Miller | JE748368 | Owner Manual | Miller SWINGARC SINGLE 12 AND 16 User manual

Miller SWINGARC SINGLE 12 AND 16 User manual
October 1984
FORM: OM-1516r
Effective With Serial No. JE748368
te
0~
MODEL
SWINGARC?
SWINGARC
SINGLE 12
SINGLE 16
F~LE COPY
RJETURN TO FOLDER
OWNERS
IDSUIER
MANUAL
MILLER ELECTRIC MFG. CO.
718 S. BOUNDS ST. P.O. Box 1079
APPLETON.WI 54912 USA
ADDITIONAL COPY PRICE $1.00
NWSA CODE NO. 4579
PRINTED IN U.S.A.
~
..r
O.~~~
LIMITED WARRANTY
EFFECTIVE: JUNE 1. 1979
This warranty supersedes all previous MILLER warranties and is ex
ulusive 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 war
ranty is made by Miller with respect to engines, trade ac
cessories or other items manufactured by others. Such
engines, trade accessories and other items are sold subject to
All
the warranties of their respective manufacturers, if any
engines are warranted by their manufacturer for one year from
date of original purchase.
As
the reasonable cost of
Miller service station
of notice of apparent defect or failure, Miller shall instruct the clai
mant on the warranty claim procedures to be followed.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
MILLERMATIC parts that come in contact with the welding
wire including nozzles and nozzle insulators where failure does
or
or
writing by Mille~ in appropriate cases, 131
repair or replacement at an authorized
(4) payment of or credit for the purchase
price (less reasonable depreciation based upon actual use) upon
return of the goods at Customers risk and expense. Upon receipt
specified below, Millers warranty does not apply
to components having normal useful life of less than one (1)
year, such as spot welder tips, relay and contactor points,
in workmanship
of general policy only, Miller may honor claims
original user within the foregoing periods.
where authorized in
or,
as
not result from defect
matter
In the case of Millers breach of warranty or any other duty
with respect to the quality of any goods, the exclusive remedies
therefore shall be, at Millers option 11) repair or (2) replacement
.
Except
a
submitted by the
ANY
TION
IMPLIED WARRANTY, GUARANTY OR REPRESENTA
AS TO PERFORMANCE, AND ANY REMEDY FOR
BREACH OF CONTRACT WHICH, BUT FOR THIS PROVISION,
MIGHT ARISE BY IMPLICATION, OPERATION OF LAW,
material.
CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING
ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF
required to honor warranty claims on war
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:
Miller shall be
ranted
FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO
ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EX
CLUDED AND DISCLAIMED BY MILLER.
Arc welders, power sources and components
2. Original main power rectifiers
1.
llabor
3.
4.
..
5.
Replacement
6.
Batteries
or
repair parts, exclusive of labor
AS
90 days
1 year
.
ULTIMATE
PRODUCTS
BY
PURCHASE
ARE
BY
MILLER
INTENDED
IN
FOR
COMMERCIAL/INDUSTRIAL
USERS AND FOR OPERATION BY PERSONS TRAINED AND
MAINTENANCE
AND
OF
IN
THE
EXPERIENCED
USE
60 days
6 months
WELDING
EQUIPMENT
AND
CONSUMER USE. MILLER
provided that Miller is notified in writing within thirty 130) days
TO,
of the date of such failure.
MILLERS
a,-
PROVIDED
EXPRESSLY
MILLER
WRITING,
welding guns and
All other Millermatic Feeders
All
EXCEPT
1 year
only)
feeder/guns
-
1 year
3 years
~
...~
AND
~
NO
RESELLER
NOT FOR
CONSUMERS
OR
WARRANTIES DO NOT EXTEND
IS
AUTHORIZED
WARRANTIES TO, ANY CONSUMER.
TO
EXTEND
Nov. 18, 1986
ERRATA SHEET
After this manual
appearing
printed, refinements
was
in
equipment design
occurred. This sheet lists
FORM: OM-1516E
exceptions
to
data
later in this manual.
The 115 vo/ts/contactor cord has been extended to 12.5 ft. (3.8 m).
IMPORTANT
_____________
AMENDMENT TO SECTION 3
Amend Section 3
Delete
-
Steps h, i, j,
Add Section 3
-
c
INSTALLATION
LOCATION AND ASSEMBLY
1.
and k of Subsection B.
Amend Subsection B.
Complete Steps
-
Assembly, Step 2. Post Support
Assembly, Steps lc., 3c., and 4c.
thru g in Subsection 2.
to read as
follows:
Post Support
hA. SAFETY COLLAR REMOVAL
RELEASE OF SPRING PRESSURE WITHOUT BOOM ATTACHED
WARNING
can cause
serious personal
__________
equipment damage.
Perform installation exactly as outlined in the following step-by-step instructions.
Do not remove safety collar until instructed to do so.
Retain safety collar for future disassembly use.
injury
and
safety collar is provided on top of the post to maintain spring pressure and prevent vertical movement during in
stallation. The collar is required whenever the boom is disassembled or relocated. To remove the safety collar, pro
ceed as follows:
A
1.
Grasp
pull boom down slightly. The boom
applied to the safety collar.
bar and
which is
2.
Remove the safety collar, and retain for future
3.
The boom should
not
pulled down only far enough
to remove the pressure
use.
now balance in any position from horizontal to 60 degrees above horizontal. If the boom does
balance properly, proceed to Section 3-12.
AMENDMENT TO SECTION 7
Amend
should be
Figure
7
-
1. Circuit
See page 2 for circuit
-
TROUBLESHOOTING
Diagram
diagram.
HLE copy
RETURN ro FOLDER
-
Dia.
**
Mkgs.
2-1
2-4
2-7
2-15
22-18
2-19
5-
**First
PLG2
PLG9
R8
Part
No.
Replaced
081 964
604571
049 455
+099 522
604571
080 328
079 534
079 878
079 535
079 878
079 535
030 944
080 328
079 534
110 429
digit represents
+Swingarc Single
With
Description
CORD, control-interconnecting
CORD(qtychg)
049 455 CORD (qty chg)
.
.
.
.
HOUSING PLUG & PINS (consisting of)
TERMINAL, male
RECEPTACLE W/SOCKETS, free hanging (consisting of)
TERMINAL, female
Quantity
1
l3ft
2ft
1
.
4
.
4
POTENTIOMETER, cermet 1 turn 0.5 watt 5K ohm
110 158 SNUBBER, poly-metal film 0.5 uf 200 volts DC (Eff w/JG070373)
110 016 BRACKET, burnback timer
digits following dash represents item no.
page no
12 Effective with Serial No. JF897200 and Swingarc
1
1
1
1
-
Single 16 Effective With Serial No.
JF901869
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
F:~J~L1 3.
L_5___j
sc~
Circuit Diagram No. B-hO 642-A
Figure 7
OM-1516E Page 2
-
1. Circuit
Diagram For Models Effective With Serial No. JG070373
TABLE OF CONTENTS
Page No.
Section No.
SECTION 1
SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
-
1
1.
Introduction
2.
General Precautions
1
1 -3.
ArcWelding
7
1
Standards Booklet Index
11
1
1
-
-
-
4.
SECTION 2
2
2
2
-
-
-
-
1.
General Information And Safety
13
Receiving-Handling
Description
13
13
3.
3
3
3
-
-
-
-
-
INSTALLATION
Location And Assembly
DriveMotor
13
3.
4.
Installation Of Wire Support
Reinstallation Of Hub Assembly
15
5.
Installation Of
1.
3~-2.
3
INTRODUCTION
2.
SECTION 3
3
-
15
Spool-Type Wire
Installation Of Reel-Type Wire
6.
Installation Of Wire Reel
15
15
15
16
16
17
18
7.
3
3-8.
3 -9.
DriveRollAndWireGuidelnstallation
Water Connections
3-10.
3 -11.
3-12.
3-13.
WeldingGunConnections
Shielding Gas Connections
BoomAdjustments
Wire Pulley
3-14.
Motor Control Connections
19
3-15.
3-16.
GunTriggerConnection
19
Weld Cable Connection
3-17.
Remote Control Connections
19
19
3-18.
3-19.
Adjustment Of Hub Tension
19
115 Volts/Contactor Connections
19
-
SECTION 4
-
PowerSwitch
4
Remote Control
2.
Receptacle
4-3.
PurgeButton
4
4.
Inch Button
5.
6.
Wire Speed Control
Start Switch
4
4
4
4
4
-
-
-
-
-
-
7.
Retract-Feed Switch
8.
Reset Circuit Breaker
9.
Burnback Control
SECTION 5
5
5
5
-
-
-
And Switch
20
20
20
20
20
20
20
20
20
SEQUENCE OF OPERATION
1.
Welding
2.
3.
Wire Threading
Gas Metal-Arc Welding (GMAW)
20
21
Shutting
21
SECTION 6
6
-
18
19
FUNCTION OF CONTROLS
4-1.
-
18
-
Down
MAINTENANCE
1.
Inspection And Upkeep
2.
Cleaning Of
6-3.
Fuse
22
22
22
6
Brush Inspection & Replacement
22
6
-
-
-
4.
SECTION 7
-
Drive Rolls
TROUBLESHOOTING
SECTION 1
SECTION 1
-
-
REGLES
SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
SECURITE POUR LE FONCTIONNEMENT DU POSTE DE SOUDAGE A LARC
DE
We learn by experience.
Learning safety through personal experience, like a
child touching a hot stove is harmful, wasteful, and un
wise. Let the experience of others teach you.
1-1. INTRODUCTION
-
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, opera
tion, 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.
1-1. INTRODUCTION
-
Contrairement
a
lappren
tissage de Ia vie, lapprentissage de Ia sØcuritØ par ex
pØrience personnelle, comme lenfant qui touche un
poŒle chaud, est dangereux, imprudent et inutile.
lnstruisez-vous donc de IexpØrience dautrui.
Des mØthodes de sØcuritØ issues de lexpØrience du
et du coupage sont dØcrites dans le manuel. La
recherche, le progrŁs et IexpØrience dans ce domaine
ont dØveloppØ un materiel fiable et des mØthodes de
sØcuritØ pour linstallation, le fonctionnement et Ientre
tien. Des accidents se produisent lorsque le materiel est
inadequatement utilisØ ou entretenu. La raison de ces
mØthodes de sØcuritØ peut ne pas Œtre toujours donnØe.
Certaines sont fondØes sur le sens commun, dautres
demanderont a Œtre expliquees par des livres techni
ques. II est plus sage de suivre les regles.
soudage
Read and understand these safe practices before at
tempting to install, operate, or service the equipment.
Comply with these procedures as applicable to the par
ticular equipment used and their instruction manuals,
for personal safety and for the safety of others.
dessayer dinstaller, de faire fonctionner ou de rØparer
Pour votre sØcuritØ personnelle et celle
Iappareil.
dautrui, conformez-vous a ces rØgles et aux manuels
Failure to observe these safe practices may cause
serious injury or death. When safety becomes a habit,
the equipment can be used with confidence.
Manquer dobserver ces mØthodes de sØcuritØ pourrait
entrainer des blessures graves ou mŁme Ia mort. Quand
Ia sØcuritØ devient une habitude, le materiel peut alors
Œtre utilisØ en toute confiance.
These safe practices are divided into two Sections:
1
General Precautions, common to arc welding and
Ces mØthodes de sØcuritØ sont divisØes en deux sec
1
Precautions gØnØrales,
tions:
communes
au
soudage et au coupage a larc, et 2 Soudage a Iarc
-
Lisez et comprenez
ces
mØthodes de sØcuritØ avant
dinstructions.
-
-
cutting;
and 2
-
Arc
Welding (and Cutting) (only).
(et coupage) (uniquement).
Reference standards: Published Standards on safety are
also available for additional and more complete pro
cedures than those
given in this manual. They are listed
in the Standards Index in this manual. ANSI Z49.1 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 equip
ment installation, use, and service.
Normes de rØfØrence: Des publications des normes
amØricaines de sØcuritØ sont aussi a votre disposition
modes opØratoires plus complets que
pour dautres
ceux du present manuel. Elles sont donnØes dans lln
dex des Normes de ces regles de sØcuritØ. ANSI Z49-1
est Ia plus complete.
les codes provinciaux et
Les codes de IACNOR,
municipaux donnent aussi les exigences pour une in
stallation,
1-2.
1-2. GENERAL PRECAUTIONS
Different
arc
and fluxes
welding processes, electrode alloys,
produce different fumes, gases,
can
and radiation levels. In addition to the information
in this manual, be sure to consult flux and elec
trode manufacturers for
and
precautionary
specific technical data
concerning their
measures
material.
utilisation et
un
entretien srs.
PRECAUTIONS GENERALES
Plusieurs procØdØs du soudage a larc, des lec
trodes allies, et les flux peuvent produire des
et
niveaux
de
vapeurs,
gaz,
rayonnement
diffØrents. Pour tout renseignement supplØmen
taire a ce manuel, consultez aussi los fabricants
des electrodes et des flux af in dobtenir les
renseignements techniques spØcifiques at les
do
mesures
precaution concernant leurs
matriaux.
A.
A.
une
Prevention des brOlures
Burn Prevention
Portez des vŒtements de protection des gants a crispin
pour le soudage, un casque et
des chaussures de sØcuritØ. Boutonnez le col de votre
chemise et les pattes de vos poches, et portez des pantalons sans revers pour Øviter que des Øtincelles et du
laitier ne sy introduisent.
-
protective clothing gauntlet gloves designed
welding, hat, and high safety-toe shoes. Button
shirt collar and pocket flaps, and wear cuff less trousers
to avoid entry of sparks and slag.
Wear
use
-
for
in
Wear helmet with safety goggles or glasses with side
shields underneath, appropriate filter lenses or plates
(protected by clear cover glass). This is a MUST for
welding or cutting, (and chipping) to protect the eyes
spØcialement dØsignes
Portez un masque avec lunettes de sØcuritØ ou avec
Øcrans latØ-raux de protection, des lunettes filtrantes ou
des couvre-lentilles (proteges par un verre clair). Pour le
soudage ou le coupage (et le burinage), ii est
OM-l5l6Pagel
from radiant energy and flying metal. Replace cover
glass when broken, pitted, or spattered. See 1-3A.2.
OBLIGATOIRE de protØger ses yeux contre lØnergie de
rayonnement et les Øclats de metal. Remplacez le verre
protecteur lorsquil
Avoid oily
or
greasy
Hot metal such
should
never
clothing.
A
spark
ignite
may
them.
electrode stubs and workpieces
be handled without gloves.
as
projections.
mediate treatment of flash burns of the eyes and skin
burns.
plugs should
Ear
in
be
when
worn
working
on
overhead
confined space. A hard hat should be
others work overhead.
a
worn
or
Flammable hair preparations should not be used by per
intending to weld or cut.
or
a
reu
des
Øtincelle
manipulez jamais
pourrait
sans
des chutes dØlectrode
gants
et des
ou
de
les enflammer.
un
metal chaud tel que
piŁces a souder.
Premiers soins et traitement des yeux: Tout atelier
devrait avoir a sa disposition un poste de premiers soins
ainsi quune personne compØtente, a moms quur, ser
vice medical ne soit a proximitØ pour soigner immediate
ment les brOlures des yeux et de Ia peau.
