Miller | LE069022 | Owner Manual | Miller XR GUNS User manual

Miller XR GUNS User manual
OM-1594
181 715S
January 2004
Processes
MIG (GMAW) Welding
Description
Wire Feeder And Feeder Gun

XR Control

XR Air- And Water-Cooled Guns
Visit our website at
www.MillerWelds.com
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard.
particular model are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 7/03
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. . . . . . . . . . . .
2-4. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Rating Label For CE Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Connections With A Constant Current (CC), Constant Voltage (CV) Or Constant Current/Constant
Voltage (CC/CV) Welding Power Source Having A 14-Socket Receptacle . . . . . . . . . . . . . . . . . . . . . .
5-2. Air-Cooled Feeder Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Air-Cooled Gun Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Water-Cooled Feeder Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Water-Cooled Gun Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. 14-Pin Plug Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. (Optional) Voltage Sensing Lead Connections And CC/CV Jumper Plug Settings . . . . . . . . . . . . . . . .
5-8. Meter Circuit Board Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9. Adjusting FasTipE Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10. Opening Top Cover Of XR-Edge Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-11. Removing Top Cover Of Pistol Grip Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-12. Installing Wire Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-13. Threading Welding Wire Through Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-14. Threading Welding Wire Through Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-15. Adjusting Wire Feed Starting Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-16. Setting Switches For Preflow And Postflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-17. Adjusting Trigger Hold Actuation Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Internal Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Gun Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Shielding Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Coolant Supply For Water-Cooled Models Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Sequence Of Gas Metal Arc Welding (GMAW) − Continuous Or Spot . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Feeder Drive Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Gun Drive Assembly Maintenance For An XR-Edge Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Removing Diffuser In XR-Edge Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Replacing Head Tube Liner In XR-Edge Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-5. Replacing The Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS
7-6. Changing Gun Contact Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-7. Replacing Or Cleaning Gun Drive Roll In Pistol-Grip Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-8. Replacing Or Cleaning Gun Drive Roll Bearing In Pistol-Grip Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-9. Replacing Head Tube Liner In Pistol-Grip Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-10. Removing Diffuser In Air-Cooled Pistol-Grip Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-11. Removing Diffuser In Water-Cooled Pistol-Grip Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-12. Replacing Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-13. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-14. Water Flow Switch (Optional For Water-Cooled Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-15. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPTIONS AND ACCESSORIES
WARRANTY
35
35
36
36
37
37
38
39
39
40
42
46
Declaration of Conformity for
European Community (CE) Products
Note
This information is provided for units with CE certification (see rating label on unit).
Miller Electric Mfg. Co.
Manufacturer’s Name:
1635 W. Spencer Street
Appleton, WI 54914 USA
Manufacturer’s Address:
Declares that the product:
XR-Control
conforms to the following Directives and Standards:
Directives
Low Voltage Directive: 73/23/EEC
Electromagnetic Compatibility (EMC) Directive: 89/336/EEC
Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC
Standards
Arc Welding Equipment Part I: Welding Power Sources: IEC 60974-1
(September 1998 − Second Edition)
Arc Welding Equipment: Wirefeed Systems: IEC 974-5
(September 1997 − Draft Revision)
Degrees of Protection Provided By Enclosures (IP Code): IEC 529:1989
(November 1989 - First Edition)
Insulation Coordination For Equipment With Low-Voltage Systems:
Part I: Principles, Requirements and Tests: IEC 664-1: 1992
(October 1992 − First Edition)
Electromagnetic Compatibility, (EMC): EN 50199
(August 1995)
Torches And Guns For Arc Welding, EN 50078
European Contact:
Telephone:
Fax:
dec_con1_11/02
Mr. Danilo Fedolfi, Managing Director
ITW WELDING PRODUCTS ITALY S.r.l.
Via Privata Iseo 6/E
20098 San Giuliano
Milanese, Italy
39(02)98290-1
39(02)98290−203
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _8/03
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
Y Marks a special safety message.
. Means “Note”; not safety related.
1-2. Arc Welding Hazards
Y The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-5. Read and follow all
Safety Standards.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Y Only qualified persons should install, operate, maintain, and
repair this unit.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
Y During operation, keep everybody, especially children, away.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
ELECTRIC SHOCK can kill.
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.
D Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
D Keep your head out of the fumes. Do not breathe the fumes.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first − double-check connections.
D Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not drape cables over your body.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
D If ventilation is poor, use an approved air-supplied respirator.
D Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and if necessary, while wearing an
air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
Return To Table Of Contents
OM-1594 Page 1
ARC RAYS can burn eyes and skin.
BUILDUP OF GAS can injure or kill.
D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D Wear a welding helmet fitted with a proper shade of filter to protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards).
HOT PARTS can cause severe burns.
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant material (leather and wool) and foot protection.
D Do not touch hot parts bare handed.
D Allow cooling period before working on gun or
torch.
MAGNETIC FIELDS can affect pacemakers.
WELDING can cause fire or explosion.
D Pacemaker wearers keep away.
D Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D Protect yourself and others from flying sparks and hot metal.
D Do not weld where flying sparks can strike flammable material.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
D Connect work cable to the work 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.
D Do not use welder to thaw frozen pipes.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
FLYING METAL can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
OM-1594 Page 2
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is
high.
CYLINDERS can explode 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.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
Return To Table Of Contents
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
MOVING PARTS can cause injury.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
FALLING UNIT can cause injury.
H.F. RADIATION can cause interference.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
D
OVERUSE can cause OVERHEATING
D
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
D
D
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
MOVING PARTS can cause injury.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
D
D
WELDING WIRE can cause injury.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
D
D
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
1-4. California Proposition 65 Warnings
Y Welding or cutting equipment produces fumes or gases which
contain chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California Health &
Safety Code Section 25249.5 et seq.)
For Gasoline Engines:
Y Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
Y Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
For Diesel Engines:
Y Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
Return To Table Of Contents
OM-1594 Page 3
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(phone: 305-443-9353, website: www.aws.org).
Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:
800−463−6727 or in Toronto 416−747−4044, website: www.csa−international.org).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard
AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (phone: 305-443-9353, website: www.aws.org).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900,
website: www.ansi.org).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269−9101 (phone: 617−770−3000, website: www.nfpa.org and www.
sparky.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone:
617−770−3000,website: www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202−4102 (phone: 703−412−0900, website: www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
are 10 Regional Offices−−phone for Region 5, Chicago, is
312−353−2220,website: www.osha.gov).
1-6. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-1594 Page 4
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
Return To Table Of Contents
SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT
UTILISATION
som_fre 8/03
2-1. Signification des symboles
Signifie « Mise en garde. Faire preuve de vigilance. »
Cette procédure présente des risques identifiés par les
symboles adjacents aux directives.
Ce groupe de symboles signifie « Mise en garde. Faire preuve de vigilance. » Il y a des dangers liés aux CHOCS ÉLECTRIQUES, aux
PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Se reporter
aux symboles et aux directives ci-dessous afin de connaître les mesures à prendre pour éviter tout danger.
Y Identifie un message de sécurité particulier.
. Signifie « NOTA » ; n’est pas relatif à la sécurité.
2-2. Dangers relatifs au soudage à l’arc
Y Les symboles ci-après sont utilisés tout au long du présent
manuel pour attirer l’attention sur les dangers potentiels et les
identifier. Lorsqu’on voit un symbole, faire preuve de vigilance et
suivre les directives mentionnées afin d’éviter tout danger. Les
consignes de sécurité énoncées ci-après ne font que résumer le
contenu des normes de sécurité mentionnées à la section 2-4.
Lire et respecter toutes ces normes.
D N’utiliser que du matériel en bon état. Réparer ou remplacer sur−le−
champ les pièces endommagées. Entretenir l’appareil conformément
au présent manuel.
Y L’installation, l’utilisation, l’entretien et les réparations ne doivent être confiés qu’à des personnes qualifiées.
D Fixer le câble de retour de façon à obtenir un bon contact métal sur
métal avec la pièce à souder ou la table de travail, le plus près possible
de la soudure.
Y Pendant l’utilisation de l’appareil, tenir à l’écart toute personne,
en particulier les enfants.
D Porter un harnais de sécurité quand on travaille en hauteur.
D Maintenir solidement en place tous les panneaux et capots.
D
Ne pas connecter plus d’une électrode ou plus d’un câble de masse à un
même terminal de sortie.
LES DÉCHARGES ÉLECTRIQUES
peuvent être mortelles.
Un simple contact avec des pièces sous tension peut
causer une électrocution ou des blessures graves.
L’électrode et le circuit de soudage sont sous tension
dès que l’appareil est en fonctionnement. Le circuit
d’entrée et les circuits internes de l’appareil sont également sous tension.
En soudage semi−automatique ou automatique, le fil, le dévidoir, le
logement des galets d’entraînement et les pièces métalliques en contact
avec le fil de soudage sont sous tension. Tout matériel mal installé ou mal
mis à la terre présente un danger.
Il subsiste un COURANT CONTINU IMPORTANT
dans les convertisseurs après la suppression de
l’alimentation électrique.
D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions
énoncées à la section Entretien avant de toucher les pièces.
D Ne jamais toucher aux pièces électriques sous tension.
D Porter des gants et des vêtements de protection secs et exempts de
trous.
D S’isoler de la pièce et de la terre au moyen de tapis ou autres dispositifs isolants suffisamment grands pour empêcher tout contact
physique avec la pièce ou la terre.
D
D
D
Ne pas se servir d’une source de courant alternatif dans les zones humides, les endroits confinés ou là où on risque de tomber.
Ne se servir d’une source de courant alternatif QUE si le procédé de soudage l’exige.
Si l’utilisation d’une source de courant alternatif s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé.
D Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Couper/étiqueter
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir les normes de sécurité).
D Installer et mettre à la terre correctement l’appareil conformément à
son manuel d’utilisation et aux codes nationaux, provinciaux et
municipaux.
D Toujours vérifier la terre du cordon d’alimentation − Vérifier et s’assurer que le fil de terre du cordon d’alimentation est bien raccordé à la
borne de terre du sectionneur ou que la fiche du cordon est raccordée
à une prise correctement mise à la terre.
D Pour exécuter les branchements d’entrée, fixer d’abord le conducteur
de mise à la terre adéquat et contre−vérifier les connexions.
D Vérifier fréquemment le cordon d’alimentation et s’assurer qu’il n’est
ni endommagé ni dénudé ; le remplacer immédiatement s’il est endommagé − tout câble dénudé peut causer une électrocution.
D Mettre l’appareil hors tension quand on ne l’utilise pas.
D Ne pas utiliser de câbles usés, endommagés, de calibre insuffisant ou
mal épissés.
D Ne pas s’enrouler les câbles autour du corps.
D Si la pièce soudée doit être mise à la terre, le faire directement avec un
câble distinct.
D Ne pas toucher l’électrode quand on est en contact avec la pièce, la
terre ou une électrode d’une autre machine.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz dont
l’inhalation peut être dangereuse pour la santé.
D Se tenir à distance des fumées et ne pas les inhaler.
D À l’intérieur, ventiler la zone et/ou utiliser un dispositif d’aspiration au
niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.
D Si la ventilation est insuffisante, utiliser un respirateur à adduction
d’air agréé.
D Lire les fiches techniques de santé−sécurité (FTSS) et les instructions du fabricant concernant les métaux, les consommables, les
revêtements, les nettoyants et les dégraisseurs.
D Ne travailler dans un espace clos que s’il est bien ventilé ou porter un
respirateur à adduction d’air. Demander toujours à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de soudage
peuvent se substituer à l’air, abaisser la teneur en oxygène et causer
des lésions ou des accidents mortels. S’assurer que l’air est respirable.
D Ne pas souder à proximité d’opérations de dégraissage, de nettoyage
ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir en
présence de vapeurs et former des gaz hautement toxiques et irritants.
D Ne pas souder de métaux munis d’un revêtement, tels que la tôle
d’acier galvanisée, plombée ou cadmiée, à moins que le revêtement
n’ait été enlevé dans la zone de soudage, que l’endroit soit bien ventilé, et si nécessaire, porter un respirateur à adduction d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques lorsqu’on les soude.
Revenez à la table des matières
OM-1594 Page 5
LES RAYONS DE L’ARC peuvent causer des brûlures oculaires et cutanées.
Le rayonnement de l’arc génère des rayons visibles et
invisibles intenses (ultraviolets et infrarouges) susceptibles de causer des brûlures oculaires et cutanées.
Des étincelles sont projetées pendant le soudage.
D Porter un masque de soudage muni d’un filtre de la nuance adéquate
pour se protéger le visage et les yeux pendant le soudage ou pour regarder (voir les normes de sécurité ANSI Z49.1 et Z87.1).
D Porter des lunettes de sécurité à écrans latéraux sous le masque.
D Utiliser des écrans ou des barrières pour protéger les tiers de l’éclat
éblouissant ou aveuglant de l’arc ; leur demander de ne pas regarder
l’arc.
D Porter des vêtements de protection en matière durable et ignifuge
(cuir ou laine) et des chaussures de sécurité.
LES ACCUMULATIONS DE GAZ peuvent causer des blessures ou même
la mort.
