Miller | KE621826 | Owner Manual | Miller SWINGARC SS-12 AND 16 User manual

Miller SWINGARC SS-12 AND 16 User manual
Miller
April
1994
Form:
OM-1583D
Effective With Serial No. KE621 826
OWNERS
MANUAL
~11c~
~'' c~r~1
SWINGARCTM SS-12 And SS-16
24
Volts, 10 Amperes, 50/60 Hertz Boom Mounted Wire Feeder
For Use With CV/DC
Welding Power Source
For GMAW And FCAW
Welding
Rated At 100 Volts, 750
Wire Feed
Amperes,
Speed Range:
Wire Diameter
Range:
With Contactor
100%
50 To 780
.023 To 1/8 in
Vertical Lift Of Boom: Horizontal To
Duty Cycle
ipm (1.3 To
19.8
mpm)
(0.6 To 3.2 mm)
600 Above Horizontal
See Rear Cover For Options And Accessories
Read and follow these instructions and all
U
Give this manual to the operator.
safety blocks carefully.
Have
U
only
trained and
install, operate,
U
cover
1/94
or
qualified
persons
For
service this unit.
Call your distributor if you do not understand
the directions.
ST-142 705-B
'
1994 MILLER Electflc
or:
help,
call your distributor
MILLER Electric
Appleton, WI 54912
Mfg. Co.
Mfg. Co., P.O.
Box 1079,
414-734-9821
PRINTED IN USA
---
Ui___________________
MILLERS
This limited warranty
Subject
Mtg. Co., Appleton, Wisconsin,
Li
TRUE BLUETM LIMITED WARRANTY
with
(Equipment
LIMITED WARRANTY
I
________________
supersedes att previous MILLER
to the terms end conditions
Effective January 1, 1992
serial number preface of KC
or
warrenties and is exclusive with no other
guarantees
a
werrents to its original retsil purcheser thet new
MILLER equipment sold after the effective date ot this limited warranty is free of de
workmanship et the time it is shipped by MtLLER. THIS WAR
RANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FIT
NESS.
or
replace any
MILLERS
war
ranted parta or components that tail due to auch defects in material orwoilimanahip.
MILLER must be notified in writing within thirty (30) days of such detect or failure, at
which time MILLER wilt
instructions
provide
on
2.
the warranty claim procedurea to be
True
BIueTM
3.
relays
or
Cuning
Equipment
*
the
engine
manufacturer
Process Controllers
Syatema
that has been modified
REMEDY FOR
Running Gear/Trailera
Field Options
(NOTE: Field options
are
covered under True
warranty period of the product they
whichever is
are
BIueTM
metalled in,
or
for the
for I he
equipment.
BREACH OF CONTRACT TORT OR ANY 0 IHER
LEGAL
Some stales in the U.S.A. do not ellow limitations of how long an implied warranty
lasts, or the exclusion of incidental, indirect, special or consequential damages, so
the ebove limitation or exclusion may not apply to you. This warranty provides ape
citic legal rights, end other rights may be available, but may very from stale to stale.
remaining
fore minimum of
greater.)
Batteries
In
Days
specifications
CLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS
FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EOUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER.
SDX Transformers
90
equip
misused
THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, IN
Welders
Load Banks
6.
or
RANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY
Grids
year
by any party other than MILLER,
improperly installed, improperty operated or
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WAR
HF Units
one
nozzes, contactors
TO THE EXTENT PERMtTTED BY LAW, THE REMEDIES PROV:DED HEREIN
ARE THE SOLE AND EXCLUStVE REMEDIES. IN NO EVENT SHALL MILLER BE
LIABLE FOR DIRECT INDIRECT, SPECIAL, INCIDENTAL OR CONSEOUENTIAL
DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CON
TRACT, TORT OR ANY OTHER LEGAL THEORY.
Parts and Labor
Water Coolant
6 Months
tips, cutting
warranty claim covered by this werranty, the exclusive remsdies
option: (1) repair; or (2) replacement; or, where authorized in
in eppropriale cases, (3) the reasonable coal of repair or replace
ment stan authorized MILLER seivice elation; or (4) payment of or ci edit for the pur
chase price (less reasonable depreciation based upon actual use) upon return of the
goods el customers risk and expense. MILLERS option of repair or replacement
wilt be FOB., Feclory at Appleton, Wisconsin, or FOB. eta MILLER authorized ser
vice facility as determined by MILLER. Therefore no compensation or reimburse
ment for Irensportetion costs ot any kind will be allowed.
Motor Driven Guns
5.
contact
writing by MtLLER
Parts and Labor
Spot
as
to normel wear.
shell be, at MILLERS
Engine Driven Welding Generators
(NOTE: Engines are warranted aeparalely by
for a period of two years.)
Air Compreaaors
1 Year
to:
In the event of e
Power Sources
Robots
4.
apply
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMER
CIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN
THE USE AND MAINTENANCE OF WELDING EOUIPMENT.
Semi-Automatic and Automatic Wire Feeders
2 Years
shell not
Years Labor
Transformer/Rectifier Power Sources
3.
Warranty
parts that fail due
ment that has been
Parts and Labor
Plasma Arc
implied.
based upon industry standards, or equipment which has not had reasonable
end necesasry maintenance, or equipment which has been used for operation
main power rectifiers
Original
Limited
Consumable components; such
outside of the
3 Years
or
Items tumished by MILLER, but menutectured by others, such as engines or
trade ecceesoriee. These items are covered by the manufacturers warranty, it
end
MILLER shalt honor warranty claims on warranted equipment hated below in the
event ot such a failure within the warranty time periods. All warranty time perioda
alan on the date that the equipment was delivered to the originst retail purchaser, or
one year efter the equipment is sent to the distributor.
2.
espressed
any.
followed.
5 Years Parts 3
wsrranties
Accessory Kits
Replacement Parts
1.
wsrranty periods listed below, MILLER wilt repair
or
Remote Controls
betow, MILLER Electric
fects in material snd
Within the
newer)
in some provinces provides for certain additional warranties
remedies other than as staled herein, end to the extent that they may not be
the
limitations end exclusions set out above mey not eppiy. This Limited
waived,
Warrenty provides specific legal rights, end other rights may be available, but may
vary from province to province.
MIG Guns/TIG Torches
Plasma
Cutting
Canada, legislation
or
Perle end Labor
Torches
~~1
xwd,
RECEIVING-HANDLING
Before unpacking equipment, check carton for any damage that may have occurred during shipment. File any claims for loss or damage
with the delivering carrier. Assistance for filing or settling claims may be obtained from distributor and/or equipment manufacturers
Transportation Department.
When
requesting information about this equipment, always provide Model Designation
Use the
or
following
nameplate.
spaces to record Model
Designation
and Serial
or
Style
and Serial or
Style Number.
Number of your unit. The information is located
on
the
rating label
Model
_________
Serial
or
Style
No.
Date of Purchase
miller 9/93
ERRATA SHEET
After this manual
appearing
was
printed,
43-
43-
**First
FORM: OM-1583D
Use above FORM number when
ordering
equipment design
occurred. This sheet lists
extra manuals.
exceptions
to data
PARTS LIST
Parts List as follows:
**
43-16
43-
refinements in
June 1, 1994
later in this manual.
CHANGES TO SECTION 7
Change
-
..
Part
No.
Replaced
133 603
...
165 934
...
165 799
..
...
165 798
..
...
.163 282
..
Added
Added
Added
With
digit represents page
no
Description
..
SPRING, cprsn .573 OD x .088 wire x 1.062
WASHER, flat .257 ID stl (Elf w/KE644333)
Quantity
Ig (Eff w/KE644333)
SPRING, pressure arm retaining (Elf w/KE644333)
NUT, .250-28 stl (Elf w/KE644333)
digits following
dash represent item
no.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
F~LE
COPY
~E1U~ TO ~OLOER
..
1
1
1
1
ARC WELDING SAFETY PRECAUTIONS
WARNING
a
ARC WELDING
be hazardous.
can
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.
In welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The
safety information given below is only a summary of the more complete safety information that will be found in the
Safety Standards listed on the next page. Read and follow all Safety Standards.
HAVE ALL
INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY
QUALIFIED PEOPLE.
-
ELECTRIC SHOCK
can
kill.
5.
live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
Touching
1.
6.
Owners
Manual and national, state, and local codes.
When
Wear
3.
Insulate
dry, hole-free insulating gloves and body protection.
yourself from work and ground using dry insulating
Disconnect input power
this
or
ARC RAYS
NOISE
~
stop engine before installing
or
equipment.
can
burn eyes and
can
skin;
damage hearing.
Arc rays from the welding process produce intense
heat and strong ultraviolet rays that can burn eyes
and skin. Noise from some processes can damage
making input connections,
7.
Turn off all equipment when not in
Do not
attach proper
to its
grounding
use.
damaged, undersized,
worn,
use
or
poorly spliced
cables.
9.
Do not wrap cables around your body.
10.
Ground the
11.
Do not touch electrode if in contact with the work
12.
Use
13.
Wear
a
14.
Keep
all
workpiece
good
to a
electrical
(earth) ground.
only well-maintained equipment.
damaged parts at once.
safety
harness if
panels
and
replace
or
above floor level.
working
covers
ground.
or
Repair
securely
in
place.
ARC RAYS
2.
Wear
3.
eyes when welding or watching.
Wear approved safety glasses. Side shields recommended.
4.
hearing.
equipment according
8.
mats or covers.
servicing
ground
this
conductor first.
Do not touch live electrical parts.
2.
4.
Properly
install and
a welding helmet fitted with a proper shade of filter (see
ANSI Z49. I listed in Safety Standards) to protect your face and
protective screens or barriers to protect others from flash
glare; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
Use
and
NOISE
5.
1.
Use
approved
ear
plugs
or ear
muffs if noise level is
FUMES AND GASES
to your health.
can
high.
be hazardous
5.
Weldingproducesfumesandgases. Breathingthese
fumes and gases
6.
Keep
2.
If inside, ventilate the area and/or
remove
3.
4.
welding fumes
use
exhaust at the
7.
Watch for fire, and
Be
yourself
and others from
flying sparks
Protect
Do not weld where
3.
Remove all flammables within 35 ft
flying sparks
can
(10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers,
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
I
cause
can
degreasirig, cleaning,
unless the
the
can
or
spraying
react with vapors to
galvanized, lead,
as
or
is removed from the
coating
is well ventilated, and if necessary, while
fire
keep
welding
on
a
fire
on a
extinguisher nearby.
ceiling, floor, bulkhead,
7.
Do not weld
Connect work cable to the work
9.
Do not
10.
closed containers such
use
as
as
tanks
or
drums.
close to the
welder to thaw frozen
pipes.
Remove stick electrode from holder
tip
when not in
Wearoil.free
or
Wear
cut off
welding
wire at
use.
protective garments such
as
shirt, cuffless trousers, high shoes, and
1.
partition
welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
contact
11.
on
or
the hidden side.
8.
approved face shield
or
leather
a
gloves, heavy
cap.
safety goggles. Side
shields
recommended.
injury,
Chipping and grinding cause flying
cool, they can throw off slag.
aware
that
can cause
and hot metal,
strike flammable material.
FLYING SPARKS AND HOT METAL
I
area
5.
or
sure
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
6.
fire
near
coated metals, such
explosion.
1.
I
on
plated steel,
Sparks and spatter fly off from the welding arc. The
flying sparks and hot metal, weld spatter, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode orwelding wire
to metal objects can cause sparks, overheating, or
fire.
2.
4.
Do not weld
weld area, the
and cleaners,
can cause
while
air is safe.
Do not weld in locations
cadmium
use an
WELDING
or
used for
arc to
and gases.
approved air-supplied respirator.
Read the Material Safety Data Sheets (MSDS5) and the
manufacturers instruction for metals, consumables, coatings,
If ventilation is poor,
air-supplied respirator. Shielding gases
can displace air causing injury or death. Be
an
operations. The heat and rays of the arc
form highly toxic and irritating gases.
your head out of the fumes. Do not breathe the fumes.
1.
a
wearing
welding
breathing
be hazardous to your health.
can
confined space only if it is well ventilated,
Work in
metal. As welds
2.
Wear proper
body protection
to protect skin.
Sri 9/92
CYLINDERS
J
..
if
damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully,
~
~.z
.
explode
can
3.
Protect
compressed gas cylinders from excessive heat,
mechanical shocks, and
2.
welding
or
other electrical
a welding electrode to touch any cylinder.
only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is
Never allow
4.
Use
5.
6.
1.
from any
Keep cylinders away
circuits.
~
~
7.
arcs.
in
cylinders in
them to a stationary support
prevent falling or tipping.
Install and secure
an
or
upright position by chaining
equipment cylinder rack to
associated
ENGINE EXHAUST GASES
Engines produce harmful
ENGINE
use.
compressed gas cylinders,
on
and CGA
equipment,
publication
P-i listed in
Safety
Standards.
WARNING
a
connected for
use or
Read and follow instructions
8.
FUEL
ENGINES
can
kill.
or
explosion.
outside in open, well-ventilated
equipment
1.
Use
If used in a closed area, vent
away from any
fire
cause
be hazardous.
2.
exhaust gases.
can
can
building
before
1.
Stop engine
2.
Do not add fuel while
~1
engine
areas.
exhaust outside and
air intakes.
checking
adding
or
smoking
fuel.
if unit is
or
near
any sparks
or
open flames.
3.
I
I
Engine
fuel is
highly
flammable.
engine to cool belore fueling. If possible, check and add
engine before beginning job.
allow room for fuel to expand.
not overfill tank
not spill fuel. If fuel is spilled, clean up before starting
Allow
fuel to cold
A
4.
5.
Do
Do
engine.
MOVING PARTS
can cause
injury.
3.
only qualified people remove guards or
troubleshooting as necessary.
Have
covers
for
maintenance and
Moving parts, such as fans, rotors, and belts can
fingers and hands and catch loose clothing.
4.
cut
1.
Keep all doors, panels,
securely
2.
Stop eng
in
covers,
and
guards
before
installing
or
connecting
),
.
Y
generate explosive
-.
/
STEAM AND PRESSURIZED HOT
COOLANT can burn face, eyes, and
skin.
The coolant in the
r adiator can
Keep hands, hair,
parts.
6.
Reinstall
panels
cable from
loose
or
battery.
and tools away from
clothing,
guards and close
starting engine.
doors when
moving
servicing
is
finished and before
ases.
ff1..
5.
unit,
SPARKS can cause BATTERY GASES
TO EXPLODE; BATTERY ACID can
burn eyes and skin,
Batteries contain acid and
prevent accidental starting during servicing, disconnect
negative () battery
closed and
place.
ne
To
1.
Always
2.
Stop engine
wear a
face shield when
before
working
disconnecting
on a
battery.
connecting battery
or
cables.
3.
Do not allow tools to
4.
Do not
5.
Observe correct
1.
Do not
use
cause
welder to
remove
sparks
charge
polarity (+
when
batteries
and
)
radiator cap when
on
working
or
battery.
on a
jump start vehicles.
batteries.
engine
is hot. Allow
engine
tocool.
gloves and put a rag over cap area when removing cap.
2.
Wear
3.
Allow pressure to escape before
be very h ot and
under pressure.
completely removing cap.
