Miller Electric Mw 4150 Users Manual O113336d_mil

SPW-1 to the manual 8f299325-a97f-491e-999c-9666f5649f69

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AUTO

ARCJ~

May

1991

FORM:OM-113

336D

Effective

With

Serial

No.

KA898403

MODEL:

AUTO

ARCfi

MW

4150

AUTO

ARCfi

MW

4200

SPW-1

OWNERS

MANUAL

IMPORTANT:

Read

and

understand

the

entire

contents

of

this

manual,

with

special

emphasis

on

the

safety

material

throughout

the

manual,

before

MILLER

ELECTRIC

Mfg.

Co.

AMIerGroupLld..Company

installing,

operating,

or

maintaining

this

equipment.

This

unit

and

these

instructions

are

for

use

only

by

persons

trained

and

experienced

in

the

safe

Box

1079

Appleton,

WI

54912

USA

operation

of

welding

equipment.

Do

not

allow

untrained

persons

to

Install,

Tel.

414-734-9821

operate,

or

maintain

this

unit.

Contact

your

distributor

if

you

do

not

fully

understand

these

instructions.

SB-087

313D

PRINTED

IN

U.S.A.

-~

~

ONE

YEAR

LIMITED

WARRANTY

EFFECTIVE:

FEBRUARY

17,

1989

This

warranty

supersedes

all

previous

AUTO

ARC

warranties

and

is

exclusive

with

no

other

guarantees

orwarranties

expressed

or

implied.

COVERAGE



MILLER

Electric

Mfg.

Co.

warrants

to

the

for

the

purchase

price

(less

reasonable

depreciation

based

buyer

who

purchases

this

AUTO

ARC

Welder

(Welder)

for

upon

actual

use)

upon

return

of

the

goods

at

Consumers

risk

personal,

family

or

household

purposes

(Consumer)

that

this

and

expense.

MILLERs

option

of

repair

or

replacement

will

be

j

Welderwillbefreefromdefectsinmaterialandworkmanshipfor

FOB.,

Factory

at

Appleton,

WI

or

FOB.

at

a

MILLER

autho-

A

a

period

of

one

year

from

the

date

of

purchase.

This

warranty

rized

service

facility,

therefore,

no

compensation

for

transporta

covers

only

the

original

purchaser

of

this

Welder.

MILLER

Elec-

tion

costs

of

any

kind

will

be

allowed.

Upon

receipt

of

notice

of

tric

does

not

authorize

any

party,

including

its

authorized

dis-

apparentdefectorfailure,

MILLER

shall

instructtheclaimanton

tributors,

to

offer

any

other

warranty

on

behalf

of

MILLER

Elec-

the

warranty

claim

procedures

to

be

followed.

tric.

Upon

expiration

of

the

warranty

period,

MILLER

Electric

shall

have

no

further

liability

related

to

the

Welder,

except

on

THIS

WARRANTY

IS

OFFERED

IN

LIEU

OF

ANY

OTHER

warranty

claims

made

during

the

warranty

period.

No

warranty

EXPRESS

WARRANTY;

AND,

EXCEPT

TO

THE

EXTENT

is

made

by

MILLER

with

respect

to

engines,

trade

accessories

PROHIBITED

BY

APPLICABLE

LAW,

THE

DURATION

OF

or

other

items

manufactured

by

others.

Such

engines,

trade

ac-

ALL

IMPLIED

WARRANTIES,

INCLUDING

BUT

NOT

cessories

and

other

items

are

sold

subject

to

the

warranties

of

LIMITED

TO

THE

IMPLIED

WARRANTIES

OF

MERCHAN

their

respective

manufacturers,

if

any.

All

engines

are

war-

TABILITYAND

FITNESS

FORAPARTICULAR

PURPOSE,

IS

ranted

by

their

manufacturer

for

two

years

from

date

of

original

LIMITED

TO

THE

DURATION

OF

THIS

WARRANTY.

purchase,

except

Deutz

engines

which

have

a

one

year,

2000

hour

warranty.

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

ANY

IMPLIED

WARRANTY.

GUARANTY

OR

REPRE

MILLER

shall

be

required

to

honor

warranty

claims

on

war-

SENTATION

AS

TO

PERFORMANCE,

AND

ANY

REMEDY

ranted

Equipment

in

the

event

of

failure

resulting

from

a

defect

FOR

BREACH

OF

CONTRACT

WHICH,

BUT

FOR

THIS

within

the

following

periods

from

the

date

of

delivery

of

Equip-

PROVISION,

MIGHT

ARISE

BY

IMPLICATION,

OPERATION

ment

to

the

original

user:

OF

LAW,

CUSTOM

OF

TRADE

OR

COURSE

OF

DEALING,

1

A

Id

d

1

INCLUDING

ANY

IMPLIED

WARRANTY

OF

MERCHANT-

2

rc

we

ers,

power

sources,

an

comporien

s

.

year

ABILITY

OR

OF

FITNESS

FOR

PARTICULAR

PURPOSE,

Ibr

rnai

power

re

I

iers

years

WITH

RESPECT

TO

ANY

AND

ALL

EQUIPMENT

FUR

3.

AU

welding

guns,

feeder/guns

and

torches

90

days

NISHED

BY

MILLER

IS

EXCLUDED

AND

DISCLAIMED

BY

4.

Replacement

or

repair

parts,

exclusive

of

labor

.

60

days

LLE

5.

Batteries

6

months

. 

Some

states

do

not

allow

limitations

on

how

long

an

implied

provided

that

MILLER

is

notified

in

writing

within

thirty

(30)

days

warranty

lasts,

so

the

above

limitation

may

not

apply

to

you.

of

such

failure.

This

warranty

gives

you

specific

legal

rights,

and

you

may

also

have

other

rights

which

vary

from

state

to

state.

WHAT

IS

NOT

COVERED



This

warranty

does

not

extend

to

any

Welder

subjected

to

misuse,

neglect,

accident,

or

in-

THE

PURCHASERS

REMEDIES

FOR

A

DEFECTIVE

warranty

repair

by

anyone

except

MILLER

Electric

or

its

autho-

WELDER,

TO

THE

EXTENT

PERMITTED

BY

APPLICABLE



rized

service

stations.

Further,

thiswarranty

only

extends

to

the

LAW,

ARE

LIMITED

TO

THE

REMEDY

PROVIDED

BY

THIS

original

purchaser

of

this

Welder.

WARRANTY.

TO

THE

EXTENT

ENFORCEABLE

UNDER

APPLICABLE

LAW,

MILLER

ELECTRIC

SHALL

IN

NO

In

the

case

of

MILLERs

breach

of

warranty

or

any

other

duty

EVENT

BE

LIABLE

FOR

CONSEQUENTIAL,

INCIDENTAL

with

respect

to

the

quality

of

any

goods,

the

exclusive

remedies

OR

SPECIAL

DAMAGES

ARISING

OUT

OF

THE

USE

OF,

OR

therefore

shall

be,

at

MILLERs

option

(1)

repair

or

(2)

replace-

INABILITY

TO

USE,

THE

WELDER,

WHETHER

BASED

ON

p

ment

or,

where

authorized

in

writing

by

MILLER

in

appropriate

BREACH

OF

THIS

WARRANTY,

MILLER

ELECTRICS

NEG



cases,

(3)

the

reasonable

cost

of

repair

or

replacement

at

an

LIGENCE

OR

OTHER

TORT,

OR

ON

ANY

THEORY

OF

authorized

MILLER

service

station

or

(4)

payment

of

or

credit

STRICT

LIABILITY.

-~

~

ERRATA

SHEET

After

this

manual

was

printed,

refinements

in

equipment

design

occurred. This

sheet

lists

exceptions

to

data

appearing

later

in

this

manual.

AMENDMENT

TO

SECTION

7

MAINTENANCE

&

TROUBLESHOOTING

Amend

Section

7-lA.

ROUTINE

MAINTENANCE:

Fan

Motor

This

unit

is

equipped

with

an

exhaust

fan

and

relies

on

forced

draft

for

adequate

cooling.

The

fan

motor

needs

oiling

every

six

months

using

SAE

20

oil.

OM-113

3360

5191

RECEIVING-HANDLING

Before

unpacking

equipment,

check

carton

for

any

dam-

Use

the

following

spaces

to

record

the

Model

Designa

age

that

may

have

occurred

during

shipment.

File

any

tion

and

Serial

or

Style

Number

of

your

unit.

The

infor

claims

for

loss

or

damage

with

the

delivering

carrier.

mation

is

located

on

the

data

card

or

the

nameplate.

Assistance

for

filing

or

settling

claims

may

be

obtained

from

the

distributor

and/or

the

equipment

manufactur-

Model

________________________________

ers

Transportation

Department.

Serial

or

Style

No.

____________________

When

requesting

information

about

this

equipment,

al

ways

provide

the

Model

Description

and

Serial

or

Style

Date

of

Purchase

_____________________

Number.

TABLE

OF

CONTENTS

Section

No.

Page

No.

SECTION

1



SAFETY

RULES

FOR

OPERATION

OF

ARC

WELDING

POWER

SOURCE

1-1.

Introduction

1

1-2.

General

Precautions

1

1-3.

Arc

Welding

4

1-4.

Standards

Booklet

Index

5

SECTION

2-

SAFETY

PRECAUTIONS

AND

SIGNAL

WORDS

2-1.

General

Information

And

Safety

6

2-2.

Safety

Alert

Symbol

And

Signal

Words

6

SECTION

3SPECIFICATIONS

3-1.

Volt-Ampere

Curves

8

3-2.

Duty

Cycle

8

3-3.

Description

8

3-4.

Supplied

Equipment

8

3-5.

Additional

Required

Equipment

9

3-6.

Optional

Equipment

10

3-7.

Consumable

Parts

10

SECTION

4INSTALLATION

OR

RELOCATION

4-1.

Site

Selection

10

4-2.

Transporting

Methods

10

4-3.

Running

Gear

Installation

11

4-4.