D
D
Couper l’alimentation en gaz protecteur en cas de
non utilisation.
Veiller toujours à bien ventiler les espaces confinés ou porter un respirateur à adduction d’air agréé.
LES PIÈCES CHAUDES peuvent causer des brûlures graves.
D Ne pas toucher les pièces chaudes à main nue.
D Prévoir une période de refroidissement avant
d’utiliser le pistolet ou la torche.
LE SOUDAGE peut causer un incendie ou une explosion.
LES CHAMPS MAGNÉTIQUES peuvent
perturber le fonctionnement des stimulateurs cardiaques.
Le soudage effectué sur des récipients fermés tels que
des réservoirs, des fûts ou des conduites peut causer
leur éclatement. Des étincelles peuvent être projetées
de l’arc de soudure. La projection d’étincelles, les
pièces chaudes et les équipements chauds peuvent causer des
incendies et des brûlures. Le contact accidentel de l’électrode avec tout
objet métallique peut causer des étincelles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, vérifier et
s’assurer que l’endroit ne présente pas de danger.
D Se protéger et protéger les tiers de la projection d’étincelles et de métal chaud.
D Ne pas souder à un endroit où des étincelles peuvent tomber sur des
substances inflammables.
D Placer toutes les substances inflammables à une distance de 10,7 m
de l’arc de soudage. En cas d’impossibilité, les recouvrir soigneusement avec des protections agréées.
D Des étincelles et des matières en fusion peuvent facilement passer
même par des fissures et des ouvertures de petites dimensions.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.
D Le soudage effectué sur un plafond, un plancher, une paroi ou une
cloison peut déclencher un incendie de l’autre côté.
D Ne pas souder des récipients fermés tels que des réservoirs, des fûts
ou des conduites, à moins qu’ils n’aient été préparés conformément à
l’AWS F4.1 (voir les normes de sécurité).
D Brancher le câble sur la pièce le plus près possible de la zone de soudage pour éviter que le courant ne circule sur une longue distance, par
des chemins inconnus, et ne cause des risques d’électrocution et d’incendie.
D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
D En cas de non utilisation, enlever la baguette d’électrode du porte−
électrode ou couper le fil au raz du tube−contact.
D Porter des vêtements de protection exempts d’huile tels que des
gants en cuir, une chemise en tissu épais, des pantalons sans revers,
des chaussures montantes et un masque.
D Avant de souder, retirer tout produit combustible de ses poches, tel
qu’un briquet au butane ou des allumettes.
LES PARTICULES PROJETÉES peuvent blesser les yeux.
D Le soudage, le burinage, le passage de la pièce à
la brosse métallique et le meulage provoquent
l’émission d’étincelles et de particules métalliques. Pendant leur refroidissement, les soudures risquent de projeter du
laitier.
D
Porter des lunettes de sécurité à écrans latéraux agréés, même sous le
masque de soudage.
OM-1594 Page 6
D
D
Les personnes qui portent un stimulateur cardiaque
doivent se tenir à distance.
Ils doivent consulter leur médecin avant de s’approcher d’un lieu où on exécute des opérations de soudage à l’arc, de gougeage ou de soudage par points.
LE BRUIT peut affecter l’ouïe.
Le bruit de certains processus et équipements peut
affecter l’ouïe.
D
Porter des protecteurs d’oreille agréés si le niveau
sonore est trop élevé.
Les BOUTEILLES
peuvent exploser.
endommagées
Les bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Toute bouteille endommagée
peut exploser. Comme les bouteilles de gaz font
normalement partie du procédé de soudage, les
manipuler avec précaution.
D Protéger les bouteilles de gaz comprimé de la chaleur excessive, des
chocs mécaniques, du laitier, des flammes nues, des étincelles et des
arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire
ou dans un porte−bouteilles pour les empêcher de tomber ou de se
renverser.
D Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électriques.
D Ne jamais poser une torche de soudage sur une bouteille de gaz.
D Ne jamais mettre une électrode de soudage en contact avec une bouteille de gaz.
D Ne jamais souder une bouteille contenant du gaz sous pression − elle
risquerait d’exploser.
D N’utiliser que les bouteilles de gaz protecteur, régulateurs, tuyaux et
raccords adéquats pour l’application envisagée ; les maintenir en bon
état, ainsi que les pièces connexes.
D Détourner la tête lorsqu’on ouvre la soupape d’une bouteille.
D Laisser le capuchon protecteur sur la soupape, sauf en cas d’utilisation ou de branchement de la bouteille
D Lire et suivre les instructions concernant les bouteilles de gaz comprimé, les équipements associés et les publications P−1 de la CGA,
mentionnées dans les normes de sécurité.
Revenez à la table des matières
2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de
l’appareil.
Risque D’INCENDIE OU D’EXPLOSION
LES ORGANES MOBILES peuvent
causer des blessures.
D Ne pas placer l’appareil sur une surface inflammable, ni au−dessus ou à proximité d’elle.
D Se tenir à l’écart des organes mobiles comme les
ventilateurs.
D Maintenir fermés et bien fixés les portes,
panneaux, recouvrements et dispositifs de
protection.
D Ne pas installer l’appareil à proximité de produits inflammables.
D Ne pas surcharger l’installation électrique − s’assurer que l’alimentation est correctement dimensionnée et protégée avant de mettre
l’appareil en service.
LE RAYONNEMENT HAUTE FRÉQUENCE (H. F.) risque de causer des
interférences.
LA CHUTE DE L’APPAREIL peut
blesser.
D N’utiliser que l’anneau de levage pour lever l’appareil. NE PAS utiliser le chariot, les bouteilles de
gaz ou tout autre accessoire.
D Utiliser un engin de capacité adéquate pour lever
l’appareil.
D Si on utilise un chariot élévateur pour déplacer l’unité, s’assurer que
les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil.
L’EMPLOI EXCESSIF peut FAIRE
SURCHAUFFER L’ÉQUIPEMENT.
D Prévoir une période de refroidissement ; respecter le cycle opératoire nominal.
D Réduire le courant ou le cycle opératoire avant de
reprendre le soudage.
D Le rayonnement haute fréquence peut causer
des interférences avec les équipements de radionavigation et de communication, les services de
sécurité et les ordinateurs.
D Ne demander qu’à des personnes qualifiées familiarisées avec les
équipements électroniques de faire fonctionner l’installation.
D L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences causées par l’installation.
D Si la Federal Communications Commission signale des interférences, arrêter immédiatement l’appareil.
D Faire régulièrement contrôler et entretenir l’installation.
D Maintenir soigneusement fermés les panneaux et les portes des sources de haute fréquence, maintenir le jeu d’éclatement au réglage
adéquat et utiliser une terre et un blindage pour réduire les interférences éventuelles.
LE SOUDAGE À L’ARC peut causer
des interférences.
D Ne pas obstruer les orifices ou filtrer l’alimentation en air du poste.
D L’énergie électromagnétique peut causer des
interférences avec l’équipement électronique
sensible tel que les ordinateurs et l’équipement
commandé par ordinateur tel que les robots.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
D Mettre un bracelet antistatique AVANT de manipuler des cartes ou des pièces.
D Utiliser des pochettes et des boîtes antistatiques
pour stocker, déplacer ou expédier des cartes de
circuits imprimés.
LES PIÈCES MOBILES peuvent causer des blessures.
D Se tenir à l’écart des pièces mobiles.
D Se tenir à l’écart des points de coincement tels
que les dévidoirs.
D Veiller à ce que tout l’équipement de la zone de soudage soit compatible au point de vue électromagnétique.
D Pour réduire la possibilité d’interférence, maintenir les câbles de soudage aussi courts que possible, les grouper, et les poser aussi bas
que possible (par ex. : à terre).
D Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
D Veiller à ce que le poste de soudage soit posé et mis à la terre conformément au présent manuel.
D En cas d’interférences après exécution des directives précédentes, il
incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés,
l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de
travail.
LES FILS DE SOUDAGE peuvent causer des blessures.
D Ne pas appuyer sur la gâchette avant d’en avoir
reçu l’instruction.
D Ne pas diriger le pistolet vers soi, vers d’autres
personnes ou vers toute pièce mécanique en engageant le fil de soudage.
Revenez à la table des matières
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
D Porteurs de stimulateur cardiaque, restez à distance.
D Les porteurs d’un stimulateur cardiaque doivent
d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de gougeage ou de soudage par points.
OM-1594 Page 7
2-4. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1,
de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(téléphone : (305) 443−9353, site Web : www.aws.org).
Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800)
463−6727 ou à Toronto : (416) 747−4044, site Web : www.csa−international.org).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, norme American Welding Society AWS
F4.1, de l’American Welding Society, 550 N.W. LeJeune Rd, Miami, FL
33126 (téléphone : (305) 443−9353, site Web : www.aws.org).
Practice For Occupational And Educational Eye And Face Protection,
norme ANSI Z87.1, de l’American National Standards Institute, 11 West
42nd Street, New York, NY 10036−8002 (téléphone : (212) 642−4900,
site Web : www.ansi.org).
National Electrical Code, norme NFPA 70, de la National Fire Protection
Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269−9101 (téléphone : (617) 770−3000, sites Web : www.nfpa.org et
www.sparky.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, norme NFPA 51B, de la National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (téléphone : (617) 770−3000, site Web : www.nfpa.org et www.sparky.org).
Safe Handling of Compressed Gases in Cylinders, brochure CGA P−1,
de la Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202−4102 (téléphone : (703) 412−0900,
site Web : www.cganet.com).
Code for Safety in Welding and Cutting, norme CSA W117.2, de la Canadian Standards Association, Standards Sales, 178 boulevard
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, de l’U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a
10 bureaux régionaux − Téléphone pour la Région 5, Chicago : (312)
353−2220, site Web : www.osha.gov).
2-5. Information sur les champs électromagnétiques
Données sur le soudage électrique et les effets des champs magnétiques basse fréquence sur l’organisme
En parcourant les câbles de soudage, le courant crée des champs électromagnétiques. Les effets potentiels de tels champs restent
préoccupants. Cependant, après avoir examiné plus de 500 études qui
ont été faites pendant une période de recherche de 17 ans, un comité
de spécialistes du National Research Council a conclu : « L’accumulation de preuves n’a pas démontré que l’exposition aux champs
magnétiques et aux champs électriques à haute fréquence constitue un
risque pour la santé humaine ». Toutefois, les études et l’examen des
preuves se poursuivent. En attendant les conclusions finales de la recherche, il serait souhaitable de réduire l’exposition aux champs
électromagnétiques pendant le soudage ou le coupage.
OM-1594 Page 8
Afin de réduire les champs électromagnétiques en milieu de travail, respecter les consignes suivantes :
1. Garder les câbles ensemble en les torsadant ou en les fixant avec du
ruban adhésif.
2. Mettre tous les câbles du côté opposé à l’opérateur.
3. Ne pas s’enrouler les câbles autour du corps.
4. Garder le poste de soudage et les câbles le plus loin possible de soi.
5. Placer la pince de masse le plus près possible de la zone de soudage.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur médecin. Si ce dernier les déclare aptes, il leur est recommandé de respecter les consignes ci-dessus.
Revenez à la table des matières
SECTION 3 − DEFINITIONS
3-1. Warning Label Definitions
A
B
1
1.1
2
2.1
3
3.1
4
4.1
1.2
2.2
1.3
2.3
3.2
+
5
C
3.3
+
+
6
+
S-178 936
Return To Table Of Contents
A. Warning! Watch Out! There
are possible hazards as
shown by the symbols.
B. Drive rolls can injure fingers.
C. Welding wire and drive parts
are at welding voltage during
operation − keep hands and
metal objects clear.
1 Electric shock can kill.
1.1 Wear dry insulating gloves.
Do not touch electrode with
bare hand. Do not wear wet or
damaged gloves.
1.2 Protect yourself from electric
shock by insulating yourself
from work and ground.
1.3 Disconnect input plug or
power before working on
machine.
2 Breathing welding fumes can
be hazardous to your health.
2.1 Keep your head out of the
fumes.
2.2 Use forced ventilation or local
exhaust to remove the fumes.
2.3 Use ventilating fan to remove
fumes.
3 Welding sparks can cause
explosion or fire.
3.1 Keep flammables away from
welding. Don’t weld near
flammables.
3.2 Welding sparks can cause
fires. Have a fire extinguisher
nearby and have a watch
person ready to use it.
3.3 Do not weld on drums or any
closed containers.
4 Arc rays can burn eyes and
injure skin.
4.1 Wear hat and safety glasses.
Use ear protection and button
shirt collar. Use welding
helmet with correct shade of
filter. Wear complete body
protection.
5 Become trained and read the
instructions before working on
the machine or welding.
6 Do not remove or paint over
(cover) the label.
OM-1594 Page 9
1
2
3
Read the Owner’s Manual.
Do not overtighten wire spool
brake pressure. Tighten only
until wire does not overspool
from wire supply spool.
Do not overtighten drive roll
pressure. Tighten only until
drive roll will not slip (motor
will not stall) on a stationary
wire.
