Miller SWINGARC SINGLE 12 AND 16 Owner's Manual

August 1983
FORM: OM-1516D
Effective With Serial No. JD699352
0~
MODEL
SWINGARC SINGLE 12
SWINGARC SINGLE 16
OWN ERS
MANUAL
hullER
MILLER ELECTRIC MFG. CO.
718 S. BOUNDS ST. P.O. Box 1079
APPLETON,WI
54912 USA
NWSA CODE NO. 4579
PAINTED IN U.S.A.
7%,
4~~fr
9~
LIMITED WARRANTY
EFFECTIVE: JUNE 1, 1979
14
This warranty supersedes all previous MILLER warranties and is exclusive with no other guarantees or warranties expressed or implied.
I
LIMITED WARRANTY-Subject to the terms and conditions
hereof, Miller Electric Mfg. Co., Appleton, Wisconsin warrants
to its Distributor/Dealer that all new and unused Equipment
furnished by Miller is free from defect in workmanship and
material as of the time and place of delivery by Miller. No warranty is made by Miller with respect to engines, trade accessories or other items manufactured by others. Such
engines, trade accessories and other items are sold subject to
the warranties of their respective manufacturers, if any
All
engines are warranted by their manufacturer for one year from
date of original purchase.
.
r
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,
MILLERMATIC parts that come in contact with the welding
wire including nozzles and nozzle insulators where failure does
not result from defect in workmanship or material.
Except
S
as
Miller shall be
ranted
Equipment
within the
ment to
~5iJ
(~1
required
honor warranty claims
resulting from
on
following periods
original user:
war-
a
defect
from the date of delivery of
Equip-
general policy only, Miller may honor claims
original user within the foregoing periods.
matter of
a
14
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 (1) repair or 12) replacement
I
writing by Miller in appropriate cases, 13)
repair or replacement at an authorized
Miller service station or (4) payment of or credit for the purchase
price (less reasonable depreciation based upon actual use) upon
return of the goods at Customers risk and expense. Upon receipt
I
or, where
authorized in
the reasonable cost of
of notice of apparent defect or failure, Miller shall instruct the claimant on the warranty claim procedures to be followed.
1~
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
GUARANTY OR REPRESENTA-
ANY IMPLIED WARRANTY,
PERFORMANCE, AND ANY REMEDY FOR
BREACH OF CONTRACT WHICH, BUT FOR THIS PROVISION,
MIGHT ARISE BY IMPLICATION, OPERATION OF LAW,
CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING
TION
?
TO
AS
ANY IMPLIED WARRANTY OF MERCHANTABILITY OR
14
14
OF
FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO
ANY AND ALL EOUIPMENT FURNISHED BY MILLER IS EX
the
CLUDED AND DISCLAIMED BY MILLER.
1. Arc welders, power sources and components
2. Original main power rectifiers
(labor
S
to
in the event of failure
As
submitted by the
-
1 year
.
.
1 year
3 years
only)
3.
Allweldinggunsandfeeder/guns
90days
4.
All other Millermatic Feeders
5.
Replacement
1 year
60 days
6.
Batteries
or
AS
EXCEPT
repair parts, exclusive of labor
.
6 months
EXPRESSLY
MILLER
WRITING,
is notified in
writing
within
thirty (30) days
of the date of such failure.
ARE
BY
MILLER
INTENDED
IN
FOR
COMMERCIAL/INDUSTRIAL
BY
PURCHASE
USERS AND FOR OPERATION BY PERSONS TRAINED AND
OF
MAINTENANCE
AND
USE
IN
THE
EXPERIENCED
WELDING EOUIPMENT AND NOT FOR CONSUMERS OR
ULTIMATE
CONSUMER USE. MILLER
provided that Miller
PROVIDED
PRODUCTS
TO,
AND
MILLERS
NO
RESELLER
I
I!
)
14
WARRANTIES DO NOT EXTEND
IS
AUTHORIZED
TO
EXTEND
?
WARRANTIES TO, ANY CONSUMER.
14
it
I
7%,
7~,
J~
7%,
7%,
Jr
5%,
5%,
4
July 1984
FORM: OM-1516D
ERRATA SHEET
After this cnanual
was
printed, refinements
equipmer~t design occurred. This sheet lists exceptions
in
to
data
in this manual.
appearing later
AMENDMENT TO SECTION 3
INSTALLATION
-
Amend Section 3-14. WELD CABLE CONNECTION
Add the
following WARNING
to
beginning
of section:
ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Disconnect input power to the we/ding power
WARNING:
source or employ lockout/tagging procedures on the welding.
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.
power source before
AMENDMENT TO SECTION 7
Amend
Figure
7
-
1. Circuit
TROUBLESHOOTING
-
Diagram
MMRC
SHIELD
OPTIONAL-EXTRA)
/L.
PLO,
AL.~
SC6
~g
EM)
C~ADOSTD~C~MAR~
4)
~
7
P
~
_
EED
~YT~d
_____________
_________-~
> X>
~~~~~1
~3
______________
t.ij-.-1
ORE
SOLETLO 0
~TL
Os
__
-<3~-~,
JR
_
~
<
1~
~< 2<
PiL
C
r<
DCX
OPT!ONA
P1.0a
C~A
~
~J
___A~0O~C,I
I
EXTRA
~
cL!~
DC):
dREW)
BO~AD
-
~
36
0
3)38
0
0~_,e
~
E
Q2
-~
JO>
_____________
L_..~___I
506
051
LEAD END VIEW
Circuit
.04 SX%ING~DC ONLY
Figure 7
-
1.
Page
Part
Replaced
No.
No.
With
082 722
Deleted
4
-
Diagram
No. B-044 859-C
Circuit Diagram For Models Effective With Serial No. JD698944
Description
(Eff w/JD698944)
TABLE OF CONTENTS
Page No.
Section No.
SECTION 1
1
1
-
-
1.
2.
1 -3.
1
4.
-
SECTION 2
2
2
2
-
-
-
-
1.
5.
-
3-15..
3-16.
3-17.
3-18.
3-19.
SECTION 4
-
11
-
INTRODUCTION
13
13.
-
-
Standards Booklet Index
1
13
3-6.
3 -7.
3
8.
3
9.
3-10.
3-11.
3-12.
3-13.
3-14.
4
7
Receiving-Handling
Description
-
4
ArcWelding
General Information And Safety
3 -3.
4.
3
-
1
1.
3-2.
3
Introduction
General Precautions
2.
3~
SECTION 3
3
SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
-
-
INSTALLATION
Location And
Assembly
13
DriveMotor
Installation Of Wire Support
Reinstallation Of Hub Assembly
15
Installation Of Wire Reel
DriveRollAndWireGuidelnstallation
15
16
Water Connections
17
Welding Gun Connections
Shielding Gas Connections
Boom Adjustments
WirePulley
17
Motor Control Connections
Gun Trigger Connection
WeldCableConnection
Remote Control Connections
Installation Of Spool-Type Wire
Installation Of Reel-Type Wire
Adjustment Of Hub Tension
115 Volts/Contactor Connections
-
15
15
18
18
18
18
18
19
19
19
19
19
19
FUNCTION OF CONTROLS
1.
Power Switch
2.
Remote Control
Receptacle And Switch
19
19
19
4-3.
PurgeButton
4
4.
Inch Button
19
5.
Wire Speed Control
Start Switch
20
4
4
4
4
4
-
-
-
-
-
-
6.
7.
8.
9.
SECTION 5
5
-
1.
5.- 2.
5
-
3.
SECTION 6
6
6
-
-
1.
2.
6-3.
6
-
4.
SECTION 7
Retract-Feed Switch
Reset Circuit Breaker
Burnback Control
-
SEQUENCE OF OPERATION
Welding
Wire
Threading
Gas Metal-Arc Welding (GMAW}
Shutting Down
-
20
20
20
20
20
21
21
MAINTENANCE
Inspection And Upkeep
Cleaning Of Drive Rolls
21
Fuse
22
22
Brush
-
Inspection
&
Replacement
TROUBLESHOOTING
21
SECTION 1
SECTION 1
-
-
REGLES
1-1. INTRODUCTION
-
SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
DE SECURITE POUR LE FONCTIONNEMENT DU POSTE DE SOUDAGE A LARC
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.
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.
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.
Failure to observe these safe practices may cause
serious injury or death. When safety becomes a habit,
the equipment can be used with confidence.
Contrairement a lappren
1-1. INTRODUCTION
tissage de Ia vie, lapprentissage de Ia sØcuritØ par ox
pØrience personnelle, comme lenfant qui touche un
poØle chaud, est dangereux, imprudent et inutile.
lnstruisoz-vous donc de lexpØrience dautrui.
-
Des mØthodes de sØcuritØ issues de loxpØrience du
et du coupage sont dØcrites dans lo manuel. La
recherche, le progres et lexpØrienco dans ce domaine
ont dØveloppØ un materiel fiable et des mØthodes do
sØcuritØ pour linstallation, le fonctionnemont et Ientre
tien. Des accidents so produisent lorsque lo materiel est
inadequatement utilisO ou entretenu. La raison do ces
mØthodes de sØcuritØ peut no pas Øtre toujours donnØe.
Certaines sont fondØes sur le sons commun, dautres
demanderont a Otre expliquØes par des Iivres techni
ques. II est plus sage do suivre los rØgles.
soudage
Lisez et compronez
ces
mØthodes do sØcuritØ avant
dessayer dinstaller, de faire fonctionner ou do rØparer
lappareil. Pour votre sØcuritØ personnelle ot cello
dautrui, conformez-vous a ces rŁgles et aux manuels
dinstructions.
Manquer dobserver ces mØthodes do sØcuritØ pourrait
entrainor dos blossures graves ou mŁme Ia mort. Quand
Ia sØcuritØ devient uno habitude, le materiel pout alors
Œtre utilisØ en touto confiance.
divided into two Sections:
Gener& Precautions, common to arc welding and
1
cutting; and 2 Arc Welding (and Cutting) (only).
Ces mØthodes do sØcuritØ sont divisØes en deux sec
Precautions generales,
1
tions:
communes
au
soudage et au coupage a larc, et 2 Soudage a larc
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
Normes de rØfOrence: Des publications des normes
amØricaines de sØcuritØ sont aussi a votre disposition
modes opØratoires plus complets quo
pour dautres
ceux du present manuel. Ellos sont donnØes dans lln
dex dos Normes do cos regles do sØcuritØ. ANSI Z49-1
est Ia plus complete.
These safe practices
are
-
-
-
-
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.
(ot coupage) (uniquomont).
los codes provinciaux ot
Les codes de IACNOR,
municipaux donnent aussi los oxigoncos pour uno in
stallation,
1-2.
1-2. GENERAL PRECAUTIONS
Different arc welding processes, electrode alloys,
and fluxes can produce different fumes, gases,
and radiation levels. In addition to the information
In this manual, be sure to consult flux and elec
frode manufacturers for speific technical data
and precautionary measures concerning their
material.
utilisation ot
un
entretien sUrs.
PRECAUTIONS GENERALES
Plusiours procØdØs du soudage Ł l~arc, des Ølec
trodes alIiØe, et lee flux peuvent produlre des
at
niveaux do rayonnement
vapeurs,
gaz,
diffØrents. Pour tout renseignement supplØmen
taire a ce manuel, consultez aussi lee fabricants
des electrodes et des flux afin dobtenir
lee
renseignements techniques
do
precaution
mesures
spØcifiques
concernant
lee
leurs
et
matØriaux.
A.
A.
une
Prevention des brUlures
Burn Prevention
Portez des vØtements do protection des gants a crispin
pour le soudage, un casque et
des chaussures de sØcuritØ. Boutonnez le col do votro
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 for
use in 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
Wear helmet with
-
safety goggles
or
glasses with side
or plates
shields underneath, appropriate filter lenses
(protected by clear cover glass). This is a MUST for
welding or cutting, (and chipping) to protect the eyes
spØcialement designØs
Portez un masque avec lunottos do sØcuritO ou avec
Øcrans latØ-raux do protection, des lunettes filtrantes ou
des couvre-lentilles (proteges par un vorre clair). Pour le
soudago ou le coupage (ot lo burinago), ii ost
OM-1516
Page 1.
from radiant energy and flying metal. Replace cover
glass when broken, pitted, or spattered. See 1-3A.2.
Avoid
Hot
oily
metal
should
or
greasy
such
clothing.
A spark may
ignite
them.
electrode stubs and workpieces
be handled without gloves.
never
as
Medical first aid and eye treatment. First aid facilities
and a qualified first aid person should be available for
each shift unless medical facilities are close by for im
mediate treatment of flash burns of the eyes and skin
burns.
Ear
plugs should be
worn when working on overhead or
confined space. A hard hat should be worn when
others work overhead.
in
OBLIGATOIRE de proteger ses yeux contre lØnergie de
rayonnement et les Øclats de metal. Remplacez le verre
protecteur lorsquil est brisØ, piquØ ou quil a reu des
projections. Voir 1.3A.2.
Evitez de porter des habits imprØgnØs dhuile
graisse. Une Øtincelle pourrait les enflammer.
ou
de
Ne manipulez jamais sans gants un metal chaud tel que
des chutes dØlectrode et des 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 brQlures des yeux et de Ia peau.
a
Flammable hair preparations should not be used by per
sons
intending
B.
to weld or cut.
Les personnes devant souder
employer des preparations
Toxic Fume Prevention
Severe discomfort,
illness
fumes, vapors, heat,
or
Portez des bouche-oreilles lorsque vous travaillez au
un espace restreint. Portez un casque
personnes travaillent au plafond.
plafond ou dans
lorsque dautres
ou couper ne doivent pas
inflammables pour leurs
cheveux.
or death can result from
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
Les gaz,
un
vapeurs, Ia
es
doxygene
manque
toxiques
chaleur, un enrichissement ou
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
de llndex
des Normes.
NE ventilez JAMAIS a lox
ygŁne.
