Miller | JB512073 | Owner Manual | Miller SWINGARC SINGLE 12 AND 16 User manual

Miller SWINGARC SINGLE 12 AND 16 User manual
October 1981
FORM: OM-1516C
Effective With Serial No. JB512073
MODEL
SWINGARC SINGLE 12
SWINGARC SINGLE 16
OWN ERS
MANUAL
inulliEl
MILLER ELECTRIC MFG. CO.
718 S. BOUNDS ST. P.O. Box 1079
APPLETON,
WI
54912 usA
ADDITIONAL COPY PRICE 85 CENTS
NWSA CODE NO. 4579
PRINTED
IN
U.S.A.
~
.,~
~
LIMITED WARRANTY
EFFECTIVE: JUNE 1, 1979
This warranty supersedes all previous MILLER warranties and is ex
clusive with no other guarantees or warranties expressed or implied.
ff1:LIMITED
WARRANTY-Subject to the terms and conditions
hereof, Miller Electric Mfg. Co., Appleton, Wisconsin warrants
to its Distributor/Dealer that all new and unused Equipment
furnished by Miller is free from defect in workmanship and
material as of the time and place of delivery by Miller. No war
ranty is made by Miller with respect to engines, trade ac
cessories
engines,
or
other
items
manufactured
by
trade accessories and other items
are
Such
others.
sold
subject
to
the warranties of their respective manufacturers, if any
All
engines are warranted by their manufacturer for one year from
.
date of
original purchase.
Except
to
as specified below, Millers
warranty does not apply
components having normal useful life of less than one Ill
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
year,
not result
from defect in
workmanship
or
material.
Miller shall be
required to honor warranty claims on war
Equipment in the event of failure resulting from a defect
within the following periods from the date of delivery of Equip
ment to the original user:
ranted
As
general policy only, Miller may honor claims
original user within the foregoing periods.
matter of
a
submitted
In the
by the
of Millers
case
with respect to the
breach of warranty or any other duty
any goods, the exclusive remedies
quality of
therefore shall be, at Millers
option (1) repair or 12) replacement
writing by Miller in appropriate cases, (3)
the reasonable cost of repair or replacement at an authorized
Miller service station or (41 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
of notice of apparent defect or failure, Miller shall instruct the clai
mant on the warranty claim procedures to be followed.
or, where authorized in
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY
GUARANTY OR REPRESENTA
IMPLIED WARRANTY,
ANY
AS
TO
IMPLIED WARRANTY OF MERCHANTABILITY OR OF
FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO
ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EX
CLUDED AND DISCLAIMED BY MILLER.
1.
2.
Arc welders, power sources and components
Original main power rectifiers
Ilabor
.
.
1 year
onlyl
3. All welding guns and feeder/guns
-
4.
All other Miltermatic Feeders
5.
Replacement
6.
Batteries
or
1 year
3 years
EXCEPT
AS
WRITING,
90 days
1 year
repair parts, exclusive of labor
60
.
days
6 months
EXPRESSLY
MILLER
ULTIMATE
that Miller is notified
of the date of such failure.
in
writing
within
thirty (301 days
PROVIDED
PRODUCTS
PURCHASE
BY
ARE
BY
MILLER
INTENDED
IN
FOR
COMMERCIAL/INDUSTRIAL
USERS AND FOR OPERATION BY PERSONS TRAINED AND
EXPERIENCED
WELDING
IN
USE
THE
EQUIPMENT
AND
CONSUMER USE. MILLER
provided
*
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,
AND
MILLERS
NO
RESELLER
AND
NOT
MAINTENANCE
FOR
CONSUMERS
OF
OR
WARRANTIES DO NOT EXTEND
IS
AUTHORIZED
WARRANTIES TO, ANY CONSUMER.
TO
EXTEND
*
TABLE OF CONTENTS
Page No.
Section No.
SECTION 1
SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
-
1
1.
Introduction
2.
General Precautions
1
1 -3.
ArcWelding
4
1
Standards Booklet Index
5
1
1
-
-
-
4.
SECTION 2
2
2
2
-
-
-
1.
General Information And Safety
7
2.
Receiving-Handling
Description
7
3.
SECTION 3
3
-
1.
2.
3
3-3.
3
4.
3-5.
3 -6.
3 -7.
3
8.
-
-
-
3
-
INTRODUCTION
-
9.
-
7
INSTALLATION
7
Location And Assembly
Drive Motor
Installation Of Wire Support
9
Reinstallation Of Hub Assembly
Installation Of Wire Reel
9
9
9
DriveRollAndWireGuidelnstallation
10
Water Connections
Welding Gun Connections
Shielding Gas Connections
11
11
12
Boom Adjustments
WirePulley
12
3-11.
3-12.
Motor Control Connections
12
3-13.
12
3-14.
Gun Trigger Connection
WeldCableConnection
3-15.
Remote Control Connections
13
3-16.
Installation Of
13
3-17.
3-18.
Installation Of
Adjustment Of Hub Tension
13
3-19.
115 Volts! Contactor Connections
13
3-10.
SECTION 4
4
-
1.
-
Spool-Type Wire
Reel-Type Wire
Remote Control
4-3.
PurgeButton
4
-
-
13
13
FUNCTION OF CONTROLS
Power Switch
4 -2.
4
12
13
Receptacle And Switch
13
13
4.
Inch Button
13
5.
Wire
14
Speed Control
4-6.
Start Switch
14
4
Retract-Feed Switch
14
-
7.
4-8.
Reset Circuit Breaker
14
4-9.
Burnback Control
14
SECTION 5
5- 1.
5
5
-
-
2.
3.
SECTION 6
-
SEQUENCE OF OPERATION
WeldingWireThreading
Gas Metal-Arc Welding (GMAW)
Shutting Down
-
14
15
15
MAINTENANCE
Inspection And Upkeep
CleaningOfDriveRolls
15
6-2.
6-3.
Fuse
15
6
Brush
6
-
-
1.
4.
SECTION 7
-
Inspection & Replacement
TROUBLESHOOTING
15
16
SECTION
1
-
SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
INTRODUCTION
We learn by experience.
Learning safety through personal experience, like a
child touching a hot stove is harmful, wasteful, and un
wise. Let the experience of others teach you.
1-1.
-
Medical first aid and eye treatment. First aid facilities
a qualified first aid person should be available for
each shift unless medical facilities are close by for im
and
mediate treatment of flash burns of the eyes and skin
burns.
Safe practices developed from experience in the use of
and cutting are described in this manual.
plugs should be
when
welding
Ear
Research,
confined space. A hard hat should be
others work overhead.
development, and field experience have
evolved reliable equipment and safe installation, operation, and servicing practices. Accidents occur when
equipment is improperly used or maintained. The
reason for the safe practices may not always be given.
Some are based on common sense, others may require
technical volumes to explain. It is wiser to follow the
in
worn
working
on
a
Flammable hair
sons
intending
preparations should
to
weld
overhead
worn
not be used
or
when
by per
or cut.
Toxic Fume Prevention
B.
rules.
Severe discomfort, illness or
fumes, vapors, heat, or oxygen
depletion that welding (or cutting) may
Adequate ventilation.
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
injury or death. When safety becomes a habit,
the equipment can be used with confidence.
serious
These safe practices are divided into two Sections:
1
General Precautions, common to arc welding and
cutting; and 2 Arc Welding (and Cutting) (only).
-
-
Reference standards: Published Standards
on safety are
complete pro
cedures than those given in this manual. They are listed
also available for additional and
more
in the Standards Index in this manual. ANSI Z49.1 is
the most
death
enrichment
or
produce. Prevent them with adequate ventilation
as
described in ANSI Standard Z49.1 listed 1 in Standards
index. NEVER ventilate with oxygen.
Lead
cadmium
-,
bearing
produce
-,
zinc
-,
mercury
-,
and
beryllium
-
materials, when welded (or cut) may
harmful concentrations of toxic fumes. Ade
and similar
quate local exhaust ventilation must be used,
person in the area as well as the operator must
air-supplied respirator.
For
beryllium,
or
each
wear an
both must be
us
ed.
Metals coated with or containing materials that emit
toxic fumes should not be heated unless coating is
removed from the work surface, the area is well ven
tilated,
the operator
or
wears an
air-supplied respirator.
complete.
Work in
Code, Occupational Safety and
Health Administration, local industrial codes, and local
inspection requirements also provide a basis for equip
ment installation, use, and service.
The National Electrical
1-2. GENERAL PRECAUTIONS
A.
result from
can
a
confined space only while it is
necessary, while wearing an
and, if
respirator.
tilated
being ven
air-supplied
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.
Gas
Burn Prevention
Leaving confined space, shut OFF yas supply at source
prevent possible accumulation of gases in the space
if downstream valves have been accidently opened or
(or asbestos)
protective clothing
gauntlet gloves, hat, and high safety-toe shoes. Button
shirt collar and pocket flaps, and wear cuff less trousers
to avoid entry of sparks and slag.
to
Wear helmet with safety goggles or glasses with side
shields underneath, appropriate filter lenses or plates
Vapors from chlorinated solvents can be decomposed
by the heat of the arc (or flame) to form PHOSGENE, a
(protected by clear cover glass). This is a MUST for
welding or cutting, (and chipping) to protect the eyes
from radiant energy and flying metal. Replace cover
gla~s when broken, pitted, or spattered. See 1-3A.2.
highly toxic gas, and other lung and eye irritating pro
ducts. The ultraviolet (radiant) energy of the arc can
Wear
-
leather
left open. Check to be
re-entering it.
Hot
or
greasy
metal such
should
never
as
clothing.
A
spark
may
electrode stubs and
be handled without
gloves.
ignite
them.
workpieces
that the space is safe before
decompose trichioroethylene and per
chloroethylene vapors to form phosgene. DO NOT
also
WELD
Avoid oily
sure
or cut
where solvent vapors
can
be drawn into
cutting atmosphere or where the radiant
energy can penetrate to atmospheres containing even
of
amounts
minute
trichloroethylene or pet
chloroethylene.
the
welding
,-
or
Page
1
Fire and
C.
A container with unknown contents should be cleaned
(see paragraph above). Do NOT depend on sense of
Explosion Prevention
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.
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.
BE AWARE THAT
To prevent fires and
explosion:
smell
Hollow
dip tanks, storage
areas, yen
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
tilators.
snug-fitting,
fire-resistant
containers must be vented before
or
cutting. They
can
explode.