3-2. Rating Label For CE Products
S/N:
50/60
U1 = 24 V
I1 = 5.0 A
1
U2 = 100 V I2 = 400 A
50/60 Hz
IP 23
X 100 %
ST-178 794-A
OM-1594 Page 10
Return To Table Of Contents
3-3. Symbols And Definitions
Note
Some symbols are found only on CE products.
A
IP
Amperes
X
Volts
Alternating Current
Hertz
Circuit Breaker
Wire Feed
Jog
Output
Trigger
Gun
Press To Set
Increase
Trigger Hold On
Trigger Hold Off
Purge
Spot Weld Time
Percent
Run-In
Load Voltage
Read Instructions
Rated Current
Line Connection
Water (Coolant) Input
Fuse
Continuous
Spot Welding
Degree Of
Protection
Burnback Time
I1
V
Hz
Primary Current
U1
I2
Water (Coolant)
Output
Primary Voltage
U2
Duty Cycle
SECTION 4 − INTRODUCTION
4-1. Specifications
Type of Input
Power
Welding Power
Source Type
24 Volts AC
Single-Phase
5 Amperes
50/60 Hertz
Constant Voltage (CV)
DC For GMAW Or
Constant Voltage(CV) /
Constant Current (CC) DC
For GMAW-P
All Need 14-Pin And
Contactor Control
Wire Feed
Speed Range
70 To 875 ipm (1.8
To 22.2 mpm)
Wire
Diameter
Range
.030 To .062 in
(0.8 To 1.6
mm)
Max Spool
Capacity: 12 in
(305 mm)
Return To Table Of Contents
Welding
Circuit Rating
All Models: 100%
Duty Cycle, 100
Volts;
Water-Cooled
Models: 400
Amperes,
Air-Cooled
Models: 200
Amperes
Overall
Dimensions
Weight
Length: 21-1/4 in
(540 mm)
Width: 9-1/2 in
(241 mm)
38 lb
(17.2 kg)
Height: 16 in
(406 mm)
OM-1594 Page 11
4-2. Duty Cycle And Overheating
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
Y Exceeding duty cycle can
damage unit and void
warranty.
Air-Cooled Models
100% Duty Cycle At 200 Amperes Using Argon
Continuous Welding
60% Duty Cycle At 250 Amperes Using Argon
6 Minutes Welding
4 Minutes Resting
Water-Cooled Models
100% Duty Cycle At 400 Amperes Using Argon
Continuous Welding
sduty1 5/95
OM-1594 Page 12
Return To Table Of Contents
SECTION 5 − INSTALLATION
NOTE
Be sure that contact tip, liner, and drive rolls are correct for wire size and type. See
Parts List to change parts as needed.
NOTE
Many procedures apply to both guns covered in this manual. Where procedures
differ, separate instructions are given.
5-1. Connections With A Constant Current (CC), Constant Voltage (CV) Or Constant
Current/Constant Voltage (CC/CV) Welding Power Source Having A 14-Socket
Receptacle
1
2
3
4
1
CC, CV Or CC/CV Welding
Power Source
24 VAC/Contactor Control
14-Pin Plug
Workpiece
Voltage Sensing Lead
(Optional)
Connect lead to workpiece for CC
welding only.
2
5
6
7
8
Gun
Wire Feeder
24 VAC/Contactor Control
Cord
Y Do not use gas pressure
above 50 psi (345 kPa).
8
Gas Cylinder
3
6
7
4
5
5
801 559-B / Ref. 151 666-D
Return To Table Of Contents
OM-1594 Page 13
5-2. Air-Cooled Feeder Connections
1
Gas Fitting
Route one end of 10 ft (3 m) gas
hose to rear of unit, and connect
hose to gas solenoid fitting.
Connect remaining end of hose to
regulator/flowmeter.
2
Weld Cable To Welding Power
Source
Select and prepare weld cable
according to welding power source
manual.
3
4
5
2
4
Route one end of weld cable
through grommet, through reed
relay, and connect to weld cable terminal in feeder. Connect remaining
end of cable to positive (+) weld
output terminal on welding power
source.
5
Rear Panel
Close and latch door.
2
Connect To 14-Socket
Receptacle On Welding
Power Source
5
Top View
1
3
Connect To Positive (+)
Weld Output Terminal On
Welding Power Source
OM-1594 Page 14
Weld Cable Grommet
Current Sensing (Reed) Relay
Weld Cable Terminal In
Feeder
Tools Needed:
9/16 in
Ref. 801 578-A
Return To Table Of Contents
5-3. Air-Cooled Gun Connections
1
Gun Control Cable
Insert plug into Gun Control
receptacle, and tighten threaded
collar.
2
3
4
5
2
7
6
8
3
4
Gas Hose
Reed Relay
Weld Cable
Weld Cable Terminal In
Feeder
Route weld cable from welding
power source through reed relay to
weld cable terminal in feeder and
connect to weld cable terminal.
6
7
8
Gun Connector
Gun Securing Knob
Gun Connector Block
Loosen gun securing knob, and
insert gun connector through Wire
opening until it bottoms against
block. Tighten knob. Close and
latch door.
5
Left Side
6
1
Tools Needed:
9/16, 3/4 in
Ref. 801 577-A / 801 564-C / Ref. 151 666-D
Return To Table Of Contents
OM-1594 Page 15
5-4. Water-Cooled Feeder Connections
Obtain coolant supply.
1
Gas Fitting
Route one end of 10 ft (3 m) gas
hose to rear of unit, and connect
hose to gas solenoid fitting.
Connect remaining end of hose to
regulator/flowmeter.
2
Weld Cable To Welding Power
Source
Select and prepare weld cable
according to welding power source
manual.
3
4
5
2
5
4
7
Rear Panel
2
5
Weld Cable Grommet
Current Sensing (Reed) Relay
Weld Cable Terminal In
Feeder
Route one end of weld cable
through grommet, through reed
relay, and connect to weld cable terminal in feeder. Connect remaining
end of cable to positive (+) weld
output terminal on welding power
source.
6
7
Coolant Hose Grommet
Location Of Coolant Fittings
On Front Panel
Route one end of a coolant hose
through grommet, and connect to
rear of Coolant Out fitting in feeder.
Connect remaining end to supply
fitting on coolant supply.
Connect To 14-Socket
Receptacle On Welding
Power Source
6
Top View
Route one end of remaining coolant
hose through grommet, and connect to rear of Coolant In fitting in
feeder. Connect remaining end of
hose to return fitting on coolant
supply.
Close and latch door.
1
3
Connect To Positive (+)
Weld Output Terminal On
Welding Power Source
Application
GTAW Or Where
HF* Is Used
GMAW Or Where Coolant
Contacts Aluminum Parts Or
Where HF* Not Used
MILLER Low
Conductivity Coolant
No. 043 810**
MILLER Aluminum Protecting
Coolant No. 043 809**;
Distilled Or Deionized Water OK
Above 32° F (0° C)
Coolant
Tools Needed:
9/16 in
*HF: High Frequency Current
**MILLER coolants protect to -37° F (-38°C) and resist algae growth.
OM-1594 Page 16
Return To Table Of Contents
Ref. 152 431-A / Ref. 801 578-A
5-5. Water-Cooled Gun Connections
1
Gun Control Cable
Insert plug into Gun Control
receptacle, and tighten threaded
collar.
2
3
4
5
2
7
6
8
3
4
Gas Hose
Reed Relay
Weld Cable
Weld Cable Terminal In
Feeder
Route weld cable from welding
power source through reed relay to
weld cable terminal in feeder and
connect to weld cable terminal.
6
7
8
Gun Connector
Gun Securing Knob
Gun Connector Block
Loosen gun securing knob, and
insert gun connector through Wire
opening until it bottoms against
block. Tighten knob. Close and
latch door.
5
9
Left Side
Water In Hose
Connect to Water In fitting on feeder
(left-hand threads).
10 Water Out Hose
Connect to Water Out fitting on
feeder (left-hand threads)
Close and latch door.
10
1
9
Tools Needed:
9/16 in
Ref. 801 577-A / 801 563-B / Ref. 151 666-D
Return To Table Of Contents
OM-1594 Page 17
5-6. 14-Pin Plug Information
Pin*
J
K
I
H
A
B
L C
M D
E
N
G
F
Pin Information
A
24 volts ac with respect to socket G.
B
Contact closure to A completes 24 volts ac contactor control circuit.
G
Circuit common for 24 volts AC circuit.
C
+10 volts dc output to remote control with respect to socket D.
D
Remote control circuit common.
E
0 to +10 volts dc input command signal from remote control with respect to socket D.
H
Voltage feedback; 0 to +10 volts dc, 1 volt per 10 arc volts.
F
Current feedback; 0 to +10 volts dc, 1 volt per 100 amperes.
*The remaining pins are not used.
5-7. (Optional) Voltage Sensing Lead Connections And CC/CV Jumper Plug Settings
Installing voltage sensing lead
1
2
Terminal Strip 2T
Strain Relief
Loosen screws of strain relief.
3
2
Voltage Sensing Lead
Route ring terminal end of lead
through strain relief, and connect
ring terminal to terminal A of
terminal strip 2T. Tighten screws on
strain relief.
4
5
6
Motor Speed Control Board
PC1
Jumper Plug
Receptacle RC5
Unit is factory set for constant
voltage (CV) welding. To set unit for
constant current (CC) welding. Volt
sensing lead kit must be installed in
feeder. Volt sensing lead kit 209867
6
For constant voltage (CV) welding,
place jumper plug in INT. position.
Voltage sensing lead clamp does
not need to be connected to
workpiece.
B A
For constant current (CC) welding,
place plug in EXT. position.
Connect clamp end of voltage
sensing lead to workpiece.
5
E D C
4
1
RC5
3 2 1
EXT INT
Reinstall right side panel.
3
Tools Needed:
1/4 in
801 557-A
OM-1594 Page 18
Return To Table Of Contents
5-8. Meter Circuit Board Settings
1
Meter Board PC2
2
DIP Switch S2
Set DIP switch S2 for type of
welding power source, and desired
wire feed speed display.
Reinstall hinged door and side
panel.
1
2
X Means switch position does not affect
specified function.
.
Means switch must be in this position.
1
1
2
3
4
5
Switch settings from the factory.
2
. For sense lead, connect PLG51 to PLG50.
Before feeder can be used with a power
source that does not support pins F and H, a
voltage sensing lead must be installed in feeder. Volt sensing lead kit 209867. See section
5-7 for information regarding installation of
voltage sensing lead.
For voltage feedback, connect PLG51 to
PLG52.
Voltage Sensing Function
Arc Voltage Sensing Using Voltage Sensing
Lead For Welding Power Source That Does
Not Support Pins F And H
Digital Meter Display
Meters/Minute
1
1
2
3
4
2
3
Inches/Minute
Arc Voltage Sensing Using Feedback From
Welding Power Source That Does Support
Pins F And H
1
2
3
5
Or
Or
1
4
5
4
2
3
4
5
5
Tools Needed:
1/4 in
Ref. 802 359 / Ref. 186 266
Return To Table Of Contents
OM-1594 Page 19
5-9. Adjusting FasTip Position
XR Edge Gun And
Air Cooled Pistol Grip
1
2
Contact Tip
Nozzle
Adjusting barrel changes contact
tip location from 1/16 in (1.6 mm)
out beyond end of nozzle to 1/4 in
(6.3 mm) inside nozzle.
3
Nozzle Lock Nut
To change contact tip location, loosen nozzle lock nut, and turn nozzle
adapter. Tighten nozzle lock nut.
3
2
4
Jam Nut
5
Nozzle Adaptor
To change contact tip location, loosen jam nut, and nozzle adaptor.
Tighten jam nut.
1
Air and Water-Cooled Model
Pistol Grip Gun
4
5
2
1
Water-Cooled Model
Ref. 801 556 / 150 434 / Ref. 150 431 / Ref. 151 666-A
5-10. Opening Top Cover Of XR-Edge Gun
1
Top Cover
Squeeze sides of cover to release
clips and lift up as shown.
1
To close cover, pivot cover closed
on gun, and push cover down until
clips lock tight.
Ref. 801 556-B
OM-1594 Page 20
Return To Table Of Contents
5-11. Removing Top Cover Of Pistol Grip Gun
1
Top Cover Triangular Boss
Push up on triangular boss to open
door. Door hinges on handle.
1
To open door fully, push up on door
until it clicks into position.
. If door is pushed too far it will
separate from handle. If this
happens the door can be reinstalled.
Push door back into original position to close.
802 528-B
5-12. Installing Wire Spool
1
2
3
4
10
Wire Spool
Top Cover
Pressure Roll Assembly
Gun Contact Tip
If wire spool is being replaced, open
top cover, open pressure roll assembly in gun, and cut welding wire
off at contact tip.
Retract wire onto spool.
5
6
7
8
6
9
2
Hub
Hub Pin
Notch
Compression Spring (Optional
For 8 Inch Spool)
Retaining Ring
Slide spool onto hub so wire feeds
off bottom. Turn spool until hub pin
fits hole in back of spool (notch on
hub aligns with hub pin for guidance). Reinstall retaining ring.
6
10 Motor Torque Switch
5
Place motor torque switch in
appropriate position for wire type
and size (see Section 6-2).