Lead
cadmium
-,
bearing
zinc -, mercury -, and beryllium
materials, when welded (or cut) may
-,
and similar
-
produce harmful concentrations
of toxic fumes. Ade
quate local exhaust ventilation
person in the
area as
must be used, or each
the operator must wear an
For beryllium, both must be us
well
air-supplied respirator.
as
ed.
coupant, les p10mb, cadmium, zinc,
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 lieux,
En soudant
mercure
et
ou en
beryllium
de mŒme que le soudeur, doit porter un masque a ad
duction dair.
On doit employer les deux pour le
beryllium.
Metals coated with or containing materials that emit
toxic fumes should not be heated unless coating is
removed from the work
tilated,
or
surface, the area is well ven
the operator wears an air-supplied respirator.
Work in
a confined space only while it is being ven
tilated and, if necessary, while wearing an air-supplied
respirator.
Les mØtaux enrobØs
tant des gaz
ou
composes de matØriaux Ømet
doivent pas Łtre chauffØs a
de Ia surface a
ne soit tØ
que
travailler, que le local ne soit bien ventilØ, ou que le
soudeur ne porte un masque a adduction dair.
moms
toxiques
lenrobage
ne
Ne travaillez dans un espace restreint que sil est bien
ventilØ et, si nØcessaire, portez un masque a adduction
dair.
Gas
leaks in a confined space should be avoided.
Leaked gas in large quantities can change oxygen con
centration dangerously. Do not bring gas cylinders into
a
confined space.
Leaving confined space, shut OFF gas supply at source
prevent possible accumulation of gases in the space
if downstream valves have been accidently opened or
to
left open. Check to be
it.
sure
that the space is safe before
re-entering
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
also
decompose trichloroethylene and per
chloroethylene
WELD
the
vapors to form phosgene. DO NOT
where solvent vapors can be drawn into
or cutting atmosphere or where the radiant
or cut
welding
OM-1516 Page2
On doit Øviter les fuites de gaz dans un espace restreint.
Les fuites de gaz en grande quantite peuvent
transformer dangereusement Ia concentration dox
ygŁne. Namenez pas de bouteilles de gaz dans un
espace restreint.
En
quittant
espace restreint, FERMEZ le robinet
de gaz de Ia bouteille. Ainsi on pourra
rentrer en toute sØcuritØ dans Ia piŁce, mŒme Si les
robinets aval
ont etØ ouverts par accident, OU Si Ofl les
a laissØs ouverts.
un
dalimentation
Les vapeurs de dissolvants chiorØs 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. Lenergie
ultra-violette de Iarc peut aussi decomposer les vapeurs
de trichloroØthylŁne et de perchloroethylene pour
former du phosgene. NE SOUDEZ PAS ou ne coupez
pas dans des endroits oCi les vapeurs de dissolvants peu
vent Œtre attirØes dans IatmosphŁre
de soudage ou de
posØes
energy can penetrate to
minute amounts of
atmospheres containing
trichloroethylene or
even
per
chioroethylono.
coupage et o~i Ienergie de rayonnemont peut pØnØtrer
dans des atmospheres contenant des quantites mOme
minuscules
de
trichloroØthylŁne ou de per
chloroØthylŁne.
Fire and
C.
Explosion
Prevention
C.
Prevention des incendles et dee
explosions
Causes of fire and explosion are: combustibles reached
by the arc, flame, flying sparks, hot slag or heated
material; misuse of compressed gases and cylinders;
and short circuits.
Les causes dincendio
sont les com
et dexplosion
bustibles atteints par larc, Ia flamme, los Øtincellos, le
laitier chaud ou les matØriaux chauffØs, le mauvais
ernploi des gaz comprimØs et des bouteilles ainsi que les
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.
Sachoz que los Øclats dØtincelies ou Ia chute du laitier
dans les fissures, le long des
peuvont sinfiitrer
tuyauteries, par los fenØtres et los portes et par les
couvertures des murs ou du sol, sans que le soudeur
portant des lunettes ne les voie. Les Øtincelles et los
35 pieds.
scones peuvent voler jusqu
To prevent fires and
explosion:
Pour prØvenir les incendies et les
explosions: Veillez a
ce
Keep equipment
operable, free of oil, grease,
and (in electrical parts) of metallic particles that can
cause short circuits.
que votre apparoil soit propre et en Øtat de marcho,
dØnuØ dhuile et de graisse, et de particulos de metal sun
los piŁces Ølectriquos qui pourraiont entramner des
courts-circuits.
If combustibles are in area, do NOT weld or cut. Move
the work if practicable, to an area free of combustibles.
Avoid paint spray rooms, dip tanks, storage areas, 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.
so trouvent a proximitØ, no soudoz
coupoz pas. Si possible, dØplacez votre travail
loin dos combustibles. Evitez los ateliers do pointure au
pistolet, los cuves dimmersion, los ontrepOts, los von
tilateurs. Si cola nest pas possible, placoz los com
bustibles a au moms 35 pieds dos Øtincelles ot do Is
clean and
Si des combustibles
pas,
chaleur ot protØgoz-los dos Øtincelles avec des couver
tures ou dos Øcrans protecteurs adØquats, bien ajustØs
et
opposite sides should
not be welded on (or cut). Wails, ceilings, and floor near
work should be protected by heat-resistant covers or
Walls
touching combustibles
on
no
On
ignifugØs.
shields.
doit pas soudor (ou coupor) le cOtØ oppose dos
touchant los combustibles. Los murs, plafonds at
planchers prochos du travail doivent ºtre protØgØs par
dos couvertures ou Øcrans protocteurs ignifugØs.
Fire watcher must be standing by with suitable fire ex
tinguishing equipment during and for some time after
Un surveillant doit so tonir a proximitØ avec un matØrial
do lutte contre lincendio adequat, pendant at quelque
temps aprŁs le soudage ou le coupage Si:
welding
or
cutting
no
murs
if:
a.
a.
appreciable combustibles (including building
b.
appreciable combustibles are further than 35
feet but can be ignited by sparks
openings (concealed or visible) in floors or
construction)
c.
walls
within
are
(y compris
feet
may
b.
expose
combustibles
adjacent
to
walls,
metal partitions can be
radiant or conducted heat.
roofs,
or
c.
com
ceilings,
ignited by
d.
Hot work
ensure
permit should be obtained before operation to
supervisors approval that adequate precautions
have been taken.
After work is done, chock that
glowing embers, and flames.
area
is free of
sparks,
An empty container that held combustibles, or that can
produce flammable or toxic vapors when heated, must
be welded on or. cut, unless container has first
been cleaned as described in AWS Standard A6.O,
listed 3 in Standards index.
never
This includes:
a
solvent
or
thorough steam or caustic cleaning (or
water washing, depending on the corna
construction en chantior)
35 piods.
so
Des quantites apprØciables do combustibles
a plus do 35 pieds mais peuvont Øtre
enflamrnØos par des Øtincolles.
Des ouverturos (cachØos ou visibles) sr los
planchers ou las murs a moms do 35 pieds
pouvont exposer dos combustibles aux
Øtincoiles.
Los combustibles adjacents aux murs,
plafonds, toits ou cloisons metalliques peu
vent ºtro onflammOs par uno chaleur rayon
nante ou transmiso.
sont
bustibles to sparks
d.
apprØciablos do combustibles
une
trouvent a moms do
within 35 feet
35
Des quantites
Avant do commencer, avisez le contromaitro pour quil
sassure que los precautions adequates soient prisos.
Uno fois le travail torminØ, vØrifiez quiI ny ait pas
dØtincelles, do cendros ardentos ou do flammos dans le
local.
On no doit jamais souder ni couper sur un recipient
ayant contonu des combustibles, ou pouvant produiro
des vapeurs inflammables ou toxiquos a Ia chauffe, a
moms quo le recipient nait OtØ lavØ au prØalable, com
me dØcrit dans Ia Norma AWS A6.O, figurant au
paragraphe 3 de llndex des Normes.
Cela comprond: un nettoyago a fond a Ia vapour ou au
caustique (ou un lavage avec dissolvant ou eau solon Ia
solubilitØ du combustible) suivi dune
purge at duno
in
Page 3
OM-1 516
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.
jection dazote ou de gaz carbonique, en utilisant un
Øquipement de protection comme recommandØ dans
lA6-O. LatmosphŁre inerte peut ºtre remplacØe par un
arrivant au-dessous du travail a effectuer.
niveau deau
Vous devez layer
A container with unknown contents should be cleaned
(see paragraph above). Do NOT depend on sense of
smell or sight to determine if it is safe to weld or cut.
Hollow
castings
welding
or
or
containers must be vented before
cutting. They
can
explode.
Explosive atmospheres. Never weld
may contain flammable
dust, gas,
or cut
where the air
liquid
vapors (such
or
gasoline).
as
recipient dont Ia
un
nature de contOnu
(voir paragraphe ci-dessus). NE
est inconnue
vous
PAS a lodorat ou a Ia vue pour dire si lon
souder ou le couper en toute sØcuritØ.
Vous devez
pratiquer
pients creux
exploser.
avant de Ies souder ou couper: ils
un
event
sur
les
piŁces
fiez
peut le
ou
red
peuvent
Atmospheres explosives: Ne soudez ni ne coupez
jamais dans des lieux oCi lair pout contenir des
poussiŁres, gaz ou vapeurs liquides inflammables (tels
que essence).
D.
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 Stan
dards index.
Gaz comprimØ
D.
Precautions gØnØrales: Suivez es 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 Normos.
manuel,
1.
1.
Pressure Regulators
DØtendeurs de pression
La soupape de sOretØ dun dØtendeur est destinØe a pro
le dØtendeur do Ia surpression. Elle na
paS pour but do protØger les boyaux et le chalumeau: on
protege ceux-ci par des soupapes do retenue concues
tØger seulemont
Regulator relief valve is designed to protect only the
regulator from overpressure; it is not intended to pro
any downstream equipment. Provide such protec
tect
tion with
one or more
spØcialement
pour cette fonction.
relief devices.
Ne montez
Never connect a regulator to a cylinder containing gas
other than that for which the regulator was designed.
Remove faulty regulator from service immediately for
repair (first close cylinder valve). The following symp
toms indicate a faulty regulator:
Leaks
if gas leaks externally.
Excessive Creep
if delivery pressure continues to rise
with downstream valve closed.
jamais
dØtendeur
un
sur une
nant un gaz different de celui pour
bouteille conte
le dØterideur a
lequel
ØtØ concu.
Enlevez immØdiatement
le
un
dØtendeur dØfectuoux pour
faire
rØparer (dabord, fermez le robinet do Ia
bouteille). Los symptmes 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
-
pressure release.
Repair. Do NOT attempt repair. Send faulty regulators
for repair to manufacturers designated repair center,
where special techniques and tools are used by trained
personnel.
2.
Cylinders
Cylinders must
damage to
and
be handled carefully to prevent leaks
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.)
ICC
DOT marking must be on each cylinder. It is an
of safety when the cylinder is properly
handled.
Fuites Si le gaz fuit extØrieurement.
Ascension excessive si Ia pression do debit continue a
monter, le robinet du chalumeau Øtant formØ.
ManomŁtre dØfectuoux Si Iaiguille du manomŁtre no
sØcarte pas do Ia goupille do butØe lors do Ia.mise on
pression, ou no revient pas sur Ia goupille aprŁs IØchap
pement do Ia pression.
-
-
-
Reparation. NESSAYEZ PAS de rØparer vous-mØmes.
Envoyez los dØtendeurs dØfectuoux a rØparer aux
ateliers do. reparation agrees du fabricant, oCi des techni
ques et des outils spØciaux sont utilisØs par un person
nel formØ.
2.
Bouteilles
Los bouteilles doivent Œtre manipulØes avec soin pour
prØvenir les. fuites ou dØgts a leurs parois, robinets ou
systŁmes do s~retØ. Evitez quun circuit Ølectrique soit
en contact avec los bouteilles, y compris los rails de con-.
tact, los fils Ølectriques ou los circuits do soudago. Cola
pourrait crØer des arcs courts-circuits pouvant entralner
des accidents graves (Voir i.3C.).
or
assurance
OM-1516
Page4
Chaque bouteille doit porter
los inscriptions ICC ou
DOT. Cost un gage de sØcuritØ pourvu quo 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
DEFACE or alter name, number, or other markings on a
cylinder. It is illegal and hazardous.
Identification du gaz: Nutilisez que los bouteillos mdi
nature du gaz; no vous fiez pas a Ia coulour
pour reconnaltre Ia nature du gaz. Adressez-vous a
votre fournisseur si cela nest pas indiquØ.
quant Ia
NEFFACEZ
Empties: Keep valves closed, replace caps securely;
mark MT; keep them separate from FULLS and return
promptly.
Prohibited use. Never use a cylinder or its contents for
other than its intended use, NEVER as a support or
roller.
numØros
est
ou
illegal
no
modifioz
JAMAIS
los
noms,
autres indications sur uno bouteille. Cola
ou
dangeroux.
et
Vides: Maintenez los robinets fermØs, roplacoz bien los
sØparoz-Ios des Pleinos
chapeaux; inscrivez Vides;
et retournoz-les rapidement.
Emploi interdit: Nutilisez une bouteille ou son contenu
ce a quoi elle est dostinØe, mais JAMAIS corn-
quo pour
Locate
or secure
cylinders
so
they
cannot be knocked
over.
Passageways and work areas. Keep cylinders
areas where they may be struck.
clear of
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 not
Cool with water spray
Protect cylinders particularly valves from bumps, falls,
falling objects, and weather. Replace caps securely
when moving cylinders.
Stuck valve. Do NOT use a hammer or wrench to open
cylinder valve that can not be opened by hand. Notify
a
me
support
rouleau.
Placez los bouteilles pour quellos no tombent
quun dØtendeur (ot un boyau) est monte
placez los ou attachez-les debout.
pas. Lois
sur
olles,
Passages et lieux do travail. Enlevoz los boutoilles dun
endroit oCi Ion pourrait los frapper.
des boutoillos. Avec uno grue, utilisoz un sup
plato-formo ou un cadro. NE
port fiablo tel quune
SOULEVEZ PAS dos boutoillos du sol par leur robinet
ou chapeau, ou avoc des chaines, Ølinguos ou aimants.