Optional

SPW-1

Panel

Installation

11

4-5.

Shielding

Gas

Installation

12

4-6.

Work

Cable

Assembly

12

4-7.

Weld

Polarity

Selection

14

4-8.

MWG-200

Welding

Gun

Connections

14

4-9.

Installation

Of

Optional

Spool

Gun

14

4-10.

Welding

Wire

Spool

Installation

16

4-11.

Hub

Tension

Adjustment

16

4-12.

Electrical

Input

Connections

16

4-13.

Welding

Wire

Threading

18

Section

No.

Page

No.

SECTION

5OPERATOR

CONTROLS

5-1.

Power

Switch

And

Pilot

Light

19

5-2.

Thickness

Volts

Selector

19

5-3.

Fine

Tuning

Wire

Speed

Control

20

5-4.

Fan-On-Demand~

20

5-5.

Optional

Spot/Pulse

Panel

Controls

20

SECTION

6

SEQUENCE

OF

OPERATION

6-1.

Gas

Metal

Arc

Welding

(GMAW)-Continuous

And

Gas

Metal

Arc

Welding-Pulsed

Arc

(GMAW-P)

21

6-2.

Gas

Metal

Arc

Welding

(GMAW)-Spot

(Models

With

Optional

SPW-1

Panel

Only)

22

6-3.

Shutting

Down

23

SECTION

7

MAINTENANCE

&

TROUBLESHOOTING

7-1.

Routine

Maintenance

24

7-2.

Replacing

Drive

Roll

And

Wire

Inlet

Guide

25

7-3.

Drive

Housing Realignment

26

7-4.

Replacing

Hub

Assembly

26

7-5.

Inspecting

And

Replacing

Motor

Brushes

27

7-6.

Overload

Protection

27

7-7.

Thermal

Overload

Protection

28

7-8.

Printed

Circuit

Board

Replacement

28

7-9.

Troubleshooting

28

SECTION

8

ELECTRICAL

DIAGRAMS

Diagram

8-1.

Circuit

Diagram

For

MW

4150

Models

30

Diagram

8-2.

Circuit

Diagram

For

MW

4200

Models

31

Diagram

8-3.

Circuit

Diagram

For

SPW-1

Panel

31

Diagram

8-4.

Wiring

Diagram

For

SPW-1

Panel

32

Diagram

8-5.

Circuit

Diagram

For

SPW-1

Panel

Dual

Timer/Pulser

Board

PC5O

33

SECTION

9

WELDING

TECHNIQUES

&

TROUBLESHOOTING

9-1.

Gas

Metal

Arc

Welding

(GMAW)



Continuous

Seam

34

9-2.

Gas

Metal

Arc

Welding

(GMAW)-Pulsed

35

9-3.

Gas

Metal

Arc

Welding

(GMAW)-Spot

36

9-4.

Plug

Welds

37

9-5.

Skip

Welding

37

9-6.

Troubleshooting

The

Gas

Metal

Arc

Welding

Process

37

SECTION

10

AUTO

BODY

REPAIR

APPLICATION

10-1.

Pointers

For

Welding

Auto

Body

Sheet

Metal

40

10-2.

Procedure

For

Welding

Mild

Steels

40

10-3.

Procedures

For

Welding

Door

Panels

40

10-4.

How

To

Prevent

Glass

Breakage

And

Spatter

On

Windows

41

10-5.

Procedures

For

Welding

Fenders

And

Quarter

Panels

41

10-6.

Welding

Frames

And

High

Strength

(HSS)

Steels

41

Section

No.

Page

No.

SECTION

11



PARTS

LIST

Figure

11-1.

Main

Assembly

42

Figure

11-2.

Baffle,

Air

w/Components

44

Figure

11-3.

Drive

Assembly,

Wire

46

Figure

11-4.

Panel,

Rear

w/Components

47

Figure

11-5.

Panel,

Front

w/Components

48

Figure

11-6.

SPW

1

Spot

Panel

(Optional)

50

Figure

11-7.

Circuit

Card,

Dual

Timer/Pulser

P050

51

Figure

11-8.

Running

Gear

52

LIST

OF

CHARTS

AND

TABLES

Table

3-1.

Specifications

7

Chart

3-1.

Volt-Ampere

Curves

7

Chart

3-2.

Duty

Cycle

7

Table

4-1.

Input

Conductor

And

Fuse

Size

17

Table

6-1.

Suggested

Parameters

For

Continuous

Gas

Metal

Arc

Welding

(GMAW)

22

Table

6-2.

Checking

Weld

Parameters

23

Table

7-1.

Maintenance

Schedule

24

Table

7-2.

Troubleshooting

29

SECTION

1



SAFETY

RULES

FOR

OPERATION

OF

ARC

WELDING

POWER

SOURCE

1-1.

INTRODUCTION

We

learn

by

experience.

Learning

safety

through

per

sonal

experience,

like

a

child

touching

a

hot

stove

is

harmful,

wasteful,

and

unwise.

Let

the

experience

of

oth

ers

teach

you.

Safe

practices

developed

from

experience

in

the

use

of

welding

and

cutting

are

described

in

this

manual.

Re

search,

development,

and

field

experience

have

evolved

reliable

equipment

and

safe

installation,

opera

tion,

and

servicing

practices.

Accidents

occur

when

equipment

is

improperly

used

or

maintained.

The

rea

son

for

the

safe

practices

may

not

always

be

given.

Some

are

based

on

common

sense,

others

may

require

technical

volumes

to

explain.

It

is

wiser

to

follow

the

rules.

Read

and

understand

these

safe

practices

before

at

tempting

to

install,

operate,

or

service

the

equipment.

Comply

with

these

procedures

as

applicable

to

the

par

ticular

equipment

used

and

their

instruction

manuals,

for

personal

safety

and

for

the

safety

of

others.

Failure

to

observe

these

safe

practices

may

cause

seri

ous

injury

or

death.

When

safety

becomes

a

habit,

the

equipment

can

be

used

with

confidence.

These

safe

practices

are

divided

into

two

Sections:

1-General

Precautions,

common

to

arc

welding

and

cut

ting;

and

2-Arc

Welding

(and

Cutting)

(only).

Reference

standards:

Published

Standards

on

safety

are

also

available

for

additional

and

more

complete

pro

cedures

than

those

given

in

this

manual.

They

are

listed

in

the

Standards

Index

in

this

manual.

ANSI

Z49.1

is

the

most

complete.

The

National

Electrical

Code,

Occupational

Safety

and

Health

Administration,

local

industrial

codes,

and

local

inspection

requirements

also

provide

a

basis

for

equip

ment

installation,

use,

and

service.

1-2.

GENERAL

PRECAUTIONS

Difterent

arc

welding

processes,

electrode

alloys,

and

fluxes

can

produce

difterent

fumes,

gases,

and

radiation

levels.

In

addition

to

the

information

in

this

manual,

be

sure

to

consult

flux

and

electrode

manu

facturers

Material

Safety

Data

Sheets

(MSDS5)

for

specific

technical

data

and

precautionary

measures

concerning

their

material.

A.

Burn

Prevention

Wear

protective

clothing-gauntlet

gloves

designed

for

use

in

welding,

hat,

and

high

safety-toe

shoes.

Button

shirt

collar

and

pocket

flaps,

and

wear

cuffless

trousers

to

avoid

entry

of

sparks

and

slag.

Wear

helmet

with

safety

goggles

and

glasses

with

side

shields

underneath,

appropriate

filter

lenses

or

plates

(protected

by

clear

cover

glass).

This

is

a

MUST

for

welding

or

cutting,

(and

chipping)

to

protect

the

eyes

from

radiant

energy

and

flying

metal.

Replace

cover

glass

when

broken,

pitted,

or

spattered.

See

1

-3A.2.

Avoid

oily

or

greasy

clothing.

A

spark

may

ignite

them.

Hot

metal

such

as

electrode

stubs

and

workpieces

should

never

be

handled

without

gloves.

Medical

first

aid

and

eye

treatment.

First

aid

facilities

and

a

qualified

first

aid

person

should

be

available

for

each

shift

unless

medical

facilities

are

close

by

for

immediate

treatment

of

flash

burns

of

the

eyes

and

skin

burns.

Ear

plugs

should

be

worn

when

working

on

overhead

or

in

a

confined

space.

A

hard

hat

should

be

worn

when

others

work

overhead.

Flammable

hair

preparations

should

not

be

used

by

per

sons

intending

to

weld

or

cut.

B.

Toxic

Fume

Prevention

Severe

discomfort,

illness

or

death

can

result

from

fumes,

vapors,

heat,

or

oxygen

enrichment

or

depletion

that

welding

(or

cutting)

may

produce.

Prevent

them

with

adequate

ventilation

as

described

in

ANSI

Standard

Z49.1

listed

in

Standards

Index.

NEVER

ventilate

with

oxygen.

Lead

-,

cadmium

-,zinc-,

mercury-,

and

beryllium-bear

ing

and

similar

materials,

when

welded

(or

cut)

may

pro

duce

harmful

concentrations

of

toxic

fumes.

Adequate

local

exhaust

ventilation

must

be

used,

or

each

person

in

the

area

as

well

as

the

operator

must

wear

an

air-sup

plied

respirator.

For

beryllium,

both

must

be

used.

Metals

coated

with

or

containing

materials

that

emit

toxic

fumes

should

not

be

heated

unless

coating

is

removed

from

the

work

surface,

the

area

is

well

ventilated

and,

if

necessary,

while

wearing

an

air-supplied

respirator.

Work

in

a

confined

space

only

while

it

is

being

ventilated

and,

if

necessary,

while

wearing

an

air-supplied

respira

tor.

Gas

leaks

in

a

confined

space

should

be

avoided.

Leaked

gas

in

large

quantities

can

change

oxygen

con

centration

dangerously.

Do

not

bring

gas

cylinders

into

a

confined

space.