PRINCIPAL SAFETY STANDARDS
Safety in Welding and Cutting, ANSI Standard Z49.1, from
Welding Society. 550 N.W. LeJeune Rd. Miami FL 33126
Safety and Health Standards, OSHA
American
Superinten.
Printing Office, Washington,
Safe
Handling of Compressed Gases
in
Cylinders,
CGA
Pamphlet
P-i, from Compressed Gas Association, 1235 Jefferson Davis High
way, Suite 501, Arlington, VA 22202.
29 CFR 1910, from
dent of Documents, U.S. Government
D.C. 20402.
Code for Safety in Welding and Cutting, GSA Standard Wi 17.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale Bou
levard, Rexdale, Ontario, Canada M9W 1 R3.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, Ameri
Safe Practices For Occupation And EducationalEyeAnd Face Protec
Welding Society Standard AWS F4.i ,from American Welding So
ciety, 550 N.W. LeJeune Rd, Miami, FL 33126
tion, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
National Electrical Code, NFPA Standard 70, from National Fire Pro
Cutting And Welding Processes, NFPA Standard 51 B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
can
tection Association,
srI 9/92
Batterymarch Park, Quincy,
MA 02269.
PRECAUTIONS
DE
SECURITE
MISE EN GARDE
PROTEGEZ-VOUS,
AINSI QUE LES
ENFANTS SAPPROCHER,
Le soudage,
precautions.
respectez
A
EN SOUDAGE
A
LE SOUDAGE
LARC est
LARC
dangereux.
AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES
(A MOINS QUILS NAIENT CONSULTE UN MEDECIN).
NI LES PORTEURS DE STIMULATEtJR CARDIAQUE
a plupart des activitØs industrielles, expose a certains nsques. Le soudage nest pas dangereux lorsquon
prend des
consignes de sOcuritØ suivantes ne font que rØsumer linformation contenue dans es normes ØnumØrØes ci-apres. Lisez et
comme
Les
toutes ces normes.
SEULES DES PERSONNES
QUALIFIEES DOIVENT FAIRE DES TRAVAUX DINSTALLATION,
DE
REPARATION,
DENTRETIEN
El
DESSAI.
LELECTROCUTION
Une
peut Œtre mortelle.
dØcharge Ølectrique pout
vous
6.
les circuits internes des matØriels sont aussi
7.
des
Ia mise
en
sous
En soudage
dernier, le support de
marche.
automatique ou semi-automatique avec fil, ce
roquette, le logement des galets dentrainement et toutes los piŁces
mØtalliques en contact avec le tilde soudage sont sous tension. Des
matØriels mal installØs ou mal mis a Ia terre sont dangereux.
1. Ne touchez pas a des piŁces sous tension.
3.
4.
Portez des gants et des vŒtements isolants, secs et non trouØs.
lsolez-vous de Ia fob a souder et de Ia mise ala terre au moyen
de petits tapis isolants ou autres.
DØconnectez Ia prise dentrØe des matØriels ou arrŒtez leur
Veillez a installer
matØriels eta les mettre a Ia terre solon le
ces
manuel dutilisation et los codes nationaux,
bocaux applicables.
brler gravement. LØlectrode et le circuit de soudage
sont sous tension au dØmarrage. Le circuit dentrØe et
tension
2.
5.
tuer ou vous
8.
9.
provinciaux
ArrŒtez tous les matØriels aprŁs utilisation.
Nutilisez pas de cables uses, endommages, mal ØpissØs
calibre trop petits.
Nenroulez pas de cables autour de votre corps.
Mettez ala terre Ia tOte a souder
au
moyen dune bonne
ou
et
do
priso do
terre.
10.
Ne touchez pas a lØlectrode
circuit de
11.
Si
vous
Œtes
contact avec 10
en
soudage (terre).
Nutilisez que des matØriels en bon Øtat. RØparez
los piŁces endommagees.
ou
remplacez
sur-le-champ
12.
Portez
13.
Fermez solidemont tous los panneaux of les capots.
un
harnais do sØcuritØ si
vous
travaillez
en
hauteur.
moteur avant de les installer ou den faire lentretien.
C~
Le RAYONNEMENT DE LARC
peut
Ia peau; le BRUIT peut
brUler les yeux et
I ouIe.
endommager
Larc de
ultraviolets intenses,
une
bruit cause par certains procedØs peut endommager loule.
1. Portez un casque de soudeur avec Øcran filtrant de teinte
4.
appropnee (consultez Ia norme ANSI Z49 indiquee ci-aprØs),
pour vous proteger le visage et los yeux lorsque vous soudez ou
5.
I
1
I
9..
Les VAPEURS ET LES
FUMEES
sont
dangereuses pour Ia sante.
Le soudage dØgage des vapeurs et des fumØes quil
est dangereux de respirer.
1. Ecartez le visage pour Øviter de respirer les
3.
A lintØrieur,
quo lairo de soudage eSt bien
ventilØe ou que les fumØes et les vapeurs sont aspirØes a larc.
Si Ia ventilation est mauvaise, portez un respirateur a adduction
dair
4.
approuve.
relatives
aux
revŒtements et
signalØtiques
mØtaux,
aux
aux
Entourez laire de soudage do ridoaux ou do cloisons de
protection contre los coups darc ou leblouissement; avertissez
les observateurs de ne pas regarder arc.
Portez des vØtements en tissus ignifuge durable (lame of cuir)
Portez
5.
ou une
incendie
explosion.
Ne soudez pas a
toxiques
7.
incendie et des brOlures. Lo
avoc un objet
contact accidontol de electrode
metallique pout provoquer des Øtincelles, un Øchauffement ou un
incendie.
1. Protegez-vous, ainsi quo les autres, contre les Øtincelles et los
peuvent
3.
endroit o
Ne soudez pas dans un
attoindro des matØnaux inflammables.
des Øtincelles peuvent
Enlevez toutes les matiŁres inflammables dans un rayon de
10,7 metres autourde larc, ou couvrez-les soigneusement avec
des bches
4.
approuvØes.
MØfiez-vous des Øtincelles et des Øclats brUlants, susceptibles
de penetrer dans des aires adjacentes par de petites ouvertures
ou
de
degraissage, do
et irritants.
qui
en
contient, peuvent alors
dØgager
des
fumØes toxiques. Assuroz-vous dune bonne ventilation et portez
5.
respiratour a adduction dair si
MØfiez-vous des incendies et
Ia main.
Noubliez
cloison
7.
cost nØcessaire.
gardez
un
extincteur a
portØe
pas quune soudure sur un plafond, un plancher,
paroi pout on enflammer Iautre cOtØ.
do
une
ou uno
Ne soudez pas
un
recipient fermØ,
comme un
reservoir
ou un
causer un
projections.
2.
proximitØ doperations
Ne soudoz pas de tOles galvanisØes ou plaquØes en p10mb ou
en cadmium sans los avoir grattØes a fond, car ces mØtaux, et
tout revŒtement
Larc
elles
approuvØs
nettoyage ou de pulvØrisation. La chaleur et les rayons do Iarc
peuvent reagir avec des vapeurs et former des gaz hautement
6.
produit des Øtincelles of des projections. Avec Ia
chaleur intense dŁgagee par Ia tle et los matØriels,
des bouchons doreillo
Ne travaillez dans un espace confine quo sil est bien ventilØ;
sinon, portez un respirateur a adduction dair. Los gaz protecteurs
un
causer un
ou
respiration.
6.
et les consignes du fabricant
produits consummables, aux
peut
casque antibruit
de soudage peuvent dØplacer loxygene de lair of causer des
blessures ou Ia mort. Assurez-vous quo lair ost propre a Ia
produits nettoyants.
Le SOUDAGE
un
si le niveau de bruit est ØlevØ.
assurez-vous
Lisez les fiches
dune soudure.
et des chaussures de sØcuritØ.
fumØes.
2.
observez lexØcution
vous
Portezdeslunettesdesecuriteapprouvees. DesØcranslatØraux
sont recommandØes.
3.
chaleur et des rayons
de brOler es yeux et Ia peau. Le
soudage produit
susceptibles
que
2.
fissures.
-______________________________________
tonnoau.
8.
Connectez le cable de
soudage le plus prŁs possible de Ia tOle
soudage pour empecher le courant do suivre un parcours
long et inconnu, et prØvenir ainsi los risques dØlectrocution et
do
dincendie.
9.
10.
Ne faites pas dØgoler dos tuyaux avoc un chalumeau.
Videz votre carquois porte-electrodes ou coupez le f ii au tubecontact
11.
apres le soudage.
Portez des vØtements protecteurs
cuir,
une
chemise
Øpaisso,
chaussures montantes et
un
un
huileux, tels des gants on
pantalon sans revers, des
non
casque.
ETINCELLES
LES
ET LES
1.
PROJECTIONS BRULANTES peuvent
causer
Le
des blessures.
piquage
et le
meulage produiserit des Øclats de
Les BOUTEILLES
endommagees peuvent
2.
4.
5.
exploser.
Les bouteilles contiennent des gaz protecteurs sous
haute pression. Des bouteilles endommagees peuvent
exploser. Comme
les bouteilles font normalement
du procede de soudage, traitez-les avec soin.
Les bouteilles doivent Œtre protegees contre es
6.
partie
sources de
chaleur intense, les chocs et les arcs de soudage.
EnchaInez verticalement es bouteilles a un support ou .a un
cadre fixe pour les empŒcher de tomber ou dŒtre renversØes.
1.
2.
7.
8.
MISE EN GARDE
DECHAPPEMENT D ES MOTEURS
PEUVENT ETRE MORTELS.
dØchappement
des gaz
produisent
Ne mettez pas le visage devant le robinet de bouteille
louvrant.
Remettez le chapeau de bouteille aprŁs utilisation.
1.
Utilisez des machines a lextØrieur dans des aires ouvertes et
2.
Si
vous
causer un
incendie ou
3.
explosion.
Le carburant est hautement inflammable.
1. ArrŒtez le moteur avant de verifier le niveau de
carburant ou de faire le plein.
2.
Ne faites pas le plein
PIECES
Des
causer
Des
en
fumant
ou
proche dune
EN MOUVEMENT
4.
source
mouvement, telles des ventilateurs,
peuvent couper les doigts
et les mains, ou accrocher des vŒtements amples.
2.
Avant dinstaller
ou
es
panneaux,
de connecter
4.
pour
son
expansion.
Faites attention de ne pas renverserde carburant. Nettoyez tout
carburant renversŁ avant de faire dŁmarrer le moteur.
ou
des capots
pourfaire Ientretien
ou
le
dØpannage
un
es
capots
5.
et les
systŁme, arrŒtez-en
le
Pour empŒcher un demarrage accidentel dun systŁme pendant
dØbranchez le cable daccumulateur a Ia borne
lentretien,
6.
negative.
Napprochez
pas les mains ou les cheveux de piŁces en
mouvement; elles peuvent aussi accrocher des vŒtements
amples et des outils.
RØinstallez les capots ou les protecteurs et fermez les portes
travaux dentretien et avant de faire dØmarrer le
aprŁs des
moteur.
3.
confine, les
nØcessaire.
en
Assurez-vous que les portes,
protecteurs sont bien fermes.
endroit
dØtincelles ou dune flamme nue.
Si cest possible, laissez le moteur refroidir avant de faire le plein
de carburant ou den verifier le niveau au debut du soudage.
Ne faites pas le plein de carburant a ras bord : prØvoyez de
protecteurs
peuvent
des rotors et des courroies
1.
un
dØchappement doivent Œtre envoyees a lextØneur, loin
prises dair du btiment.
Iespace
5.
des blessures.
piŁces
utilisez des machines dans
fumØes
des
Le CARBURANT peut
dangereux.
bien ventilØes.
nocifs.
une
en
Lisez et respectez les consignes relatives aux bouteilles de gaz
et aux matØriels connexes, ainsi que Ia publication
P-i de Ia CGA, ŁnumØrŁes dans les normes ci-dessous.
Les MOTEURS peuvent Œtre
Les GAZ
Les moteurs
tout contact entre une bouteille et une electrode.
Nutilisez que des bouteilles de gaz protecteur, des detendeurs,
des flexibles et des raccords concus pour chaque application
spŁcifique; ces matØriels et les piŁces connexes doivent Œtre en
bon Øtat.
EmpŒchez
comprimØ
Eloignez les bouteilles de tout circuit electrique ou de soudage.
3.
metal. En retroidissant, Ia soudure peut projeter du laitier.
Portez un Øcran facial ou des lunettes a coques approuvØes.
Des Øcrans lat~raux sont recommandØs.
Portez des vŒtements de protection individuelle appropriØs.
Seules des personnes
qualifiØes doivent dŁmonter des
ETINCELLES peuvent FAIRE EXPLOSER
UNACCUMULATEUR; LELECTROLYTE DUN
ACCUMULATEUR peut brUler Ia peau et les
moteur.
Des
2.
~
yeux.
Les accumulateurs contiennent de
degagent des vapeurs explosives.
1. Portez toujours un Łcran facial
La
VAPEUR
ET
REFROIDISSEMENT
PRESSION
LE
IØlectrolyte
4.
Nutilisezpasunpostedesoudagepourchargerunaccumulateur
connecter provisoirement un vŁhicule.
Utilisez Ia polaritØ correcte (+ et -) de laccumulateur.
ou
en
travaillant
LIQUIDE
BRULANT
peuvent brUler
et
un accumulateur.
ArrŒtez le moteur avant de connecter ou de dŁconnecter des
cables daccumulateur.
Nutilisez que des outils anti-Łtincelles pour travailler sur un
accumulateur.
sur
5.
DE
1.
Ntez
pas le bouchon de
refroidi.
2.
Mettez des gants et posez un torchon sur le bouchon pour lter.
Laissez Ia pression sechapper avant dter
complŁtement le
sous
Ia peau et les
3.
yeux.
radiateurtantque le
moteur na
pas
bouchon.
liquide de refroidissement dun radiateur peut Œtre
brUlant et sous pression.
Le
PRINCIPALES NORMES DE
Safety in Welding and Cutting norme ANSI Z49. 1, American
Society, 550, N.W. LeJeune Rd., Miami FL 33128.
Welding
Safety and Health Standards OSHA 29 CFR 1910, Superintendent
of Documents, U.S. Government Printing Office, Washington D.C.
20402.
Recommended Safe Practices For the Preparation For Welding and
Cutting of Containers That Have Held Hazardous Substances, norme
AWS F4.1, American Welding Society, 550, N.W. LeJeune Rd.,
SECURITE
Safe Handling of Comoressed Gases in Cylinders document P-i,
Compressed Gas Association, 1235 Jefferson Davis Highway, Suite
501, Arlington, Va 22202.
Code for Safety in Welding and Cutting norme GSA Wi 17.2, Asso
ciation canadienne de normalisation, Standards Sales, 176 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1 R3.
Miami FL 33128.
Safe Practices for Occuoation and Educational Eye and Face Protec
norme ANSI Z87. 1, American National Standards Institute, 1430
Broadway, New York, NY 10018.
National Electrical Code norme 70 NFPA, National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269.
