Miller XR CONTROL AND XR A GUN Owner's Manual

/1
~MiHerfi
June 1992
FORM: OM-1581B
Effective With Serial No. KC248746
MODEL:
XR ATM
And XR WTM
Wire Feeder And ~Gun
OWNERS
MANUAL
IMPORTANT: Read and understand the entire contents of both this manual and
the power source manual used with this unit, with special emphasis on the safety
material throughout the manual, before installing, operating, or maintaining this
equipment. This unitand these instructions are foruse only by persons trained and
experienced in the safe operation of welding equipment. Do not allow untrained
persons to install, operate, or maintain this unit. Contact your distributor if you do
not fully understand these instructions.
4~.A
MILLER ELECTRIC
A Mifler
Mfg. Co.
Group Ltd.. Company
P.O. Box 1079
Appleton,
WI
54912 USA
Tel. 414-734-9821
PRINTED IN LISA
La
J
MILLERS
TRUE BLUE~ LIMiTED WARRANTY
Effective
(Equipment
with
a
January I, 1992
preface of KC
serial number
This limited warranty supersedes alt previous MILLER warranties snd is exclusive with
Subject to the terms snd conditions below. MILLER Electric
Mtg. Co.. Appleton. Wisconsin. warrsnts to its originsl retsil purchaser that new
MILLER equipment sold after the effective date of this limited warrsnly is free ot de
or
newer)
other gusrsntees
no
or
warrenties espressed
tects in msterisl end workmanship at the time it is shipped by MILLER. THIS WAR
RANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES. EXPRESS OR
MILLERS
IMPLIED. INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FIT
NESS.
1.
r
Umited
True Blue
Warranty
shall not
procedures
to:
by
as
the manufacturers
engines
or
warranty.
it
any.
Within the wsrranty periods listed below. MILLER wilt repair or replace sny war
rsnted parts or components that tell due to such detects in material or workmanship.
MILLER must be notified In writing within thirty (30) days ot such detect or failure, at
the warranty claim
epply
by MILLER. but manufactured by others. such
Items furnished
trade accessories. These items are covered
on
implied.
Accessory Kits
Replacement Parts
LIMITED WARRANTY
which time MILLER wilt provide instructions
or
Consumable components: such
2.
and
to be
as contact
tips, cutting nozzles, contactora
relays.
followed.
Equipment
3.
start on the date that the
and
Original
2.
was
delivered to the
original
based upon industry standards,
or
equipment which has not had reasonable
and necessary maintenance, or equipment which has been used for
outside of the specifications for the equipment.
retail purchaser.
are aa follows:
main power rectifiers
THE USE AND MAINTENANCE OF WELDING EOUIPMENt
Parts and Labor
3 Years
In the event of a warranty claim covered
Transformer/Rectifier Power Sources
Plasma Arc
Cutting
Power Sources
Robots
3.
goods
vice
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
*
1
4.
at
option of repair
or
replacement
Appleton. Wisconsin. or FOB, at a MILLER authorized ser
by MILLER. Therefore no compensation or reimburse
determined
transportation costs of any kind
will be allowed.
TO THE EXTENT PERMITTED BY LAW. THE REMEDIES PROVIDED HEREIN
ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE
LIABLE FOR DIRECT INDIRECT SPECIAL. INCIDENTAL OR CONSEOUENTIAL
DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CON
Process Controllers
TRACT. TORT OR ANY OTHER LEGAL THEORY.
Systems
HF Units
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED wAR
RANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE. AND ANY
Grids
REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL
THEORY WHICH, BUT FOR THIS PROVISION. MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW. CUSTOM OF TRADE OR COURSE OF DEALING. IN
Welders
Spot
risk and espense. MILLERS
Factory
as
engine manufacturer.)
Motor Driven Guns
Water Coolant
facility
ment for
the
Parts and Labor
Year
at customers
will be FOB..
Parts and Labor
2 Years
by this warranty, the eacluaive remedlea
shall be, at MILLERS option: (1) repair: or (2) replacement: or, where authorized In
writing by MILLER in appropriate cases, (3) the reasonable cost of repair or replace
ment at an authorized MILLER service station: or (4) payment ot or credit for the pur
chase price (less reasonable depreciation based upon actual use) upon relum of the
Semi-Automatic and Automatic Wire Feeders
*
operation
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY CDMMER
CIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN
3 Years Labor
5 Years Parts
1.
equipment
by any party other than MILLER, or equip
improperly installed, improperly operated or misused
that hsa been moditled
ment that has been
MILLER shall honor warranty claims on warranted equipment listed below in the
event ot such a failure within the warranty time periods. Alt warranty time periode
Load Banks
SDX Transtormers
CLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS
FOR PARTICULAR PURPOSE. WITH RESPECT TO ANY AND ALL EOUIPMENT
Running Gear/Trailers
Field Options
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED DY MILLER.
TM
Field options are covered under True Blue
warranty period ot the product they are installed in.
tor the
(NOTE:
one
5.
6 Months
6.
90
year
Days
whichever is
or
for
a
remaining
Some states in the U.S.A. do not allow limitations of how long an implied warranty
lasts, or the exclusion of incidental, indirect, special or consequential damages, so
the above limitation or esclusion may not apply to you. This warrsnty provides ape
minimum ot
grester.l
citic
Batteries
MIG Guns/TIG Torches
Plasma
legal rights,
and other
rights may
be available, but may very from state to state.
provinces provides for certain additional warrantIes
or remedies other than as stated herein. snd to the extent that they may not be
waived, the limitations and esciusiona set out above may not apply. This Limited
Warranty providea specific legal rights, and other rights may be available, but may
vary from province to province.
In
Parts and Labor
Cutting Torches
Remote Controls
Canada. legislation
in some
a
ii
RECEIVING-HANDLING
unpacking equipment, Check carton for any damage that may have occurred during shipment. File any claims for loss or damage
delivering carrier. Assistance for filing or settling claims may be obtained from distributor and/or equipment manufacturers
Transportation Department.
Before
with the
When
requesting
Use the
or
information about this
following spaces to
equipment, always provide Model Designation
record Model
Designation
and Serial
or
Style
and Serial
or
Style
Number.
Number of your unit. The information is located
on
the
rating label
nameplate.
Model
_________
Serial
or
Style
No,
Date of Purchase
miller 5/92
ERRATA SHEET
FORM: OM-1581B
1992
September 18,
Use above FORM number when
After this manual
to data
was
appearing
printed, refinements
in
ordering extra,
occurred. This sheet lists
equipment design
manuals.
exceptions
later in this manual.
CHANGES TO SECTION 3- INSTALLATION
Replace Section 3-7.
115 VAC/Contactor Control
Plug Information
Cord
I
Interconnecting
2
115 VAC/Contactor Control
Plug PLG5
If
welding power source is
eauipped with matching 14-socket
receptacle, insert plug, and tighten
threaded collar. Proceed to Section
3-9 in manual.
If plug PLG5 will not connect to
welding power source receptacle.
use the following pin information
and following Section 3-8 to re
place PLG5 with a suitable plug.
2
Pin Information to connect the
following equipment:
Remote Contactor
A,B
Remote
Contact closure
completes
Control
(Optional)
Voltage
the contactor control circuit
C
Command reference; +10 volts dc.
D
Remote control circuit
E
Input command signal from potentiometer wiper;
common.
0 to +10 volts dc.
Remote Contactor
G
l,J
1<
Circuit
for 115 volts
common
ac
circuit.
Contact closure completes the 115 volts
Circuit
ac
contactor control circuit.
common.
Remaining pins
are not
used.
Ref. S-0004.A / Ref. ST.tSl 772
Figure
3-12. 115
VAC/Contactor Control Plug Information
Replace Section 3-8. Replacing
a
115 VAC/Contactor
Control.Plug
With
Supplied
5-Pin Or Twistlock
Plug
WARNING
ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
Turn OFF wire feeder and
welding generator.
Have only aualified
welding
persons make
power source, and disconnect
wiring
input power before inspecting
or
installing. Stop engine
on
connections.
wiwarni i gigi
1
115 VAC/Contactor Control
2
Contactor Control Cord
3
I15VACCord
Plug PLG5
Find and label cords
by following
leads back to PLG5:
Contactor control cord connects to
pins A & B of PLG5
115 VAC cord connects to
PLG5.
Cut off
pin
plug PLG5.
Plug
4
5-Pin
5
Twistlock
Plug
For connections shown in
3-3
or
5-pin
J of
Figure
3-4 in manual, install
twistlock plug onto contac
Figure
or
tor control cord.
For Figure 3-2 connection in manu
al, obtain plug to match contactor
control
er
receptacle
source,
on
welding
plug
and install
pow
onto
contactor control cord.
Obtain 115 VAC
to 115 VAC cord
and connect
follows:
plug
as
green lead to ground
white lead to 11 5VAC common
black lead to 11 5VAC hot.
PLG5O
6
Plug
7
Plug PLG51
8
Plug PLG52
Unit
shipped
PLG5O
with
nected to PLG5I
to
con
provide 115
VAC for contactor.
If contact closure needed for con
tactor. connect PLG5O to PLG52.
ST-151 773-B
Figure
OM-1581B
Page
3-13.
2
Replacing
115 VAC/Contactor Control
Plug
With
Supplied
5-Pin Or Twistlock
Plug
CHANGES TO SECTION6
ELECTRICAL DIAGRAMS
Replace Figure 6-1. Circuit Diagram For Wire Feeder (see Page
4 on this Errata
Sheet)
IReplace Figure 6-2. Wiring Diagram For Wire Feeder (see Page
5
this Errata
Sheet)
IReplace Figure
6-3. Circuit
on
For Gun
Diagram
~1
PULL
MOTOR
GUN
ASSEMBLY
B2
I
.~
TRIGGER
L
flPBI~~I
\V
0
B
C
PLG2
0
A
G
E
F
V
CORD
#1
CORD
#2
SA.138 956-B
Figure
CHANGES TO SECTION 7
Change
Parts List
as
Dia.
Part
No.
Replaced
With
33-
007 826
34-
601 219
007826
601 219
-.
34-
Added
131 204
PLG51,52
..
...
113 746
34-
PLG5O
For Gun
PARTS LIST
-.
...
Diagram
follows:
Mkgs.
-~
6-3. Circuit
...
Added
131 203
114 656
Description
..
..
-.
.
.
.
..
-
.
.
Quantity
CABLE, (qty chg) (order by ft)
LINK, (qty chg)
HOUSING PLUG & SOCKET, (consisting of)
TERMINAL, female lskt 24-18 wire
HOUSING PLUG & PINS, (consisting of)
TERMINAL, male 1 pin 24-18 wire
-
-.
.
22ft
.2
.
.
~First digit represents page no
digits following dash represent item no.
l3E SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1581B
Page
3
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Figure
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.
INSTALLATION, OPERATION, MAINTENANCE,
HAVE ALL
AND REPAIR WORK PERFORMED ONLY BY
QUALIFIED PEOPLE.
ELECTRIC SHOCK
can
kill.
5.
Touching 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.
install and
Properly
this equipment
ground
according
to itS
Owners Manual and national, state, and local codes.
6.
Turn off all
7
Do not
when not in
equipment
use
use.
damaged. undersized,
worn,
poorly spliced
or
cables.
8.
Do not wrap cables around your
9.
Ground the workpiece to
10.
body.
good electrical (earth) ground.
a
Do not touch electrode while
in
contact with the work
(ground)
circuit.
1.
Do not touch live electrical parts.
2.
Wear
3.
Insulate
dry. hole-free insulating gloves and body protection.
yourself from work and ground using dry insulating
mats or covers.
4.
Disconnect
input
power or
stop engine before installing
/~
...Li
Use
12.
Wear
13.
Keep
all
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
1.
Wear
a
Arc rays from the welding process produce intense
heat and strong ultraviolet rays that can burn eyes
and skirt. Noise from some processes can damage
2.
hearing.
FUMES AND GASES
can
be hazardous
Welding produces
fumes and gases
remove
3.
4.
welding
If ventilation
Read
the
is
use an
Safety
Material
(MSDS5)
and
Use
plugs
5.