Transport
PAS los bouteilles a une chalour excessive,
au laitier ot aux flammes, etc., pouvant
lour rupture. Lo contonant no doit jamais
causer
depasser 55C. Refroidissez en pulvØrisant do loau si
nØcessaire.
NEXPOSEZ
aux
Øtincolles,
ProtØgez los bouteilles et particuliŁrement los soupapes
chocs, los chutes, los chutes dobjets ot (a
temperature. Romottoz bien los chapeaux lorsquo vous
dØplacez los bouteilles.
contre los
supplier.
your
Mixing
gases. Never try to mix any gases in
Never refill any
cylinder.
a
cylinder.
Cylinder fittings should
never
be modified
or
exchang
ed.
Robinet coincØ. NUTILISEZ PAS un martoau ou une
clØ metallique pour ouvrir un robinet do bouteillo quo
lon ne peut pas ouvrir a Ia main. Avisoz votre four
nisseur.
MØlange
dans
3.
Hose
Prohibited
for the
use.
Never
specified
gas. A
hose other than that designed
general hose identification rule
No copper
tubing splices. Use
to splice hose.
only
standard brass fit
Avoid long runs to prevent kinks and abuse. Suspend
hose off ground to keep it from being run over, stepped
on, or otherwise
excess
do gaz. Nessayoz
bouteille.
jamais do mØlangor des gaz
use
Use ferrules or clamps designed for the hose (not or
dinary wire or other substitute) as a binding to connect
hoses to fittings.
tings
une
Ne rochargoz jamais une bouteille. Los ØlØments do Ia
bouteille no doivent jamais Œtro modifies ou remplacØs.
is: red for fuel gas, green for oxygen, and black for inert
gases.
Coil
ou
damaged.
Boyau
Utilisation interdite. Nutilisoz
quo celui
appropriO
jamais
un
boyau
autro
gaz indiquØ. La rØglo gØnØralo
didentification est: rouge pour les gaz combustibles,
vert pour loxygŁno, et noir pour los gaz inortes.
au
Utilisez dos baguos ou colliers appropriØs au boyau (et
non du fil ordinaire ou autre substitution) pour brancher
los boyaux a lappareillago.
Nutilisez pas des raccords en cuivre. Nutilisez quo des
accessoires standard on laiton pour raccordor un boyau.
Utilisez une petite longueur do boyau. Cola Øvitera los
noouds et Iusure prØrnaturØe. Suspondoz le boyau au
dessus du sal pour Øviter quil no soit ØcrasØ, piØtinØ ou
hose to prevent kinks and tangles.
Protect hose from damage by
sparks, slag, and open flame.
3.
ondommagO.
sharp edges,
and
by
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 Oviter los noeuds ot
emmØloments. Evitez quo lo boyau no soit endommagØ
par des tranchants, Øtincelles, laitier ot flamme nue.
OM-1516
Page
5
Repair leaky
or worn
ing (1-2D3).
Do NOT
4.
hose by cutting
use tape.
area
out and
splic
Proper Connections
Clean cylinder valve outlet of impurities that may clog
orifices and damage seats before connecting regulator.
Except for hydrogen, crack valve momentarily, pointing
outlet away from people and sources of ignition. Wipe
with a clean lintless cloth.
Match regulator to cylinder. Before connecting, check
that the regulator label and cylinder marking agree, and
that the regulator inlet and cylinder outlet match.
NEVER CONNECT a regulator designed for a particular
gas or gases to a cylinder containing any other gas.
Tighten,
connections. When
assembling
threaded
con
nections, clean and smooth seats where necessary.
Tighten. If connection leaks, disassemble, clean, and
retightefl using properly fitting
wrench.
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.
VØrifiez rØguliŁrement les fuites, lusure et les rac
cordements lches.
Plongez le boyau sous pression
dans de leau; los bulles indiqueront los fuites.
Reparation. Coupez Ia partie percØe ou usØe, et rac
cordez (1-2D3). NUTILISEZ JAMAIS do ruban adhØsif.
4.
Branchements corrects
Avant de brancher le dØtendeur, nettoyez Ia sortie du
robinet de Ia bouteille des impuretØs qui peuvent
obstruer les orifices et endommager los sieges. Sauf
pour lhydrogŁne, ouvrez momentanØment le robinet,
eloignant Ia sortie des personnes et des sources in
Essuyoz avec un tissu propre et non
graisseux.
en
flammables.
Appareillez le dØtendeur a Ia bouteille. Avant do bran
cher, vØrifiez quo Ia marque du dØtendeur et Ia descrip
tion do Ia bouteille concordent, et que lorifice dentrØe
du dØtendeur ot lorif ice do sortie de Ia bouteille aillent
ensemble. NE BRANCHEZ JAMAIS un dØtendeur
conu 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 oCi
cest nØcessaire. Serrez. Si les branchements perdent,
dØmontez-les, nettoyoz et resserez avec une clef adØ
quato.
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.
Pressurizing Steps:
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.
Stand to side of
regulator
while
opening cylinder
valve.
Open cylinder valve slowly so that regulator pressure in
creases slowly. When gauge is pressurized (gauge
reaches regulator maximum) leave cylinder valve in
following position: For oxygen, and inert gases, open
fully to seal stem against possible leak. For fuel gas,
open to less than one turn to permit quick emergency
shutoff.
Use pressure charts (available from your supplier) for
safe and efficient, recommended pressure settings on
regulators.
Check for leaks on first pressurization and regularly
there-after. Brush with soap solution (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 Page6
est, un adaptatour CGA
(en vente chez votre fournisseur) entre Ia bouteillo et le
dØtendeur. Avec deux clefs, serrez ladaptateur filetØ A
DROITE et A GAUCHE.
Adaptateurs. Placez, si bosom
On peut reconnaltre los branchements de sortie du
dØtendeur (ou boyau) a Iaide du filetage a droite pour
loxygŁne ot a gauche (identifiØ par un Øcrou cannelØ)
pour les gaz combustibles.
5.
DØmarches de mise
en
pression
Purgez le dØtendeur do rØsidu de gaz avant douvrir Ia
bouteille (ou le robinet do canalisation) en serrant Ia vis
do rØglage (dans le sens des aiguilles dune montre).
Cette operation permet au siege de haute pression do
souvrir a Ia mise en pression, supprimant ainsi toute
surchauffe do compression. Maintenez Ia vis do rØglage
des dØtendeurs a simple dØtente legerement engagØe.
Avant douvrir le robinet do Ia bouteille, assurez-vous
que les boyaux sont branches et que les soupapos aval
sont fermØos.
-
Tenez-vous latØralement au dØtendeur en ouvrant le
robinet de Ia bouteille. Ouvrez-le lentement pour quo Ia
pression du dØtendeur monte progrossivement. Lorsque
le manomŁtre est mis sous prossion (indique lo max
imum) le robinet do Ia bouteille do gaz inerte ou dox
ygŁne devra Œtre ouvert a fond pour assurer lØtanchØitØ
et celui do Ia bouteille de gaz combustible ouvert do
moms dun tour pour pouvoir le refermer rapidoment en
cas
durgence.
aux tableaux do pression (distribuØs par
fournissour) pour un rØglage recommandØ do
pression sOr et efficace sur los dØtendeurs. VØrifiez los
RØfØrez-vous
votre
fuites a Ia premiere miso en prossion puis rØgulierement,
brossoz avec une solution savonneuse (un bouchon
dlvory Liquid* ou semblable par gallon deau). Los
bulbs indiquent une fuite. Enlevez loau savonneuse
aprŁs examen; be savon sec est inflammable.
*Marque de Commerce do Proctor & Gamble
F.
Leaving Equipment Unattended
Close gas supply at
E.
Otez immØdiatement les parties percØes ou dØfec
Voir les ResponsabilitØs de lUsager du manuel
and drain gas.
source
ResponsabilitØs de Iusager
tueuses.
G.
de
Rope Staging-Support
Rope staging-support should not be used for welding
cutting operation; rope may burn.
F.
or
G.
-
tects himself and others from accidents.
Precautions
described here and in standards referenced in index.
A.
Burn
Protection
Comply with precautions in 1-2.
The welding arc is intense and visibly bright. Its radia
tion can damage eyes, penetrate lightweight clothing,
reflect from light-colored surfaces, and burn the skin
and eyes. Skin burns resemble acute sunburn, those
from gas-shielded arcs are more severe and painful.
GET BURNED; COMPLY WITH PRECAU
DOFs~T
TIONS.
1.
Protective
Clothing
Wear long-sleeve clothing (particularly for gas-shielded
arc) in addition to gloves, hat, and shoes (1-2A). As
necessary, use additional
leather jacket or sleeves,
resistant
laissØ
of untreated
cotton.
sans
surveillance
de gaz a Ia
Liens et supports
source ot
purgez.
temporaires
Pour vos travaux de soudage ou de coupage, nutilisez
pas de Ia corde comme soutien, elle est inflammable.
LARC
Conformez-vous aux
1-3. SOUDAGE A
precautions des paragraphos 1.1 et 1.2 de cette section.
Le soudage a larc bien exØcutØ est s~r, mais un
soudeur negligent est un danger. Le poste de soudage
-
sous de fortes tensions.
Los Øtincelles volent, los
vapeurs montent, lØnorgie ultra-violette et infrarouge
rayonnent, los soudures sont chaudes, et dos gaz corn
primes peuvent Œtre utilisØs. Le soudeur prudent Øvite
les risques inutiles, se protege ot protege autrui contre
les accidents. Los precautions sont dØcrites ici et dans
les normes donnØes dans llndex.
transporte des courants ØlovØs
Larc
A.
est trŁs vif et chaud.
Protection contre les brOlures
Conformez-vous aux precautions du paragraphe 1.2.
Larc do soudage est intense et visiblement vif. Son
rayonnement pout blesser les yeux, traverser los habits
lØgers, so rØflØchir sur los surfaces claires, et brUler Ia
peau et les yeux. Les bri~Iures do Ia peau ressemblent a
un gros coup do soleil. Cellos darcs sous gaz protocteur
sont plus graves et plus douloureuses. NE VOUS
SUIVEZ LES PRECAUTIONS.
BRULEZ PAS
-
protective clothing such as
flame-proof apron, and f ire-
leggings. Avoid outergarments
Appareil
Fermez lalimentation
1-3. ARC WELDING
Comply with precautions in
1-1, 1-2, and this section. Arc Welding, properly done,
is a safe process, but a careless operator invites trouble.
The equipment carries high currents at significant
voltages. The arc is very bright and hot. Sparks fly,
fumes rise, ultraviolet and infrared energy radiates,
weldments are hot, and compressed gases may be us
ed. The wise operator avoids unnecessary risks and pro
are
lappareil.
1.
VŒtements de
protection
Portez des vŒtements a manches longues (surtout pour
larc en atmosphere inerte) avec gants, masque et
chaussuros (1.2A.).
Bare skin
protection. Wear dark, substantial clothing.
Button collar to protect chest and neck and button
pockets to prevent entry of sparks.
Si nØcessaire portez en plus une vesto ou des manches
cuir, un tablier et des guŒtres ignifugØs. Do
en
prØfØrence
2.
Eye and Head Protection
Protect eyes from exposure to
electric arc without protection.
ne
portez ~85 de vŒtements
en
coton non
traitØ.
arc.
NEVER look at
an
Protection de Ia peau. Portez des vØtements Øpais
foncØs. Boutonnez le col pour protØger Ia poitrino et le
cou, et boutonnez los
poches
pour
prØvenir
linfiltration
dØtincelles.
Welding helmet
no.
over
or shield containing a filter plate shade
denser must be used when welding. Place
face before striking arc.
12
or
2.
Evitez
Protect filter
Cracked
or
plate, with
a
clear
broken helmet
worn; radiation can pass
Cracked, broken,
or
plate.
shield should NOT be
through
to cause burns.
loose filter plates must be replaced
clear cover plate when
IMMEDIATELY.
Replace
broken, pitted,
spattered.
or
or
cover
Protection dos yeux et de Ia tŒte
que
JAMAIS
vos
yeux soiont
un arc
Ølectrique
exposØs a larc. NE regardez
sans protection.
vous soudoz, portoz un Øcran ou masque avec
filtrant teintØ N 12 ou plus foncØ. Mettez-le sur le
visage avant damorcer Iarc.
Lorsque
verre
le verre filtrant dun
couvre-verre clair. NE
PORTEZ PAS un masque fendu ou brisØ; le rayonne
ment peut sinfiltrer et causer des brOlures.
ProtØgez
Les verres filtrants fendus, brisØs ou lØches doivent Œtre
remplacØs IMMEDIATEMENT. Remplacez un couvre
verre brisØ, piquØ ou tachØ par des projections.
OM-1516
Page
7
Flash goggles with side shields MUST be worn under
the helmet to give some protection to the eyes should
the helmet not be lowered over the face before an arc is
struck. Looking at an arc momentarily with unprotected
eyes
(particularly
a
high intensity gas-shielded arc)
retinal burn that may leave
in the field of vision.
cause a
area
a
can
permanent dark
Vous devez portez des lunettes a Øcrans latØraux sous le
o le masque
masque pour protØger les yeux dans le cas
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 in
tensitØ) peut brQler Ia rØtine et laisser un point sombre
permanent dans le champ de vision.
Protection du
3.
3.
Protection of Nearby Personnel
welding
Enclosed
separate
room or
For production welding; a
enclosed bay is best. In open areas,
area.
Local do
tion, il
soudage
personnel
a
proximitØ
fermØ. Pour le
vaut mieux utiliser une salle
soudage de produc
sØparØe ou une baie
surround the operation with low-reflective, noncombustible screens or panels. Allow for free air circula
tion, particularly at floor level.
formØe. Dans los locaux ouvorts, ontourez los travaux
dØcrans ou panneaux peu rØflØchissants et ininflam
mables. Laissez lair circuler librement, particuliŁrement
au niveau du sol.
the weld. Provide face shields for all persons
who will be looking directly at the weld.
Donnez des masques aux personnes
directement Ia souduro.
Others working in
flash goggles.
area.
Autres personnes travaillant sur los Iieux. Veillez a ce
quo toutes les personnes portent les lunettes de protec
tion.