Les personnes devant souder
ou
couper
ne
doivent pas
employer des preparations inflammables pour leurs
Toxic Fume Prevention
illness
quil
Portez des bouche-oreilles Iorsque vous travaillez au
plafond ou dans un espace restreint. Portez un casque
Iorsque dautres personnes travaillent au plafond.
sons
Severe discomfort,
ou
when
-
B.
brisØ, piquØ
Evitez de porter des habits imprØgnØs dhuile
graisse. Une
Ne
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
est
Voir 1 .3A.2.
cheveux.
death
result from
can
fumes, vapors, heat, or oxygen enrichment or depletion
that welding (or cutting) may produce. Prevent them
with adequate ventilation as described in ANSI Stan
dard Z49.1 listed 1 in Standards index. NEVER ventilate
with oxygen.
B.
Prevention des gax
toxiques
Les gaz, les vapeurs, Ia chaleur, un enrichissement ou
manque doxygene
peuvent entrainer un malaise,
une maladie ou mŒme Ia mort. RemØdiez-y par Ia ven
tilation dØcrite dans Ia Norme ANSI Z49.1 paragraphe 1
des Normes. NE ventilez JAMAIS a Iox
de Ilndex
un
ygene.
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
the operator must wear an
For beryllium, both must be us
well
air-supplied respirator.
as
ed.
En soudant
mercure
et
ou en
coupant, les p10mb, cadmium, zinc,
beryllium
ou
autres matØriaux
semblables
peuvent crØer des concentrations nocives de gaz toxi
ques. On doit avoir recours a une ventilation aspirante
adequate du local, ou alors toute personne sur les Iieux,
de mŁme que le soudeur, doit porter un masque a ad
On doit employer les deux pour le
duction dair.
beryllium.
Metals coated with
containing materials that emit
should not be heated unless coating is
toxic fumes
or
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
tilated and, if necessary, while wearing an
being ven
air-supplied
respirator.
Gas
in
leaks
confined
a
should
space
be
Leaving confined
space, shut OFF gas
supply
left open. Check to be
re-entering it.
sure
accidently opened
or
that the space is safe before
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 pro
ducts. The ultraviolet (radiant) energy of the arc can
decompose trichloroethylene and per
also
chloroethylene
WELD
the
or
Page2
to
form
phosgene. DO NOT
cut where solvent vapors can be drawn
welding
OM-1516
vapors
or
cutting atmosphere
or
On doit Øviter les fuites de gaz dans un espace restreint.
Les fuites de gaz en grande quantitØ peuvent
transformer dangereusement Ia concentration dox
ygene. Namenez pas de bouteilles de gaz dans un
espace restreint.
at source
prevent possible accumulation of gases in the space
if downstream valves have been
Ne travaillez dans un espace restreint que sil est bien
ventilØ et, si nØcessaire, portez un masque a adduction
dair.
avoided.
Leaked gas in large quantities can change oxygen con
centration dangerously. Do not bring gas cylinders into
a confined space.
to
Les mØtaux enrobØs ou composes de matØriaux Ømet
des gaz toxiques ne doivent pas Œtre chauffØs a
moms que Ienrobage
ne soit OtØ de Ia surface a
travailler, que le local ne soit bien ventilØ, ou que le
soudeur ne porte un masque a adduction dair.
tant
into
where the radiant
En quittant un espce
restreint, FERMEZ le robinet
dalimentation de gaz de Ia bouteille. Ainsi on pourra
rentrer en toute sØcuritØ dans Ia piŁce, mŒme si les
robinets aval
ont ØtØ ouverts par accident, ou si on les
a laissØs ouverts.
Les vapeurs de dissolvants chlorØs peuvent Œtre dØcom
(ou de Ia flamme) et
par Ia chaleur de Iarc
former du PHOSGENE, gaz trŁs toxique, et dautres
produits irritant les poumons et les yeux. LØnergie
ultra-violette de Iarc peut aussi dØcomposer les vapeurs
de trichloroØthylŁne et de perchloroethylŁne pour
former du phosgene. NE SOUDEZ PAS ou ne coupez
pas dans des endroits oii les vapeurs de dissolvants peu
de soudage ou de
vent Œtre attirØes dans latmosphŁre
posees
energy can penetrate to
of
minute
amounts
atmospheres containing
trichloroethylene
even
or
per
chloroethylene.
coupage et oci lØnergie do rayonnement pout pØnØtrer
dans des atmospheres contenant des quantitØs memo
minusculos
de
trichloroØthylŁne ou de per
chloroØthylŁne.
Fire and
C.
Explosion Prevention
Prevention des incendies et des
C.
explosions
explosion are: combustibles reached
flying sparks, hot slag or heated
compressed gases and cylinders;
Les causes dincendie
et dexplosion
sont les com
bustibles atteints par larc, Ia flamme, los Øtincelles, le
laitier chaud ou les matØriaux chauffØs, le mauvaiS
emploi des gaz comprimØs et des bouteilles ainsi quo los
courts-circuits.
BE AWARE THAT flying sparks or falling slag 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.
Sachez quo los Øclats dØtincelles ou Ia chute du laitier
sinfiltrer
dans les fissures, le long des
tuyauteries, par les fenØtres et les portes et par los
couvertures des murs ou du sol, sans quo le soudour
portant des lunettes ne les voie. Los Øtincelles et los
35 pieds.
scones peuvent voler jusqu
Causes of fire and
by the arc, flame,
material; misuse of
and short circuits.
To prevent fires and
explosion:
peuvent
Pour
Keep equipment clean and operable, free of oil, grease,
and (in electrical parts) of metallic
cause short circuits.
particles that
can
Avoid paint spray rooms, dip tanks, storage areas, von
tilators. If the work cannot be moved, move com
bustibles 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.
touching combustibles
not be welded on
on
los incendies et los explosions: Veillez a ce
appareil soit propre et en Øtat do marcho,
dØnuØ dhuile ot de graisse, et do particules do metal sur
los piŁces Ølectriques qui pourraient entrainer des
courts-circuits.
are in area, do NOT weld or cut. Move
the work if practicable, to an area free of combustibles.
If combustibles
Walls
prØvenir
que votre
opposite sides should
(or cut). Walls, ceilings, and floor
work should be protected by heat-resistant
shields.
near
covers or
Fire watcher must be standing by with suitabe fire ex
tinguishing equipment during and for some time after
welding or cutting if:
Si des combustibles
a proximitØ, ne soudez
possible, dØplacez votre travail
loin des combustibles. Evitoz los atoliors do pointure au
pistolet, los cuves dimmorsion, los entrepts, los von
tilateurs. Si cola nest pas possible, placez los com
bustibles a au moms 35 pieds des Øtincelles et do Ia
chaleur et protegez-les des Øtincelles avec des couver
tures ou des Øcrans protectours adØquats, bien ajustØs
et ignifuges.
On ne doit pas soudor (ou couper) le ctØ oppose des
murs touchant los combustibles. Los murs, plafonds ot
planchers proches du travail doivent Łtre proteges par
des couvertures ou Øcrans protecteurs ignifuges.
Un surveillant doit se tenir a proximitØ evec un materiel
de lutte contro lincendie adØquat, pendant et quelque
temps aprŁs le soudage ou !e coupage Si:
ne
pas,
a.
a.
appreciable combustibles (including building
construction)
b.
c.
are
within 35 feet
walls within 35 feet
bustibles to sparks
d.
b.
appreciable combustibles are further than 35
feet but can be ignited by sparks
openings (concealed or visible) in floors or
combustibles
roofs,
radiant
or
or
may
expose
com
adjacent to walls, ceilings,
partitions can be ignited by
conducted heat.
Hot work permit should be obtained before operation to
supervisors approval that adequate precautions
have been taken.
done, check that
glowing embers, and flames.
area
is free of
be welded on or cut, unless container has first
been cleaned as described in AWS Standard 46.0,
listed 3 in Standards index.
never
a
solvent
or
thorough steam or caustic cleaning (or
water washing, depending on the corna
Des
quantites apprØciables de combustibles
(y compris une construction en chantier) se
trouvont a moms de 35 pieds.
Des quantites apprØciables de combustibles
sont a plus de 35 pieds mais peuvent Œtre
enflammØes par des Øtincelles.
Des ouvortures (cachØes ou visibles) sur los
planchers ou les murs a moms de 35 piods
peuvent exposer des combustibles aux
Øtincelles.
Les combustibles adjacents aux
murs,
plafonds, toits ou cloisons mØtalliquos peu
vent Œtre enflammØs par une chaleur rayon
nante ou transmiso.
Avant do commencor, avisez le contremaItre pour quil
sassuro quo los precautions adequates soient prises.
Une fois le travail
sparks,
An empty container that held combustibles, or that can
produce flammable or toxic vapors when heated, must
This includes:
d.
metal
ensure
After work is
c.
so trouvent
coupez pas. Si
terminØ, vØrifiez quil
dØtincelles, do cendres ardentes
ou
ny ait pas
do flammos dans le
local.
On
doit jamais soudor ni coupor sur un recipient
des combustibles, ou pouvant produire
des vapeurs inflammablos ou toxiques a Ia chauffe, a
moms quo Ic recipient nait ete lavØ au prØalable, cornme dØcrit dans Ia Norme AWS A6.0, figurant au
paragraphe 3 de llndex des Normes.
no
aVant
contenu
Cola comprend: cm nettoyage a fond a Ia vapeur ou au
caustique (ou cm lavage avec dissolvant ou oau selon Ia
solubilitØ du combustible) suivi dune purge et dune in
OM-1516 Page3
bustibles solubility) followed by purging and inerting
with nitrogen or carbon dioxide, and using protective
equipment as recommended in A6.O. 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
determine if it is safe to weld
to
or cut.
jection dazote ou de gaz carbonique, en utilisant un
equipement de protection comme recommandØ dans
lA6-O. LatmosphŁre inerte peut Œtre remplacØe par un
arrivant au-dessous du travail a effectuer.
niveau deau
Vous devez layer un recipient dont Ia nature de contenu
est inconnue (voir paragraphe ci-dessus). NE vous fiez
PAS a lodorat ou a Ia vue pour dire si lon peut le
souder ou le couper en toute sØcuritØ.
Vous devez pratiquer
un
event
sur
les
ou rØci
ils peuvent
piŁces
avant de les souder ou couper:
castings or containers must be vented before
welding or cutting. They can explode.
pients creux
exploser.
Explosive atmospheres. Never weld
Atmospheres explosives: Ne soudez ni ne coupez
lair
jamais dans des lieux o
peut contenir des
poussiŁres, gaz ou vapeurs liquides inflammables (tels
Hollow
may contain flammable
dust, gas,
or
or
cut where the air
liquid
vapors (such
gasoline).
as
D.
que lessence).
Compressed Gas Equipment
Standard precautions. Comply with precautions in this
manual, and those detailed in CGA Standard P-i,
PRECAUTIONS FOR SAFE HANDLING OF COM
PRESSED GASES IN CYLINDERS, listed 6 in Standards index.
1.
Gaz comprimØ
D.
Precautions gØnØrales: Suivez les precautions de ce
et celles dØcrites a Ia Norme CGA P-i (PrØcau
tions de sØcuritØ pour Ia manipulation de gaz comprimØs
en bouteilles), paragraphe 6 de Ilndex
des Normes.
manuel,
1.
Pressure
Regulators
DØtendeurs de
pression
La soupape de sOretØ dun dØtendeur est destinØe a pro
seulement le dØtendeur de Ia surpression. Elle na
pas pour but de proteger les boyaux et le chalumeau: on
protege ceux-ci par des soupapes de retenue concues
spØcialement pour cette fonction.
tØger
Regulator relief valve is designed to protect only the
regulator from overpressure; it is not intended to pro
tect any downstream
tion with
one or more
equipment. Provide such protec
relief devices.
Ne montez jamais
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
Leaks
a
faulty regulator:
if gas leaks externally.
Creep if delivery pressure continues to rise
with downstream valve closed.
-
un dØtendeur sur une bouteille conte
gaz different de celui pour lequel le dØtendeur a
ØtØ concu.
nant un
Enlevez immØdiatement un dØtendeur dØfectueux pour
le faire rØparer (dabord,
fermez le robinet de a
bouteille). Les symptomes suivants dØnotent Ia dØfec
tuositØ du dØtendeur:
Faulty Gauge if gauge pointer does not move off stop
pin when pressurized, nor returns to stop pin after
Fuites Si le gaz fuit extØrieurement.
Ascension excessive si Ia pressicin de debit continue a
monter, le robinet du chalumeau Øtant fermØ.
ManomŁtre dØfectueux
Si laiguille du manomŁtre ne
sØcarte pas de Ia goupille de butØe lors de Ia mise en
pressure release.
pression,
Excessive
-
-
Repair. Do NOT attempt repair. Send faulty regulators
repair to manufacturers designated repair center,
where special techniques and tools are used by trained
personnel.
for
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 ac
cident. (See 1-3C.)
-
-
-
ou ne revient pas
pement de Ia pression.
sur
Ia
goupille aprŁs lØchap
Reparation. NESSAYEZ PAS de rØparer vous-mØmes.
Envoyez les dØtendeurs dØfectueux a rØparer aux
ateliers de reparation agrØØs du fabricant, oCi des techni
ques et des outils spØciaux sont utilisØs par un person
nel formØ.
2.
Bouteilles
Les bouteilles doivent Œtre manipulØes avec Soin pour
prØvenir les. fuites ou dØgªts a leurs parois, robinets ou
systŁmes de sretØ. Evitez quun circuit Ølectrique soit
en contact avec les bouteilles, y compris les rails de con
tact, los fils electriques ou los circuits do soudage. Cola
pourrait crØer des arcs courts-circuits pouvant entraIner
des accidents graves (Voir i.3C.).
ICC
DOT marking must be on each cylinder. It is an
assurance of safety when the cylinder is properly
handled.
or
OM-1516 Page 4
Chaque
bouteille doit porter les inscriptions ICC ou
DOT. Cest un gage de sØcuritØ pourvu que Ia bouteille
soit bien manipulØe.
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
alter name, number, or other markings
illegal and hazardous.
DEFACE
or
cylinder.
It is
on a
Empties: Keep valves closed, replace caps securely;
mark MT; keep them separate from FULLS and return
promptly.
Prohibited
use.
Never
use a
cylinder
or
other than its intended use, NEVER
roller.
its contents for
as
a
support
Identification du gaz: Nutilisez que los bouteilles mdi
quant Ia nature du gaz; ne vous fiez pas a Ia couleur
pour reconnaItre Ia nature du gaz. Adressez-vous a
votre fournisseur si cola nest pas indiquØ.
modifiez
NEFFACEZ
ou
ne
numØros ou autres indications
est
illegal
JAMAIS Ies noms,
boutoille. Cela
sur une
dangereux.
et
Vides: Maintenez los robinets fermØs, replacez bien les
sØparez-les des Pleines
chapeaux; inscrivez Vides;
et retournez-les rapidement.
or
Emploi interdit: Nutilisez une bouteille ou son contenu
ce Ø quoi elle est destinØe, mais JAMAIS corn-
que pour
Locate
or secure
cylinders
they
so
cannot be knocked
me
support
ou
rouleau.
over.
Placez los bouteilles pour
Passageways and
quun dØtendeur (et un boyau) est monte
placez los ou attachez-les debout.
work
areas.