7
1
3
Thread welding wire (see Section
5-13).
2
8
9
4
Tools Needed:
3
4
Ref. 801 578-A / Ref. 072 573-B / Ref. 801 556-B / Ref. 151 599-D
Return To Table Of Contents
OM-1594 Page 21
5-13. Threading Welding Wire Through Feeder
Tools Needed:
Hold wire tightly to keep
it from unraveling.
6 in
(150 mm)
Open tension arm.
Pull and hold wire; cut off end.
Proceed to Section 5-14.
Thread wire thru inlet guide, along drive roll groove, and
into wire conduit. Close tension arm. Adjust tension as
follows: grasp spool with one hand, press Jog switch, and
turn thumb nut clockwise until motor stalls when Jog
switch is pressed. Back thumb nut off slightly.
OM-1594 Page 22
Return To Table Of Contents
Ref. 802 193-A
5-14. Threading Welding Wire Through Gun
Refer to Section 5-13 for instructions on feeding wire
through feeder.
For XR-Edge Gun:
Welding wire is electrically live when
gun trigger is used to jog wire.
. Turn OFF coolant supply before removing head
tube on water-cooled gun.
Lay gun cable out straight. Open top cover, and open
pressure roll assembly. Remove head tube from gun.
Press Jog switch until about 2 in (51 mm) of wire is
sticking out front of gun. Insert wire into head tube liner
and secure head tube to gun.
Close top cover on gun. Press Jog switch until about
6 in (152 mm) of wire is sticking out end of contact
tip. See final pressure adjustment at bottom of page.
For Pistol-Grip Gun:
3
6
5
1
4
2
. Turn OFF coolant supply before removing head tube
1
on water-cooled gun.
groove, and .047 in (1.2 mm) and 1/16 in (1.6 mm) use
large groove.
Pressure Roll Assembly
4
Lift arm and open pressure roll assembly.
2
Cable Assembly
Lay cable assembly out straight.
Push Jog switch up to feed wire through cable assembly.
3
Contact Tip
Manually thread wire along drive roll groove and out contact tip 2 in (51 mm). Close pressure roll assembly.
Drive Roll
For wire sizes .035 in (0.9 mm) and smaller use small
5
Tension Thumbnut
6
Pressure Adjustment Knob
7
Final Pressure Adjustment
See procedure at bottom of page. Reinstall gun cover.
For Both Guns:
. Procedure is the same for
pistol-grip gun.
Nonconductive
Surface
Tools Needed:
Feed wire to check drive roll pressure.
If necessary, slightly tighten thumb nut
inside gun.
Cut off wire. Close and latch wire
feeder door.
Ref. 802 193-A / 801 556-B
Return To Table Of Contents
OM-1594 Page 23
5-15. Adjusting Wire Feed Starting Speed
To adjust wire feed starting speed,
proceed as follows:
1
2
Motor Speed Control Board
PC1
Motor Start Control
Potentiometer R3
Remove protective white rubber
cap before making adjustment.
Adjust potentiometer using a small
nonconductive screwdriver. Turn
potentiometer
clockwise
to
increase time it takes the motor to
ramp up to speed.
Reinstall side panel.
1
2
Top Of PC1
Tools Needed:
Nonconductive
1/4 in
Ref. 801 557 / 197 716
OM-1594 Page 24
Return To Table Of Contents
5-16. Setting Switches For Preflow And Postflow
. Unit
arrives from the factory
with preflow Off and postflow
turned On.
To set switches for preflow and
postflow, proceed as follows:
1
2
Motor Speed Control Board
PC1
DIP Switch S1
. Preflow and postflow have pre-
set time values and cannot be
changed.
To provide a 3.5 second preflow
time, use a small nonconductive
screwdriver to set switch S1-1 in
the up position. To turn preflow time
off, set S1-1 in the down position.
To provide a 0.5 second postflow
time, use a small nonconductive
screwdriver to set switch S1-2 in
the up position. To turn postflow
time off, set S1-2 in the down
position.
1
Reinstall side panel.
Top Of PC1
2
Tools Needed:
Nonconductive
1/4 in
Ref. 801 557 / 197 716
Return To Table Of Contents
OM-1594 Page 25
5-17. Adjusting Trigger Hold Actuation Time
To adjust trigger hold actuation
time, proceed as follows:
1
2
Motor Speed Control Board
PC1
Potentiometer R50
. Trigger
hold actuation time
range is from 0 to 4 seconds.
To decrease trigger hold actuation
time, use a small nonconductive
screwdriver
and
rotate
potentiometer
clockwise;
to
increase actuation time, rotate
potentiometer counterclockwise.
Reinstall side panel.
1
Top Of PC1
2
Tools Needed:
Nonconductive
1/4 in
Ref. 801 557 / 197 716
OM-1594 Page 26
Return To Table Of Contents
SECTION 6 − OPERATION
6-1. Controls
1
2
3
4
12
5
6
7
8
9
10
11
801 554
1
Voltage/Wire Speed Meter
4
2
Voltage/Wire Speed Switch
Use control to set wire feed speed after arc
initiation.
When switch is in Voltage position, and
operator is welding, meter displays arc
voltage. Cable resistance and poor
connections may cause displayed voltage to
vary slightly from actual voltage at welding
arc.
When switch is in Wire Speed position and
operator is welding, meter displays preset
wire speed in inches per minute. This wire
speed is the combined settings of the Weld
Speed Control on unit and Wire Speed
Control on gun.
During run-in portion of weld cycle, meter
displays run-in speed as selected on Run-In
Speed control on feeder.
Wire Speed Control
. The gun wire feed speed control adjusts
wire speed from minimum to maximum
setting on Wire Speed Control.
The scale around the control is percent of full
range, not wire speed.
5
Schedule A Indicator LED
LED illuminates when Schedule A is active.
6
Press To Set Push Button
Use push button to set wire speed for
Schedule B.
7
Schedule B Indicator LED
LED illuminates when Schedule B is active.
When welding Direct Current Electrode
Negative (DCEN), meter does not display
accurate output voltages; however, meter
displays accurate wire speed values.
3
Remote Voltage Control (Optional)
Use control to adjust arc voltage at the wire
feeder.
The scale around the control is marked in
percent.
8
Wire Speed B Control (Optional)
Use control to set wire feed speed for a
schedule B welding operation.
. A dual schedule switch must be installed
in unit to set wire speed B. There is no
run-in speed setting for wire speed B.
The scale around the control is percent of full
range, not wire speed.
Return To Table Of Contents
9 Remote Voltage B Control (Optional)
Use control to adjust arc voltage at the wire
feeder for a schedule B welding operation.
The scale around the control is marked in
percent.
10 Jog/Purge Switch
Push up to momentarily feed welding wire at
speed set on Wire Speed control without
energizing welding circuit or shielding gas
valve.
Push down to momentarily energize gas
valve to purge air from gun or adjust gas
regulator.
11 Trigger Hold Switch
Push up to weld without holding gun trigger
throughout the weld cycle.
To start weld, press gun trigger, and trigger
hold will actuate after 3 seconds of weld time.
To end weld, press and release gun trigger.
12 Flowmeter (Optional)
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 widest part of the float in the meter.
Rotate valve to change gas flow as
necessary.
A regulator is still required on shielding gas
supply with this option.
OM-1594 Page 27
6-2. Internal Controls
Open left side door.
1
Run-In Speed Control
Use this control to set run-in wire
feed speed before arc initiation.
After arc initiation, weld wire feed
speed is controlled by the wire
speed setting on the welding gun
(see Section 6-3).
The scale around the run-in speed
control is a percent of weld wire
feed speed.
1
5
2
6
7
Maximum run-in wirefeed speed is
approximately one half of weld
wirefeed speed.
Minimum run-in wirefeed speed is
approximately 40 inches per minute
(1 mpm).
3
. The
4
2
gun wire feed speed
control adjusts wire speed from
minimum to maximum setting
on Wire Speed Control.
Burnback Time Control
(Optional)
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
contact tip, decrease burnback
time.
The scale around the control is
marked in fractions of a second.
3
Spot Time Control (Optional)
Use control to set spot weld time.
Welding wire feeds at speed
selected on the gun Wire Speed
Control. Spot time starts at arc
initiation.
Rotating
switch
fully
counterclockwise until it clicks
selects an untimed continuous
weld, all other positions will provide
various timed spot welds.
The scale around the control is
marked in seconds.
4
Time Range Switch
Use switch to select spot weld time
range.
5
Fuse F1
See Section 7-13.
6
Circuit Breaker CB1
See Section 7-13.
7
Motor Torque Switch
Use switch to select the force used
to push wire. The up position is for
high force, or torque. The down
position is for low force, or torque.
Use Low position for .030 wire size
and High position for all other wire
sizes.
Close and latch door.
Ref. 801 578
OM-1594 Page 28
Return To Table Of Contents
6-3. Gun Controls
1
Trigger
Press trigger to energize welding
power source contactor (if
applicable), start shielding gas flow,
and begin wire feed.
Switches inside the wire feeder can
be set to provide timed shielding
gas preflow and postflow when
trigger is pressed and released
(see Section 5-16). When this feature is turned Off, no preflow or
postflow is provided for the welding
operation.
1
2
Wire Speed Control
Use control to fine adjust wire feed
speed set on wire feeder Weld
Speed control. The numbers
around the control are for reference
only.
2
1
2
Ref. 151 666-D
6-4. Shielding Gas
1
2
3
2
1
Shielding Gas Cylinder
Valve
Gun Trigger
Open valve on cylinder just before
welding.
3
Gun trigger turns weld output and
gas flow on and off (see Section
6-3).
Close valve on cylinder when
finished welding.
3
sb5.1 6/92 − S-0621-C / Ref. 151 666-D
6-5. Coolant Supply For Water-Cooled Models Only
1
Coolant Supply
See Section
guidelines.
1
5-4 for
coolant
Turn On coolant supply before
welding.
Turn Off coolant supply when
finished welding.
Ref. 150 755-A
Return To Table Of Contents
OM-1594 Page 29
6-6. Sequence Of Gas Metal Arc Welding (GMAW) − Continuous Or Spot
Install &
Connect
Equipment
Put On
Personal Safety
Equipment
Set Controls
Turn On Gas
And Water (If
Applicable)
Turn On Feeder
And Welding
Power Source
Begin Welding
ssb6.1* 9/92
SECTION 7 − MAINTENANCE & TROUBLESHOOTING
. Maintain more often
Y Disconnect power
before maintaining.
during severe conditions.
4 To 6 Weeks
Apply Conductive Grease To
Drive Roll Screw (See
Sections 7-2 And 7-7)
Conductive
Grease
3 Months
Clean
And
Tighten
Weld
Terminals
Replace
Damaged Or
Unreadable
Labels
Replace Damaged
Gas Hose
Repair Or Replace
Cracked Cables
And Cords
6 Months
Clean
Drive
Rolls
Blow Out Or
Vacuum Inside
OM-1594 Page 30
Return To Table Of Contents
7-1. Feeder Drive Assembly Maintenance
Retract wire onto spool.
1
1
2
3
4
Pressure Roll Assembly
Drive Motor Shaft
Drive Roll
Screw
Use wire brush to clean drive roll.
5
6
5
Drive Roll Idler
Shoulder Washers
Use wire brush to clean idler.
7
8
Outlet Guide
Wire Inlet Guide
Pull guide toward rear of feeder to
remove. Install new guide.
Thread welding wire and adjust
drive roll pressure, if necessary
(see Section 5-13).
6
8
7
Drive roll and idler are available for
the following wire size ranges:
.030-.035 wire size
2
.047 wire size
.062 wire size
3
4
Tools Needed:
When changing wire size, change
control box drive roll and idler, gun
pressure roll and drive roll (see
Section 7-2 for XR-Edge guns; see
Sections 7-7 and 7-8 for pistol-grip
guns), and gun liner (see Section
7-4 for XR-Edge guns; see Section
7-9 for pistol-grip guns).
5/16 in
802 193-A
Return To Table Of Contents
OM-1594 Page 31
7-2. Gun Drive Assembly Maintenance For An XR-Edge Gun
Retract wire onto spool.
1
2
1
2
Screw
Drive Roll
Use wire brush to clean drive roll.
Install drive roll with hex opening
down toward shaft hex, and secure
with screw.
. Apply
conductive grease to
drive roll post every 4 to 6
weeks.
3
4
Post
Pressure Roll w/Bearing
Use wire brush to clean pressure
roll. Install pressure roll so that gear
teeth mesh with drive roll gear
teeth, and secure with screw.
If changing drive roll in feeder, see
Section 7-1.
Thread welding wire through gun.
Close and secure pressure roll
assembly. Adjust drive roll
pressure, if necessary (see Section
5-13).
3
Drive roll and pressure roll are
available for the following wire
sizes:
.030 wire size
.035 wire size
Conductive
Grease
.047 wire size
.062 wire size
When changing wire size, change
control box drive roll and idler (see
Section 7-1), gun pressure roll and
drive roll, and gun liner (see Section
7-4 and 7-9).
4
Tools Needed:
Close top cover.