Work in
a
wearing
welding
an
to metal
fire
can cause
or
explosion.
can cause
oblects
can cause
and others from
displace
The
hot
in
air
causing
locations
toxic and
highly
Do not weld
an
area
Be
the
or
spraying
with vapors to
lead,
galvanized,
or
is removed from the
is well ventilated, and if necessary. while
that
fire
keep
welding
on
a
can
fire
on a
give off
toxic fumes if welded.
extinguisher nearby.
ceiling,
floor, bulkhead,
or
partition
the hidden side,
7.
Do not weld
Connect work cable to the work
11.
and hot metal
strike flammable material.
welding sparks and hot materials from welding can
through small cracks and openings to adjacent areas.
FLYING SPARKS AND HOT METAL
on
closed containers such as tanks or drums.
as
close to the
welding
area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
Be alert that
9,
Do not
use
tip when
not
pipes.
or cut
off
welding
wire at
in use.
Wear oil-free protective
shirt. cuffless trousers,
Wear
can
welder to thaw frozen
Remove stick electrode from holder
contact
garments
high
such as leather
shoes. and
approved face shield
or
a
gloves, heavy
cap.
safety goggles. Side
shields
recommended,
injury.
grinding
arc can react
coating
unless the
8.
10
can
aware
can cause
Remove allflammables within 35 ft(10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
and
sure
airsupplied respirator. The coatings and any metals
Watch for fire, and
3.
they
degreasing. cleaning,
near
coated metals, such as
on
5
Do not weld where
Chipping
while
irritating gases.
plated steel.
6.
Protect
cause
death. Be
or
n~ury
or
used for
fires and
welding wire
sparks. overheating, or
flying sparks
well ventilated.
sate.
air is
Do not weld
wearing
1.
can
is
high.
air-supplied respirator. Shielding gases
weld area, the
2.
flying sparks
muffs if noise level is
confined space only if it
can
cadmium
fire.
cool,
or ear
operations. The heat and rays of the
the
burns. Accidental contact of electrode or
i
ear
containing these elements
workpiece. and hot equipment
4.
approved
breathing
coatings,
Sparks and spatter fly off from the welding arc.
flying sparks and hot metal, weld spatter.
yourself
made from durable. flame-resistant
clothing
5.
and cleaners.
WELDING
proper shade of filter (see
leather) and foot protection.
7.
Sheets
Data
a
place.
material (wool and
approved air-supplied respirator.
instruction for metals, consumables,
helmet fitted with
welding
in
arc to
fumes and gases
poor.
manufacturers
exhaust at the
securely
covers
Safety Standards) to protect your face and
eyes when welding or watching.
Wear approved safety glasses. Side shields recommended.
form
use
panels and
Wear protective
head out of the fumes. Do not breath the fumes.
If inside, ventilate the area and/or
above floor
4.
6.
Keep your
working
Use protective screens or barriers to protect others from flash
and glare: warn others not to watch the arc.
fumes and gases. Breathing these
be hazardous to your health.
1.
if
replace
3,
can
2.
falling
harness to prevent
or
ANSI Z49. I listed in
to your health.
Q
safety
a
Repair
level.
or
this equipment.
servicing
only well-maintained equipment.
damaged parts at once.
11
cause
throw off
flying
metal. As welds
2.
Wear proper
body protection
to
protect skin.
slag.
S.
9~
CYLINDERS
explode
can
if
damaged.
Keep cylinders away from
3.
welding
any
other electrical
or
circuits.
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.
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.
Protect
2.
Install and secure
them to
a
cylinders
in an
stationary support
or tipping.
or
from
excessive
heat.
7.
upright position by chaining
equipment cylinder rack to
8.
compressed gas cylinders
mechanical shocks, and arcs.
1.
in
~.
~
WARNING
ENGINE EXHAUST GASES
Engines produce harmful
ENGINE
use.
Standards.
prevent tailing
a
connected for
use or
Read and follow instructions on compressed gas cylinders.
associatedequipment. and CGA publication P-i listed in Safety
FUEL
ENGINES
can
kill.
1.
Use equipment outside in open, well-ventilated
2.
II used in
exhaust gases.
can
fire
cause
or
areas.
closed area, vent engine exhaust outside and
a
away from any
explosion.
be hazardous.
can
building
1.
Stop engine
2.
Do not add fuel while
before
air intakes.
checking
adding fuel.
or
smoking
if unit is near any
or
sparks
or
open flames.
3.
Engine
fuel
is
flammable.
highly
Allow
engine
fueling. If possible, check and add
beginning job.
allow room for fuel to expand.
fuel is spilled, clean up before starting
to cool before
fuel to cold engine before
Do not overfill tank
4.
Do not spill fuel. If
5.
engine.
~
MOVING PARTS
can cause
injury.
Moving parts, such as fans, rotors, and belts can
fingers and hands and catch loose clothing.
3.
Have only qualified people remove guards or
maintenance and troubleshooting as necessary.
4.
To prevent accidental starting
negative () battery cable from
cut
Keep all doors, panels,
securely in place.
2.
Stop engine before installing
covers,
and
guards
closed and
connecting
Reinstall panels
unit.
or
guards
1.
Always
2.
Stop engine
burn eyes and skin,
wear a
working
disconnecting
Do not
gases.
5.
Observe correct polarity (+ and )
STEAM AND PRESSURIZED HOT
COOLANT can burn face, eyes, and
skin.
1.
and
The coolant in the radiator
battery.
sparks when working
Do not allow tools to
4.
acid
on a
connecting battery
or
cables.
3.
Batteries contain
is
engine.
face shield when
before
servicing
and close doors when
finished and before starting
SPARKS can cause BATTERY GASES
TO EXPLODE; BATTERY ACID can
disconnect
during servicing,
battery.
parts.
6.
or
for
Keep hands, hair, loose clothing, and tools away from moving
5.
1.
covers
generate explosive
can
Do not
use
cause
welder to
remove
charge
batteries
radiator cap when
on
jump
or
on a
battery.
start vehicles.
batteries.
engine
is
hot. Allow engine
to cool.
2.
Wear
3.
Allow pressure to escape before
gloves
and put
a
rag
over
cap
area
when
removing
cap.
be very hot and
under pressure.
completely removing
cap.
PRINCIPAL SAFETY STANDARDS
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeurie Rd. Miami FL 33126
Safety
and Health Standards, OSHA 29 CFR 1910. from
dent of Documents, U.S. Government
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.
Superinten
Printing Office. Washington,
D.C. 20402.
Code for
Safety
in
Welding
and
Cutting, GSA Standard
Wi 17.2. from
Canadian Standards Association, Standards Sales, 178 Pexdale Bou
levard, Rexdale, Ontario, Canada M9W 1 P3.
Recommended Safe Practices for the
Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances. Amen.
can Welding Society Standard AWS F4. 1, from American Welding So
ciety. 550 N.W. LeJeune Pd, Miami, FL 33126
Safe Practices For Occupation And Educational Eye And Face Protec
tion, ANSI Standard Z87.1. from American National Standards Insti
National Electrical Code, NFPA Standard 70, from National Fire Pro
Cutting
tection Association.
Sri 9/Si
Batterymarch Park. Quincy,
MA 02269.
tue. 1430
Broadway.
And
Welding
New York. NY 10018.
Processes. NFPA Standard 518. from National
Fire Protection Association,
Batterymarch Park. Quincy,
MA 02269.
TABLE OF CONTENTS
SECTION 1
SAFETY SIGNAL WORDS
SECTION 2
SPECIFICATIONS
2-1.
.
Duty Cyc!e
1
1
SECTION 3INSTALLATION
Equipment Connection Diagrams
Removing Top Cover Of Gun
2
3-2.
3-3.
Gun To Feeder Connections
5
3-4.
Internal Connections To Feeder
6
3-5.
9
3-10.
Adjusting Contact Tube Position
Voltage Sensing Lead Connections
115 VAC/Contactor Control Plug Information
Replacing 115 VAC/Contactor Control Plug With Supplied 5-Pin Or Twistlock Plug
Installing Wire Spool
Threading Welding Wire
3-11.
Coolant Guidelines To Prevent Corrosion
3-1.
3-6.
3-7.
3-8.
3-9.
SECTION 4
5
9
10
10
ti
12
13
OPERATION
14
SECTION 5- MAINTENANCE & TROUBLESHOOTING
5-1.
Routine Maintenance
19
5-2.
Changing Or Cleaning Gun Drive Roll
20
5-3.
21
5-9.
Changing Feeder Drive Roll And Wire Inlet Guide
Replacing Or Cleaning Gun Drive Roll Bearing
Replacing Or Cleaning Feeder Drive Roll Bearing
Changing Gun Contact Tube And Liner
Replacing Contact Tube Adapter
Replacing Hub Assembly
Adjusting Hub Tension
5-10.
Overload Protection
25
5-11.
Water Flow Switch
5-12.
Troubleshooting
5-4.
5-5.
5-6.
5-7.
5-8.
(Optional
For Water-Cooled
SECTION 6
ELECTRICAL DIAGRAMS
SECTION 7
PARTS LIST
Figure
Figure
Figure
Figure
7-1. Main
Models)
Assembly
7-2. Motor & Wire Drive
w/Components (XR-W Model Illustrated)
Exploded View Of Gun
22
22
23
23
24
25
26
26
28
32
35
7-3. Panel, Front
36
7-4.
38
OM.1 581 B 692
SECTION 1
-
SAFETY SIGNAL WORDS
modl.1 991
The
following safety
symbol and signal words
alert
are
used
throughout this
manual to call attention to and
identify
different levels of hazard and special instructions.
WARNING
4~
WARNING statements
injury or loss of life.
CAUTION statements
or
or
practices
which must be followed to avoid serious
personal
CAUTION
a
injury
identify procedures
damage
identify procedures
equipment.
or
practices which
must be followed to avoid minor
personal
to this
~l M PORTANT: statements identify special instructions necessary for the most efficient operation of this equipment.
SECTION 2SPECIFICATIONS
Table 2-1. ~1ire Feeder
Specification
Type Of Input
Control Circuit
Wire Feed
Power
115 Volts AC, 3
Voltage
Provided At Gun
Speed Range
Cooling
19 in.
12 in. (305
(483 mm);
Width: 9-1/4 in,
(235 mm); Height: 15-1/4
in.
(387 mm)
mm)
Air-Cooled (A Models) Or Water-Cooled (W Models)
Method
Weight (Feeder
At 50/GO Or 100 Hz Power
ipm (1.9-22.2 mpm)
Length:
Spool Capacity
Amperes
30 Volts DC
70.875
Overall Dimenstons
Maximum
Description
With
Gun)
Models With 15 ft. (4.6 m) Cable Assembly
Net: 56 lbs. (25 kg): Ship: 58 lbs. (26 kg)
Models With 30 ft. (9.1 m) Cable Assembly
Net: 63 lbs. (29 kg); Ship: 65 lbs. (30 kg)
Table 2-2. Gun
Specification
Description
Input Voltage
30 Volts DC
Duty Cycle (Air-Cooled Models)
At 200
At 250
tion
Duty Cycle (Water-Cooled Models)
Amperes.
Amperes,
Using Argon Or Argon Mixture Shielding Gas
Using Argon Or Argon Mixture Shielding Gas (See
100%
60%
Sec
2.1)
At 400
Amperes,
100%
Using Argon Or Argon
Mixture
Shielding
Gas
(See
Section 2-1)
Wire Size
2-1.
.030 Thru 1/16 in. (0.8 Thru 1.6 mm) Aluminum Wire
.030 Thru .045 in. (0.8 Thru 1.1 mm) Hard Or Cored Wire
Range
Duty Cycle
a
CAUTION
USING GUN BEYOND DUTY CYCLE RATING
S
Do not exceed indicated
can
damage
gun.
duty cycles.
OM.1581
Page
1
long the gun can operate within a ten minute period without causing overheating
rated using argon or argon mixture shielding gas.
Duty cycle is
models are
how
or
damage. Both
The air-cooled model is rated at 100% duty cycle when operated at 200 amperes, allowing continuous welding. When
operated at 250 amperes, the air-cooled model is rated at 60% duty cycle, allowing welding 6 minutes out of every 10
minutes.
The water-cooled model ~s rated at 100% duty
cycle
when operated at 400 amperes,
allowing continuous welding.