Explosive atmospheres. Never weld
may contain flammable dust, gas,
or Cut
where the air
liquid
vapors (such
or
gasoline).
as
Compressed Gas Equipment
D.
precautions. Comply with precautions in
manual, and those detailed in CGA Standard
PRECAUTIONS FOR SAFE HANDLING OF
COMPRESSED GASES IN CYLINDERS, listed 6 in
P-i,
Standards index.
If combustibles are in area, do NOT weld or cut. Move
the work if practicable, to an area free of combustibles.
spray rooms,
or
or cut.
Standard
Keep equipment clean and operable, free of oil, grease,
and (in electrical parts) of metallic particles that can
cause short circuits.
paint
determine if it is safe to weld
to
castings
welding
this
Avoid
sight
or
covers or
1.
Regulators
Pressure
Regulator relief valve is designed to prctect only the
regulator from overpressure; it is not intended to
protect any downstream equipment. Provide such
protection with
one or more
relief devices.
shields.
Walls touching combustibles on opposite sides should
not be welded on (or cut). Walls, ceilings, and floor near
work should be protected by heat-resistant covers or
shields.
Never connect a regulator to a cylinder containing
gas other than that for which the regulator was
designed.
faulty regulator from service immediately
repair (first close cylinder valve). The following
symptoms indicate a faulty regulator:
Remove
for
Fire watcher must be standing by with suitable fire ex
tinguishing equipment during and for some time after
welding or cutting if:
Leaks
if gas leaks
-
Creep
Excessive
a.
b.
combustibles (including building
construction) are within 35 feet
appreciable combustibles are further than 35
appreciable
can be ignited by sparks
openings (concealed or visible) in
feet but
c.
walls within 35 feet
bustibles to sparks
d.
may
floors
expose
externally.
delivery pressure continues
if
-
rise with downstream valve closed.
Faulty Gauge if gauge pointer does not
-
stop pin when pressurized,
after pressure release.
nor
returns
to
move
to
off
stop pin
or
com
combustibles adjacent to walls, ceilings,
roofs, or metal partitions can be ignited by
radiant or conducted heat.
Repair. Do NOT attempt repair. Send faulty
designated
regulators for repair to manufacturers
repair center, where special techniques and tools
are used by trained personnel.
Cylinders
2.
permit should be obtained before operation to
supervisors approval that adequate precautions
Hot work
ensure
have been taken.
Cylinders
be
must
and
leaks
damage
to
handled cirefully to prevent
their walls, valves, or safety
devices:
After work is done, check that
glowing embers, and flames.
area
is free of sparks,
Avoid
electrical
third
An empty container that held
cluding
cuits. They
produce flammable
lead
to a senous
ICC
or
never
be welded
been cleaned
as
or
combustibles, or that can
toxic vapors when heated, must
or cut, unless container has first
described in AWS Standard A6.O,
circuit
contact
with
rails, electrical wires,
or
produce short circuit
can
cylinders
in
welding
cir
arcs
that may
accident. (See 1-3C.)
on
listed 3 in Standards index.
an
DOT marking must be on each cylinder. It is
of safety when the cylinder is properly
assurance
handled.
thorough steam or caustic cleaning (or
a solvent or water washing, depending on the com
bustibles solubility) followed by purging and inerting
with nitrogen or carbon dioxide, and using protective
equipment as recommended in A6O. Waterfilling just
below working level may substitute for inerting.
THs includes:
Page 2
a
gas content. Use only cylinders with
of gas marked on them; do not rely on color to
identify gas content. Notify supplier if unmarked.
Identifying
name
NEVER
markings
DEFACE
on a
or
alter
cylinder.
It is
name,
number,
illegal and
or
other
hazardous.
valves closed, replace caps securely;
keep them separate from FULLS and
promptly.
Empties: Keep
MT;
mark
return
Repair leaky or worn hose by cutting
ing (1-2D3). Do NOT use tape.
use.
Never
use a
cylinder
or
other than its intended use, NEVER
roller.
Locate
or secure
cylinders
so
they
and
splic
Proper Connections
4.
Prohibited
area out
its contents for
as
a
support
or
cannot be knocked
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
a clean lintless cloth.
sources
of
ignition. Wipe
with
over.
Passageways and work areas. Keep cylinders clear
where they may be struck.
of
Match regulator to cylinder. Before connecting, check
regulator label and cylinder marking agree, and
that the
areas
that
regulator inlet and cylinder outlet match.
a regulator designed for a particular
gases to a cylinder containing any other gas.
the
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.
Tighten connections. When assembling threaded
Do NOT expose
nections, clean and smooth seats where necessary.
Tighten. If connection leaks, disassemble, clean, and
slag, and flame,
cylinders
to excessive
etc. that may cause
allow contents to exceed 130F.
where such exposure exists.
heat, sparks,
rupture. Do not
NEVER CONNECT
gas
or
retighten using properly fitting wrench.
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
a cylinder valve that can not be opened by hand. Notify
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.
Regulator outlet (or hose) connections may be iden
by right hand threads for oxygen and left hand
threads (with grooved hex on nut or shank) for fuel gas.
tified
supplier.
your
5.
Mixing gases. Never try
Never refill any
to mix any gases in a
Drain regulator of residual gas through suitable vent
before opening cylinder (or manifold valve) by turning
adjusting screw in (clockwise). Draining prevents ex
cylinder.
Cylinder fittings should
Pressurizing Steps:
cylinder.
never
be modified
or
exchang
ed.
compression heat at high pressure seat by
allowing seat to open on pressurization. Leave adjusting
screw engaged slightly on single-stage regulators.
cessive
Hose
3.
Stand to side of
Prohibited use. Never use hose other than that designed
for the specified gas. A general hose identification rule
is: red for fuel gas, green for oxygen, and black for inert
gases.
Use ferrules or clamps designed for the hose (not or
dinary wire or other substitute) as a binding to connect
fittings.
hoses to
to
tubing splices. Use only standard brass
splice hose.
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
damaged.
hose to prevent kinks and
Protect hose from
sparks, slag, and
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.
No copper
tings
Coil
con
tangles.
damage by sharp edges,
Use pressure charts (available from your supplier) for
safe and efficient, recommended pressure settings on
regulatory.
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.
and
by
open flame.
Examine hose regularly for leaks, wear, and loose con
nections. Immerse pressured hose in water; bubbles in
dicate leaks.
E.
User
Responsibilities
leaky or defective equipment from service im
mediately for repair. See User Responsibility statement
in equipment manual.
Remove
*Trademark of Proctor & Gamble.
Page 3
F.
Leaving Equipment Unattended
with side shields MUST be worn under
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
Flash
goggles
the helmet to
Close gas supply at
G.
source
and drain gas.
Rope Staging-Support
eyes
give
(particularly
a
high intensity gas-shielded ar)
retinal burn that may leave
in the field of vision.
cause a
Rope staging-support should not be
cutting operation; rope may burn.
used for
welding
or
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
area
3.
tects himself and others from accidents.
are
Precautions
described here and in standards referenced in index.
Enclosed
For production welding, a
area.
enclosed bay is best. In open areas,
surround the operation with low-reflective,
noncombustible screens or panels. Allow for free air circula
tion, particularly at floor level.
separate
Viewing
the weld. Provide face shields for all persons
looking directly at the weld.
who will be
flash
Comply with precautions
working
goggles.
in
area.
See that all persons
are
wearing
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.
DONT
GET
TIONS.
welding
room or
Others
Burn Protection
A.
can
permanent dark
Protection of Nearby Personnel
-
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
a
COMPLY
BURNED;
WITH
Before starting to weld, make
bay doors are closed.
B.
sure
that
screen
flaps
or
Toxic Fume Prevention
Comply
with
precautions in 1-2B.
PRECAU
Generator engine exhaust must bevented to the outside
can kill.
air. Carbon monoxide
Protective
1.
Clothing
C.
Fire and Explosion Prevention
long-sleeve clothing (particularly for gas-shielded
arc) in addition to gloves, hat, and shoes (1-2A). As
necessary, use additional protective clothing such as
leather jacket or sleeves, flame-proof apron, and f ireresistant leggings. Avoid outergarments of untreated
welding equipment. It
cotton.
fire.
Wear
Bare skin protection. Wear dark, substantial clothing.
Button collar to protect chest and neck and button
pockets
Equipments
rated
in 1 -2C.
capacity.
Do
not
overload
may overheat cables and
Loose cable connections may overheat
fire.
or
arc
cause a
flash and
cause a
prevent entry of sparks.
to
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
Eye and Head Protection
2.
Comply with precautions
Protect eyes from exposure to
arc without protection.
arc.
NEVER look at
an
handling.
electric
D.
Welding
no.
over
12
shield containing a filter plate shade
denser must be used when welding. Place
helmet
or
face before striking
Protect filter
Cracked
or
plate
with
a
C~icked, broken,
clear
or
loose filter
Replace
broken, pitted,
spattered.
or
or
cover
Comply with precautions
E.
plate.
shield should NOT be
through
IiIIMEDIATELY.
4
Gas
Equipment
in 1-2D.
arc.
broken helmet
worn; radiation can pass
Page
Compressed
or
to cause
plates
clear
burns.
replaced
plate when
must be
cover
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
DO NOT STAND, SIT, LIE,
a conductor.
ON, OR TOUCH a wet surface when welding,
without suitable protection.
becomes
LEAN
To protect
against shock:
5.
Keep body and clothing dry. Never work in damp area
adequate insulation against electrical shock.
Stay oh a dry duckboard, or rubber mat when damp
ness or sweat can not be avoided. Sweat, sea water, or
moisture between body and an electrically HOT
reduces the body surface
or grounded metal
part
electrical resistance, enabling dangerous and possibly
lethal currents to flow through the body.
without
-
-
1.
Grounding
the
Terminals And Other Exposed Parts
Terminals and other exposed parts of electrical units
should have insulating covers secured before operation.
6.
Electrode Wire
Electrode wire
becomes
electrically HOT when the
power switch of gas metal-arc welding equipment is ON
and welding gun trigger is pressed. Keep hands and
body clear of wire and other HOT parts.
Equipment
7.
Safety Devices
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
quid such
as
oil
pipe carrying ANY
or
gas
or a
flammable li
fuel.
devices such
Safety
-
welding, check ground for continuity. Be sure
bare metal of equipment
are touching
Before
conductors
interlocks and circuit breakers
Before installation,
or
shunted out.
inspection,
or
service, of equip
ment, shut OFF all power and remove line fuses (or lock
or red-tag switches) to prevent accidental turning ON of
power. Disconnect all cables from welding power
source, and
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.
as
should not be disconnected
pull all 115 volts line-cord plugs.