5/16 in
Ref. 801 556-B
OM-1594 Page 32
Return To Table Of Contents
7-3. Removing Diffuser In XR-Edge Guns
1
2
6
5
Nozzle
Nozzle Locking Nut
Loosen locking nut to remove
nozzle.
3
4
Contact Tip
Diffuser
Remove contact tip from diffuser.
5
6
4
Insulator
Head Tube
Install insulator, then install and
tighten new diffuser into head tube.
Reinstall contact tip and nozzle.
3
2
1
Tools Needed:
3/8 in
Ref. 802 253-C
7-4. Replacing Head Tube Liner In XR-Edge Guns
. Turn OFF coolant supply before
removing head
water-cooled gun.
tube
on
The standard head tube liner will accommodate wire diameters from
.030-1/16 wire size.
4
3
2
When changing wire size, change
control box drive roll and idler (see
Section 7-1), gun pressure roll and
drive roll (see Sections 7-2 and 7-7).
1
2
Head Tube
Head Tube Nut
Loosen head tube nut and remove
head tube from gun.
1
3
4
O-Ring
Liner
Pull liner out of head tube. Be sure oring stays in place in groove. Replace o-ring if necessary. If o-ring is replaced, o-ring must be installed before liner is inserted.
Insert new liner into head tube and
reinstall head tube onto gun.
. A twisting motion may be needed to feed liner thru head tube.
. Be sure head tube nut is secure-
ly tightened before operating
gun. If head tube nut is not adequately tightened, unwanted
arcing may occur between head
tube and gun housing.
Ref. 802 328-F
Return To Table Of Contents
OM-1594 Page 33
7-5. Replacing The Liner
Y Turn Off welding power
source and wire feeder.
1
2
Drive Roll
Collet Nut
Lay gun cable out straight. Remove
drive roll on gun and collet nut on liner tube assembly.
3
Gun Connector
Remove inlet guide from gun connector, and remove old liner.
1
4
1
2
2
New Liner
Insert split end of new liner into gun
connector and continue feeding liner through cable assembly until liner is through liner tube assembly
and all of split portion is visible.
. If gun is a 15 ft (4.5 m) model,
push the split end of liner
through until the opposite end
is sticking out of the gun connector 1 to 2 inches (2.5 to 5
cm). After trimming, the section
with the split on it can be saved
to use as another replacement
liner.
Cut off split portion of liner. Replace
collet nut with new nut from this kit.
Reinstall inlet guide at gun connector and tighten onto liner.
The liner end will not stick out of the
collet nut supplied with this kit.
At the gun connection end, cut liner
as close as possible to control
(push motor) drive rolls.
Refer to Owner’s Manual for instructions on rethreading wire.
XR-Edge Gun
Pistol Grip Gun
. On pistol grip models it may be
easier to replace the collet nut
with the liner conduit removed
from the gun housing block.
3
3
4
Split End
Ref. 151 599-E / Ref. 801 556-B / 801 564−C / Ref. 151 666-D / Ref. 200 371
OM-1594 Page 34
Return To Table Of Contents
7-6. Changing Gun Contact Tip
Remove nozzle
1
Nozzle
2
FasTip
Unscrew FasTip
Install new FasTip.
2
1
Ref. 150 437
7-7. Replacing Or Cleaning Gun Drive Roll In Pistol-Grip Guns
Turn Off wire feeder and welding
power source.
1
Top Cover
2
Pressure Roll Assembly
Cut off wire where it enters
pressure roll assembly area.
5
1
3
4
3
Setscrew
4
Current Pick-Up Tab
This tab helps prevent burnback
caused by welding arcs inside the
contact tip. This tab may be removed to provide an insulated drive
roll. (If tab is removed, a smaller diameter contact tip is recommended. See options in Parts List.)
Lightly grease top of tab before reinstalling.
5
Drive Roll
Use wire brush to clean drive roll.
Install drive roll with desired groove
down, and turn drive roll so one
setscrew faces flat side of shaft.
6
Bearing
7
Liner
Line up drive roll groove with bearing groove and liner opening.
Tighten setscrews.
If changing drive roll in feeder, see
Section 7-1.
2
Thread welding wire through gun,
and adjust drive roll pressure, if
necessary (see Section 5-14).
Close and secure pressure roll
assembly. Reinstall top cover.
Tools Needed:
6
7
5/64 in
Ref. 151 599-E
Return To Table Of Contents
OM-1594 Page 35
7-8. Replacing Or Cleaning Gun Drive Roll Bearing In Pistol-Grip Guns
Turn Off wire feeder and welding
power source.
1
1
Top Cover
2
Pressure Roll Assembly
3
Screw
4
Pressure Roll
Remove as shown.
Use a wire brush to clean bearing.
Reinstall with washers, and tighten
screw.
Close pressure roll assembly.
Reinstall top cover.
4
2
3
Tools Needed:
Ref. 151 599−E
7-9. Replacing Head Tube Liner In Pistol-Grip Guns
. Turn
OFF coolant supply
before removing head tube on
water-cooled gun.
The standard head tube liner will
accommodate wire diameters from
.030-1/16 wire size.
When changing wire size, change
control box drive roll and idler (see
Section 7-1), gun drive roll (see
Sections 7-2 and 7-7).
6
5
4
2
1
3
1
2
3
Cover
Screw
Clamp
Loosen clamp screws and remove
clamp.
4
Head Tube
Remove head tube from gun.
4
5
6
O-Ring
Liner
Pull liner and o-ring out of head
tube.
Insert new o-ring and liner (o-ring
first) into head tube and reinstall
head tube onto gun.
. A twisting motion may be need-
ed to feed liner thru head tube.
Tool Needed:
5/32 in
Ref. 803 551-B
OM-1594 Page 36
Return To Table Of Contents
7-10. Removing Diffuser In Air-Cooled Pistol-Grip Guns
Turn Off wire feeder and welding
power source.
1
Nozzle
2
Nozzle Locking Nut
Remove as shown.
3
FasTip
To remove, see Section 7-6.
6
5
4
Diffuser
5
Insulator
6
Head Tube
Remove nozzle and FasTip.
4
Remove diffuser and replace.
3
2
1
Tools Needed:
3/8 in
Ref. 800434-C
7-11. Removing Diffuser In Water-Cooled Pistol-Grip Guns
WARNING
WATER IN GUN PARTS can cause ELECTRIC SHOCK and can lower weld quality.
•
•
•
Turn Off welding power source and water supply before working on gun. Stop engine on welding generators.
Always point gun downward when removing water-cooled barrel to keep water out of gun parts.
Wipe gun dry before putting it back together.
Turn Off weld control and welding
power source.
5
4
3
1
Nozzle
2
Nozzle Adaptor
Remove as shown.
2
1
3
FasTip
4
Diffuser
5
Nozzle Locking Nut
Remove nozzle and FasTip.
Remove diffuser and replace.
Ref. 150 431 / Ref. 150 431-A
Return To Table Of Contents
OM-1594 Page 37
7-12. Replacing Hub Assembly
Remove gun top cover and release
pressure arm (see Sections 5-10
and 5-11).
Retract wire onto spool and remove
spool. Take hub apart as shown.
1
2
3
4
5
6
7
8
Metal Brake Washer
Flat Washer
Brake Washer
Hub
Keyed Washer
Spring
Cap Screw
Retaining Ring
Replace broken or worn parts and
slide parts onto shaft as shown.
Adjust hub tension and thread
welding wire. Close and latch door.
1
Close gun pressure roll assembly
and reinstall gun cover.
2
5
3
6
4
2
7
8
Tools Needed:
7/16 in
OM-1594 Page 38
801 577 / Ref. 143 223-A
Return To Table Of Contents
7-13. Overload Protection
Y Turn Off wire feeder and
welding power source. Stop
engine
on
welding
generator.
If fuse opens, unit shuts down. To
replace fuse, proceed as follows:
3
1
2
3
1
2
Fuse Holder Cover
Fuse F1 (See Parts List)
Circuit Breaker CB1
If CB1 opens, the gun drive motor,
gas valve, and contactor will not
operate when trigger is pulled. The
gun drive motor operates in the Jog
mode with CB1 open.
Check for blocked gun liner.
Check for jammed wire, binding
drive gear or misaligned drive rolls
in feeder. Correct problem.
Allow cooling period and manually
reset breaker. Close and latch door.
Ref. 801 577 / Ref. 800 185-A
7-14. Water Flow Switch (Optional For Water-Cooled Models)
The water flow switch protects the gun from overheating. If coolant flow rate drops below 1 qt/min, the water flow
switch opens and stops the welding wire from feeding. See Section 7-15 for remedies to this trouble.
Return To Table Of Contents
OM-1594 Page 39
7-15. Troubleshooting
Y Disconnect power before troubleshooting.
Trouble
Remedy
Pressing gun trigger does not energize Secure plug from gun control cable into Gun Control receptacle on feeder (see Section 5-3 or 5-5 as applifeeder. Welding wire is not energized. cable).
Shielding gas does not flow.
Have nearest Factory Authorized Service Agent check optional water flow switch, if applicable.
Wire feeds, shielding gas flows, but See Troubleshooting section in welding power source manual.
welding wire is not energized.
Check position of Motor Torque switch (see Section 6-2).
Wire feeds erratically.
Adjust drive roll pressure if necessary (see Section 5-13).
Clean or replace drive rolls as necessary (see Sections 7-2 and 7-7).
Arc varies and welding wire is kinked Place Motor Torque switch in low torque position if welding with .030 (0.8 mm) aluminum welding wire (see
when feeding out gun.
Section 6-2).
No weld output; gun/feeder does not Check gun trigger plug connection on wire feeder front panel (see Sections 5-3 and 5-5).
work.
Place Power switch on welding power source in the On position.
Tighten and clean all connections.
Erratic weld output.
Check drive roll pressure in wire feeder and gun (see Section 5-13).
Check and replace liner if necessary (see Section 7-4 and 7-9).
Wire does not feed; burnback in contact Check drive roll pressure in wire feeder and gun (see Section 5-13).
tip.
Check and replace liner if necessary (see Section 7-4 and 7-9).
Reinstall voltage sensing lead (see Section 5-1).
Check drive roll pressure in wire feeder and gun (see Section 5-13).
Wire feeds erratically.
Clean or replace drive rolls as necessary (see Sections 7-2 and 7-7).
Check and replace liner if necessary (see Section 7-4 and 7-9).
Gun
overheating
models).
(water-cooled Be sure coolant flow rate is at least 1 qt/min.
Corrosion buildup in gun decreasing coolant flow rate. Backflush coolant system, clean coolant system
filter, and clean fittings.
Voltmeter does not display voltage
OM-1594 Page 40
If welding power source does not support pins F and H, a volt sense lead kit must be installed in feeder
(see Section 5-7 and 5-8). Volt sensing lead kit 209867.
Return To Table Of Contents
Notes
Return To Table Of Contents
OM-1594 Page 41
SECTION 8 − ELECTRICAL DIAGRAMS
Figure 8-1. Circuit Diagram For Wire Feeder
OM-1594 Page 42
Return To Table Of Contents
186 931-E
Return To Table Of Contents
OM-1594 Page 43
195 712-A
Figure 8-2. Circuit Diagram For XR Edge Gun
198 344-A
Figure 8-3. Circuit Diagram For XR Pistol Grip Gun
OM-1594 Page 44
Return To Table Of Contents
Notes
Return To Table Of Contents
OM-1594 Page 45
SECTION 9 − PARTS LIST
. Hardware is common and
43
41
44
59
42
55
56
45 − Figure 9-3
46
47
48
1
2
3
58
4
5
6
49 − Figure 9-2
51
7
50
8
52
9
10
53
11
54
12
57
13
14
40
39
38
37
36
16
15
17
35
18
34
33
19
25
60
23
26
24
27
28
29
30
31
20
32
21
22
not available unless listed.