Leaving

confined

space,

shut

OFF

gas

supply

at

source

to

prevent

possible

accumulation

of

gases

in

the

space

if

downstream

valves

have

been

accidentally

opened

or

left

open.

Check

to

be

sure

that

the

space

is

safe

before

re-entering

it.

Vapors

from

chlorinated

solvents

can

be

decomposed

by

the

heat

of

the

arc

(or

flame)

to

form

PHOSGENE,

a

highly

toxic

gas,

and

other

lung

and

eye

irritating

prod

ucts.

The

ultraviolet

(radiant)

energy

of

the

arc

can

also

decompose

trichloroethylene

and

perchloroethylene

va

pors

to

form

phosgene.

DO

NOT

WELD

or

cut

where

sol

vent

vapors

can

be

drawn

into

the

welding

or

cutting

at

mosphere

or

where

the

radiant

energy

can

penetrate

to

OM-113

336

Page

1

atmospheres

containing

even

minute

amounts

of

trichloroethylene

or

perchioroethylene.

C.

Fire

and

Explosion

Prevention

Causes

of

fire

and

explosion

are:

combustibles

reached

by

the

arc,

flame,

flying

sparks,

hot

slag

or

heated

mate

rial;

misuse

of

compressed

gases

and

cylinders;

and

short

circuits.

BE

AWARE

THAT

flying

sparks

or

falling

slag

can

pass

through

cracks,

along

pipes,

through

windows

or

doors,

and

through

wall

or

floor

openings,

out

of

sight

of

the

goggled

operator.

Sparks

and

slag

can

fly

35

feet.

To

prevent

fires

and

explosion:

Keep

equipment

clean

and

operable,

free

of

oil,

grease,

and

(in

electrical

parts)

of

metallic

particles

that

can

cause

short

circuits.

If

combustibles

are

in

area,

do

NOT

weld

or

cut.

Move

the

work

if

practicable,

to

an

area

free

of

combustibles.

Avoid

paint

spray

rooms,

dip

tanks,

storage

areas,

venti

lators.

If

the

work

cannot

be

moved,

move

combustibles

at

least

35

feet

away

out

of

reach

of

sparks

and

heat;

or

protect

against

ignition

with

suitable

and

snug-fitting,

fire-resistant

covers

or

shields.

Walls

touching

combustibles

on

opposite

sides

should

not

be

welded

on

(or

cut).

Walls,

ceilings,

and

floor

near

work

should

be

protected

by

heat-resistant

covers

or

shields.

Fire

watcher

must

be

standing

by

with

suitable

fire

extin

guishing

equipment

during

and

for

some

time

after

weld

ing

or

cutting

if:

a.

appreciable

combustibles

(including

building

construction)

are

within

35

feet

b.

appreciable

combustibles

are

further

than

35

feet

but

can

be

ignited

by

sparks

c.

openings

(concealed

or

visible)

in

floors

or

walls

within

35

feet

may

expose

combustibles

to

sparks

d.

combustibles

adjacent

to

walls,

ceilings,

roofs,

or

metal

partitions

can

be

ignited

by

radiant

or

conducted

heat.

Hot

work

permit

should

be

obtained

before

operation

to

ensure

supervisors

approval

that

adequate

precautions

have

been

taken.

After

work

is

done,

check

that

area

is

free

of

sparks,

glowing

embers,

and

flames.

An

empty

container

that

held

combustibles,

or

that

can

produce

flammable

or

toxic

vapors

when

heated,

must

never

be

welded

on

or

cut,

unless

container

has

first

been

cleaned

as

described

in

AWS

Standard

A6.O,

listed

7

in

Standards

Index.

This

includes:

a

thorough

steam

or

caustic

cleaning

(or

a

solvent

or

water

washing,

depending

on

the

combusti

bles

solubility)

followed

by

purging

and

inerting

with

ni

trogen

or

carbon

dioxide,

and

using

protective

equip-

ment

as

recommended

in

A6.O.

Waterfilling

just

below

working

level

may

substitute

for

inerting.

A

container

with

unknown

contents

should

be

cleaned

(see

preceding

paragraph).

Do

NOT

depend

on

sense

of

smell

or

sight

to

determine

if

it

is

safe

to

weld

or

cut.

Hollow

castings

or

containers

must

be

vented

before

welding

or

cutting.

They

can

explode.

Explosive

atmospheres.

Never

weld

or

cut

where

the

air

may

contain

flammable

dust,

gas,

or

liquid

vapors

(such

as

gasoline).

D.

Compressed

Gas

Equipment

Standard

precautions.

Comply

with

precautions

in

this

manual,

and

those

detailed

in

CGA

Standard

P-i,

SAFE

HANDLING

OF

COMPRESSED

GASES

IN

CYLIN

DERS,

listed

ii

in

Standards

Index.

1.

Pressure

Regulators

Regulator

relief

valve

is

designed

to

protect

only

the

regulator

from

overpressure;

it

is

not

intended

to

protect

any

downstream

equipment.

Provide

such

protection

with

one

or

more

relief

devices.

Never

connect

a

regulator

to

a

cylinder

containing

gas

other

than

that

for

which

the

regulator

was

designed.

Remove

faulty

regulator

from

service

immediately

for

re

pair

(first

close

cylinder

valve).

The

following

symptoms

indicate

a

faulty

regulator:

Leaks-if

gas

leaks

externally.

Excessive

Creep-if

delivery

pressure

continues

to

rise

with

downstream

valve

closed.

Faulty

Gauge-if

gauge

pointer

does

not

move

off

stop

pin

when

pressurized,

nor

returns

to

stop

pin

after

pressure

release.

Repair.

Do

NOT

attempt

to

repair.

Send

faulty

regulators

for

repair

to

manufacturers

designated

repair

center,

where

special

techniques

and

tools

are

used

by

trained

personnel.

2.

Cylinders

Cylinders

must

be

handled

carefully

to

prevent

leaks

and

damage

to

their

walls,

valves,

or

safety

devices:

Avoid

electrical

circuit

contact

with

cylinders

including

third

rails,

electrical

wires,

or

welding

circuits.

They

can

produce

short

circuit

arcs

that

may

lead

to

a

serious

acci

dent.

(See

1-3C.)

ICC

or

DOT

marking

must

be

on

each

cylinder.

It

is

an

assurance

of

safety

when

the

cylinder

is

properly

han

dled.

Identifying

gas

content.

Use

only

cylinders

with

name

of

gas

marked

on

them;

do

not

rely

on

color

to

identify

gas

content.

Notify

supplier

if

unmarked.

NEVER

DEFACE

or

alter

name,

number,

or

other

markings

on

a

cylinder.

It

is

illegal

and

hazardous.

Empties:

Keep

valves

closed,

replace

caps

securely;

mark

MT;

keep

them

separate

from

FULLS

and

return

promptly.

OM-113

336

Page

2

Prohibited

use.

Never

use

a

cylinder

or

its

contents

for

other

than

its

intended

use,

NEVER

as a

support

or

roller.

Locate

or

secure

cylinders

so

they

cannot

be

knocked

over.

Passageways

and

work

areas.

Keep

cylinders

clear

of

areas

where

they

may

be

struck.

Transporting

cylinders.

With

a

crane,

use

a

secure

sup

port

such

as

a

platform

or

cradle.

Do

NOT

lift

cylinders

off

the

ground

by

their

valves

or

caps,

or

by

chains,

slings,

or

magnets.

Do

NOT

expose

cylinders

to

excessive

heat,

sparks,

slag,

and

flame,

etc.

that

may

cause

rupture.

Do

not

al

low

contents

to

exceed

130F.

Cool

with

water

spray

where

such exposure

exists.

Protect

cylinders

particularly

valves

from

bumps,

falls,

falling

objects,

and

weather.

Replace

caps

securely

when

moving

cylinders.

Stuck

valve.

Do

NOT

use

a

hammer

or

wrench

to

open

a

cylinder

valve

that

can

not

be

opened

by

hand.

Notify

your

supplier.

Mixing

gases.

Never

try

to

mix

any

gases

in

a

cylinder.

Never

refill

any

cylinder.

Cylinder

fittings

should

never

be

modified

or

exchanged.

3.

Hose

Prohibited

use.

Never

use

hose

other

than

that

designed

for

the

specified

gas.

A

general

hose

identification

rule

is:

red

for

fuel

gas,

green

for

oxygen,

and

black

for

inert

gases.

Use

ferrules

or

clamps

designed

for

the

hose

(not

ordi

nary

wire

or

other

substitute)

as

a

binding

to

connect

hoses

to

fittings.

No

copper

tubing

splices.

Use

only

standard

brass

fit

tings

to

splice

hose.

Avoid

long

runs

to

prevent

kinks

and

abuse.

Suspend

hose

off

ground

to

keep

it

from

being

run

over,

stepped

on,

or

otherwise

damaged.

Coil

excess

hose

to

prevent

kinks

and

tangles.

Protect

hose

from

damage

by

sharp

edges,

and

by

sparks,

slag,

and

open

flame.

Examine

hose

regularly

for

leaks,

wear,

and

loose

con

nections.

Immerse

pressured

hose

in

water;

bubbles

in

dicate

leaks.

Repair

leaky

or

worn

hose

by

cutting

area

out

and

splic

ing

(1-2D3).

Do

NOT

tape.

4.

Proper

Connections

Clean

cylinder

valve

outlet

of

impurities

that

may

clog

orifices

and

damage

seats

before

connecting

regulator.

Except

for

hydrogen,

crack

valve

momentarily,

pointing

outlet

away

from

people

and

sources

of

ignition.

Wipe

with

a

clean

lintless

cloth.

Match

regulator

to

cylinder.

Before

connecting,

check

that

the

regulator

label

and

cylinder

marking

area,

and

that

the

regulator

inlet

and

cylinder

outlet

match.

NEVER

CONNECT

a

regulator

designed

for

a

particular

gas

or

gases

to

a

cylinder

containing

any

other

gas.

Tighten

connections.

When

assembling

threaded

con

nections,

clean

and

smooth

seats

where

necessary.

