eeesreeai eo, 1 149 602 934 FITTING, pipe - galvanized coupling 1/4 NPT ..............e.em...—.rrcer 2 150 F1 036 135 TRANSFORMER, control 115-24 voitsac............02002004 04 aa caen La La 1. 151 1T 038 782 BLOCK, terminal - 20 amp 10 pole. ................ 0000... reee. 1 152 047 102 BRACKET, mounting - relayS. 2... .rec0corrarenoenaa 1 153 048 029 CLIP, retaining - socket relay .................—.—.—.—.—esr000rea.ererao aa. 1 154 53,5 911 232 SWITCH, push button SPDT.................. 2... a aa a aa ea a ea ea aa 2 155 852,4 011 043 SWITCH, toggle - DPDT multiple contact 6 amp 125 volts .................. 2 156 56,7 011 770 SWITCH, toggle - SPDT 5 amp 125 voits.. 111040000044 eau a sea aa 2 OM-1523 Page 6 Item Dia. Factory No. Mkgs. Part No. Description Quantity Figure B Control Box (See Fig. A Page 2 Item 38) (Cont'd.] 157 RC16,19 073687 RECEPTACLE, 4 socket MS-3102A-14S-256 ..............eerecererereva 2 158 046 751 CASE SECTION, front/bottom/back ..........eeoeoosoeee0errredoorereeoo 1 159 PL1,2 027 645 LIGHT, indicator - red lens 125 volts ac............ee.eereerescorrrreneao 2 160 024 366 KNOB, pointer ..............o_n.ericororrriacarivrecor»narenreaeroaeno 2 161 F1 *073 426 FUSE, miniature-glasssloblobamp ......... oii einen, 1 162 012 617 HOLDER, fuse - miniature (consisting Of). ............._.—.—.....0.00m--. e... 1 163 059 139 . CAP, holder-fuse.............002014 LL LL LL Aa aa a aa aa Lan ea aan 1 164 RC6 028 598 CONNECTOR, edge - circuit card 15 socket ..................._eeéececr... 1 165 081 798 METER, digital ............... RR RR a a ea a a a aa 1 166 031 643 CAPACITOR, ceramic 0.01 ufb00voltsdec. . ........ co... ee 1 167 NAMEPLATE (order by model & serialnumber)... ......................... 1 O 0208 1050 | Е [Th] Te) ЗОО НС > > | ceo Re? =D a 5 5 ED X (©) - VS == [Rag <C68 > ( ~ EE a с С = as cd E a В: @ © [Ris] | cea | ces (À T50 ¡E < ER = Q 8° Eos 0099 ее A an. 66 = =) 5 CR50 = Ta o С - al @50 > TES _ ABCDEFHJKLMNPRSTUVWXYZ COMPONENTS TO BE REPLACED BY "QUALIFIED PERSONNEL ONLY Figure B1 - Circuit Card, Motor Speed | B-047 869-A *Recommended Spare Parts. t When ordering a component originally displaying a precautionary label, the label should aiso be ordered. + When Ordering Coils Be Sure To Provide Manufacturer's Name. | BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. Page 7 Dia. Factory Mkgs. Part No. Description Quantity Figure B1 071 642 Circuit Card, Motor Speed (See Fig. B Page 6 Item 140) А50-53 009 159 AMPLIFIER, operational 32 volts de .............._—e—em2eerrervreneerereren e. 4 C50 039 482 CAPACITOR, electrolytic 100 uf 35 volts dc .........200202 1100210000 e ea see 0 06 1 CS1 031699 CAPACITOR, mylar 0.0022 uf 200 volts de .............e_..es2eserexrerere 1 Ch2,61 073 739 CAPACITOR, ceramic 0.1ufB0volts . . . .... iii ee ieee 2 C53,62 035 833 CAPACITOR, myiar 0.033 uf 100 volts de ...........eem_e..-ee.02eseeaverece 2 C54 005 023 CAPACITOR, tantalum 2.2 uf 20 voits.........2220400 440000 e ea see ae a access 1 C55, 66-75,77 031 643 CAPACITOR, ceramic0.01 ufb00voltsdc . .......... oc iin, 12 C56 073 549 CAPACITOR, mylar0.015 uf200 volts ...... commie 1 C57 031 677 CAPACITOR, tantalum 5.6 uf 35 volts dc .......22200000 2002 see ae ace es 2 C60 035 561 CAPACITOR, mylar 4 uf200 volts .............._.