SECTION 3INSTALLATION
Table 3-1. Items Included With Feeder And Gun
Item
Feeder Drive Roll
Quantity
(Small Groove For .030
Thru 1/16 in.
I
Wire, Large Groove For .045 Thru 1/16 in. Wire) Shipped
With
Large Groove
In Feed Position
Gun Drive Roll* (Small Groove For .025 Thru .035 in. Wire,
Large Groove For .047 Thru 1/16 in. Wire) Shipped With
Large Groove In Feed Position
I
Contact Tubes (1 For Each Wire Size
.023/.025, .030.
.035, .047, And 1/16 in.) Shipped With .047 Installed
5
lOft.
(3 m) Gas
lOft.
(3 m) Water
Models
10 ft.
Hose
I
Hose With Adapter
Fitting (Water-Cooled
I
Only)
(3 m)
Water Hose
(Water-Cooled Models Only)
I
Contact Tube Wrench
i
5-Pin
1
Plug
Twistlock
Plug
1
*A .023/025 contact tube is
supplied
with gun, but feeder is not
designed
to feed
these wire sizes.
~ IMPORTANT: Be
change parts
as
sure that contact tube, line,; and drive rolls are correct for wire size and type,
needed. See Section 7 for list of other available contact tubes.
see
Section 5 to
Equipment Connection Diagrams
3-1.
a
WARNING
CYLINDERS
can
explode
if
ELECTRIC SHOCK
damaged.
Keep cylinders away from welding and
other
electrical circuits.
Never touch
Turn OFF wire feeder and
cylinder
with
Always secure cylinder
other stationary support.
HOT SURFACES
can
can
Allow gun to cool before
welding
to
electrode.
running gear, wall,
burn skin.
disconnect
connections.
and
or
kill.
Do not touch live electrical parts.
input
welding
power
power
before
source.
making
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.
touching.
Have
only qualified
persons install this unit.
wtwarn71
Review
Figure
Figure 3-1 through Figure 3-4 to determine how equipment will be connected. Air-cooled models are shown in
through Figure 3-4. For water-cooled models, supplied water hoses must be connected from wire feeder to
supply.
3-1
coolant
Read entire Section 3 before
OM-1581
9/91
Page
2
installing equipment.
1
2
CV Or CC/CV
Source
Power
115 VAC/Contactor Control
14-Pin
3
Welding
Plug
PLG5
Positive (+) Weld Cable
4
Negative () Weld Cable
5
Workpiece
6
Voltage Sensing
Lead
Connect lead to workpiece for CC
welding only.
7
Gun
8
Wire Feeder
9
lOft.(3m)Gas
10
115 VAC/Contactor Controt
Hose
Cord
11
Gas
Cylinder
ST-t5t 774
Figure
3-1. Connections With A Constant
Welding
Voltage (CV) Or Constant Voltage/Constant
Having A 14-Socket Receptacle
Current
(CV/CC)
Power Source
1
CV
2
Plug
Obtain
ing
Welding
Power Source
matching plugs for connect
receptacles.
to power source
3
Positive 1+) Weld Cable
4
Negative ()
5
Workpiece
6
Voltage Sensing
Weld Cable
Do not connect to
Lead
workpiece.
7
Gun
8
Wire Feeder
9
lOft.(3m)GasHose
10
115 VAC/Contactor Control
Cord
11
Gas Cylinder
10
9
8
STt51
Figure
3-2. Connections With A Constant
Voltage (CV) Welding Power Source Having Separate
Receptacles
775A
115 VAC
And Contactor Control
OM-1581
Page
3
Power Source
1
CC
2
5-Pin Or Twistlock
Welding
Plug
(Supplied)
3
Positive
(+) Weld Cable
Weld Cable
4
Negative ()
5
Workpiece
6
Voltage Sensing
Lead
7
Gun
8
Wire Feeder
9
lOft.(3m)GasHose
10
2-Conductor Contactor Con
11
3-Conductor 115 VAC Cord
12
Gas
Cylinder
13
115
VACPIug
trol Cord
Obtain plug for wire feeder.
ST-151 176
FIgure
3-3. Connections With A Constant Current
(CC) Welding
Power Source
Having Contactor
Control Receptacle
I
CC
Welding Power Source
2
Positive (+) Weld Cable
3
Negative () Weld Cable
4
Workpiece
5
Voltage Sensing
6
Gun
7
Wire Feeder
Lead
8
lOft.(3m)GasHose
9
3-Conductor 115 VAC Cord
10
2-Conductor Contactor Con
trol Cord
11
5-Pin
12
Secondary Contactor
13
Gas
Cylinder
14
115
VACPIug
Plug
Obtain plug for wire feeder.
ST.~5~
Figure
3-4. Connections With A Constant Current
(CC) Welding
Secondary
Contactor
177
Power Source And A 115VAC/12VDC
3-2.
Removing Top Cover Of Gun
1
Top Cover
Push back and lift off
as
shown.
To reinstall cover, set rear of cover
in gun, and push cover back and
down until it clicks into
position.
Ret. ST.150 862-A
Figure
3-3.
3-5.
Removing Top
Cover Of Gun
Gun To Feeder Connections
a
WARNING
ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
Turn OFF wire feeder and
welding
power source, and disconnect
input power before inspecting
or
installing. Stop engine
on
welding generator.
wtwarnl
A.
9J9~
Air-Cooled Gun Connections
1
Gun Control Cable
Insert
plug
into GUN CONTROL
receptacle, and tighten threaded
collar.
2
Gas Hose
Connect to GAS
fitting
on
feeder.
3
Wetd Cable
4
Weld Cable Terminal In
Feeder
Connect gun weld cable to weld
cable terminal in feeder.
5
Wire Conduit
6
Thumbscrew
7
Wire Conduit Block
Loosen
conduit
til it
thumbscrew,
and
insert
through WIRE opening un
bottoms against block. Tighten
thumbscrew. Close and latch door.
3
Tools Needed;
~Z~
5/6 in., 3/4
Figure
~fl.
Ref. ST.151 778-A / ST151
666 / S1.145
432.A
3-6. Air-Cooled Gun Connections
OM-1581
Page
5
B.
Water-Cooled Gun Connections
Gas Hose
I
Connect to GAS
2
fitting
on
feeder.
Water Hose
Connect to WATER TO GUN
on
feeder
fitting
(left-hand threads).
Wire Conduit
3
4
Thumbscrew
5
Wire Conduit Block
Loosen
thumbscrew,
and
insert
conduit
through WIRE opening un
bottoms against block. Tighten
til it
thumbscrew.
Gun Control Cable
6
Insert
plug
into GUN CONTROL
receptacle, and tighten threaded
collar.
Strain Relief
7
Remove strain relief
8
shown.
as
PoweriWater Cable
Route cable
and
through
to
connect
FROM GUN outlet
stall strain relief.
strain relief
WELD/WATER
on feeder. Rein
Close and latch
door.
2
I
7
8
6
Tools Needed:
:~
FIgure
3-4.
518in.. l-1/8in.
Ref
ST-151 778-A/ ST-152 456
3-7. Water-Cooled Gun Connections
Internal Connections To Feeder
a
WARNING
ELECTRIC SHOCK
HiGH GAS PRESSURE
gas valve to leak.
kill.
can
Do not touch live electrical parts.
Turn OFF wire feeder and welding power source,
and disconnect input power before inspecting or
installing. Stop engine
on
welding generator.
CYLINDERS
can
explode
Keep cylinders away
from
if
damaged.
welding
and
Do not use gas pressure above 50 psi (345
mechanical gas valve in gun can leak.
OVERHEATING
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.
If
can
gun
kPa)
or
damage gun parts.
using recirculating
coolant system, do not make
connections from coolant system to water valve;
instead make connections directly from coolant
system to gun hoses.
INCORRECT
other
can cause
can
COOLANT
FLOWRATE
damage gun parts.
electrical circuits.
Maintain minimum 1
Never touch
cylinder
with
Always secure cylinder
other stationary support.
OM-1581
Page 6
qt./min.
flowrate at all times.
welding electrode.
to
running gear, wall,
or
w~warn7 1.9191
A.
Air-Cooled Feeder Connections
Gas Hose Grommet
1
Rear Panel
2
lOft.(3m)GasHose
3
Rear Of Gas
Fitting
one end of gas hose through
grommet, and connect hose to rear
Route
of GAS
fitting
maining
end
feeder. Connect re
of hose to regulator/
in
flowmeter.
Weld Cable To
4
Welding
Power
Source
Select and prepare weld cable
cording
welding
to
power
ac
source
manual.
5
Weld Cable Grommet
6
Reed Switch
7
Weld Cable Terminal In Feeder
Route
one
end of weld cable
connect to
feeder.
through
reed switch, and
grommet. through
weld cable terminal in
Connect
remaining
end of
cable to
minal
ter
Gun Weld Cable
8
Be
positive (+) weld output
on welding power source.
sure
that terminal of
er source
tact
with
welding
weld cable is in direct
terminal
from
gun
pow
con
weld
cable. Close and latch door.
4
2
6
7
3
Tools Needed:
5/8 in.. 1-1/8 in.
Ref. ST.151 771
Figure
3-8.
Air-Cooled Feeder Connections
OM-1581
Page
7
B.
Water-Cooled Feeder Connections
Obtain coolant supply.
Rear Panel
1
Gas Hose Grommet
2
lOft.(3m)GasHose
3
Rear Of Gas
Route
one
grommet.
of GAS
Fining
end of gas hose through
and connect hose to rear
fitting in feeder.
Connect
end of hose to
maining
re
regulator/
flowmeter.
4
Coolant
Supply
Hose Grom
met
5
10 ft.
(3 m) Water Supply
Adapter
Hose With 5/8 in.
Fit
ting
6
Rear Of Water
Fitting
Remove 5/8 in. adapter fining from
hose. Route one end of a water
hose through grommet, and con
nect to rear of WATER TO GUN fit
ting
in feeder. Connect
end to
supply fitting
on
remaining
coolant sup
ply.
7
Coolant Return Hose Grom
met
8
lOft. (3
m) Water
Return
Hose
Connect To
Positive (+) Weld
Output Terminal On
Welding Power
Source
Connect To
9
Regulator/
Flowmeter
Connection Block
Route one end of remaining water
hose through grommet. and con
nect to rear of connection block
(not shown). Connect remaining
end of hose to return fining on cool
ant
supply.
10
Weld Cable Grommet
11
Weld Cable To
er
Pow
Welding
Source
Select and prepare weld cable
to
cording
welding
power
ac
source
manual.
6
12
Reed Switch
13
Weld Cable Screw In Feeder
Route
one
end
of
weld
through grommet. through
cable
reed
switch, and connect to block in
feeder using hardware shown.
Connect
remaining
end of cable to
positive (+) weld output terminal
welding power
on
source.
Close and latch door.
11
2
9
3
Tools Needed:
~
5/Bin., 1-1/Bin.
Ref. ST.152 43l.A
Figure
OM-1581
Page
8
3-9. Water-Cooled Feeder Connections
3-5.
Adjusting Contact
a
Tube Position
WARNING
ELECTRIC SHOCK
~
can
Do not touch live electrical
Turn OFF wire feeder and
kill.
parts.
welding
power source, and disconnect
input
power before
inspecting
or
installing. Stop engine
on
welding generator.
wlwaml.1 9/91
1
Contact Tube
2
Nozzle
Adjusting
barrel changes contact tube
location from 1/16 in. (1.6mm) out end
of nozzle to 1/4 in. (6.3 mm) inside
nozzle.
3
Jam Nut
4
Barrel
change contact tube location, 100$en jam nut, and turn barrel. Tighten jam
To
nut.
sT-i 50 434/ Ref. 5T-150 431
Fig ure
3-6.
Voltage Sensing
a
3-10.
Adjusting
Contact Tube Position
Lead Connections
WARNING
E LECTRIC SHOCK
can
STATIC ELECTRICITY
kill.
on
Do not touch live electrical parts.
Turn OFF wire feeder and welding power source,
and disconnect input power before inspecting or
installing. Stop engine
on
damage parts
can
circuit boards.
Put on
boards
grounded wrist strap BEFORE handling
or
parts.
welding generators.
Iwam5.1
9/91
Unit is
factory set for constant volt
(CV) welding. To set unit for
constant current (CC) welding, pro
age
ceed
follows:
as
Strip
1
Terminal
2
Strain Relief
Loosen
3
screws
2T
of strain relief.