Tighten.

If

connection

leaks,

disassemble,

clean,

and

retighten

using

properly

fitting

wrench.

Adapters.

Use

a

CGA

adapter

(available

from

your

sup

plier)

between

cylinder

and

regulator,

if

one

is

required.

use

two

wrenches

to

tighten

adapter

marked

RIGHT

and

LEFT

HAND

threads.

Regulator

outlet

(or

hose)

connections

may

be

identified

by

right

hand

threads

for

oxygen

and

left

hand

threads

(with

grooved

hex

on

nut

or

shank)

for

fuel

gas.

5.

Pressurizing

Steps:

Drain

regulator

of

residual

gas

through

suitable

vent

be

fore

opening

cylinder

(or

manifold

valve)

by

turning

ad

justing

screw

in

(clockwise).

Draining

prevents

exces

sive

compression

heat

at

high

pressure

seat

by

allowing

seat

to

open

on

pressurization.

Leave

adjusting

screw

engaged

slightly

on

single-stage

regulators.

Stand

to

side

of

regulator

while

opening

cylinder

valve.

Open

cylinder

valve

slowly

so

that

regulator

pressure

in

creases

slowly.

When

gauge

is

pressurized

(gauge

reaches

regulator

maximum)

leave

cylinder

valve

in

fol

lowing

position:

For

oxygen,

and

inert

gases,

open

fully

to

seal

stem

against

possible

leak.

For

fuel

gas,

open

to

less

than

one

turn

to

permit

quick

emergency

shutoff.

Use

pressure

charts

(available

from

your

supplier)

for

safe

and

efficient,

recommended

pressure

settings

on

regulators.

Check

for

leaks

on

first

pressurization

and

regularly

there-after.

Brush

with

soap

solution

(capfull

of

Ivory

Liq

uid*

or

equivalent

per

gallon

of

water).

Bubbles

indicate

leak.

Clean

off

soapy

water

after

test;

dried

soap

is

com

bustible.

E.

User

Responsibilities

Remove

leaky

or

defective

equipment

from

service

im

mediately

for

repair.

See

User

Responsibility

statement

in

equipment

manual.

F.

Leaving

Equipment

Unattended

Close

gas

supply

at

source

and

drain

gas.

G.

Rope

Staging-Support

Rope

staging-support

should

not

be

used

for

welding

or

cutting

operation;

rope

may

burn.

*Trademark

of

Proctor

&

Gamble.

OM-113

336

Page

3

1-3.

ARC

WELDING

Comply

with

precautions

in

1-1, 1-2,

and

this

section.

Arc

Welding,

properly

done,

is

a

safe

process,

but

a

careless

operator

invites

trouble.

The

equipment

carries

high

currents

at

significant

voltages.

The

arc

is

very

bright

and

hot.

Sparks

fly,

fumes

rise,

ultraviolet

and

in

frared

energy

radiates,

weidments

are

hot,

and

com

pressed

gases

may

be

used.

The

wise

operator

avoids

unnecessary

risks

and

protects

himself

and

others

from

accidents.

Precautions

are

described

here

and

in

stan

dards

referenced

in

index.

A.

Burn

Protection

Comply

with

precautions

in

1-2.

The

welding

arc

is

intense

and

visibly

bright.

Its

radiation

can

damage

eyes,

penetrate

lightweight

clothing,

reflect

from

light-colored

surfaces,

and

burn

the

skin

and

eyes.

Skin

burns

resemble

acute

sunburn,

those

from

gas-

shielded

arcs

are

more

severe

and

painful.

DONT

GET

BURNED;

COMPLY

WITH

PRECAUTIONS.

1.

Protective

Clothing

Wear

long-sleeve

clothing

(particularly

for

gas-shielded

arc)

in

addition

to

gloves,

hat,

and

shoes

(1

-2A).

As

nec

essary,

use

additional

protective

clothing

such

as

leather

jacket

or

sleeves,

flame-proof

apron,

and

fire-resistant

leggings.

Avoid

outer

garments

of

untreated

cotton.

Bare

skin

protection.

Wear

dark,

substantial

clothing.

Button

collar

to

protect

chest

and

neck

and

button

pock

ets

to

prevent

entry

of

sparks.

2.

Eye

and

Head

Protection

Protect

eyes

from

exposure

to

arc.

NEVER

look

at

an

electric

arc

without

protection.

Welding

helmet

or

shield

containing

a

filter

plate

shade

no.

12

or

denser

must

be

used

when

welding.

Place

over

face

before

striking

arc.

Protect

filter

plate

with

a

clear

cover

plate.

Cracked

or

broken helmet

or

shield

should

NOT

be

worn;

radiation

can

pass

through

to

cause

burns.

Cracked,

broken,

or

loose

filter

plates

must

be

replaced

IMMEDIATELY.

Replace

clear

cover

plate

when

broken,

pitted,

or

spattered.

Flash

goggles

with

side

shields

MUST

be

worn

under

the

helmet

to

give

some

protection

to

the

eyes

should

the

helmet

not

be

lowered

over

the

face

before

an

arc

is

struck.

Looking

at

an

arc

momentarily

with

unprotected

eyes

(particularly

a

high

intensity

gas-shielded

arc)

can

cause

a

retinal

burn

that

may

leave

a

permanent

dark

area

in

the

field

of

vision.

3.

Protection

of

Nearby

Personnel

Enclosed

welding

area.

For

production

welding,

a

sepa

rate

room

or

enclosed

bay

is

best.

In

open

areas,

sur

round

the

operation

with

low-reflective,

non-combusti

ble

screens

or

panels.

Allow

for

free

air

circulation,

par

ticularly

at

floor

level.

Viewing

the

weld.

Provide

face

shields

for

all

persons

who

will

be

looking

directly

at

the

weld.

Others

working

in

area.

See

that

all

persons

are

wearing

flash

goggles.

Before

starting

to

weld,

make

sure

that

screen

flaps

or

bay

doors

are

closed.

B.

Toxic

Fume

Prevention

Comply

with

precautions

in

1

-2B.

Generator

engine

exhaust

must

be

vented

to

the

outside

air.

Carbon

monoxide

can

kill.

C.

Fire

and

Explosion

Prevention

Comply

with

precautions

in

1

-2C.

Equipments

rated

capacity.

Do

not

overload

arc

welding

equipment.

It

may

overheat

cables

and

cause

a

fire.

Loose

cable

connections

may

overheat

or

flash

and

cause

a

fire.

Never

strike

an

arc

on

a

cylinder

or

other

pressure

ves

sel.

It

creates

a

brittle

area

that

can

cause

a

violent

rup

ture

or

lead

to

such

a

rupture

under

rough

handling.

D.

Compressed

Gas

Equipment

Comply

with

precautions

in

1

-2D.

E.

Shock

Prevention

Exposed

hot

conductors

or

other

bare

metal

in

the

weld

ing

circuit,

or

in

ungrounded,

electrically-HOT

equip

ment

can

fatally

shock

a

person

whose

body

becomes

a

conductor.

DO

NOT

STAND,

SIT,

LIE,

LEAN

ON,

OR

TOUCH

a

wet

surface

when

welding,

without

suitable

protection.

To

protect

against

shock:

Wear

dry

insulating

gloves

and

body

protection.

Keep

body

and

clothing

dry.

Never

work

in

damp

area

without

adequate

insulation

against

electrical

shock.

Stay

on

a

dry

duckboard,

or

rubber

mat

when

dampness

or

sweat

can

not

be

avoided.

Sweat,

sea

water,

or

moisture

be

tween

body

and

an

electrically

HOT

part

or

grounded

metal

reduces

the

electrical

resistance,

and

could

en

able

dangerous

and

possibly

lethal

currents

to

flow

through

the

body.

A

voltage

will

exist

between

the

electrode

and

any

con

ducting

object

in

the

work

circuit.

Examples

of

conduct

ing

objects

include,

but

are

not

limited

to,

buildings,

elec

trical

tools,

work

benches,

welding

power

source

cases,

workpieces,

etc.

Never

touch

the electrode

and

any

metal

object

unless

the

welding

power

source

is off.

1.

Grounding

the

Equipment

Arc

welding

equipment

must

be

grounded

according

to

the

National

Electrical

Code,

and

the

work

must

be

grounded

according

to

ANSI

Z49.1

Safety

In

Welding

And

Cutting.

When

installing,

connect

the

frames

of

each

unit

such

as

welding

power

source,

control,

worktable,

and

water

cir

culator

to

the

building

ground.

Conductors

must

be

ade

quate

to

carry

ground

currents

safely.

Equipment

made

OM-113

336

Page

4

6.

ANSI

Standard

Z49.2,

FIRE

PREVENTION

IN

THE

USE

OF

CUTTING

AND

WELDING

PROC

ESSES

obtainable

from

the

American

National

Standards

Institute,

1430

Broadway,

New

York,

NY

10018.

7.

AWS

Standard

A6.0,

WELDING

AND

CUTTING

CONTAINERS

WHICH

HAVE

HELD

COMBUS

TIBLES

obtainable

from

the

American

Welding

Society,

550

N.W.

LeJeune

Rd,

Miami,

FL

33126.

8.

NFPA

Standard

51,

OXYGEN-FUEL

GAS

SYS

TEMS

FOR

WELDING,

CUTTING,

AND

ALLIED

PROCESSES

obtainable

from

the

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

9.

NFPA

Standard

70,

NATIONAL

ELECTRICAL

CODE

obtainable

from

the

National

Fire

Protec

tion

Association,

Batterymarch

Park,

Quincy,

MA

02269.

10.

NFPA

Standard

51B,

CUTTING

AND

WELDING

PROCESSES

obtainable

from

the

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

11.

CGA

Pamphlet

P-i,

SAFE

HANDLING

OF

COM

PRESSED

GASES

IN

CYLINDERS

obtainable

from

the

Compressed

Gas

Association,

1235

Jef

ferson

Davis

Highway,

Suite

501,

Arlington,

VA

22202.