Cutting and Welding Processes norme 51 B NFPA, National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
srlf 9/91
~
45
42
40
39
36
35
32
EMF INFORMATION
NOTE ~
I
Considerations About
Magnetic Fields
Welding
And The Effects Of Low
The
following is a quotation from the General Conclusions Section
Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields
Background Paper, OTA-BP-E-53 (Washington, DC: U.S.
To reduce
of the U.S.
procedures:
Government Printing Office, May 1989):.
there is now a very
large volume of scientific findings based on experiments at the
cellular level and from studies with animals and people which clearly
2.
Arrange
3.
Do not coil
4.
Keep welding power
practical.
source
5.
Connect work
to
.
1.
fields in the
workplace,
Keep cables close together by twisting
cables to
one
or
Electric And
use
taping
the
following
them.
side and away from the cperator.
.
frequency magnetic fields can interact with, and
produce changes in, biological systems. While most of this work is
of very high quality, the results are complex. Current scientific
understanding does not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet
allow us to draw definite conclusions about questions of possible
risk or to offer clear science-based advice on strategies to minimize
establish that low
or
magnetic
Frequency
or
drape
cables around the
clamp
body.
and cables
workpiece
as
as
far away
as
close to the weld
as
possible.
About Pacemakers:
The above procedures are among those also normally
recommended for pacemaker wearers. Consult your doctor for
complete information.
avoid potential risks.
modlo.1 4/93
TABLE OF CONTENTS
SECTION 1
SAFETY INFORMATION
1
SECTION 2- SPECIFICATIONS
SECTION 3
1
INSTALLATION
3-4.
Equipment Connection Diagrams
Installing Swivel Into Pipe Post
Installing Boom And Reel Support
Installing Wire Guide Extension
3-5.
Wire Guide And Drive Roll Installation
5
3-6.
6
3-9.
Welding Gun Connections
Wire Feed Motor And Gas Valve Control Connections
14-Pin Plug Connection
Shielding Gas And Weld Cable Connections
3-10.
Voltage Sensing
3-11.
3-12.
Removing Safety Collar And Adjusting
Welding Wire Installation
3-13.
Motor Start Control
3-14.
Dip Switches Options
Changing Optional Digital Voltage Control
MILLER Inverter-Type Power Source
Threading Welding Wire
3-1.
3-2.
3-3.
3-7.
3-8.
3-15.
3-16.
Lead
3
4
4
5
(Optional)
5-1.
8
9
Boom
9
9
11
12
For Use With A
SECTION 4OPERATION
SECTION 5
7
7
15
16
18
MAINTENANCE & TROUBLESHOOTING
Routine Maintenance
The Hub
24
5-2.
Replacing
5-3.
Overload Protection
25
5-4.
Troubleshooting
26
Assembly
SECTION 6
ELECTRICAL DIAGRAMS
SECTION 7
PARTS LIST
Figure
Figure
Figure
Figure
Figure
Figure
25
27
7-1. Main
7-2.
Assembly
Support, Hub &
Reel
7-3. Control Box
7-4. Control Panel
7-5. Boom
7-6. Drive
Assembly
Assembly, Wire
Table 7-1. Drive Roll And Wire Guide Kits
OM-1583D
-
4/94
SECTION 1
-
SAFETY INFORMATION
modl.1 2/93
Read all
safety messages throughout this manual.
Obey all safety messages
Learn the
1
meaning
to avoid
injury.
of WARNING and CAUTION.
1
Safety Alert Symbol
2
SignalWord
2
2
\
WARNING
or
:
a CAUTION
3
_______
ELECTRIC SHOCK
can
kiIl.~
can
Keep away from moving parts.
panels and
when operating.
installing
or
Keep
alt
I
means possible minor
injury or equipment damage can
happen.
I
3
Statement Of Hazard And
Result
4
Safety
5
Hazard
6
Safety
Injure.
Disconnect
before
covers
closed
r
5
a
READ SAFETY BLOCKS at start of
SectIon 3-1 before proceedIng.
WARNING
6
7H
NOTE
~
Instructions To Avoid
Hazard
using high frequency.
NOTE
Special instructions
ation
Figure
1-1.
Symbol (If Available)
Banner
Read safety blocks for each sym
bol shown.
7
Turn Off switch when
possible death
happen.
can
CAUTION
MOVING PARTS
Do not touch live electncal parts.
input power
servicing.
means
serious injury
for best oper
not related to
safety.
Safety Information
SECTION 2- SPECIFICATIONS
Table 2-1. Wire Feeder
Specification
Type Of Input Power From Welding
Power Source
Maximum Weld Circuit
Rating
Welding Power Source Type
Wire Feed
Welding
Single-Phase 24 Volts AC, 10 Amperes, 50/60 Hertz. (If
Use Optional Power Supply Adapter Model PSA-2.)
100 Volts, 750
Constant
Amperes,
Voltage (CV) DC,
.023 To 1/8 in
Range
(0.6 To
Gas Metal Arc
Process
3.2
Power Available,
Duty Cycle
With Contactor
mm)
(GMAW) Or
12 ft
Height
Only
Flux Cored Arc
Welding (FCAW)
lOft(3.1 m)
Input Power Cord
Maximum
Post
100%
115 Volts AC Is The
50 To 780 ipm (1.3 To 19.8 mpm); Standard Motor
14 To 213 ipm (0.6 To 5.4 mpm); Low Speed Motor
90 To 1400 ipm (2.3 To 35.6 mpm); High Speed Motor
Speed Range
Wire Diameter
Description
With 4 ft
Weight
(1.2 m)
Boom
16 ft
17ft(5.2m)
21 ft
Net: 160 lb
Net: 210 lb
Ship:
Vertical Lift Of Boom
(37 m)
(73 kg)
280 lb
(127 kg)
Horizontal To
60 Above
Ship:
Horizontal
(4.9 m)
Boom
(6.4 m)
(95 kg)
350 lb
(159 kg)
Horizontal To 60
Above Horizontal
OM-1583 Page 1
Table 2-2.
Options
The table below should be used to determine the options that can be used together on a wire feeder. Use the column
the table to choose the desired option and follow the line across to see which options are compatible.
Burn-
Desired
Option
back
Control
Burnback Control
4-In-i
Control
No
Digital
Meter(s)
Digital
Voltage
Remote
Schedule
Schedule
Control
Pendant
Control
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
Yes
No
Yes
Yes
No
Yes
Yes
Yes
No
No
No
Yes
Yes
Yes
Yes
Yes
No
No
No
No
No
Control
Control
Yes
Yes
Yes
Yes
Yes
Yes
Cord #137
552 (For
Dual
Dual
Run-In
Control
the left side of
Digital
Voltage
Tech
Feedback
on
RCSP-45)
4-in-i Control
(includes preflow/post
flow, spotlburnback,
and
trigger
control)
No
hold
Digital Meter(s)/Tach
Feedback (one ortwo
meter option)
Yes
Yes
Digital Voltage
(DVC)
Yes
Yes
Reqd
Voltage Control
Yes
Yes
Yes
No
Run-In Control (Option
Interface Required)
Yes
Yes
Yes
Yes
Yes
Digital Dual Schedule
(Option Interface
Required)
Yes
Yes
Reqd
Reqd
No
Yes
Yes
Yes
No
No
No
Yes
No
Yes
Yes
Yes
Yes
No
Yes
No
No
Yes
Yes
Yes
Yes
Yes
Yes
No
No
Control
Dual Schedule Control
(Option Interface
Required)
Remote Pendant
Control (Option
Interface Required)
No
Cord #137 552
(For
RCSP-45) (Option
Interface Required)
OM-1583 Page 2
No
SECTION 3- INSTALLATION
3-1.
Equipment Connection Diagrams
a
WARNING
CYLINDERS
can
explode
Keep cylinders away
from
it
ELECTRIC SHOCK
damaged.
welding
and
other
electrical circuits.
Never touch
cylinder
with
welding
HOT SURFACES
can
Allow gun to cool before
kill.
TurnOffwirefeederandwelding power source, and
disconnect
before
input
power
making
electrode.
Always secure cylinder to running gear, wall,
other stationary support.
can
Do not touch live electrical parts.
connections.
or
The welding wire, drive rolls, drive assembly, and all
metal parts touching the welding wire are electrically
live when welding or feeding wire using gun trigger.
burn skin.
touching.
Have
only qualified persons install
this unit.
wfwam9.1 2/93
Power Source
1
Welding
2
Remote 14 Connection
3
Positive
Cable
4
(+)
Weld
Negative ()
Output
Weld
Output
Cable
13
5
12
Workpiece
6
Voltage Sensing Clamp
7
Weld Control
8
Boom
9
Gun
10
Swivel
11
Pipe Post
12
Gas Hose
13
Gas
And Base
Supply
11
9
ST.152 324
Figure
3-1.
Typical System
Connections
OM.1583
Page
3
3-2.
Installing
Swivel Into
Post
WARNING
AA
1
Pipe
RELEASE OF SPRING PRESSURE
WITHOUT BOOM ATTACHED can cause
serious personal Injury.
S
Do not
remove
FALLING
BOOM
can
serious
cause
personal injury and equipment damage.
safety collar until instructed to do so.
Securely mount pipe post to base that can support
weight of unit with boom in horizontal position.
Use proper equipment for lifting swivel and boom
into place.
CBC Cart
1
Swingpak
Base
2
Pipe Post
With Base
3
Steel Bolt
or
Secure as shown using as a mini
mum 1/2 in diameter SAE grade 5
steel bolts.
4
Swivel Assembly
Insert into
pipe post. Lubricate
swivel.
5
Safety
Do not
Collar
remove
until instructed to.
Tools Needed:
~ 3/4 in
ST-152 268
Figure
3-3.
Installing
Boom And Reel
3-2. Swivel Installation
Support
READ SAFETY BLOCKS at start of
Section 3-2 before proceeding.
1
Swivel Plates
2
Yoke
Remove
hardware
from
swivel
plates and yoke.
3
Boom
Set boom into swivel
4
as
shown.
Yoke Pin
Install
ter
5
pin through yoke. Install cot
pin and spread ends.
Bolt
Install bolt, tighten hardware, and
back bolt off one half turn.
1
6
Locking Knob
Install
locking
knob but do not
tighten.
7
Tools Needed:
Reel
Support
Install reel support.
~ 3/4, 3/8 in
Ret. ST-i 42 596.C
Figure
OM-1 583
Page
4
3-3. Boom Installation
3-4.
Installing
Wire Guide Extension
4
1
Wire Guide
2
Bolt
Fitting
3
Monocoil Liner
4
Wire Guide Extension
Tighten bolt to secure liner in wire
guide fitting. Do not overtighten
bolt and crush liner.
Tools Needed:
~
3/B in
ST-152 323
Figure
3-5.
Wire Guide And Drive Roll Installation
I 4.~
~
7
A.
3-4. Wire Guide Extension Installation
I
READ SAFETY BLOCKS at start of
Section 3-1 before proceeding.
Wire Guide Installation
When
check
1
changing wire size or type,
guide size. See Table 7-1.
Drive Rolls
Remove drive rolls before installing
wire guides (see Figure 3-6).
2
Wire Guide
Securing Screws
Loosen wire guide
screws.
3
Inlet Wire Guide
4
Intermediate Wire Guide
Insert intermediate guide until
flange on guide rests against cast~
ing, and secure with guide screw.
Install drive rolls
(see Figure 3.6).
1
Tools Needed:
Ref. ST~137 391-FISI-142 597-A
Figure
3-5. Wire Guide Installation
OM-1583
Page
5
B.
Drive Roll ~nstaIlation
When changing wire size or type,
check
drive
size.
See
roll
Table 7-1.
1
Spring Shaft Carrier
spring shaft carrier.
Close
2
Drive Roll Nut
3
Drive Roll Carrier
Turn all nuts one click until lobes of
nut line up with lobes of drive roll
carrier.
Open spring
4
Slide drive rolls onto drive roll carri
ers. Close spring shaft carrier. Turn
4
~
2
3
nut one click.
5
Drive
Close
Figure 3-6.
3-6.
Welding
a
shaft carrier.
Drive Roll
Assembly Cover
cover.
ST-142 597-A
Drive Roll Installation
Gun Connections
WARNING
ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
Turn Ott wire feeder and
welding power
source, and disconnect
input power before inspecting
installing.
or
wfwami.1 2/93
1
Drive
Assembly Cover
Securing
2
Gun
3
Gun Connector
Loosen
securing
Knob
knob. Insert gun
connector until it bottoms
drive
against
assembly. lighten knob.
4
Gun
Trigger Plug
5
Gun
Trigger Receptacle
Insert plug into free-hanging recep
tacle and tighten threaded collar.
6
Trigger Cord
7
Trigger Plug
8
Weld Control
Trigger
Receptacle
3
4
Insert
plug into receptacle and
tighten
threaded collar.
Ret. ST-i 53 072 / ST-i 52 321 I Ref. 5T-142 708-B
Figure
OM-1 583
Page
6
3-7. Gun And
Trigger Lead
Connections
3-7.
Wire Feed Motor And Gas Valve Control Connections
1
Wire Feed Motor And Gas
Valve Control Receptacle
2
Plug From Boom
3
Cord From Boom
Insert plug from boom cord into re
ceptacle on rear of control, and
tighten threaded collar.
Ref. ST-142 708-B
Figure
3-8.
14-Pin
Plug
3-8. Boom Connections
Connection
1
Plug PLG1O
2
Keyway
3
Threaded Collar
Connect
14-pin plug PLGIO to
matching receptacle on welding
power source as follows: align key
ways, insert plug, and tighten
threaded collar.
3
ST-162 179 / Ref. S-0512
Figure
3-9. 14-Pin
Plug Connection
Table 3-1. Remote 14 Pin Information
Pin Information
~j~*
A
24 volts
B
Contact closure to A
The
ac.
completes
for 24 volts
24 volts
ac
contactor control circuit.
circuit.
G
Circuit
C
+10 volts dc
D
Remote control circuit
E
0 to +10 volts dc
F
Current feedback; 0 to +10 volts dc, 1 volt per 100 amperes.
H
Voltage feedback;
common
remaining pins
are
input
ac
to remote control.
common.
output
command
signal from
remote control.
0 to +10 volts dc, 1 volt per 10 arc volts.
not used.
OM-1 583
Page
7
3-9.
Shielding
£~
Gas And Weld Cable Connections
WARNING
CYLiNDERS
can
explode
it
ELECTRIC SHOCK
damaged.
Keep cylinders away from welding and other
electrical circuits.
Never touch
kill.
can
Do not touch live electrical parts.
The
cylinder with welding electrode.
Always secure cylinder to running gear, wall,
other stationary support.
or
welding wire, drive rolls, drive assembly, and all
metal parts touching the welding wire are electrically
live when welding or feeding wire using gun trigger.
BUILDUP OF SHIELDING GAS
health or kill.
Shut oft
shielding gas supply
can
when not in
harm
use.
wam4.1
2/93
The weld cable and shielding gas
hose extend 10 ft (3 m) from the
boom.
If the welding power source or gas
supply are further from the boom,
extend cable
or
1
Weld Cable
2
Insulated
Bolt
hose
follows:
as
Sleeving
together
welding power
weld
cables from
and boom.
Use electrical tape and insulated
sleeving to cover connection.
3
Shielding
source
Gas Hose
Connect hose to gas supply or ex
tension hose. The hose from the
boom
has
threads.