Before
weld, make
-
Viewing
starting
bay doors
B.
are
to
See that all persons
sure
that
are
screen
wearing
flaps
or
closed.
Ia soudure, assurez-vous
Avant dattaquer
rebords dØcran ou les portos soient fermØs.
quo
los
Toxic Fume Prevention
B.
Comply
with
Prevention des gaz toxiques
precautions in 1-2B.
Generator engine exhaust must be vented to the outside
air. Carbon monoxide can kill.
C.
qui regarderont
Fire and
Suivez los precautions du paragraphe 1.2B. LØchappe
ment du moteur do Ia gØnØratrice doit Otre ventilØ a Iair
extØrieur. Loxyde de carbone pout tuer.
Explosion Prevention
Comply with precautions
C.
Prevention des incendies et des explosions
in 1-2C.
Suivez los
rated capacity. Do
Equipments
welding equipment. It may overheat
not
overload
cables and
arc
cause a
lappareil.
precautions 1.2C. Puissance nominale de
surchargoz pas le poste de soudage a
Ne
Iarc. Cola pout surchauffer les cables et
condie.
causer un
in
fire.
Loose cable connections may overheat
cause a fire.
or
flash and
Los branchements lches do cable pouvent surchauffer
faire des Øtincelles ot causer un incondie.
ou
Never strike an arc on a cylinder or other pressure
vessel. It creates a brittle area that can cause a violent
rupture or lead to such a rupture later under rough
Namorcez
pient
sous
jamais un arc sur uno bouteille ou autre rØci
pression. Cola crØerait un point do rupture
a plus ou moms longuo ØchØance lexplosion
entraInant
du reservoir.
handling.
D.
Comply with precautions
E.
0.
Compressed Gas Equipment
Suivez les
in 1-2D.
E.
Shock Prevention
Exposed hot conductors or other bare metal in the
welding Circuit, or in ungrounded, electrically-HOT
equipment can fatally shock a person whose body
becomes
a
conductor.
DO NOT STAND,
LEAN ON, OR TOUCH a wet surface when
without suitable protection.
OM-1 516
Page 8
Gaz comprimØ
SIT, LIE,
welding,
precautions
1.2D.
Prevention des decharges Øloctriques
Des conducteurs charges ou metal nu incorporØs au cir
cuit do soudage ou a un appareil chargØ sans mise a Ia
terre peuvont 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 protec
tion appropriØe.
To protect
against shock:
Keep body and clothing dry. Never work in damp area
adequate insulation against electrical shock.
Stay on a dry duckboard, or rubber mat when damp
without
be avoided. Sweat, sea water, or
body and an electrically HOT
ness or sweat can not
moisture
between
reduces the body surface
part or grounded metal
electrical resistance, enabling dangerous and possibly
lethal currents to flow through the body~
-
-
Pour vous protØger contre les dØcharges electriques,
maintenez votre corps et vØtements secs. Ne travaillez
jamais dans un endroit humide sans isolation adequate
contre les dØcharges Øleciriques. Lorsque vous ne
un
pouvez Øviter lhumiditØ ou Ia sueur, placez-vous sur
caillebotis sec ou un tapis en caoutchouc. La sueur,
Ieau de mer, ou lhumiditØ entre le corps et une piŁce
CHARGEE, ou une piŁce de metal Ł Ia masse, rØduisent
Ia rØsistance Ølectrique de Ia surface du corps, permet
tant lentrØe de courants dangereux, voire mortels.
1.
1.
Grounding
the
Mise a Ia terre de
When arc 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
conducting object. Examples of conducting objects
include, but are not limited to, buildings, electrical
toots, work benches, welding power source cases,
workpieces, etc. Never touch the electrode and any
metal object unless the welding power source is
any
Lorsque lappareil de soudage a larc 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
lØlectrode et un objet conducteur. Certaines de ces ob
exemple (mais pas seulement), des
outils Ølectriques, des Øtablis, des
chassis de postes de soudure, des piŁces douvrage,
etc. Ne jamais touchez IØlectrode ou des objets en
jets
sont
btiments,
par
des
metal avant davoir
off.
When
installing, connect the frames of each unit such
as 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
lappareil
Equipment
fuel.
mis Ia poste de soudure Ł larrt.
A linstallation, branchez les chassis de chaque ØlOment
(source de courant, commande, Øtabli et circuit deau) a
Ia terre. Les conducteurs doivent pouvoir conduire les
courants telluriques en toute sØcuritØ. Lappareil chargØ
vagabonds peut donner une decharge
mortelle. NE BRANCHEZ PAS VOTRE
PRISE DE TERRE a une conduite Ølectrique, ou a un
tuyau de gaz ou de liquide inflammable tel que Ihuile ou
par Ies courants
risquant dŒtre
un
combustible.
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.
vØrifiez Ia
Connexion triphasØe. Avant Iinstallation
phase nØcessaire a Iappareil. Si seul le triphasØ est
disponible, ne branchez lappareil monophasØ qu deux
des fils de Ia ligne triphasØe. NE BRANCHEZ PAS le
conducteur de terre de Iappareil au troisiŁme fil (sous
tension), autrement lappareil serait chargØ: condition
dangereuse pouvant donner une dØcharge fatale.
Before welding, check ground for continuity. Be sure
conductors are touching bare metal of equipment
frames at connections.
Avant le soudage, vØrifiez Si Ia prise de terre est
uniforme. En branchant, assurez-vous que les con
ducteurs touchent le metal flu du chØssis de Iappareil.
-
If
line cord with
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.
a
2.
a
Electrode Holders
Fully insulated electrode holders should
NOT use holders with protruding screws.
3.
Lorsquun
Do
cof
le conducteur de terre doit Otre reliØ
Si vous avez en plus une fiche a trois broches pour Ia
Ia broche
terre, ne brarichez le conducteur de terre qu
de terre. Si le cordon dalimentation a une fiche a trois
broches, reliez-le a une prise femelte tripolaire reliØe Ł Ia
terre. Nenlevez jamais Ia broche de terre dune fiche ou
nutilisez jamais une fiche dont Ia broche de terre serait
brisØe.
2.
be used.
appareil doit Œtre alimentØ a partir dun
f ret dalimentation,
a celui-ci.
Pince-Ølectrodes
Utilisez des pince-Ølectrodes bien isolØes. NUTILISEZ
PAS des pince-Olectrodes 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-1516 Page 9
4.
Cables
4.
Frequently inspect
cables for wear, cracksand damage.
IMMEDIATELY REPLACE those with excessively worn
or damaged insulation to avoid possibly
lethal shock
from bared cable. Cables with damaged areas may be
-
taped
to
give
resistance
equivalent
to
original
cable.
Keep cable dry, free of oil arid grease, and protected
sparks.
from hot metal and
5.
Terminals And Other Exposed Parts.
6.
VØrifiez frØquemment lusure, les fissures et laltØration
des cables. REMPLACEZ IMMEDIATEMENT ceux dont
lisolation serait trop usØe ou altØrØe pour prØvenir les
dØcharges mortelles provoquØes par un cable dØnudØ.
Vous pouvez enrouler les parties endommagees de
ruban adhØsif en Øpaisseur suffisante pour donner une
rØsistance de cable neuf. Maintenez los cables secs,
dØpourvus dhuile et de graisse et mettez-les a labri du
metal chaud et des Øtincelles.
5.
Terminals and other exposed parts of electrical units
should have insulating covers secured before operation.
Electrode
TŒtes do cables et autres
parties dØnudØes
Avant Ia mise en marche, los tŒtes de cables et autres
parties dØnudØes dun appareil electrique doivent Œtre
munies de leurs couvrefils isolants.
6.
a.
Cables
Electrode
Equipment with output on/off control (con
tactor)
a
Appareil
.
equipØ
dune
commande
mar
che/arrŒt (contacteur)
Welding
metal
power
sources
for
use
with the gas
En
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
arc
so equipped the electrode wire
electrically HOT when the power
switch is ON and the welding gun
becomes
switch is closed. Never touch the electrode
wire or any conducting object in contact
with the electrode circuit unless the welding
power source is off.
b.
Equipment without output on/off control
b
(no contactor)
Welding
metal
power
sources
used with shielded
Safety Devices
prevent accidental turning ON of
power. Disconnect all cables from welding power
source, and pull all 115 volts line-cord plugs.
to
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.
postes
soudage a
7.
Before installation, inspection, or service, of equip
ment, shut OFF all power and remove line fuses (or lock
red-tag switches)
mar
de soudure utilisØs pour le
larc
avec electrode enrobØe
(SMAW) et des procŁs semblabes peuvent
commande mar
Œtre non-ØquipØs dune
che/arrŁt de Ia puissance de sortie. Lorsque
linterrupteur est en position MARCHE
Ne touchez
lØlectrode
devient chargØ.
jamais lØlectrode sans couper le courant au
poste de soudure.
Les
welding (SMAW) and similar pro
may not be eqoipped with welding
Safety devices such as interlocks and circuit breakers
should not be disconnected or shunted out.
or
commande
che/arrŒt (sans contacteur)
power output on-off control devices. With
such equipment the electrode is electrically
HOT when the power switch is turned ON.
the electrode unless the
Never touch
welding power source is off.
7.
protection
avec
Appareil non-ØquipØ dune
.
arc
cesses
soudure utilisØs
sous
electrode fusible (GMAW), ou
avec electrode tungstene (GTAW) et des
procŁs semblables sont ØquipØs dune corn
mande marche/arrŒt de Ia puissance de sor
tie. Lorsque linterrupteur est en position
MARCHE
et linterrupteur 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
poste de soudure.
gazeuse
put. When
source
general, les postes de
le soudage a larc
pour
Dispositif de sØcuritØ
Le dispositif de sØcuritØ-verrouillage et
doit pas Œtre dØbranchØ ou dØshuntØ.
coupe-circuit
ne
Avant linstallation, linspection ou Ia reparation de lap
pareil, mettez lalimentation sur ARRET et enlevez les
fusibles genØraux (ou verrouillez les interrupteurs) pour
Øviter une remise en MARCHE accidentelle. DØbran
chez tous les cables de Ia source de courant ainsi que los
prises des cordons dalimentation en 115 volts.
et ne
soudage, nouvrez pas le circuit dalimentation
changez pas Ia polaritØ. Sil est dØbranchØ au
Leaving equipment unattended. Always shut OFF and
disconnect all power to equipment.
cours
dune
Power disconnect switch must be available
Appareil laissØ sans surveillance. Mettez toujours
ARR~T et dØbranchez Iappareil.
welding
power
OM-1516 Page 10
source.
near
the
Lors du
decharge
urgence, faites attention
ou aux
aux
brQlures de
jaillissements dØtincelles.
sur
1-4. STANDARDS BOOKLET INDEX
-
formation, refer to the following standards
revisions and comply as applicable:
For
or
more
in
their latest
Linterrupteur
imitØ de Ia
1-4.
1.
2.
3.
ANSI Standard Z49.1, SAFETY IN WELDING
AND CUTTING obtainable from the American
Welding Society, 550 Le Jeune Rd, P.O. Box
351040, Miami, FL 33135.
NIOSH, SAFETY AND HEALTH IN ARC
WELDING AND GAS WELDING AND CUTTING
obtainable from the Superintendent of
Documents, U.S. Government Printing Office,
Washington, D.C. 20402.
4.
Printing Office, Washington,
D.C. 20402.
National Standards Institute,
Broadway, New York, NY 10018.
5.
ou aux normes
1430
ANSI Standard Z41 .1, STANDARD FOR MENS
SAFETY -TOE FOOTWEAR obtainable from the
American National Standards Institute, 1430
Broadway, New York, NY 10018
se
trouver a prox
DES
NORMES
Pour
plus de
de IACNOR
amØricaines Suivantes:
-
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,
1910, distribuØ par U.S. Government
Printing Office, Washington, D.C. 20402.
29CFR
ANSI Standard Z87.1, SAFE PRACTICES FOR
OCCUPATION AND EDUCATIONAL EYE AND
FACE PROTECTION obtainable from the
American
INDEX
renseignements, rØfØrez-vous
OSHA, SAFETY AND HEALTH STANDARDS,
29CFR 1910, obtainable from the U.S. Govern
ment
darrŁt doit toujours
de courant.
source
Z87.1, SAFE PRACTICES FOR
OCCUPATION AND EDUCATIONAL EYE AND
FACE PROTECTION distribuØ par IAmerican
National Standards Institute, 1430 Broadway,
New York, NY 10018.
4.
ANSI Standard
5.
ANSI Standard Z41.i, STANDARD FOR MENS
SAFETY
TOE FOOTWEAR distribuØ par lad
dresse donnee en 4.
-
6.
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.
7.
AWS 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.
8.
NFPA
9.
10.
Standard 51, OXYGEN
FUEL GAS
SYSTEMS FOR WELDING AND CUTTING ob
tainable from the National Fire Protection
Association, 470 Atlantic Avenue, Boston, MA
02210.
-
6.
ANSI Standard Z49.2, FIRE PREVENTION IN
THE USE OF CUTTING AND WELDING PRO
CESSES distribuØ par Iaddresse donnee en 4.
7.
AWS
8.
NFPA
-
NFPA Standard 70-1978, NATIONAL ELEC
TRICAL CODE obtainable from the National Fire
Protection Association, 470 Atlantic Avenue,
Boston, MA 02210.
NFPA Standard 51 B, CUTTING AND WELDING
PROCESSES obtainable from the National Fire
Protection Association, 470 Atlantic Avenue,
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.
FUEL GAS
Standard 51, OXYGEN
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
en8
10.
NFPA Standard 51B, CUTTING AND WELDING
PROCESSES distribuØ par Iaddresse donnØe en
8
11.
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 distribuØ par Ia Cana
dian Standards Association, Standards Sales,
178 Rexdale
Boulevard, Rexdale, Ontario,
Canada M9W 1 R3.
Boston, MA 02210.
11.
Standard A6.O, WELDING AND CUT
TING CONTAINERS WHICH HAVE COM
BUSTIBLES distribuØ par laddresse donnee en
OM-1516
Page
11
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.
13.