12.

CSA

Standard

W117.2,

CODE

FOR

SAFETY

IN

WELDING

AND

CUTTING

obtainable

from

the

Canadian

Standards

Association,

Standards

Sales,

178

Rexdale

Boulevard,

Rexdale,

Ontario,

Canada

M9W

1

R3.

13.

NWSA

booklet,

WELDING

SAFETY

BIBLIOG

RAPHY

obtainable

from

the

National

Welding

Supply

Association,

1900

Arch

Street,

Philadel

phia,

PA

19103.

14.

American

Welding

Society

Standard

AWSF4.1,

RECOMMENDED

SAFE

PRACTICES

FOR

THE

PREPARATION

FOR

WELDING

AND

CUTTING

OF

CONTAINERS

AND

PIPING

THAT

HAVE

HELD

HAZARDOUS

SUBSTANCES,

obtainable

from

the

American

Welding

Society,

550

NW.

LeJeune

Rd,

Miami,

FL

33126.

15.

ANSI

Standard

Z88.2,

PRACTICE

FOR

RESPI

RATORY

PROTECTION,

obtainable

from

the

American

National

Standards

Institute,

1430

Broadway,

New

York,

NY

10018.

SECTION

2



SAFETY

PRECAUTIONS

AND

SIGNAL

WORDS

2-1.

GENERAL

INFORMATION

AND

SAFETY

A.

General

Information

presented

in

this

manual

and

on

various

la

bels,

tags,

and

plates

on

the

unit

pertains

to

equipment

design,

installation,

operation,

maintenance,

and

troubleshooting

which

should

be

read,

understood,

and

followed

for

the

safe

and

effective

use

of

this

equipment.

The

nameplate

of

this

unit

uses

international

symbols

for

labeling

the

front

panel

controls.

The

symbols

also

ap

pear

at

the

appropriate

section

in

the

text.

B.

Safety

The

installation,

operation,

maintenance,

and

trouble

shooting

of

arc

welding

equipment

requires

practices

and

procedures

which

ensure

personal

safety

and

the

safety

of

others.

Therefore,

this

equipment

is

to

be

in

stalled,

operated,

and

maintained

only

by

qualified

per

sons

in

accordance

with

this

manual

and

all

applicable

codes

such

as,

but

not

limited

to,

those

listed

at

the

end

of

Section

1



Safety

Rules

For

Operation

Of

Arc

Weld

ing

Power

Source.

2-2.

SAFETY

ALERT

SYMBOL

AND

SIGNAL

WORDS

The

following

safety

alert

symbol

and

signal

words

are

used

throughout

this

manual

to

call

attention

to

and

iden

tify

different

levels

of

hazard

and

special

instructions.

a

This

safety

alert

symbol

is

used

with

the

signal

words

WARNING

and

CAUTION

to

call

atten

tion

to

the

safety

statements.

a

WARNING

statements

identify

procedures

or

practices

which

must

be

followed

to

avoid seri

ous

personal

injury

or

loss

of

life.

a

CAUTION

statements

identify

procedures

or

practices

which

must

be

followed

to

avoid

minor

personal

injury

or

damage

to

this

equipment.

IMPORTANT

statements

identify

special

instructions

necessary

for

the

most

efficient

operation

of

this

equip

ment.

OM-113

336

Page

6

electrically

HOT

by

stray

current

may

shock,

possibly

fa

tally.

Do

NOT

GROUND

to

electrical

conduit,

or

to

a

pipe

carrying

ANY

gas

or

flammable

liquid

such

as

oil

or

fuel.

Three-phase

connection.

Check

phase

requirements

of

equipment

before

installing.

If

only

3-phase

power

is

available,

connect

single-phase

equipment

to

only

two

wires

of

the

3-phase

line.

Do

NOT

connect

the

equip

ment

ground

lead

to

the

third

(live)

wire,

or

the

equip

ment

will

become

electrically

HOT-a

dangerous

condi

tion

that

can

shock,

possibly

fatally.

Before

welding,

check

ground

for

continuity.

Be

sure

conductors

are

touching

bare

metal

of

equipment

frames

at

connections.

If

a

line

cord

with

a

ground

lead

is

provided

with

the

equipment

for

connection

to

a

switchbox,

connect

the

ground

lead

to

the

grounded

switchbox.

If

a

three-prong

plug

is

added

for

connection

to

a

grounded

mating

re

ceptacle,

the

ground

lead

must

be

connected

to

the

ground

prong

only.

If

the

line

cord

comes

with

a

three-

prong

plug,

connect

to

a

grounded

mating

receptacle.

Never

remove

the

ground

prong

from

a

plug,

or

use

a

plug

with

a

broken

off

ground

prong.

2.

Electrode

Holders

Fully

insulated

electrode

holders

should

be

used.

Do

NOT

use

holders

with

protruding

screws.

3.

Connectors

Fully

insulated

lock-type

connectors

should

be used

to

join

welding

cable

lengths.

4.

Cables

Frequently

inspect

cables

for

wear,

cracks

and

damage.

IMMEDIATELY

REPLACE

those

with

excessively

worn

or

damaged

insulation

to

avoid

possibly-lethal

shock

from

bared

cable.

Cables

with

damaged

areas

may

be

taped

to

give

resistance

equivalent

to

original

cable.

Keep

cable

dry,

free

of

oil

and

grease,

and

protected

from

hot

metal

and

sparks.

5.

Terminals

And

Other

Exposed

Parts

Terminals

and

other

exposed

parts

of

electrical

units

should

have

insulating

covers

secured

before

operation.

6.

Electrode

a.

Equipment

with

output

on/off

control

(contactor)

Welding

power

sources

for

use

with

the

gas

metal

arc

welding

(GMAW),

gas

tungsten

arc

welding

(GTAW)

and

similar

processes

nor

mally

are

equipped

with

devices

that

permit

on

off

control

of

the

welding

power

output.

When

so

equipped

the

electrode

wire

becomes

electri

cally

HOT

when

the

power

source

switch

is

ON

and

the

welding

gun

switch

is

closed.

Never

touch

the

electrode

wire

or

any

conducting

ob

ject

in

contact

with

the

electrode

circuit

unless

the

welding

power

source

is

off.

b.

Equipment

without

output

on/off

control

(no

contactor)

Welding

power

sources

used

with

shielded

metal

arc

welding

(SMAW)

and

similar

proc

esses

may

not

be

equipped

with

welding

power

output

on-off

control

devices.

With

such

equip

ment

the

electrode

is

electrically

HOT

when

the

power

switch

is

turned

ON.

Never

touch

the

electrode

unless

the

welding

power

source

is

off.

7.

Safety

Devices

Safety

devices

such

as

interlocks

and

circuit

breakers

should

not

be

disconnected

or

shunted

out.

Before

installation,

inspection,

or

service,

of

equipment,

shut

OFF

all

power

and

remove

line

fuses

(or

lock

or

red-

tag

switches)

to

prevent

accidental

turning

ON

of

power.

Disconnect

all

cables

from

welding

power

source,

and

pull

all

115

volts

line-cord

plugs.

Do

not

open

power

circuit

or

change

polarity

while

weld

ing.

If,

in

an

emergency,

it

must

be

disconnected,

guard

against

shock

burns,

or

flash

from

switch

arcing.

Leaving

equipment

unattended.

Always

shut

OFF

and

disconnect

all

power

to

equipment.

Power

disconnect

switch

must

be

available

near

the

welding

power

source.

F.

Protection

For

Wearers

of

Electronic

Life

Sup

port

Devices

(Pacemakers)

Magnetic

fields

from

high

currents

can

affect

pacemaker

operation.

Persons

wearing

electronic

life

support

equipment

(pacemaker)

should

consult

with

their

doctor

before

going

near

arc

welding,

gouging,

or

spot

welding

operations.

1-4.

STANDARDS

BOOKLET

INDEX

For

more

information,

refer

to

the

following

standards

or

their

latest

revisions

and

comply

as

applicable:

1.

ANSI

Standard

Z49.1,

SAFETY

IN

WELDING

AND

CUTTING

obtainable

from

the

American

Welding

Society,

550

N.W.

LeJeune

Rd,

Miami,

FL

33126.

2.

NIOSH,

SAFETY

AND

HEALTH

IN

ARC

WELD

ING

AND

GAS

WELDING

AND

CUTTING

ob

tainable

from

the

Superintendent

of

Documents,

U.S.

Government

Printing

Office,

Washington,

D.C.

20402.

3.

OSHA,

SAFETY

AND

HEALTH

STANDARDS,

29CFR

1910,

obtainable

from

the

Superinten

dent

of

Documents,

U.S.

Government

Printing

Office,

Washington,

D.C.

20402.

4.

ANSI

Standard

Z87.1,

SAFE

PRACTICES

FOR

OCCUPATION

AND

EDUCATIONAL

EYE

AND

FACE

PROTECTION

obtainable

from

the

Ameri

can

National

Standards

Institute,

1430

Broad

way,

New

York,

NY

10018.

5.

ANSI

Standard

Z41

.1,

STANDARD

FOR

MENS

SAFETY-TOE

FOOTWEAR

obtainable

from

the

American

National

Standards

Institute,

1430

Broadway,

New

York,

NY

10018.

OM-113

336

Page

5

SECTION

3

SPECIFICATIONS

Table

3-1.

SpecificatIons

Rated

~

Duty

Cycle

M

Ci~cuit

Input

At

Rated

Load

Output

60

Hz

Single-Phase

kw

Control

Circuit

Voltage

At

Gun

Electrode

Wire

Feed

Speed

Electrode

Wire

Diameter

Capability

Amperes

At

230V

460V

kva

e

Voltag

200V

575V

150

Amperes

At

23

Volts

DC

32

26.5

24

12

9.6

5.5

4.8

24

Volts

DC

60to486

ipm

(1.5

to

12.3

mpm)

.023/.025

in.

(0.6

mm)

.030

in.

(0.8

mm)

.035

in.