Do not open power circuit or change polarity while
welding. If, in an emergency, it must be disconnected,
guard against shock burns, or flash from switch arcing.
Leaving equipment unattended. Always shut OFF
to equipment.
and
disconnect all power
Power disconnect switch must be available
welding
power
near
the
source.
frames at connections.
1-4. STANDARDS BOOKLET INDEX
line cord with a ground lead is provided with the
equipment for connection to a switchbox, connect the
If
a
lead to the grounded switchbox. If a threeprong plug is added for connection to a grounded
mating receptacle, the ground lead must be connected
ground
For
or
more
1.
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.
to
the
2.
2.
information, refer
their latest revisions and
Electrode Holders
ANSI Standard Z49.1, SAFETY IN WELDING
AND CUTTING obtainable from the American
Welding Society, 2501 NW 7th St., Miami, FL
33125.
NIOSH,
SAFETY
obtainable
be used.
Do
Connectors
frc,
1
taped
ARC
avoid
possibly
-
the
Superintendent
of
4.
ANSI Standard Z87.1, SAFE PRACTICES FOR
OCCUPATION AND EDUCATIONAL EYE AND
be used to
FACE
PROTECTION obtainable from the
American National Standards Institute, 1430
Broadway, New York, NY 10018.
lethal shock
bared cable. Cables with damaged areas may be
to give resistance equivalent to original cable.
5.
ANSI Standard Z41 .1, STANDARD FOR MENS
SAFETY-TOE FOOTWEAR obtainable from the
National Standards Institute,
Broadway, New York, NY 10018.
American
Keep cable dry, free of oil and
from hot metal and sparks.
from
OSHA, SAFETY AND HEALTH STANDARDS.
29CFR 1910, obtainable from the U.S. Govern
ment Printing Office, Washington, D.C. 20402.
for wear, cracks and damage.
IMMEDIATELY REPLACE those with excessively worn
to
IN
3.
Cables
damaged insulation
HEALTH
Documents, U.S. Government Printing Office,
Frequently inspect cables
or
AND
Washington, D.C. 20402.
Fully insulated lock-type connectors should
join welding cable lengths.
4.
following standards
as applicable:
WELDING AND GAS WELDING AND CUTTING
Fully insulated electrode holders should
NOT use holders with protruding screws.
3.
to the
comply
grease, and
protected
1430
Page 5
6.
ANSI Standard Z49.2, FIRE PREVENTION IN
THE USE OF CUTTING AND WELDING PRO
CESSES obtainable from the American National
Standards In5titute, 1430 Broadway, New York,
11.
CGA Pamphlet P-i, SAFE HANDLING OF COM
PRESSED GASES IN CYLINDERS obtainable
from the
Compressed Gas Association, 500 Fifth
Avenue, New York, NY 10036.
NY 10018.
12.
7.
AWS Standard A6.0, WELDING AND CUT
TING CONTAINERS WHICH HAVE HELD COM
BUSTIBLES obtainable from the American
Welding Society, 2501 NW 7th Street, Miami,
FL 33125.
Canada
13.
8.
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,
FUEL GAS
NFPA Standard 51, OXYGEN
SYSTEMS FOR WELDING AND CUTTING ob
tainable from the National Fire Protection
-
M9W 1 R3.
SAFETY
WELDING
NWSA
booklet,
BIBLIOGRAPHY obtainable from the National
Welding Supply Association, 1900 Arch Street,
Philadelphia,
PA 19103.
Association, 470 Atlantic Avenue, Boston, MA
02210.
9.
10.
NFPA Standard 70-1978, NATIONAL ELEC
TRICAL CODE obtainable from the National Fire
Protection Association, 470 Atlantic Avenue,
Boston, MA 02210.
NFPAStandard5lB, CUTTING AND WELDING
PROCESSES obtainable from the National Fire
Protection Association, 470 Atlantic Avenue,
Boston, MA 02210.
I
Page6
14.
American Welding Society Standard AWSF4.1
Recommended Safe Practices for the Prepara
tion for
Piping
Welding and Cutting
of Containers and
That Have Held Hazardous Substances,
obtainable from the American
W:ding Society,
2501 NW 7th Street, Miami, FL 33125.
15.
ANSI Standard Z88.2 Practice for Respiratory
Protection obtainable from the American Na
tional Standards Institute, 1430 Broadway, New
York, NY 10018.
SECTION 2
-
INTRODUCTION
Model
Single
16
Single
12
(1.78 ml to
750
(19 ml per
70
Speed Range
minute
Boom
12 ft. (3.7 ml
Length
Swing
3600
Vertical Lift
Maximum
Height (With
Horizontal To 60
4 Ft Postl
Above
21 ft. (6.4 ml
17 ft. (5.2 m)
At Full Lift Of Boom
Compression Spring
Is Designed
Any
Adjustment
At
Counterbalance
Pressure
To Balance Boom
Angle.
Is
Provided
To Hold The Boom At Any Desired Angle Or To
Limit The Vertical Lift At 40, 50, or 60.
(Patented(
Net 155 lbs.
~
Ship 265
lbs.
Net 205 lbs.
Ship 335
lbs.
Weight
Figure
2
-
1.
A.
2-1.
Specifications
carefully followed could result
or damage to this equipment.
GENERAL INFORMATION AND SAFETY
in minor
personal injury
General
signal word, IMPORTANT, highlights instruc
special emphasis to obtain the most
efficient operation of this equipment.
A third
Information presented in this manual pertains to equip
ment design, installation, operation, maintenance, and
troubleshooting which should be read, understood, and
tions which need
followed for the safe and effective
2
of this
use
equip-
B.
Safety
The
installation, operation, maintenance, and
troubleshooting of arc welding equipment requires
practices and procedures which ensure personal safety
and the safety of others. Therefore, this equipment is to
be installed, operated, and maintained only by qualified
persons in accordance with this manual and all ap
plicable codes such as, but not limited to, those listed at
the end of Section 1
Arc
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. RECEIVING-HANDLING
Safety Rules
Welding Power Source.
-
For
Operation Of
to this unit ap
concerning this equip
Description and/or
ment,
Stock Number and Serial (or Style) Numbers of the
equipment be supplied.
When
requesting
-
boom is
in serious
personal injury
CAUTION statements include installation, operating,
or practices which if not
Model
-
with
loss of life.
that
3. DESCRIPTION
This unit is a boom mounted
wire feeder. The wire feeder is of the constant wire feed
speed type and is designed to be used in conjunction
ferent levels of hazard.
carefully followed could result
information
is essential
it
pear throughout this manual highlighted by the signal
words WARNING and CAUTION which identify dif
WARNING statements include installation, operating,
and maintenance procedures or practices which if not
to file claim arises.
quest if occasion
2
Safety instructions specifically pertaining
or
-
this
ment.
potential welding power source. The
patented design aIlowin~ joth vertical lift and
swing. Cables are routed through the boom from the
feeder control to the weld head assembly.
a
constant
a
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.
and maintenance procedures
SECTION 3
3
-
1.
A.
LOCATION AND ASSEMBLY
-
(Figure 3-1)
A suitable location for this unit will allow
swing horizontally
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
Location
boom to
INSTALLATION
room
for the
in the desired arc, and to
be of sufficient construction to support the
the unit when the boom is in the horizontal
weight of
position.
OM-1516
Page
7
B.
Assembly
a.
Uncrate and
all
remove
packing material
from the unit.
1.
Existing Support (Customer Supplied)
b.
IYiYfl:1~lI~lLef FALLING BOOM
and
personal injury
thickness
cause
serious
of 0.203)
Schedule 40 pipe (wall
as
support pipe
for
12
booms.
I~fl:l~Il~cf FALLING BOOM
injury and
personal
S
Securely
b.
Uncrate and
from the unit.
Mount
to
all
remove
can
cause
unit to
a
structure that can sup
c.
position.
Remove yoke pin (1), nut (10), washers (9 &
17) and bolt (18) from the yoke (3) and
swivel plates (16).
to the desired struc
pipe post (14)
RELEASE
WARNING
OF
SPRING
PRESSURE
serious
__________
WITHOUT BOOM AUACHED
Proceed
to
serious
equipment damage.
mount
the horizontal
packing material
ture.
c.
desired
the
port the weight of the unit when the boom is in
diameter, Schedule 40 pipe (wall thickness
of 0.258) as support pipe for 16 booms.
Use 5
a.
post support (14)
Mount
structure.
equipment damage.
diameter,
Use 2-1/2
can
Subsection 2.
Post
Support,
Steps c-k.
can
cause
personal injury and equipment damage.
Perform installation exactly as outlined in step-b y
step instructions be/ow.
1
Do not
remove
safety collar until instructed
to do
so.
Retain
d.
safety collar for future disassembly
e.
bearing (13) on top of post (14) and in
swivel (8) into post (14).
Place
sert
.7
Place the boom base
the two swivel
f.
I0
use.
plate (19)
in between
plates.
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
(10) 1/2
nut
(10); then back off
nut
turn.
.12
g.
Insert
pin (1) through yoke (3), hole (2), and
through pin (1).
install cotter pin (4)
h.
i.
Connect
the
assembly
as
welding gun to the drive
instructed in the Owners
Manual for the desired welding gun.
Grasp
bar (20) and
pull boom down slightly.
pulled down only far
The boom should be
enough
plied to
to remove
the
the pressure which is ap
safety collar (11).
j.
Remove and retain the
safety collar (11).
k.
The boom should
balance in any posi
degrees above
now
tion from horizontal to 60
horizontal.
TB-080 040
If the boom does not balance
to Section 3-10.
properly, proceed
Figure 3-1.
Base And Boom
Assembly
CAUTION
I!iTL~li~II~~Icf 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.
Page
8
Post
Support (Optional)
EXCESSIVE
equipment.
Periodically
FRICTION
Base
damage
lubricate swivel to prevent wear.
not required or recommended.
Excessive lubrication is
3.
can
Support (Optional)
IMPORTANT If
an
optional base support was pur
provided for
2.
chased with the unit, mounting ho/es are
fastening the base support to the floor.
3.
IY,l~lI~Ic~ FALLING BOOM
can
cause
serious
personal injury and equipment damage.