Voltage Sensing
Route
Lead
terminal end of lead
ring
through strain relief, and connect
ring terminal to terminal A of termi
nal strip 2T. Tighten screws of
strain relief.
Motor
4
Speed Control
Board
PCi
5
Jumper Plug
6
Receptacle RC5
For constant
voltage (CV) welding,
place jumper plug in tNT. position.
Do not connect
lead
clamp
to
voltage sensing
workpiece.
For constant current
(CC) welding,
place plug in EXT. position. Con
nect clamp end of voltage sensing
lead to
workpiece.
Reinstall right side panel.
Tools Needed:
EE~ZJz1J
1/4 in.
Ref. ST-151 772
Figure
3-11.
Voltage Sensing Lead Connections
OM-1581
Page9
3-7.
115 VAC/Contactor Control
Plug Information
Cord
1
Interconnecting
2
115 VAC/Contactor Control
Plug PLG5
If
welding power source is
equipped with matching 14-socket
receptacle, insert plug, and tighten
threaded collar. Proceed to Section
3-9.
If plug PLG5 will not connect to
welding power source receptacle.
use the following pin information
and Section 3-8 to replace PLG5
with a suitable plug.
PIn information to connect the
Remote
following equipment:
Voltage Control (Optional)
C
Command reference; +10 volts dc.
0
Remote control circuit
common.
E
Input
from potentiometer
command
signal
wiper;
0 to +10 volts dc.
Remote Contactor
G
l,J
K
Circuit
for 115 volts
common
Contact closure
Circuit
ac
completes the
circuit.
115 volts
ac
contactor control circuit.
common.
Remaining pins
are not
used.
Ref. S-0004.Af Ref. ST-151 772
Figure
Replacing
a
115 VAC/Contactor Control
Plug
With
Plug
Information
Supplied
5-Pin Or Twistlock
Plug
WARNING
ELECTRIC SHOCK
~-
115 VAC/Contactor Control
can kill.
Do not touch live electrical parts.
Turn OFF wire feeder and
welding power
source, and disconnect
input
power before
inspecting
or
installing. Stop engine
on
welding generator.
Have
only qualified persons
make
wiring
connections.
wlwarnl .1
-
3-8.
3-12.
gf9l
1
Interconnecting Cord
2
115 VAC/Contactor Control
Plug PLG5
Cut off plug.
3
5-Pin Plug
4
TwistloCk
5
2-Conductor Cord
Plug
For connections shown in either
Figure 3-3 or Figure 3-4, install
5-pin or twistlock plug as required,
onto 2-conductor cord.
For
Figure
3-2 connection, obtain
proper plug for connecting to con
tactor control receptacle on weld
ing power source. Install plug onto
2
2-conductor cord.
6
3-Conductor Cord
Obtain 115 VAC plug and connect
to 3-conductor cord as follows:
green lead to ground
white lead to 1I5VAC common
black lead to 11 5VAC hot.
Tools Needed:
7
Strip
Terminal
2T
3-2 connection, locate
white unnumbered lead in 2-con
ductor cord, disconnect lead from
For
Figure
terminal C, and reconnect to termi
nal E.
For either
Figure 3-3 or Figure 3-4,
jumper link from between
terminals B and C.
remove
Ret. ST-I 51 773
Figure
3-9.
3-13.
Replacing
115 VAC/Contactor Control
Plug
With
Supplied
5-Pin Or Twistlock
Plug
Installing Wire Spool
Turn OFF wire feeder and welding
power
1
2
source.
Spool
Top Cover
Wire
3
Pressure Roll
4
Gun Contact Tube
Assembly
If wire
spool is being replaced, open
pressure roll assembly in gun, and
cut welding wire off at contact tube.
For welding power sources without
contactor, retract wire onto spool.
For welding power sources with a
contactor, energize power source.
turn ON feeder, press Brake Re
lease button (see Figure 4-11), and
retract wire onto
spool.
Close gun pressure roll
and reinstall top cover.
5
assembly
Hub
6
Hub Pin
7
Compression Spring (Option
al)
8
Retaining Ring
Slide spool onto hub
so
wire feeds
off bottom. Turn spool until hub pin
fits hole in back of spool. Reinstall
retaining ring.
Tools Needed:
Thread
welding
3-10). Close
wire
(see Section
and latch door.
Ret. ST-151 771 / Ret. ST~O72 573~B / Ref. 5T-151 599
Figure
3-14.
Installing Wire Spool
OM-1581
Page
11
3-10.
Threading Welding
a
Wire
WARNING
ELECTRIC SHOCK
can
kill.
CYLINDERS
Do not touch live electrical parts.
explode
can
if
damaged.
Keep cylinders away from welding
and
other
electrical circuits.
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.
HOT SURFACES
can
Allow gun to cool before
Never touch
cylinder with welding electrode.
cylinder
Always
other stationary support.
secure
WELDING WIRE
burn skin.
running
to
gear, wall,
cause
can
or
puncture
wounds.
touching.
Do not press gun
trigger
until instructed to do
so.
Do not point gun toward any part of the
people,
or
any metal when
body, other
threading welding wire.
wfwaml.1
A.
9191
Threading Welding Wire Through Feeder
Turn OFF wire feeder and
power
8
1
welding
source.
Spool
Wire
Loosen wire from
spool, cutoff bent
wire, and pull Gin. (150 mm) of wire
off spool.
2
Tension Arm
3
Mounting
Arm
To open pressure roll assembly,
open tension arm and lift mounting
arm.
Wire Inlet Guide
4
1
5
Drive Roll
6
Wire Conduit
Thread
3
wire
guide, along
Fitting
through
wire
inlet
drive roll, and into fit
ting.
Close and
0
secure
pressure roll
as
sembly.
2
7
Tension Thumbnut
8
Jog
Switch
Loosen thumbnut until drive roll
slips when JOG switch is pushed
up. Grasp Spool with one hand, and
turn thumbnut clockwise until mo
tor
stalls
when
JOG
switch
is
pushed up.
Feed
welding wire through gun
(see Figure 3.16). Close and latch
door.
4
5
6
Tools Needed:
Ret. ST131 328 / Ret. ST151 778
Figure
3-15.
Threading Welding
Wire
Through Feeder
B.
Feeding Welding Wire Through Gun
Pressure Roll
1
Lift
arm
Assembly
and open pressure roll
as
sembly.
2
Wire Conduit
Lay
wire conduit Out
3
Jog Switch
straight.
Push JOG switch up to feed wire
wire conduit.
through
4
Drive Roll
5
Contact Tube
Manually
thread wire
along
drive
roll groove and out contact tube 2
in. (51 mm). Close pressure roll as
sembly.
6
Tension Thumbnut
7
Pressure
8
Final Pressure
Adjustment
Knob
Adjustment
Turn ON feeder and check drive roll
pressure by feeding wire against a
piece of wood or concrete surface;
wire should feed steadily without
slipping. If necessary, adjust pres
sure adjustment knob in gun.
Turn OFF feeder and welding pow
Reinstall gun cover.
er source.
Close and latch feeder door.
7
Ref. ST-131 328 / Ret. St-157 779 / Ref S-0651
Figure
3-16.
Feeding Welding
Wire
Through Gun
3-11. Coolant Guidelines To Prevent Corrosion
a
CAUTION
INCORRECT COOLANT OR COOLANT CONTAINING STOP-LEAK ADDITIVES
feeder cooling passages.
Use
only
Do not
a
use
mix of 50% distilled water and 50%
antifreeze
high quality
automotive antifreeze
as
can
corrode and/or
proper coolant for this
plug gun/
product.
containing stop-leak additives.
Use of other coolant voids
warranty.
OM-1581
Page
13
Minimize corrosion in the
1.
Use
and
gun/feeder
cooling system by following
only a mix of 50% distilled water and
50%
these
guidelines:
high quality automotive antifreeze that does
not contain
stop-leak
additives. Use of other coolant voids the warranty.
2.
3.
Do not
Be
unless it is discolored
change coolant
sure
electrical connections
are
or
dirty.
Add distilled water to maintain water level.
Do not make electrical connections with connectors made of different
tight.
metals.
SECTION 4-OPERATION
WARNING
4~
ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
Always
9,-~.
dry insulating gloves.
wear
ARC RAYS can burn eyes and
NOISE can damage hearing.
P
Wear
welding
skin;
helmet with correct shade of filter.
-
Insulate
from work and
yourself
Keep all panels and
covers
FUMES AND GASES
to your health.
m-~~
=~1
Keep your head
Ventilate area,
ground.
securely
can
Wear correct eye,
in
place
MOVING PARTS
0
be hazardous
~
or use
breathing device.
Do not weld
near
Do not weld
on
Allow work and
or
explosion.
flammable material.
Watch for fire: keep
Do not locate unit
fire
=~
Pacemaker
~
can cause
pinch points
injury.
such
covers,
as
and
drive rolls.
guards
wearers
keep
closed
away.
Wearers should consult their doctor before
s
near
extinguisher nearby.
over
body protection.
and
MAGNETIC FIELDS FROM HIGH CUR
RENTS can affect pacemaker operation.
I
~
can cause
away from
Keep all doors, panels,
and securely in place.
out of the fumes.
Read Material Safety Data Sheets (MSDSs) and
manufacturers instructions for material used.
WELDING
Keep
ear,
any
going
welding operations.
See Safety Precautions at beginning of manual for ba
sic welding safety information.
combustible surfaces.
closed containers.
equipment
to cool before
handling.
wfwarn3,1
1
Voltage/Wire Speed
(Optional)
2
Voltage/Wire Speed Switch
(Optional)
2
3
3
Run-In
4
Jog
1O!91
Meter
Speed Control
Switch
4
Burnback Time Control (Op
5
tional)
5
Spot/Continuous
6
Switch
(Op
tional)
Remote
7
6
Voltage Control (Op
tional)
8
Power Switch
9
Time
7
.
Range Switch (Option
al)
8
Time Control
10
Spot
11
Flowmeter
(Optional)
(Optional)
ST151 780
Figure
OM-1581
Page
14
4-1. Front Panel Controls Of Feeder
(Air-Cooled
Model
Shown)
2
1
3
1
Insulating Gloves
2
Safety Glasses With Side
Shields
3
Welding Helmet
/
~
Wear
d~ insulating gloves, safety
glasses with side shields, and a
welding
helmet
with
correct
a
shade of filter (see ANSI
Z49.1).
sb3.1 ¶0/91
Figure
4.2.
Safety Equipment
1
~/2
Work
Clamp
Use wire brush
or
clean metal at weld
sandpaper
joint area.
Connect work clamp to
a
to
clean,
paint-free
as
2
location on workpiece,
close to weld area as possible.
Voltage Sensing Cable
Clamp
Tools Needed:
Connect to work clamp for constant
current (CC) operations (see Sec
tion 3-6).
Figure
4-3. Work And
Voltage Sensing
Cable
Ref
S0~144 aSiA
Clamps
I
Run-In
Speed Control
Use control to set wire feed speed
before arc initiation.
After
arc
initiation, wire feed speed
is controlled
Control
on
by
the
the Wire Speed
welding gun (see
Figure 4-12).
1
The scale around the Control is per
cent of full range, not wire speed.
Ref. ST-131 326
Figure
4-4. Run-In
Speed
Control
1
~
Use switch to
energize
drive mo
tots in feeder and gun without ener
JOG
gizing welding
power source con
tactor. When Switch is held up in
1
JOG position, wire speed is set by
Wire Speed Control on gun.
~\~.-~:~!:i i i i
Figure
Jog Switch
4-5.
Jog Switch
OM-1581
Page
15
1
Voltage/Wire Speed Meter
2
Voltage/Wire Speed Switch
When switch is in VOLTAGE posi
tion, and operator is welding, meter
displays arc voltage. Cable resis
tance and poor connections may
~OLT~E/WIRE SPEED
METER (OPflO~AL)
V/olo
displayed voltage to vary
slightly from actual voltage at weld
ing arc.
cause
1
When switch is in WIRE SPEED
2
position and operator is welding,
meter displays wire speed in in
ches per minute. This wire speed is
set by Wire Speed Control on the
gun.