5/8-18
right-hand
Tools Needed:
5/8in
81-152 800-A
Figure
OM-1583 Page 8
3-10.
Shielding
Gas And Weld Cable Connections
3-10.
Voltage Sensing
Lead
A 35 ft
(10.6 m) voltage sensing
Figure 3-1).
3-11.
Removing Safety
(Optional)
lead is
provided with several options. Connect voltage sensing lead to workpiece (see
Collar And
Adjusting
Boom
WARNING
4~
RELEASE OF SPRING
PRESSURE
WITHOUT BOOM ATTACHED can cause
serious personal injury.
Do not
remove
FALLING
personal
BOOM can cause
in jury and equipment
Adjustment rod
yoke.
safety collar until instructed to do so.
must be threaded
1
serious
damage.
fully through
Locking Knob
Tighten
knob
prevent boom
to
movement. Loosen knob to allow
4
boom movement.
Change knob
position to limit upward movement.
3
Pull boom down
move
safety
slightly
and
re
collar. Boom should
balance in any position from hori
zontal to 60 degrees above hori
zontal. If necessary, adjust boom
as
3
~~
2
Tools Needed:
~
1-1/8 in
Increasing Spring
Decreasing Spring
Pressure ForA
Heavy Gun
Pressure ForA
Light Gun
Figure
3-12.
A.
Welding
3-11. Boom
follows:
2
Threaded Rod
3
Jam Nut
4
Yoke
Loosen jam nut and turn threaded
rod until boom balances. Tighten
jam nut. Be sure several full
threads are through yoke to pre
vent boom falling.
Retain safety collar for use In dis
assembling or moving boom.
Ret. ST-152 380-A
Adjustments
Wire Installation
Installation Of
Spool-Type
Wire
1
Retaining Ring
2
Wire
3
Hub
Remove
spool
4
Spool
retaining ring and
slide
onto hub.
Hub Pin
Turn
spool until hub pin fits hole
spool. Reinstall retaining ring.
in
~
E
ST-152 ~8-A
Figure
3-12. Installation Of
Spool-Type
Wire
OM-1 583
Page
9
B.
Installation Of
Wire Reel And Reel
Optional
7
Type
Wire
1
Retaining Ring
2
Spanner
3
Lock
4
Wire Retainer
5
Wire Reel
5
Nut
4
6
Hub
7
Hub Pin
8
ReelSupport
Remove retaining ring. Pull lock
and turn. Remove spanner nut,
wire retainer, and wire reel from
hub.
Lay wire
reel
assembly
face, and install wire
as
flat sur
shown.
on
Tighten spanner nut until lock is in
position over hole in wire retainer.
Pull lock and turn to insert locking
pin into wire retainer.
Slide wire reel assembly onto hub,
and tum assembly until hub pin is
seated in hole in reel. Reinstall re
taining ring.
4
_____________
I
Iii
~
ST-143 478-A / ST-152 463
Figure
C.
Adjusting
3-13. Installation Of
Optional Wire Reel And Reel Type Wire
Hub Tension
Turn Off unit and
welding
power
source.
1
Hex Nut
2
Spool
Grasp spool in one hand and turn
while using a wrench to adjust hex
nut. When a slight force is needed
to turn spool, tension is set.
2
1
E
Tools Needed:
~ 5/8in
ST-152 649
Figure
OM-1 583
Page
10
3-14.
Adjusting
Hub Tension
3-13. Motor Start Control
WARNING
AA
ELECTRIC SHOCK
can
Do not touch live electrical
kill.
parts.
Turn Off wirefeederandwelding powersource, and
disconnect input power before inspecting or
STATIC ELECTRICITY
on circuit boards.
Put
on
boards
grounded
or
wrist
can
damage parts
strap BEFORE handling
parts.
installing.
wfwaml.1
To
2/93
change wire feed starting speed
proceed
as
follows:
Turn Off unit and
welding power
source.
Remove wrapper.
1
Front Panel
Remove
screw
nor, and open
from upper left cor
front panel.
hinged
2
Motor Board PCi
3
Motor Start Control Poten
tiometer R70
Turn
potentiometer clockwise to in
time it takes the motor to
ramp up to speed. Remove protec
tive white rubber cap before
crease
making adjustment. Adjust poten
tiometer R70 using a small
conductive screwdriver.
Close and secure front panel,
reinstall wrapper.
non-
and
Toots Needed:
-
non-conductive
1/4 in
ST-152 378 / SB-146 862-0
Figure
3-15. Motor Start Control On Motor Control Board PCi
OM-l 583
Page
11
3-14.
Dip Switches Options
a
WARNING
ELECTRIC SHOCK
can
kill.
STATIC ELECTRICITY
circuit boards.
can
damage parts
on
Do not touch live electrical parts.
Turn Off wire feeder and welding power source, 2
disconnect input power before inspecting
Put on
boards
grounded
or
wrist strap BEFORE
handling
parts.
installing.
wtwaml.1
A.
Spot
2/93
Time DIP Switch Si
Change DIP switch position if a
different range of Spot Time is
desired.
Turn Off wire feeder and
power
welding
source.
Remove wrapper.
1
Front Panel
Remove
screw
ner, and open
from upper left cor
front panel.
hinged
2
4-In-i Board PC3O
3
Spot Time
DIP Switch Si
Place switch in desired position:
Long Time for 0-5 seconds, and
Short Time for 0-2.5 seconds (see
Figure
4-13 for control
operation).
Close and secure front panel, and
reinstall wrapper.
Tools Needed:
c~~zJ=it1
1/4 in
SA-146 866-A / Ref. 5B-152 378
Figure
OM-i 583
Page
12
3-16.
Spot
Time DIP Switch Si
B.
Digital
Meter Functions And Positions
-
NOTE ~
The Digital Meter Board PC6O for the Two Meter Option is equipped with DIP switch
shipped from the factoiy in the Off position, and should not be
S3. This switch is
_____________________
changed.
DIP switch positions if a
different mode of operation Is de
sired.
Change
I
I
High Speed Motor
Standard Motor
Meters/Minute
Standard Motor
Inches/Minute
Motor
Meters/Minute
High Speed
Inches/Minute
Turn Off wire feeder and
1w
I
l~o
IN
1w
I
1w
Or
1
I~
Remove
I
1w
ner, and open
Or
C,
><-
><-
Low Speed Motor
Inches/Minute
Low Speed Motor
Meters/Minute
0~
1w
1w
1w
N
IN
1w
1w
,;:,
I
~
I
~
Or
1w
C,,
I
><
><
><
><
><
><
><
><
I
c~
><.-
><.-
screw
from upper left
cor
hinged front panel.
2
Digital Meter Board PC6O
3
Meter Functions DIP Switch
S2
><.-
Voltage Hold
I
Front Panel
I,,
I
I
~
I
Remove the three (3) screws from
front edge of wrapper.
1w
I
welding
source.
1w
IC-
IN
(;
I
I,
I~
power
Voltage
Monitor
Place DIP switch in appropriate po
sition for desired mode (see Figure
4-7 for meter operation). Some
units have
N
Or
U,
I
which
a 5-position DIP switch
corresponds to the bottom
five positions
switch shown.
Close and
of
the
secure
front
reinstall wrapper
9-position
panel,
and
screws.
I
Means place switch
in this position.
IC,,
X Means switch
in either
can
be
position.
3
2
Tools Needed:
czj=~n
1/4 in
sB-i 37 395-B / SA-135 461 -K / S-0389-A
Figure
3-17.
Digital
Meter Functions DIP Switch S2
OM-1583
Page
13
C.
Remote
Input/
Run-In DIP Switch Si
Change DIP
ferent
switch
mode
of
position if a
operation
dif
is
desired.
Standard
Dual Schedule Or
Remote Pendant
Turn Off wire feeder and
power
welding
source.
Remove wrapper.
1
Front Panel
Front
panel shown open for illustra
tion purposes.
Or
.
OFF
2
Option Interface Board PC7O
3
Remote Input/Run-In DIP
Switch Si
Place DIP Switch Si in appropriate
OFF
position for desired
Means place switch
in this position.
x
/
mode.
Close and secure front panel, and
reinstall wrapper.
Means switch can be
in either position.
3
2
Tools Needed:
c~zj=n
1/4 in
Ref. 8-0380 / ST-152 378 / SA-150 588-c
Figure
OM-1 553
Page
14
3-18. Remote
Input/Run-In
DIP Switch Si
3-15.
Changing Optional Digital Voltage
Control For Use With A MILLER
Inverter-Type
Power Source
WARNING
a
ELECTRIC SHOCK
can
Do not touch live electrical
STATIC ELECTRICITY can
on circuit boards.
kill.
parts.
Turn Oft wire feederand welding power source, and
disconnect input power before inspecting or
Put on
boards
grounded
parts.
damage parts
wrist strap BEFORE
handling
or
installing.
wfwaml.r v9~
A.
Electrical Connections
Turn Off wire feeder and
power
welding
source.
Remove the three (3) screws from
edge of wrapper.
front
If
optional Digital Voltage Control is
a MILLER inverter-type
welding power source, make the
following changes:
used with
1
Front Panel
Remove
screw
ner, and open
2
from upper left cor
front panel.
hinged
Digital Voltage
Control Board
PC4O
3
Receptacle RC42
Disconnect
from
PLG82
plug
RC42.
4
Receptacle
RC44
Reconnect PLG82 to RC44.
5
Receptacle RC45
Disconnect
from RC45.
6
jumper plug PLG61
Receptacle RC41
Disconnect
plug PLG43
or
PLG44
from RC41.
Reconnect PLG43
RC45.
Reconnect
or
PLG44 to
jumper plug PLG61
to
RC41.
7
Potentiometer R31
Calibrate
3-15B.
according
to
Section
Close and secure front panel, and
reinstall wrapper screws.
Tools Needed:
c~~~::::~:z:J=:=4J
1/4 in
ST-137 395-B / SA-134 539-B
Figure
3-19.
Digital Voltage
Control Connections
flM-1583
Page
15
B.
Calibrating
The
Digital Voltage
N OTE ~
Meter For Use With A MILLER
If wire feeder is
If wire feeder is
with One Meter
used with
a
MILLER
Power Source
inverter-type power source that has
no calibration is required.
a
range of 10 to 35 volts in the CV mode,
voltage
1.
being
Inverter-Type
equipped with Two Meter option, read voltage from the voltage meter. If wire feeder is equipped
option (see Figure 4-7 for meter operation), place Wire SpeedNoltage switch in the Voltage
position.
2.
Rotate Schedule A
for control
3.
4.
or
Schedule B
Voltage Control, whichever is active, to the maximum position (see Figure 4-9
operation).
Turn On wire feeder and
welding
power
source
(see Figure 4-16).
Adjust potentiometer R31 (see Figure 3-19 for location) until wire feeder voltage meter displays a voltage equal
voltage listed on the Voltage/Amperage control of the welding power source nameplate. Make a
sample weld (at desired preset voltage) to see if actual arc voltage displayed by the wire feeder voltage meter is
different than preset arc voltage due to cable resistance, poor connections, etc. If there is a difference, R31 can
be adjusted until preset voltage is closer to actual arc voltage.
to the maximum
3-16.
Threading Welding
A~
Wire
WARNING
CYLINDERS
can
Keep cylinders
explode
away from
if
damaged.
welding
and other
electrical circuits.
Never touch
WELDING WIRE
wounds.
Do not press gun
cylinder with welding
Always secure cylinder
stationary support.
electrode.
running gear, wall,
to
or
can
trigger
cause
puncture
until instructed to do
so.
Do not point gun toward any part of the body, other
people, or any metal when threading welding wire.
other
ELECTRIC SHOCK
can
Do not touch live electrical
kill.
HOT SURFACES
can
burn skin.
parts.
The welding wire, drive rolls, drive assembly, and all
metal parts touching the welding wire are electrically
live when welding or feeding wire using gun trigger.
Allow gun to cool before
touching.
wfwam2.1 /wfwam7.1 9/91
OM-1583
Page 16
1
1
Wire
2
Wire Tube
SpooVReel
3
Pulley
4
Wire Guides
5
Drive Rolls
6
Jog/Purge
7
Gun Conduit Cable
8
Pressure
9
Drive Roll Pressure Indicator
Scale
Switch
Adjustment Knob
5
8
Tools Needed:
7
Hold wire tight!ytokeep
it from unraveling.
(c0wTfrcT0~i
ON
OFF
OFF
ION
Wire Feeder
(see Figure 4-16)
Welding
Power Source
Set switches.
Pull and hold wire; cut off end.
Manually feed
wire thru tube, over
and up to wire inlel guide.
pulley,
wire is electrically
live when feeding welding
wire with gun trigger.
Welding
JOG
O~O
0
up to drive rolls; continue
Press gun trigger or Jog switch
until drove rolls grab wire. Adjust tension until
wire does not slip. Indicator is for reference only.
Push wire thru
to hold
welding
guides
wire.
Press trigger or Jog switch until wire comes out
out of gun. Feed wire to check drive roll pressure.
Adjust knob enough to prevent slipping.
Figure 3-20. Threading Welding
Cut off wire. Close
cover~
ST-i 52 760/ ST-i53 073/ Ref. S-0627-Al Ref. SC-i 50922
Wire
OM-1583
Page
17
SECTION 4- OPERATION
WARNING
a
ELECTRIC SHOCK
can
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
kill.
Do not touch live electrical parts.
Always
wear
Insulate
Keep
all
Wear
dry insulating gloves.
yourself
panels
from work and
and covers
FUMES AND GASES
S
ground.
securely
in
Keep
MOVING PARTS
,..~
~
to your health.
or use
breathing
can cause
Do not weld
near
Watch for fire;
or
on
Allow work and
I
explosion.
over
injury.
such
as
covers, and
drive rolls.
guards closed
MAGNETIC FIELDS FROM HIGH CUR
RENTS can affect pacemaker operation.
Pacemaker
wearers
flammable material.
keep away.
Wearers should consult their doctor before
~
keep extinguisher nearby.
Do not locate unit
Do not weld
fire
can cause
Keep all doors, panels,
and securely in place.
device.
Read Material Safety Data Sheets (MSDSs) and
manufacturers instructions for material used.
WELDING
body protection.
Keep away from pinch points
0
your head out of the fumes.
Ventilate area,
with correct shade of filter.
place
be hazardous
can
welding helmet
Wear correct eye, ear, and
near
.~
any
going
welding operations.
combustible surfaces.
closed containers.
equipment to cool before handling.
See Safety Precautions at beginning of manual for ba
sic welding safety information.
~am3.1 8/92
We ar the
following
while
welding:
1
Dry, Insulating
2
Safety Glasses With Side
Shields
3
Welding
Gloves
Helmet With Correct
Shade Of Filter (See ANSI
Z49.1)
sb3.1 1/94
Figure
4-1.
Safety Equipment
1
Work
Clamp
Connect work clamp to
paint-free
as
1
~/2
location
close to weld
area
Use wire brush or
clean metal at weld
2
a
clean,
workpiece,
as possible.
on
sandpaper
joint area.
to
Voltage Sensing Clamp
Connect to
workpiece (see Section
3-10).