(0.9

mm)

Dimensions

Weight

A:

Width

13-1/2

in.

Net

Ship

(343

mm)

B:

Length

27

in.

(686

mm)

205

lbs.*

215

lbs.~

C:

Height

(93

kg)

(98

kg)

30

in.

(762

mm)

*Add

2-3/4

lbs.

(1.25

kg)

for

units

with

spot

~Add

5

lbs.

(2.27

kg)

for

units

with

spot

panel.

Figure

3-1.

Overall

Dimensions

Chart

3-1.

Volt-Ampere

Curves

Chart

3-2.

Duty

Cycle

RATED

OUTPUT,

6

I~I3H

5

4

3

2

1LOW

100

.

~

- -

-







-





-









-~

30

40

60

60

70

60

90100

Z

DUTY

CYCLE

SB-I

46

687

0

>

C)

0

200

160

Cl)

w

w

0.

0

-J

w

SB.146

888

OM-113

336

Page

7

3-1.

VOLT-AMPERE

CURVES

(Chart

3-1)

3-3.

DESCRIPTION

(~3*

RATED

OUTPUT

The

volt-ampere

curves

show

the

voltage

and

amper

age

output

capabilities

of

the

unit.

Voltage

and

amper

age

adjustment

is

provided

by

the

FINE

TUNING

WIRE

SPEED

control.

Curves

of

other

setting

fall

between

the

curves

shown.

With

the

use

of

the

volt-ampere

curves,

it

is

possible

to

determine

the

weld

amperage

at

any

particular

load

volt-

age.

3-2.

DUTY

CYCLE

(Chart

3-2)

The

duty

cycle

is

the

percentage

of

a

ten

minute

period

that

a

welding

power

source

can

be

operated

at

a

given

output

without

overheating

and

damaging

the

unit.

This

welding

power

source

is

rated

at

60

percent

duty

cycle

when

operated

at

150

amperes.

The

unit

can

be

oper

ated

at

150

amperes

for

six

consecutive

minutes,

but

it

must

operate

at

no

load

for

the

remaining

four

minutes

to

allow

proper

cooling.

If

the

welding

amperes

decrease,

the

duty

cycle

increases.

Refer

to

the

Duty

Cycle

chart

(Chart

3-2)

to

determine

the

output

of

the

welding

power

source

at

various

duty

cycles.

a

CAUTION:

EXCEEDING

DUTY

CYCLE

RATINGS

will

damage

the

welding

power

source.



Do

not

exceed

indicated

duty

cycles.

This

unit

is

a

single-phase

constant

voltage

dc

arc

weld

ing

power

source

and

wire

feeder

system.

This

unit

is

de

signed

for

Gas

Metal

Arc

Welding

(GMAW)

with

short

circuit

or

spray

transfer.

It

is

designed

primarily

for

use

as

a

dc

Electrode

Positive/Reverse

Polarity

machine.

Rated

weld

output

is

150

amperes,

23

volts

dc,

at

60%

duty

cycle.

Models

with

the

optional

SPOT/PULSE

WELD

PANEL

provide

the

controls

for

regulating

spot

weld

time/pulse

on

time,

burnback

time,

and

pulse

off

time.

3-4.

SUPPLIED

EQUIPMENT

(Figure

3-2)

The

following

equipment

is

supplied

with

the

welding

power

source

and

requires

customer

installation

or

as

sembly:

A.

Running

gear

with

gas

cylinder

rack

and

bracket.

B.

Wall

receptacle

(200/230

volt

models

only).

C.

Work

cable,

work

clamp,

and

jack

plug.

D.

MWG-200

gun

with

5/8

in.

(16

mm)

nozzle

and

two

contact

tubes

for

each

wire

size.

E.

Drive

rolls

for

.023/.025,

.030,

and

.035

in.

(0.6,

0.8,

and

0.9

mm)

hard

wire.

The

welding

power

source

is

factory

equipped

with

9

ft.

(2.7

m)

power

cord

(with

plug

on

200/230

volt

models),

gas

valve,

and

facilities

for

a

Spool

gun.

Spreader

Bar

Figure

3-2.

Supplied

Equipment

Wall

Bracket

Receptacle

OM-113

336

Page

8

3-5.

ADDITIONAL

REQUIRED

EQUIPMENT

(Fig

ure

3-3)

The

additional

equipment

required

to

complete

the

Gas

Metal

Arc

Welding

(GMAW)

setup

can

be

obtained

from

your

local

welding

supplies

distributor.

A.

Gas

Cylinder

Two

types

of

gas

are

generally

used

with

Gas

Metal

Arc

Welding

(GMAW)

of

thin

gauge

sheet

steel.

Carbon

dioxide

(002)

is

the

gas

recommended

for

use

with

this

welding

power

source/gun

combination.

A

mixture

of

75

percent

argon

and

25

percent

carbon

dioxide

also

gives

favorable

results.

Obtain

a

cylinder

of

selected

shielding

gas

from

your

supplier.

B.

Regulator/Flowmeter

Regulator/flowmeters

provide

a

constant

shielding

gas

pressure

and

flow

rate

during

the

welding

process.

Be

cause

gases

have

different

properties,

each

regulator!

flowmeter

is

designed

to

be

used

with

a

specific

gas

or

mixture

of

gases.

Regulator/flowmeters

cannot

be

changed

from

one

gas

to

another

unless

the

proper

adapters

are

installed.

Obtain

the

proper

regulator/flow-

meter

for

the

type

of

gas

used.

Gas

Hose

Safety

Regulator/Flowmeter

Glasses

Figure

3-3.

Additional

Required

Equipment

C.

Gas

Hose

Measure

distance

from gas

cylinder

to

welding

power

source.

Obtain

good

quality

5/8

in.

(16

mm)

outside

di

ameter,

S.A.E.

gas

hose,

and

install

5/8-18

right-hand

thread

fittings

on

both

ends

of

hose.

D.

Wire

Spool

For

GMAW

Process

Selection

of

the

correct

welding

wire

is

important

in

Gas

Metal

Arc

Welding

(GMAW).

There

are

many

types

to

choose

from,

but

certain

wires

are

best

suited

for

weld

ing

thin

gauge

sheet

steel.

The

American

Welding

Soci

ety

(AWS)

classification

for

GMAW

wires

is

usually

indi

cated

on

the

label

of

the

wire

spool.

Two

AWS

wire

classes

recommended

are

E7OS-6

and

E705-3.

The

E7OS-6

provides

a

more

fluid

(wetter)

weld

puddle

and

a

flatter

bead

than

E7OS-3.

Obtain

a

spool

of

selected

wire.

E.

Personal

Safety

Equipment

When

using

this

welding

power

source,

wear

a

welding

helmet,

fitted

with

the

proper

filter

lens,

to

protect

the

eyes

from

the

welding

arc.

Also

wear

protective

clothing,

safety

glasses,

and

gloves

to

prevent

injury.

F.

Offset/Punching

Tool

(Figure

3-4)

The

repair

of

automotive

sheet

steel

is

easier

when

an

OffsetlPunching

tool

is

used.

This

tool

has

a

dual

pur.

pose,

rotating

head.

The

damaged

area

is

cutaway

and

the

jaws

of

the

offset

portion

of

the

head

are

placed

over

the

sheet

steel.

When

pressure

is

applied

to

the

handles,

the

tool

indents

a

small

offset

in

the

sheet

steel.

A

new

piece of

sheet

steel,

cut

to

size,

is

placed

in

position

to

overlap

the off

set

portion.

The

new

piece

of

sheet

steel

is

welded

into

place,

sanded,

filled

with

body

putty,

and

finish

sanded.

The

head

of

the

tool

can

be

rotated

one-half

turn

to

be

used

as

a

punching

tool.

The

punching

tool

expedites

riveting

operations.

The

use

of

this

tool

will

keep

material

use

and

finishing

time

to

a

minimum.

Figure

3-4.

Offset/Punching

Tool



Gas

Cylinder

Helmet

Wire

Spool

Gloves

Li.

/

1.

I

OM-113

336

Page

9

3-6.

OPTIONAL

EQUIPMENT

3-7.

CONSUMABLE

PARTS

The

following

equipment

can

be

obtained

to

extend

the

capabilities

of

the

basic

unit

or

to

suit

special

applica

tions:

A.

SPW-1,

Spot,

Pulse,

Continuous

Panel

(in

cludes

three

spot

nozzles)

(for

installation

see

Section

4-4)

Spool

gun

Gun

cable

holder

D.

25

ft.

(7.6

m)

power

cord

extension.

The

following

parts

are

subject

to

wear

or

damage

in

nor

mal

use:

SECTION

4

INSTALLATION

OR

RELOCATION

4-1.

SITE

SELECTION

(Figure

4-1)

Figure

4-1.

Location

Select

an

installation

site

which

provides

the

following:

1.

Correct

input

power

supply

(see

unit

nameplate)

2.

Shielding

gas

supply

3.

Adequate

ventilation

and

fresh

air

supply

4.

No

flammables

5.

A

clean

and

dry

area

6.

Proper

temperature

that

avoids

extremes

of

heat

or

cold

7.

Proper

airflow

around

unit

8.

Adequate

space

for

opening

side

access

doors

for

installation,

maintenance,

and

repair

func

tions.

Base

mounting

holes

provide

the

capability

to

install

and

secure

the

unit

on

a

running

gear

or

in

a

permanent

location.

a

WARNING:

FIRE

OR

EXPLOSION

can

result

from

placing

unit

on

or

over

combustible

surfaces;

RESTRICTED

AIRFLOW

can

cause

overheating

and

possible

damage

to

internal

parts.



Do

not

locate

unit

overcombustible

surfaces.



Maintain

at

least

18

inches

(457

mm)

of

unrestricted

space

on

all

sides

of

unit,

and

keep

underside

free

of

obstructions.



Do

not

place

any

filtering

device

over

the

in

take

air

passages

that

provide

airflow

for

cooling

this

unit.