802 230-B
Figure 9-1. Main Assembly
OM-1594 Page 46
Return To Table Of Contents
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-1. Main Assembly
. . 1 . . . . . . . . . . . . . . 089 572
. . 2 . . . . . . . . . . . . . . . 112 167
. . 3 . . . . . . . . . . . . . . 134 327
. . 3 . . . . . . . . . . . . . . 178 936
. . 4 . . . . . . . . . . . . . +169 085
. . 5 . . . . . . . . . . . . . . 126 415
. . 6 . . . . . . . . . . . . . . 126 416
. . 7 . . . . . . . . . . . . . . 058 427
. . 8 . . . . . . . . . . . . . . 602 233
. . 9 . . . . . . . . . . . . . . 057 543
. . 10 . . . . . . . . . . . . . . . 113 168
. . 11 . . . . . . . . . . . . . . 058 428
. . 12 . . . . . . . . . . . . . . 089 561
. . 13 . . . . . . . . . . . . . . 058 424
. . 14 . . . . . . . . . . . . . . 151 697
. . 15 . . . . . . . . . . . . . . . 112 198
. . 16 . . . . . . . . . . . . . . 057 357
. . 17 . . . . . . . . . . . . . . 010 494
. . 18 . . . . . S1 . . . . . . 111 997
. . 19 . . . . . . . . . . . . . . . 115 104
. . 20 . . . . . . . . ♦♦♦♦176 089
. . 21 . . . . . . . . ♦♦♦♦600 399
. . 22 . . . . . . . . ♦♦♦♦601 222
. . 23 . . . PLG5 . . . . 141 162
. . 24 . . . . . . . . . . . . . . 079 739
. . . . . . . . . . . . . . . . . . . 182 475
. . 25 . . . . . . . . . . . . . . 605 227
. . 26 . . . . . . . . . . . . . . 073 302
. . 27 . . . . . . . . . . . . . . . 113 161
. . 28 . . . . . . . . . . . . . . . 113 165
. . 29 . . . . . . . . . . . . . . 120 396
. . 30 . . . . MP1 . . . . . 163 304
. . 31 . . . . . . . . . . . . . . 073 302
. . 32 . . . . . . . . . . . . . . . 113 900
. . 33 . . . . GS1 . . . . . 125 785
. . 34 . . . . . . . . . . . . . . 089 120
. . 35 . . . . . . . . . . . . . . 176 357
. . 36 . . . . . 2T . . . . . 038 783
. . . . . . . . . . . . . . . . . . . 601 219
. . . . . . . . . . . . . . . . . . . . 111 008
. . 37 . . . . PC1 . . . . . 210 370
. . 38 . . . . . . . . . . . . . . 105 567
. . 39 . . . . CB1 . . . . . . 011 991
. . 40 . . . . . S7 . . . . . . 011 770
. . 41 . . . . . . . . . . . . . +187 704
. . 42 . . . . . . . . . . . . . ♦194 282
. . 43 . . . . . . . . . . . . . . 090 439
. . 44 . . . . . . . . . . . . . . 089 573
. . 45 . . . . . . . . . . . . . . . Fig 9-3
. . 46 . . . . . . . . . . ♦♦♦134 834
. . 47 . . . . . . . . . . ♦♦♦089 120
. . 48 . . . . . S8 . ♦♦♦194 195
. . 49 . . . . . . . . . . . . . . . Fig 9-2
. . 50 . . . . . . . . . . . . . . 187 789
. . 50 . . . . . . . . . . . . . . 197 645
. . 51 . . . . . F1 . . . . . *073 426
. . 52 . . . . . . . . . . . . . . 046 432
. . 53 . . . . . . . . . . . . . . 193 919
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
Catch, Link-lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Insulator, Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Label, Warning General Precautionary (Non-ce Units) . . . . . . . . . . . . . . . . 1
Label, Warning General Precautionary (Ce Units) . . . . . . . . . . . . . . . . . . . . 1
Wrapper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Clamp, Saddle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Handle, Molded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Ring, Retaining Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Washer, Flat Stl .250 Id X .875 Od X .062thk . . . . . . . . . . . . . . . . . . . . . . . . 1
Spring, Cprsn .845 Od X .091 Wire X 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . 1
Washer, Locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hub, Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Washer, Anti-turn Stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Washer, Fbr Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Strip, Brake Surface Anti-turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Shroud, Spool Wire 12 In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Bushing, Snap-in Nyl .937 Id X 1.125mtg Hole . . . . . . . . . . . . . . . . . . . . . . 2
Bushing, Snap-in Nyl 1.375 Id X 1.750mtg Hole . . . . . . . . . . . . . . . . . . . . . 1
Switch, Rocker Spst 10A 250VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Connector, Clamp Cable .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tubing, Plstc PVC Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1ft (0.3 m)
Wire, Strd 14Ga(Order By Ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35ft (10.7 m)
Clamp, Univ 50A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Housing Plug & Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Clamp, Cable Strain Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Cable, Port No 18 6/C 10 Ft 8 In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Nut, .750-14 Knurled Nyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Bearing, Ball Rdl Sgl Row .669 X 1.378 X .39 . . . . . . . . . . . . . . . . . . . . . . . 1
Block, Bearing Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Stand-Off, .250-20 X 1.000 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Shaft, Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Brake, W/Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Bearing, Ball Rdl Sgl Row .669 X 1.378 X .39 . . . . . . . . . . . . . . . . . . . . . . . 1
Block, Bearing Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Valve. 24VAC 2way Custom Port 1/8 Orf . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Clamp, Hose .375-.450clp Dia Slfttng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Hose, Sae .187 Id X .410 Od X 21.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Block, Term 20A 12P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Link, Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Label, Term Mkg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Circuit Card, Motor Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Skid, Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Circuit Breaker, Main Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Switch, Tgl Spdt 6A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Cabinet, Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Potentiometer, C Sltd Sft 1t 1w 1m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Label, Warning Electric Shock Can Kill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Plate, Keeper Link-lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Panel, Front W/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Hose, Sae .187 Id X .410 Od (Order By Ft) . . . . . . . . . . . . . . . . . . . 2ft (0.6 m)
Clamp, Hose .375-.450Clp Dia Slfttng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Switch, Flow W/Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Motor & Wire Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Plate, Control Side (Non-CE Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Plate, Control Side (CE Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Fuse, Mintr Gl Slo-blo 5A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Holder, Fuse Mintr .250 X 1.250 Panel Mtg . . . . . . . . . . . . . . . . . . . . . . . . . 1
Knob, Pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Return To Table Of Contents
OM-1594 Page 47
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-1. Main Assembly (Continued)
. . 54
. . 55
. . 56
. . 57
. . 58
. . 59
. . 60
. . . . . . . . . . . . . ♦028 770
. . . . . . . . . . . . . . 073 562
. . . . . . . . . . . . . . 134 201
. . . REED . . . . 140 786
. . . . . . . . . . . . . . 169 089
. . . . . . . . . . . . . . 605 970
. . . . . . . . . . . . . . . 211 989
..
..
..
..
..
..
..
Potentiometer, Cp Std Slot 1t 2w 1m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Potentiometer, Cp Std Slot 1t 2w 10k . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stand-Off Support, PC Card .312/.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, Reed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Door, Side Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer, Shldr.252 Id 0.310 Odx.064t .500 Odx.250h Nyl . . . . . . . . . . . . .
Fitting, W/Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
4
1
1
2
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
♦Part of 114 144 Spot Weld Control Option
♦♦Part of 144 931 Voltage Control Option
♦♦♦Part of 130 838 Water Flow Shutdown Switch Option
♦♦♦♦Part of 209 867 Voltage Sensing Lead Kit
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
. Hardware is common and
4
*1
not available unless listed.
10
9
11
8
12
7
13
6
3
2
14
5
4
16
15
17
18
19
20
21
22
23
25
24
26
17
27
* Includes items 22 thru 24
29
28
ST-802 237-A
Figure 9-2. Motor & Wire Drive
OM-1594 Page 48
Return To Table Of Contents
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-2. Motor & Wire Drive (Figure 9-1 Item 49)
...
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...
...
...
...
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...
...
...
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...
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...
...
...
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1
2
3
4
4
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
. . . . . . . . . . . . . 193 186
. . . . . . . . . . . . . 124 778
. . . . . . . . . . . . . . 111 630
. . . . . . . . . . . . ♦194 118
. . . . . . . . . . . . ♦194 119
. . . . . . . . . . . . ♦195 591
. . . . . . . . . . . . . 151 828
. . . . . . . . . . . . . 090 416
. . . . . . . . . . . . . 191 826
. . . . . . . . . . . . . 189 714
. . . . . . . . . . . . ♦188 098
. . . . . . . . . . . . . 189 716
. . . . . . . . . . . . . 092 237
. . . . . . . . . . . . . . 189 911
. . . . . . . . . . . . . 085 244
. . . . . . . . . . . . . 085 242
. . . . . . . . . . . . . 010 224
. . . . . . . . . . . . . 058 549
. . . . . . . . . . . . . 602 306
. . . . . . . . . . . . . 189 823
. . . . . . . . . . . . . 189 920
. . . . . . . . . . . . . 189 605
. . . . . . . . . . . . . 079 625
. . . . . . . . . . . . . 196 613
. . . . . . . . . . . . . 196 604
. . . . . . . . . . . . . 144 172
. . . . . . . . . . . . . . 113 162
. . . . . . . . . . . . . 605 798
. . . . B1 . . . . . 163 326
. . . . . . . . . . . . . . 113 169
. . . . . . . . . . . . . 604 612
. . Drive Assembly, Wire (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Knob, T 2.000 Bar W/.312 - 18 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Screw, 010-32 X .25 Hexwhd-pln Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Kit, Drive Roll .030−.035 (Part Of Wire Guide Kits 193 520 & 193 521)
. . . . Kit, Drive Roll .047−.062 (Part Of Wire Guide Kit 193 522) . . . . . . . . . .
. . . . Kit, Drive Roll .062 (Part Of Wire Guide Kit 193 523) . . . . . . . . . . . . . . .
. . . . Pin, Cotter Hair .042 X .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Pin, Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Screw, Mtg Idler Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Pressure Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Washer, Shlder .192 Id X .375 Od . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Housing, Wire Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Knob, Adjust Tension 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Spring, Cprsn .720 Od X .063 Wire X 1.500 . . . . . . . . . . . . . . . . . . . . . . .
. . . . Washer, Cupped .328 Id X .812 Od X 16 Ga X .125 Lip . . . . . . . . . . . . .
. . . . Fastener, Pinned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Pin, Spring Cs .187 X 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Guide, Wire Inlet 1/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Pin, Spring Cs .125 X .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Insulator, Front Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Gear Assy, Shaft/Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bearing Assy, Upper Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Washer, Wave .500 Id X .750 Od . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Case, Gear Wire Drive (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . Washer, Shldr .187 Id .343 Od X .045t .234 Od X .138t Nyl . . . . . . . .
. . . . Fitting, Hose Brs Barbed M 3/16 Tbg X .250-20 . . . . . . . . . . . . . . . . . . . .
. . Insulator, Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Washer, Shldr .168 Id 0.375 Od X .047t .246 Od X .030t Nyl . . . . . . . . . .
. . Motor, Torque 24VAC 50/60hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Gear, Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Screw, Set Stl Sch 8-32 X .125 Cup Point . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
2
1
1
1
1
1
3
1
1
3
1
1
1
♦Part of 194 118, 194 119, or 195 591 Drive Roll Kits
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Return To Table Of Contents
OM-1594 Page 49
. Hardware is common and
not available unless listed.
See Figure 9-1
Item 45
7
8
9
10
6
11
4
5
12
13
3
12
4
14
15
2
1
16
17
18
802 236-A
Figure 9-3. Panel, Front w/Components (Water-Cooled Model Illustrated)
OM-1594 Page 50
Return To Table Of Contents
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-3. Panel, Front w/Components (Figure 9-1 Item 45)
. . . 1 . . . . . . . . . . . . . . . . ♦111 569 . . . Meter, Flow 6-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . . . ♦111 633 . . . Guard, Flow Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nameplate, (Order By Model And Serial Number) . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . . . . . 605 798 . . . Washer, Shldr. Nyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . 5 . . . . . . . . . . . . . . . . . . 173 259 . . . Insulator, Water Flow Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . . . . . . . . . . . . . . . . . 139 678 . . . Fitting, Water (Supplied With Water-cooled Gun) . . . . . . . . . . . . . . . . 2
. . . 7 . . . . . . . . . . . . . . . . ♦176 357 . . . Hose, Sae .187 Id X .410 Od (Order By Ft) . . . . . . . . . . . . . . . 4ft (1.2 m)
. . . 8 . . . . . . . . . . . . . . . . ♦089 120 . . . Clamp, Hose .375-.450Clp Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 9 . . . . . . . . . . . . . . . . ♦112 090 . . . Fitting, Pipe Brs Elb 1/8npt X 3/16 Hose . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . ♦056 851 . . . Fitting, Hose Brs Barbed Nipple 3/16tbg . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . ♦010 606 . . . Fitting, Hose Brs Nut .625-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . ♦056 108 . . . Fitting, Hose Brs Ferrule .425 Id X .718 Lg . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . ♦045 852 . . . Clip, Component .687dia Mtg Adh Back . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . PC2 . . . . . . . . 186 268 . . . Circuit Card, Meter (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . . . . . 115 443 . . . . Stand-Off, No. 6-32 X .750 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . . 133 644 . . . Frame, Snap-in Switch Rocker Panel Mtg . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . . . . . 073 562 . . . Potentiometer, Cp Std Slot 1t 2w . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 13 . . . . . . . . . . . . . . . . . . 011 232 . . . Switch, Pb Spdt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . S4 . . . . . . . . . 134 847 . . . Switch, Tgl SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . S2 . . . . . . . . . 211 476 . . . Switch, Tgl SPTT 6A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . PC4, RC20 . . . . . 197 719 . . . Circuit Card, Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . 146 212 . . . Plug, 10 Pin MS-3106A-18-1PX Amphenol . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG14 . . . . . . . 115 092 . . . Housing Plug & Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . . . . . 194 152 . . . Led, Green . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 18 . . . . . . . . . . . . . . . . . . 193 919 . . . Knob, Pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
♦Part of 114 101 Gas Flow Meter Option.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Return To Table Of Contents
OM-1594 Page 51
. Hardware is common and
51
49
16
13
17
55
22
39
56
21
24
25
36
37
35
33
34
23
32
See Figure 9-5
1
43
53
43
2
54
4
41
42
5
3
9
8
10
7
6
11
31
12
30
26
13
14
40
38
18
15
29
16
45
44
28
17
18
46
19
26
20
25
21
47
23
24
27
47
48
22
52
50
27
not available unless listed.