For mounting base support use, as a minimum,
1/2 diameter, S. A. E. grade 5 bolts.
Use equivalent strength, non-corrosive bolts if
unit is mounted in an extremely damp environ-
Lift the wire support (7) in
place
over
the holes in
the swivel base (8).
Insert
and
3
-
4.
securing
tighten.
screws
REINSTALLATION
(5) with lock washers (6)
OF
HUB
ASSEMBLY
If it should become necessary to replace
(Figure 3-2)
the hub assembly, reinstall the new hub assembly as
-
follows:
ment.
a.
Uncrate and
all
remove
packing material
from the unit.
b.
Fasten base support to the floor.
c.
Complete Steps
Support.
CAUTION
EXCESSIVE
equipment.
Periodically
c-k in Subsection 2. Post
FRICTION
can
56
damage
9
10
11
lubricate swivel to prevent wear.
or recommended.
Excessive lubrication is not required
Swingpak
4.
a.
Base
(Optional)
Uncrate and
from the
remove
Swingpak
all
packing material
12
base.
TB-080 037
FALLING BOOM can cause serious
personal injury and equipment damage.
Mount welding power source on Swingpak base
before mounting Swingarc.
Figure
~NARNlNG
b.
Uncrate and remove all
from the Swingarc unit.
1.
packing material
Slide the following items onto the spindle sup
port shaft (1) in order given:
a.
b.
c.
c.
Complete Steps
Support.
c
-
d.
k in Subsection 2. Post
e.
f.
CAUTION
EXCESSIVE FRICTION
can
damage
g.
h.
equipment.
Periodically lubricate
swivel to prevent wear.
Excessive lubrication is not required or recommended.
2.
-
the hole (21)
through
shroud (see Figure 3-1).
removed
Fiber Washer (2)
Flat Washer (3)
Hub (4)
Flat Washer (5)
Fiber Washer (6)
Keyed Washer (7)
Spring (8)
Flat Washer (9)
Rotate hex nut (10) onto support shaft (1). Hex
nut should be rotated only until a slight drag is
felt while
2. DRIVE MOTOR
The drive motor is provided
3
with a vent screw which must be removed prior to the
operation of the wire feeder. The vent screw can be
-
3-2. Wire Support And Hub Assembly
3.
provided in the motor
turning hub (4).
Depress the
two spring ba-led stops (11) on the
retaining ring (12) and slide the retaining ring
(12) into proper position
the two stops (11).
on
the hub (4). Release
.MUIl.1~E PRESSURE IN WIRE DRIVE MOTOR
3
GEAR BOX will damage motor.
Remove vent
Warranty is void
to operation.
3
-
3.
screw
prior
if the vent
to
screw
-
5. INSTALLATION OF WIRE REEL (Optional)
(Figure 3-3)
operation.
is not removed prior
INSTALLATION OF WIRE SUPPORT (Figure
1.
Remove the
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
3-1)
1.
Remove
the
securing
screws
(5)
washers (6) from the swivel base (8).
and
retaining ring (5).
lock
two
retaining ring (5)
spring-loaded stops (4) on the
and slide the retaining ring (5)
OM-1516
Page9
position
into proper
two
on
the hub (6). Release the
(Figures 3-4
Drive Roll Installation
A.
& 3-5)
stops (4).
Loosen pressure adjustment wing nut (item 2,
Figure 3-4) and pivot it free of the cover.
1.
Pivot gear
2.
(4) away
cover
to expose pressure
gear.
Loosen and
3.
& 12)
4.
For
one
remove
the three
securing
screws
(7
each gear (5 & 9).
on
piece drive rolls (8 & 13): slide
a
drive roll
(9) and pressure gear (5) with
holes aligned and secure with screws (7 & 12).
onto the drive gear
7
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
One-Piece drive rolls (8 & 13) are of
the grooves become
IMPORTANT
______________
Figure
3
-
6.
3-3. Reel Installation
tighten.
the double usage type. When
worn, reverse each drive roll,
TB-080 038
groove in
position
locating
the
unused
to feed the wire.
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.
-
Spilt drive rolls (6 & 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
IMPORTANT Base selection of drive rolls upon the
following recommended usages:
edges will
now
provide
a new
knurled groove.
______________
3.
To ensure proper gripping action of
drive rolls, both rolls should be installed showing
slots on the side or both should show the side without
slots. Also, it is necessary to ilne up the blunted teeth
hard
on
V-Groove rolls for hard wire.
2.
U-Groove rolls for soft and soft shelled cored wires.
U-Cog rolls for extremely soft shelled wires (usually
surfacing typesi.
4. Split V-Knurled rolls for hard shelled cored wires
(seff-shielding and C02 shielded types).
5. Drive roll types may be mixed to suit particular re
quirements (example: V-knurled roll in combination
with U-groove).
Having selected
guides, proceed
tions:
the
to
IMPORTANT:
U-Cog
1.
the pressure gear roll directly over the spaces bet
the teeth on the drive gear roll.
ween
appropriate drIve rolls and wire
the
following
installation instruc
22
TB-080 158
Figure
TB-080 030-A
Figure 3-4. Drive
Page 10
Rolls Installation
3-5.
U-Cog
B.
Inlet Wire Guides
1.
For .030
-
5/64
Drive Rolls Installation
(Figure 3-4)
wire.
Insert liner (21) into inlet wire
with set screw.
a.
guide (20) and
secure
b.
Loosen the inlet wire
guide securing
so
Connect the water out hose to the adapter on the weld
cable terminal on the drive assembly. These fittings
have left-hand threads. Route the water out hose to a
proper disposal or cooling system. Water is available
as
when the POWER switch is
screw
(3).
I WA I ~ 1 V~ I ~ Wire
guides
that the tip of the guide is
possible without touching.
as
should be installed
close to the drive roll
from the water supply, to the water input fitting on the
rear of the control. This fitting has left-hand threads.
Electrical Reconnection Of Water Solenoid
B.
Insert
c.
assembly into drive
guide
tightening
Secure by
2.
For 3/32
-
1 /8
screw
assembly.
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
The control is
(3).
wire.
trigger is depressed.
the gun
Remove anti-wear
a.
wire
guide(s) (22)
placed in the ON position.
from inlet
Shut the unit down and disconnect from line
1.
guide.
power.
b.
Loosen the inlet wire
guide securing
screw
I~~:l~lI~Ief
(3).
should be installed
Wire
guides
that the tip of the guide is as
possible without touching.
IMPORTANT
so
c.
d.
as
Insert the inlet wire guide (1) into drive
assembly as illustrated in Figure 3-4. Secure
by tightening screw (3).
Install anti-wear guide(s) (22) onto inlet wire
guide and secure with setscrew.
kill.
can
or
employ lockout/tagging procedures on the
welding power source before internally inspecting
or servicing.
______________
close to the drive roll
ELECTRIC SHOCK
Do not touch live electrical parts.
Disconnect input power to the wire feeder
Lockout/tagging procedures consist of padlocking line
position, removing fuses
disconnect switch in open
from fuse box, or tagging
disconnecting
Work
breaker
or
other
performed by qualified
internal parts to be
on
circuit
device.
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
The drive roll on the
or out of the desired position.
pressure gear will locate itseff on the wire when the gear
______________
is
cover
replaced and
The wire drive
the gears mesh
housing
sufficient clearance to
2.
3.
Remove control box wrapper.
Locate terminal
strip iT
on
bottom
panel of
con
trol.
together.
4.
Move lead No. 35 from terminal A
strip 11 to terminal B.
5.
Replace
is made with
mounting holes of
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 (18). 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
3
-
on
terminal
wrapper.
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
(Optional)
of
Gas
Metal-Arc
Welding (GMAW) gun can damage gun.
If using a water cooled gun and recirculating
coolant system, do not make connections from
the coolant pump to water valve; instead, make
connections directly from the coolant system to
connector
securing
knob
Wire guides should be installed so
tip of the guide is as close to the drive roll as
possible without touching.
IMPORTANT:
_________
2.
Insert the connector (14) which includes the in
guide (15) into the drive assembly
stalled outlet
opposite the inlet
Figure 3-4.
wire
guide
as
illustrated in
Installation Of Water Hoses
3.
When
gun/feeder
that the
gun hoses.
A.
Loosen the
(16).
a
water-cooled gun is used, route the water hose
Tighten
the
gun/feeder
connector
securing knob
(16).
OM-1516
Page
11
Weld Cable (If
B.
Applicable) (Figure 3-4)
ingarc,
rotate the
adjustment rod
yoke.
so
that the
adjustment
rod threads out of the
A terminal is
provided
the lower
portion of the drive
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
assembly
to
shielding
The
serve
on
as
a
gas hose from the gun is to be connected
the gas hose which
the boom.
to
protrudes from the
motor end of
B.
Locking Knob
By rotating the Locking Knob in
a
clockwise direction,
the boom may be held in any desired position. Rotating
the Locking Knob in a counterclockwise direction will
permit the boom to free travel. Changing the position of
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.
Position of the
3-11. WIRE PULLEY (Figure 3-1)
wire 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
-
integral gas input fitting is provid
ed on 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
assembly.
II~I~.];lI.i~I~ An
D.
Trigger
running wire of smaller diameter. 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,
position wire guide pulley through lower set of holes.
for
Control
plug from the gun trigger is to be inserted fully into
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
The
the
-Yoke
feed.
Jam Nut
Water (If
E.
Applicable)
Adjustment
Connect the water input hose from the gun to the water
output hose from the control.
Rod
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
3
be accomodated.
9. SHIELDING GAS CONNECTIONS
A hose is
with the unit for making connections from the
shielding gas source to the Shielding Gas input fitting at
the rear of the control. These fittings have right-hand
threads.
-
TB-072 727
-
Figure 3-6. Boom Adjustments
supplied
The gas hose routed
through the boom connects to the
Shielding Gas output fitting at the front of the control.
3-10. BOOM ADJUSTMENTS
A.
3-12. MOTOR CONTROL CONNECTIONS (Figure
A receptacle is provided for connecting the
motor control plug to the control. Align keyways and in
sert the plug from the control end of the boom into the
3-7)
-
receptacle and rotate the plug threaded collar clockwise
far as possible.
as
(Figure 3-6)
Weight Lift Adjustment
LYAYI~II~Ecr
FALLING BOOM
can
cause
serious
personal injury and equipment damage.