Tools Needed:
sb4.1
FIgure
OM-1583
Page
18
4-2. Work And
Voltage Sensing Clamps
2/93/Ret. ST-144 451-A
~~jL~1
1
Voltmeter
2
Wire
3
Schedule A Wire
Control
4
Schedule A Voltage Control
5
Schedule B Indicator
2
(Optional)
Speed Meter (Optional)
Speed
(Optional)
Light
(Optional)
6
3
4
7
Schedule B Wire Speed
Control (Optional)
Schedule B
Voltage Control
(Optional)
8
PressToSetButton
(Optional)
11~
___
.
10~~
9
6
9
Jog/Purge Switch
10
Gun
11
Trigger Hold Switch
(Optional)
Trigger Receptacle
7
8
ST-151 845
Figure
4-3. Front Panel Controls
1
Jog Position
Push switch up to momentarily
feed welding wire at speed set on
Wire Speed control without ener
gizing welding circuit or shielding
gas valve.
2
Purge
Position
Push switch down to momentarily
energize gas solenoid and purge
2
air from gun shielding gas line, and
to allow shielding gas regulator to
be adjusted without energizing the
welding circuit.
The center
position
is Off.
Ret. ST-149 655
Figure
4-4.
Jog/Purge
Switch
1
Wire
Speed Control
Use control to select wire feed
speed in inches per minute.The
scale is calibrated in inches per
minute x 100.
This scale is not used with a meter
option. Read wire speed from me
ter
Figure
4-5. Wire
Speed
display.
Control
OM-1583
Page
19
1
1
or
Voltage Control
Use control
(one-turn control) to
voltage. The scale is for ref
erence only.
2
set arc
2
Digital Voltage Control (Op
Digital Meter(s) Need
ed)
tional
Use control (ten-turn control) to
arc voltage to the nearest
0.1 volt.
preset
When control is used with a
MILLER
inverter-type welding
powersource, the control functions
as a remote digital voltage control
and allows arc voltage to be preset.
Figure
4-6.
Voltage Control
Or
Digital Voltage
Control
(Optional)
TWO METER OPTION
1
Volts Meter
The Volts Meter is factory set to op
erate in the Voltage Hold mode
when unit is not equipped with Digi
VOLTS
V
______
WIRE SPEED
Two Meter
2
do
tal Voltage Control. This means
that 5 seconds after the trigger is
pulled, the meter holds the voltage
value displayed at that time. This
value is displayed while welding
and for 15 seconds after the gun
trigger is released. After 15 sec
onds the meter clears to zero volts,
or open-circuit voltage, if present.
Pulling the gun trigger again before
the 15 seconds has passed makes
the meter display arc voltage. After
5 seconds it holds the voltage dis
played
at that time.
The Volts Meter can be operated in
a
Voltage Monitor mode. This
means the meter displays actual
arc voltage while welding, and zero
volts (or open-circuit voltage, if
present), or preset voltage if unit is
equipped with Digital Voltage Con
trol, when not welding. See
Figure 3-17.
Option
2
Wire
Speed
Meter
WIRE SPEED! VOLTS
The Wire Speed Meter is factory
set to display Inches Per Minute
(ipm). To change display to Meters
Per
Minute
see
(mpm),
Figure 3-17.
~o/v
Units
equipped with a high speed
factory set to display the
high speed motor rate of wire feed
in inches per minute (1pm). To
change display to Meters Per Min
ute, see Figure 3-17.
motor are
4
ONE METER OPTION
3
Wire
SpeedNolts Meter
Depending upon position of Wire
Wire
switch,
SpeedNoltage
SpeedNolts Meter operates same
as meters
One Meter
Option
4
Wire
1 and 2 above.
SpeedNoltage
Place switch in desired
Figure
OM-1583 Page 20
4-7.
Digital Meter(s) (Optional)
Switch
position.
1
Trigger
Hold Switch
To start preflow, and feed
wire without holding gun
welding
trigger,
place switch in up position, and
press and release gun trigger. To
end weld and start Burnback and
Postflow, press and release trigger.
Trigger Hold cannot be used
when Spot/Continuous switch
in the Spot position.
Figure
4-8.
Trigger
Hold Switch
is
(Optional)
Dual Schedule
Schedule Controls
Digital
Or
Dual
Dual Schedule controls are onepotentiometers, and Digital
turn
Dual Schedule controls
3
are
ten-
turn
potentiometers.
1
Schedule A Wire
Control
Speed
2
Schedule B Wire
Control
Speed
3
Schedule A
Voltage Control
4
Schedule B
Voltage Control
5
Schedule B Indicator Light
Schedule A or B controls will be ac
tive depending on the position of
the dual schedule switch. When
Schedule B is selected, Schedule
B indicator light is on. When the
5
light is oft, Schedule
A is selected.
For Digital Dual Schedule only, the
Wire Speed Meter (see Figure 4-7)
displays wire feed speed for
Schedule A or B, depending on the
position of the dual schedule
switch. The Volts Meter (see
Figure 4-7) displays preset voltage
to the nearest tenth of a volt for ei
ther Schedule A or B, depending on
the position of the dual schedule
switch.
6
Press To Set Button (Digital
Dual Schedule Only)
The Press To Set button allows the
operator to preset Schedule B volt
age andJor wire feed speed while in
Schedule A. To preset Schedule B
voltage and/or wire feed speed,
push and hold Press To Set button
and adjust control(s).
6
NOTE ~
Figure
A dual schedule switch for the gun is required for use with this option. Obtain
proper dual schedule switch and install switch according to its instructions.
4-9.
Digital
Dual Schedule Or Dual Schedule Controls
a
(Optional)
OM-1 583
Page
21
1
Circuit Breaker CB1
Section 5-3)
2
Run-In
3
Spot/Continuous
4
Postf low Control
5
Burnback Control
6
Spot Time Control
7
Pref low Control
(See
Speed Control
Switch
4
I
10
Oo
o
0000
Ref. ST-142 741-A/ ST-152 643
Figure
4-10. Inner Control Panel Controls
(Optional)
1
Preflow Control
Use control to
flows before
adjust the time gas
wdding wire is
energized.
1
Ref. ST-133 379-A
Figure
4-11. Preflow Control
(Optional)
1
RUN-IN SPEED
400
2OOE~~O
ing run-in, the selected speed is
displayed by wire speed meter if
unit is so equipped.
700
~
Figure
OM-1583
Page
22
Speed Control
Use control to select the rate at
which welding wire feeds after pre
flow and before arc initiation. Our
300
1O0~ ~ ~
Run-In
1
4-12. Run-In
This unit is factory set to provide
Run-In Speed control without volt
age sensing. For Run-In Speed
control with voltage sensing, see
Figure 3.18.
Speed
Control
(Optional)
SPOT
1
Spot/Continuous Switch
Use switch to select either an un
timed continuous weld cycle or a
timed spot weld cycle. A continu
ous weld cycle consists of the fol
lowing
CONTINUOUS
sequence:
trigger pull,
pre
flow, run-in, untimed weld, trigger
release, burnback, and postf low.
2
A
spot weld cycle consists of the
following sequence: trigger pull,
pref low, timed weld cycle, or trigger
release, burnback, and postf low.
4
2
.5
2
Spot Time Control
This unit
comes factory set to pro
vide 0 to 5 seconds of spot time
control. If 0 to 2.5 seconds of spot
time control is
required, see
Figure 3-16.
5
Figure
4-13.
Spot/Continuous
Switch And
Spot
Time Control
(Optional)
1
1
Burnback Control
Use control to adjust the time that
the welding wire is energized after
wire feeding stops.
By adjusting control properly, the
welding wire does not freeze in
weld puddle or in contact tip of gun.
If welding wire freezes to work, in..
crease burnback time. If welding
wire burns back into contact tip, de
crease
Figure
4-14. Burnback Control
bumback time.
(Optional)
1
1
Postliow Control
Use control to adjust time gas flows
after completion of burnback cycle.
Figure
4-15. Postflow Control
(Optional)
1
a
~
1
Power Switch
o
0
Use power switch to turn unit On
and Off.
~
~C~~=)=)
~
~
Ref. ST-i 42 708-8
Figure
4-16. Power Switch
OM-1583
Page 23
WARNING
4~
BUILDUP OF SHIELDING GAS
harm health
can
Shut off shielding gas supply when not in
or
kill.
use.
waml.1 9191
Customer-Supplied Shielding
Cylinder
1
3
Gas
1
Valve
2
Open valve
welding.
on
cylinder just before
Close valve on cylinder when fin
ished welding.
Regulator/Flowmeter
3
sb5.1
Figure
)
Feeder))
)
Install &
Connect
Wire
Prepa~
nstall And
Gun And
Power
Put On
Personal
)
Shielding
~\ ~\
Gas
Set
Safe~))
Source~,/)
All
Controls
Equipment
S-0621-C
))
Shield~~\
})I~Sourc~II~~
Turn On
Gas
(If Applicable)
Turn On
Wire Feeder And
~ ~\ Readjust Cont~\
Do
)
Sample
Weld
Figure
~\
4-17.
1/92
)
JJ
And Prepare
For Production
4-18. Gas Metal Arc
J
Welding (GMAW)
And Flux Cored Arc
Welding (FCAW)
SECTION 5- MAINTENANCE & TROUBLESHOOTING
a
WARNING
ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
TurnOffwirefeederandwelding powersource, and
disconnect
maintaining,
from
can cause
injury.
can cause severe
burns.
cooling period before servicing gun
or
unit.
such
Maintenance
to
performed only by qualified
be
persons.
moving parts.
Keep away from pinch points
5-1.
inspecting,
Allow
or
MOVING PARTS
Keep away
before
input power
servicing.
S
HOT PARTS
as
drive rolls.
wfwam4.1 2/93
Routine Maintenance
Table 5-1. Maintenance Schedule
6 Months
Oft all power before maIn
a Turn
taining.
Blow Out
Or
Vacuum
Inside
I
Service
Clean Monthly
During Heavy
Clean
Drive
Rolls
OM-1583
Page
24
5-2.
Replacing
The Hub
Assembly
READ SAFETY BLOCKS at start of
Section 5 before proceeding.
Turn Off wire feeder and welding
power source. Retract wire onto
spool and remove. Take hub apart
as shown.
9
1
Retaining Ring
2
Nut
3
Flat Washer
4
Spring
5
Keyed Washer
6
7
8
65
6
FiberWasher
7
Brake Washer
8
Hub
9
HubSupport Shaft
4
3
Replace worn
slide parts
shown.
Tools Needed:
or
broken parts, and
shaft in order
onto
hex nut until a slight force
is needed to turn hub. Install weld
ing wire (see Section 3-12).
Tighten
15/16 in
ST-142 709
Figure
5-3.
5-1. Hub
Assembly
Overload Protection
READ SAFETY BLOCKS at start of
Section 5 before proceeding.
Turn Off unit and
welding power
source.
1
Circuit Breaker CB1
CB1 protects the wire feeder from
overload. It CB1 trips, the wire
feeder shuts down.
Allow
reset
cooling period
breaker.
and
Close
manually
and
latch
door.
Ret. ST-~42 74~-AI ST-152 843
Figure
5-2. Circuit Breaker CBI
()M-1583
Page
25
5-4.
Troubleshooting
WARNING
a
ELECTRIC SHOCK
kill.
can
HOT PARTS
Do not touch live electrical parts.
Allow
can cause severe
burns.
cooling period before servicing gun
or
unit.
Turn Off wire feeder and welding power source, and
disconnect
input power before inspecting,
maintaining,
or
servicing.
MOVING PARTS
Keep
away from
can cause
injury.
moving parts.
;hooting
Keep away from pinch points such
as
Table 5-2.
Troubleshooting
~
-~
Wire feeder is on, meter(s) do not light
up, motor does not run, gas valve and
welding power source contactor do not
pull in.
i.
-~
Electrode wire feeding stops
erratically during welding.
or
Check interconnecting cord connections.
continuity and repair or replace.
If secure, check cord for
1--i 3.8
Check and reset CB1.
5-3
Check gun
trigger connection.
Check gun
trigger.
3-6
-~
--~
Readjust
drive roll pressure.
----
3-16
Readjust
hub tension.
--~
3-12
---
3-5B
--~
5-1
--~
3-5A
Change
to correct size drive roll.
or
replace dirty
Incorrect size
Replace
ing
wire
contact
tip
or
drive roll.
guides.
liner.
--~
matter from around nozzle open
--~
Factory Authorized Service Station/Service Distributor
--~
with
Have
or worn
or worn
Remove weld spatter
a
or
foreign
wood stick.
check drive motor
or
motor control board PCi.
-.~ Check for correct input voltage.
slowly.
Wire does not feed until trigger is pulled,
but continues to feed after trigger is re
leased, and trigger hold is not on.
Gas valve in feeder is
--~
or
Check for
cable.
rattling loudly
erratic
]
I
Clean
along with possible
feed speed.
Section
Remedy
Wire feeds, shielding gas flows, but
electrode wire is not energized.
runs
performed only by qualified
wlwam4.r 2/93
Trouble
Motor
to be
drive rolls.
--~
slow wire
Unit does not switch out of Run-In
~
Speed.
I
-~
a
-
I
short between welding gun trigger leads and weld
short or replace welding gun.
Repair
Check for a short between welding gun trigger leads and weld
cable. Repair short or replace welding gun.
Install, reconnect,
or
replace reed relay
or
voltage sensing
lead.
~
-~
3-10
I
____________
OM-1 583
Page
26
Trouble
Section
Remedy
Wire feeder power is on, meter lights up,
but unit is inoperative.
-~
I
i
-~
Wire Feed Speed Meter display does
not match actual wire feed speed.
~
-~
arc voltage display on meter is
held after trigger is released, or arc volt
age does not change while welding.
~
DiP Switch Si(l)
On position.
Option
on
Set DIP Switch S2
on
1
Interface Board PC7O must be in the
Meter Board PC6O in Inches/Minute
-~
I
j__-.._Figure4-16
Turn off power to unit to reset 4-In-i circuit board PC3O.
Schedule A Wire Feed Speed works,
but Schedule B Wire Feed Speed does
not work or is erratic.
1
welding gun trigger leads for continuity, and repair leads or
replace gun.
Check
model
-~
3-14C
-~
3-14B
-~
3-i 4B
I
Actual
-~
Set DIP Switch S2
on
Meter Board PC6O in
~
Voltage Monitor mode.
SECTION 6- ELECTRICAL DIAGRAMS
r12
r
I
PLOS8
/
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2~ 2
<12 E~<
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DETACI+IENT
<
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LP5~2~V_
RC6
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PLG78
2
RCI..3>>1
(.1
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__________
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S
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RC4-6
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OR
DETACII4ENT
OPTION
AA
I
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LJSZDWITH
SWINGAPC
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I
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USED WITH SWINGARC
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I
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vvvvv
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c
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PZAA
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PLO 19
<I
F(~
5B-164 371
-<2
Figure
6-1. Circuit
Diagram
For Wire Feeder
OM-i583
Page
27
>-
I
TRIGGER
I
72
13>
>3 >~
I
>21
~F
~ELD
_________
TRIGGER
RECEPTACLE
_______________
I
2>~-
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<<RC3-2
>11>
RCA
~
<(RC4-5
I
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OEIAcI+ENT
~TI~
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OR
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PCI-I
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6
RCI-2
>>~
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I
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(<RC4-I0
MITOR BOARD
RC4-2
~OSl
7
RC I-B>
8
A
(
~J
(ORTI~4AL1
PREFLOW
POSTFLOW
SPOTTIIE
BLPI~6ACK
TRIGGER I0D
RC3I-5
>_?~_<<
>-L~~.<<
.