-eeeorredcrceaaoenedene eee. 1 C63,64 031 694 CAPACITOR, mylar 0.47 uf 200 voltsdc .......12202120000 0 aa ae ae nan aa aa 00 2 C65 031 721 CAPACITOR, mylar 0.22 uf 200 volts de .................e00eresaaaooreaZ.. 1 . CR50 081 797 RELAY, enclosed 24 volts ac 4PDT ................ ee ite eee 1 D50-54, 56-60 026 202 DIODE, rectifier 1 amp 400 volts straight polarity ................_ec_eoexcxecre00 10 D55 080 910 DIODE, zener 15 volts5Dwatt..........__.eoeeoecerenerorrerrecanerene recae 1 1С50 081 800 INTEGRATED CIRCUIT, converter .............eereeeeroaerecarorenrenre—.. 1 Q50,53 037 200 TRANSISTOR, 200 MA 40 voits NPN 1.222000 4 a 401112 0 aa aa seen a sa ea eue» 2 051 037 824 THYRISTOR, SCR 7.4 amp 200 vOolt$ . eK ARE ERA 1 Q52 039 355 TRANSISTOR, unijunction 15 MA 40 VOIS. . o.oo otic 1 R50 030 839 RESISTOR, WW fixed 5 watt 220 ohm 122020204044 a aa aa ea a a eee» 1 R51,53-55,57, 63,67,68,74,75, 81,82,85,89 035 827 RESISTOR, carbon film 0.25 watt TOK ohm .......... iin. 14 R52,56,61 052 138 RESISTOR, carbon film 0.25 watt 20K ohm «Lo ooo tite eee ee eee ees 3 R58,62,65, 66,71,72, 76,77,90 035 884 RESISTOR, carbon film 0.25 watt 100K ohm ....... cc ii iii i iin 9 R59 030 007 POTENTIOMETER, cermet trimmer 15 turn 0.75 watt 50K ohm ................. 1 R60,87,88 039335 RESISTOR, carbon film 0.25 watt 47K ohm ............. oii... 3 R64 039 331 RESISTOR, carbon film 0.25watt4700 ohm... .......... iii 1 R70 049 015 RESISTOR, carbon film 0.25watt10megohm................ oot. 1 R73,83 039 328 RESISTOR, carbon film 0.25 watt1500ohm........ ccc. iia. 2 R78 039 108 RESISTOR, carbon fim0.25 watt82Kohm............ ci aio... 1 R79 039 106 RESISTOR, carbon film 0.25 watt 470 ohm ........... iii а 1 R80 035 886 RESISTOR, carbon film 0.25 watt 22K ohm...........—._.—._—.eeeeerenecmcoe. 1 R85 030 937 RESISTOR, carbon. bwatt10ohm......... iii iii, 1 R86 030 090 RESISTOR, carbon0.5wattd7 ohm. ...... K KK 1 T50 036 143 TRANSFORMER, pulse controi ........120201000 44410000 aa a a aa eee ea a a aa a 0» 1 VR50 081 799 REGULATOR, voltage8 volts3terminals . ............... coon. 1 VR51 047 272 REGULATOR, voltage 12 volts3terminals. ................... oii... 1 079 844 SPRING, holddown -relay . ....... iii iii 1 1 10000 1 079 843 SOCKET, relay............_..ececaccroecorereaeiaecarecrearereecnm e" 1 037 261 HEAT SINK, rectifier...........200 022020014444 ea sea ea 1 ea eee ae a en ee een 1 BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. OM-1523 Page 8 woog - J adnbi4 g-2¢5 180-01 ——— €GL 661 002 102 002 CLL ELL TLL ‘| 181 081 6ZL 8ZL LLL - 9CL Page 9 Quantity Item Factory Model No. Part No. ; Description 12 | 16 Figure C Boom (See Fig. À Page 3 Item 52) 171 010 313 PIN, cotter- hair 0.072 x 1.437 long........22220 004 a a 0 0 aa 0e ee ea a aa aa un 6 4 4 172 079 622 BUSHING, nylon 0.622 ID x 0.075 0D x 0.501 thick . ............... ree 4 4 173 079 621 PULLEY, V single groove ...... ee ee a a aa a aa a + 2 2 174 079 632 BOLT, Usteel 1-5/8 highx1-1/8widex 1/4... ...... cco... 8 10 175 079 667 PIPE, plastic 1/2 X 133-3/4 oi KK a ae 00 0 ry 2 175 080 812 PIPE, plastic 1/2x 181-3/4 ee eter 2 176 079 665 GUIDE, wire .............o.eeeerorrerecorarecer enyar torreon nooracer. 