Warranty

is

void

if

any

type

of

filtering

device

is

used

at

intake

air

passages.

4-2.

TRANSPORTING

METHODS

This

welding

power

source

is

equipped

with

a

lifting

eye

for

moving

the

unit

during

installation.

Weight

capacity

of

the

lifting

eye

only

allows

for

supporting

the

welding

power

source.

4~

WARNING:

ELECTRIC

SHOCK

can

kill.

~.

Do

not

touch

live

electrical

parts.



Disconnect

input

power

conductors

from

deenergized

supply

line

BEFORE

moving

welding

power

source.

FALLING

EQUIPMENT

can

cause

serious

personal

injury

and

equipment

damage.



Use

lifting

eye

to

lift

unit

only,

NOT

running

gear,

gas

cylinders,

or

any

other

heavy

accessories

or

devices.



Use

equipment

of

adequate

capacity

to

lift

the

unit.



If

lifting

or

moving

this

unit

with

lift

forks

under

the

base,

be

sure

that

lift

forks

are

long

enough

to

extendbeyond

opposite

side

of

the

base.

Using

lift

forks

too

short

can

damage

internal

parts

if

tips

of

the

lift

forks

penetrate

the

unit

base,

or

may

cause

personal

injury

and/or

equipment

damage

if

unit

falls

off

the

lift

forks.

B.

C.

A.

Contact

tubes

B.

Nozzles

C.

Gun

liner

D.

Drive

rolls.

SB-087

313-0

OM-113

336

Page

10

4-3.

RUNNING

GEAR

INSTALLATION

(Figure

4-2)

a

WARNING:

UNCONTROLLED

TILTING

OR

TIPPING

of

unit

can

result

in

personal

injury

or

equipment

damage.



Use

equipment

of

adequate

capacity

to

lift

the

unit.



If

using

lift

forks

to

handle

this

unit,

be

sure

the

lift

forks

are

long

enough

to

extend

out

of

the

opposite

side

of

the

base.



Do

not

place

any

part

of

the

body

under

the

unit

while

it

is

suspended.

Place

blocks

under

frame

of

unit

before

installing

running

gear.

1.

Install

the

two

4

in.

(102

mm)

casters

and

spread

er

bar

onto

the

front

corners

of

the

welding

power

source

base

a

shown

in

Figure

4-2

using

3/8

in.

hardware.

2.

Blockthe

unit

up

securely

in

middleto

ease

instal

lation

of

rear

wheel/gas

cylinder

rack

assembly.

3.

Slide

axle

through

cylinder

rack,

and

install

a

wheel

on

each

end

of

axle

with

a

3/4

in.

flat

wash

er

on

each

side

of

wheel.

4.

Secure

wheels

in

place

with

supplied

retaining

rings.

5.

Install

cylinder

rack

onto

welding

power

source

base

using

5/16-18

x

3/4

cap

screws

and

asso

ciated

hardware

(see

Figure

4-2).

6.

Remove

the

two

front

cap

screws

in

top

of

welding

power

source

wrapper

and

discard.

Install

run

ning

gear

handle

onto

wrapper

using

1/4-20

x

3/4

cap

screws

as

shown

in

Figure

4-2.

7.

Install

cylinder

bracket

onto

rear

panel

of

welding

power

source

as

shown

in

Figure

4-2

using

1/4-20

x

3/4

cap

screws

and

existing

holes

in

rear

panel.

8.

Install

safety

chain

onto

cylinder

bracket.

4-4.

OPTIONAL

SPW-1

PANEL

INSTALLATION

(Figure

4-3)

a

WARNING:

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Shut

down

welding

power

source,

and

dis

connect

input

power

employing

lockout/tag

ging

procedures

before

inspecting

or

install.

ing.

Lockout/tagging

procedures

consist

of

remov

ing

input

power

plug

from

receptacle,

pad

locking

line

disconnect

switch

in

open

position,

removing

fuses

from

fuse

box,

or

shutting

off

and

red-tagging

circuit

breaker

or

other

discon

necting

device.

.wheel

SC-049

808-E

Figure

4-2.

Running

Gear

Installation

Cylinder

Safety

chain

Flat

Washers

Nut

Cylinder

Rack

Axle

Spreader

Bar

Washer

Casters

Nut

Cap

Screw

Flat

Washers

OM-113

336

Page

11

IMPORTANT:

SPW-

1

Spot

Panel

will

not

provide

spot

capabilities

for

the

Spool

gun.

Retain

all

hardware

re

moved

during

this

procedure

for

reinstallation.

All

direc

tions,

such

as

left

or

right,

are

with

respect

to

the

opera-

for

facing

the

front

panel.

1.

Remove

module

cover

plate

from

upper

right-

hand

corner

of

front

panel.

2.

Locate

wiring

harness

clamped

to

air

baffle.

Re

move

wiring

harness

from

first

clamp

and

careful

ly

pull

end

of

wiring

harness

with

connectors

through

opening

in

front

panel



it

will

come

through

approximately

2

in.

(51

mm).

3.

Disconnect

jumpered

connector

from

plug

PLG2.

4.

Connect

receptacle

RC55

from

SPW-1

panel

to

PLG2.

Be

sure

the

connectors

are

locked

togeth

er

(see

Figure

4-3).

5.

Install

SPW-1

panel

into

upper

right

corner

of

front

panel,

and

secure

using

screws

removed

in

Step

1.

a

WARNING:

PRESSURIZED

CYLINDERS

can

rupture

causing

serious

personal

injury

and

loss

of

life;

FALLING

CYLINDERS

can

cause

serious

injury

and

equipment

damage.



Keep

cylinders

away

from

welding

or

other

electrical

circuits.



Never

allow

a

welding

electrode

to

touch

any

cylinder.



Always

fasten

cylinder

securely

to

running

gear

bracket,

a

wall,

or

other

stationary

sup

port.

B.

Regulator/Flowmeter

(Customer

Supplied)

(Fig

ure

4-4)

1.

With

the

cylinder

correctly

installed,

remove

cylin

der

cap

(see

Figure

4-4).

Stand

to

one

side

of

the

cylinder

valve,

and

open

the

valve

slightly.

When

gas

flows

from

cylinder,

close

valve.

This

proce

dure

gets

rid

of

any

dust

or

dirt

that

may

have

ac

cumulated

around

the

valve

seat.

2.

The

regulator/flowmeter

must

be

properly

equipped

with

a

stem,

nut

connectors,

and

gasket

for

use

with

either

CO2

cylinders

or

Argon/CO2

cylinders.

IMPORTANT:

A

gasket

should

be

installed

to

prevent

leaks.

Do

not

use

lubricants

or

sealing

agents.

3.

Install

gas

regulator

onto

gas

cylinder

valve;

keep

the

face

of

the

regulator/flowmeter

gauge

in

the

vertical

position,

and

tighten

stem

nut

securely

onto

gas

cylinder.

4.

A

shielding

gas

output

fitting

is

provided

at

the

rear

of

the

welding

power

source

for

making

gas

connections.

Attach

one

end

of

the

gas

hose

to

this

output

fitting.

Attach

other

end

of

the

gas

hose

to

the

regulator/f

lowmeter.

4-6.

WORK

CABLE

ASSEMBLY

A

10

ft.

(3

m)

cable

with

a

lug

attached

to

one

end

is

supplied

with

the

unit.

To

install

the

work

clamp

and

jack

plug

onto

the

cable,

proceed

as

follows:

A.

Work

Clamp

Installation

(Figure

4-5)

FIgure

4-3.

SPW-1

Panel

Installation

4-5.

SHIELDING

GAS

INSTALLATION

A.

Gas

Cylinder

(Customer

Supplied)

(Figure

3-3)

Secure

gas

cylinder

to

running

gear

using

safety

chain

on

cylinder

bracket.

If

the

running

gear

is

not

to

be

used,

chain

cylinder

to

wall

or

other

stationary

support

to

pre

vent

the

cylinder

from

falling

over

and

breaking

off

the

valve.

1.

Insert

the

end

of

the

work

cable

with

the

terminal

lug

on

it

through

one

of

two

supplied

insulating

sleeves.

2.

Lay

the

work

cable

inside

the

handle

of

the

work

clamp

which

has

the

flattest

inner

surface.

3.

Align

the

smaller

hole

in

the

work

clamp

handle

with

the

hole

in

the

work

cable

terminal

lug.

Se

cure

the

terminal

lug

to

the

work

clamp

with

the

supplied

nut

and

bolt.

4.

Bend

the

tabs

on

the

end

of

the

work

clamp

han

dle

around

the

work

cable.

5.

Slide

the

insulating

sleeve

on

the

work

cable

over

the

work

clamp

handle.

Plug

_....~

PLG2

Receptacle

RC55

SPw-1

._~

Spot

Panel

OM-113

336

Page

12

Regulator

CO2

Installation

SB-109

492-A

6.

Slide

the

remaining

insulating

sleeve

over

the

other

work

clamp

handle.

Step

3

Figure

4-5.

Work

Clamp

Installation

B.

Jack

Plug

Installation

(Figure

4-6)

0250

The

supplied

jack

plugs

are

used

to

connect

the

weld

cables

to

the

weld

output

receptacles.

Install

jack

plugs

onto

weld

cables

as

follows:

1.

Remove

3/4

in.

(19

mm)

of

insulation

from

one

end

of

each

weld

cable.

2.

Clamp

cable

in

a

vise

with

the

uninsulated

end

ex

tending

upward

out

of

vise

approximately

1-3/4

in.

(44

mm).

3.

Place

steel

tie

wire

(item

A,

Figure

4-6)

approxi

mately

1/4

in.

(6

mm)

from

end

of

insulation.

4.

Make

a

half

turn

around

cable

bringing

looped

ends

of

tie

wire

together.

5.

Insert

a

3/8

in.

(9.5

mm)

diameter

rod

through

looped

ends

of

tie

wire.

6.

Twist

tie

wire

(B)

until

entire

tie

wire

is

twisted

and

is

tight

around

insulation

of

cable.