NWSA
WELDING
SAFETY
booklet,
BIBLIOGRAPHY obtainable from the National
Welding Supply Association, 1900 Arch Street,
Philadelphia, PA 19103.
14.
15.
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.
ANSI Standard Z88.2 Practice for Respiratory
Protection obtainable from the American Na
tional Standards Institute, 1430 Broadway, New
York, NY 10018.
OM-1516 Page 12
13.
SAFETY
NWSA
WELDING
booklet,
National
BIBLIOGRAPHY distribuØ par Ia
Welding Supply Association, 1900 Arch Street
Philadelphia, PA 19103.
14.
American
Welding Societe Standard
AWSF4.1
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 33135
Recommended
15.
ANSI Standard Z88.2 Practice For Respiratory
National
Protection
distribuØ par lAmerican
Standards Institute, 1430 Broadway, New York,
NY 10018.
SECTION 2
-
INTRODUCTION
Model
Single 16
Single 12
70~(1.78m)to
750 (19 m) per
Speed Range
minute
Boom
Swing
3600
Vertical Lift
~1aximum
16 ft. (4.9 m)
12 ft. (3.7 m)
Length
Horizontal To 60
Height (With
4 Ft Post)
21 ft. (6.4 ml
17 ft. (5.2 ml
At Full Lift Of Boom
Above
Is Designed To Balance Boom
Any
Angle.
Provided
Is
Pressure
Adjustment
To Hold The Boom At Any Desired Angle Or To
Limit The Vertical Lift At 40, 50, or 60.
Compression Spring
At
.
Counterbalance
(Patented)
Net 155 lbs.
.
Weight
Figure
2
-
2-1.
ment design, installation, operation, maintenance,
troubleshooting which should be read, understood,
followed for the safe and effective
use
and
of this equip-
Safety
installation,
operation, maintenance, and
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
of
arc
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
-
Welding
Specifications
A third signal word, IMPORTANT
highlights instruc
tions which need special emphasis to obtain the most
efficient operation of this equipment.
Prior to installing
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
-
2. RECEIVING-HANDLING
quest if occasion
When
____________
___________
different levels of hazard.
WARNING
include installation, operating,
____________statements
and maintenance procedures or practices which if not
carefully followed could result in serious personal injury
loss of life.
CAUTION
statements include
___________
and maintenance
procedures
or
installation, operating,
practices which if not
SECTION 3
3-1. LOCATION AND ASSEMBLY
-
(Figure 3-1)
Location
A suitable location for this unit will allow
boom to
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
equipment be supplied.
3. DESCRIPTION
2
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
boom is a patented design allowing both vertical lift and
-
A.
-
Power Source.
Safety instructions specifically pertaining to this unit ap
pear throughout this manual highlighted by the signal
words WARNING and CAUTION which identify
or
Ship335 lbs.
(152 kg)
this
troubleshooting
Arc
kg)
and
mont.
The
(93
General
Information presented in this manual and on various
labels, tags, and plates on the unit pertains to equip
B.
lbs. Net205 lbs.
(120 kg)
carefully followed could result in minor personal injury
or damage to this equipment.
1. GENERAL INFORMATION AND SAFETY
A.
Ship265
(70 kg)
swing horizontally
room for the
in the desired arc, and to
-
swing. Cables are routed through the boom from the
feeder control to the weld head assembly.
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 shielding gas to the welding gun.
INSTALLATION
pivot upward to the desired angle. Proper placement
will also 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.
OM-1518 Page 13
B.
Assembly
a.
Uncrate and
all
remove
material
packing
from the unit.
1.
Existing Support (Customer Supplied)
b.
FALLING BOOM can cause serious
personal injury and equipment damage.
Use 2-1/2 in. (63.5 mm) diameter, Schedule 40
WARNING
pipe (wall thickness
support pipe for 12
of 0.203 in.
5.2 mm) as
foot (3.7 ml booms.
Use 5 in. (127 mm) diameter, Schedule 40 pipe
(wall thickness of 0.258 in. or 6.6 mm)as support
pipe
or
Mount post support
(14)
the desired
to
structure.
___________
FALLING BOOM
WARNING
can
serious
cause
___________
personal injury and equipment damage.
Securely
mount unit to a structure that can sup
port the weight of the unit when the boom is in
the horizontal position.
for 16 foot (4.9 ml booms.
c.
a.
b.
Uncrate and
from the unit,
Mount
all
remove
packing material
to the desired struc
pipe post (14)
ture.
c.
WARNING
RELEASE
OF
SPRING
_________
WITHOUT BOOM AUACHED
Proceed
Steps
Remove yoke pin (1), nut (10), washers (9 &
17) and bolt (18) from the yoke (3) and
swivel plates (16).
to
Subsection 2.
Post
Support,
c-k.
can
PRESSURE
serious
cause
personal injury and equipment damage.
Perform installation exactly as outlined in step-b y
step instructions below.
1~
Do not
remove
safety collar until instructed
to do
so.
Retain safety collar for future disassembly
d.
on top of post (14) and in
(8) into post (14).
bearing (13)
Place
sert swivel
e.
use.
Place the boom base
plate (19)
in between
the two swivel plates.
f.
Slide washer (17) onto bolt (18) and insert
bolt (18) through hole (15). Slide washer (9)
onto bolt (18) and install nut (10) onto bolt
(18). Tighten nut (10); then back off nut
(10) 1/2
turn.
.12
g.
Insert
pin (1) through yoke (3), hole (2), and
through pin (1).
install cotter pin (4)
h.
Connect
the
assembly
as
welding gun
instructed in
to
the
the
drive
Owners
Manual for the desired welding gun.
i.
Grasp bar (20) and pull boom down slightly.
The boom should be pulled down only far
enough to remove the pressure which is ap
plied
TB-080 040
to the
safety collar (11).
j.
Remove and retain the safety collar (11).
k.
The boom should now balance in any posi
tion from horizontal to 60 degrees above
horizontal. If the boom does not balance
properly, proceed
to Section 3-10.
Figure 3-1. Base And Boom Assembly
CAUTION
WARNING
FALLING BOOM
can
cause
serious
personal injury and equipment damage.
Securely mount unit to a structure that can sup
port the weight of the unit when the boom is in
the horizontal position.
2.
Post
OM-1516 Page 14
Support (Optional)
EXCESSIVE FRICTION
can
damage
equipment.
Periodically lubricate swivel to prevent wear.
Excessive lubrication is not required or recommended.
3.
Base
Support (Optional)
IMPORTANT If an
chased with the
fastening the
optional base support was pur
unit, mounting holes are provided for
2.
Lift the wire support (7) in place
the swivel base (8).
over
the holes in
base support to the floor.
3.
FALLING BOOM can cause serious
personal injury and equipment damage.
For mounting base support use, as a minimum,
1/2 in. (12.7mm) diameter, S. A. E. grade 5 bolts.
Use equivalent strength, non-corrosive bolts if
unit is mounted in an extremely damp environ-
Insert
securing
screws (5) with lock washers (6)
and tighten.
WARNING
___________
3 -4.
REINSTALLATION
OF
HUB
ASSEMBLY
If it should become necessary to replace
the hub assembly, reinstall the new hub assembly as
(Figure 32)
-
follows:
ment.
a.
Uncrate and
remove
all
packing material
from the unit.
b.
Fasten base support to the floor.
c.
Complete Steps c-k in Subsection 2. Post
Support.
5678
CAUTION EXCESSIVE FRICTION can damage
equipment.
Periodically lubricate swivel to prevent wear.
Excessive lubrication is not required or recommended.
4.
Swingpak
a.
Base (Optional)
Uncrate and
from the
remove
Swingpak
all
packing material
12
base.
TB.080 037
Figure 3-2. Wire Support And Hub Assembly
FALLING BOOM can cause serious
personal injury and equipment damage.
Mount welding power source on Swingpak base
before mounting Swingarc.
WARNiNG
___________
b.
Uncrate and
from the
c.
remove
Swingarc
Complete Steps
Support.
c
all
1.
packing material
b.
Fiber Washer (2)
Flat Washer (3)
c.
Hub (4)
d.
Flat Washer (5)
e.
Fiber Washer (6)
Keyed Washer (7)
Spring (8)
Flat Washer (9)
a.
unit.
-
Slide the following items onto the spindle sup
port shaft (1) in order given:
k in Subsection 2. Post
f.
CAUTION
EXCESSIVE FRICTION
can
damage
g.
h.
equipment.
Periodically lubricate swivel to prevent wear.
Excessive lubrication is not required or recommended.
2.
felt while
2. DRIVE MOTOR
3
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 (21) provided in the motor
shroud (see Figure 3-1).
-
Rotate hex nut (10) onto support shaft (1). Hex
nut should be rotated only until a slight drag is
-
3.
turning hub (4).
Depress the two spring loaded stops (11) on the
retaining ring (12) and slide the retaining ring
(12) into proper position on the hub (4). Release
the two stops (11).
PRESSURE IN WIRE DRIVE MOTOR
GEAR BOX will damage motor.
CAUTION:
Remove vent screw prior to operation.
Warranty is void if the vent screw is not removed prior
S
to
3
operation.
-
3. INSTALLATION OF WIRE SUPPORT (Figure
3
-
5.
Remove the securing screws (5) and
washers (6) from the swivel base (8).
OF WIRE REEL
(Optional)
1.
Rem9ve
2.
Slide the wire reel (1) onto the hub (6). Rotate
the wire reel (1) until the hub guide pin (7) is
seated in the reel (1).
3.
Depress the two spring-loaded stops (4) on the
retaining ring (5) and slide the retaining ring (5)
3-1)
1.
INSTALLATION
(Figure 3-3)
the
retaining ring (5).
lock
OM-1516 Page 15
into proper
two
position
on
the hub (6). Release the
A.
Drive Roll Installation
(Figures
3-4 & 3-5)
stops (4).
1.
Loosen pressure
adjustment knob (item 2, Figure
3-4) and pivot it free of the
2.
Pivot gear
cover
(4) away
cover.
to expose pressure
gear.
3.
Loosen and
& 12)
4.
~7
For
on
one
remove
the three
securing
screws
(7
each gear (5 & 9).
piece drive rolls (8 & 13): slide
a
drive roll
onto the drive gear
(9) and pressure gear (5) with
holes aligned and secure with screws (7 & 12).
0
For split drive rolls (6 & 10): align holes on each
pair of split drive rolls, insert a securing screw (7
& 12) and slide a drive roll onto a drive gear (9)
and pressure gear (5) with screw in line with one
of the threaded holes. Insert remaining screws (7
& 12) and tighten.
IMPORTANT One-Piece drive rolls (8 813) are of
the double usage type. When the grooves become
worn, reverse each drive roll, locating the unused
groove in position to feed the wire.
______________
Figure 3-3. Reel Installation
TB-080 038
3 -6. 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
8 10) are of the double usage type.
When the knurled groove of the drive rolls becomes
worn, the spilt halves may be reversed so that the unus
ed edges will now provide a new knurled groove.
Base selection of drive rolls upon the
following recommended usages:
IMPORTANT
V-Groove rolls for hard wire.
2. U-Groove rolls for soft and soft shelled cored wires.
3. U-Cog rolls for extremely soft shelled wires (usually
hard surfacing types).
1.
4.
Split drive rolls (6
Split V-Knurled rolls for hard shelled
and C02 shielded types).
cored wires
U-Cog
drive
To
ensure
proper
gripping
action of
rolls, both rolls should be installed showing
slots
on the side or both should show the side without
slots. Also, it is necessary to line up the blunted teeth
on the pressure gear roll directly over the spaces bet
ween
the teeth
on
the drive gear roll.
(seff-shielding
5. Drive roll types may be mixed to suit particular re
quirements (example: V-knurled roll in combination
with U-groove).
Having
Drive Gear
U-Cog
Roll
selected the appropriate drive rolls and wire
to the following installation instruc
guides, proceed
tions:
TB-080 158-A
Figure 3-5. U-Cog Drive
B.
Inlet Wire Guides
1.
For .030 in.
Rolls Installation
(Figure 3-4)
TB-080 030-B
Figure 3-4. Drive Rolls Installation
OM-1 516
Page 16
-
5/64 in. (0.8-2.0 mm) wire.
a.
Insert liner (21) into inlet wire
with set screw.
guide (20) and
secure
b.
Loosen the inlet wire
rear
guide securing
screw
(3).
IMPORTANT
guides should be installed so
guide is as close to the drive roll as
possible without touching.
tip
2.
fitting
input fitting on the
has left-hand threads.
Connect the water out hose to the adapter on the weld
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.
Wire
of the
B.
c.
to the water
supply,
of the control. This
cable terminal
______________
that the
from the water
Electrical Reconnection Of Water Solenoid
Insert
guide assembly into drive assembly.
Secure by tightening screw (3).
For 3/32 in.
-
1/8 in. (2.4-3.2 mm) wire.
The control is shipped connected to supply water when
the POWER switch is in the ON position. The water
solenoid circuitry can be modified to supply water when
trigger is depressed.
the gun
a.
Remove anti-wear
wire
guide(s) (22) from
inlet
guide.
1.
Shut the unit down and disconnect from line
power.
b.
Loosen the inlet wire
guide securing
screw
I!AThI:h~ll~e~ ELECTRIC SHCCK
(3).
IMPORTANT Wire guides should be installed
that the tip of the guide is as close to the drive roll
possible without touching.
c.
d.
so
Install anti-wear
guide
and
guide(s) (22)
secure
onto inlet wire
Lockout/tagging procedures consist of padlocking line:
disconnect switch in open position, removing fuses
from fuse box, or taggingcircuit
breaker or other
disconnecting device.
Work
with setscrew.
or
employ lockout/tagging procedures on the
welding power source before internally inspecting
or servicing.
as
Insert the inlet wire guide (1) into drive
assembly as illustrated in Figure 3-4. Secure
by tightening screw (3).
kill.
can
Do not touch live electrical parts.
Disconnect input power to the wire feeder
on
internal parts to be performed
by qualified
per-
Sons.
IMPORTANT Drive roll alignment has been factory
set, but if readjustment is necessary rotate the drive
gear securing bolt (11) thereby moving the drive roll in
or out of the desired position.