Maintain full threads on adjustment rod through
the yoke.
weight which the boom can retract into
upright position when released can be varied by ad
justing the jam nut and adjustment rod located at the
The amount of
the
base of the boom. If
of the boom
amount of
a
heavier gun is installed on the end
it necessary to increase the
thereby making
lift, loosen the jam
r~ut and rotate the adjustment rod so that the adjust
ment rod threads into the yoke. When the proper ad
justment is obtained, tighten the jam nut against the
base of the yoke. If a lighter gun is used with the SwPage 12
weight
that the boom
TA-072 726
Figure 3-7. Rear
3-13. GUN
can
4-1)
gun
Panel Connections
TRIGGER
CONNECTION
(Figure
receptacle is provided for making
trigger control connections. The gun trigger control
-
A TRIGGER
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.
-
making secondary connections
source.
a
1/2
fingers (2). Ensure
to the
welding power
equipped with a
The end of the weld cable is
terminal for
Install the wire onto the reel (1) over the four
that the wire feeds off the top
of the reel (1). The reel (1) turns in a clockwise
3.
A weld cable
3-14. WELD CABLE CONNECTION
extends out of the wire support end of the boom for
direction.
stud.
Rotate the four fingers (2) back to their
position. Tighten the four wing nuts (3).
4.
3-15. REMOTE CONTROL CONNECTIONS (Figure
A receptacle is provided for connecting a remote
4-1)
proper
-
Align keyways and insert plug from
control into the receptacle and rotate the
control to the unit.
the remote
threaded collar clockwise
far
as
as
possible.
3-18. ADJUSTMENT OF HUB TENSION
taut
3-16. INSTALLATION
-
ceases.
(Figure 3-2)
prevent backlash when the wire feeding
adjustment is required, loosen or tighten the
(10) on the end of the spindle support shaft (1)
and
WIRE
SPOOL-TYPE
OF
hex nut
If
accordingly.
retaining ring (12).
1.
Remove the
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.
3-19. 115
3.
spool until the hole in the spool aligns
with the pin in the hub (4). Slide the spool onto
the hub until it seats against the back flange of
Rotate the
the hub.
4.
Depress the two spring-loaded stops (11) on the
retaining ring (12) and slide the retaining ring
(12) into proper position
the two stops (11).
3-17.
INSTALLATION
on
the hub (4). Release
WIRE
REEL-TYPE
OF
(Figure 3-7)
VOLTS/CONTACTOR CONNECTIONS
A 10 ft. cable is provided for 115 volts ac
-
power and contactor control connections between con
trol 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 in
sert the plug into receptacle on the control and rotate
the threaded collar clockwise as far as possible. Insert
the 115 volts power plug into the 115 volts ac recep
tacle on the welding power source and rotate clockwise
to lock in place. Insert contactor control plug into the
control
contactor
source
on
the
Loosen the four
wing
nuts
(3)
on
the
fingers (2)
SECTION 4
-
power
source.
we/ding power source contactor control
circuitry requires external supply of 115 vac for
control.
Wire feeder supplies 115 volts
source for contactor control.
ac
to the
welding
power
FUNCTION OF CONTROLS
operational condition, ready to feed wire and permit
shielding gas to flow. Placing the POWER switch in the
OFF position will shut the wire feeder down.
Retract/Feed
Switch
Fuse
power
Ensure
S
con tactor
Pull the four fingers (2) out until they can be
rotated toward the center of the reel (1).
welding
place.
t~.U1I.1~~ IMPROPER VOLTAGE APPLIED TO
WELDING POWER SOURCE CONTACTOR can
of the wire reel (1).
2.
receptacle
and rotate clockwise to lock in
damage wire feeder and welding
(Figure 3-3)
1.
(Figure
Check the hub tension by slowly pulling the wire
toward the feed roll. The wire should unwind freely, but
the hub tension should be sufficient to keep the wire
3-2)
Button
4
-
2.
REMOTE
CONTROL
SWITCH
is
AND
-
controls. If
a
remote 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 remr~te control receptacle
provided for use in conjunction with certain optional
as
Switch
4
TA-o72 725
Figure
4
-
1.
4-1. Control
Components
POWER SWITCH (Figure 4-1)
Placing the
on the control in the ON position will
-
a
-
POWER switch
apply 115 volts
3. PURGE BUTTON
(Figure 4-1) The PURGE
momentary contact switch. This switch
energizes the gas solenoid and purges the shielding gas
line of the gun. The PURGE button also allows the
shielding gas regulator to be adjusted without energiz~
ing the welding circuit.
-
button is
Receptacle
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 corn-
OM-1516 Page 13
pletes the circuit
to
the motor without
having
to
depress
CHANGING
CAUTION
FEED
RETRACT
_________
the gun trigger switch. This switch permits jogging of
the wire at the WIRE SPEED control setting, without
energizing the welding
circuit
the
or
shielding
gas valve.
POSITION while welding can damage
switch and wire drive motor.
Do not change position of switch while the wire
SWITCH
drive motor is
4
5. WIRE SPEED CONTROL
(Figure 4-1)
The
running.
Rotating the WELD SPEED control clockwise increases
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
the rate of the wire feed.
put. Should this breaker trip, the RESET button would
-
-
WIRE SPEED control
the rate at
provides a means of determining
which welding wire will be fed into the weld.
4
-
-
depressed
have to be manually
4
-
6. START SWITCH
switch
either
provides the
(Figure 4-1)
capability of being
The START
-
able to select
slow wire feed
speed for 1/2 second
of
wire
the wire feed speed
or
feed,
beginning
a
rate set on the WIRE
at the
at the
SPEED control. The SLOW posi
provides the 1/2 second of
tion of the START switch
slow wire feed, and the FAST position provides wire
on the WIRE SPEED control.
feed at the rate set
The
7. RETRACT-FEED SWITCH (Figure 4-1)
RETRACT-FEED switch determines whether the wire
feeds out of the gun or retracts back into the gun when
4
-
-
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.
SECTION 5
5
-
ELECTRIC SHOCK
4
-
9.
The
-
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
workpiece nor the contact tube. If the welding wire
sticks to the contact
tube,
rotate the BURNBACK con
trol counterclockwise. If the
workpiece,
5.
can
(Optional)
CONTROL
BURNBACK
burnback
welding
wire sticks to the
BURNBACK control clockwise.
rotate the
SEQUENCE OF OPERATION
-
1. WELDING WIRE THREADING
WARNING
in order to reset the cir
cuit breaker.
Feed the wire
through
the inlet wire
guide, past
the drive rolls, and on into the outlet wire guide.
Feed approximately 4 inches of wire into the
kill.
__________
Do not
energize we/ding
power
feeder until instructed to do so.
source
or
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
outlet wire
wire
IMPORTANT: If when the gear
WELDING WIRE can cause puncture
wounds; HOT SURFACES can burn skin.
ts~tUII]~
Do not activate gun
trigger
6.
other
until instructed to do
point gun towards any part of the body
personnel when threading we/ding wire.
Allow gun to cool before
1.
Install the wire
(reel-type
or
or
7.
Pivot the gear cover closed making sure the
on the pressure gear mesh with the teeth
Pivot the pressure adjustment wing nut until the
on the pressure adjustment is seated on
washer
spool-type)
as
in
top of the gear
Turn
the
the side of the
boom,
assembly.
the drive
4.
Loosen the
wing
adjustment, pivot
of
the
cover,
assembly
Page
14
the
guide tube on
wire pulley, and to
the drive roll pressure
adjustment free
nut
in
a
and the wire feeder
are
are
put into opera
tion.
9.
nut on
adjustment wing
tight
against the welding wire. Do not overtighten.
Further adjustment to attain desired clamping
pressure can be made after the welding power
the wire
over
pressure
clockwise direction until the drive rolls
source
through
cover.
3-17.
Cut off any portion of the free end of the wire
which is not straight. Ensure that the cut end is
free from rough surfaces to permit proper
Route the wire
tooth.
or
feeding.
3.
one
the drive gear. The welding wire must also be
in the grooves of the drive rolls.
8.
2.
the pressure gear
on
touching.
structed in Section 3-16
is closed the
teeth
so.
Do not
cover
U-Cog drive rolls are not aligned properly (see Section
3-6), pivot the gear cover away from the drive gear and
rotate
energized.
guide.
10.
Draw the gun cable out
Energize
the
welding
straight.
power
source.
the pressure
and
pivot the
away until it is in
an
pressure
open
gear
position.
11.
Place the control POWER switch in the ON
tion.
posi
12.
Depress the JOG switch. This will run the
welding wire through the gun without placing
setting.
weld current on the welding wire. Release the
JOG switch when the welding wire extends ap
proximately one inch Out of the gun tip.
I~YI~1:I~II~cf ARC
SURFACES
RAYS,
SPARKS,
AND
Turn
9.
Depress the PURGE button for
on
Hold the tip of the gun
10.
can
from the
damage hearing.
Wear correct eye, ear, and body protection.
AND GASES can seriously harm your
health.
enough ventilation to keep fumes and
from the breathing zone.
one
minute.
approximately 1/2
inch
workpiece.
Depress the trigger
11.
FUMES
Use
gas at the source.
shielding
the
8.
HOT
burn eyes and skin; NOISE
can
Rotate the WIRE SPEED control to the desired
7.
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
gases
adjustment wing nut 1/2 turn
clockwise. Repeat until slippage stops. Do not
pressure
Safety Rules For Operation Of Arc
Power
for basic welding safety infor
Sources
Welding
See Section 1
-
overtighten wing
nut.
mation.
ELECTRIC SHOCK
WARNING
5 -2. GAS METAL-ARC WELDING (GMAW)
2.
Make all necessary connections
Section 3.
instructed in
as
welding wire or
with it while we/ding.
Do not touch
contact
1.
kill.
can
_________
Place the Remote Control switch in the desired
any metal part in
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
energized.
is
position.
5 -3. SHUTFING DOWN
position.
3.
Place the START switch in the desired
4.
Place the RETRACT-FEED switch in the desired
position.
5.
Energize
6.
Place the POWER switch in the ON
the
welding
power
source.
position.
shielding
gas at the
1.
Turn off the
2.
Place the POWER switch in the OFF
3.
Turn off all associated
WARNING Gases
can
source.
position.
equipment.
harm health
or
kill.
_________
supply
Shut off gas
SECTION 6
-
1. INSPECTION
-
SHOCK
can
kill;
WARNING ELECTRIC
WELDING WIRE can cause puncture wounds; HOT
SURFACES can burn skin.