Ref. 802 328-F
Figure 9-4. Exploded View Of XR-Edge Gun
OM-1594 Page 52
Return To Table Of Contents
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-4. Exploded View Of XR-Edge Gun
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1
2
3
3
3
3
3
4
5
6
7
8
9
10
11
12
13
14
15
15
16
16
17
17
17
18
18
18
19
19
19
20
20
21
21
21
22
22
22
23
23
23
24
25
26
27
27
27
28
29
30
31
32
33
34
35
36
37
. . . . . . . . . . 187 000
. . . . . . . . . . 187 002
. . . . . . . . . . 194 114
. . . . . . . . . . 194 115
. . . . . . . . . . 194 116
. . . . . . . . . . 194 117
. . . . . . . . ♦191 135
. . . . . . . . . ♦111 630
. . . . . . . . . . 185 098
. . . . . . . . . . 191 098
. . . . . . . . . . 191 097
. . . . . . . . . . 191 096
. . . . . . . . . . 000 364
. . . . . . . . . . 216 001
. . . . . . . . . . 191 090
. . . . . . . . . . 602 306
. . . . . . . . . . 203 557
. . . . . . . . . . 191 104
. . . . . . . . . . 135 580
. . . . . . . . . . 135 580
. . . . . . . . . . 149 332
. . . . . . . . . . 149 332
. . . . . . . . . . 191 058
. . . . . . . . . . 191 059
. . . . . . . . . . 191 060
. . . . . . . . . . 191 072
. . . . . . . . . . 191 073
. . . . . . . . . . 191 074
. . . . . . . . . . 203 599
. . . . . . . . . . 203 671
. . . . . . . . . . 203 673
. . . . . . . . . . 191 065
. . . . . . . . . . 191 066
. . . . . . . . . . 191 052
. . . . . . . . . . 191 053
. . . . . . . . . . 191 054
. . . . . . . . . . 203 579
. . . . . . . . . . 203 672
. . . . . . . . . . 203 674
. . . . . . . . . . 191 049
. . . . . . . . . . 191 050
. . . . . . . . . . 191 051
. . . . . . . . . . 152 577
. . . . . . . . . . 141 694
. . . . . . . . . . 137 495
. . . . . . . . . . 191 055
. . . . . . . . . . 191 056
. . . . . . . . . . 191 057
. . . . . . . . . . 191 121
. . . . . . . . . . 191 119
. . . . . . . . . . 191 082
. . . . . . . . . . 189 078
. . . . . . . . . . 190 906
. . . . . . . . . . 191 131
. . . . . . . . . . 191 141
. . . . . . . . . . 190 907
. . . . . . . . . . 135 773
. . . . . . . . . . 191 087
. . Cover,Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Handle, Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Kit, Drive Roll .030 (Part Of Wire Guide Kit 193 520) . . . . . . . . . . . . . . . . . . . . .
. . Kit, Drive Roll .035 (Part Of Wire Guide Kit 193 521) . . . . . . . . . . . . . . . . . . . . .
. . Kit, Drive Roll .047 (Part Of Wire Guide Kit 193 522) . . . . . . . . . . . . . . . . . . . . .
. . Kit, Drive Roll .062 (Part Of Wire Guide Kit 193 523) . . . . . . . . . . . . . . . . . . . . .
. . Shaft, Hot Drive Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Screw, 010-32 X .25 Hexwhd Slt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Pin, Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Screw, Shld Stl Sch 008-32 X .188 X .188 Shld . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Arm, Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Arm, Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Ring, Rtng Ext .188 Shaft X .025 Thk E Style . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Nut, Liner Collet Retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Guide Assy, Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Pin, Spring Cs .125 X .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Clamp, 1−ear Type Nom Dim .391 X .236 Wide Special . . . . . . . . . . . . . . . . . .
. . Power Block Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Fitting, Gas (Air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Fitting, Gas (Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Clamp, Hose .405 − .485 Clp Dia (Air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Clamp, Hose .405 − .485 Clp Dia (Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Hose, Gas In 15ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Hose, Gas In 30ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Hose, Gas In 50ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Hose, Water In 15ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Hose, Water In 30ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Hose, Water In 50ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Conduit, Monocoil Double Wound 15ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Conduit, Monocoil Double Wound 30ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Conduit, Monocoil Double Wound 50 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Liner, .180 Od X .140 Id (15 ft or 30ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Liner, .180 Od X .140 Id (50ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Cable, Power/Water Out 15ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Cable, Power/Water Out 30ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Cable, Power/Water Out 50ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Jacket, Cable Combination 15ft W/Molded Strain Relief . . . . . . . . . . . . . . . . . .
. . Jacket, Cable Combination 30ft W/Molded Strain Relief . . . . . . . . . . . . . . . . . .
. . Jacket, Cable Combination 50ft W/Molded Strain Relief . . . . . . . . . . . . . . . . . .
. . Cable, Power 15ft (Air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Cable, Power 30ft (Air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Cable, Power 50ft (Air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Strip, Copper .010 X 2.000 X .750 (Air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Screw, Set 312-18 X .37 Conept Sch Stl Pln . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Fitting, Connection Power Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Cable, Control 15ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Cable, Control 30ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Cable, Control 50ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Screw, 006-32 X .37 Btn Hd-Soc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Strain Relief, Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Motor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Insulator, Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Insulator, Motor Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Spacer, Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Spring, Cprsn .360 Od X .032 Wire X .875 Free . . . . . . . . . . . . . . . . . . . . . . . . .
. . Shaft, Spring Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Knob, Adjust Tension Thumb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Ring, Rtng Ext .094 Shaft X .015 Thk E Style . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return To Table Of Contents
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OM-1594 Page 53
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-4. Exploded View Of XR-Edge Gun (Continued)
. . . 38 . . . . . . . . . . 191 235
. . . 39 . . . . . . . . . . 191 205
. . . 40 . . . . . . . . . . 187 001
. . . 41 . . . . . . . . . . 196 045
. . . 42 . . . . . . . . . . 191 212
. . . 43 . . . . . . . . . . 210 763
. . . 43 . . . . . . . . . . 194 073
. . . 44 . . . . . . . . . . 203 539
. . . 45 . . . . . . . . . . 189 812
. . . 46 . . . . . . . . . . 196 177
. . . 47 . . . . . . . . . . 202 513
. . . 47 . . . . . . . . . . 202 513
. . . 48 . . . . . . . . . . 193 896
. . . 49 . . . . . . . . . . 079 974
. . . 50 . . . . . . . . . . 202 216
. . . 51 . . . . . . . . . . 187 029
. . . 52 . . . . . . . . . . 189 811
. . . 53 . . . . . . . . . . 156 579
. . . 54 . . . . . . . . . . 143 480
. . . 55 . . . . . . . . . . 203 560
. . . 56 . . . . . . . . . . 203 562
. . . . . . . . . . . . . . ♦605 107
. . Potentiometer, Cp Flat 1t .5w 10k Ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Knob, Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Handle, Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Housing, Drive W/Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Trigger Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Head Tube Assy, Water (See Figure 8-5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Head Tube Assy, Air (See Figure 8-5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Fitting, Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Housing, Power Pin Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Hose, Water Out 10in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Fitting, Hose Brs Barbed M 3/16 Tbg X .250-20 (Air) . . . . . . . . . . . . . . . . . . . . .
. . Fitting, Hose Brs Barbed M 3/16 Tbg X .250-20 (Water) . . . . . . . . . . . . . . . . . .
. . Pin, Power Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . O-ring, .500 Id X .103 Cs Rbr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Guide, Wire Outlet .030-1/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Connector, Power/Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Housing, Power Pin Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Screw, 004−40 X .37 Soc Hd−hex Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Screw, 006−32 X .62 Soc Hd−hex Gr 8 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Strain Relief, Spring Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Spring, Strain Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Grease Minicap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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♦Part of 194 114, 194 115, 194 116, or 194 117 Drive Roll Kits
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1594 Page 54
Return To Table Of Contents
. Hardware is common and
12
not available unless listed.
11
12
10
11
9
10
8
8
13
14
15
7
6
6
5
Air Gun Barrel
5
Water Gun Barrel
4
4
3
3
1
1
802 253-C
Figure 9-5. Barrel Assembly Of XR-Edge Gun
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-5. Barrel Assembly Of XR-Edge Gun (Figure 9-4 Item 41)
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197 728
185 102
206 176
206 177
206 178
206 179
206 180
206 181
209 875
185 097
185 111
191 180
210 764
194 261
191 191
164 485
212 523
210 771
210 767
210 766
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Nozzle, 5/8 Orf X 2-1/2 (Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut, Nozzle Adapter Locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tip, Fastip .281 Od .030 Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tip, Fastip .281 Od .035 And .030al Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tip, Fastip .281 Od .040 And .035al Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tip, Fastip .281 Od .045 And .040al Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tip, Fastip .281 Od .052 And 3/64al Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tip, Fastip .281 Od 1/16 Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diffuser, Fastip Slotted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Insulator, Contact Tip Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut, Molded Head Tube Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Head Tube, Air (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Head Tube, Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
O-ring, .551 Id X .070cs (Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
O-ring, .312 Id X .070cs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
O-ring, .176 Id X .070cs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Liner, Phos Bronze .030−1/16 Wire X 7.875 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
O-ring, 14.99mm Id X 1.27mm cs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Insulator, Head Tube Tapered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut, Molded Headtube Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
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1
1
3
2
1
1
1
1
1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Return To Table Of Contents
OM-1594 Page 55
OM-1594 Page 56
74
Figure 9-6. Exploded View Of Pistol-Grip Gun
Return To Table Of Contents
73
74
72
1
58
70
69
68
67
66
75
3
4
5
6
7
11
8
14
9
30
10
12
11
13
9
15 (Fig. 8-7)
32
5
21
33
7
18
63
17
16*
64
19
20
22
8
34
35
65
76
37
24
23
6
62
26
25
23
4
61
48
47
55
57
53
54
52
51
28
38
56
49 50
27
38
46
45
58
14
41
44
43
42
40
39
. Hardware is common and
not available unless listed.
Ref. 143 117-L
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-6. Exploded View Of Pistol-Grip Gun
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9 .............
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11 . . . . . . . . . . . .
11 . . . . . . . . . . . .
12 . . . . . . . . . . . .
13 . . . . . . . . . . . .
14 . . . . . . . . . . . .
14 . . . . . . . . . . . .
15 . . Fig 9-7 . .
16 . . . . . . . . . . . .
214 745
Deleted
135 580
135 580
149 332
149 332
191 072
191 073
191 058
191 059
203 691
203 692
191 065
191 052
191 053
141 694
203 758
203 759
152 577
137 495
198 330
196 466
210 646
163 704
. . 16 . . . . . . . . . . . . 163 692
. . . . . . . . . . . . . . . . . . 151 661
. . 17 . . . . . . . . . . . . 133 365
. . 18 . . . . . . . . . . . . 000 417
. . 19 . . . . . . . . . . . . 162 041
. . . . . . . . . . . . . . . . . . 604 638
. . . . . . . . . . . . . . . . . . 143 480
. . 20 . . . . . . . . . . . . 162 042
. . 21 . . . . . . . . . . . . 136 135
. . . . . . . . . . . . . . . . . . 604 612
. . 21 . . . . . . . . . . ♦183 357
. . 21 . . . . . . . . . . ♦183 357
. . 21 . . . . . . . . . . ♦183 358
. . 21 . . . . . . . . . . ♦183 358
. . 23 . . . . . . . . . . . . 114 045
. . 24 . . . . . . . . . . . . 602 198
. . 25 . . . . . . . . . . . . 134 624
. . 26 . . . . . . . . . . . . 134 623
. . 27 . . . . . . . . . . . . 132 852
. . 28 . . . . . . . . . . . . 605 798
. . 29 . . . . . . . . . . . . Deleted
. . 30 . . . . . . . . . . . . 203 689
. . 30 . . . . . . . . . . . . 203 690
. . 31 . . . . . . . . . . . . Deleted
. . 32 . . . . . . . . . . . . 203 562
. . 33 . . . . . . . . . . . . 203 560
. . 34 . . . . . . . . . . . . 203 539
. . 35 . . . . . . . . . . . . 189 812
. . 36 . . . . . . . . . . . . Deleted
. . 37 . . . . . . . . . . . . 166 412
. . 38 . . . . . . . . . . . . 202 513
. . 38 . . . . . . . . . . . . 202 513
. . Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.....................................................................