Keep cylinders clear of
quelles
ne
tombent pas. Lors
elles,
sur
where they may be struck.
areas
Passages
Transporting cylinders. With a crane, use a secure sup
port 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
slag, and flame,
cylinders
to excessive
etc. that may cause
allow contents to exceed 130F.
where such exposure exists.
heat, sparks,
rupture. Do
et
endroit o
lieux de travail. Enlevez les bouteilles dun
lon
Transport
pourrait les frapper.
des bouteiiles. Avec
une
grue, utilisez
un
sup
port fiable tel quune plate-forme ou un cadre. NE
SOULEVEZ PAS des bouteilles du sol par leur robinet
ou chapeau, ou avec des chalnes, elingues ou aimants.
not
Cool with water spray
cylinders particularly valves from bumps, falls,
and weather. Replace caps securely
objects,
falling
when moving cylinders.
Protect
PAS les boutoilles a une chaleur excessive,
au laitier et aux flammes, etc., pouvant
leur rupture. Le contenant ne dolt jamais
causer
dØpassor 55C. Refroidissez en pulvØrisant de leau si
nØcessaire.
NEXPOSEZ
aux
Øtincolles,
les bouteilles et particuliŁrement les soupapes
chocs, les chutes, los chutes dobjets et (a
temperature. Remettez bien les chapeaux Iorsque vous
deplacez los bouteilles.
ProtØgez
contre les
Stuck valve. Do NOT
cylinder valve
your supplier.
a
Mixing
that
use a
can not
hammer
be
or
wrench to open
opened by hand. Notify
gases. Never try to mix any gases in a
Never refill any
cylinder.
cylinder.
Cylinder fittings should
never
be modified
or
exchang
ed.
Robinet coincØ. NUTILISEZ PAS un marteau ou uno
clØ mØtallique pour ouvrir un robinet de bouteille que
Ion ne peut pas ouvrir a Ia main. Avisez votre four
nisseur.
MØlange
dans
3.
une
de gaz. Nessayoz
bouteille.
jamais
do
mØlanger
des gaz
Ne rechargez jamais une bouteille. Les ØlØmonts de Ia
bouteille no doivent jamais Œtre modifies ou remplacØs.
Hose
Prohibited
for the
use. Never use hose other than that designed
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
wire or other substitute) as a binding to connect
hoses to
fittings.
No copper
to
tubing splices. Use only standard brass fit
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
Boyau
Utilisation interdite. Nutilisez
que celui
dinary
tings
3.
excess
hose to prevent kinks and
tangles.
approprie
jamais
un
boyau
autre
gaz indique. La rŁgle gØnØrale
didentification est: rouge pour les gaz combustibles,
vert pour (oxygØne, et noir pour les gaz inertes.
au
Utilisez des bagues ou colliers appropriØs au boyau (et
non du fil ordinaire ou autre substitution) pour brancher
les boyaux a lappareillage.
Nutilisez pas des raccords en cuivre. Nutilisez quo des
accessoires standard en laiton pour raccorder un boyau.
Utilisez une petite Iongueur do boyau. Cola Øvitera los
noeuds et (usure prØmaturØe. Suspendez le boyau au
dessus du sol pour Øviter quil no soit ØcrasØ, piØtinØ ou
endommagØ.
Protect hose from
sparks, slag,
damage by sharp edges, and by
and open flame.
Examine hose regularly for leaks, wear, and loose con
nections. Immerse pressured hose in water; bubbles in
dicate leaks.
Enroulez le surplus do boyau pour Øviter les noeuds et
emmŒlements. Evitez que Is boyau no soit endommagØ
par des tranchants, Øtincolles, laitier ot flamme flue.
OM-1516 Page 5
Repair leaky or worn hose by cutting
ing (1-2D3). Do NOT use tape.
4.
area out
and
splic
Proper Connections
Reparation. Coupez Ia partie percØe
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
VØrifiez reguliŁrement Ies fuites, lusure
et les rac
cordements lØches. Plongez le boyau sous pression
dans de leau;
es bulles indiqueront les fuites.
cylinder containing
any other gas.
connections. When assembling threaded con
nections, clean and smooth seats where necessary.
Tighten. If connection leaks, disassemble, clean, and
retighten using properly fitting wrench.
Tighten
Adapters. Use a CGA adapter (available from your sup
plier) between cylinder and regulator, if one is required.
Use two wrenches to tighten adapter marked RIGHT
and LEFT HAND threads.
ou
usØe,
et ra
cordez (1-2D3). NUTILISEZ JAMAIS de ruban adhØs
4.
Branchements corrects
Avant de brancher le dØtendeur, nettoyez (a sortie du
robinet de Ia bouteille des impuretØs qui peuvent
obstruer les orifices et endommager les sieges. Sauf
ouvrez momentanØment le robinet,
pour lhydrogŁne,
en
des
flammables.
Øloignant Ia sortie des personnes et
Essuyez avec un tissu
graisseux.
propre
Appareillez
sources
et
in
non
le dØtendeur a Ia bouteille. Avant de bran
cher, vØrifiez que Ia marque du dØtendeur et Ia descrip
tion de Ia bouteille concordent, et que lorifice dentrØe
du dØtendeur et lorifice de sortie de Ia bouteille aillent
ensemble. NE BRANCHEZ JAMAIS un dØtendeur
concu pour un gaz special (ou des gaz spØciaux) a une
bouteille contenant dautres gaz.
Serrez les branchements. Lorsque vous assemblez des
branchements filetØs, nettoyez et polissez les sieges oU
cest nØcessaire. Serrez. Si les branchements perdent,
dØmontez-les, nettoyez et resserez avec une clef adØ
quate.
Regulator outlet (or hose) connections may be iden
tified by right hand threads for oxygen and left hand
threads (with grooved hex on nut or shank) for fuel gas.
5.
Drain regulator of residual gas through suitable vent
before opening cylinder (or manifold valve) by turning
adjusting screw in (clockwise). Draining prevents ex
cessive compression heat at high pressure seat by
allowing seat to open on pressurization. Leave adjusting
screw engaged slightly on single-stage regulators.
regulator
while
opening cylinder valve.
Open cylinder valve slowly so that regulator pressure in
When gauge is pressurized (gauge
creases slowly.
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 (capful of Ivory
Liquid* or equivalent per gallon of water). Bubbles in
dicate leak. Clean off soapy water after test; dried soap
is combustible.
E.
User
Responsibilities
Remove leaky or defective equipment from service im
mediately for repair. See User Responsibility statement
in equipment manual.
*Trademark of Proctor & Gamble
OM-1516 Page 6
(en vente chez
votre
fournisseur)
dØtendeur. Avec deux clefs,
DROITE et A GAUCHE.
Pressurizing Steps:
Stand to side of
Adaptateurs. Placez, si besoin est,
un
adaptateur CGA
entre Ia
serrez
bouteille et le
ladaptateur filetØ A
On peut reconnaItre les branchements de sortie du
dØtendeur (ou boyau) a laide du filetage a droite pour
loxygene et a gauche (identifiØ par un Øcrou cannelØ)
pour les gaz combustibles.
5.
DØmarches de mise
en
pression
Purgez le dØtendeur de rØsidu de gaz avant douvrir Ia
bouteille (ou le robinet de canalisation) en serrant Ia vis
de reglage (dans le sens des aiguilles dune montre).
Cette operation permet au siege de haute pression de
souvrir a Ia mise en pression, supprimant ainsi toute
surchauffe de compression. Maintenez Ia vis de rØglage
des dØtendeurs a simple dØtente lØgerement engagee.
Avant douvrir le robinet de Ia bouteille, assurez-vous
que les boyaux sont branches et que les soupapes aval
sont fermØes.
Tenez-vous IatØralement au dØtendeur en ouvrant le
robinet de Ia bouteille. Ouvrez-Ie lentement pour que Ia
pression du dØtendeur monte progressivement. Lorsque
le manomŁtre est mis sous pression (indique le max
imum) le robinet de Ia bouteille de gaz inerte ou dox
ygene devra Œtre ouvert a fond pour assurer letanchØitØ
et celui de Ia bouteille de gaz combustible ouvert de
moms dun tour pour pouvoir le refermer rapidement en
cas
durgence.
RØfØrez-vous aux tableaux de pression (distribuØs par
fournisseur) pour un rØglage recommandØ de
pression sr et efficace sur les dØtendeurs. VØrifiez les
fuites a Ia premiere mise en pression puis reguliŁrement,
brossez avec une solution savonneuse (un bouchon
dIvory Liquid* ou semblable par gallon deau). Les
bulles indiquent une fuite. Enlevez leau
savonneuse
aprŁs examen; le savon sec est inflammable.
votre
*Marque de Commerce de Proctor & Gamble
Leaving Equipment Unattended
F.
Close gas
ResponsabilitØs
do
lusager
Otez immØdiatement les parties percØes Cu dØfec
Voir les ResponsabilitØs de lUsager du manuel
drain gas.
at source and
supply
E.
tueuses.
G.
Rope staging-support should not be used for welding
cutting operation; rope may burn.
Appareil
laissØ
Fermez lalimentation
G.
-
equipment carries high currents at significant
voltages. The arc is very bright and hot. Sparks fly,
The
rise, ultraviolet and infrared energy radiates,
weldments are hot, and compressed gases may be us
fumes
ed. The wise operator avoids unnecessary risks and pro
tects himself and others from accidents. Precautions
are described here and in standards referenced in index.
Burn Protection
A.
F.
or
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.
1-3. ARC WELDING
lappareil.
de
Rope Staging-Support
Comply with precautions in 1-2.
welding arc is intense and visibly bright. Its radia
can damage eyes, penetrate lightweight clothing,
reflect from light-colored surfaces, and burn the skin
The
sans
surveillance
de gaz a Ia
Liens et supports
source et
purgez.
temporaires
Pour vos travaux de soudage ou de coupage, nutilisez
pas de Ia corde comme soutien, elle est inflammable.
A LARC
Conformez-vous aux
1-3. SOUDAGE
1.1 et 1.2 de cette section.
des
paragraphes
precautions
bien exØcutØ est sUr, mais un
Le soudage a larc
soudeur negligent est un danger. Le poste de soudage
transporte des courants ØlevØs sous de fortes tensions.
Larc est trŁs vif et chaud. Les Øtincelles volent, les
vapeurs montent, lenergie ultra-violette et infrarouge
rayonnent, les soudures sont chaudes, et des gaz corn
primes peuvent Œtre utilisØs. Le soudeur prudent Øvite
les risques inutiles, se protege et protege autrui contre
les accidents. Les precautions sont dØcrites ici et dans
les normes donnØes dans IIndex.
-
tion
and eyes. Skin burns resemble acute sunburn, those
gas-shielded arcs are more severe and painful.
from
DONT
GET
WITH
COMPLY
BURNED;
PRECAU
TIONS.
Clothing
Protective
1.
long-sleeve clothing (particularly for gas-shielded
to gloves, hat, and shoes (1-2A). As
necessary, use additional protective clothing such as
leather jacket or sleeves, flame-proof apron, and fireresistant leggings. Avoid outergarments of untreated
Wear
A.
Protection contre los brOlures
Conformez-vous aux precautions du paragraphe 1.2.
Larc de soudage est intense et visiblement vif. Son
rayonnement peut blesser les yeux, traverser les habits
lØgers, se rØflØchir sur les surfaces claires, et brOler Ia
peau et les yeux. Les brOlures de Ia peau ressemblent a
un gros coup de soleil. Celles darcs sous gaz protecteur
sont plus graves et plus douloureuses. NE VOUS
SUIVEZ LES PRECAUTIONS.
BRULEZ PAS
-
arc) in addition
cotton.
Bare skin
Protect eyes from exposure to
arc without protection.
arc.
NEVER look at
an
electric
no.
over
12
helmet
or
or
shield
containing
a
Portez des vOtements a manches longues (surtout pour
larc
en atmosphere inerte) avec gants,
masque et
chaussures (1.2A.).
Protect filter
or
striking
plate
with
a
Cracked, broken,
IMMEDIATELY.
broken, pitted,
or
or
plate shade
welding. Place
Protection de Ia peau. Portez des vŒternents epais
foncØs. Boutonnez le col pour proteger Ia poitrine et le
cou, et boutonnez les poches pour prØvenir Iinfiltration
dØtincelles.
2.
Protection des yeux et de Ia tŒte
arc.
clear
broken helmet
worn; radiation can pass
Si nØcessaire portez en plus une veste ou des manches
cuir, un tablier et des guetres ignifuges. De
prØfØrence ne portez pas de vŒtements en coton non
en
filter
denser must be used when
face before
Cracked
protection
traitØ.
Eye and Head Protection
Welding
VŒtements de
protection. Wear dark, substantial clothing.
Button collar to protect chest and neck and button
pockets to prevent entry of sparks.
2.
1.
or
cover
shield should NOT be
through
loose filter
Replace
spattered.
Evitez que vos yeux soient exposØs a Iarc. NE
JAMAIS un arc Ølectrique sans protection.
plate.
to cause
plates
clear
burns.
replaced
plate when
regardez
vous soudez, portez un Øcran ou masque avec
filtrant teintØ N 12 ou plus foncØ. Mettez-le sur le
visage avant damorcer arc.
Lorsque
verre
must be
cover
le verre filtrant dun
couvre-verre clair. NE
PORTEZ PAS un masque fendu ou brisØ; le rayonne
ProtØgez
ment
Les
peut sinfiltrer
verres
et causer
des brOlures.
filtrants fendus, brisØs
cu
Iches
doivent Œtre
remplacØs IMMEDIATEMENT. Remplacez un couvre
verre brisØ, piquØ ou tachØ par des projections.
CM-i 516
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
eyes
(particularly
retinal burn that may leave
cause a
area
momentarily with unprotected
high intensity gas-shielded arc) can
an arc
a
a
permanent dark
in the field of vision.
Vous devez portez des lunettes a Øcrans latØraux sous le
masque pour protØger les yeux dans le cas o le masque
de
ne serait pas abaissØ sur le visage avant lamorage
larc. Regarder momentanØment un arc sans protection
(principalement un arc en atmosphere inerte a haute i
terisitØ) peut brler Ia rØtine et laisser un point som
permanent dans le champ de vision.
Protection du
3.
Protection of Nearby Personnel
3.
Enclosed welding
For
area.
Local de
production welding,
a
enclosed bay is best. In open areas,
operation with low-reflective, noncombustible screens or panels. Allow for free air circula
tion, particularly at floor level.
separate
room or
the
surround
the weld. Provide face shields for all persons
looking directly at the weld.
Viewing
who will be
Others
flash
working
goggles.
in
area.
See that all persons
Before starting to weld, make
bay doors are closed.
B.
sure
that
are
wearing
screen
flaps
tion, il
a
proximitØ
soudage fermØ. Pour le soudage de produc
mieux utiliser une salle sØparØe ou une baie
vaut
fermØe. Dans les locaux ouverts, entourez les travaux
dØcrans ou panneaux peu rØflØchissants et ininflam
mables. Laissez lair circuler librement, particuliŁrement
au niveau du sol.
Donnez des masques aux personnes
directement Ia soudure.
qui regarderont
Autres personnes travaillant sur les lieux. Veillez a ce
que toutes les personnes portent les lunettes de protec
tion.
or
Avant dattaquer
Ia soudure, assurez-vous
rebords dØcran ou les portes soient fermØs.
que
les
Toxic Fume Prevention
B.