The drive roll on the
pressure gear will locate itseif on the wire when the gear
cover is replaced and the gears mesh together.
______________
2.
Remove control box wrapper.
3.
Locate terminal
trol.
4.
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 (item 17,
Figure 3-4), weld terminal nut (18) and bolt, located
behind mounting plate (19). Slide the wire drive hous
ing 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
strip 1 T
on
bottom
panel of
Move lead No. 35 from terminal A
to terminal B.
on
con
terminal
strip iT
5.
Replace wrapper.
3 -8. WELDING GUN CONNECTIONS
A.
Outlet Wire Guide
IMPORTANT
the gun
(Figure 3-4)
The outlet
guide is provided as part of
assembly.
nut.
1.
3 -7. WATER CONNECTIONS
CAUTION OVERHEATING
of
Gas
Metal-Arc
Loosen the gun/feeder connector
IMPORTANT
Wire
guides
______________
_________
Welding (GMAW) gun can damage gun.
If using a water coo/ed gun and recirculating
coolant system, do not make connections from
the coolant pump to water valve; instead, make
connections
directly
that the
tip of the
2.
from the coolant system to
guide is
as
should be installed
close to the drive roll
so
as
Insert the connector (14) which includes the in
stalled outlet guide (15) into the drive assembly
opposite the inlet wire guide
Figure
as
illustrated in
3-4.
Installation Of Water Hoses
3.
When
knob
possible without touching.
gun hoses.
A.
securing
(16).
(Optional)
a
water-cooled gun is used, route the water hose
Tighten
the
gun/feeder
connector
securing knob
(16).
OM-1 516 Page 17
B.
Weld Cable (If
Applicable) (Figure 3-4)
provided on the lower portion of the drive
assembly to serve as a junction point for joining
together the weld cables from the welding power
source and the gun (if so equipped). Remove weld ter
minal nut (18), lock washer, and flat washer; slide the
weld cable from the gun onto weld terminal; replace flat
washer, lock washer, nut (18) and tighten.
C. Shielding Gas
A terminal is
The
shielding
gas hose from the gun is to be connected
protrudes from the motor end of
to the gas hose which
the boom.
IMPORTANT An
integral gas input fitting is provid
the weld head for guns utilizing this type of con
nection. See the appropriate welding gun Owners
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
____________
ed
on
assembly.
ingarc,
rotate the
adjustment
rod
so
that the
adjustment
rod threads Out of the yoke.
Locking Knob
B.
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
Locking Knob to the other threaded holes provided
along the side of the swivel plate, limits the lift of the
boom to 50 degrees or 40 degrees respectively during
the
free travel.
3-11. WIRE PULLEY (Figure 3-1)
Position of the
guide pulley is 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
-
wire
for
running wire
of smaller diameter (.030
5/64 in. or
2.0 mm). If excessive wear is noticed in the inlet
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.
0.8
-
-
-
D.
Trigger Control
The 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
energize, shielding gas will flow and wire will begin to
feed.
Water (If Applicable)
E.
Connect the water input hose from the gun to the water
output hose from the control.
Connect the water return hose from the gun to the
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
can
be accomodated.
3 -9. SHIELDING GAS CONNECTIONS
-
A hose is
supplied with the unit for making connections from the
shielding gas source to the Shielding Gas input fitting at
Figure 3-6. Boom Adjustments
fittings have right-hand
3-12. MOTOR CONTROL CONNECTIONS (Figure
A receptacle is provided for connecting the
3-7)
The gas hose routed through the boom connects to the
Shielding Gas output fitting at the front of the control.
plug to the control. Align keyways and in
plug from the control end of the boom into the
receptacle and rotate the plug threaded collar clockwise
as far as possible.
the
rear
of the control. These
threads.
-
motor control
3-10. BOOM ADJUSTMENTS
A.
(Figure 3-6)
sert
the
Weight Lift Adjustment
WARNING
FALLING BOOM
can
cause
serious
___________
personal injury and equipment damage.
Maintain full threads
the
-
on
adjustment
rod
through
yoke.
-
The amount of weight which the boom can retract into
the upright position when released can be varied by ad
115 Volts/Contactor
Control Receptacle
Motor Control
justing
the jam nut and adjustment rod located at the
base~f 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
Figure 3-7.
3-13. GUN
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
OM-1 516
Page 18
yoke. If
a
lighter
gun is used with the Sw-
Rear Panel Connections
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.
-
nut and rotate the
TA-072 726
Cord
3-14. WELD CABLE CONNECTION
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.
Install the wire onto the reel (1) over the four
fingers (2). Ensure that the wire feeds off the top
of the reel (1). The reel (1) turns in a clockwise
3.
-
direction.
fingers (2) back to their
position. Tighten the four wing nuts (3).
Rotate the four
4.
3-15. REMOTE CONTROL CONNECTIONS (Figure
A receptacle is provided for connecting a remote
4-1)
control to the unit. Align keyways and insert plug from
the remote control into the receptacle and rotate the
threaded collar clockwise as far as possible.
proper
-
OF
3-16. INSTALLATION
WIRE
SPOOL-TYPE
(Figure 3-2)
3-18. ADJUSTMENT OF HUB TENSION (Figure
Check the hub tension by slowly pulling the wire
3-2)
toward the feed roll. The wire should unwind freely, but
the hub tension should be sufficient to keep the wire
taut and prevent backlash when the wire feeding
ceases. If adjustment is required, loosen or tighten the
hex nut (10) on the end of the spindle support shaft (1)
-
accordingly.
ring (12).
1.
Remove the retaining
2.
Slide the spool of wire onto the hub (4) so that
the wire will feed off the top of the spool. The
spool turns in a clockwise direction.
3.
Rotate the spool until the hole in the spool aligns
with the pin in the hub (4). Slide the spool onto
VOLTS/CONTACTOR CONNECTIONS
AlOft. (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
3-19. 115
the hub until it seats
the hub.
4.
against the back flange of
two spring-loaded stops (11) on the
retaining ring (12) and slide the retaining ring
112) into proper position on the hub (4). Release
the two stops(1 1).
Depress the
OF
3-17. INSTALLATION
REEL-TYPE
WIRE
(Figure 3-3)
1.
Loosen the four wing nuts (3)
of the wire reel (1).
on
the
(Figure 3-7)
-
place.
CAUTION: IMPROPER VOLTAGE APPLIED TO
WELDING POWER SOURCE CONTACTOR can
damage wire feeder and welding power source.
fingers (2)
Ensure
welding
power
source
contactor control
circuitry requires external supply of 115
vac
for
contactor control.
2.
Pull the four fingers (2) out until they can be
rotated toward the center of the reel (1).
Wire feeder supplies 115 volts
source for contactor control.
ac to
the
welding
power
SECTION 4- FUNCTION OF CONTROLS
Fuae
operational condition, ready to feed wire and permit
shielding gas to flow. Placing the POWER switch in the
Retract/Feed
Switch
I
Circuit Breaker
OFF
Jog
position
will shut the wire feeder down.
Button
4 -2.
REMOTE
CONTROL
is
AND
-
controls. If
control is to be used, make con
instructed in Section 3-15 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.
nections
Control
RECEPTACLE
(Figure 4-1) The remote control receptacle
provided for use in conjunction with certain optional
SWITCH
a remote
as
Switch
Gee
Fitting
Receptacle
1~A-o72 725
Figure
4
-
4-1. Control
1. POWER SWITCH
-
Placing
-
-
line of the gun. The PURGE button also allows the
Components
(Figure 4-1)
3. PURGE BUTTON (Figure 4-1)
The PURGE
button is a momentary contact switch. This switch
energizes the gas solenoid and purges the shielding gas
4
Remote Control
shielding gas regulator to be adjusted without energiz
ing the welding circuit.
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
is
-
a
4. JOG BUTTON
(Figure 4-1) The JOG button
momentary contact switch. When actuated it com
-
OM-1516 Page 19
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.
RETRACT FEED
CAUTION CHANGING
SWITCH POSITION while welding can damage
switch and wire drive motor.
I
Do not change position of switch while the wire
_________
drive motor is
4
5. WIRE SPEED CONTROL (Figure -4-1)
The
WIRE SPEED control provides a means of determining
the rate at which welding wire will be fed into the weld.
-
-
Rotating the WELD SPEED control clockwise increases
the rate of the wire feed.
4
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
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 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
causes the wire to feed out of the gun. The switch
should be in the FEED position for normal operation.
4
-
-
running.
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
-
-
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 BURNBACK control. This delay action permits the welding
wire to burn back to a point where it neither sticks to the
4
-
-
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, rotate the BURNBACK control clockwise.
workpiece
SECTION 5- SEQUENCE OF OPERATION
5
-
5.
1. WELDING WIRE THREADING
ELECTRIC SHOCK
WARNING
can
kill.
Feed the wire through the inlet wire guide, past
the drive rolls, and on into the outlet wire guide.
Feed approximately 4 inches (102 mm) of wire
_________
Do not
energize welding
or wire
feeder until instructed to do so.
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
power
into the outlet wire guide.
source
IMPORTANT: If when the gear
U-Cog drive rolls
3-6), pivot the gear
CAUTION WELDING WIRE can cause puncture
wounds; HOT SURFACES can burn skin.
Do not activate gun trigger until instructed to do
__________
6.
so.
Do not point gun towards any part of the body
other personnel when threading weldihg wire.
Allow gun to cool before
cover
away from the drive gear and
7.
touching.
2.
Cut off any portion of the free end of the wire
which is not straight. Ensure that the cut end is
as
in
8.
rough surfaces
to
Pivot the gear cover closed making sure the
teeth on the pressure gear mesh with .the teeth
on the drive gear. The welding wire must also be
in the grooves of the drive rolls.
Pivot the pressure adjustment knob until the
on the pressure adjustment is seated on
top of the gear cover.
washer
Install the wire (reel-type or spool-type)
structed in Section 3-16 or 3-17.
from
tooth.
or
1.
free
is closed the
aligned properly (see Section
rotate the pressure gear one
energized.
cover
not
are
permit
proper
feeding.
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 opera-~
source
3.
4.
OM-1 516
Route the wire through the wire guide tube on
the side of the boom, over the wire pulley, and to
the drive assembly.
Loosen the knob
tion.
9.
Draw the gun cable out
straight.
the drive roll pressure ad
10.
Energize
justment, pivot the pressure adjustment free of
the cover, and pivot the pressure gear assembly
away until it is in an open position.
11.
Place the control POWER switch in the ON
tion.
Page
20
on
the
welding
power
source.
posi
12.
Depress the JOG switch. This will run the
wire through the gun without placing
weld current on the welding wire. Release the
JOG switch when the welding wire extends ap
Rotate the WIRE SPEED control to the desired
7.
welding
proximately
tip.
one
setting.
WARNING ARC
RAYS, SPARKS, AND HOT
burn eyes and skin; NOISE can
_________
SURFACES
can
the
shielding
gas at the
8.
Turn
9.
Depress the PURGE button for
on
source.
inch (25.4 mm) out of the gun
Hold the
10.
minute.
tip of the gun approximately 1/2 inch
(12.7 mm) from the workpiece.
damage hearing.
Wear correct eye, ear, and body protection.
FUMES AND GASES can seriously harm your
health.
Use enough ventilation to keep fumes and gases
from the breathing zone.
See Section 1
Safety Rules For Operation Of Arc
Welding Power Sources for basic welding safety infor
mation.
one
Depress the trigger
11.
on
the gun handle. Gas will
start to flow and wire will start to feed if drive roll
pressure is properly adjusted to prevent slippage.
If wire slippage is noticed, tighten the drive roll
pressure adjustment knob 1/2 turn clockwise.
Repeat until slippage stops. Do not overtighten.
-
WARNING
ELECTRIC SHOCK
can
kill.
__________
Do not touch we/ding wire or any metal part in
contact with it while welding.
6 -2. GAS METAL-ARC WELDING (GMAW)
1.
MØke all necessary connections
as
instructed in
Section 3.
Do not touch live electrical parts.
wire and all metal parts in contact with it carry
weld current when the welding power source contactor
Welding
is
2.
energized.
Place the Remote Control switch in the desired
position.
5 -3. SHUTTING DOWN
3.
Place the START switch in the desired
position.
1.
Turn off the
4.
Place the RETRACT-FEED switch in the desired
2.
Place the POWER switch in the OFF
3.
Turn off all associated
shielding
gas at the
source.
position.
position.
5.
Energize the welding
6.
Place the POWER switch in the ON position.
power
equipment.
source.
Gases can harm health or kill.
Shut off gas supply when not in use.
WARNING
___________
SECTION 6- MAINTENANCE
6
1. INSPECTION AND
UPKEEP
Usage and
shop conditions will determine the frequency and type
of maintenance. inspect equipment as follows:
-
-
WARNING
ELECTRIC
__________
WELDING WIRE can cause
SHOCK
can
kill;
puncture wounds; HOT
SURFACES can burn skin.
Disconnect unit from input power before internal
ly inspecting
or
1.
2.
3.
Make
sure
5.
gun.
welding
power
source
is shut down.
Inspect gun for broken areas, cracks and loose
parts: tighten, repair, and replace as required.
remove any weld spatter or foreign
matter which may accumulate around the nozzle
Carefully
orifice. Use
4.
on
a
guide liner with compress
changing wire. This will remove any
chips
and dirt that may have accumulated.
metal
IMPORTANT:
Periodically inspect the labels
on
the
All labels must be maintained in a
c/early readable state and replaced when necessary.
See Parts List for part number of labels.
unit for
legibility.
servicing.
Allow gun and unit to cool before touching.
Do not activate gun trigger while performing
maintenance
ed air when
Blow out the gun wire
6.
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.
Remove grease and grime from components;
moisture from electrical parts and cable.
6
2. CLEANING OF DRIVE ROLLS
Occasionally
it will become necessary to clean the wire groove on the
drive rolls. This cleaning operation can be performed
with a wire brush.
-
-
HIGH ROTATIONAL SPEED may
damage to drive rolls.
Do not allow drive rolls to rotate at high speed if
compressed air is used for cleaning the drive roll
WARNING
_________
cause
assembly.