. . Fitting, Gas (Air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Fitting, Gas (Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Clamp, Hose .405 − .485 Clp Dia (Air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Clamp, Hose .405 − .485 Clp Dia (Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . Hose, Water In 15ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Hose, Water In 30ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Hose, Gas In 15ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Hose, Gas In 30ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Conduit W/Fitting, Molded 15 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Conduit W/Fitting, Molded 30 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Liner, .180 Od X .140 Id (15ft or 30ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Cable, Power/Water Out 15ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Cable, Power/Water Out 30ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Screw, Set 312-18 X .37 Conept Sch Stl Pln . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Cable, Power 15ft (Air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Cable, Power 30ft (Air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Strip, Copper .010 X 2.000 X .750 (Air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Fitting, Connection Power Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Cable, Control 15ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Cable, Control 30ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Barrel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Housing, Wire Drive (15A & 30A Models)
(Includes Items 3, 48, 50, 51, 52, 60 & 65) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Housing, Wire Drive (15w & 30w Models)
(Includes Items 3, 48, 50, 51, 52, 60 & 65) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Screw, Set 10-32 X .125 Cup Sch (30w Models Only) . . . . . . . . . . . . . . . . . . 2
. . Clamp, Head Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Screw, Cap Stl Sch 10-24 X 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Bearing Block Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Screw, Cap Stl Sch 6-32 X .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . Screw, 6-32 X .625 Soc Hd-hex Stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Contact, Current Pick-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Roll, Drive Vk Groove .023-1/16 Wire (Includes) . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Screw, Set Stl Sch 8-32 X .125 Cup Point . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Kit, Drive Vk Groove .030-.035 Wire (Part Of Wire Guide Kit 198 384) . . . 1
. . Kit, Drive Vk Groove .040 Wire (Part Of Wire Guide Kit 198 383) . . . . . . . . 1
. . Kit, Drive Vk Groove .047-.062 Wire (Part Of Wire Guide Kit 198 382) . . . 1
. . Kit, Drive Vk Groove .047-.062 Wire (Part Of Wire Guide Kit 198 381) . . . 1
. . Screw, 6-32 X .500 Hexwhd Slt Stl Slffmg . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . Washer, Lock .141 Id Stl Split . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . Bearing, Flg Nyl .140 Id X .187 Od X .375Flg X .031Thk . . . . . . . . . . . . . . . 2
. . Bearing, Idler Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Arm, Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Washer, Shldr Nyl .375 Od X .168 Id X .080 . . . . . . . . . . . . . . . . . . . . . . . . . . 2
.....................................................................
. . Jacket, Cable Combination 15ft Molded Strain Relief . . . . . . . . . . . . . . . . . . 1
. . Jacket, Cable Combination 30ft Molded Strain Relief . . . . . . . . . . . . . . . . . . 1
.....................................................................
. . Spring, Strain Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Strain Relief, Spring Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Fitting, Liner Double Wound Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Housing, Power Pin Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.....................................................................
. . Hose, Water 14in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Fitting, Hose Brs Barbed M 3/16 Tbg X .250-20 (Air) . . . . . . . . . . . . . . . . . . . 1
. . Fitting, Hose Brs Barbed M 3/16 Tbg X .250-20 (Water) . . . . . . . . . . . . . . . . 2
Return To Table Of Contents
OM-1594 Page 57
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-6. Exploded View Of Pistol-Grip Gun (Continued )
. . 39 . . . . . . . . . . . . 193 896
. . 40 . . . . . . . . . . . . 079 974
. . 41 . . . . . . . . . . . . 202 216
. . 42 . . . . . . . . . . . . 187 029
. . 43 . . . . . . . . . . . . 189 811
. . 44 . . . . . . . . . . . . 133 083
. . 45 . . . . . . . . . . . . 144 860
. . 46 . . . . . . . . . . . . 058 968
. . 47 . . . . . . . . . . . . 135 474
. . 48 . . . . . . . . . . . . 155 565
. . . . . . . . . . . . . . . . . . 134 799
. . 49 . . . . . . . . . . . . 135 126
. . 50 . . . . . . . . . . . . 170 353
. . 51 . . . . . . . . . . . . 170 351
. . 52 . . . . . . . . . . . . 170 352
. . 53 . . . . . . . . . . . . 112 896
. . 54 . . . . . . . . . . . . 135 773
. . 55 . . . . . . . . . . . . 143 360
. . 56 . . . . . . . . . . . . 136 679
. . 57 . . . . . . . . . . . . 132 269
. . 58 . . . . . . . . . . . . 214 743
. . 59 . . . . . . . . . . . . 173 527
. . 60 . . . . . . . . . . . . 173 528
. . 61 . . . . B2 . . . . 161 813
. . 62 . . . . . . . . . . . . 191 121
. . 63 . . . . . . . . . . . . 164 592
. . 64 . . . . . . . . . . . . 184 101
. . 65 . . . . . . . . . . . . 058 262
. . 66 . . . . R4 . . . . 200 096
. . 67 . . . . . . . . . . . . 144 861
. . 68 . . . . . . . . . . . . 135 127
. . 69 . . . . . . . . . . . . 602 169
. . 70 . . . . . . . . . . . . 134 856
. . 71 . . . . . . . . . . . . Deleted
. . 72 . . . PB1 . . . . 000 369
. . 73 . . . . . . . . . . . . 183 884
. . 74 . . . . . . . . . . . . 217 934
. . 75 . . . . . . . . . . . . 185 106
. . . . . . . . . . . . . . . . ♦605 107
. . 76 . . . . . . . . . . . . 203 557
. . Pin, Power Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . O-ring, .500 Id X .103 Cs Rbr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Guide, Wire Outlet .030-1/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Connector, Power/Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Housing, Power Pin Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Spring, Tension Adj Drive Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Screw, Mach Stl Flh 8-32 X .437 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Ring, Retainer E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Pin, Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Screw, Thumb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . O-ring, .176 Id X .070 Cs (Used W/Thumbscrew) . . . . . . . . . . . . . . . . . . . . . 1
. . Screw, Set Stl Sch 6-32 X .125 Cup Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Plunger, Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Spring, Cprsn .150 Od X .01 Wire X .375 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Plunger, Gas Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Spring, Cprsn .240 Od X .020 Wire X .437 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Knob, Thumb Tension Adjusting 8-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Screw, Mach Stl Rdh 8-32 X .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Clamp, Strain Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Screw, Mach Stl Rdhph 8-32 X .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Case, Gun Lh/Rh (Molded Halves) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Screw, 8−32 X 1.50 Soc Hd-hex Gr 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Screw, 8-32 X .875 Soc Hd-hex Gr 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Motor, Gear Pm 24VDC 420RPM 10.2:1 Ratio . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Screw, Mach Stl Trh 6-32 X .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Trigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Washer, Shldr.140 Id 0.250 Od X .047 T .340 Od X .078 T Nyl . . . . . . . . . . 1
. . Cap, Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Potentiometer, C Sltd Sft 1/T .5w 10k Ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Washer, Anti-turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Lock, Shaft Pot .250-32 X .125dia Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Screw, Set Stl Sch 8-32 X .187 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Knob, Speed Control 1-10 .140 Shaft X 1.125 Od . . . . . . . . . . . . . . . . . . . . . 1
.....................................................................
. . Switch, Lim 10A 125/250VAC Dpst Plgr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Spring, Cprsn .240 Od X .026 Wire X 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Screw, K40x 20 Pan Hd-Trx Stl Pld Pt Thread Forming . . . . . . . . . . . . . . . . 4
. . Nut, Liner Collet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Grease Minicap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Clamp, 1−Ear Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
♦Optional
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1594 Page 58
Return To Table Of Contents
. Hardware is common and
not available unless listed.
1
2
3
4
29
6
5
7
28
27
26
25
21 20
24
3
4
19 18
16 15
17
14
11
13 12
29
8
9
10
23
22
Ref. 800 434-C
Figure 9-7. Barrel Assembly Of Pistol-Grip Gun
Item
No.
Part
No.
Description
Quantity
Figure 9-7. Barrel Assembly Of Pistol-Grip Gun (Figure 9-6 Item 15)
. . 1 . . . . . . . . . . . . . 197 728 . . Nozzle (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 2 . . . . . . . . . . . . . 185 102 . . Nut, Nozzle Adapter Locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 3 . . . . . . . . . . . . . 206 176 . . Tip, Fastip .281 Od .030 Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 3 . . . . . . . . . . . . . 206 177 . . Tip, Fastip .281 Od .035 And .030al Wires . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 3 . . . . . . . . . . . . . 206 178 . . Tip, Fastip .281 Od .040 And .035al Wires . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 3 . . . . . . . . . . . . . 206 179 . . Tip, Fastip .281 Od .045 And .040al Wires . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 3 . . . . . . . . . . . . . 206 180 . . Tip, Fastip .281 Od .052 And 3/64al Wires . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 3 . . . . . . . . . . . . . 206 181 . . Tip, Fastip .281 Od 1/16 Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 4 . . . . . . . . . . . . . 209 875 . . Diffuser, FasTip Slotted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 5 . . . . . . . . . . . . . 185 097 . . Insulator, Contact Tip Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 6 . . . . . . . . . . . . . 210 511 . . Head Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 7 . . . . . . . . . . . . . 203 675 . . Manifold, Water (15w & 30w Models) (Includes) . . . . . . . . . . . . . . . . . . . . . . .
. . 8 . . . . . . . . . . . . . 175 946 . . . . O-ring, .614 Id X .070cs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 9 . . . . . . . . . . . . . 135 128 . . Screw, Cap Stl Sch 6-32 X 1.000 (15, 30w Models) . . . . . . . . . . . . . . . . . . . .
. . 10 . . . . . . . . . . . . 198 348 . . Barrel Assembly, Water Cooled (15, 30w Models) (Includes) . . . . . . . . . . . .
. . 11 . . . . . . . . . . . . 134 800 . . . . O-ring, .614 Id X .070cs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 12 . . . . . . . . . . . . 134 799 . . . . O-ring, .176 Id X .070cs (15w & 30w Models) . . . . . . . . . . . . . . . . . . . . . . .
. . 13 . . . . . . . . . . . . 215 504 . . . . Fitting Assembly, Barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 14 . . . . . . . . . . . . 215 497 . . . . Tubing, Teflon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 15 . . . . . . . . . . . . 136 834 . . . . Washer, Flat .594 Id Fbr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 16 . . . . . . . . . . . . 180 966 . . . . O-ring, .926 Id X .070cs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 17 . . . . . . . . . . . . 215 498 . . . . Barrel, Outer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 18 . . . . . . . . . . . . 136 836 . . . . Insulator, Head Tube From Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 19 . . . . . . . . . . . . 136 835 . . . . Washer, Flat .390 Id Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 20 . . . . . . . . . . . . 136 833 . . . . Nut, 1.000-12 Stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 21 . . . . . . . . . . . . 136 832 . . . . Adapter, Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 22 . . . . . . . . . . ♦009 925 . . Nozzle, Spot Outside Corner .937 ID X 2.375 . . . . . . . . . . . . . . . . . . . . . . . . .
. . 23 . . . . . . . . . . . ♦050 116 . . Nozzle,13/16 Orf X 1-5/8 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 24 . . . . . . . . . . . ♦050 115 . . Nozzle, 1/2 Orf X 1-5/8 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 25 . . . . . . . . . . . . 050 622 . . . . Nozzle, 5/8 Orf X 1-5/8 Lg (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 26 . . . . . . . . . . ♦000 442 . . Nozzle, Spot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 27 . . . . . . . . . . ♦004 466 . . Nozzle, Spot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 28 . . . . . . . . . . ♦000 443 . . Nozzle, Spot Inside Corner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 29 . . . . . . . . . . . . 212 156 . . Liner, Phos Bronze .030−1/16 Wire X 7.313 . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . ♦193 794 . . Kit, Nozzle Adapter
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Required For items 22 Thru 28 if using with item 6) . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
♦Optional
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Return To Table Of Contents
OM-1594 Page 59
Effective January 1, 2003
(Equipment with a serial number preface of “LC” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants
to its original retail purchaser that new Miller equipment sold
after the effective date of this limited warranty is free of defects
in material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Your distributor also gives
you ...
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to
such defects in material or workmanship. Miller must be
notified in writing within thirty (30) days of such defect or
failure, at which time Miller will provide instructions on the
warranty claim procedures to be followed.
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that
the equipment was delivered to the original retail purchaser, or
one year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to an
International distributor.
1.
5 Years Parts — 3 Years Labor
*
*
2.
3 Years — Parts and Labor
*
*
*
*
*
*
*
3.
Original main power rectifiers
Inverters (input and output rectifiers only)
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Supplies
Intellitig
Maxstar 150
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
1 Year — Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources
Water Coolant Systems
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Maxstar 85, 140
Spot Welders
Load Banks
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True
Blue for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
4.
6 Months — Batteries
5.
90 Days — Parts
*
MIG Guns/TIG Torches
*
*
*
*
*
*
*
Induction Heating Coils and Blankets
APT & SAF Model Plasma Cutting Torches
Remote Controls
Accessory Kits
Replacement Parts (No labor)
Spoolmate Spoolguns
Canvas Covers
Miller’s True Blue Limited Warranty shall not apply to:
1.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.
(Exception: brushes, slip rings, and relays are
covered on Bobcat, Trailblazer, and Legend models.)
2.
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other
than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE
AND MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods
at customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
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
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
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, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND
DISCLAIMED BY MILLER.
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 exclusion may not apply to you. This warranty
provides specific legal rights, and other rights may be
available, but may vary from state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may
be available, but may vary from province to province.
miller_warr 8/03
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
www.MillerWelds.com
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
PRINTED IN USA
 2004 Miller Electric Mfg. Co.
1/03
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