2 176 080 811 GUIDE, wire ................. 00. a n0rarecicoaoraaremenecarercaneme 2 177 079 664 GUIDE, inlet .............—._.....—e—eeeerraaarecaraavrearaaoocanevacoren. 2 2 178 007 280 PIN, clevis 5/8-18 x 1-7/8 long ............—..e..e.errerreconer erre 1 178 073 742 PIN, clevis 3/4 OD x2.156 long ..........._eereexvordsar2eraceneenapero, 1 179 045 391 TUBING, neoprene 3/81D x 3/32 wallx8........ La ee a a a a aa aa ea ana Nu a 6 2 2 180 605 538 CABLETIE .......2202 22440424 AA a ee 4 4 4e ee 8 a a a a ee ee ee a a aa ea eau 2 2 181 045 390 LINER, monocoil 3/32-1/8wirex9 1.110200 24014 a ee 4e ea aa a see a ea a 2 2 182 007 279 CLEVIS LL. 112110024444 ee a a da ee ee eee RR 1 182 073 741 CLEVIS ...............00000rírrveear ar eacerCaraavrerreneoceceneror vna 1 183 601 883 NUT, steel - hex jam 5/8-18................,0.000000 00800 rv rara a aa 120 2 183 605 884 NUT, steel - hex half 3/4-16 (top of shaft) ................e..---rred0c0o. o... 1 183 079 029 NUT, hex -full3/4-16 (bottomofshaft) ............ ccc... .. eee 1 184 007 995 SHAFT, boom - counter balance..........10220200 0000 0 eee ea ea a aa a aa aa aa 1 184 075 462 SHAFT, boom - counter balance............22201000000 04 4 aa aa a na a ae aa ann 1 185 Figure C1 SUPPORT, hub & reel (See Page 11)...................0s00000rea.arenpan 1 1 186 079 020 NUT, steel - hex elastic stop 3/4-16 ................000....e00resoricece.. 1 1 187 602 250 WASHER, flat - steel SAE 3/4 1111120444 114 a 4e a a a 8 4 ieee a ae ea a aa nue 2 2 188 602 249 WASHER, flat - steel GAE 5/8 LL... 10211124 a a ae a a aa a a a ea ee a a a a aa» 1 188 075 102 WASHER, steel shield 3 inch square ............._......-2029eoc0sirre00 ere... 1 189 024 505 BEARING, bail ................. a A aa de a a ea a ea de a ae ra 1 189 073 664 BEARING, ball ............... 2222000000 aaaoaioo0nonaCec,n a aa aa о 1 190 075 100 NUT, steel 5/8-18 x 1-1/4 special ................0000.. RE 1 190 075 101 NUT, steel 3/4-16 x 1-1/4 special .................700000 000. | 1 191 602 219 WASHER, lock - steel external tooth 5/8 ...............e——._e-reeceaoreere ze. 1 191 079 030 WASHER, lock - steel external tooth 3/4 ......LLL 1211212 a a ae Lea ea a aa ane 1 192 080 449 SPRING, compression 2OD x 1IDx 12.....11211 RR уе куе, 3 192 080 723 SPRING, compression 3-3/8 OD x 37-3/4 111111111101 seein 1 193 075 421 SPACER, spring - BOOM «Le at aa ae ana a Ra Lena een 1 194 075 403 BEARING, thrust - booem..............—.—.—.—.e0ee0e00raeaorennoredreaawerecano 1 195 072 091 BASE, swivel - bbom.............eee0sreaiareneraceo00ereraconanacere. 1 195 1072 083 BASE, swivel - bbom .................ececocc.erecorecrrecececerecececo, 1 047 497 LABEL, general precautionary ................eecreorooreran e erario, 1 1 196 602 246 WASHER, flat - steel 1/2 ................ LL Aa da aa a aa LL 1 1 197 047 224 KNOB, T Bar ...............o.erereereroeorenarecarecenederarameoonoea 1 1 198 073 666 BOLT, machine - steel hex hd 3/4-16 x 2-3/4 ................ 