Disconnect unit from input power before internal
ly inspecting
or
maintenance
2.
Inspect gun
sure
on
gun.
welding
Make
power
source
is shut down.
for broken areas, cracks and loose
parts: tighten, repair, and replace
3.
as
required.
weld spatter or foreign
matter which may accumulate around the nozzle
orifice. Use a hardwood stick, never a metal tool.
Carefully
ed air when
metal
chips
changing
guide
liner with compress
wire. This will
remove any
and dirt that may have accumulated.
IMPORTANT: Periodically inspect the labels on the
unit for legibility. All labels must be maintained in a
clearly readable state and replaced when necessary.
See Parts List for part number of labels.
_______
servicing.
Allow gun and unit to cool before touching.
Do not activate gun trigger while performing
1.
Blow Out the gun wire
6.
-
__________
use.
MAINTENANCE
UPKEEP
AND
Usage and
shop conditions will determine the frequency and type
of maintenance. Inspect equipment as follows:
6
when not in
remove
any
2. CLEANING OF DRIVE ROLLS
Occasionally
it will become necessary to clean t e wire groove on the
drive rolls. This cleaning operation can be performed
6
-
-
with
a
wire brush.
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).
properly maintain the drive
build-up of wire particles which will
decrease the efficiency of the wire feeding operation.
IMPORTANT Failure to
______________
4.
5.
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.
rolls
can
result in
a
(Figure 4-1) The control is protected
damage due to an internal short or excessive
overload by fuse Fl. Should Fl open, the control would
be completely inoperative.
6
-
3. FUSE
-
from
OM-1516 Page 15
6
4.
-
BRUSH
(Figures
INSPECTION
6-1 & 6-2)
&
REPLACEMENT
If
6.
replacement is necessary (brushes
in
than 1/4
length)
from the brush box tab and
WARNING ELECTRIC SHOCK
are
disconnect the brush
less
pigtail
brush.
remove
kill.
can
__________
Do not touch live electrical parts.
Disconnect input power to the wire feeder
employ lockout/tagging procedures on welding
power source before internally inspecting or ser
vicing.
Lockout/tagging procedures consist of padlocking line
position, removing fuses
disconnect switch in open
from fuse box, or tagging
circuit breaker
Connect
7.
Route
8.
on
internal parts to be
performed by qualified
9.
per
towards the
10.
Grasp spring retaining bracket
pliers.
4.
Push
with
in
11.
assembly and
Pull brush out
5.
it
can
using
brush
box
wall
as
il
6-2.
If the spring retaining bracket is in place, it will be
against the brush box wall when the pliers are
released.
long-nose
lightly and
towards brush~ This should release the
the
on
Figure
under
12.
spring retaining bracket
the top of the brush is
on
spring.
hooks
lustrated in
3.
a
Using long-nose pliers insert spring assembly
beside brush sliding the spring retaining bracket
along the brush box wall. The spring retaining
bracket
Open brush cap by sliding screwdriver
catch and lifting. Remove brush cap.
brush box. Ensure
into contact with
Insert brush into brush box. Ensure that the low
end of the bevel
Shut unit and associated equipment off.
2.
box tab.
to brush
metal surface.
sons.
1.
pigtail
pigtail through slot in
pigtail will not come
disconnecting device.
Work
brush
that the
other
or
new
or
Ensure that the
spring is
Figure 6-1.
illustrated in
move
in the proper
position
as
spring
be removed.
13.
brush
14.
pigtail.
Replace and latch the brush
Reconnect power to all
cap.
equipment
and
resume
operation.
Spring
Brush Box
Spring
Bracket
Brush
Brush
NOTE:
Pigtail
Spring
assembly
TA-046 226
Figure 6-1. View Of Spring Assembly
And Brush
When Brush Cap Is Opened
SECTION 7
WARNING
ELECTRIC SHOCK
can
-
hooks
here.
Figure 6-2.
View Of
kill.
trouble
Do not touch live electrical parts.
Disconnect unit from input power before internal
or
servicing.
Troubleshooting of internal parts
by qualified persons.
to be
The
diagnose
is
not
performed only
cedures, the
remedied
nearest
after peiorming these pro
Factory Authorized Service Sta
tion should be contacted.
In all
remedies for
some
to
and
of the troubles that may
provide
develop in
this unit.
cases
malfunction, the manufacturers
should be strictly followed.
CAUTION DISASSEMBLY
following chart is designed
And Brush
TROUBLESHOOTING
__________
ly inspecting
Spring Assembly
From Armature End Of Motor
OF
of
equipment
recommendations
MOTOR
FIELD
_________
MAGNETS
ment
can
result in
personal injury
or
equip
damage.
Limit wire drive motor
repairs
to brush
replace
ment.
It is assumed that proper installation has been made, ac
cording to Section 3 of this manual, and that the unit
his
been
functioning
properly
until
this
trouble
The field magnets
are
tempted, injury
fingers
to
very strong. If disassembly is at
and hands may result from a
Use this chart in
magnet being drawn back into the motor. The field
magnets are matched sets and operation may be af
fected if the magnets are tampered with.
while
Warranty is
developed.
Page 16
conjunction with the circuit diagram
performing troubleshooting procedures. If the
void if the motor is
tampered
with.
TROUBLE
PROBABLE CAUSE
Depressing gun switch will
energize wire feeder.
not
Electrode
energized
wire
and
is
shielding
not
Control
wrong
tive.
REMEDY
POWER switch in
defecor
Place switch
to
ON
position.
position
~
gas
does not flow.
Replace defective POWER switch.
115
volts
input fuse
Fl
*Replace fuse
Fl.
open.
115 volts/contactor control
plug is
Secure
plug
in
receptacle.
not secure in recep
tacle.
Plug from gun trigger control cable is not secure in
Secure plug in TRIGGER receptacle.
TRIGGER receptacle.
Coil of relay CR1 defective.
Replace relay CR1.
Circuit breaker CB1
Manually
tripped.
button
reset circuit breaker
on
the front
panel of
by depressing the
the control labeled
RESET.
Wire feeds, shielding gas
flows, but electrode wire is
not
energized.
115 volts/contactor control
power
source.
Defect
Wire feeds
erratically.
in
welding
power
See
TROUBLESHOOTING
Section
in
welding
instruction manual.
source.
power
Pressure on drive rolls is insufficient.
Rotate pressure adjustment wing nut clockwise in
1/4 turn increments until wire slippage stops.
Drive roll
Change
wire size
*lf it becomes necessary to
Secure plug in receptacle.
plug is not secure in contac
tor receptacle on welding
is too large for
used.
source
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
replace
any fuse in the wire
feeder,
ensure
that
a
as
instructed in Section 6-2.
fuse of the proper
rating, type, and size is
used.
OM-1 516
Page
17
>~
10>.
4>
G4N
LL~.__~
ON SWINGARCONLY
Circuit
Figure 7-1. Circuit Diagram
Page
18
Diagram
No. B-083 019
October 1981
FORM: OM-1516C
Effective With Serial No. JB512073
MODEL
SWINGARC SINGLE 12
SWINGARC SINGLE 16
PARTS
LIST
728
TD-072
38
C
37-Fig
16 23 25 26
31
35
Asembly
Main
-
A
Figure
20
52
46
D
1
0
a,
0
Quantity
Item
Dia.
Part
No.
Mkgs.
No.
Figure A
1
2
PLG3
3
PLG8
4
5
6
PLG1
Model
Description
081
039
039
605
964 CORD, control interconnecting (consisting of)
635
CONNECTOR BODY, twistlock 2P2W
687
CAP, twistlock grounded 2P3W
156
CORD, portable No.18 4/c(orderbyft)
-
.
-
.
.
CLAMP, cable
079 531
.
048 284
HOUSING PLUG & SOCKETS
079 534
(consisting of)
8
TERMINAL, female
CORD, portable No.18 2/c(orderbyft.)
048 837 HOSE ASSEMBLY, gas (consisting of)
9
051 297
10
010 603
11
010 606
12
056 112
13
603 106
14
049 012
14
048 618
15
PLG2
080 328
079 534
16
079 531
17
605 156
18
19
PLG9
079 878
079 535
.
.
.
.
ADAPTER
FITTING, hose brass barbed nipple 1/4 TBG
FITTING, hose-brass nut5/8-18 RH
FITTING, hose-brassferrule0.475 IDx23/32
HOSE, neoprene-braided No.1 (order byft.)
CORD, trigger 16 ft. (consisting of)
CORD, trigger 20 ft. (consisting of)
RECEPTACLE W/PINS, free hanging (consisting of)
TERMINAL, female
CLAMP, cable
CORD, portable No.18 4/c (order byft.)
-
.
.
.
.
.
.
.
.
.
HOUSING PLUG & PINS
TERMINAL, male
HOSE, gas (consisting of)
HOSE, gas (consisting of)
.
.
079 202
079 204
21
22
056 851
010 606
23
24
056 112
604 550
.
25
26
010 604
079 196
.
27
072 088
CONTROL BOX
28
28
29
PLG7(M)
.
.
.
(consisting of)
.
20
20
16
Main Assembly
049 455
7
J
12
FITTING, hose-brassbarbednipple3/16TBG
FITTING, hose-brassnut5/8-16
FITTING, hose-brassferrule0.475 lDx23/32
HOSE, neoprene No.1 x3/16 ID(orderbyft.)
FITTING, hose brass bushing 1/4 NPT x 5/8-18 RH
FITTING, brass-barbedfemale3/16TBGx1/4 NPT
-
.
(Fig
Pg 4)
072 103 CORD, motor 17 ft. (consisting of)
072 102 CORD, motor2l ft. (consisting of)
RECEPTACLE & PINS (consisting of)
048 306
B
.
079 535
.
TERMINAL, male
CLAMP, cable
CORD. portable No.18 3/c(orderbyft.)
.
30
31
32
079 706
007 826
078 992
CORD, power 27 ft. (consisting of)
32
33
078 993
600 323
34
35
600 742
36
079 628
37
Figure C
38
t079 591
38
t079214
38
t078 264
38
39
t079 216
39
t079 215
39
075 078
39
t079 217
40
080 157
41
010910
42
079 624
CORD, power 30 ft. (consisting of)
CABLE, weld copper No. 3/0 (order by ft.)