Comply with precautions
Fire and
Comply
with
Prevention des gaz
toxiques
in 1-2B.
Generator engine exhaust must be vented
air. Carbon monoxide can kill.
C.
personnel
to the
outside
Suivez les precautions du paragraphe 1.2B. LØchappe
ment du moteur de Ia gØnØratrice dolt Łtre ventilØ a lair
extØrieur. Loxyde de carbone peut tuer.
Explosion Prevention
C.
Prevention des incendies et des explosions
in 1-2C.
precautions
rated capacity. Do
Equipments
welding equipment. It may overheat
overload
not
cables and
arc
cause a
Suivez les precautions 1.2C. Puissance nominale de
Ne surchargez pas le poste de soudage a
larc. Cela peut surchauffer les cables et causer un in
cendie.
lappareil.
fire.
Loose cable connections may overheat
fire.
or
flash and
Les brarichements lches de cable peuvent surchauffer
faire des Øtincelles et causer un incendie.
ou
cause a
Never strike
an
arc
on
cylinder
a
vessel. It creates a brittle
rupture or lead to such
area
a
that
or
can
other pressure
cause a violent
rupture later under rough
Namorcez
jamais un arc sur une bouteille ou autre rØci
pression. Cela crØerait un point de rupture
entraInant a plus ou moms longue ØchØance lexplosion
pient
sous
du reservoir.
handling.
D.
Compressed Gas Equipment
Comply
E.
with
in 1-2D.
precautions
or
other bare metal in the
welding Circuit, or in ungrounded, electrically-HOT
equipment can fatally shock a person whose body
becomes
LEAN
a
conductor.
ON, OR TOUCH
DO NOT STAND, SIT, LIE,
wet surface when welding,
a
without suitable protection.
OM-1516
Page 8
Gaz comprimØ
Suivez les precautions 1 .2D.
E.
Shock Prevention
Exposed hot conductors
D.
Prevention des
dØcharges Ølectriques
Des conducteurs charges ou metal nu incorporØs au cir
cuit de soudage ou a un appareil chargØ sans mise a Ia
terre peuvent donner une decharge fatale a Ia personne
dont le corps devient conducteur. NE SOUDEZ PAS
DEBOUT, ASSIS, COUCHE, PENCHE sur une surface
humide ni en contact avec une telle surface sans prote
tion appropriØe.
To protect
against shock:
Keep body and clothing dry. Never work in damp area
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
reduces the body surface
or grounded metal
part
electrical resistance, enabling dangerous and possibly
lethal currents to flow through the body.
without adequate insulation
-
-
Pour vous protØger contre les dØcharges Ølectriques,
maintenez votre corps et vŒtements secs. Ne travaillez
jamais dans un endroit humide sans isolation adequate
contre les dØcharges Ølectriques. Lorsque vous ne
pouvez Øviter IhumiditØ ou Ia sueur, placez-vous sur un
caillebotis sec ou un tapis en caoutchouc. La sueur,
de mer,
leau
tant IentrØe
the
Grounding
arc
include, but are not limited to, buildings, electrical
tools, work benches, welding power source cases,
workpieces, etc. Never touch the electrode and any
metal
object
entre le corps et une
piŁce
de courants
dangereux, voire mortels.
lappareil
Equipment
welding equipment is grounded according to
the National Electrical Code, and the work is grounded
according to ANSI Z49.1 Safety In Welding And Cut
ting, a voltage may exist between the electrode and
any conducting object. Examples of conducting objects
When
lhumiditØ
ou une
Mise a Ia terre de
1.
1.
ou
piŁce cie metal a Ia masse, rØduisent
Ia rØsistance Ølectrique de Ia surface du corps, permet
CHARGEE,
unless the
welding
power
source
is
Lorsque Iappareil de soudage a larc
objet conducteur. Certaines de ces ob
exemple (mais pas seulement), des
des outils electriques, des Øtablis, des
btiments,
chassis de postes de soudure, des piŁces douvrage,
ou des objets en
etc. Ne jamais touchez IØlectrode
electrode
jets
sont
et un
par
mis le poste de soudure a Iarrt.
metal avant davoir
off.
installing, connect the frames of each unit such
welding power source, control, work table, and
water circulator to the building 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 li
quid such as oil or fuel.
When
as
est mise a Ia terre
suivant Ia norme National Electrical Code, et Ia masse
est mise a Ia terre suivant Ia norme ANSI Z49.1 Safety
in Welding and Cutting, une tension peut exister entre
A Iinstallation, branchez les chassis de chaque ØlØment
(source de cou rant, commande, Øtabli et circuit deau) a
Ia terre. Les conducteurs doivent pouvoir conduire les
courants telluriques en toute sØcuritØ. Lappareil chargØ
par les courants vagabonds peut donner une dØcharge
risquant dŒtre mortelle. NE BRANCHEZ PAS VOTRE
une conduite electrique, ou a
liquide inflammable tel que lhuile
PRISE DE TERRE a
un
tuyau de gaz ou de
un combustible.
ou
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 equip
ment ground lead to the third (live) wire, or the equip
ment will become electrically HOT
a dangerous condi
tion that can shock, possibly fatally.
Connexion triphasØe. Avant linstallation
vØrifiez Ia
phase nØcessaire a lappareil. Si seul le triphasØ est
disponible, ne branchez Iappareil monophasØ qu deux
des fils de Ia ligne triphasØe. NE BRANCHEZ PAS le
conducteur do terre de Iappareil au troisiŁrne fil (sous
tension), autrement lapparØil serait chargØ: condition
dangereuse pouvant donner une dØcharge fatale.
Before
Avant
-
welding, check ground
conductors are touching
frames at connections.
If
a
line cord with
a
for
bare
continuity. Be sure
of equipment
metal
ground lead is provided with the
equipment for connection to a switchbox, connect the
ground lead to the grounded switchbox. If a threeprong 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 recep
tacle. Never remove the ground prong from a plug, or
use a plug with a broken off ground prong.
2.
Electrode Holders
Lorsquun
appareil doit Œtre alimente a partir dun
f ret dalimentation,
a celui-ci.
cof
le conducteur de terre doit Œtre reliØ
Si vous avez en plus une fiche a trois broches pour Ia
terre, ne bra nchez le conducteur de terre qua Ia broche
de terre. Si le cordon dalimentation a une fiche a trois
brochØs, reliez-Ie a une prise femelle tripolaire reliØe a Ia
terre. Nenlevez jamais Ia broche de terre dune fiche ou
nutilisez jamais une fiche dont Ia broche de terre serait
brisØe.
2.
Fully insulated electrode holders should be used. Do
NOT use holders with protruding screws.
3.
le soudage, vØrifiez si Ia prise de terre est
uniforme. En branchant, assurez-vous que los con
ducteurs touchent le metal nu du chassis de lappareil.
Pince-Ølectrodes
Utilisez des pince-Ølectrodes bien isolØes. NUTILISEZ
PAS des pince-Ølectrodes avec vis saillantes.
Connectors
3.
Fully insulated lock-type connectors should be used
join welding cable lengths.
Connecteurs
to
Utilisez des connecteurs a verrouillage bien isolØs pour
assembler de longs cables.
OM-1 516
Page
9
4.
4.
Cables
Frequently inspect cables
for wear, cracks and
damage.
IMMEDIATELY REPLACE those with excessively worn
lethal shock
or damaged insulation to avoid possibly
from bared cable. Cables with damaged areas may be
-
taped
to
give
resistance
equivalent
to
original
cable.
Keep cable dry, free of oil arfd grease, and protected
from hot metal and sparks.
5.
Terminals And Other
Exposed
should have
6.
VØrifiez frequemment lusure, les fissures et laltØration
des cØbles. REMPLACEZ IMMEDIATEMENT ceux dont
lisolation serait trop usØe ou altØrØe pour prØvenir les
decharges mortelies provoquØes par un cØble dØnudØ.
Vous pouvez enrouler les parties endommagØes de
ruban adhØsif en Øpaisseur suffisante pour donner une
rØsistance de cable neuf. Maintenez les cØbles secs,
dØpourvus dhuile et de graisse et mettez-les a labri du
metal chaud et des Øtincelles.
Parts.
5.
exposed parts of electrical units
insulating covers secured before operation.
Terminals and other
Cables
TŒtes de cØbles et autres
Avant Ia mise en marche, les tŒtes de cables et autres
parties dØnudØes dun appareil Ølectrique doivent Œtre
munies de leurs couvrefils isolants.
Electrode
6.
Electrode
Equipment with output on/off control (con
a.
tactor)
a
Welding
power
sources
for
use
equipØ dune
che/arrŒt (contacteur)
Appareil
.
with the electrode circuit unless the
power source is off.
Equipment
without
les postes de soudure utilisØs
arc
a
sous
protection
pour
gazeuse avec electrode fusible (GMAW), ou
avec electrode tungstene (GTAW) et des
procŁs semblables sont equipØs dune com
mande marche/arrŒt de Ia puissance de sor
le
metal
power
welding
poste de soudure.
output on/off control
b
.
sources
used with shielded
Les
welding (SMAW) and similar pro
may not be equipped with welding
welding
Safety
touch
power
as
the
electrode
source
unless
the
is off.
or
Do not open power circuit or change polarity while
welding. If, in an emergency, it must be disconnected,
guard against shock burns, or flash from switch arcing.
Leaving equipment unattended. Always
disconnect all power to equipment.
shut OFF and
Power disconnect switch must be available
OM-1516
Page
10
soudure
utilisØs
pour
le
Dispositif
de sØcuritØ
the
ne
soudage, nouvrez pas le circuit dalimentation
changez pas Ia polaritØ. SiI est dØbranchØ au
Lors du
ne
cours
dune
dØcharge
near
coupe-circuit
Avant linstallation, linspection ou Ia reparation de rap
pareil, mettez lalimentation sur ARRET et enlevez les
fusibles generaux (ou verrouillez les interrupteurs) pour
Øviter une remise en MARCHE accidentelle. DØbran
chez tous les cables de Ia source de courant ainsi que les
prises des cordons dalimentation en 115 volts.
et
source.
de
Le dispositif de securite-verrouillage et
doit pas Œtre dØbranchØ ou dØshuntØ.
shunted out.
pull all 115 volts line-cord plugs.
power
postes
interlocks and circuit breakers
Before installation, inspection, or service, of equip
ment, shut OFF all power and remove line fuses (or lock
or red-tag switches) to prevent accidental turning ON of
power. Disconnect all cables from welding power
welding
mar
poste de soudure.
7.
should not be disconnected
source, and
commande
electrode enrobØe
Iarc
avec
soudage
(SMAW) et des procŁs semblabes peuvent
commande mar
Łtre non-ØquipØs dune
che/arrŒt de Ia puissance de sortie. Lorsque
linterrupteur est en position MARCHE
Ne touchez
devient chargØ.
lØlectrode
le
courant au
IØlectrode
sans
couper
jamais
Devices
Safety devices such
dune
a
With
power output on-off control devices.
such equipment the electrode is electrically
HOT when the power switch is turned ON.
Never
Appareil non-ØquipØ
che/arrŒt (sans contacteur)
arc
cesses
soudage
tie. Lorsque Iinterrupteur est en position
MARCHE
et Iinterrupteur du pistolet est
fermØ, le fil dØlectrode devient chargØ. Ne
touchez jamais le fil electrode ou tout autre
objet conducteur faisant contact avec le cir
cuit dØlectrode sans couper le courant au
(no contactor)
Welding
mar
gØnØral,
En
arc
switch is closed. Never touch the electrode
wire or any conducting object in contact
b.
commande
with the gas
welding (GMAW), gas tungsten
arc welding (GTAW) and similar processes
normally are equipped with devices that per
mit on-off control of the welding power out
put. When so equipped the electrode wire
becomes electrically HOT when the power
source switch is ON and the welding gun
metal
7.
parties dØnudØes
urgence, faites attention
ou aux
aux
laissØ sans surveillance. Mettez
ARRET et dØbranchez Iappareil.
Appareil
brQlures de
jaillissements dØtincelles.
toujours
sur
F.
Protection For Wearers Of Electronic Life
Linterrupteur
Support Devices (Pacemakers)
imitØ de Ia
Magnetic fields from high currents can affect
pacemaker operation. Persons wearing electronic life
support equipment (pacemaker) should consult with
their doctor before going near arc welding, gouging, or
spot welding operations.
For more in
1-4. STANDARDS BOOKLET INDEX
their latest
standards
or
the
refer
to
following
formation,
-
revisions and
1.
comply
as
applicable:
ANSI Standard Z49.1, SAFETY IN WELDING
AND CUTTING obtainable from the American
Welding Society,
550 Le Jeune Ad, P.O. Box
351040, Miami, FL 33135.
2.
F.
6.
7.
8.
from
the
Superintendent
of
OSHA, SAFETY AND HEALTH STANDARDS,
29CFR 1910, obtainable from the U.S. Govern
ment Printing Office, Washington, D.C. 20402.
ANSI Standard Z87.1, SAFE PRACTICES FOR
OCCUPATION AND EDUCATIONAL EYE AND
PROTECTION obtainable from the
FACE
American National Standards Institute, 1430
ANSI Standard Z41.1, STANDARD FOR MENS
SAFETY -TOE FOOTWEAR obtainable from the
American National Standards Institute, 1430
Broadway, New York, NY 10018
ANSI Standard Z49.2, FIRE PREVENTION IN
THE USE OF CUTTING AND WELDING PRO
CESSES obtainable from the American National
Standards Institute, 1430 Broadway, New York,
NY 10018.
Inducteurs de courant ØlevØ peuvent nuire le fonction
appareil pour le reglement de battement
de coeur. Toute personne portant un appareil Ølec
tronique de sauvetage (appareil pour le reglement de
battement de coeur), devrait consulter un docteur avant
dapprocher toute operation de soudage a Iarc, a Ia
gouge ou a point.
nement dun
1-4.
10.
INDEX
Pour
plus de
de IACNOR
amØricaines suivantes:
DES
NORMES
ou aux normes
-
aux normes
1.
ANSI Standard Z49.1, SAFETY IN WELDING
AND CUTTING distribuØ par IAmerican Welding
Society, 550 Le Jeune Rd., P.O. Box 351040
Miami, FL 33135
2.
NIOSH, SAFETY AND HEALTH IN ARC
WELDING AND GAS WELDING AND CUTTING
distribuØ par le Superintendent of Documents,
U.S. Government Printing Office, Washington
D.C. 20402
3.
OSHA, SAFETY AND HEALTH STANDARDS,
29CFR 1910, distribuØ par U.S. Department of
Labor, Washington D.C. 20210
4.
ANSI Standard Z87.1, SAFE PRACTICES FOR
OCCUPATION AND EDUCATIONAL EYE AND
FACE PROTECTION distribuØ par IAmerican
National Standards Institute, 1430 Broadway,
New York, NY 10018
5.
ANSI Standard Z41.1, STANDARD FOR MENS
SAFETY
TOE FOOTWEAR distribuØ par Iad
dresse donnee en 4.
Standard A6.0, WELDING AND CUT
TING CONTAINERS WHICH HAVE HELD COM
BUSTIBLES obtainable from the American
Welding Society, 550 Le Jeune Rd., P.O. Box
351040, FL 33135.
-
AWS
6.
ANSI Standard Z49.2, FIRE PREVENTION IN
THE USE OF CUTTING AND WELDING PRO
CESSES distribuØ par Iaddresse donnee en 4.