During
run-in portion of weld cycle.
run-in speed as se
lected on RUN-IN SPEED control
I
meter
WIRE
SPEED
on
displays
feeder (see
Figure 4-4).
When
welding Direct Current Elec
trode Negative (OCEN), meter
does not display accurate output
voltages; however,
accurate wire
Figure
4-6.
Voltage/Wire Speed Switch
And Meter
meter displays
speed values.
(Optional)
1
Spot/Continuous Switch
Use switch to select either an un
timed continuous weld cycle or a
timed spot weld cycle. Both weld
cycles consist of the following
steps: run-in, weld (untimed
time), and burnback.
2
Time
Range
or
spot
Switch
3
Use switch to select spot weld time
range.
3
Spot
Time Control
Use control to set spot weld time.
wire feeds at speed se
Welding
lected
trol.
on
the gun Wire Speed Con
starts at arc initia
Spot time
tion.
The scale around the control
2
is
marked in seconds.
4
Burnback Time Control
Use control to
adjust
time
(up
to
0.25 seconds) that the welding wire
is electrically energized after the
wire stops
feeding.
If
welding wire sticks in the weld
puddle, increase burnback time. If
wire burns back into the gun con
tact tube, decrease burnback time.
The scale around the control
marked in seconds.
Figure
OM-1581
Page
16
4-7.
Spot Controls (Optional)
is
Voltage Control
1
Use control to adjust
the wire feeder.
arc
voltage
at
The scale around the control is
marked in percent.
Figure
4-8. Remote
Voltage
Control
(Optional)
I
Power Switch
Use switch to turn unit ON and OFF.
I
POWER
0 OFF
Figure
a
Wire
Be
4-9. Power Switch
CAUTION
feeding system is designed for maximum of
sure
that
regulator/flowmeter
has
preset conditions of
50
no more
psi (345 kPa) gas pressure.
than 50
psi (345 kPa) gas
pressure.
1
Flowmeter
2
Valve
________
Use flowmeter to control shielding
gas flow at the feeder. The scale on
the flowmeter is in cubic feet per
hour (CFH). Read gas flow at the
1
_______
CFI-~
Ar
CO2
widest part of the float in the meter.
Rotate valve to change gas flow as
necessary.
60
A
50
40
regulator is still required
shielding gas supply with this
~
40
30
30
20
20
on
op
tion.
100101
S 06 59
Figure
4-10. Flowmeter
(Optional)
OM-1581
Page
17
Open left
side door.
FuseFi
1
See Section 5-10.
Circuit Breaker CBI
2
See Section 5-10.
3
Motor
Torque Switch
Use switch to select the force used
to push wire. The up position is for
low force, or torque. The down po
sition is for
2
If
3
high force,
welding
wire
kinked, nicked,
Switch in low
4
4
or
torque.
appears
to
be
damaged, place
torque position.
or
Brake Release Button
Whenever power is ON and the
welding power source is ener
gized, button may be pressed torelease spool brake so wire spool can
turn
freely.
Close and latch door.
Ret. ST151 779 / Ref S120 552-A
Figure
4-11. Internal Controls
1
Trigger
Press trigger to energize welding
power source contactor (if applica
start shielding gas flow, and
ble),
wire feed.
begin
For
shielding gas preflow and postflow, lightly press trigger before
and after welding.
2
Trigger Hold
Use button to
without
Button
continually feed
holding
down the
wire
trigger.
2
Press button while
trigger,
pressing the
trigger, and wire
teed until trigger is
release
continues to
pressed again.
3
Wire
Speed Control
to adjust wire feed
speed. The numbers around the
control are for reference only.
Use
3
control
Ref ST.,51 666
Figure
a
WARNiNG
BUILDUP OF SHIELDING GAS
Shut off
..
4-12. Gun Controls
shielding
gas
supply
can
harm health
or
kill.
w hen no tin use.
~
warni
2
I
Shielding Gas Cylinder
2
Valve
3
Gun
ODen
welding.
9/91
Trigger
valve
Purge
I
on
cylinder just
air from gas line
before
by lightly
pressing gun trigger.
Close valve on
ished welding.
cylinder
5b5 l~ 1O91S0621-CRef
Figure
OM-158t
Page
18
4-13.
Shielding
Gas
when fin
ST.151 666
Coolant Supply
1
Turn
1
on
coolant
supply
before
welding.
\~
Turn oft coolant
ished welding
~De
supply
when fin.
eQe
,~
...
4-14. Coolant
Figure
Install &
Connect
)
)
Put On
Personal Safety
Equipment~,JJ
I
For Water-Cooled Models
Supply
Shielding~\
)
Set
I I
On
Gas And Water
All
,JJ
Equipment
Ref. ST-150 755-A
-..-_.
Controls
( Applicable)
I
Only
Turn On
)
Equipment
J,
Readjust Controls~\
I
And Prepare
)
For
Production}
Figure
4-15.
Sequence Of
Gas Metal Arc
Welding (GMAW)
-
Continuous Or
Spot
SECTION 5- MAINTENANCE & TROUBLESHOOTING
a
WARNING
ELECTRIC SHOCK
can
kill.
HOT PARTS
Do not touch live electrical parts.
Allow
can cause severe
cooling period
before
burns.
servicing gun
or
unit.
Turn OFF wire feeder and welding power source,
and disconnect input power before inspecting,
maintaining,
generators..
or
servicing. Stop engine
MOVING PARTS
can cause
on
welding
injury.
Keep away from moving parts.
ance
Keep away from pinch points such
5-1.
as
to
be
performed
only by qualified
drive rolls.
wfw arn4
9~9~
Routine Maintenance
Table 5-1. Maintenance Schedule
Maintenance
Time
Before each
use.
Check gun parts for looseness, cracks, and breaks: tighten, repair, and replace parts as re
clean weld spatter or dirt from around nozzle opening using a hardwood stick,
never a metal tool.
quired. Carefully
Every month.
More than normal
equipment use: Check all labels (see 6 month entry), repair any damaged
replace gun or work cable, clean internal parts (see 6 month entry), clean and tight
connections at gun cable and work clamp.
insulation
en
Every
3 months.
or
Repair cable insulation damage
clamp connections.
or
replace gun
or
work cable. Clean and
tighten
gun cable and
work
Every
6 months.
Replace any labels that
are
unreadable
unit outer enclosure to blow out
or vacuum
or
or vacuum
damaged (see Section
7 for
dust and dirt from inside
using
part number). Remove
a
clean, dry airstream
suction.
OM-1581
Page
19
5-2.
a
Changing Or Cleaning Gun
WARNING
Drive Roll
ELECTRIC SHOCK, MOVING PARTS, AND HOT PARTS HAZARDS. Read safety infor
mation at beginning of Section 5 before proceeding.
Turn OFF wire feeder and
welding
power source.
1
Top Cover
2
Pressure Roll
Assembly
Cut oft wire where it enters pres
sure roll assembly area.
3
Setscrew
4
Current Pick-Up Tab
This tab
burnback
caused
inside the
helps prevent
by welding arcs
contact tube. This tab may be re
moved to provide an insulated
drive roll.
(If tab is removed, a
smaller diameter contact tube is
recommended. See options in
Parts List). Lightly grease top of tab
before reinstalling.
Drive Roll
5
Use wire brush to clean drive roll.
Install drive roll with desired groove
down, and turn drive roll so one set
screw faces flat side of shaft.
6
Bearing
7
Liner
Line up drive roll groove with bear
ing groove and liner opening. Tight
en
If
setscrews.
changing
drive roll in feeder, pro
ceed to Section 5-3.
Thread
welding wire through gun.
adjust drive roll pressure, if
)see Figure 3-16).
necessary
and
Close and
sembly.
secure pressure roll
Reinstall top cover.
as
Tools Needed:
5/16 in.
Ret. ST~151 599
Figure
OM-1581
Page
20
5-1.
Removing Gun
Drive Roll
5-3.
a
Changing Feeder
WARNING
Drive Roll And Wire Inlet Guide
ELECTRIC SHOCK, MOVING PARTS, AND HOT PARTS HAZARDS. Read
mation at beginning of Section 5 before proceeding.
safety
Turn OFF wire feeder and
power
source.
Lay wire
infor
welding
conduit Out
straight.
Open gun pressure roll assembly,
and cut welding wire oft at contact
tube.
1
Pressure Roll
2
Wire
Assembly
Spool
For welding power sources without
contactor, retract wire onto spool.
For
2
welding
contactor,
power
sources
with
a
energize
power source.
turn ON feeder, press Brake Re
lease button, and retract wire onto
spool.
6
3
Shaft
4
Setscrew
5
Drive Roll
Use wire brush to clean drive roll.
Install drive roll with desired groove
in, and turn drive roll so one set
screw
faces flat side of shaft.
6
Bearing
7
Wire Conduit
Fitting
Line up drive roll groove with bear
ing groove and opening in conduit
fitting. Tighten
setscrews.
8
Wire Inlet Guide
Pull
guide
remove.
Thread
(see
rear
new
welding
drive roll
cure
toward
Install
of feeder to
guide.
wire and
pressure.
adjust
if
necessary
Section 3-10). Close and se
pressure roll assembly. Close
and latch door.
Close gun pressure roll
and reinstall gun cover.
assembly,
Tools Needed:
5/16 in.
Ret
Figure
5-2.
Changing
ST.151 781
Feeder Drive Roll Or Wire In let Guide
OM1581
Page
21
5-4.
a
Replacing Or Cleaning Gun
WARNING
Drive Roll
Bearing
ELECTRIC SHOCK, MOVING PARTS, AND HOT PARTS HAZARDS. Read
mation at beginning of Section 5 before proceeding.
safety
Turn OFF wire feeder and
power
infor
welding
source.
1
Top Cover
2
Pressure Roll
3
Screw
4
Shoulder Washer
5
Drive Roll
Remove
as
Assembly
Bearing
shown.
Use a wire brush to clean bearing.
Reinstall with washers, and tighten
screw.
Close pressure roll assembly. Re
install top cover.
Tools Needed:
Ref. ST.151 599
Figure
5-5.
a
5-3.
Removing
Replacing Or Cleaning Feeder
WARNING
Gun Drive Roll
Drive Roll
Bearing
Bearing
ELECTRIC SHOCK, MOVING PARTS, AND HOT PARTS HAZARDS. Read safety infor
beginning of Section 5 before proceeding.
mation at
Turn OFF wire feeder and
welding
power source.
1
Pressure Roll
2
Retaining Ring
3
Mounting
4
Hinge
5
Screw
6
Shoulder Washer
7
Drive Roll
Remove
Use
a
Assembly
Arm
Pin
as
Bearing
shown.
wire brush to clean
Reinstall, and
tighten
Close pressure roll
Close and latch door.
bearing.
screw.
assembly.
Tools Needed:
R& ST.~5~ iSi
Figure
OM-1581
Page
22
5-4.
Replacing
Or
Cleaning
Feeder Drive Roll
Bearing
5-6.
Changing
Gun Contact Tube And Liner
ELECTRIC SHOCK, MOVING PARTS, AND HOT PARTS HAZARDS. Read safety infor
a WARNING
mation at
beginning
of Section 5 before
proceeding.
Turn OFF wire feeder and
welding
power source.
Remove top
roll
sure
Figure
1
and open pres
as shown in
cover
assembly
5-3.
Contact Tube Wrench
2
Insert wrench into nozzle
over con
tact tube.
2
Compression
Nut
Loosen nut. Pull out contact tube.
3
3
Contact Tube
4
Nozzle
Pull
4
wire out nozzle and liner
should slide out. If necessary. lilt
nozzle down to remove liner.
Close pressure roll assembly. Re
install top cover.
Install
over
liner and contact tube
new
wire. Cut off wire at end of
con
tact tube.
Tighten
Tools Needed.
nut
secure.
just
until contact tube is
Overtightening
will
nut
damage adapter.
ST-150 437
Figure
5-7.
A.
Replacing
5-5.
Contact Tube
Changing Gun Contact
Tube And Liner
Adapter
Air-Cooled Models
a WARNING
ELECTRIC SHOCK, MOVING PARTS, AND HOT PARTS HAZARDS. Read
mation at beginning of Section 5 before proceeding.
safety infor
Turn OFF wire feeder and
power
1
Barrel Extension
Remove
as
Contact Tube
3
Compression
see
Nut
Section 5-6.