TERMINAL, ring tongue 1/2 stud No. 3/0 wire
TERMINAL, ring tongue 3/8 stud No.3/0 wire
BRACKET, retaining spring
BOOM (Pg 8)
BASE, 4 ft. or
BASE,6ft
BASE, 4 ft. or
BASE, 6ft
POST, support boom 4 ft. (consisting of) or
POST, support boom 6 ft. (consisting of)
POST, support boom 4 ft. (consisting of) or
POST, support boom 6 ft.(consisting of)
FITTING, grease 1/8 NPT
WASHER,flat-SAE3/8
SCREW, cap steel hex hd 3/8-16 x2
077 455
t075 390
.
.
1
1
1
1
1
1
10 ft.
10 ft
1
1
1
1
1
1
1 ft
1 ft.
1
1
1
1
2
2
2
10 ft.
2
2
2
lOft.
1
1
1
1
4
4
2
2
16 ft.
20 ft.
1
1
4
4
1
1
1
1
1
1
2
16 ft.
2
20 ft.
1
1
1
1
1
1
1
1
1
1
6
6
1
1
17 ft.
21 ft.
1
1
28 ft.
.
24 ft.
1
.
1
1
1
1
1
1
-
.
-
-
-
1
1
1
1
1
1
1
-
1
-
.
-
1
1
1
1
1
1
1
OM-1516
Page2
Quantity
Item
No.
Dia.
Mkgs.
Figure
Model
Part
No.
Description
44
075 150 WASHER, nylon -shoulder0.622x1 x3/8
080 802 MOTOR, gear 1/8 hp 115 volts dc 2000 rpm
080 283
1
(consisting of)
COVER, brush
080282 .SPRING, brush
45
46
*080 281
015 713
079 635
.
.
BRUSH
GROMMET, rubber 5/16 ID x 1/2 mounting hole 3/16
INSULATOR, motor
WIRE DRIVE & GEARS (Pg 10) (consisting of)
FITTING, hose brass carded nipple 3/16 TBG
47
Figure
48
079 633
072 010 BUSHING
601 872 NUT, hex-fuII3/8
602213 WASHER, lock-split3/8
602 243 WASHER, flat 3/8
49
50
51
52
*Recommended
I
16
Main Assembly (Contd.)
A
43
12
Spare
tOptional Equipment.
D
-
.
groove
1
1
1
2
2
2
2
2
2
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
TD-072 729
Figure
Page
3
B
-
Control Box
Item
Dia.
Part
No.
Mkgs.
No.
Figure
B
1
2
SRi
VR1
3
Ti
4
Cl
5
6
CR2
7
2T
8
9
10
RC5
PCi
ii
12
16
16
072 088
Control Box
049 289
WRAPPER
(Fig
Pg 2 Item 27)
A
.
1
1
RECTIFIER, integrated 30 amp 400 volts
082 722 VARISTOR,0.6wattl75voltsdc
036 135 TRANSFORMER, control 115-24 volts ac
031 692 CAPACITOR, electrolytic 750 uf 200 volts dc
035 914
006
006
038
045
039
057
010
BRACKET, mounting
426
1
1
1
1
capacitor
-
393 RELAY, 24 volts ac DPDT flanged case
784 STRIP, terminal 1 pole
139 BRACKET, mounting-connector
756 CONNECTOR, edge circuit card 10 pin
314 CIRCUIT CARD (Fig Bi Pg 5)
296 FITTING, hose elbow male 1/4 NPT 5/8-18 RH
602 934 FITTING, pipe galvanized coupling 1/4 NPT
046 724 BRACKET, mounting control box
079 573 FITTING, pipe galvanized nipple L 1/4 NPT x 6
056 265 CONNECTOR, male 6 contact 10 amp
035 601 VALVE, 115 volts ac 2 way 1/4 IPS port 1/8 orifice (consisting of)
053 894 VALVE, 115 volts ac 2 way 1/4 IPS port 1/8 orifice (consisting of)
+033 050
COIL, valve 115 voltsac (Singer)
+053 964
COIL, valve 115 volts ac(Eemco)
010 199 TUBING, 0.275 IDxO.O48waIlxl
045 812 BUSHING, 1/4ODxO.141 lDxl
010193 TUBING,3/8ODxl8gawallxl/4
034841 RELAY,24voltsacDPDT
079 497 RESISTOR, WWfixed25watt2000 ohm
030 651 RESISTOR,WWfixed25watti0ohm
604311 GROMMET,1/4lDx3/8mtghole
056 170 SHIELD1 resistor
1
1
1
1
-
1
2
-
1
-
13
14
15
Quantity
Description
1
-
1
-
PLG4
GS1
GS1
1
1
or
1
1
.
1
.
17
18
19
20
CR1
21
22
R13
Ri
23
24
25
26
030 949
R2
079 683
28
010 476
007 826
BUSHING,strain-relief5/8x0.57hoIe
CORD, portable No.18 3/c(orderbyft)
079 706 CLAMP, cable
29
30
PLG7(F)
32
048 380
079 534
601 219
LINK,jumperterminalblock
BLOCK, terminal 20 amp 6 pole
33
34
iT
038 772
S1,3,6
011 233
35
36
S4,5
S2
HOUSING PLUG & SOCKETS (consisting of)
.
TERMINAL, female
1
6
1
1
1
.
1
1
1
1
1
1
3 ft
1
1
3
1
1
SWITCH, toggle SPDT1Oamp25O voltsac
011 059 SWITCH, toggle DPDT 15 amp 125 volts
011 232 SWITCH, push button SPDT
3
1
-
37
R5
030 943
POTENTIOMETER, carbon 1
38
RC1
048 283
079 535
RECEPTACLE W/PINS
CONNECTOR,female6contact7.5amp
39
RC4
056 266
40
RC6
039 825
.
turn
2 watt 15K ohm
(consisting of)
TERMINAL, male
1
2
1
4
1
1
42
RECEPTACLE, 6 socket MS-3102A-14S-6S
046 709 CASE SECTION, front/bottom/rear
NAMEPLATE (order by model & serial numbers)
43
079 772
1
41
44
Fl
45
46
47
48
RC2
CB1
*Recommended
+
030 941
27
31
HEAT SINK, rectifier
RESISTOR, WWfixed 100 watt 5 ohm
HEAT SINK, resistor
2
KNOB
*073 426
046 432
FUSE, miniature glass sb blo 5 amp
HOLDER, fuse panel mounting (consisting of)
059 139
CAP, holder-fuse
048 282 RECEPTACLE W/SOCKETS (consisting of)
079 534
TERMINAL, female
011 991 CIRCUITBREAKER, 1 polel.5amp25ovolts
Spare
-
-
1
1
1
1
.
1
.
4
1
1
Parts.
Be Sure To Provide Name Of Manufacturer When
Ordering Coils.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-1516 Page 4
Dia.
Part
Mkgs.
No.
Fig
Bi 057 314
044 602
C2,3
C4,8,9 031 643
C7
Cl 0
C12
D1-4
D5
Qi
031 693
031 633
031 721
026 202
037 250
037 824
010 915
602 208
601 867
02
R3
R4
R6
R7,10
R8
R9
Ri 1
R12
R12
R20
T2
037
037
030
030
030
028
030
030
030
030
030
030
036
602
Quantity
Description
Circuit Card Assembly
CAPACITOR,
CAPACITOR,
CAPACITOR,
CAPACITOR,
CAPACITOR,
(Fig
B
Pg
4 Item 10)
poly film 0.47 uf 400 volts dc
2
ceramic 0.01 uf 500 volts dc
3
mylar 0.33 uf 75 volts dc
electrolytic 80 uf 25 volts dc
1
-
1
1
mylaro.22uf200voltsdc
DIODE, 1 amp400 voltsstraight polarity
DIODE, zener24 volts 1 watt
THYRISTOR,7.4amp200volts
WASHER,flat-brassl/4(mountingQl)
WASHER, lock steel external tooth 1/4 (mounting Qi)
NUT, steel hex jam 1/4-20 (mounting Qi)
4
1
1
1
1
-
1
-
261
HEAT SINK
1
289
937
854
TRANSISTOR, unijunction 5OMA 35 volts
RESISTOR,carbon0.5wattl0ohm
RESISTOR,carbon0.5wattl8Kohm
RESISTOR, carbon 2 watt 4700 ohm
RESISTOR,carbon0.5watt2200 ohm
POTENTIOMETER, WW 1 turn 2 watt 5000 ohm
RESISTOR, carbon 0.5 watt 33K ohm
RESISTOR, carbon 0.5 watt 1200 ohm
RESISTOR, carbon 0.5 watt 6800 ohm
RESISTOR, carbon 0.5 watt 6800 ohm
RESISTOR, carbon 0.5 watt 47 ohm
TRANSFORMER, pulse
WASHER, lock steel internal tooth No. 4 (mounting 12)
NUT, steel hex 4-40 (mounting T2)
1
945
276
944
936
938
934
934
090
143
196
601 858
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.
Page
5
NOTE
Base selection of drive rolls upon the
1.
following
recommended usages:
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).
(self.shielding and CO2 shielded types).
particular requirements (example: V-knurled roll in combination
4. Split V-Knurled rolls for hard shelled cored wires
5.
Drive roll types may be mixed to suit
~/ith
U-groove).
Wire Diameter &
Type
Kit No.
Roll Drive
Inlet Wire
Part No.
Type
Guide
079 594
053 695
V-groove
056 192
079 595
053 700
V-groove
056 192
1.2MM
079 596
053 697
Vgroove
056 193
.052
1.3MM
079 597
053 698
V-groove
056 193
1/16
.062
1.6MM
079 598
053 699
Vgroove
056 195
035
035
9MM
044 749
072 000
U qir~ove
056 192
.045
045
1.2MM
079 599
053 701
U~groove
056 193
.052
.052
1.3MM
079 600
053 702
Ugroove
056 193
1/16
.062
1.6MM
079601
053706
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
Ugroove
056 196
7/64
.110
2.8MM
079 604
053 705
U-groove
056 196
1/8
.126
3.2MM
079 605
053 707
U~groove
056 197
.035
.035
.9MM
079 606
079 726
V-knurled
056 192
.045
.045
1.2MM
079 607
079 728
Vknurled
056 193
.052
.052
1.3MM
079608
079727
V-knurled
056 193
1/16
.062
1.6MM
079 609
056 771
Vknurled
056 195
5/64
.079
2.0MM
079 610
056 773
V-knurled
056 195
056 196
Fraction
Decimal
Metric
.030
.030
.8MM
.035
035
.9MM
.045
.045
.052
3/32
.094
2.4MM
079 611
056 774
V~knurled
7/64
.110
2.8MM
079612
056 775
V~knurIed
056 196
1/8
.126
3.2MM
079 613
056 776
V-knurled
056 197
.045
.045
1.2MM
083 318
083 489
U-Cogged
056 193
.052
.052
1.3MM
083 317
083 490
U-Cogged
056 193
1/16
.062
1.6MM
079 614
053 708
Ucogged
056 195
5/64
.079
2.0MM
079615
053710
U-cogged
056 195
3/32
.094
2.4MM
079 616
053 709
Ucogged
056 196
7/64
.110
2.8MM
079617
053 711
ti-cogged
056 196
1/8
.126
3.2MM
079 618
053 712
Ucogged
056 197
Drive Roll & Wire Guide Kits
*When 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
C.)