7.
AWS Standard A6.O, WELDING AND CUT
TING CONTAINERS WHICH HAVE COM
BUSTIBLES distribuØ par Iaddresse donnee en
8.
NFPA
Standard 51, OXYGEN
FUEL GAS
SYSTEMS FOR WELDING AND CUTTING
distribuØ par Ia National Fire Protection Associa
tion, 470 Atlantic Avenue, Boston, MA 02210
9.
NFPA Standard 70-1978, NATIONAL ELEC
TRICAL CODE distribuØ par Iaddresse donnØe
en 8
10.
NFPA Standard 51B, CUTTING AND WELDING
PROCESSES distribuØ par Iaddresse donnØe en
8
FUEL GAS
Standard 51, OXYGEN
SYSTEMS FOR WELDING AND CUTTING ob
tainable from the National Fire Protection
Association, 470 Atlantic Avenue, Boston, MA
NFPA
-
02210.
9.
a prox
coeur)
Broadway, New York, NY 10018.
5.
trouver
Protection pour toute personne portant doe
renseignements, rØfØrez-vous
SAFETY AND HEALTH IN ARC
WELDING AND GAS WELDING AND CUTTING
se
apparoils Ølectroniques do sauvotago (ap
pareil pour le rOglement do battomont do
Documents, U.S. Government Printing Office,
Washington, D.C. 20402.
4.
doit toujours
de courant.
NIOSH,
obtainable
3.
darrŒt
source
NFPA Standard 70-1978, NATIONAL ELEC
TRICAL CODE obtainable from the National Fire
Protection Association, 470 Atlantic Avenue,
Boston, MA 02210.
B, CUTTING AND WELDING
PROCESSES obtainable from the National Fire
Protection Association, 470 Atlantic Avenue,
NFPA Standard 51
Boston, MA 02210.
-
OM-1516 Page 11
11.
CGA Pamphlet P-i, SAFE HANDLING OF COM
PRESSED GASES IN CYLINDERS obtainable
from the Compressed Gas Association, 500 Fifth
Avenue, New York, NY 10036.
ii.
CGA Pamphlet P-i, SAFE HANDLING OF COM
PRESSED GASES IN CYLINDERS distribuØ par
Ia Compressed Gas Association, 500 Fifth
Avenue, New York, NY 10036.
12.
CSA Standard Wi 17.2, CODE FOR SAFETY IN
WELDING AND CUTTING obtainable from the
Canadian Standards Association, Standards
Sales, 178 Rexdale Boulevard, Rexdale, Ontario,
Canada M9W 1 R3.
12.
CSA Standard Wi17.2, CODE FOR SAFETY IN
WELDING AND CUTTING distribuØ par Ia Cana
dian Standards Association, Standards Sales,
178
Rexdale
Boulevard, Rexdale, Ontario,
Canada M9W 1R3.
13.
NWSA
13.
NWSA
WELDING
booklet,
SAFETY
BIBLIOGRAPHY
distribuØ par Ia
National
Welding Supply Association, 1900 Arch Street
Philadelphia, PA 19103.
14.
American
Welding Societe Standard AWSF4.i
Recommended Safe Practices for the Prepara
tion for Welding and Cutting of Containers and
Piping That Have Held Hazardous Substances,
distribuØ par lAmerican Welding Societe, 550 Le
Jeune Rd., P.O. Box 351040, Miami, FL 33i35
15.
ANSI Standard Z88.2 Practice For Respiratory
Protection
distribuØ par IAmerican
National
Standards Institute, 1430 Broadway, New York,
NY 10018.
WELDING
SAFETY
booklet,
BIBLIOGRAPHY obtainable from the National
Welding Supply Association, 1900
Philadelphia,
14.
Arch Street,
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,
550 Le Jeune Rd., P.O. Box 351040, Miami, FL
33135.
15.
ANSI Standard Z88.2 Practice
Protection
for
Respiratory
obtainable from the American Na
tional Standards Institute, 1430 Broadway, New
York, NY 10018.
OM-1516 Page 12
SECTION 2
-
INTRODUCTION
Model
Single
12
70
Speed Range
16
Single
750
(1.78 m) to
(19 ml per
minute
Boom
J
12 ft. (3.7 ml
Length
Swing
16 ft. (4.9 ml
3600
Vertical Lift
Horizontal To 60
Height (With 4 Ft Post)
At Full Lift Of Boom
Aaximum
Above
21 ft. (6.4 m)
17 ft. 15.2 ml
Compression Spring Is Designed To Balance Boom
Any Angle. Pressure Adjustment Is Provided To
H~IWTIºB~OiwArAny-Desired-.leOr To Limit
The Vertical Lift At 40, 50, or 60.
At
(Patented(
Net 155 lbs.
Weight
2
1.
-
170 kg)
Ship 265 lbs.
1120 kg)
Net 205 lbs.
Ship
(93 kg)
335 lbs.
(152 kg)
carefully followed could result in minor personal injury
damage to this equipment.
GENERAL INFORMATION AND SAFETY
or
A.
General
IMPORTANT highlights instruc
signal word, _______________,
tions which need special emphasis to obtain the most
efficient operation of this equipment.
A third
Information presented in this manual and on various
labels, tags, and plates on the unit pertains to equip
ment design, installation, operation, maintenance, and
troubleshooting which should be read, understood, and
followed for the safe and effective use of this equip
The
-
2.
-
this
ment.
B.
Prior to installing
RECEIVING-HANDLING
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
2
Safety
installation,
operation,
maintenance,
and
troubleshooting of arc welding equipment requires
practices and procedures which ensure personal safety
and the safety of others. Therefore, this equipment is to
be installed, operated, and maintained only by qualified
persons in accordance with this manual and all ap
plicable codes such as, but not limited to, those listed at
the end of Section 1
Safety Rules For Operation Of
Arc Welding Power Source.
-
quest if occasion to file claim arises.
requesting information concerning this equip
ment, it is essential that Model Description and/or
Stock Number and Serial (or Style) Numbers of the
When
equipment
2
Safety instructions specifically pertaining to this unit ap
pear throughout this manual highlighted by the signal
words I~I.~hIh~IcI and CAUTION which identify
be
supplied.
3. DESCRIPTION
This unit is a boom mounted
wire feeder. The wire feeder is of the constant wire feed
speed type and is designed to be used in conjunction
-
with
-
a
constant
potential welding
power
source.
The
___________
different levels of hazard.
boom is
ITiTL~ ~h I I~IeI statements include
swing. Cables are routed through the boom from the
feeder control to the weld head assembly.
installation, operating,
and maintenance procedures or practices which if not
carefully followed could result in serious personal injury
or
loss of life.
CAUTION
statements include
installation, operating,
a
patented design allowing both vertical lift and
The wire feeder is a heavy duty wire feeding unit com
bining both the wire feeder and the control. It contains
all the controls and equipment needed to supply
welding wire
and
____________
and maintenance
procedures
or
practices which
SECTION 3
3
-
1. LOCATION AND ASSEMBLY
shielding
gas to the
welding
gun.
if not
-
(Figure 3-1)
INSTALLATION
pivot upward to the desired angle. Proper placement
provide sufficient clearance from obstruction at
the wire support end of the unit when the boom swings.
The structure to which the unit is being installed should
be of sufficient construction to support the weight of
the unit when the boom is in the horizontal position.
will also
A.
Location
A suitable location for this unit will allow
boom to
swing horizontally
room
for the
in the desired arc, and to
OM-1516
Page
13
Assembly
B.
a.
Uncrate and
remove
packing material
all
from the unit.
Existing Support (Customer Supplied)
1.
b.
WARNING
FALLING BOOM
can
Mount post support to the desired structure.
serious
cause
___________
and equipment damage.
Use 2-1/2 in. (63.5 mm) diameter, Schedule 40
pipe (wall thickness of 0.203 in. or 5.2 mm) as
personal injury
support pipe for 12 foot (3.7 m) booms.
Use 5 in. (127 mm) diameter, Schedule 40 pipe
(wall thickness of 0.258 in. or 6.6 mm) as support
pipe for 16 foot (4.9 m) booms.
a.
Uncrate and
from the unit.
remove
all
IAY1~l~Il~rer FALLING BOOM
can
serious
cause
equipment damage.
personal injury
Securely mount unit to a structure that can
port the weight of the unit when the boom
the horizontal position.
and
c.
sup
is in
Remove yoke pin, nut, washers and bolt
from the yoke and swivel ilates.
packing material
WARNING: RELEASE OF SPRING PRESSURE
WITHOUT BOOM ATTACHED can cause serious
______
b.
Mount
pipe post
to the
desired structure.
personal injury
and
equipment damage.
Perform installation
c.
Proceed
to
Subsection 2.
exactly
as
outlined in
step-b y
step instructions below.
Support,
Post
Do not
Steps c-k.
remove
safety collar until instructed
to do
so.
Retain safety collar for future
Yoke Pin
disassembly
use.
Yoke
d.
Vent Screw
e.
f.
top of post and insert
Place bearing on
swivel into post.
Place the boom base plate between the two
swivel plates.
Slide
washer
onto
bolt
and
insert
bolt
through hole. Slide washer onto bolt and in
stall nut onto bolt Tighten nut; then back
.
off nut 1/2 turn.
Nut
g.
Swivel
h.
pin through yoke, hole,
pin through pin.
Insert
ter
Connect
assembly
Bar
the
as
welding
gun
instructed in
and install cot
to
the
the
drive
Owners
Manual for the desired welding gun.
Plates
Post
i.
Grasp bar 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.
j.
Remove and retain the
k.
The boom should
Support
now balance in any posi
tion from horizontal to 60 degrees above
horizontal. If the boom does not balance
properly, proceed
TB-080 040
Figure 3-1. Base And
WARNING
Boom
FALLING BOOM
can
Assembly
cause
personal injury and equipment damage.
Securely mount unit to a structure that
serious
can
sup
port the weight of the unit when the boom is in
the horizontal
2.
position.
Post Support (Optional)
OM-1516 Page 14
safety collar.
to
Section 3-12.
CAUTION EXCESSIVE. FRICTION can damage
equipment.
Periodically lubricate swivel to prevent wear.
Excessive lubrication is not required or recommended.
3.
Base
Support (Optional)
~ If
an
optional base support was pur
provided for
chased with the unit, mounting holes are
fastening the base support to the floor.
I~iTIi~lI~e~ FALLING
BOOM
can
serious
cause
personal injury and equipment damage.
For mounting base support use, as a minimum,
1/2/n. (12.7mm) diameter, S.A.E. grade 5 bolts.
Use equivalent strength, non-corrosive bolts if
unit is mounted in an extremely damp environ
3 -4. REINSTALLATION
Uncrate
and
remove
all
1.
a.
c.
Fasten base support to the floor.
c-k in Subsection 2. Post
Complete Steps
Support.
CAUTION:
FRICTION
EXCESSIVE
can
ASSEMBLY
Slide the following items onto the spindle sup
port shaft in order given:
packing material
from the unit.
b.
HUB
-
follows:
ment.
a.
OF
If it should become necessary to replace
the hub assembly, reinstall the new hub assembly as
(Figure 3-2)
Fiber Washer
b.
Flat Washer
c.
Hub
d.
Flat Washer
e.
Fiber Washer
f.
Keyed Washer
g.
Spring
h.
Flat Washer
damage
equipment.
Periodically lubricate swivel to prevent wear.
Excessive lubrication is not required or recommended.
4.
Swingpak
a.
Base
(Optional)
Shaft
all
Uncrate
and
from the
Swingpak base.
remove
FALLING BOOM
WARNING:
packing material
can
cause
Washer
serious
equipment damage.
personal injury
Mount welding power source on Swingpak base
before mounting Swingarc.
and
b.
c.
all
Uncrate
and
from the
Swingarc unit.
remove
Complete Steps
Support.
c
-
packing
material
Flat WasherS
k in Subsection 2. Post
Retaining Ring
TB-080 037
Figure 3-2. Wire Support And Hub Assembly
CAUTION
EXCESSIVE FRICTION can damage
equipment.
Periodically lubricate swivel to prevent wear.
Excessive lubrication 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 wire feeder. The vent screw can be
removed through the hole provided in the motor shroud
-
-
3
2.
Rotate hex nut onto support shaft. Hex nut
should be rotated only until a slight drag is felt
while turning hub.
3.
Install
5.
-
retaining ring
INSTALLATION
onto hub.
OF
SPOOL-TYPE
WIRE
(Figure 3-2)
(see Figure 3-1).
1.
Remove
2.
Slide the spool of wire onto the hub so that the
wire will feed off the top of the spool. The spool
turns in a clockwise direction.
CAUTION: PRESSURE IN WIRE DRIVE MOTOR
GEAR BOX will damage motor.
Remove vent
screw
Warranty is void if the
to operation.
prior
to
operation.
vent screw is not removed
prior
3.
3
3. INSTALLATION OF WIRE SUPPORT
-
(Figure
retaining ring.
Rotate the
spool until the hole in the spool aligns
pin in the hub. Slide the spool onto the
hub until it seats against the back flange of the
with the
3-1)
hub.
1.
Remove the
securing
screws
and lock washers
from the swivel base.
2.
3.
4.
Lift the wire support in place
swivel base.
Insert
securing
tighten.
screws
over
the holes in the
with lock washers and
3
-
6.
Reinstall
retaining ring.
INSTALLATION
OF
REEL-TYPE
WIRE
(Figure 3-3)
1.
Lay the wire reel flat
on a
table
or
floor.
OM-1516
Page
15
3
-
7.
INSTALLATION OF WIRE REEL (Optional)
(Figure 3-3)
Fingers
1.
Remove retaining ring.
2.
Slide the wire reel onto the hub. Rotate the wire
reel until the hub guide pin is seated in the reel.
3.
Reinstall retaining ring.
Nuts
Hub
Pin
3 -8. DRIVE ROLL AND WIRE GUIDE INSTALLA
TION (Figure 3-4)
Upon initial installation, or as a
result of changes in wire size and type, it is necessary to
install the required drive rolls and wire guides.
-
IMPORTANT Base selection of drive rolls upon the
recommended usages:
V-Groove rolls for hard wire.
U-Groove rolls for soft and soft shelled cored wires.
following
1.
2.
3.
U-Cog rolls for extremely
surfacing types).
soft shelled wires
(usually
hard
Split V-Knurled rolls for hard shelled cored wire (se/fshielding and C02 shielded types).
5. Drive roll types may be mixed to suit particular re
quirements (example: V-knurled roll in combination
with U-groove).
4.
Figure 3-3. Reel
Installation
2.
Loosen the four
wire reel.
3.
Pull the four fingers out until they
toward the center of the reel.
4.
Install
the wire
wing
nuts on the
the
onto
reel
fingers. Ensure that the wire
tom
of
the
reel.
The
TB-080 038
fingers of the
can
be rotated
Having selected
guides, proceed
Rotate the four
tion.
Tighten
fingers
the four
appropriate drive rolls and wire
following installation instruc
the
over
the
four
A.
Drive Roll Installation
(Figures
3-4 & 3-5)
feeds off the bot
reel
in
turns
a
1.
Loosen pressure adjustment knob
pivot it free of the cover.
(Figure 3-4)
and
back to their proper
wing
to
tions:
counterclockwise direction.
5.
the
posi
2.
Pivot gear
cover
away to expose pressure gear.
nuts.