4
Contact Tube Adapter
5
Head Tube
6
Head Tube Setscrew
Loosen
Tools Needed:
shown.
2
To remove,
2
welding
source.
setscrews
and
remove
adapter.
Install
new
screws.
3/32
fl.
adapter and tighten
Reinstall
compression
contact
set
tube,
nut, and nozzle.
ST150 430.A
Figure
5-6.
Removing
Contact Tube
Adapter
OM-1 581
Page
23
B.
Water-Cooled Models
WARNING
a
WATER IN GUN PARTS
Turn OFF
welding
power
can cause
source
and water
Always point gun downward
when
Wipe gun dry before putting
it back
ELECTRIC SHOCK and
supply
removing
before
working
on
water-cooled barrel to
can
lower weld
gun. Stop engine
keep
on
water Out of gun
quality.
welding generators.
parts.
together.
Turn OFF weld control and
power
I
Nozzle
2
Nozzle
Remove
2
3
Adapter
as
shown.
Contact Tube Adapter
Use wrench to
Coat
Tools Needed:
welding
source.
remove
adapter.
adapter with thread locking compound (such as Loctite No.
242), and install.
new
3/32 in.
ST.150431
Figure
5-8.
a
Replacing
Hub
WARNING
5-7.
Removing Contact Tube Adapter
Assembly
ELECTRIC SHOCK, MOVING PARTS, AND HOT PARTS HAZARDS. Read
beginning of Section 5 before proceeding.
safety
infor
mation at
Turn OFF wire feeder and
power
cover
sembly
as
shown in
Retract wire onto
move
welding
Remove gun top
and open pressure roll as
source.
Figure
5-3.
and
re
spool. Take hub apart
as
spool
shown.
1
Metal Brake Washer
2
Flat Washer
3
Brake Washer
4
Hub
5
l(eyed
6
Spring
7
Cap Screw
8
Retaining Ring
Washer
Replace broken
or worn
slide parts onto shaft
as
parts and
shown.
Adjust hub tension (see Section
5-9). Thread welding wire (see
Section 3-10). Close and latch
door.
Close gun pressure roll assembly
and reinstall gun cover.
Tools Needed:
ST~l51 778 / Ref ST.143 223-A
Figure 5-8. Hub Assembly
OM-1581
Page
24
5-9.
Hub Tension
Adjusting
WARNING
a
ELECTRIC SHOCK
can
kill.
Do not touch live electrical
parts.
The welding wire, drive rolls, drive assembly, and all metal parts touching the welding wire are electrically live when welding power
source is energized.
This procedure requires an energized welding power source and wire feeder. Only qualified persons are to make this adjustment.
Turn ON welding power source and
wire feeder to make this adjustment.
1
Wire
Speed Control
Adjust
welding.
control to wire
2
speed for
Jog Switch
Push up, and then release JOG
switch. Hub tension is okay if wire
freely, but wire does not
backlash when JOG switch is re
unwinds
leased.
3
Cap Screw
Turn cap screw to adjust hub ten
sion. Do not overtighten. Turn OFF
power source and wire
feeder. Close and latch door.
welding
Tools Needed:
Pet. ST-i 51 666 / Pet
Figure
5-9.
Adjusting
ST.13I 328 1ST-I 51 778
Hub Tension
5-10. Overload Protection
a
WARNING
ELECTRIC SHOCK AND HOT PARTS HAZARDS. Read
of Section 5 before proceeding.
safety
information at
beginning
3
Turn OFF wire feeder and
welding
power
2
Fuse Fl (See Parts List For
Size)
trigger
Insert
opens.theunitshutsdown.Tocheckor
change Fl, proceed as follows:
fF1
1
Fuse Holder Cover
new
with cover
fuse into
cover,
by pressing
and install fuse
and
turning
pulled. The gun
drive motor oper
clockwise.
3
Check for blocked gun liner.
cover
Circuit Breaker CBI
Check for jammed wire, binding drive gear or
misaligned drive rolls in feeder. Correct prob
lem.
Allow
Press and turn
is
ates in the JOG mode with CB1 open.
source.
cover
counterclockwise. Pull
out fuse with cover.
Figure
If CBI opens, the gun drive motor and confactor will not operate, but gas flows when
cooling period
and
manually
reset
breaker. Close and latch door.
Pet. ST.1S1 179/ Pct
ST.15i 186
5-10. Fuse Fl And Circuit Breaker CB1
OM-1581
Page
25
5-11. Water Flow Switch
For Water-Cooled
(Optional
Models)
The water flow switch protects the gun from overheating. If coolant flowrate drops below 1 qt.Imin., the water flow
switch opens and stops the welding wire from feeding. See Table 5-2 for remedies to this trouble.
5-12.
Troubleshooting
WARNING
a
ELECTRIC SHOCK
can
M OVING PARTS can
kill.
Keep away from
Do not touch live electrical parts.
Turn OFF
welding
power source, and disconnect
input power before inspecting, maintaining,
servicing. Stop engine on welding generators.
HOT PARTS
Allow
can cause severe
cooling period
before
or
servicing
or
injury.
moving parts.
Keep away from pinch points
such
drive rolls.
as
or
burns.
gun
1~
cause
unit.
9~
Troubleshooting
to
be
performed only by qualified
persons.
swarn9 2
10/91
Table 5-2. Wire Feeder Trouble
Trouble
Section
Remedy
Pressing gun trigger does not energize
Welding wire is not energized.
Shielding gas flows.
-~
feeder.
Secure plug from gun control cable into GUN CONTROL recep
tacle on feeder.
---
--
Secure 115 VAC input plug connection.
Check fuse Fl.
Check water connection to feeder
-~
--a
sure
coolant
supply
Factory
is turned ON.
Authorized Service Station check
Troubleshooting
section in
terminals B and C
Check position of Motor
-a
or
Align drive
bearing.
Arc varies and
when
feeding
welding
wire is kinked
Pressing gun trigger Will not feed wire,
is not energized, shielding gas
wire
flows, and JOG switch activates motor.
OM-1581
Page
-~
26
-~
clean drive rolls
roll with
connection.
terminal
power
strip
source
manual.
2T.
Figure
4-14
5-11
opening
as
--
--a
--
3-8
Figure
switch.
necessary.
in gun conduit
fitting
Torque switch in low torque position
(0.8 mm) aluminum welding wire.
Reset circuit breaker COl.
--a
-a
if necessary.
Place Motor
.030
Out gun.
on
plug
welding
Torque
Adjust drive roll pressure
Replace
optional
--a
3-3. 3-4
switch, if applicable.
Secure 115 VAC/contactor control
Jumper
erratically.
--a
Be
See
Wire feeds
gun.
--a
Have nearest
but
or
Check for kinks in water hose.
water flow
Wire feeds, shielding gas flows,
welding wire is not energized.
5-10
-~
-a
3-10
-a
5-2.5-3
and groove in
if
welding
with
4-11
5-3
-~
]~i
Figure
4-11
5-10
Trouble
Remedy.
Feeder feeds wire but remains in run-in
mode after arc initiation.
-~
Route weld cable
If constant current
on
through
Section
sensing relay.
current
(CC) welding, be
sure
3-4
-~
PLG5 is in EXT. position
-~
PCi, and voltage sensing lead is connected.
If constant voltage (CV) welding, be sure PLG5 is in INT.
PCi, and that voltage sensing lead is not connected.
position
-~
3-6
-~
3-6
on
Feeder feeds wire, but switches from
weld mode to run-in mode while CV
welding
with
voltage sensing
lead in
leak
valve in
-~
Be
PLG5 is in INT.
sure
position
~
PCI.
on
stalled.
Shielding gas
through gas
~
Reduce
ceed 50
gun.
shielding gas pressure
psi (345 kPa).
at
regulator flowmeter.
Do not
ex-
-~
Table 5-3. Gun Trouble
Trouble
No weld output;
work.
gun/feeder
Section
Remedy
does not
-~
Secure 115 VAC input
Place POWER switch
Erratic weld output.
~
Pressing gun/feeder trigger does not
energize weld control; welding wire is
not energized; shielding gas does not
-~_Tighten
-~
Secure
plug
on
in 115 volts
welding
ac
receptacle.
power source in the ON
-~
position.
-~
-s~
and clean all connections.
plug from gun
control cable into 10-socket
receptacle
on
-~
3-3
-~
5-2
wire feeder.
flow.
Wire does not feed; burnback in contact
-~
tube.
Reinstall current
pick-up tab
if
~
applicable.
_______________________________________________________I
_____________
Wire feeds, shielding gas flows, but
welding wire is not energized.
Wire feeds
erratically.
Gun overheating (water-cooled mod-
els)
-~
-~
~
I
-~
See Troubleshooting section in
Manual.
welding
power
source
Owners
-~
5-2, 5-3
Check and correct drive roll pressure.
~
-~
3-10
Clean drive roll
~_
-~
5-2, 5-3
Be
sure
or
replace
drive roll.
coolant flowrate is at least I
qt./min.
-~
___________________________________________________
Corrosion buildup in gun decreasing coolant flowrate. Backilush
coolant system, clean coolant system filter, and clean fittings.
____________
~
3-11
OM-1581
Page
27
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sPt~cE-
Wiring
6-2.
RELAY
Figure
I~1
L
RE D
P. C
I
8(PLGI4-2) 86(PLG3-5) IOA(PLG3
0
I
n P1
_ L62~4r~A
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9)
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S
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PLG2
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31
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BRAKE
-
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PC4
r
GUN
ASSEMBLY
PULL
MOTOR
I
TRIGGER
-~-::-
-00-
I
PBI
___J
L.
,/
/
~,
PLG2
B
C
D
A
-/
G
~______
E
F
H
______
CORD
#1
CORD
#2
SA-138 956-A
Figure
6-3. Circuit
Diagram
For Gun
P4
HOUSING
SB-139 060-A
Figure
OM-1581 Pac~e3O
6-4.
Wiring Diagram
For Gun
NOTES
OM-1581
Page
31
SECTION 7
PARTS LIST
N
N
N
N
C
a
C)
N
0,
N
N
(%1
N
0
N
0)
C.,
C.)
0
N
U,
>.
.0
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r-
E
U)
~
I
C.)
N
CC)
0
a,
N
U,
C.)
U,
CO
U,
0
CO
U)
C.)
0,
U,
N
OM-1581 Page 32
+113
Part
No.
Dia.
Item
No.
Mkgs.
Description
Figure
089572..
112167..
.2
3
134327
.4
569
..
5
126415
..
6
7
126416
058 427
8
602 233
..
9
057 543
..
10
113 168
..
..
.
.
11
058428
..
12
089 561
..
13
058 424
14
151 697
.
.
15
112 198
.
.
16
030 170
17
057 357
.
..
..
.
17
057 357
..
17
070 371
..
18
057 358
.
19
20.... PC3
PLG7,8,ll
083
147
114
538
..
115
094
..
113 746
PLG9
..
115
.
.
..
113746
PLG1O
115
..
093
113746
21
073302
22
113161
113165..
.23
120396
24
25....MP1
....
113180..
113900
26
.28
601228..
601226..
29
600848..
30
603106
31
115 104
32
000527..
.27
049455
33
34...
PLG5
...
.
141 162
134731
079739
35
007826
36
139042
37
139042
37
38.... PC1
PLG1
.
.
.
.
.
.
.
.
PLG2....
142053
115092
PLG3....
PLG4....
21
.40....C13
.41....SN1
.39....
1
HANDLE, molded
RING, retaining spool
1
WASHER, flat stl .250 ID x .875 OD x .O62thk
SPRING, cprsn .845 OD x .091 wire x 1.500
1
WASHER, locking
2
1
HUB, spool
WASHER, anti-turn stl
WASHER, fbr brake
STRIP, brake surface anti-turn
SHROUD, spool wire 12 in
BUSHING, snap-in nyl .750 ID x 1.000mtg hole
BUSHING, snap-in nyl .937 ID x 1.l25mtg hole (XR-W model)
BUSHING, snap-in nyl .937 ID x 1 .1 25mtg hole (XR-A model)
BLANK, snap-in nyl 1.093/1 .l25mtg hole (XR-A model)
BUSHING, snap-in nyl 1.000 ID x 1 .375mtg hole
GROMMET, scr No. 8/10 panel hole .312sq .500 high
CIRCUIT CARD, spot-burnback
HOUSING PLUG & SOCKETS, (consisting of)
TERMINAL, female lskt 24-18 wire
BEARING, ball rdl sql
BLOCK, bearing front
row
STAND-OFF, .250-20
SHAFT, spool
x
..