0
0
9
C
I
0
Cv,
I-
I-
N
CD
I-
I~
E
0
0
C)
a)
to
I-
0,
LI~
!to
I-
to
N,
N
N
I-
N
N
I-
cv)
N
e
N
N
7
Page
7
N
to
I-
Quantity
Item
Part
No.
No.
Figure
PIN,cotter-hairo.072x1.4371ong
BUSHING,nylon0.622lDx0.075x0.501
PULLEY,Vsinglegroove
SHAFT, pulley
BOLT, U-steel 1-5/8 high
010313
079 622
123
079 621
124
082 970
125
079 632
601 865
602 207
079 667
128
080812
079665
080811
079 664
129
047 170
130
047 171
131
007 280
127
127
131
073 742
132
007 279
132
133
133
134
134
135
136
137
138
139
140
140
073 741
601 883
A
Pg
148
148
+072 089
149
047 497
150
602 246
151
047224
073 666
082 966
144
145
145
146
146
147
152
153
153
154
155
156
157
When
1
NUT,hex-steelfulll/4-20
WASHER, lock-steel split 1/4
8
8
10
PIPE,plasticl/2x133-3/4
PIPE,plasticl/2x181-3/4
1
GUIDE,wire
GUIDE,wire
GUIDE, inlet
TUBING,neoprene3/8IDxO.O93waIlxl2
LINER,monocoilxl3
PIN, clevis 5/8-18 x 1-7/8 long
1
1
1
1
1
1
1
1
1
1
1
1
-
hex
1
jam 5/8-18
1
NUT, steel hex half 3/4-16
SHAFT, boom counter balance
-
1
-
1
-
2
-
1
1
4
4
4
1
1
1
1
1
1
1
NUT,steel5/8-18x1-1/4special
NUT,steel3/4-16x1-1/4special
1
WASHER, lock steel external tooth 5/8
030 WASHER, lock steel external tooth 3/4
883 NUT, steel-hexjam5/8-18
029 NUT, steel half full 3/4-16
1
449
SPRING,compression2ODxl IDxl2
2
722
SPRING, compression 3-3/8 OD x 22-1/4 inches long
SPACER, spring boom
PIPE, black3x8
BEARING,thrust-boom
BASE, swivel boom
BASE,swivel-boom
LABEL, general precautionary
WASHER, flat-steell/2
KNOB,T-bar
BOLT, machine-steelhexhd3/4-16x2-3/4
BOOM, single
BOOM, single
NUT, steel-hexfull3/8-16
WASHER, lock-steel split3/8
GUARD, motor protector
-
1
-
1
1
-
421
-
128
403
090
-
082 967
601 872
602 213
079 643
079631
ordering
-
BRACKET,hanger-gun
a
component originally displaying
2
4
-
101
219
10
1
PIN,clevis3/4diax2-5/32long
075 100
144
1
1
141
075
602
079
601
079
080
080
075
048
075
+072
2
2
5
142
143
143
2
2
thick
4
SHAFT, boom counter balance
WASHER,flat-steelSAE3/4
SUPPORT, hub & reel (Pg 9)
SCREW,cap-hexhd3/8-16x1
WASHER, lock-split3/8
NUT, steel hex elastic stop
WASHER,flat-steeISAE5/8
WASHER, steel shield 3 inch
073 663 BEARING, ball
024 605 BEARING, ball-thrust
142
116
1
CLEVIS
CLEVIS
NUT, steel
605 884
075 401
075 462
602250
Figure Cl
601 965
602213
079 020
602249
075 102
141
+
(Fig
1 2
2 Item 37)
Boom
121
126
Description
C
122
126
Model
a
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
4
4
1
1
1
1
precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-1516
Page8
Item
Part
No.
No.
Figure Cl
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
Quantity
Description
Support,
Hub & Reel
(Fig
C
Pg
8 Item 136)
079 638 SUPPORT, reel
010 191 WASHER,fiber5/8IDxl-1/2ODx1/8
058 628 WASHER, steel brake
058428 HUB, spool
057 971 WASHER,flat-steelkeyed 1-1/2dia 1/Bthick
010 233 SPRING, compression
605 941 WASHER,flat-steel4l/64 IDxl 00
601 884 NUT, steel-hexs/8-11
058 427 RING, retaining spool
t056 416 REEL,wire.(consistingof)
1
2
2
-
1
1
1
1
1
1
-
604051
056 312
056313
010 224
601 880
056314
1
.NUT,steel-wingl/2-13
4
FINGER, reel
.STUD,steell/2-13x7
PIN, spring-compression3/16x1 inch
4
.NUT,steel-hexjaml/2-13
4
.REEL
1
4
.
4
.
161
.163
162
161
169
170
TC-OO7 886
Figure Cl
-
Support,
Hub & Reel
tOptional Equipment.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
Page 9
Item
Part
No.
No.
Figure
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
D
Wire Drive & Gears
604
045
080
079
604
010
010
056
602
010
010
612
233
211
671
590
910
231
306
243
232
224
601 925
604 741
079 669
079 634
079 772
604 538
053 842
605 518
079 626
010 193
048 336
602 241
000 418
053 841
079 625
082 036
082 050
Quantity
Description
(Fig
A
SCREW, set socket hd 8-32
GUIDE, anti-wear
-
DRIVE ASSEMBLY
Pg 3 Item 47)
x
2
1/8
1
1
(consisting of)
HOUSING, adapter gun/feeder
NUT, steel-wing3/8-16
WASHER, flat steel SAE 3/8
SPRING, compression
FASTENER, pinned
WASHER, flat steel 3/8
SPRING, compression
PIN, spring compression 3/16 x 1
1
-
1
1
-
1
1
1
-
1
1
-
SCREW, cap steel hex hd 1/4-20
PIN, cotter-hair0.042x15/16
LEVER, mounting pressure gear
-
x
1/2
1
1
1
-
PIN, hinge
KNOB, plastic
WASHER, flat-steel SAE5/16 (asreqd)
GEAR, spur insulated w/bearing
SCREW, cap steel hex hd 1/4-20 x 1-1/4
SCREW, machine steel fillister hd 10-32 x 7/8
TUBING, steel 3/8 OD x 18 ga waIlxl/4
STOP, cover
WASHER, flat steel SAE 1/4
SCREW, cap steel hex hd 1/2-20 x 1/2 self locking
GEAR, spur insulated w/key
WASHER, spring steel 5/16 shakeproof
GUIDE, inlet-wire
LINER, monocoil inlet wire
1
As
Reqd
-
1
-
6
-
1
1
1
-
-
1
-
1
-
1
-
1
1
-
TC-080 028-C
Figure
D
-
Wire Drive & Gears
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-1516
Page 10
Dia.
Part
Mkgs.
No.
Parts For
047 946
R7
Quantity
Description
Optional Equipment
BURN BACK CONTROL
1
(consisting of)
1
POTENTIOMETER, carbon 1 turn 2 watt 10K ohm
024 366
KNOB, pointer
047 980
TIMER, delay 20 mil sec/20 sec
046 531 WATER CONTROL (12 ft models) (consisting of)
074 127
.
1
.
1
.
WSI
046 533 WATER CONTROL (16 ft models) (consisting of)
035 601
VALVE, 115 volts ac 2 way 1/4 IPS port 1/8 orifice
WS1
053 894
.
+033 050
.
.
+053 964
.
.
602 934
.
.
.
056 296
.
657
.
773
.
572
.
570
.
572
.
+
573
569
ac
2 way
1
1
or
1
1
COIL (Singer)
COIL (Eemco)
1
1
FITTING, pipe nipple L 1/4 NPT x 6
FITTING, pipe-coupling 1/4 NPT
FITTING, hose elbow male 1/4 NPT x 5/8-18 LH
FITTING, hose bushing reducing 5/8-18 LH
ADAPTER, terminal water electrode
HOSE, water 10 ft(12 & 16 ft models)
HOSE, water 15 ft(12 ft models)
HOSE, water 19ft3 inches (l6ftmodels)
HOSE, water 25 ft(12 ft models)
HOSE, water 29 ft(16 ft models)
-
010 295
008
079
000
000
000
000
000
VALVE, 115 volts
(consisting of)
1/4 IPS port 1/8 orifice (consisting of)
1
2
1
-
1
-
1
-
.
.
Be Sure To Provide Manufacturers
Name When
1
1
1
1
1
Ordering Coils.
Part
Description
No.
Common Hardware
602 072
602 078
602 109
602 088
605 188
601 939
079 620
601 925
034 055
602 241
073 914
602 198
602 203
602 207
601 859
605 321
004 862
601 890
SCREW, machine steel truss hd 6-32 x 5/8
SCREW, machine steel round hd 6-32 x 2-1 /2
SCREW, machine steel round hd 10-24 x 1/2
SCREW, machine steel round hd 10-32 x 1/4
SCREW, self tapping type F hex hd 10-32 x 3/8
SCREW, cap steel hex hd 1/4-28 x 1-1/2
SCREW, cap steel socket hd flat hd 1/4-28 x 1/2
SCREW, cap steel hex hd 1/4-20 x 1/2
BOLT, machine steel hex hd 1/4-20 x 2-1 /2
WASHER, flat steel SAE 1/4
WASHER, centering 7/16 dia
WASHER, lock steel split No. 6
WASHER, lock steel split No. 10
WASHER, lock steel split 1/4
NUT, steel hex 6-32
BUSHING, nut machined
RIVET, blind aluminum domed hd
RIVET, blind 1/8 dia 1/8 grip
*Recommended
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
Spare
Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
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