Anti-Wear Guide
Liner
Inlet Wire Guide
Wire Guide~
Pressure
Adjustement
Knob
Inlet Wire Guide
Securing
Screw
Gun/Feeder Connector
Securing
Knob
Bolt
Adapter
Securing
Screws
TB081
Figure 3
OM-1516 Page
16
-
4.
Drive Roll Installation
810D
3.
Loosen and
remove
the three
securing
For 3/32 in.
2.
screws on
1/8 in. (2.4-3.2 mm) wire.
-
each gear.
a.
For
one
piece drive rolls: slide
a
split drive rolls: align holes on each pair of
split drive rolls, insert a securing screw and slide
For
drive roll onto a drive gear and pressure gear
with screw in line with one of the threaded holes.
a
Insert
remaining
Ik~lI.].~i..UIg
screws
and
b.
are
d.
Install
guide
feed the wire.
provide
so that the unused edges will
knurled groove.
a new
the
Insert
of the double
halves may be reversed
To
ensure
proper
gripping
action of
on
inlet
secure
IMPORTANT Drive roll
screw.
should be installed
close to the drive roll
wire
in
into
guide
so
as
drive
Figure 3-4. Secure
guide(s)
onto
inlet wire
with setscrew.
alignment
has been
factory
set, but if readjustment is necessary rotate the drive
gear securing bolt thereby moving the drive roll in or out
of the desired position. The drive roll on the pressure
on
the wire when the gear
cover
is
replaced and the gears mesh together.
drive
rolls, both rolls should be installed showing
the side or both should show the side without
slots. A/so, it is necessary to line up the blunted teeth
U-Cog
slots
as
anti-wear
and
gear will locate itseff
IMPORTANT
guides
guide securing
assembly as illustrated
by tightening screw.
usage type. When the grooves become worn, reverse
each drive roll, locating the unused groove in position to
now
Wire
IMPORTANT
that the tip of the guide is
possible without touching.
c.
Split drive rolls are of the double usage type. When the
knurled groove of the drive rolls becomes worn, the spilt
guide(s) from inlet wire
Loosen the inlet wire
______________
tighten.
One-Piece drive rolls
Remove anti-wear
guide.
drive roll onto
the drive gear and pressure gear with holes align
ed and secure with screws.
4.
on
the pressure gear roll directly over the spaces bet
the teeth on the drive gear rolL
ween
The wire drive housing is made with mounting holes of
sufficient clearance to provide adjustment of the wire
guides up or down in relation to the drive rolls. This ad
justment has been factory set, but if readjustment
becomes
necessary,
loosen
mounting
bolts
(Figure
3-4), weld terminal nut and bolt, located behind moun
ting plate. Slide the wire drive housing upward or
downward until the wire can be fed straight through the
guides while seated in the drive roll groove. Tighten
mounting bolts, weld terminal bolt and nut.
Pressure Gear
U-Cog
3
-
9. WATER CONNECTIONS (Optional)
Roll
CAUTION OVERHEATING
Welding
Slotted Side
Of
U-Cog
If
Roll
using
a
of
Gas
Metal-Arc
gun.
water coo/ed gun and
recirculating
can
gun
damage
coolant system, do not make connections from
the coolant pump to water valve; instead, make
connections
directly
from the coolant system to
gun hoses.
TB-080 158-A
Figure 3-5. U-Cog Drive Rolls Installation
Installation Of Water Hoses
A.
water-cooled gun is used, route the water hose
supply, to the water input fitting on the
of the control. This fitting has left-hand threads.
When
a
from the water
B.
1.
Inlet Wire Guides
For .023 in.
a.
-
(Figure 3-4)
rear
5/64 in. (0.6-2.0 mm) wire.
Insert liner into inlet wire
guide and
secure
with setscrew.
b.
Loosen the inlet wire
Connect the water out hose to the adapter on the weld
cable terminal on the drive assembly. These fittings
have left-hand threads. Route the water out hose to a
proper disposal or cooling system. Water is available
when the POWER switch is placed in the ON position.
guide securing
screw.
B.
Electrical Reconnection Of Water Solenoid
I I~ I MIs . Wil ~I ~ 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.
tightening screw.
Secure by
The control is
shipped connected
supply water when
position. The water
solenoid circuitry can be modified to supply water when
the gun trigger is depressed.
to
the POWER switch is in the ON
OM-1516
Page
17
Shut the unit down and disconnect from line
1.
An integral gas input fitting is provid
the weld head for guns utilizing this type of con
nection. See the appropriate welding gun Owners
ed
power.
ELECTRIC SHOCK
WARNING
can
kill.
__________
Do not touch five electrical parts.
Disconnect input power to the wire feeder
or
on
Manual for instructions on making this connection. If
the hose is provided with a fitting, cut the fitting off,
and push the hose onto the barbed fitting on the drive
assembly.
employ lockout/tagging procedures on the
welding power source before internally inspecting
or servicing.
Lockout/tagging procedures consist of padlocking line
disconnect switch in open position, removing fuses
from fuse box, or shutting oft and red-tagging circuit
breaker or other disconnecting device.
Work on internal parts to be performed by qualified per-
plug from the gun trigger is to be inserted fully into
the trigger control cable and the locking ring rotated.
When the switch connected across this receptacle is
closed, the contactor in the welding power source will
sons.
energize, shielding
0.
Trigger
Control
The
gas will flow and wire will
begin
to
feed.
2.
Remove control box wrapper.
3.
Locate terminal
Water (If
E.
strip iT
on
bottom
panel
of
Connect the water input hose from the gun
output hose from the control.
trol.
4.
5.
Move lead 35 from terminal A
on
terminal
strip
Connect the water return hose from the gun to the
Replace
adapter at the weld terminal on the drive assembly. A
reducing bushing is provided to accept a 5/8-18 L.H.
fitting. If the bushing is removed, a 7/8-14 L.H. fitting
wrapper.
The outlet
IMPORTANT
guide
is
3-11. SHIELDING GAS CONNECTIONS
A hose is
supplied with the unit for making connections from the
-
provided
as
part of
the gun assembly.
Loosen
the
gun/feeder
connector
securing
guides should be installed
guide is as close to the drive roll
possible without touching.
Wire
IMPORTANT
so
______________
tip
of the
guide into the drive assembly opposite
wire guide as illustrated in Figure 3-4.
outlet
inlet
the
rear
The gas hose routed through the boom connects to the
Shielding Gas output fitting at the front of the control.
3-12.
BOOM ADJUSTMENTS (Figure 3-6)
the
A.
Weight
WARNING
Tighten
the
gun/feeder
connector
securing
knob.
Applicable) (Figure 3-4)
Weld Cable (If
B.
of the drive
portion
junction point for joining
together the weld cables from the welding power
source and the gun (if so equipped). Remove weld ter
minal nut, lock washer, and flat washer; slide the weld
cable from the gun onto weld terminal; replace flat
washer, lock washer, nut and tighten.
A terminal is provided
assembly
C.
The
to
on
as
a
Shielding Gas
shielding gas hose from the gun is to be connected
hose which protrudes from the motor end of
to the gas
the boom.
OM-1516
serve
the lower
Page 18
Lift
Adjustment
FALLING BOOM
can
cause
serious
____________
personal injury and equipment damage.
Maintain full threads on adjustment rod through
the
3.
gas source to the Shielding Gas input fitting at
of the control. These fittings have right-hand
as
Insert the connector which includes the installed
2.
shielding
threads.
knob.
that the
be accomodated.
can
Outlet Wire Guide (Figure 3-4)
1.
to the water
iT to terminal B.
3-10. WELDING GUN CONNECTIONS
A.
Applicable)
con
yoke.
The amount of weight which the boom can retract into
the upright position when released can be varied by ad
justing the jam nut and adjustment rod located at the
base of the boom. If a heavier gun is 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
the adjustment rod so that the adjust
ment rod threads into the yoke. When the proper ad
justment is obtained, tighten the jam nut against the
base of the yoke. If a lighter gun is used with the Sw
ingarc, rotate the adjustment rod so that the adjustment
rod threads out of the yoke.
nut and rotate
B.
Locking Knob
By rotating the Locking Knob 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
3-16. WELD CABLE CONNECTION
respectively during
Do not touch live electrical parts.
Disconnect input power to the
boom to 50
degrees
or
40 degrees
free travel.
WARNING ELECTRIC SHOCK
can
kill.
we/ding power
employ lockout/tagging procedures
on the welding power source before connecting
the weld cable to the welding power source.
Lockout/tagging procedures consist of padlocking line
disconnect switch in open position, removing fuses
from fuse box, or shutting off and red-tagging circuit
breaker or other disconnecting device.
source or
3-13. WIRE PULLEY (Figure 3-1)
-
Position of the
guide pulley adjusted by placing the axle through
the holes in the support arms. The boom is shipped with
wire guide pulley positioned through upper set of holes
for running wire of smaller diameter (.030 5/64 in. or
2.0 mm). If excessive wear is noticed in the inlet
0.8
is
wire
-
-
guide and/or guide tube, or if the boom is to be used for
running wire of larger diameter (3/32 1/8 in. or 2.4
-3.2 mm), position wire guide pulley through lower set
-
of holes.
A weld cable extends out of the wire support end of the
boom for making secondary connections to the welding
power source. The end of the weld cable is equipped
with a terminal for a 1/2 in. (12.7 mm) stud.
3-17. REMOTE CONTROL CONNECTIONS (Figure
A receptacle is provided for connecting a remote
4-1)
control to the unit. Align keyways arid insert plug from
-
the remote control into the receptacle arid rotate the
threaded collar clockwise as far as possible.
3-18. ADJUSTMENT OF KUB TENSION
3-2)
(Figure
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
-
Check the hub tension
hex nut
on
the end of the
spindle support shaft
accor
dingly.
Figure 3-6.
Boom
Adjustmfnts
3-19. 115
MOTOR CONTROL CONNECTIONS (Figure
A receptacle is provided for connecting the
3-7)
motor control plug to the control. Align keyways and in
sert the plug from the control end of the boom into the
receptacle and rotate the plug threaded collar clockwise
as far as possible.
3-14.
-
VOLTS/CONTACTOR
CONNECTIONS
(Figure 3-7) A loft. (3 m) cable is provided for 115
volts ac power and contactor control connections bet
ween control and welding power source. Route the
cable through the handles on the wire feeder base and
ensure that it will not interfere with wire feed. Align
keyways and insert the plug into receptacle on the con
-
trol and rotate the threaded collar clockwise
as
far
as
possible. Insert the 115 volts power plug into the 115
volts ac receptacle on the welding power source and
rotate clockwise to lock in place. Insert contactor con
trol plug into the contactor control receptacle on the
welding power source and rotate clockwise to lock in
place.
115 Volts/Contactor
Control Receptacle
Motor Control1
Cord
TA-072726
Figure 3-7. Rear Panel Connections
3-15. GUN TRIGGER CONNECTION (Figure
A TRIGGER receptacle is provided for making
4-1)
gun trigger control connections. The gun trigger control
cables extend out of the control end of the boom. Insert
the gun trigger control plug into the TRIGGER recep
tacle and rotate threaded collar clockwise.
-
tI~uile]~f IMPROPER VOLTAGE APPLIED TO
WELDING POWER SOURCE CONTACTOR can
damage wire feeder and welding power source.
Ensure welding power source contactor control
cIrcuitry requires external supply of 115 vac for
contactor control.
Wire feeder supplies 115 volts
ac to
the
welding
power
source.
OM-1516 Page 19
SECTION 4
Fuse
-
FUNCTION OF CONTROLS
Retractf Feed
Switch
4
-
5. WIRE SPEED CONTROL
(Figure 4-1)
-
The
WIRE SPEED control provides a means of determining
the rate at which welding wire wilt be fed into the weld.
Rotating
the WELD SPEED control clockwise increases
the rate of the wire feed.
6. START SWITCH (Figure 4-1)
The START
switch provides the capability of being able to select
either a slow wire feed speed for 1/2 second at the
beginning of wire feed, or the wire feed speed at the
4
-
-
rate set on the WIRE SPEED control. The SLOW posi
tion of the START switch provides the 1/2 second of
slow wire feed, and the FAST position provides wire
feed at the rate set
TA-072725
Figure
4-1. Control
Components
1. POWER SWITCH (Figure 4-1)
Placing the
POWER switch on the control in the ON position will
apply 115 volts ac to the unit and thereby place it in an
4
-
-
operational condition, ready to feed wire and permit
shielding gas to flow. Placing the POWER switch in the
OFF position will shut the wire feeder down.
4
on
the WIRE SPEED control.
7. RETRACT-FEED SWITCH (Figure 4-1)
The
RETRACT-FEED switch determines whether the wire
feeds out of the gun or retracts back into the gun when
the gun switch is closed. The RETRACT position causes
the wire to go back into the gun, and the FEED position
-
-
the wire to feed out of the gun. The switch
should be in the FEED position for normal operation.
causes
FEED
RETRACT
CHANGING
CA U tI O~ N
________
POSITION while welding can damage
switch and wire drive motor.
Do not change position of switch while the wire
SWITCH
2. REMOTE CONTROL RECEPTACLE AND
SWITCH (Figure 4-1)
The remote control receptacle
is provided for use in conjunction with certain optional
controls. If a remote control is to be used, make con
nections as instructed in Section 3-17 and place the
Remote Control switch in the REMOTE position. If a
remote control is not to be used, place the Remote Con
trol switch in the STANDARD position.
4
-
-
4
-
3. PURGE BUTTON
button is
a
(Figure 4-1) The PURGE
momentary contact switch. This switch
purges the shielding gas
line of the gun. The PURGE button also allows the
shielding gas regulator to be adjusted without energiz
the
welding circuit.
4. JOG BUTTON
(Figure 4-1) The JOG button
momentary contact switch. When actuated it com
pletes the circuit to the motor without having to depress
the gun trigger switch. This switch permits jogging of
the wire at the WIRE SPEED control setting, without
energizing the welding circuit or the shielding gas valve.
4
is
-
A
8. RESET CIRCUIT BREAKER (Figure 4-1)
circuit breaker 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 out
put. Should this breaker trip, the RESET button would
have to be manually depressed in order to reset the cir
4
-
-
-
a
cuit breaker.
The
9. BURNBACK CONTROL (Optional)
burnback circuitry in this control provides a means of
keeping the welding wire from sticking to the workpiece
after the gun switch is released. The burnback capabili
ty in this wire feeder keeps weld current present on the
welding wire from 0 to 15 cycles after the wire has stop
ped feeding, depending upon the setting of the BURN-
4
-
-
BACK control. This delay action permits the welding
wire to burn back to a point where it neither sticks to the
workpiece nor the contact tube. If the welding wire
sticks to the contact tube, rotate the BURNBACK con
trol counterclockwise. If the welding wire sticks to the
workpiece,
SECTION 5
5
-
running.
-
energizes the gas solenoid and
ing
drive motor is
-
rotate the BURNBACK control clockwise.
SEQUENCE OF OPERATION
1. WELDING WIRE THREADING
CAUTION: WELDING WIRE
can cause
puncture
________
wounds; HOT SURFACES
WARNING: ELECTRIC SHOCK
can
kill.
Do not activate gun
can
burn skin.
trigger until instructed
to
do
____
Do not
energize we/ding
power
feeder until instructed to do so.
source
or
wire
so.