.669
x
1 .378
110079
..
1
1
4
1
3
x
.39
1
2
1
1 .000
Ig
...
..
1
2
4
BRAKE, fsbr reverse mtg power off
BLOCK, bearing rear
CLAMP, Univ 25A
INSULATOR, vinyl clamp univ 25A
WIRE, lead mot 1 2ga strd (order by ft)
HOSE, nprn brd No. 1 x .250 ID (order by ft)
CONNECTOR, clamp cable .500
BLANK, snap-in nyl .875mtg hole
CABLE, port No. 18 2/c (order by ft)
HOUSING PLUG & PINS, (consisting of)
TERMINAL, male 1 pin 18-14 wire
CLAMP, cable strain relief sz 17
CABLE, port No. 18 3/c (order by ft)
BUSHING, strain relief .270/.480 ID x .BO4mtg hole
BUSHING, strain relief .270/480 ID x .8O4mtg hole
CIRCUIT CARD, motor speed control
HOUSING PLUG & SOCKETS, (consisting of)
TERMINAL, female lskt 24-18 wire
HOUSING PLUG & SOCKETS, (consisting of)
TERMINAL, female lskt 24-18 wire
HOUSING PLUG & SOCKETS, (consisting of)
TERMINAL, female lskt 24-18 wire
HOUSING RECEPTACLE & SOCKETS, (consisting of)
TERMINAL, female iskt 24-18 wire
BLOCK, term 20A 12P
....
..
1
1
6
113 746
117 500
1
8
115 091
038 783
1
HOUSING PLUG & SOCKETS, (consisting of)
TERMINAL, female lskt 24-18 wire
....
.
1
HOUSING PLUG & SOCKETS, (consisting of)
TERMINAL, female lskt 24-18 wire
..
113 746
1
1
....
..
1
CLAMP saddle
115 094
131 054
2
WRAPPER
113 746
113 746
Assembly
CATCH, link-lock
INSULATOR, door
LABEL, warning general precautionary
....
092
7-1. Main
Quantity
4
1
1
1
35ff
ift
1
1
lift
14
lift
2
8
1
4
10
1
2
1
CAPACITOR
SNUBBER, polye MF .5uf200VDC
1
OM-~581 Page 33
Part
No.
Dia.
Item
No.
Mkgs.
Figure
42
.
43...
.
44.
.
.
.
45...
.
.
46..
.
.
.
.
.
R35
.
C9
C14
...
..
..
4T
47
605 741
.
.
030 087
.
.
114 215
.
.
044602
.
.
038 785
.
.
083 147
.
.
.
.
.
.
.
48
111 152
.
.
49
+131 308
.
.
153 901
.
.
50
605 970
.
.
50
605 970
.
.
090 465
.
.
52
53
090 439
.
.
089 573
.
.
54
131 318
.
54
113 166
.
.
117 498
.
.
51
.
.
.
..
.
.
Ti
.
.
117 496
.
.
075 150
.
.
010 910
.
.
601 872
.
.
.
.
55
131 311
56
150 067
.
.
7-3
.
.
121 276
.
.
834
.
.
+089
120
.
.
13i
429
.
.
62
62
604 657
.
.
079 240
.
63
602 213
.
.
64
602 243
.
.
65
151 663
.
.
664
.
.
Fig
57
58
134
59
60
61
.
.
.
.
S8
15i
65
151 662
66
67.
.
.
.
S7
68
.
.
.
Oil 770
.
.
113 565
.
.
432
Fig
69
7-2
010 546
70
REED
71
...
....
72
Fl
73.
.
.
.
.
.
.
.
74
75.
..
.
76..
.
.
77..
.
.
S4
CB1
31
.
.
.
.
140 786
.
.
010 493
.
.
.
.
*0i2 663
046 432
.
.
Oil 232
.
.
011 002
.
038 861
.
601 219
.
.
.
.
7-1. Main
Assembly (Continued)
CLIP, mtg resistor .312 ID core
RESISTOR, WW fxd 25W 200 ohm
CAPACITOR, polye film 2.3uf 25OVAC
CAPACITOR, polye film .47uf400VDC
STRIP, term 3P
GROMMET, scr No 8/10 panel hole .312sq .500 high
SKID, base
CABINET, control
LABEL, caution the recommended coolant to be
WASHER, shldr nyl .310 OD x .252 ID x .064 (XR-W model)
WASHER, shldr nyl .310 OD x .252 ID x .064 (XR-A model)
TRANSFORMER, signal 115V 24VCT 4A
LABEL, warning electric shock can kill
PLATE, keeper link-lock
INSULATOR, block connection (XR-W model)
INSULATOR, term (XR-A model)
TERMINAL, pwr weld (XR-A model)
WASHER, fbr .312 ID x .750 OD x .O62thk (XR-A model)
WASHER, shldr nyl 1.000 OD x .375 ID (XR-A model)
WASHER, flat stl SAE .375 (XR-A model)
NUT, stl hex full .375-16
BLOCK, connection
FITTING, water block extension
PANEL, front w/components
BUSHING, strain relief .709 lOx 1.li5mtg hole
HOSE, SAE .187 ID X .41000 (order by ft)
CLAMP, hose .375-.450c1p dia slfttng
SWITCH, flow w/fittings
SCREW, cap stl hexhd .375-16 x 1.250 (XR-W model)
SCREW, cap sti hexhd .375-16 x 1 .750 (XR-A model)
WASHER, lock sti split .375
WASHER, flat stl std .375
FITTING, plug water block
FITTING, diverter water block
FITTING, pipe brs plug hex .125NPT
FITTING, brs barbed M 3/i6tbg x iJ8NPT
Part
a
DOOR, RH
BUSHING, snap-in nyl .375 ID
34
1
1
1
4
2
1
4
3
1
2
1
2
1
2
2
1
1
2ft
4
1
1
1
2
2
1
hole
1
SWITCH, reed
BUSHING, snap-in nyl .625 ID x .875mtg hole
FUSE, mintr gI slo-blo 3A
HOLDER, fuse mintr .250 x 1 .250 panel mtg
SWITCH, PB SPDT
1
CIRCUIT BREAKER,
BLOCK, term 20A 3P
x
man reset
.500mtg
1
1
1
.7A
LINK, jumper term blk 20A
2
the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
Page
1
1
MOTOR & WIRE DRIVE
of 114 ~
OM-1581
2
SWITCH, tgl SPDT 5A 125V
component originally displaying a precautionary label,
Spot Weld Control Option
of 144 931 Voltage Control Option
Part
Part
of 130 838 Water Flow Safety Switch Option
*Recommended Spare Parts.
+When
ordering
....
.
.
073
66
Quantity
Description
115191
058
147625
604612
Part
No.
Dia.
Item
No.
Mkgs.
Description
Figure
2.
058 968
3.
605 798
4.
120395
5.
112713
6.
409
7.
112887
8.
057 544
9.
10.
120397
147626
11
058549
12.
602 306
13.
008 667
14.
113170
15.
147624
16.
17.
054 263
18.
120398
19.
20.
602169
605971
21
113162
22. ..B1.
113178
23.
113169
24.
7-2. Motor & Wire Drive
DRIVE ASSEMBLY, wire
RING, retainer E
Quantity
(Fig
7-1 Item
69)
(consisting of)
WASHER, shldr nyl .37500 x .168 ID
SPRING, tension pressure roll
ARM, pressure roll
x
.O8Othk.
4
BEARING
PIN, hinge
1
SPRING, cprsn .240 OD x .026 wire x 1 .000
NUT, thumb tension adjustment
COVER, gear wire drive
GUIDE, wire inlet 1/16
PIN, spring CS .125 x .500
BEARING, ball rdl dbl row .250 x .687 x .31
GEAR &SHAFT, motor
CASE, gear wire drive
BLOCK, anchor conduit
SCREW, thumb stl .250-20 x .500
ROLL, drive V groove .030-1/16 wire
SCREW, set stl sch 8-32 x .187 cup point
WASHER, shldr nyl .236 OD x .195 ID x .O42thk
INSULATOR,motor
MOTOR, torque 115VAC
GEAR, driver
SCREW, set sti sch 8-32 x .125 cup point
1
1
2
2
1
1
1
1
2
3
2
1
12
15
19
18
17
22
*Includes
Items 15-19
S8.lI4 IES.F
Figure
7-2. Motor & Wire Drive
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM.1581 Page 35
See F~g 7-1
Item
.12
.13
14
15
16
.17
23
22
21
20
SB-145 t27-A
Figure
OM-1581
Page 36
7-3.
Panel, Front w/Components (XR-W Model Illustrated)
Item
No.
Part
No.
Dia.
Mkgs.
Description
Figure
Panel, Front w/Components (Fig 7-1 Item 57)
METER, flow 6-60
GUARD, flow meter
++134 834.. HOSE, SAE .187 ID x .410 OD (order by ft)
++056 851
FITTING, hose brs barbed nipple 3/l6tbg
1
1
++111 569..
2
1
++111 633..
3
.
.
++010 606
.
.
++056 108
.
.
++045 852
.
.
4
++089 120..
5
++112 090..
6
097 922..
7
8
139 678..
000 527..
9
000 434..
8
iis
10
11
7-3.
Quantity
....
PC2
....
PLG12
.
..
443..
139
897..
iis
090..
114 656
PLG13
...
113 746
PLG15
...
...
12.... R44
14
.
.
.
.
.
.
.
.
.
.
.
.
.
073562..
S2
120400..
+4028770..
R45,46
15....
.
4131 055..
113 746
136 339
120 304
13....
.
+115092..
113 746
PLGI6
.
094..
115
S6
.oii
770..
4ft
2
FITTING, hose brs nut .625-18
FITTING, hose brs ferrule .425 ID x .718 Ig
CLIP, component .687dia mtg adh back
CLAMP, hose .375-.4SOclp dia
FITTING, pipe brs elb 1/8NPT x 3/16 hose
KNOB, pointer
NAMEPLATE, (order by model and serial number)
FITTING, water (XR-W model)
BLANK, snap-in nyl .875mtg hole (XR-A model)
FITTING, gas
STAND-OFF No. 6-32 x .750 Ig
CIRCUIT CARD, meter
HOUSING PLUG & PINS, (consisting of)
TERMINAL, male 1 pin 24-18 wire
HOUSING RECEPTACLE & SOCKETS, (consisting of)
TERMINAL, female lskt 24-18 wire
HOUSING PLUG &SOCKETS, (consisting of)
TERMINAL, female lskt 24-18 wire
HOUSING RECEPTACLE & SOCKETS, (consisting of)
TERMINAL, female lskt 24-18 wire
COVER, opening meter
BLANK, snap-in nyl .25Omtg hole
POTENTIOMETER, C sltd sit l/T 2W 10K ohm
SWITCH, tgl 3PDT MC 15A 125VAC
POTENTIOMETER, C sltd sit 1/12W 1 meg ohm
SWITCH, tgl SPDT5A 125V
2
2
1
2
2
1
1
1
1
1
2
1
I
.
4
.
4
1
1
8
.
1
5
.
1
1
1
1
2
1
SWITCH, tgl SPDT 15A 125VAC
4035
897.. POTENTIOMETER, C sltdsft lIT 2W 1000 ohm
17.... R50
011 609.. SWITCH, tgl SPDT iSA 125VAC
18.... Si
19. PC4, RC2O... 139508.. CIRCUIT CARD, filter
146212.. PLUG, 10 pin MS-3106A-18-lPXAmphenol
PLG14
115092.. HOUSING PLUG & SOCKETS, (consisting of)
16....
S5
44011 609..
1
1
.
113 746
.
.
20
44097 922..
21
444097922..
22
057 357..
22
070 371
23
030 170..
..
++Part of 114 101 Gas Flow Meter
Part
of 139 736 Meter Kit
+Part
of 114 144
Spot
.