To clean the wire grooves it will be necessary to discon
nect unit from line power before removing the drive
roll(s) (see Section 3-6 for removal and installation in
structions).
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.
_____________
OM-1516
Page
21
6
3. FUSE (Figure 4-1)
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.
-
-
6 -4. BRUSH INSPECTION
(FIgures 6-1 & 6-2)
WARNING
&
ELECTRIC SHOCK
5.
Pull brush out
6.
If replacement is necessary (brushes are less
than 1/4 in length) disconnect the brush pigtail
from the brush box tab and remove brush.
7.
Connect
using brush pigtail.
REPLACEMENT
can
8.
kill.
Route
__________
I
Do not touch live electrical parts.
I
Disconnect input power to the wire feeder
new
brush
pigtail
to brush box tab.
pigtail through slot in brush box. Ensure
pigtail will not come into contact with a
that the
metal surface.
or
employ lockout/tagging procedures on welding
power source before internally inspecting or ser
vicing.
9.
Insert brush into brush box. Ensure that the low
end of the bevel
towards the
Lockout/tagging procedures consist of padlocking line
disconnect swith
in open position, removing fuses
from fuse box, or tagging circuit breaker or other
disconnecting device.
Work on internal parts to be performed by qualified per
10.
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
bracket hooks on the
lustrated in Figure 6-2.
SOnS.
1.
Shut unit and associated equipment off.
2.
Open brush cap by sliding screwdriver
catch and lifting. Remove brush cap.
box
brush
wall
as
il
If the spring retaining bracket is in place, it will be
against the brush box wall when the pliers are
11.
under
released.
3.
Grasp spring retaining bracket with long-nose
pliers.
12.
Ensure that the spring is in the proper position
illustrated in Figure 6-1.
4.
Push spring retaining bracket in lightly and move
towards brush. This should release the spring
assembly and it can be removed.
13.
Replace and latch the brush
14.
as
cap.
Reconnect power to all equipment and
resume
operation.
Spring
Long-Nose Pliers
Brush B~
Tab
Brush
BrushPIgteiI
NOTE:
Spring
assembly
TA-046 228
Figure 6-1. View Of Spring Assembly And Brush
When Brush Cap Is Opened
hooks
here.
TA-046 226
Figure 6-2. View Of Spring Assembly And Brush
From Armature End Of Motor
SECTION 7- TROUBLESHOOTING
ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Disconnect unit from input power before internal-
WARNING:
4 inspecting
Troubleshooting
by qualified
or
servicing.
of internal parts to be performed only
trouble is not remedied after
performing these pro
Factory Authorized Service Sta
tion should be contacted. In all cases of equipment
malfunction, the manufacturers
recommendations
should be strictly followed.
cedures, the
nearest
persons.
CAUTION
DISASSEMBLY
OF
MOTOR
FIELD
_________
The
following
chart is designed to diagnose and provide
remedies for some of the troubles that may develop in
this unit.
It is assumed that proper installation has been made, ac
to Section 3 of this manual, and that the unit
has been functioning properly until this trouble
cording
developed.
Use this chart in conjunction with the circuit diagram
while performing troubleshooting procedures. If the
OM-1 516
Page 22
MAGNETS
ment
I
can
result in
personal injury
or
equip.~
damage.
Limit wire drive motor
repairs
to
brush replace
ment.
The field magnets
are
tempted, injury
fingers
very strong. If disassembly iØ at
and hands may result from a
drawn back into the motor. The field
to
magnet being
I
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.
TROUBLE
REMEDY
PROBABLE CAUSE
Depressing gun switch will
energize wire feeder.
not
Electrode
wire
is not
energized and shielding gas
does not flow.
Control POWER switch in
position or defec-
Place switch to ON
position.
wrong
tive.
.
.
Replace defective POWER switch.
volts
115
input fuse
Fl
*
Replace fuse
Fl.
open.
115 volts/contactor control
not secure in recep
in
receptacle.
Secure
plug
Secure
plug in TRIGGER receptacle.
plug is
~
tacle.
Plug from gun trigger controt cable is not secure in
~
TRIGGER receptacle.
Coil of
.
relay CR1
~
defective.
Circuit breaker CB1 tripped.
Replace relay CR1.
Manually
button
by depressing the
panel of the control labeled
reset circuit breaker
the front
on
RESET.
Wire
feeds, shielding gas
flows, but electrode wire is
not
energized.
115 volts/contactor control
plug is not secure in contac
tor
receptacle
power
Defect
Wire feeds
erratically.
on
Secure
plug
in
receptacle.
welding
source.
in
welding
power
See
TROUBLESHOOTING Section
source instruction manual.
source.
power
Pressure on drive rolls is insufficient.
turn increments until
Drive roll
Change
wire size
is too large for
used.
in
welding
Rotate pressure adjustment knob clockwise in 1/4
wire slippage stops.
to proper size drive roll. See Section 3-6.
being
Worn drive roll.
Replace drive roll. See Section 3-6.
Dirt in drive roll.
Clean drive roll
*lf it becomes necessary to replace any fuse in the wire feeder,
used.
ensure
that
a
as
instructed in Section 6-2.
fuse of the proper
and size is
rating, type,
OM-1516 Page 23
S
-
5~A
Circuit
Figure
OM-1516 Page 24
7-1. Circuit
Diagram
Diagram No. B-083 019-A
August 1983
FORM: OM-1516D
Effective With Serial No. JD699352
PARTS
LIST
728
TD-072
38
36
35
C
Item
37-Fig
32
Asembly
16 23 25 26
31
18
Main
-
A
Figure
44
46
1
0
U
U -v U
C
Quantity
Item
Dia.
No.
Mkgs.
Figure
Model
Part
No.
A
Description
Main
I
12
16
Assembly
081 964 CORD, control interconnecting (consisting of)
039 635
CONNECTOR BODY, twistlock 2P2W
039 687
CAP, twistlock grounded 2P3W
605 156
CORD, portable No.18 4/c (order byft)
079 531
CLAMP, cable
048284 HOUSING PLUG & SOCKETS (consisting of)
079 ~34
TERMINAL, female
1,
-
2
3
4
5
6
PLG3
PLG8
PLG1
7
8
9
10
-
12
13
14
-
-
14
15
PLG2
16
17
18
19
20
20
21
22
23
24
PLG9
30
31
32
32
33
34
35
36
37
38
38
38
38
39
39
39
39
40
41
42
lOft.
1
lOft.
ift.
ift
:
1
2
2
2
2
2
2
lOft.
lOft.
1
4
4
2
2
16 ft.
20 ft.
4
4
1
1
1
-
25
26
27
28
28
29
049 455
CORD, portable No.18 2/c (order byft.)
048 837 HOSE ASSEMBLY, gas (consisting of)
ADAPTER
051 297
010603
FITTING, hose brass barbed nipple 1/4 TBG
010 606
FITTING, hose brass nut 5/8-18 RH
056112
FITTING, hose brass ferrule 0.475 ID x 23/32
603 106
HOSE, neoprene braided No. 1 (order by ft.)
049 012 CORD, trigger 16 ft. (consisting of)
048 618 CORD, trigger 20 ft. (consisting of)
RECEPTACLE W/PINS, free hanging (consisting of)
080 328
079 534
TERMINAL, female
079 531
CLAMP, cable
605 156
CORD, portable No.18 4/c (order byft.)
HOUSING PLUG & PINS (consisting of)
079 878
079 535
TERMINAL, male
079 202 HOSE, gas (consisting of)
079 204 HOSE, gas (consisting of)
056 851
FITTING, hose brass barbed nipple 3/16 TBG
-
11
1
-
PLG7(M)
010
056
604
010
079
072
072
072
048
079
079
007
078
606
112
550
604
196
088
103
102
306
535
706
826
992
FITTING, hose brass nut 5/8-16
FITTING, hose brass ferrule 0.475 ID x 23/32
HOSE, neoprene No.1 x3/161D(orderbyft.)
FITTING, hose brass bushing 1/4 NPT x 5/8-18 RH
FITTING, brass barbed female 3/16 TBG x 1/4 NPT
CONTROL BOX (Fig B Pg 4)
CORD, motor 17 ft. (consisting of)
CORD, motor 21 ft. (consisting of)
-
-
2
16 ft.
-
-
RECEPTACLE & PINS (consisting of)
TERMINAL, male
CLAMP, cable
CORD, portable No.18 3/c (order byft.)
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 (Pg8)
t079 591 BASE, 4 ft. or
t079 214 BASE,6ft
t078 264 BASE, 4 ft. or
t079 216 BASE, 6 ft
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)
080157
FITTING, grease 1/8 NPT
010910 WASHER, flat- SAE3/8
079 624 SCREW, cap steel hex hd 3/8-16 x 2
-
-
-
-
20 ft.
1
1
1
6
6
1
17 ft.
21 ft.
1
24ft.
1
28ft.
1
1
1
1
1
1
1
1
1
1
1
-
-
-
1
1
1
1
1
1
OM-1516
Page
2
Quantity
Item
Dia.
No.
Mkgs.
Figure
A
43
44
Model
Part
No.
Description
Main
075 150 WASHER, nylon -shoulder 0.622 x 1 x 3/8
080 802 MOTOR, gear 1/8 hp 115 volts dc 2000 rpm (consisting of)
080 283
COVER, brush
080282 .SPRING, brush
*080 281
BRUSH
015 713 GROMMET, rubber5/l6lDxl/2mountinghole3/l6groove
.
48
49
50
51
52
I
16
Assembly (Contd.)
.
45
46
47
12
079 635 INSULATOR, motor
D WIRE DRIVE & GEARS (Pg 10) (consisting of)
079 633
FITTING, hose-brass carded nipple3/16TBG
072010 BUSHING
601 872 NUT, hex-fuII3/8
602213 WASHER,Iock-split3/8
602243 WASHER,flat3/8
Figure
.
1
1
1
1
2
2
2
2
2
1
1
1
1
2
1
2
1
1
1
1
2
1
1
1
1
1
*R~ommended
Spare Parts.
tOptional Equipment.
BE SURE TO PROVIDE MODEL
AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
TD-072 729
Figure
OM-1516
Page3
B
-
Control Box
Item
Dia.
No.
Mkgs.
B
Figure
Part
No.
Quantity
DescriptiOn
072 088 Control Box
(Fig
Pg
A
2 Item 27)
.
1
2
SRi
VR1
3
Ti
-
4
Cl
5
6
7
8
9
10
11
CR2
2T
RC5
PCi
049 289 WRAPPER
035 914 RECTIFIER,
082
036
031
006
006
038
722
135
692
426
393
784
045 1.39
039 756
057314
010 296
.
12
13
14
15
16
PLG4
GS1
16
17
18
19
20
21
22
23
GS1
CR1
R13
Ri
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
R2
PLG7(F)
1T
S1,3,6
S2
S4,5
R5
RC1
RC4
RC6
Fl
RC2
CB1
602
046
079
010
056
035
053
1
integrated
VARISTOR,0.6wattl75voltsdc
TRANSFORMER, controlll5-24voltsac
CAPACITOR, electrolytic 750 uf 200 volts dc
BRACKET, mounting capacitor
1
RELAY,24voltsacDPDTflangedcase
STRIP, terminal 1 pole
BRACKET, mounting connector
CONNECTOR, edge circuit card 10 pin
CIRCUITCARD(FigBi Pg5)
1
1
1
1
-
1
1
-
1
-
FITTING, hose
-
934
FITTING, pipe
724
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 voltsac2wayl/4 IPS port 1/8 orifice
VALVE, ll5voltsac2wayl/4lPSportl/8orifice
TUBING, 0.275 lDxO.O48wallxl
-
1
2
1
elbow male 1/4 NPT 5/8-18 RH
galvanized coupling 1/4 NPT
1
-
573
141
265
601
894
010 199
045812 BUSHING,1/4ODxO.141 lDxl
010193 TUBING,3/8ODxl8gawaIIxl/4
034 841 RELAY, 24 volts ac DPDT
079 497 RESISTOR,WWfixed25watt2000 ohm
030 651 RESISTOR,WWfixed25wattl0 ohm
604311 GROMMET,1/4lDx3/8mtghole
056 170 SHIELDS resistor
1
1
1
-
030 949
030 941
079 683
010476
007 826
079 706
048 380
079 534
601 219
038 772
011 233
011 059
011 232
030 943
048 283
079 535
056 266
039 825
046 709
079
*073
046
059
048
079
011
1
30 amp400 volts
or
HEAT SINK, rectifier
RESISTOR, WW fixed 100 watt 5 ohm
HEAT SINK, resistor
BUSHING, strain-relief5/8x0.57 hole
CORD, portable No.18 3/c (order byft)
CLAMP, cable
HOUSING PLUG & SOCKETS (consisting of)
TERMINAL, female
.
LINK,jumperterminalblock
BLOCK, terminal 20 amp 6 pole
SWITCH,toggleSPDTloamp25ovoltsac
SWITCH,toggleDPDTi5ampl25volts
SWITCH, push button SPDT
-
POTENTIOMETER, carbon 1
turn 2 watt 15K ohm
RECEPTACLE W/PINS (consisting of)
TERMINAL, male
CONNECTOR, female 6 contact 7.5 amp
RECEPTACLE, 6 socket MS-3102A-14S-6S
CASE SECTION, front/bottom/rear
NAMEPLATE (order by model & serial numbers)
KNOB
FUSE, miniature glass sb bbo 5 amp
HOLDER, fuse panel mounting (consisting of)
CAP, holder fuse
RECEPTACLE W/SOCKETS (consisting of)
.
772
426
432
139
282
534
TERMINAL, female
991 CIRCUIT BREAKER, 1 pole 1.5 amp 250 volts
-
-
1
1
2
.1
6
1
1
1
1
1
1
1
1
1
3 ft
1
.
1
3
1
1
3
1
2
1
1
4
1
1
1
1
1
1
1
.
1
.
4
-
1
1
*Recommended Spare Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-1516 Pago4
Dia.
Part
Mkgs.
No.