PC3O
RCII-7
RC3I/PLGI I
RC35/PLG3D
RC3I-8
RED/PIGS
I
I
J
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P1~G 10
~
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RC4/PLG4
~RC4-4
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6~-<6<~
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5
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PCI-B>
RC2/PLG2
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>-~-<<RC3I-6
>-~<< RC3I-2
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>_L_.<< RC3I 4
PC I /PLG I
P~GE
~
RCI-3>
RCI-7>
/
£
).Z~_(<RC3I~I~
I
RC3-3
___________
r
PLG I
1Z<RC3-l
MEN USED
AS SWftGARC
-
~ r~SPOT
2/
~
>
2 H~
RC6/P1_G6
Z~RC4-6
2/
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~<<
PLGB2~
RC2-I
RC4- I
PC2-2>
2
RC2-3>
3
RCA- I
___________
j~._J11Lz
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RcBO
-
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RCB4-I
PGB6/PLG56
~
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>
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PCBO
RCB3-2
PLGB4
>
pC54-2>
BOARD
RC2-4
RC6-3
>>-~
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RCS3-4
PCB4-4>
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RC5~-6
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L
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PLGI9
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P1.0374
WIRE
SPEED
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p
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P10334,1
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P1.67
P1G57
~
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PC6O
I
ITAc~BETERI
I
I
I
,~
MEN DIGITAL ~TER
ORTIOR IS USED.
PLG63 IS PLUGGED INTO RC4~
PLGB(R2) IS REMOVED FROI RED
PLGB(R6) IS PLUGGED INTO RCB
I
I
RC63-2>2~
I-,
4
I
__________
I
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I
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<<RC42-3
32
A
I
I
A
A
I
<<RC42-
RC42-PLGB2
PC43-PLG42
RC44-
RC4S-PU161
DVC
<<RC4A-3
~__j
RC4I-PLG6I
ci,
~
UPTI~AL)
FOR RC/Pt.G CGECTI~
SEE MOTES
I
<(RC64-
Diagram
lIEN DIGITAL V~TAGE CQ9TRU
IS USED WITH AN INVERTER
ThE F~LOWIPG
COPIIECTICRAS AT PC4O,
POWER SCLRCE MAKE
RC4B-4>>--1
I
~WN WITh COVENTIONAI.
POWER SQ.mCE CZBIIECTI~S
RC4B- I>
P1.643
~ I
-3>>~-
~ >
RC4 I
-2>>~_&I~13
2 )
RCA
For Wire Feeder With
RC42-N/C
RC43-PLG42
RC44-PLGB2
RC45-P1.044
4>
RCA 1-4>
I.I)>~~ _Y3CW
I
6-2. CIrcuit
N/C
________
PC4O
I
<<RC44-2
Figure
LEAD
IORTI~1AI_)
RC4I-PLG44
RC45-2>
I
PLG85
J
A
I
_______
PLG7I
VILTAGE
I
~
~-< RC42-2
17
lIEN DVC ORTIOR IS USED.
PLG85 IS PLUGGED INTO PLGTh
P1.064 IS REMOVED FRO4 RC64
P1.641 IS PLUGGED INTO P644.
Page
10J51M3
A
,,
CW
L
28
TO ORIVE
IBEN DIGITAL VI~TAGE cORTRI2_
IS L~D WITH A C3~VENTIDAAL
POWER S~PCE MAKE TFE FOLOWDG
c~,ECTI~S
AT PCAO,
V
V
V
V
V
ISP ISP 157 56 55 /0
I
<3
65
I
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PLG4IV
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65
r
REMOTE RO_TAGE
CDNTR(L
A(OPTIONAL)
I
(DPTIORAL)
MEN REMOTE VD..TAGE C~ATRO. CPTIOR IS USED.
P1_Gil IS PLUGGED INTO PLG7S.
I
PIO(-LP
(Y10~AL1
I
-
DIGITAL
~ETER
BOARD
________V
OM-1 583
SWIPOARC
PLG7y,0V~
SILO ~
PLGIO
AS
73
V
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P1033w
J.~J/oJ/oJ66J6o
WIENI.65D
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ci
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273
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~
RC2-B
Rc2-6
SPEED
>~
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(ORTI(BAAL)
L
WIRE
2
TACIETER
RC5~3-3
56
5,
________________________
I
DIGITAL VCLTAGE
6
cONTRO.
Optional Equipment
>
WPN
SPOT/B&~PeACK PRE-FLOW/
POST-FLOW AlL) TRIGGER lO..D
~ BI.Rl8A0C ~TION IS USED.
PLGI(J.APER) IS RDL)VED FRO4
PCI P161 FR~4 EITIR
OPTIGI
IS PLLL)GED INTO PCI.
PLOt
>
I
6
2
3
4
<<RCII-I
> ~-< PCI 1-6
> < PC I -2
> <<RCII-3
~
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(~TI~4AL)
RCII/PLGII
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7
>
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>
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((PCII-8
~ RC78-2
~- PC18-
USD81
MiEN
P134-IN C~4TR~ ~TI~4.
REICVE P1676 FROM RC76
P1677 IS PUMICED INTO PC76
I
r
<(
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P1677
I
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RC7O
6>~IM
RC76-6 >
P1670
<4(
J
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<<
PC79-4
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(<
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INTERFACE BOARD
RC76-4
>
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I
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~
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RC76/P1G76
I
(~TIONAL)
L
RC78/PL678
RC79/P1679
MiEN USD81 DIGITAL DUAL SC*ED(.LE
~TII39.
IS PUMICED INTO P1675
IS PUMICED INTO PC4I
IS PUMICED INTO P1644
IS PILMIGED INTO P1647
PL672 IS PUMICED INTO PC72
P1674 IS PuMICED INTO PC7S
lOT C~ECTI~4S ARE MADE.
P1685
P1643
P1645
MiEN INTERFACE CPTIOM IS USED.
CI)*ECT PL654 TO RC2. OM MiEN
PCSO IS USED C~IIECT P1654 TO
PCS4 I. P1652 TO RC2 WITH P162
WIEN USD81 DUAL SClEDU.E ~TIa4.
P1675 IS PLL81GED INTO RC75
PLG72 IS PLL81GED INTO RC72
701 C~ECTI~IS ARE MADE.
P1688
MiEN USD81 REI4~TE PEIICANT
PLG7S IS P1181050 INTO Sd!
70T C~CTI~MI
ARE MADE.
r
I
DUAL
SOEDLLE
(~T62IAL)
I
DIGITAL DUAL SQEIELE
REICTE PEJL)ANT
(~TI~IAL)
I
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I
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SPEED
PE~MIANT
I
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I
I
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_____________________________________________________________
I~j
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<<
STLO
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80
60
I
_________
90
70
C7I
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RC72-I
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~
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Cw
P1649
_j
SD-164 370
OM-1 583
Page
29
cw
2C (CS I)
PLG33
Figure
OM-1583
Page
30
6-3.
Wiring Diagram
For Wire Feeder
00 NOT
PLGI9
TIE
TO HARNESS
FREE.
PL675
PLG78
10
SPLICE
42
00 NOT TIE P1056 TO HARtESS.
ALLOW TO HAJ~G FREE IN
POSITI~ SH~WN.
I~.
)
RC37
PLG38
C
N
r
CM
I.,
I,
0
C
C
N
-C I)
I
I
C
p
r
U
C
C 0
N
x
3
SD-164 473
OM-1 583 Page 31
SECTION 7- PARTS LIST
U)
cJ
N.
U)
-
Li~
U,
F
C)
C
IJI_L~
C.,
N.
0)
LI~
C.)
C
U,
cJ
Co
C
Co
F-N.
C~J
~
U-
00
c~j
Figure
OM-1 583 Page 32
7-1. Main
Assembly
ST-142 600-1<
Quantity
Item
No.
Dia.
Model
Part
No.
Mkgs.
Description
Figure
1
7-1. Main
I
..
149252
PLG23
...
PLG24
...
3
1
..4....
..2....
.l7ft..
..
4
1
.1
1
.2....
17ff
..
1
....
.2....
5
REED
PLG7O
10
11
12
13
.
.
1
PIPE POST, 6ft w/base
,078264..
PIPE POST, 4ft w/base
15
,079216..
16
,075078..
PIPE POST, 6ft w/base
PIPE POST, 4ft w/o base
16
,079217..
20
.
.
PLG33
...
PLG7
22
23
24
25
26
..
GS1
....
1
4
8
4
1
1
1
1
or
1
or
(consisting of)
CONNECTOR, circ skt push-in 14-lBga
048 144
CONNECTOR, circ pin plug keying
135409.. CONNECTOR & PINS, (consisting of)
114656.... CONNECTOR, rectskt24-l8ga
115092.. CONNECTOR & SOCKETS, (consisting of)
113 746
CONNECTOR, rect skt 24-1 8ga Molex 39-00-0038
605 227.. NUT, nyl hex jam .75ONPST
125 785.. VALVE, 24VAC 2 way custom port 1/8 orf
134834.. HOSE, SAE .187 ID x .410 OD (order by ff)
139265.. COVER, motor & components
156243.. CLAMP, motor top
+159 360.. INSULATOR, screw machine
145 639.. STRIP, buna N compressed sheet .062 x 4.000sq
....
....
21
or
PIPE POST, 6ft w/o base
BOOM ASSEMBLY
CONNECTOR & SOCKETS,
..
19
4
1....
,149839..
Fig7-5..
1
.4....
4
hub & reel
15
047 637..
.1....
NUT, stl hex full .375-16
15
079 534
2
30ff
1
PIPE POST, 4ft w/base
RC37....
..
.1....
149838..
.
26ff
.1....
15
18
..
.2....
2
30ff
....
Fig7-2.. SUPPORT,
17
26ft
2
..
601872..
14
2
21ff
.1
.2....
..
2
14...14
.2....
..
....
2
21ff
.1....
..
..
4
..4....
..
PLG37,38
16
Assembly
CABLE, trigger (consisting of)
CABLE, trigger (consisting of)
CONNECTOR & PINS, (consisting of)
079 878
079535
CONNECTOR, circ pin push-in 14-l8ga Amp 66359-6
079531
CONNECTOR, circ clamp str rif size 11 Amp 206358-2
605156
CABLE, port No. 18 4/c (order by ft)
CONNECTOR w/SOCKETS, free hanging (consisting of)
080328
079 534
CONNECTOR, circ skt push-in 14-l8ga Amp 66358-6
CONTROL BOX, (Fig 7-3)
See Note
164 475.. CABLE, interconnecting (consisting of)
164 474
CABLE, interconnecting (consisting of)
047 636.... CONNECTOR & PINS, (consisting of)
079 535
CONNECTOR, circ pin push-in 14-l8ga
079 739.... CONNECTOR, circ clamp str rlf sz 17-20
163519.... CABLE, port No. 18-14 8/c (order by ft)
139 600
HOSE, gas (consisting of)
139 599
HOSE, gas (consisting of)
010 603
FITTING, hose brs barbed nipple 1/4tbg
010 606
FITTING, hose brs nut .625-18RH
603 106
HOSE, nprn brd No. 1 x .250 ID (order by ft)
056 112
FITTING, hose brs ferrule .475 ID x .718 Ig
600 323.. CABLE, weld cop strd No. 3/0 (order by ft)
.140789
SWITCH, reed (consisting of)
079 531
CONNECTOR, circ clamp str nt size 11 Amp 206358-2
079 878.... CONNECTOR & PINS, (consisting of)
079 535
CONNECTOR, circ pin push-in 14-lBga Amp 66359-6
149884.
BRACKET, spring retaining
080947.. BRACKET, spring retaining
132053.. SCREW, cap sti hexhd .375-16 x 1.500 Ig
602243.. WASHER, flat stl std .375
602213.. WASHER, lock stl split .375
149 251
12
1....
1
1....
1
1....
1
1....
1
14
14
2
2
1
1
8
8
1
1
8
8
1
1
1
1
2ff
2ff
1.
1
1.
1
4.
4
1.
1
OM-1583 Page 33
Quantity
Item
No.
Dia.
Model
Part
No.
Mkgs.
Description
Figure
..
27
..
27
.167 774..
..
27
.167 775
.167776
..
27
..
27
..
27
..
28
..
29
..
30
31
..
32
..
167 773
.
.
.
.
.
.
.
.167 777..
.
.167 778
157 295
604 612..
.
.
.
.
082 050..
159 646
159 647
Note: When
Part of
.
.
.
.
7-1. Main
Assembly (Continued)
DRIVE ASSEMBLY, wire
DRIVE ASSEMBLY, wire
DRIVE ASSEMBLY, wire
DRIVE ASSEMBLY, wire
DRIVE ASSEMBLY, wire
(Fig 7-6)
(w/tach) (Fig 7-6)
(high speed) (Fig 7-6)
(high speed w/tach) (Fig 7-6)
(low speed) (Fig 7-6)
(low speed w/tach) (Fig 7-6)
DRIVE ASSEMBLY, wire
GUIDE, monocoll
SCREW, set stl sch 8-32 x .125 cup
LINER, monocoil inlet wire
service
1
1
..
point
department for proper
..
.
.
1
..
.
.
1
1
.
.
.
.
1
1
.
.
.
.
1
.
.
.
.
.
.
.
.
1
.
.
.
.
1
.
.
.
.
2
.
.
.
.
.
.
.
.
..
.
.
1
1
2
1
CLAMP, motor base
INSULATOR, motor clamp
ordering Control Box contact factory
Optional 132 131 Run-In Control.
16
12
1
1
number.
,OPTIONAL
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1583
Page
34
1
1
1
1
1
14
Part
No.
Item
No.
Figure
3
142399..
010191..
058628..
4
058428..
5
108008..
124900..
+168104..
1
2
6
7
166594..
168103..
057971..
8
9
10
11
12
13
010233..
605941..
136684..
058427
Quantity
Description
7-2.
Support,
Hub & Reel
(Fig
7-1 Item
14)
SUPPORT, reel
WASHER, fbr .656 ID x 1.500 OD x .l25thk
WASHER, brake stl
HUB, spool
REEL, wire 60 lb (consisting of)
SUPPORT, reel spool
RETAINER, spool support (consisting of)
LABEL, caution falling wire reel can cause damage
NUT, spanner spool support
WASHER, flat stl keyed 1 .500dia x .125thk
1
2
2
1
1
1
1
1
1
1
SPRING, cprsn .9700Dx .l20wirex 1.250
WASHER, flat stl .640 ID x 1.000 OD x l4ga thk
1
NUT, stl slflkg hex reg .625-11 w/nylon insert
RING, retaining spool
1
1
1
2
3
5
2
10
12
13
14
8
ST-i 46 339-A
Figure
7-2.
Support,
Hub & Reel
OPTIONAL
+When
ordering
a
component originally displaying
a
precautionary label,
the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1583
Page
35
N
O
.-
N
c~J
/\
I
/
/
0
/
cj
/
.-
c\J
c~jc.,J
(~
c,J
/
L()CD
c\J
C~J
C\j
/
c~)
0
c~)
c~)
I
Co
ST-146 338-C
Figure
OM-1 583
Page
36
7-3. Control Box
Item
No.