1
1
I
TERMINAL, female lskt 24-18 wire
KNOB, pointer
KNOB, pointer
BUSHING, snap-in nyl .937 ID x 1 .l25mtg hole (XR-W model)
BLANK, snap-in nyl 1.093/1 .l25mtg hole (XR-A model)
BUSHING, snap-in nyl .750 ID x I .000mtg hole
8
.
2
1
1
1
1
Option.
Option.
Weld Control
Option.
Control Option.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
44Part
of 144 931
Voltage
OM-1581
Page
37
Il -A
.59
SC143
60
Ref.
58
57
&
56
38
61
58
9
6
62
Gun
Of
View
Explode
64
7-4.
Figure
3
97
80
81
82
87
83
84
85
86
Part
No.
Dia.
Item
No.
Mkgs.
Description
Figure
.
.
.
.
.
1
133479
2
135 196
.
3
112 715
.
.
3
112716
.
.
4
137 474
.
.
4
137 475
.
.
5
137 473
.
.
.
.
137 472
5
056 851
010 607
.
.
.
6
7
.
.
.
.
.
010 606
.
.
.
056 108
.
.
.
.
.
.
134 834
134 834
.
.
.
.
.
.
089 120
.
.
000 571
.
.
056 851
.
.
.
010 607
.
.
.
056 108
.
.
.
134 834
.
.
.
.
.
048 837
.
010 603
.
010 606
056 112
8
8
PLG2
.
.
.
.
.
.
.
.
.
138458
138 459
.
.
.
.
.
ii
137 478
11
137 479
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
152 577
.
13
137 495
.
14
141 694
.
.
15
133 362
.
.
R4
.
.
...
.
137 854
..
.
.
.
144 861
.
.
.
.
135127
.
19
602 169
.
.
20
134 856
21
602 172
.
.
22
136 730
.
.
.
.
23
134 800
24
132 985
134 799
.
25
26
152 579
26
152 578
27
135 580
27
135 580
28
058262
.
.
12
18
.
.
.
.
.
.
073 476
17
.
.
073 476
.
.
.
.
10
.
.
.
10
.
.
.
.
.
.
.
127 893
.
.
.
.
9
16
.
.
600 318
.
.
.
138 033
600 318
.
.
.
053 212
600 722
.
.
137 476
137 477
9
.
.
.
.
053 212
.
.
603 106
146212
.
.
.
.
.
.
.
.
.
.
.
.
.
.
..
.
..
.
..
7-4.
Quantity
Exploded View Of Gun
COVER
I
SPRING, closure cover
CONDUIT w/FITTING, 15ff (XR-15A & W models)
CONDUITw/FITTING, 30ff (XR-30A&W models)
HOSE, water in (XR-1 5W model) (consisting of)
HOSE, water in (XR-30W model) (consisting of)
HOSE, gas in (XR-15A & W models) (consisting of)
HOSE, gas in (XR-30A & W models) (consisting of)
FITTING, hose brs barbed nipple 3/l6tbg
FITTING, hose brs nut .625-18 LH (water hose)
FITTING, hose brs nut .625-18RH (gas hose)
FITTING, hose brs ferrule .425 ID x .718 Ig
HOSE, SAE .187 ID x .410 OD (XR-15A & W models) (order by ft)
HOSE, SAE .187 ID x .410 OD (XR-30A & W models) (order by ft)
CLAMP, hose .375-.450c1p dia slfttng
HOSE, water (XR-15 & 30W models) (consisting of)
FITTING, hose brs barbed nipple 3/l6tbg
FITTING, hose brs nut .625-18LH
1
FITTING, hose brs ferrule .425 ID
1
1
1
1
I
1
1
1
1
1
.
.
.
.
.
.
.
.
16ff
31ff
1
2
2
2
.718
Ig
HOSE, SAE .187 ID x .410 OD (order by ft)
HOSE, gas (consisting of)
FITTING, hose brs barbed nipple 1/4tbg
x
2
lOft
1
2
FITTING, hose brs nut .625-18RH
FITTING, hose brs ferrule .475 ID x .718 Ig
HOSE, nprn brd No. 1 x .250 ID (order by ft)
CABLE, control (XR-15A&Wmodels) (consisting of)
CABLE, control (XR-30A & W models) (consisting of)
PLUG, lOpinMS-3106A-18-1PX
CLAMP, cable 97-3057-1 010
CABLE, port No. 18 4/c (XR-15A & W models) (order by ft)
CABLE, port No. 18 4/c (XR-30A & W models) (order by ft)
CABLE, power/water out 15ff (XR-15W model)
CABLE, power/water out 30ff (XR-30W model)
CLAMP, strap rbr 5 holes .375 wide x 4.625 Ig (XR-15A & W models)
CLAMP, strap rbr 5 holes .375 wide x 4.625 Ig (XR-30A & W models)
CABLE, powEr (XR-15A model) (consisting of)
CABLE, power (XR-30A model) (consisting of)
TERMINAL, ring tng .500 stud No. 4 cable
CABLE, weld cop strd No. 3 (XR-15A model) (order by ft)
CABLE, weld cop strd No. 3 (XR-30A model) (order by ft)
RING, crimp cable
STRIP, cop .010 x 2.000 x .750
FITTING, connection power weld (XR-15A & 30A models)
SCREW, set stl sch .312-18 x .375 cone point (XR-15A & 30A models)
STRAIN RELIEF, cable
2
2
lOft
1
1
1
1
33ff
63ff
1
1
.
.
.
.
.
.
6
13
1
1
1
16ff
31ff
1
1
1
.
POTENTIOMETER, C sltd sft lIT .5W 10K ohm
WASHER, anti-turn
LOCK, shaftpot .250-32x.l25diashaft
SCREW, set stl sch 8-32 x .187
.
.
1
1
1
1
1
1
KNOB, speed control 1-10 .140 shaft x 1.125 OD
SCREW, set stt sch 10-32 x .187 cup point (XR-15A & 30A models)
ADAPTER, tube head (XR-15A & 30A models)
0-RING, .614 ID x .070 CS
MANIFOLD, water (XR-15W & 30W models)
0-RING, .176 ID x .070 CS (XR-15W & 30W models)
HOUSING, wire drive w/components (consisting of) (XR-A only)
HOUSING, wire drive wlcomponents (consisting of) (XR-W only)
FITTING, gas (XR-15A & 30A models)
FITTING, gas (XR-15W & 30W models)
1
1
1
2
1
3
1
1
1
2
CAP
1
OM-1581
Page
39
I
.2
Item
No.
Part
No.
Dia.
Mkgs.
Description
Figure
29
133365
30
000417
31
143836
32
008 033
33
146558
34
35
604612
136135
36
602 066
37
602198
38
154306
39
132270
40
134624
41
134623
42
132852
43
605 798
44
154307
45
144860
46
058 968
47
135474
48
155565
49
135126
50
7-4.
Exploded
Quantity
View Of Gun
(Continued)
CLAMP, head tube
SCREW, cap sti sch 10-24 x 1.000
SPRING, cprsn .445 OD x .023 wire x .370
WASHER, flat felt .234 ID x .500 OD x .O93thk
KIT, current pick-up contact
SCREW, set stl sch 8-32 x .125 cup point (XR-15A & 30A models)
ROLL, drive VK groove .023-1/16 wire
SCREW, mach sti trh 6-32 x .250
WASHER, lock sti split No. 6
ARM, pressure w/cmpt (consisting of)
SCREW, mach stl rdhph 6-32 x .500
BEARING, fig nyl .140 ID x .187 OD x .375f1g x .O3lthk
BEARING
2
6
3
1
1
.2
.1
134248
ARM, pressure
WASHER, shldr nyl .375 OD x .168 ID x .080
SPRING, tension adj drive roll
SCREW, mach stl flh 8-32 x .437
RING, retainer E
PIN, hinge
SCREW, thumb spring plunger
SCREW, set stl sch 6-32 x .125 cup point
SPRING, cprsn .240 OD x .020 wire x .437
NUT, thumb tension adjusting 8-32
SCREW, mach stl rdh 8-32 x .500
SCREW, cap sti sch 6-32 x .375
CLAMP, strain relief
SCREW, mach stl rdhph 8-32 x .375
BUSHING, shaft motor
CASE, gun LH
SCREW, mach sti rdhph 8-32 x 1.500
PLUNGER, trigger hold
SCREW, mach sti rdhph 8-32 x .875
MOTOR, gear PM 24VDC 420RFH 10.2:1 ratio
62
133373
TRIGGER
1
63
135128
137042
SCREW, cap stl sch 6-32 x 1 .000 (XR-1 5W & 30W models)
BARREL ASSEMBLY, water cooled (XR-1 5W & 30W models)
(consisting of)
0-RING, .614 ID x .070 CS
FITTING, end tube head
TUBE, head
2
51
112896
135773
52
602 082
53
604 638
54
136679
55
132269
56
135473
57
136128
58
135646
59
135896
60
135645
61
B2
64
....
134800
65
66
136955
67
136956
68
136943
69
136834
70
134801
71
137041
72
136836
73
136835
74
136680
75
136683
76
136748
77
135424
78
13683?
79
136832
TUBING, teflon
WASHER, fbr .594 ID x .875 OD
0-RING, .926 ID x .070 CS
BARREL, outer
x
.1
.2
.1
.1
2
1
I
1
2
1
1
3
1
1
1
1
2
1
1
1
.l25thk
INSULATOR, head tube from adapter
WASHER, flat brs .390 ID x .687 OD x .l25thk
ADAPTER, contact tube
LINER, teflon .045-1/16 wire x 6.875 Ig
NUT, compression .375-24
TUBE, contact .047-061 wire
NUT, jam adapter 1 .000-8
ADAPTER, nozzle
NOZZLE, 5/8 cr1 x 1-5/8 Ig
N0ZZ~, spot outside corner .937 ID x 2.375
NOZZLE, 13/16 orf x 1-5/Big
NOZZLE, 1/2orfx 1-5/81g
NOZZLE, 5/8 orf x 1-5/8 lg
NOZZLE, spot
NOZZLE, spot
.
050 622
80
+009 925
81
050
82
+050 115
116
83
050 622
84
+000 442
85
+004 466
OM-1561
Page
40
1
1
1
1
1
1
1
1
1
1
Item
No.
Dia.
Part
No.
Mkgs.
Description
Figure
.
86
.ooo 443
.
.
.
87
144 862
.
.
88
89
053 785
136 171
.
.
.
.
.
.
.
.
314
.
.
135 430
.
.
429
.
.
135 424
.
.
426
.
.
135 425
.
.
136 821
.
.
.
.
.
89
.
89
.
89
.
89
.
89
.
89
.
89
.
89
135
427
135 428
147
135
135
.
90
136 748
.
.
.
91
136 683
.
.
.
91
136 682
.
.
92
93
136 680
.
.
136 681
.
.
058 685
136127
.
.
.
94
95
.
96
.
.
.
.
PB1
.
000 369
.
.
97
118 774
.
.
98
135 647
.
.
.
.
.
.
..
7-4.
Exploded
View Of Gun
Quantity
(Continued)
NOZZLE, spot inside corner
E)(TENSION, nozzle (XR-15A & 30A models)
EXTENSION, barrel 2.875 Ig (XR-15A & 30A models)
TUBE, contact .025/31 wire
1
1
1
1
TUBE,
TUBE,
TUBE,
TUBE,
TUBE,
contact .030/36 wire
1
contact .030/41 wire
1
contact .035/41 wire
1
contact .035/52 wire
1
contact .047/52 wire
1
TUBE,
TUBE,
TUBE,
contact .047/61 wire
1
contact .062/73 wire
1
contact .062/81 wire
I
WRENCH, nut tube contact
NUT, compression .375-24
LINER, teflon .045-1/16 wire x 6.875 Ig
LINER, teflon .023-.035 wire x 6.875 Ig
ADAPTER, contact tube (XR-15A & 30A models)
TUBE, head (XR-15A & 30A models)
NUT, jam nozzle extension (XR-15A & 30A models)
CASE, gun RH
SWITCH, lim 1OA 125/25OVAC DPST plgr
SPRING, cprsn .240 OD x .024 wire x 1.000
NUT, stl 8-32
1
1
1
1
1
1
1
1
1
1
3
OPTIONAL
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1581
Page
41