Fig
Bi 057 314
Quantity
Description
Circuit Card Assembly
(Fig
B
Pg
4 Item 10)
2
3
1
1
1
4
C2,3 044 602 CAPACITOR, poly film 0.47 uf 400 volts dc
C4,8,9 031 643 CAPACITOR, ceramic 0.01 uf 500 volts dc
C7
031 693 CAPACITOR, mylar 0.33 uf 75 volts dc
ClO
031 633 CAPACITOR, electrolytic 80 uf 25 volts dc
C12
031 721 CAPACITOR, mylar 0.22 uf 200 voltsdc
Dl -4
026 202 DIODE, 1 amp 400 volts straight polarity
037 250 DIODE, zener 24 volts 1 watt
D5
Qi
037 824 THYRISTOR, 7.4 amp 200 volts
010 915 WASHER,flat-brassl/4(mountingQl)
602 208 WASHER, lock steel external tooth 1/4 (mounting Qi)
601 867 NUT, steel hex jam 1/4-20 (mounting Qi)
-
1
1
1
1
-
1
-
02
R3
R4
R6
R7,10
R8
R9
All
R12
R12
A20
T2
037261
037 289
030 937
030 854
030 945
028 276
030 944
030 936
030
030
030
030
085
938
934
934
090
399
602 196
601 858
HEATSINK
1
TRANSISTOR, unijunction 5OMA 35 volts
RESISTOR, carbon 0.5 watt 10 ohm
RESISTOR, carbon 0.5 watt 18K ohm
RESISTOR, carbon 2 watt 4700 ohm
RESISTOR, carbon 0.5 watt 2200 ohm
POTENTIOMETER, WW 1 turn 2 watt 5000 ohm
RESISTOR, carbon 0.5 watt 33K ohm
RESISTOR, carbon 0.5 watt 1200 ohm
RESISTOR,carbon0.5watt6800 ohm
RESISTOR,carbon0.5watt6800 ohm
RESISTOR, carbon 0.5 watt 47 ohm
TRANSFORMER, pulse
WASHER, lock steel internal tooth No. 4 (mounting T2)
NUT, steel hex 4-40 (mounting T2)
.1
1
1
1
2
1
1
1
.1
1
1
1
1
-
1
-
TA-057 314
Figure Bi
-
Circuit Card Assembly
COMPONENTS TO BE
REPLACED BY QUALIFIED
PERSONNEL ONLY
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-1516 Page5
I NOTE~
Base selection of drive rolls upon the
1. V-Groove rolls for hard wire.
following
recommended usages:
2.
U-Groove rolls for soft and soft shelled cored wires.
3.
U-Cog
rolls for extremely soft shelled wires (usually hard
4. Split V-Knurled rolls for hard shelled cored wires
surfacing types).
(self-shielding and C02 shielded types).
5.
requirements (example: V-knurled roll
Drive roll types may be mixed to suit particular
in combination
1with U-groove).
Wire Diameter &
Type
Kit No.
Roll Drive
Inlet Wire
Type
Guide
053 695
V-groove
056 192
079 595
053 700
V-groove
056 192
1.2MM
079 596
053 697
V-groove
056 193
.052
1.3MM
079 597
053 698
V-groove
056 193
1/16
.062
1.6MM
079 598
053 699
V-groove
056 195
.035
035
.9MM
044 749
072 000
Ugroove
056 192
.045
.045
1.2MM
079 599
053 701
U-groove
056 193
.052
.052
1.3MM
079 600
053 702
U-groove
056 193
1/16
.062
1.6MM
079 601
053 706
U-groove
056 195
5/64
.079
2.0MM
079 602
053 704
U-groove
056 195
3/32
.094
2.4MM
079 603
053 703
U-groove
056 196
7/64
.110
2.8MM
079 604
053 705
U-groove
056 196
1/8
.126
3.2MM
079605
053707
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
079608
079727
V-knurled
056 193
Fraction
Decimal
Metric
.030
.030
.8MM
079 594
.035
.035
.9MM
.045
.045
.052
Part No.
1/16
.062
1.6MM
079609
056771
V-knurled
056195
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
079612
056775
V-knurled
056196
1/8
.126
3.2MM
079613
056776
V-knurled
056197
.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
056195
5/64
.079
2.0MM
079615
053710
U-cogged
056 195
3/32
.094
2.4MM
079 616
053 709
U-cogged
056 196
7/64
.110
2.8MM
079617
053711
U-cogged
056196
1/8
.126
3.2MM
079 618
053 712
U-cogged
056 197
Drive Roll & Wire Guide Kits
*~J~.~en ordering replacement parts all kits listed with the exception of the V-KNURLED kits are
drive rolls are required for the one piece drive kits and four drive rolls for the split V-knurled kits.
one
piece drive rolls. Two
See Section 2-6 in Owners Manual for identification of parts.
OM-1516 Page 6
9
1,
F
0
cv,
I-
P1
I..
N
N
I-
0
0~
C.)
0
0
U-
U)
Ic,
I
N
I-
I-
N
I-
N
N
I-
U)
Ic)
N
N
I-
OM-1516 Page 7
Quantity
Item
No.
124
010313
079 622
079 621
082 970
125
079 632
123
-
126
126
127
127
128
129
130
131
131
132
132
133
133
134
134
135
136
137
138
139
140
140
141
141
142
142
143
143
144
144
145
145
146
146
147
148
148
149
150
151
152
153
153
154
155
156
157
Description
No.
Figure C
121
122
Model
Part
601 865
602 207
079 667
080 812
079665
080811
079 664
047 170
047 171
007 280
073 742
007 279
073 741
601 883
605 884
075 401
075 462
602250
Figure Cl
601 965
602 213
079 020
602249
075 102
073 663
024605
075 100
075 101
602 219
079 030
601 883
079 029
080449
080 722
075 421
048 128
075 403
+072 090
+072 089
047 497
602 246
047224
073 666
082 966
082 967
601 872
602 213
079 643
079631
Boom
(Fig
A
Pg 2
1 2
I
16
Item 37)
PIN,cotter-hairo.072x1.437long
BUSHING, nylon 0.622 lDx0.075x0.501 thick
PULLEY, V single groove
SHAFT, pulley
BOLT, U-steel 1-5/8 high
NUT,hex-steelfulll/4-20
WASHER,lock-steelsplitl/4
PIPE,plasticl/2x133-3/4
2
2
1
1
4
8
8
1
2
2
1
1
5
10
10
1
PIPE, plastic 1/2 x181-3/4
GUIDE,wire
GUIDE,wire
GUIDE, inlet
1
1
1
TUBING,neoprene3/8lDxO.093wa11x12
1
1
1
LINER,monocoilxl3
1
1
PIN,clevis5/8-18x1-7/8long
PIN, clevis3/4 dia x2-5/32 long
1
1
1
CLEVIS
CLEVIS
NUT, steel
1
-
hex
1
jam 5/8-18
NUT, steel hex half 3/4-16
SHAFT, boom counter balance
SHAFT, boom counter balance
1
WASHER,flat-steelSAE3/4
SUPPORT,hub&reel(Pg9)
SCREW, cap-hexhd3/8-16x1
WASHER, lock-split 3/8
2
1
4
4
2
NUT, steel
1
1
-
-
1
-
-
hex elastic stop
WASHER,flat-steelSAE5/8
WASHER,steel-shield3 inch
1
BEARING, ball
1
1
1
1
1
1
-
-
-
-
-
I
1
2
1
1
1
1
1
1
-
-
BOOM,single
NUT, steel-hexfull3/8-16
WASHER, lock-steel split3/8
GUARD, motor- protector
BRACKET,hanger-gun
4
1
BEARING, ball-thrust
NUT,steel5/8-18x1-1/4special
NUT,steel3/4-16x1-1/4special
WASHER, lock-steel external tooth 5/8
WASHER, lock steel external tooth 3/4
NUT, steel hex jam 5/8-18
NUT, steel-half full3/4-16
SPRING, compression2ODxl IDx12
SPRING, compression 3-3/8 ODx22-1 /4 inches long
SPACER, spring boom
PIPE, black 3 x8
BEARING, thrust boom
BASE, swivel boom
BASE, swivel boom
LABEL, general precautionary
WASHER,flat-steell/2
KNOB,T-bar
BOLT, machine steel hex hd 3/4-16
BOOM, single
1
4
x
2-3/4
1
1
1
1
1
1
1
1
1
1
4
~
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
No.
Part
No.
FIgure CI
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
079
010
058
058
057
010
605
601
058
t056
604
056
056
010
601
Quantity
Description
Support,
Hub 8 Reel
(Fig C Pg
8 Item 136)
1
638 SUPPORT, reel
191 WASHER,fiber5/8lDxl-1/2ODxl/8
628 WASHER, steel brake
428 HUB,spool
971
233
941
884
427
416
051
312
313
224
880
056 314
2
2
1
-
WASHER, flat steel keyed 1-1/2 dia 1/8 thick
SPRING, compression
WASHER, flat steel 41/64 ID x 1 OD
NUT,steel-hex5/8-11
RING, retaining spool
REEL, wire (consisting of)
NUT, steel wing 1/2-13
FINGER, reel
.STUD,steell/2-13x7
PIN, spring compression 3/16 x 1 inch
NUT, steel hex jam 1/2-13
1
-
1
1
1
-
1
-
1
4
-
4
4
4
-
4
-
REEL
1
.163
162
169
170
TC-007 886
Figure Cl
-
Support, Hub S Reel
tOptional Equipment.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-1516
Page 9
Item
Part
No.
No.
Figure
Wire Drive & Gears
D
192
193
194
195
604 612
049 233
080 211
079671
085 243
085244
010 231
085 242
010 224
601 925
604741
079 669
079634
196
079 772
197
604 538
198
199
200
201
202
203
204
205
206
207
208
053 842
605 518
079 626
010193
048 336
602 241
000 418
053 841
079 625
082 036
082 050
183
184
185
186
187
188
189
190
191
Description
(Fig
A
Quantity
Pg 3 Item 47)
SCREW,set-sockethd8-32x1/8
GUIDE, anti-wear
DRIVEASSEMBLY(consistingof)
.HOUSING,adapter-gun/feeder
KNOB, adjust-tension
.WASHER,cupped2l/64IDx13/16
SPRING, compression
FASTENER, pinned
PIN, spring compression 3/16 x 1
.SCREW,cap-steelhexhdl/4-20x1/2
.PIN,cotter-hair0.042x15/16
LEVER, mounting pressure gear
.PIN,hinge
KNOB, plastic
WASHER, flat steel SAE 5/16 (as reqd)
GEAR, spur insulated w/bearing
SCREW,cap-steelhexhdl/4-20x1-1/4
SCREW, machine steel fillister hd 10-32 x 7/8
TUBING,steel3/8ODxl8gawaIlxl/4
STOP, cover
WASHER,flat-steeISAEl/4
SCREW, cap steel hex hd 1/2-20 x 1/2 self locking
GEAR, spur insulated w/key
WASHER, spring steel 5/16 shakeproof
2
1
1
1
1
.
2
1
.
1
.
-
1
.
-
1
1
1
.
1
1
.
-
1
.
-
-
-
-
-
-
1
1
6
1
1
1
1
1
1
1
GUIDE, inlet wire
LINER, monocoil inlet wire
-
1
-
200
TC-080 028-D
Figure D
-
Wire Drive & Gears
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-1516
Page
10
Part
No.
Quantity
Description
-
Dia.
Mkgs.
Parts For
Optional Equipment
.
R7
WS1
WS1
047
073
024
047
046
046
035
053
+033
+053
602
010
056
008
079
000
000
000
000
000
+
946 BURN BACK CONTROL (consisting of)
562
POTENTIOMETER, carbon 1 turn 2 watt 10K ohm
366
KNOB, pointer
980
TIMER, delay 20 mu sec/20 sec
531 WATER CONTROL (12 ft models) (consisting of)
533 WATER CONTROL (16 ft models) (consisting of)
601
VALVE, 115 volts ac2 way 1/4 IPS port 1/8 orifice
894
VALVE, 115 volts ac 2 way 1/4 IPS port 1/8 orifice
050
COIL (Singer)
964
COIL (Eemco)
934
FITTING, pipe nipple L 1/4 NPT x 6
295
FITTING, pipe coupling 1/4 NPT
296
FITTING, hose-elbowmale 1/4 NPTx5/8-18 LH
657
FITTING, hose bushing reducing 5/8-18 LH
773
ADAPTER, terminal water electrode
572
HOSE, water 10 ft (12 & 16 ft models)
570
HOSE, water 15 ft (12 ft models)
572
HOSE, waterl9ft3 inches (l6ftmodels)
573
HOSE,water25ft(l2ftmodels)
569
HOSE,water29ft(l6ftmodels)
1
1
.
1
.
1
.
.
.
.
.
.
.
1
1
(consisting of)
(consisting of)
1
1
1
-
.
-
.
.
-
.
.
1
2
.1
1
.
1
.
1
-
.
1
.
1
.
1
.
1
Be Sure To Provide Manufacturers
Part
No.
Name When
Ordering
Coils.
Description
Common Hardware
602 072 SCREW, machine steel truss hd 6-32 x 5/8
602 078 SCREW, machine steel round hd 6-32 x 2-1/2
602 109 SCREW, machine steel round hd 10-24 x 1/2
602 088 SCREW, machine steel round hd 10-32 x 1/4
605188 SCREW, self tapping type F hex hd 10-32 x 3/8
601 939 SCREW, cap steel hex hd 1/4-28 x 1-1/2
079 620 SCREW, cap steel socket hd flat hd 1/4-28 x 1/2
601 925 SCREW, cap steel hex hd 1/4-20 x 1/2
034 055 BOLT, machine steel hex hd 1/4-20 x 2-1 /2
602 241 WASHER, flat steel SAE 1/4
073 914 WASHER, centering 7/16 die
602 198 WASHER, lock steel split No. 6
602 203 WASHER, lock steel split No. 10
602, 207 WASHER, lock steel split 1/4
601 859 NUT, steel hex 6-32
605 321 BUSHING, nut machined
004 862 RIVET, blind aluminum domed hd
601 890 RIVET, blind 1/8 dia 1/8 grip
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
*Recommended Spare Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-1516 Page 11
1
or