Do not
Do not touch live electrical parts.
Welding wire and all metal parts in contact with it carry
weld current when the welding power source contactor
is
energized.
other
point gun
towards any part of the
Allow gun to cool before
1.
Install the wire
Page 20
or
touching.
(reel-type
structed in Section 3-5
OM-1516
body
personnel when threading welding wire.
or
or
spool-type)
3-6.
as
in
Cut off any portion of the free end of the wire
which is not straight. Ensure that the cut end is
2.
free
from
surfaces
rough
to
permit
proper
See Section
Welding
1
-
Safety Rules For Operation Of Arc
welding safety in for
Power Sources for basic
mation.
feeding.
5 -2. GAS METAL-ARC WELDING
Route the wire through the wire guide tube on
the side of the boom, over the wire pulley, and to
3.
1.
the drive assembly.
2.
on the drive roll pressure ad
the
justment, pivot
pressure adjustment free of
the cover, and pivot the pressure gear assembly
Loosen the knob
4.
away until it is in
Feed the wire
5.
the drive
Feed
an
open
on
as
instructed in
Place the Remote Control switch in the desired
position.
3.
position.
the inlet wire
through
rolls, and
Make all necessary connections
Section 3.
4.
guide, past
guide.
Place the START switch in the desired position.
Place the RETRACT-FEED switch in the desired
position.
into the outlet wire
4 inches (102 mm) of wire
approximately
5.
Energize the welding
align
6.
Place the POWER switch in the ON position.
when the gear cover is closed, pivot the gear
cover away from the drive gear and rotate the pressure
gear one tooth (see Section 3-8).
7.
into the outlet wire
IMPORTANT: If the
guide.
U-Cog
drive rolls do not
power
source.
_____
properly
6.
Rotate the WIRE SPEED control to the desired
setting.
Pivot the gear cover closed making sure the
on the pressure gear mesh with the teeth
on the drive gear. The welding wire must also be
the
8.
Turn
9.
Depress the PURGE button for
on
shielding
gas at the
source.
teeth
one
minute.
in the grooves of the drive rolls.
10.
7.
Pivot the pressure adjustment knob until the
washer on the pressure adjustment is seated on
top of the gear
Hold the
tip of the
11.
cover.
Turn
the pressure adjustment knob 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
and the wire feeder are put into operation.
source
10.
11.
Draw the gun cable out
Energize
the
welding
properly adjusted to prevent slippage.
slippage is noticed, tighten the drive roll
pressure adjustment knob 1/2 turn clockwise.
Repeat until slippage stops. Do not overtighten.
If wire
IrL~:i~1ll~fef ELECTRIC SHOCK
Do not touch
source.
Place the control POWER switch in the ON
any metal part in
posi
5
tion.
12.
kill.
can
welding wire or
wit/i it while we/ding.
Do not touch live electrical parts.
Welding wire and all metal parts in contact with it carry
weld current when the welding power source contactor
is energized.
straight.
power
on the gun handle. Gas will
and wire will start to feed if drive roll
pressure is
contact
9.
approximately 1/2 inch
Depress the trigger
start to flow
8.
gun
(12.7 mm) from the workpiece.
3. SHUTFING DOWN
-
the
1.
Turn off the
welding wire through the gun without placing
weld current on the welding wire. Release the
2.
Place the POWER switch in the OFF position.
welding wire extends ap
inch (25.4 mm) out of the gun
3.
Turn off all associated
Depress the JOG switch.
This
will
run
shielding
gas at the
source.
JOG switch when the
proximately
tip.
one
RAYS, SPARKS, AND HOT
burn eyes and skin; NOISE can
WARNING: ARC
SURFACES
can
equipment.
tI~II~cr Gases can harm health or kill.
Shut off gas supply when not in use.
damage hearing.
body protection.
seriously harm your
Wear correct eye, ear, and
FUMES AND
GASES
can
health.
Use
enough ventilation to keep fumes and
breathing zone.
gases
from the
OM-1516 Page2l
SECTION 6
6
INSPECTION
shop conditions
of
AND
UPKEEP
Usage and
frequency and type
maintenance. Inspect equipment as follows:
-
1.
-
-
will determine the
MAINTENANCE
6
4. BRUSH
-
INSPECTION
&
REPLACEMENT
(Figures 6-1 & 6-2)
ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Disconnect input power to the wire feeder
WARNING
_________
~ ELECTRIC SHOCK can kill;
WELDING WIRE can cause puncture wounds; HOT
SURFACES can burn skin.
Disconnect unit from input power before internal
ly inspecting
or
servicing.
Allow gun and unit to cool before touching.
Do not activate gun trigger while performing
maintenance
on
gun.
breaker
Make
1.
sure
welding
power
is shut down.
source
or
employ lockout/tagging procedures on welding
power source before internally inspecting or ser
vicing.
Lockout/tagging procedures consist of padlocking line
disconnect switch in open position, removing fuses
from fuse box, or shutting oft and red tagging circuit
Work
other disconnecting device.
internal parts to be performed by
or
on
qualified
per
sons.
2.
3.
Inspect gun for broken areas, cracks and loose
parts: tighten, repair, and replace as required.
1.
Shut unit and associated equipment off.
Carefully
2.
Open brush cap by sliding screwdriver
catch and lifting. Remove brush cap.
3.
Grasp spring retaining bracket with long-nose
pliers.
remove
any weld spatter
or
foreign
matter which may accumulate around the nozzle
orifice. Use
a
hardwood stick,
never a
metal tool.
Repair or replace, as required, all hose and cable;
give particular attention to frayed and cracked in
sulation and areas where it enters equipment.
4.
under
4.
Push spring
retaining bracket
in
lightly
and
towards brush. This should release the
5.
Remove grease and grime from components;
moisture from electrical parts and cable.
6.
Blow out the gun wire guide liner with compress
ed air when changing wire. This will remove any
assembly and it
can
move
spring
be removed.
Spring
metal
chips
Spring Retaining
Bracket
and dirt that may have accumulated.
Brush
~lMPORTANT: Periodically inspect the labels
unit for
legibility. All
clearly readable state
on
the
labels must be maintained in
and
replaced when
a
necessary.
See Parts List for part number of labels.
Brush
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.
6
-
WARNING
HIGH
ROTATIONAL
SPEED
TA-046 226
cause
damage
to drive
Figure 6-1. View Of Spring Assembly And Brush
When Brush Cap Is Opened
5.
PUll brush out
6.
If)the
may
_________
rolls.
compressed
assembly.
air is used for
high speed if
cleaning the drive roll
Connect
8.
Route pigtail through slot in brush box. Ensure
that the pigtail will not come into contact with a
metal surface.
IMPORTANT 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.
9.
OM-1516 Page 22
brush
pigtail
to
brush box tab.
Insert brush into brush box. Ensure that the low
towards the
10.
The control is protected
from damage due to an internal short or excessive
overload by fuse Fl. Should Fl open, the control would
be completely inoperative.
-
new
end of the bevel
______________
(Figure 4-1)
less than 1/4 in. (6.4 mm)
are
7.
roll(s) (see Section 3-8 for removal and installation in
structions).
3. FUSE
brushes
brush.
To clean the wire grooves it will be necessary to discon
nect unit from line power before removing the drive
-
using brush pigtail.
long, replacement is necessary. Disconnect the
brush pigtail from the brush box tab and remove
Do not allow drive rolls to rotate at
6
Pigtail
-
on
the top of the brush is
spring.
Using long-nose pliers insert spring assembly
beside brush sliding the spring retaining bracket
along the brush box wall. The spring retaining
hooks on the
lustrated in Figure 6-2.
bracket
brush
box
wall
as
il
11.
If the spring retaining bracket is in place, it will be
against the brush box wall when the pliers are
Long-Nose Pliers
released.
Brush Box
Spring Assembly
Tab
12.
Ensure that the spring is in the proper
illustrated in Figure 6-1.
13.
Replace and latch the brush
14.
Reconnect power to all
position
as
cap.
NOTE:
equipment and
resume
Spring,
assembly
hooks
here.
operation.
TA-046 226
Figure
SECTION 7
-
Spring Assembly And Brush
From Armature End Of Motor
TROUBLESHOOTING
trouble is not remedied after performing these pro
cedures, the nearest Factory Authorized Service Sta
tion should be contacted. In all cases of equipment
ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Disconnect unit from input power before internal
WARNING
_________
iy inspecting or servicing.
Troubleshooting of internal parts
by qualified persons.
6-2. View Of
malfunction,
to
performed only
be
the
manufacturers
recommendations
should be strictly followed.
t~.1uIlI1~ DISASSEMBLY
MAGNETS
The following chart is designed to diagnose and provide
remedies for some of the troubles that may develop in
ment
S
this unit.
can
OF
result in personal
MOTOR
FIELD
injury
equip
or
damage.
Limit wire drive motor repairs to brush
replace
ment.
The field magnets are very strong. If disassembly is at
tempted, injury to fingers and hands may result from a
magnet being drawn back into the motor. The field
magnets are matched sets and operation may be af
fected if the magnets are tampered with.
Warranty is void if the motor is tampered with.
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 trouble
developed.
Use this chart in conjunction with the circuit diagram
while performing troubleshooting procedures. If the
TROUBLE
PROBABLE CAUSE
Depressing gun switch will
not energize wire feeder.
Control POWER switch Si
in wrong position or defective.
Electrode
wire
is
not
REMEDY
Place Si to ON position.
~
energized and shielding gas
does not flow.
Replace defective Si.
115
volts
input fuse
Fl
*Replace Fl.
open.
115 volts/contactor control
plug is
not secure
Secure
plug
in
Secure
plug
in TRIGGER
receptacle.
in recep
tacle.
Plug from gun trigger control cable is not secure in
receptacle.
TRIGGER receptacle.
Coil of relay CR1 defective.
Circuit breaker CB1 tripped.
Replace CR1.
Manually
the front
feeds, shielding gas
flows, but electrode wire is
not energized.
Wire
115 volts/contactor control
plug is not secure in contac
tor
receptacle
power
on
reset CB1
by depressing the button
panel of the contro~ labeled RESET.
on
Secure plug in receptacle.
welding
source.
Defect
source.
in
welding
power
See
TROUBLESHOOTING Section
power source instruction manual.
in
welding
OM-1516
Page
23
TROUBLE
Wire feeds
erratically.
REMEDY
PROBABLE CAUSE
Pressure
on
drive rolls is in-
sufficient.
Drive
roll
wire size
Rotate pressure adjustment knob clockwise in 1/4
increments until wire slippage stops.
turn
is too large
being used.
for
Change
to proper size drive roll. See
Worn drive roll.
Replace drive roll. See Section 3-8.
Dirt in drive roll.
Clean drive roll
*lf it becomes necessary to replace any fuse in the
size is used.
wi
Sc
S-5~A
OM-1516 Page 24
7
-
instructed in Section 6-2.
~ and
r~iJ~ ~
Figure
as
Section 3-8.
1. Circuit
Diagram
October 1984
FORM: OM-1516E
Effective With Serial No. JE748368
PARTS
LIST
728-A
TD-072
34
C
33
35Fig
Item
33
Asembly
.39
18
Main
-
A
Figure
42
8
44
D
1
0
a,
-o a,
a
Quantity
Item
No.
Dia.
Part
Mkgs.
No.
1
3
PLG3
PLG8
4
5
6
Description
Main
Figure A
2
Model
081 964
039 635
7
9
10
-
.
.
-
12
.
.
14
14
PLG2
.
.
16
.
PLG9
19
.
.
20
20
21
22
010 606
056 108
604 550
25
26
26
PLG7(M)
072
072
072
048
088
103
FITTING, hose-brass nut~/8-16
FITTING, hose brass ferrule 0.425 ID
HOSE, No. 1 x3/16 ID (order by ft.)
CONTROL BOX (Fig B Pg 4)
CORD, motor 17 ft (consisting of)
CORD, motor2l ft (consisting of)
.
-
.
x
23/32
.
102
306
RECEPTACLE & PINS (consisting of)
079 535
TERMINAL, male
079 706
CLAMP, cable
604 825
CORD, No.18 3/c (order byft.)
078 992 CORD, power 27 ft (consisting of)
078 993 CORD, power 30 ft (consisting of)
600 323
CABLE, weld copper No. 3/0 (order by ft.)
077 455
TERMINAL, ring tongue 1/2 stud No.3/0 wire
600 742
TERMINAL, ring tongue 3/8 stud No.3/0 wire
079 628 BRACKET, retaining spring
Figure C BOOM (Pg 8)
t079 591 BASE, 4 ft. or
t079 214 BASE,6ft
t078 264 BASE, 4 ft. or
t079 216 BASE,6ft
t075 390 POST, support boom 4 ft (consisting of) or
t079 215 POST, support boom 6 ft (consisting of)
075 078 POST, support boom 4 ft (consisting of) or
t079 217 POST, support boom 6 ft (consisting of)
080 157 .FITTING,greasel/8NPT
010910 WASHER,flat-SAE3/8
079624 SCREW, cap-hexhd3/8-16x2
.
.
40
.
.
23
24
29
30
30
31
32
33
34
35
36
36
36
36
37
37
37
37
38
39
.
.
17
28
.
.
13
16
1
1
1
1
1
1
loft
lOft
1
1
1
1
.
.
11
27
interconnecting (consisting of)
.
8
18
-
CONNECTOR BODY, twistlock 2P2W 20 amp 250 volts
039 687
CAP, twistlock grounded 2P3W 15 amp 277 volts
605 156 .CORD, No. 18 4/c(orderbyft.)
079 531
CLAMP, cable
HOUSING PLUG & SOCKETS (consisting of)
048 284
079 534
TERMINAL, female
049 455
CORD, No.18 2/c (order byft.)
048 837 HOSE ASSEMBLY, gas (consisting of)
051 297 .ADAPTER
010 603
FITTING, hose brass barbed nipple 1/4 TBG
010 606
FITTING, hose-brass nut5/8-18 RH
056 112
FITTING, hose-brassferruleO.475 lDx23/32
603 106
HOSE, No. 1 (order byft)
049 012 CORD, trigger 16 ft (consisting of)
048 618 CORD, trigger 20 ft (consisting of)
RECEPTACLE W/SOCKETS, free hanging (consisting of)
080 328
079 534
TERMINAL, female
079 531
CLAMP, cable
605 156
CORD, No.18 4/c (order byft.)
HOUSING PLUG & PINS (consisting of)
079 878
079 535
TERM(NAL, male
079 202 HOSE, gas (consisting of)
079 204 HOSE, gas (consisting of)
056 851
FITTING, hose-brass barbed nipple3/16TBG
.
PLG1
I
Assembly
CORD, control
.
15
12
.
.
.
1
1
itt
itt
1
1
1
1
2
2
2
2
2
2
loft
lOft
1
1
1
1
4
4
2
2
i6ft
20ft
1
1
4
4
1
1
1
1
1
1
1
1
17ft
21ft
1
1
1
1
1
1
6
6
1
1
16ft
2Oft
1
1
24ft
28ft
.
1
1
.
1
1
1
1
1
1
-
.
-
-
-
1
1
1
1
1
1
1
-
1
-
1
1
1
1
1
1
OM-1516 Page2
Quantity
Item
Dia.
Part
No.
Mkgs.
No.
Figure
Model
Description
12
16
Main Assembly (Contd.)