Dia.
Part
No.
Mkgs.
Figure
1
.
..
.
RC6
...
Quantity
Description
048 282..
7-3. Control Box
(Fig
7-1 Item
2)
CONNECTOR w/SOCKETS, (consisting of)
CONNECTOR, circ ski push-in 14-l8ga Amp 66358-6.
1
079 534....
2..
3..
4..
.S31...
S2
R2
.134847..
....
134846..
....
073562..
059712..
5..
6..
RC7O
.
,048282..
079534..
7..
010493..
8..
Fig7-4..
9..
.CB1
..
10
134201
136339..
11
SWITCH, tgl SPDT 15A 125VAC
SWITCH, tgl SPTT 15A 125VAC
POTENTIOMETER, C sltd sft l/T 2W 10K ohm
CLIP, component .437dia mtg adh back
CONNECTOR w/SOCKETS, (consisting of)
CONNECTOR, circ skt push-in 14-l8ga Amp 66358-6....
BUSHING, snap-in nyl .625 ID x .875mtg hole.
1
1
1
2
1
4
1
CONTROL PANEL
CIRCUIT BREAKER, man reset 1 P 1OA 250V.
STAND OFF SUPPORT, PC card .3121.375
8
COVER, opening
1
1
1
meter
ONE METER, w/tach
.,132135..
(consisting of)
TWO METER, w/tach (consisting of)
.,148098..
600399...
WIRE, lead mot l4ga (order by ft)
603106...
HOSE, nprn brd No 1 x .250 OD (order by ft)
11
12
13
14
083432..
4
1
1
35ft
ift
601222...
CLAMP, univ 50A
PLG56
131 204.. CONNECTOR & SOCKETS, (consisting of)
113746.... CONNECTOR, rect ski 24-l8ga Molex 39-00-0038
PLG63
138045.. CONNECTOR & SOCKETS, (consisting of)
081 378.... CONNECTOR, rect ski 22-lBga Amp 102100-2
,,132 131
RUN IN CONTROL, (consisting of)
600 399.... WIRE, lead mot l4ga (order by ft)
603 106
HOSE, nprn brd No. 1 x .250 OD (order by ft)
601 222
CLAMP, univ 50A
PLG77
115 093
CONNECTOR & SOCKETS, (consisting of)
113746....
CONNECTOR, rect ski 24-l8ga Molex 39-00-0038
1
1
3
1
..
.
12
13
14
R71.
C61.
15
16
17
18
19
Si
.PLG1O
2
1
.
35ft
itt
1
1
6
POTENTIOMETER, C sltd sft lIt 1W 10K ohm
KNOB, .i25dia shaft w/.125 set screw
BUSHING, strain relief .120/.150 ID x .500mtg hole
CONNECTOR, circ pin plug keying Amp 200821 -1
121 771
1
093551
138044....
048 144....
147853.... CAPACITOR
For Additional Parts see Fig 7-1
139 596.. PANEL, side lower
151187.. LATCH, slide flush mtg hole 1.000 wide x 1.500 Ig
+133337.. WRAPPER
134 464.. LABEL, warning general precautionary
iii 997.. SWITCH, rocker SPST iOA 25OVAC
141 162.. CONNECTOR & PINS, (consisting of)
134 731
CONNECTOR, circ pin push-in 14-l8ga Amp 213603-1
079 739.. CONNECTOR, cir clamp str rlf size 17-20 Amp 206322-2
163519.. CABLE, port No. 18/14 8/c (order by ft)
010325.. BUSHING, strain relief .840 ID x .875mtg hole
147859.. CAPACITOR ASSEMBLY
158719.. CONNECTOR & PINS, (consisting of)
147996.... CONNECTOR, rect pin 22-l8ga
1
1
2
1
1
1
1
1
1
1
14
....
20
21
22
23
C1,2
PLG19
PLG75
131 204..
113746
CONNECTOR & SOCKETS,
1
12ft
1
1
1
2
(consisting of)
1
CONNECTOR, rect ski 24-1 Bga Molex 39-00-0038
035 704.. RECTIFIER, integ 40A 800V
133965.. CASE SECTION, bottom/rear
047 637.. CONNECTOR & SOCKETS, (consisting of)
079 534
CONNECTOR, circ ski push-in 14-l8ga Amp 66358-6
048 144.. CONNECTOR, circ pin plug keying Amp 200821-1
115092.. CONNECTOR & SOCKETS, (consisting of)
113746.... CONNECTOR, rect ski 24-l8ga Molex 39-00-0038
135409.. CONNECTOR & SOCKETS, (consisting of)
114 656.... CONNECTOR, rect pin 24-l8ga Molex 39-00-0040
3
....
24
.SR1
25
26
RC4O
1
1
1
14
....
PLG39
RC7
2
1
8
1
8
OM.1 583
Page
37
Dia.
Item
No.
Part
No.
Mkgs.
Description
Figure
27
....
PCi
PLG1
....
....
PLG2
....
PLG3
....
PLG4
....
PLG5
...
PLG6
...
.
7-3. Control Box
(Fig
Quantity
7-1 Item
2) (Continued)
155114.. CIRCUIT CARD, motor control
115092.. CONNECTOR & SOCKETS, (consisting of)
113746.... CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
115093.. CONNECTOR & SOCKETS, (consisting of)
113746.... CONNECTOR, rect skt 24-lBga Molex 39-00-0038
115094.. CONNECTOR & SOCKETS, (consisting of)
113746.... CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
115 091
CONNECTOR & SOCKETS, (consisting of)
113746.... CONNECTOR, rect skt 24-lBga Molex 39-00-0038
130 203.. CONNECTOR & PINS, (consisting of)
113746.... CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
136810.. CONNECTOR & SOCKETS, (consisting of)
114066.... CONNECTOR, rectskt2o-14gaAmp350536-1
..
DUAL SCHEDULE, (consisting of)
CLIP, LED mtg
134209.... NUT, speed push-on type .250
158059.... LED, 5100 2.OV 2OmA
131 054.... CONNECTOR & SOCKETS, (consisting of)
113 746
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
073562.... POTENTIOMETER, C sltd sft l/T 2W 10K ohm
097 922.... KNOB, pointer
.134 379..
112 061
....
28
29
...
LED71
PLG72
..
R72-74
..
..
.
28
29
...
LED71
..
PLG43
...
PLG45
...
PLG47
..
PLG68,74
30
31
32
.134 684.. DIGITAL DUAL SCHEDULE, (consisting of)
134209.... NUT, speed push-on type .250
158059.... LED, 5100 2.OV 2OmA
115 094.... CONNECTOR & SOCKETS, (consisting of)
113 746
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
115090.... CONNECTOR & PINS, (consisting of)
114 656
CONNECTOR, rect pin 24-l8ga Molex 39-00-0040
131 203.... CONNECTOR & PINS, (consisting of)
114 656
CONNECTOR, rect pin 24-l8ga Molex 39-00-0040
131 204.... CONNECTOR & SOCKETS, (consisting of)
113 746
CONNECTOR, rect skt 24-lBga Molex 39-00-0038
131 054.... CONNECTOR & SOCKETS, (consisting of)
113 746
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
603 856.... POTENTIOMETER, WW sltd sft 10112W 10K ohm
097 922.... KNOB, pointer
153 195.... NUT, face al .250-40
150 981
BU1TON, switch black
150982.... SWITCH, PB MC SPDT 6A 125VAC
.
PLG72
..
R76,77
..
....
....
S71
....
33
34
~
35
36
37
.134 381
145 948..
097 922..
..
149657..
120 304
119 951
107 983..
024 103..
000 527..
..
..
.
Part of
Option
132 137
DIGITAL VOLTAGE CONTROL, (see
BRACKET, mtg control box
optional equipment)
KNOB, pointer
NAMEPLATE, (order by model and serial number)
PANEL,
BLANK,
BLANK,
BLANK,
BLANK,
BLANK,
Spot/Burnback,
front
snap-in
snap-in
snap-in
snap-in
snap-in
nyl
nyl
nyl
nyl
nyl
.25Omtg hole
.437mtg hole
.SOOmtg hole
.75Omtg hole
.875mtg hole
Pref Iow/Postf low.
Option 132 131 Run-In Control.
. .
Part of
..
,OPTIONAL
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1 583
Page
38
1
1
8
1
6
1
4
1
10
1
12
1
4
1
1
1
1
1
2
3
3
1
1
1
1
4
1
4
1
3
2
3
1
2
2
2
1
1
1
1
1
1
1
1
6
4
2
1
2
Item
No.
Dia.
Part
No.
Mkgs.
Description
Figure
..
.
.1
.
2
...
..
S32
PC7O
..
.
.
PLG54,76
PLG79
.
.
.
..
.
.
.
.
5
6
.
.4
.
.
.
.
5
6
.
.
7
..
.
8
..
PC1O
..
PC3O
PLG35
..
7
.8
.
150
115
113
115
113
115
+115 094
113 746
...
.
.132 139
126 689
.
.
.
..
...
.
PLG1,11
.
.
4
PLG1,11
.
605..
591
093
746
091
746
443
3
PLG78
.
893..
..
.
.
121
,141
.
..
.
.
.
.
.
146
093
115
113
857
551
092
.
.
(Fig
7-3 Item
8)
SWITCH,tgISPDT6A125VAC
OPTION INTERFACE, (consisting of)
1
1
CIRCUIT CARD, interlace
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
STAND-OFF, No. 6-32 x .750 Ig
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
BURNBACK CONTROL, (consisting of)
STAND-OFF, No. 6-32 x 1.500 Ig
CIRCUIT CARD, burnback
KNOB, .l25dia shaft w/.125 set screw
CONNECTOR & SOCKETS, (consisting of)
..
..
1
..
..
2
..
..
6
1
.
..
.
..
.
.
..
10
4
1
..
4
1
2
.
.
..
.
.
..
.
.
..
.
.
..
1
1
2
8
CONNECTOR, rect skt 24-1 8ga Molex 39-00-0038
SPOT/BURNBACK, PREFLOW/POSTFLOW, (consisting of)
STAND-OFF, No. 6-32x 1.500
CIRCUIT CARD, 4 in 1 timer
KNOB, .l25dia shft w/.125 set screw
565
PLATE, control
344
PANEL, option
CONNECTOR & SOCKETS, (consisting of)
092
746
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
CONNECTOR & SOCKETS, (consisting of)
094
746
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
843
NUT, brs hex .250-40 jam
304
BLANK, snap-in nyl .25Omtg hole
564.. PLATE, control
746
.132 137..
126689
156 636
093 551
133
133
115
113
115
113
134
120
7-4. Control Panel
Quantity
1
2
.
.
.
.
..
.
.
..
.
.
..
1
.
.
..
1
.
.
..
..
1
4
1
8
1
4
.
.
..
.
.
..
1
.
.
..
1
133
133344..
1
PANEL,option
1
2
4
ST-137 405
Figure
7-4. Control Panel
Part of Option 132 137 Spot/Burnback, Preflow/Postf low.
,OPTIONAL
+Not Included w/Option
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1583
Page
39
~L1
(0
F-
~
0)0
0
cJ
L~)
C.)
(0
CM
c1
0)
ST-142 601-C
Figure
OM-1583
Page
40
7-5. Boom
Assembly
Quantity
Model
Part
No.
Item
No.
Description
Figure
.
.
.
2
.
.
.
2
.
.
.
3
.
.
.
.
.3
.
.
.
.
.4
.
.
.
.
.
.
.
.
010 493
159 991
159 989
079 665
080811
079664..
139 633
.
.
.
.
.
073 742
..
.
.
.
073 741
..
.
.
.
.
.
.
.
.
1
..
..
..
..
..
.
5
6
7
.
.
8
.
.
.
079 029
..
..
.
9
..
.
075 462
..
.
.
10
..
.
.
602 250
079 020
..
12
.
.
149 858
..
12
.
.
.
.
.
.
.
.
.
.
..
..
11
..
13
14
..
15
..
16
..
17
..
..
..
..
080 723..
150 258
..
024 605
075 101
..
..
.
079 030
+139 831
18
.
.
080 157
142 804
..
19
.
.
134 327
..
..
20
.
.
602 246
..
..
21
.
.
..
22
.
.
..
23
.
.
..
23
.
.
..
24
.
.
..
25
.
.
.
.
..
..
26
27
..
28
..
+When
.
.
.
..
..
.
.
..
7-5. Boom
Assembly (Fig
7-1 Item
1....
1
1
1
ordering
.
.
.
.
1
1
..
.
.
1
1
..
.
.
1
1
..
.
.
1
..
2
WASHER, flat sti SAE .750
NUT, stl hex elastic stop .750-16
2
x
2
.
.
.
..
.
1
.
.
.
.
2
..
.
.
1
..
36.000
SPRING, cprsn 3.750 OD x .687 wire x 33.750
RETAINER, spring
BEARING, ball thr sgl row .750 x 1.625 x .625
NUT, stl hex special .750-16x 1.250
WASHER, lock stl ext tooth .750
BASE, swivel boom (consisting of)
FITTING, grease 1/8NPT
LABEL, Swingarc caution heavy spring
LABEL, warning general precautionary
.
..
..
.
.
.
1
.
..
.
1
.
.
.
.
1
.
.
.
.
1
.
.
.
.
1
.
.
.
.
1
.
.
.
.
1
.
..
.
1
.
.
.
.
I
.
.
.
.
1
1
1
WASHER, flat stl std .500
1
KNOB, T-bar .500-l3thd
BOLT, mach stl hexhd .750-16 x 2.750
PIPE, plstc .500 x 133.750
080 812
PIPE, plstc .500 x 181.750
079 632
BOLT, U stl .250-20 x .875 wide x 1.375 deep
602 243
WASHER, flat stl std .375
139 590
PULLEY, V sgl grv 8.875dia x 8.000P x .375 bore
010313.. PIN,cotterhair.072x1.437
139 336
GUARD, motor protector
047224
073 666
079 667
1
1
.625 wire
1
1
SHAFT, boom counterbalance
x
16
17)
BUSHING, snap-in nyl .625 ID x .875mtg hole
BOOM, single
BOOM, single
GUIDE, wire
GUIDE,wire
GUIDE,wire inlet
LINER, monocoil 3/32-1/8 wire x 15.687
PIN, clevis .750 OD x 2.156 Ig
CLEVIS, .812 yoke 6.062 Ig .750-l6thd
NUT, stl hex full fnsh .750-16
SPRING, cprsn 3.750 OD
I
12
1
1
..
1
..
.
.
1
..
1
..
.
.
1
..
1
4
..
.
.
5
4
.
.
.
.
4
.
.
.
.
.
.
.
.
.
.
.
.
1
..
..
..
..
..
a
1
component originally displaying
a
precautionary label,
1
2
1
1
2
1
the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1 583
Page
41
Item
No.
Part
No.
Dia.
Mkgs.
Figure
010 668
.
.
150 147
.
.
149 962
.
.
149 486
.
.
132 750
150 520
Quantity
Description
.
.
.
.
133 493
.
.
133 350
.
.