9... e. eco. 1 1 199 082 964 BOOM, dual 12 ft. ......... RR 1 199 082 965 BOOM, dual 16 ft... e... .earecacreradaCecennnara ca onmoa 1 200 601 872 NUT, steel - hex full 3/8-16 ..................... RR RR aa aa 4 4 201 602 213 WASHER, lock - steel split 3/8 .....................?..0060.. reccarerero. 4 4 202 079 631 BRACKET, hanger-gun................. a ee RR 2 2 203 079 643 GUARD, motor-protector...........1.1100102000 0 eee eee eee eee 1 1 204 082 970 SHAFT, PUNY «oot ee ee ee ana ana 2 2 TWhen ordering a component originally displaying a precautionary label, the label should also be ordered. BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. OM-1523 Page 10 Item Factory No. Part No. Description Quantity Figure C1 Support, Hub & Reel {See Fig. C Page 10 Item 185) 211 080 393 SUPPORT, reel + ov cee ett ee ee ee nannrnvecarocenrarao ene 1 212 010 191 WASHER, fiber 5/8 ID x 1-1/2 OD X 1/8 oo. i i i tee 1e a 111 кух. 4 213 058 628 WASHER, steel - brake .............o_eecoére:eniereavecararorent 0 eaceaerenm.. 4 214 058 428 HUB, spool ..............oesnerccaarenidecererorecrerecororecereconrertece. 2 215 057 971 WASHER, flat - steel keved 1-1/2 dia .........._.ree000r0a0r rea ieraarenereea.. 2 216 010 233 SPRING, compression ........._—_eeerecodrnvscoeneramerrrreorvran e nrererer. 2 217 605 941 WASHER, flat - steel 41/64 ID x 10D .............r0r0c000xrraraeoereneran ere... 2 218 601 884 NUT, steel - hex 5/8-11 RR RR RER RR KR RE 2 219 058 427 RING, retaining - spool.............._— re. reserererererer ninia aa ec 0 2 220 1056 416 REEL, wire (consisting Of)... RR a ea ee ane» ... As Req'd. 221 604 051 . NUT, steel - wing 1/ 2-13 ........... eee RR RR A A a ee ee ae 4 222 056 312 . FINGER, reel ... coo ee ee eee eee eee cea 4 223 056 313 . STUD, steel 1/2-13 x 7 center drilled iri ieee 4 224 010 224 . PIN, Spring - compression ...............oeeeeecrreorar ao ríearevoreaeo en as 4 225 601 880 .NUT, steel - hexjam 1/2-13 Loo ee a ea see ee a ea en 4 226 056 314 REEL ee ee ee ee 0 1 211 \ u | 212 213 214 Figure C1 - Support, Hub & Reel tParts For Optional Equipment. BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. Page 11 216 217 218 219 TC-081 760 item Factory No. Part No. Description Quantity Figure D Wire Drive & Gears (See Fig. A Page 3 Item 60) 234 082 036 GUIDE, inletwire.............ceeeeoecoee-ceeeorerisecuroreevcererecever re. 1 235 082 050 LINER, monocoll intetwire.......... ee _eñeeeereree... ere aa 1 236 604 612 SCREW, set - socket hd 8-32 x 1/8 ... iii i iii itn ranean 1 237 045 233 GUIDE, anti wear ..........._eeoceorrircdoorerernoaaroorttrnvecorcnrericaamen. 1 238 081 801 WIRE DRIVE (consisting of) .................0..0eererrererrecacern rr e. t 239 604 590 . NUT, steel -wing3/8-16...... ee ere eee area 1 240 010 910 WASHER, flat-steel SAE 3/8 .... iii eins eee 1 241 010 231 .SPRING, compression ........_..eeoecrracareorvaroeroearerecermerreravarer. 1 242 056 306 .FASTENER, pinned .............oe_errecrrereo annnorcacaraaaanenvdau enn, 1 243 602 243 .WASHER, flat - steel 3/8.........c.orrreoorerccmeacarrtredecorvorev rene e. 1 244 010 232 .SPRING, compression ........e——.