A
WASHER, nylon-shoulder0.622x1 x3/8
MOTOR, gear 1/8 hp 115 volts dc 2000 rpm (consisting of)
080 283
COVER, brush
080282 .SPRING,brush
41
075 150
1
1
42
080 802
1
1
2
2
2
2
2
2
.
*080 281
.
BRUSH
43
015713
GROMMET.rubber5/l6IDxl/2mountinghole3/l6groove
1
1
44
079 635
INSULATOR,
1
1
45
FigureD WIREDRIVE&GEARS(PglO)(consistingof)
079 633
FITTING, hose-brassbarbednipple3/16TBG
46
47
48
49
50
motor
.
072 010
601 872
BUSHING
NUT, hex-fulI3/8
602 213 WASHER, lock-split 3/8
602 243 WASHER, fIat 3/8
1
1
1
1
2
2
1
1
1
1
1
1
*Recommended Spare Parts.
tOptional Equipment.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
10-072 729
Figure
OM-1516 Page3
B
-
Control Box
Item
Dia.
Part
No.
Mkgs.
No.
Figure B
1
2
SRi
3
Ti
Cl
4
5
6
CR2
7
2T
072 088 Control Box
047 818
031 692
006 426
006 393
038 784
9
RC5
039 756
10
PCi
057 314
010 296
11
13
602 934
046 724
14
079 573
12
010 141
15
16
PLG4
GS1
17
18
19
20
CR1
21
R13
22
Ri
23
24
25
26
R2
27
28
29
30
31
PLG7(F)
(Fig
A
P9
Quantity
2 Item 25)
1
+049 289 WRAPPER
070 634 LABEL, warning electric shock can kill
035 914 RECTIFIER, integrated 30 amp400 volts
045 139
8
Description
056 265
035 601
010 199
045 812
1
1
1
TRANSFORMER, controlll5-24 volts
CAPACITOR, electrolytic 750 uf 200 volts dc
BRACKET, mounting capacitor
RELAY, 24 volts ac DPDT flanged
STRIP, terminal 1 pole
BRACKET, mounting connector
TERMINAL, header 10 pin
CIRCUITCARD(FigBl Pg5)
FITTING, hose elbow male 1/4 NPT 5/8-18 RH
FITTING, pipe galvanized coupling 1/4 NPT
BRACKET, mounting control box
FITTING, pipe galvanized nipple L 1/4 NPT x 6
CLAMP,1/4
CONNECTOR, male 6 contact 10 amp
VALVE, 115 volts ac2 way 1/4 IPS port 1/8 orifice
TUBING,0.275IDx0.O48wallxl
BUSHING, 1/4ODxO.141 IDxl
TUBING,3/8ODxl8gawallxl/4
RELAY, 24 volts ac DPDT
RESISTOR,WWfixed25watt2000ohm
RESISTOR,WWfixed25wattl0 ohm
1
1
-
1
1
1
-
1
1
2
-
1
-
1
-
1
-
1
1
1
2
1
010193
034 841
079497
030 651
604311 GROMMET,i/4IDx3/8mtghole
056 170 SHIELD, resistor
030 949 HEAT SINK, rectifier
030 941 RESISTOR, WW fixed 100 watt 5 ohm
079 683 HEAT SINK, resistor
010 476 BUSHING, strain-relief 5/8x0.57 hole
007 826 CORD, No. 18 3/c (order byft)
079 706 CLAMP, cable
048 380 HOUSING PLUG & SOCKETS (consisting of)
079 534
TERMINAL, female
601 219 LINK,jumperterminalblock2oamp
6
1
1
1
1
1.
1
1
1
3 ft
1
1
3
.
32
33
34
iT
S1,3,6
35
S2
36
S4,5
37
R5
38
RC1
39
40
RC4
RC6
41
42
43
44
Fl
45
48
3
011 059
011 232
SWITCH,toggleDPDll5ampl25volts
2
048 283
RECEPTACLE W/PINS
079 535
.
SWITCH, push button SPDT
030 943 POTENTIOMETER, carbon 1 turn 2
1
1
-
watt
15K ohm
1
(consisting of)
1
TERMINAL, male
056 266 CONNECTOR, female 6 contact 7.5 amp
039 825 RECEPTACLE, 6 socket MS-3102A-i4S-6S
046 709 CASE SECTION, front/bottom/rear
NAMEPLATE (order by model & serial numbers)
024 366
*073 426
4
1
1
1
1
KNOB
1
FUSE, miniature glass sb blo 5 amp
046 432 HOLDER, fuse panel mounting (consisting of)
059 139
CAP, holder-fuse
1
-
1
-
46
47
1
BLOCK, terminal 20 amp 6 pole
011 233 SWITCH, toggleSPDTioamp25ovoltsac
038 772
1
.
RC2
CB1
048 282
079 534
011 991
RECEPTACLE W/ SOCKETS
(consisting of)
TERMINAL, female
CIRCUIT BREAKER, 1 pole 1 .5
1
4
.
Spare Parts.
ordering a component originally displaying
amp 250 volts
1
*Recommended
+
When
a
precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-1516
Page4
Dia.
Part
Mkgs.
No.
Fig
Bi
057 314
Description
Quantity
Circuit Card (Fig B Pg 4 Item 10)
044 602
2
031 643
031 693
3
1
Dl -4
031
031
026
D5
037
Qi
037
C2,3
C4,8,9
C7
Cl 0
C12
CAPACITOR, polyfilm 0.47 uf400voltsdc
CAPACITOR, ceramic 0.01 uf 500 volts dc
CAPACITOR, mylar 0.33 uf 75 volts dc
633 CAPACITOR, electrolytic 80 uf 25 volts dc
721 CAPACITOR, mylar 0.22 uf 200 volts dc
202 DIODE, 1 amp 400 volts SP
250 DIODE, zener 24 volts 1 watt
824 THYRISTOR. 7.4 amp 200 volts
037 261
02
R3
R4
R6
R7,10
HEATSINK
TRANSISTOR, unijunction 5OMA 35 volts
RESISTOR, carbon0.5wattl0 ohm
030 854 RESISTOR, carbon 0.5 watt 18K ohm
030 945 RESISTOR, carbon 2 watt 4700 ohm
028 276 RESISTOR, carbon 0.5 watt 2200 ohm
030 944
All
R20
030 938
030 090
T2
085 399
030 936
1
4
1
1
1
037 289
030 937
R8
R9
1
POTENTIOMETER, WW 1 turn 2 watt 5000 ohm
RESISTOR, carbon 0.5 watt 33K ohm
RESISTOR, carbon 0.5 watt 1200 ohm
RESISTOR, carbon0.5watt4l ohm
TRANSFORMER, pulse
1
1
1
1
2
1
1
1
1
1
TA-057 314
Figure Bi
-
Circuit Card
COMPONENTS TO BE
REPLACED BY QUALIFIED
PERSONNEL ONLY
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-1516 Page 5
Base selection of drive rolls upon the following recommended usages:
V-Groove rolls for hard wire.
t~ISII~
1.
2.
U-Groove rolls for soft and soft shelled cored wires.
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 C02 shielded types).
5. Drive roll types may be mixed to suit particular requirements (example: V-knurled roll
U-groove).
3.
Wire Diameter &
Fraction
Type
Kit No.*
Roll Drive
in combination with
Inlet Wire
Part No.
Type
Guide
087 131
087 130
V-groove
056 192
.8MM
079 594
053 695
V-groove
056 192
.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
.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
079604
053705
U-groove
056196
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
079 609
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
Decimal
Metric
.0231.025
.023/.025
.6MM
.030
.030
.035
.035
-
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
079614
053708
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-cpgged
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.
are required for the one piece drive kits and four drive rolls for the split V-knurled kits.
Two drive rolls
OM-1516 Page 6
I-
C)
.~.
0
(9
-C~C~
0
U-
0
0
9
0
I
Co
I-
CO
N
E
0
0
C.)
1~
0
U-
Cv)
I
cv,
Co
cv,
/
OM-1516
Page
7
Quantity
Item
Part
No.
No.
Figure C
Model
Description
Boom
(Fig
A
12
116
Pg 2 Item 35)
2
2
BUSHING, 0.622 IDxO.075x0.501 thick
079 621 PULLEY, V single groove
082 970 SHAFT, pulley
2
2
4
5
8
10
8
1
10
6
6
BOLT,U1-5/8
NUT, hex full 1/4-20
602 207 WASHER, lock-split 1/4
079 667 PIPE,1/2x133-3/4
080812 PIPE, 1/2x181-3/4
7
079 665
GUIDE, wire
080811 GUIDE, wire
079 664 GUIDE, inlet
045 391 TUBING,3/8IDxO.O93waIlx8
045390 LINER, monocoil 3/32 1/8 wire
007280 PIN, clevis 5/8-18 x 1-7/8
1
1
010313
2
079 622
3
4
5
7
8
9
10
11
PIN,cotter-hair0.072x1.437
079 632
601 865
-
-
PIN, clevis3/4 dia x2-5/32
12
073742
007279
12
13
13
073741
601 883
605884
CLEVIS
14
075401
14
075462
602250
11
15
16
Figure Cl
17
601 965
18
19
20
20
21
602213
079020
602 249
075 102
073 663
024 605
075 100
075 101
602219
21
22
22
23
23
24
079 030
24
601 883
079 029
25
080 449
25
080 722
075421
048 128
075 403
+072 090
+072 089
070 634
079 423
047 702
602 246
047 224
073 666
082 966
082 967
601 872
079 643
079 631
26
26
27
28
28
29
30
31
32
33
33
34
35
36
1
1
1
1
1
1
1
x
9
1
1
1
1
1
1
1
CLEVIS
1
1
NUT, hex-jam 5/8-18
NUT, hex-half 3/4-16
SHAFT, boom counter balance
SHAFT, boom counter balance
WASHER, flat-SAE3/4
SUPPORT, hub & reel (Pg 9)
SCREW, cap-hexhd3/8-16x1
WASHER, lock-split3/8
NUT, hex elastic stop 3/4-16
WASHER,flat-SAE5/8
WASHER, shield 3 inch
BEARING, ball
BEARING, ball
NUT, 5/8-18 x 1-1/4 special
NUT, 3/4-16 x 1-1/4 special
WASHER, lock external tooth 5/8
WASHER, lock external tooth 3/4
NUT, hex-jam 5/8-18
NUT, half-full 3/4-16
SPRING,2ODx1 IDx12
SPRING,3-3/8ODx22-1/4
SPACER, spring boom
PIPE,3x8
BEARING, thrust boom
BASE, swivel boom
BASE, swivel boom
LABEL, warning electric shock can kill
LABEL, caution heavy spring etc
LABEL, remove gearing vent etc
WASHER,flat-1/2
KNOB,T-bar
BOLT, hex-hd3/4-16x2-3/4
BOOM, single
BOOM, single
NUT, hex-full 3/8-16
GUARD, motor-protector
BRACKET, hanger gun
1
1
1
-
1
-
2
2
1
1
4
4
4
4
1
1
1
1
1
1
1
1
1
-
1
-
1
1
2
1
1
-
1
1
-
1
-
1
-
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
1
1
1
1
-
+ When 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-1516 Page 8
Item
Part
No.
No.
Description
Figure Cl
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
079
010
058
058
057
010
605
601
Support.
638
191
628
428
971
233
941
884
058427
t056 416
604051
056312
056313
010224
601 880
056314
Hub & Reel
(Fig
C
Quantity
Pg 8 Item 16)
1
SUPPORT, reel
WASHER, fiber 5/8 ID x 1-1/2 OD x 1/8
WASHER, brake
HUB,spool
WASHER, flat-keyed 1-1/2 dial/8
SPRING, compression
WASHER,fIat4l/64lDx1 OD
NUT, hex5/8-11
RING, retaining spool
REEL, wire (consisting of)
NUT, wing 1/2-13
FINGER, reel
STUD, 1/2-13x7
PIN, spring compression 3/16 x 1 inch
NUT, hex-jam 1/2-13
2
2
1
1
1
1
1
-
1
4
4
4
4
-
4
REEL
1
1
.3
.2
.6
8
10
TC-007 886
Figure Cl
-
Support. Hub & Reel
tOptional Equipment.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-1516 Page 9
Item
Part
No.
No.
Wire Drive & Gears
Figure D
604612
045233
080211
4 079671
5 085243
6 010231
7 085244
8 085242
9 010224
10 601 925
11 604741
12 079669
13 079634
14 079772
15 604538
16 053842
17 605518
18 079626
19010193
20 048 336
1
2
3
21
602 241
22
23
000418
093 664
092 865
24
079 625
25
082 036
26
082 050
Quantity
Description
(Fig
Pg 3 Item 45)
A
SCREW, set socket hd 8-32
GUIDE, anti-wear
-
x
2
1/8
1
DRIVE ASSEMBLY
1
(consisting of)
HOUSING, adapter gun/feeder
KNOB, adjust-tension
SPRING, compression
1
-
1
1
.WASHER,cupped2l/64IDx13/16
FASTENER, pinned
PIN, spring compression 3/16 x 1
SCREW, cap hex hd 1/4-20 x 1/2
1
1
1
-
1
-
PIN, cotter-hair0.042x15/16
LEVER, mounting pressure gear
PIN, hinge
1
1
-
1
.KNOB
1
WASHER, flat
GEAR,
spur
SAE 5/16 (as reqd)
insulated w/bearing
-
1
-
1
SCREW, cap hex hd 1/4-20 x 1-1/4
SCREW, fillister-hd 10-32 x7/8
1
-
6
TUBING,3f800xl8gawaIIxlf4
STOP, cover
1
WASHER, flat SAE 1/4
SCREW, cap hex hd 1/2-20 x 1/2 self
GEAR, spur
KEY, .122x.122x3/4
WASHER, spring 5/16 shakeproof
GUIDE, inlet wire
LINER, monocoil inlet wire
1
1
-
-
-
locking
1
1
1
1
-
1
-
1
-
16
17
18
14
Figure
D
-
TC-080 028-E
Wire Drive & Gears
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-1 516 Page 10
Dia.
Part
Mkgs.
No.
Description
Parts For
047 946
Ri
073 562
024 366
047 980
WS1
Optional Equipment
BURNBACK CONTROL
.
.
.
(consisting of)
POTENTIOMETER, carbon 1 turn 2
KNOB, pointer
TIMER, delay 20 mil sec/20 sec
watt 10K ohm
1
1
1
1
046
1
035
602
010
056
008
079
000
WATER CONTROL (12 ft models) (consisting of)
533 WATER CONTROL (16 ft models) (consisting of)
601 .VALVE,ll5voltsac2wayl/4IPSportl/8orifice
934
FITTING, pipe nipple L 1/4 NPT x 6
295
FITTING, pipe coupling 1/4 NPT
1
046 531
-
.
-
.
296
657
773
572
000 570
000 572
000 573
000 569
.
FITTING, hose-elbow male 1/4 NPTx 5/8-18 LH
FITTING, hose bushing reducing 5/8-18 LH
ADAPTER, terminal water electrode
HOSE, waterl0ft(12 &l6ftmodels)
HOSE, water 15ft(l2ft models)
HOSE,waterl9ft3inches(l6ftmodels)
HOSE, water 25 ft (12 ft models)
HOSE,water29ft(l6ftmodels)
-
.
-
.
.
.
.
.
.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-1516 Page 11
Quantity
1
1
2
1
1
1
1
1
1
1
1
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