7-6. Drive
Assembly, Wire (Fig
7-1 Item
27)
SCREW, cap sti sch .250-20 x 1.500
CARRIER, drive roll w/components
SPACER, carrier drive roll
PIN, rotation arm rocker
ARM, pressure
SPACER, rotation pin
RING, retaining ext .250 shaft x .O25thk
PIN, hinge
2
1
See Table 7-1 For
Drive Roll & Wire Guide Kits
12
19
9
4
20
1
21
22
23
25
28
4
ST.152 711-C
Figure
OM-1 583
Page
42
7-6. Drive
Assembly,
Wire
Item
No.
Part
No.
Dia.
Mkgs.
Description
Figure
.
9
.
.
9
.
.
9
M1,2
M1,2
M1,2
..
.
...
.
..
156 354
..
.156 353
..
.166 540
..
.
153 491
153492
153 493
10
..
155 098
.
.
.
.
.
.
153 550
155 099
154031
PLG58.
...
114 656
..
.
.
11
010 837
..
..
12
137 248
..
..
13
129 351
..
..
14
..
15
.
16
602 200
604 772
133 603
..
17
132 746
..
..
18
132 824
..
..
19
132747
..
..
20
152 241
.
..
21
133 739
..
..
22
..
.
.
.
.
PC51
PLG57.
. .
...
.153 631
131 204
113 746
604 311
..
23
24
..
25
..
26
..
..
..
..
..
..
,,132
611
149 959
149 746
108 940
604 538
27
28
29
30
151 437
128 237
149 527
601 872
31
..
32
33
.
34
602 213
602 243
149 964
..
35
601 966
..
36
..
37
167 387
133 530
..
38
133 308
..
Assembly,
Wire
(Fig
7-1 Item
27)
MOTOR, gear 1/8hp 24VDC 272RPM (consisting of)
MOTOR, gear 1/8hp 24VDC 500RPM (consisting of)
MOTOR, gear 1/8hp 24VDC 79RPM (consisting of)
KIT, brush replacement (consisting of)
CAP, brush
BRUSH, carbon
KIT, cover motor gearbox (consisting of)
COVER, motor gearbox (consisting of)
GASKET, cover
2
2
2
1
2
2
1
1
1
SCREW, cover
SPACER, locating
155100
133493
131 203
7-6. Drive
Quantity
.
..
..
..
..
.
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
.
.
5
2
R~NG,rtngext.250shaftgrvx.025thk
CONNECTOR & PINS, (consisting of)
CONNECTOR, rect pin 24-l8ga Molex 39-00-0040
PIN, spring CS .093 x .625
1
1
3
1
SPRING, indicator
SCREW, hexwhd-slt stl slffmg 8-32 x .500
WASHER, lock sti split No. 8
WASHER, flat stl SAE No. 8
SPRING, cprsn .724 OD x .082 wire x 1.125
BUSHING, spring
SHAFT, spring
CARRIER, shaft
KNOB, extension
WASHER, flat .375 ID x .625 OD x .062
CIRCUIT CARD, digital tach (consisting of)
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-lBga Molex 39-00-0038
GROMMET, rbr .250 ID x .375mtg hole
1
1
1
1
2
2
1
1
1
1
1
1
3
1
OPTICAL ENCODER DISC
FITTING, brs barbed M 3/l6tbg x .312-24
ADAPTER, gun/feeder LH
SCREW, cap stl hexwhd .250-20 x .750
WASHER, flat stl SAE .312
KNOB, plstc T 1.125 Ig x .312-18 x 1.500 bar
SCREW, hexwhd-slt stl slffmg 10-32 x .500
COVER, drive roll
NUT, stl hex full .375-16
WASHER, lock stl split .375
WASHER, flat stl .375
PIN, groove .2SOdia x .500 Ig
SCREW, cap stl hexhd .375-16 x 1.250
2
SPACER, locating
DRIVE, pinion
RING, retaining ext .375 shaft
2
1
1
4
1
1
2
1
1
1
1
2
1
1
x
.O25thk
1
Part of 132 129
Optional High Speed Motor
Optional Low Speed Motor
of Optional Tach
Part of 156 725
.
.
Part
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1583
Page
43
Dia.
Part
No.
Mkgs.
Description
Quantity
Optional Equipment
132 131
..
108 008..
132 135.
148 098..
147853.
132 370..
157718.
157719.
130203.
.
C61
PC5O....
PC6O....
PC6O....
PLG5....
.
....
PLG52
.
PLG53
.
PLG62
.
.
.
.
.
.
...
PLG64
113 746
115 093
113 746
.
115 092
113 746
131 055.
.
115443.
097 132.
138044.
134 381
158409.
084 198.
..
PLG44,61
.
.
.
...
PLG85
R75
...
....
1
1
1
.
..
1
.
..
.
.
.
1
12
1
..
6
1
..
8
1
..
5
1
..
6
..
1
.
..
.
..
2
.
..
4
.
..
1
41)
1
.
..
2
081 378..
115094.
..
6
.
..
2
131 204.
.
..
113 746
131 203.
114 656
603 856
097 922.
134379..
134684..
141 605..
132 139..
132 137..
132 129..
156 725..
.
.
.
.
159288.
000 571
159772.
159 769.
057020..
159 289..
.
.
000 571
159 770.
159 771
.
.
057 020.
..
..
KNOB, pointer
DUAL SCHEDULE, (see Fig 7-3)
DIGITAL DUAL SCHEDULE, (see Fig 7-3)
OPTION INTERFACE, (see Fig 7-4)
BURNBACK CONTROL, (see Fig 7-4)
SPOT/BURNBACK, PREFLOW/POSTFLOW (see Fig 7-4)
..
HIGH SPEED MOTOR SIR (Fig 7-6)
LOW SPEED MOTOR, single/right side dual
KIT, water hose 12SS (consisting of)
HOSE, water lOft
HOSE, water 14ft
HOSE, water 23ft
FITTING, hose brs coupler .625-18 LH
KIT, water hose 16SS (consisting of)
HOSE, water lOft
HOSE, water 18ft
HOSE, water 27ft
FITTING, hose brs coupler .625-18 LH
Page
44
4
1
3
1
3
1
1
1
1
1
1
1
1
(Fig 7-6)
1
1
.
..
1
.
..
1
.
..
..
.
..
.
..
.
..
.
..
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1583
1
..
.
113 746
PLG82
1
..
..
..
PC4O....
PLG41 ,42
1
1
.
.
R6
1
..
113 746
084 198.
081378..
603 856.
...
RUN-IN CONTROL, (see Fig 7-1 & 7-3)
REEL, wire 60 lb (see Fig 7-2)
ONE METER, w/tach (consisting of)
TWO METER, w/tach (consisting of)
CAPACITOR
CIRCUIT CARD, tach converter
CIRCUIT CARD, meter kit (one meter)
CIRCUIT CARD, meter kit (two meter)
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-lBga Molex 39-00-0038
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
CONNECTOR, rect 6skt Amp 871 59-6
CONNECTOR, rectskt22-l8gaAmp 102100-2
POTENTIOMETER, WW sltd sft biT 2W 10K ohm
STAND-OFF, No. 6-32 x .750 Ig
STAND-OFF, No. 6-32 x .375 Ig
BUSHING, strain relief .120/.150 ID x .500mtg hole
For additional parts see Fig 7-3
DIGITAL VOLTAGE CONTROL, (consisting of) (See Fig 7-3 Item
CIRCUIT CARD, control voltage digital
CONNECTOR, rect 6skt Amp 871 59-6
CONNECTOR, rectskt22-l8gaAmp 102100-2
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-1 Bga Molex 39-00-0038
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
CONNECTOR & PINS, (consisting of)
CONNECTOR, rect pin 24-l8ga Molex 39-00-0040
POTENTIOMETER, WW sltd sft bIT 2W 10K ohm
1
3
1
1
1
1
3
Table 7-1. Drive Roll And Wire Guide Kits
C,
~
Wire Size
E~
E~
0
~0
V-GROOVE
U-GROOVE
VK-GROOVE
UC-GROOVE
.
w
4 Roll
~
Kit
Drive
Roll
4 Roll
Drive
Kit
Roll
4 Roll
Kit
Drive
Roll
4 Roll
Kit
Drive
Roll
Fraction
Metric
.023-.025in
0.6mm
150993
149518
151024
087130
.030in.
0.8
mm
150993
149518
151025
053695
.035in.
0.9mm
150993
149518
151026
053700
151036
072000
151052
132958
.045in.
1.1mm
150994
149519
151027
053697
151037
053701
151053
132957
151070
083489
.052in.
1.3mm
150994
149519
151028
053698
151038
053702
151054
132956
151071
083490
1.6mm
150995
149520
151029
053699
151039
053706
151055
132955
151072
053708
1.8mm
150995
149520
151056
132959
(.079in.)
2.0mm
150995
149520
151040
053704
151057
132960
151073
053710
(.094in:)
2.4mm
150996
149521
151041
053703
151058
132961
151074
053709
2.8mm
150996
149521
151042
053705
151059
132962
151075
053711
3.2mm
150997
149522
151043
053707
151060
132963
151076
053712
.068-.072in
5/64 in.
S-0549-B
Each Kit Contains An inlet Guide, Intermediate Guide, And 045 233 Antiwear Guide With 604 612 Setscrew 8-32
2 or 4 Drive Rolls.
2 Kits Required For DS-12 & DS-16.
x
.125, Along With
OM-1583 Page 45
4
OPTIONS AND ACCESSORIES
WATER FLOW SAFETY SWITCH
EXTENSION CORDS
For S64M
(Optional)
Note: For
(#157
(#157
optimum performance, do not
(18 m) between the power
exceed 60 ft.
source
model
DSS10 REMOTE INC/DEC
SWITCH
Factory)
Field)
A
833
834
(#042 749)
and 60M control.
Protects
14PIN
EXTENSION CORDS
25 ft.
(#122 973)
(#122974)
50ft.
(7.6 m)
(15m)
the
system if water is not present or
stops flowing to the gun.
Can be added to the standard 10
ft.
Note:
17PIN
gun from
interrupting the
overheating by
circuit and shutting down
water
(3 m) cord.
a
watercooled
Requires
a
water hose kit.
25 ft.
remote
ft. (3 m) cord. Two 25 ft. cords can
be used together to make a 50 ft.
(15 m) extension.
Important:
used with
Recommended
cable size
secondary
optimum performance,
the pulsed GMAW
For
especially
with
process, it is recommended that 4/0 or
equivalent secondary weld cables be
used. Work cable not
supplied.
Note: All 60M wire feeders are
with 10 ft.
(3 m) 14pin
and
supplied
17pin
control cords for connections to the
Maxtron 450 power source. Extension
cords are available when greater
distances between the power source and
feeder control are required. For optimum
performance of the system, it is
recommended not to exceed 60 ft.
Secondary weld cables should be kept
as
straight
as
possible.
optional
or
guns. Can be
Factory installed only
(#156 725) Lowspeed
The lowspeed motor has
a
(#096 746)
(3m)
recommended for wire smaller
than 5/64 in.
(2.0 mm) diameter.
(#132 129) Highspeed
The highspeed motor has
a
recommended for wire sizes
than 5/64 in.
larger
and increase the service life of the
For
WIRE REEL ASSEMBLY
with dual schedule
use
feature in the 60M control
(#108 008)
For 60 lb. (27
DSS8
(#079 691)
(3 m) gun
A
(#079 693)
For 15 ft. (4.6 m) gun
(2.0 mm).
Adapter
cord
(#157 364)
is
DSS-9M
factory preprogrammed
synergic pulse GMA W programs are
designed for use with the standard
speed range motor.
wire feeder and
welding
supplies. Height: 34
Lower tray height: 9
in.
in.
(863 mm).
(228 mm).
Shipped disassembled.
FEEDER CART
required
with the 60M control.
(#056 301)
utility cart for the
other miscellaneous
A
to use the DSS8
kg) coil of wire
CARRYING CART
For lOft.
(#142 382)
lowprofile, creeper
cart that
allows the operator to easily move
the feeder around the work area.
SPOOL COVERS
(#041 792)
For 10 ft. (3 m) gun
(#057 607)
(305 mm) spool
For 12 in.
(#041 793)
REEL COVERS
For 15 ft. (4.6 m) gun
(#058 256)
A
two-position slide switch that
easily attaches to the welding gun
and is used to select the desired
Note: The
1/8 in. (1.6-3.2 mm)
gun liner and contact tube.
wire
feed speed range of 90 to 1400
1PM (2.3 to 35.6 rn/mm.). Not
-
DUAL SCHEDULE
SWITCH ES
Note:
mm)
Helps to reduce the cast in wire to
improve wire feeding performance
lOft.
wire
feed speed range of 15 to 210 1PM
(0.4 to 5.3 rn/mm). Not
1.1
(0.9-
diameter wire
switch.
twoposition trigger switch that
easily attaches to the welding gun
and is used in place of the
standard trigger for dual
scheduling.
MOTORS
.045 in.
(#141 581)
1/16
safety
A
LOW- AND HIGH-SPEED
-
diameter wire
without the
water flow
trigger operates
trigger.
standard gun
For .035
systems and Miller
GWwatercooled
parameter increase/
(#141 580)
with Miller coolant
use
welding gun
WIRE STRAIGHTENER
Can be added to the standard 10
For
to the
decrease feature available in the
as a
WATER HOSE KITS
(7.6 m)
easily attaches
to fine tune parameters remotely
while welding. Used with the
60M control. The
EXTENSION CORDS
(#042 120)
two-position springloaded
momentary contact switch that
welding
For 60 lb. (27 kg) coil. Helps to
protect the welding wire from dust
and other contaminants.
condition for dual schedule
purposes. The trigger operates
a standard gun trigger.
Note: Reel and
as
spool
covers cannot
Installed If the wire drive
a
rotated
position.
assembly
be
is In
OPTIONS AND ACCESSORIES
TURNTABLE ASSEMBLY
(#146 236)
Allows rotation of the feeder
operator changes
work
This reduces strain and
as
WATER COOLANT
Refer to Literature Index No.
SYSTEMS
AY/7.2 for additional coolant
the
For
positions.
bending on
use
with watercooled
system information.
guns.
Radiator 1A 115 VAC
the gun cable.
Radiator tA 115 VAC, 100 Hz
HANGING BAIL
(#042 494)
Electrically isolated
(#058 435)
Used for suspending feeder
work
Radiator 2A 230 VAC
(#042 493)
over
WatermateTM 1A
area.
115 VAC
(#042 495)
ADJUSTABLE SPOOL CARRIER
(#096 075 Field only)
Designed for use with 6 ft. (1 .8 m)
pipe post only. Replaces the
standard spool assembly, allowing
the spools or coils of wire to be
positioned lower for easier loading
and unloading. Not recommended
for use with Swingarc feeder
system mounted
on
WatermateTM 2A 230 VAC
(#042 496)
CoolmateTM 4 115 VAC
(#042 288)
CoolmateTM 4 230 VAC
(#042 289)
60M DATA CARD
(#155 910) Blank
(#042 492)
A userinsertable
card
memory device
that will hold up to 32 complete
weld programs. It is ideal for
saving custom programs and
transferring programs to other 60M
controls.
CONTROL DETACHMENT KIT
Field installed only
(#134 936) 10 ft. (3 m)
(#134 937) 25 ft. (7.6 m)
Allows separation of the control
module from the wire drive
assembly
and base.
CBC cart.
12/92
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