—.ee.eeremerrscacrarereren. eee aaa 1 245 010 224 . PIN, spring-compression 3/16 xT Litt iii i aia e 0» 1 246 601 925 .SCREW, cap - steel hex hd 1/4-20 X 1/2. ..0.0000000000004 0400 00ER 1 247 604 741 .PIN, cotter - hair 0.042 x 15/16 .... ii ere eae 2 248 079 669 .LEVER, mounting - pressure Gear... KK KK KR en nece 1 249 079 634 PIN, hinge ... coi i ii ieee a aaa aaa 1 250 080 413 . RETAINER, bearing ........o_e_.eoorecreroreenmoerraartecararerereecor ena, 1 251 079 772 .KNOB, plastic .............eeeeeesaerenarrerecorerarecorvrreraeeaecenarcen 1 252 604 538 .WASHER, flat - steel SAE5/16 .............eeeaorerecovecvororerresacereerne, As Reg'd 253 080 403 . HOUSING, adapter - gun/feeder ..........._._eeeoeemreccceceeaaaorararceanonr a 1 254 028 342 .BEARING, ball.................—.e.._e_ee_eecrvecuarrareaarooarornv een 1 255 053 842 GEAR, spur- insulated w/bearing ...........—._—e—e_e_e_w_m_reecvenverrresserovrcerao 1 256 605 518 SCREW, cap - steel hex hd 1/4-20 x 1-1/4 ................ee=enervaereraao or TA 1 257 079 626 SCREW, machine - steel fillister hd 10-32 x 7/8 .............—._—ee=—esrerrvradenvorev. 6 258 010 193 TUBING, steel 3/8 OD x 18 ga walix 1/4 iii ieee, 1 259 048 336 COVER, Stop .........222204 004040 aa ea a ee de ae ee ee ea ae ea ea ea es a an ea ae 1006 1 260 602 241 WASHER, flat - steel SAE 1/4 i a ae a sa ae a sean 0 0 1 261 000 418 SCREW, cap - steel hex hd 1/2-20 x 1/2 setf-locking ..........—.—e——r—eeeereemereaaas 1 262 053 841 GEAR, spur - insulated w/key ..........e..e-eeerevereresonerendocrarecenrecrninDe 1 263 079 625 WASHER, spring - steel 5/16 shakeproof ............._..ece.errrrreeseoror rre. 2 264 080410 GUARD, drive roll .............e —.reecerrveerrerrecamerenerareanarcen A ee 1 includes Items 250-254 255 257 Figure D - Wire Drive & Gears BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. TC-081 523-B OM-1523 Page 12 LER Base selection of drive rolls upon the following recommended usages: 1. V-Groove rolls for hard wire. | 2. U-Groove rolls for soft and soft shelled cored wires. 3. U-Cog rolls for extremely soft shelled wires (usually hard surfacing types). 4. Split V-Knurled rolls for hard shelled cored wires (self-shielding and CO2 shielded types). 5. Drive roll types may be mixed to suit particular requirements (example: V-knurled roll in combination with U- groove). _ Wire Diameter & Type Kit No.* Roll Drive | Inlet Wire Fraction | Decimal | Metric Part No. | Type Guide 030" | .030 | .8MM | 079 594 | 053 695 | V-groove | 056 192 035” | .035 | .9MM | 079 595 | 053 700 | V-groove | 056 192 045” | .045 | 1.2MM | 079 596 | 053 697 | V-groove | 056 193 052 | .052 | 1.3MM | 079 597 | 053 698 | V-groove | 056 193 1/16” | .062 | 1.6MM | 079 598 | 053 699 | V-groove | 056 195 035” | .035 | .9MM | 044 749 | 072 000 | U-groove | 056 192 045” | .045 | 1.2MM | 079 599 | 053 701 | U-groove | 056 193 052” | .052 | 1.3MM | 079 600 | 053 702 | U-groove | 056 193 1/16” | .062 | 1.6MM | 079 601 | 053 706 | U-groove | 056 195 5/64” | .079 | 2.0MM | 079 602 | 053 704 | U-groove | 056 195 3/32" | .094 | 2.4MM | 079 603 | 053 703 | U-groove | 056 196 7/64” | 110 | 2.8MM | 079 604 | 053 705 | U-groove | 056 196 1/8” | .126 | 3.2MM | 079 605 | 053 707 | U-groove | 056 197 035” | .035 | .9MM | 079 606 | 079 726 | V-knurled | 056 192 045” | .045 | 1.2MM | 079 607 | 079 728 | V-knurled | 056 193 052” | .052 | 1.3MM | 079 608 | 079 727 | V-knurled | 056 193 1/16” | .062 | 1.6MM | 979 609 | 056 771 | V-knurled | 056 195 5/64” | .079 | 2.0MM | 079 610 | 056 773 | V-knurled | 056 195 3/32” | .094 | 2.4MM 079 611 | 056 774 | V-knurled | 056 196 7/64” | .110 | 2.8MM 079 612, 056 775 | V-knurled | 056 196 1/8” | .126 | 3.2MM | 079 613 | 056 776 | V-knurled | 056 197 045” | .045 | 1.2MM | 083 318 | 083 489 | U-cogged | 056 193 052” | .052 | 1.3MM | 083 317 | 083 490 | U-cogged | 056 193 1/16” | .062 | 1.6MM | 079 614 | 053 708 | U-cogged | 056 195 5/64” | .079 | 2.0MM | 079 615 | 053 710 | U-cogged | 056 195 3/32” | .094 | 2.4MM | 079 616 | 053 709 | U-cogged | 056 196 7/64” | .110 | 2.8MM | 079 617 | 053 711 | U-cogged | 056 196 1/8" | .126 | 3.2MM | 079 618 | 053 712 | U-cogged | 056 197 Drive Roll & Wire Guide Kits *When ordering replacement parts all kits listed with the exception of the V-KNURLED kits are one piece drive rolls. Two drive rolls are required for the one piece drive kits and four drive rolls for the split V-knurled kits. See Section 3-6 in Owners Manual for identification of parts. Page 13 Factory BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. Part No. Description Common Hardware 602 062 SCREW, machine - steel round hd 4-40 x 3/8 602 143 SCREW, self-tapping - round hd 6-32 x 3/8 602 070 SCREW, machine - steel truss hd 6-32 x 3/8 602 072 SCREW, machine - steel truss hd 6-32 x 5/8 604 804 SCREW, sheet metal - hexagonal washer hd No. 8 x 3/8 605 1561 SCREW, machine - steel fiat hd 8-32 x 3/8 602 080 SCREW, machine - steel round hd 8-32 x 3/8 602 144 SCREW, self-tapping round hd 8-32 x 3/8 602 088 SCREW, machine - steel round hd 10-32 x 3/8 605 188 . SCREW, self-tapping hex hd 10-32 x 3/8 602 089 SCREW, machine - steel round hd 10-32 x 3/8 602 109 SCREW, machine - steel round hd 10-24 x 1/2 601 925 SCREW, cap - steel hex hd 1/4-20 x 1/2 078 620 SCREW, cap - steel socket hd flat hd 1/4-28 x 1/2 605889 SCREW, cap - steel hex hd 1/4-28 x 1/2 601965 SCREW, cap - steel hex hd 3/8-16 x 1 049 069 SCREW, machine - steel flat hd 5/16-18 x 1-1/4 602 164 SCREW, self-tapping hexagonal washer hd 1/4-20 x 1/2 602 131 SCREW, machine - steel round hd 1/4-20 x 2-1/2 034 055 BOLT, machine - steel hex hd 1/4-20 x 2-1/2 602 243 WASHER, flat - steel 3/8 010910 WASHER, flat - steel SAE 3/8 602 196 WASHER, lock - steel internal tooth No. 4 - 602 198 WASHER, lock - steel split No. 6 602 200 WASHER, lock - steel split No. 8 602 203 WASHER, lock - steel split No. 10 602 207 WASHER, lock - steel split 1/4 602 211 WASHER, lock - steel split 5/16 604 538 WASHER, flat - steel SAE 5/16 602 213 WASHER, lock - steel split 3/8 010 929 WASHER, flat - steel spring 3/8 601859 NUT, steel - hex 6-32 601 860 NUT, steel - hex machine screw 8-32 601 861 NUT, steel - hex 10-24 601 862 NUT, steel - hex 10-32 601 872 NUT, steel - hex full 3/8-16 604 537 NUT, steel - hex full 5/16-18 601 865 NUT, steel - hex full 1/4-20 601890 RIVET, blind 1/8 dia 1/8 OM-1523 Page 14

Miller SWINGARC DIGITAL-2 12 AND 16 User manual

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