7.

Cut

off

looped

ends

of

tie

wire.

8.

Bend

the

twisted

tie

wire

over

and

along

the

side

(C)

of

uninsulated

portion

of

cable.

9.

Wrap

the

strip

of

copper

foil

tightly

around

uninsu

lated

portion

of

cable

and

twisted

tie

wire

(D).

10.

Push

the

jack plug

onto

cable

over

copper

foil

(E).

AU

B~

~

U

FP

S~0023

Figure

4-6.

Jack

Plug

Installation

Gas

Hose

Connection

CO2

Washer

(5/8.18

Male

Fitting

Required)

CO2

Cylinder

Gas

Hose

Connection

(5/8-18

Male

Fitting

Required)

Argon

Installation

Argon

Or

Argon

Mix

Cylinder

Figure

4-4.

Typical

Regulator/Flowmeter

Installation

Step

6

Step

Step

4

Steps

1

and

5

OM-113

336

Page

13

11.

Insert

the

1/4-20

setscrews

into

center

and

bot-

1.

Open

access

door.

torn

holes

in

jack

plug,

and

tighten

(E).

2.

Loosen

the

gun/feeder

connector

securing

knob

12.

Remove

cable

from

vise,

and

insert

jack

plug

into

(see

Figure

4-7).

insulating

sleeve.

Slide

insulating

sleeve

over

jack

plug

and

cable

until

hole

in

insulating

sleeve

IMPORTANT:

Wire

guides

should

be

installed

so

that

lines

up

with

rernaining

hole

in

jack

plug

(F).

the

tip

of

the

guide

is

as

close

to

the

drive

rolls

as

possi

ble

without

touching.

13.

Insert

the

8-32

self-tapping

screw

(F)

through

hole

in

insulating

sleeve

into

jack

plug,

and

tight-

3.

Insert

the

gun/feeder

connector,

which

includes

en.

outlet

guide,

through

the

access

hole

in

the

weld-

4-7.

WELD

POLARITY

SELECTION

ing

power

source

front

panel

and

into

the

drive

as

sembly

as

illustrated

in

Figures

4-7

and

4-8.

NEGATIVE

POSITIVE

4.

Tighten

the

gun/feeder

connector

securing

knob.

5.

Close

and

secure

access

door.

1

B.

Gun

Switch

Connection

(Figure

4-8)

a

WARNING:

ELECTRIC

SHOCKcan

kill;

ARC

ING

can

burn

skin

or

damage

electrical

con-

GUN

nections.

TRIGGER



Do

not

touch

live

electrical

parts.



Shut

down

welding

power

source

before

mak

ing

any

twistlock

plug

connections.

The

GUN

TRIGGER

receptacle

is

provided

for

making



Do

not

change

position

oftwistlockplug

while

switch

control

connections.

Align

the

keys

on

the

gun

welding.

switch

connector

with

the

keyway

on

the

GUN

TRIG-



Secure

twistlock

plug

in

selected

receptacle

GER

receptacle,

insert

connector,

and

rotate

threaded

before

welding.

collar

fully

clockwise.

When

the

gun

switch

is

closed,

the

IMPORTANT:

Rotate

jack

plugs

1/4

turn

clockwise

to

welding

power

source

contactor

energizes,

shielding

secure

them

in

receptacles,

gas

flows,

and

wire

feeds.

1.

Connect

jack

plug

on

weld

cable

from

unit

into

4-9.

INSTALLATION

OF

OPTIONAL

SPOOL

GUN

POSITIVE

(+)

weld

output

receptacle.

~

WARNING:

ELECTRIC

SHOCK

can

kill.

2.

Connect

jack

plug

from

work

cable

into

NEGA-

~



Do

not

touch

live

electrical

parts.

TIVE

()

weld

output

receptacle.

IMPORTANT:

For

Electrode

Negative/Straight

Polarity



Do

not

connect

two

guns

to

this

welding

pow

er

source

at

the

same

time.

Connections,

reverse

cable

connections

to

weld

output

receptacles;

electrode

becomes

negative.



Shut

down

welding

power

source,

and

dis

connect

input

power

employing

lockout/tag

ging

procedures

before

inspecting

or

install-

4-8.

MWG-200

WELDING

GUN

CONNECTIONS

ing.

~

WARNING:

ELECTRIC

SHOCK

can

kill.

Lockout/tagging

procedures

consist

of

remov



Do

not

touch

live

electrical

parts.

ing

input

power

plug

from

receptacle,

pad

locking

line

disconnect

switch

in

open

position,



Shut

down

welding

power

source,

and

dis-

removing

fuses

from

fuse

box,

or

shutting

off

connect

input

power

employing

lockout/tag-

and

red-tagging

circuit

breaker

or

other

discon

ging

procedures

before

inspecting

or

install-

necting

device.

ing.

If

two

guns

are

connected

to

this

welding

power

Lockout/tagging

procedures

consist

of

remov-

source,

both

electrode

wires

will

be

energized

ing

input

power

plug

from

receptacle,

pad-

when

either

gun

is

operated.

locking

line

disconnect

switch

in

open

position,

removing

fuses

from

fuse

box,

or

shutting

off

and

red-tagging

circuit

breaker

or

other

discon-

A.

Shielding

Gas

Connections

necting

device.

IMPORTANT:

Use

pure

argon

shielding

gas

for

alumi

num

wire

welding.

A.

Gun/Feeder

Connector

Installation

(Figures

4-7

And

4-8)

Connect

the

shielding

gas

hose

from

the

Spool

Gun

to

IMPORTANT:

The

outlet

guide

is

provided

as

part

of

the

the

gas

regulator/flowmeter

on

the

shielding

gas

supply.

gun

assembly.

The

connector

has

5/8-18

right-hand

threads.

OM-113

336

Page

14

Hub

Figure

4-8.

Welding

Gun

Connections

Drive

Roll

Cover

Wire

Outlet

Guide

Hex

Nut

Monocoil

Liner

Front

Panel

Of

Unit

Spool

Gun/Feeder

Connector

Compression

Spring

Retainer

Ring

Gun/Feeder

Connector

SA.o72

573.A

Securing

Knob

Figure

4.7.

Gun/Feeder

Connector

And

Wire

Spool

Installation

A

B

C

OM-113

336

Page

15

B.

Weld

Cable

Connections

Insert

Spool

Gun

welding

cable

plug

into

POSITIVE

(+)

weld

output

receptacle

with

flat

side

facing

the

recep

tacle

key.

Rotate

plug

clockwise

1/4

turn.

C.

SPOOL

GUN

Receptacle

Connection

(Figure

4-9)

SPOOL

GUN

A

3-socket

SPOOL

GUN

receptacle

RC3

is

provided

for

making

connections

between

the

welding

power

source

and

the

Spool

Gun.

To

connect

the

gun,

align

keyway,

insert

gun

plug

into

receptacle,

and

rotate

threaded

col

lar

fully

clockwise.

When

gun

switch

is

closed,

the

con

tactor

energizes,

shielding

gas

flows,

and

wire

feeds.

Figure

4-9.

Front

View

Of

3-Socket

Spool

Gun

Receptacle

With

Socket

Locations

The

sockets

on

the

SPOOL

GUN

receptacle

are

desig

nated

as

follows:

Socket

A:

+24

volts

ac,

60

Hz.

Socket

B:

Welding

power

source

contactor

control;

+24

volts

closes

contactor;

0

volts

opens

contactor.

Socket

C:

+24

volts

ac,

60

Hz.

4-10.

WELDING

WIRE

SPOOL

INSTALLATION

(Figure

4-7)

J~

WARNING:

ELECTRIC

SHOCK

can

kill.

______



Do

not

touch

live

electrical

parts.



Shut

down

welding

power

source,

and

dis

connect

input

power

employing

lockout/tag

ging

procedures

before

inspecting

or

install

ing.

Lockout/tagging

procedures

consist

of

remov

ing

input

power

plug

from

receptacle,

pad

locking

line

disconnect

switch

in

open

position,

removing

fuses

from

fuse

box,

or

shutting

off

and

red-tagging

circuit

breaker

or

other

discon

necting

device.

1.

Open

left

side

access

door.

2.

Remove

retaining

ring.

3.

Slide

spool

of

wire

onto

hub

so

that

wire

feeds

off

bottom

of

spool.

4.

Rotate

spool

until

hole

in

spool

aligns

with

pin

in

hub.

Slide

spool

onto

hub

until

it

seats

against

back

flange

of

hub.

5.

Compression

spring

is

not

required

for

12

in.

(305

mm)

spools.

For

8

in.

(203

mm)

spools,

use

com

pression

spring.

Reinstall

retaining

ring

onto

hub.

6.

Close

and

secure

access

door.

4-11.

HUB

TENSION

ADJUSTMENT

(Figure

4-7)

a

WARNING:

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Shut

down

welding

power

source,

and

dis

connect

input

power

employing

locko

ut/tag

ging

procedures

before

inspecting

or

install

ing.

Lockout/tagging

procedures

consist

of

remov

ing

input

power

plug

from

receptacle,

pad

locking

line

disconnect

switch

in

open

position,

removing

fuses

from

fuse

box,

or

shutting

off

and

red-tagging

circuit

breaker

or

other

discon

necting

device.

Check

the

hub

tension

by

slowly

pulling

the

wire

toward

S-0037

the

feed

roll.

The

wire

should

unwind

freely,

but the

hub

tension

should

be

sufficient

to

keep

the

wire

taut

and

pre

vent

backlash

when

the

wire

feeding

ceases.

If

adjust

ment

is

required,

loosen

or

tighten

the

hex

nut

on

the

end

of

the

spindle

support

shaft

accordingly.

4-12.

ELECTRICAL

INPUT

CONNECTIONS

a

o

INPUT

WARNING:

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Shut

down

welding

power

source,

and

dis

connect

input

power

employing

locko

ut/tag

ging

procedures

before

inspecting

or

install

ing.

Lockout/tagging

procedures

consist

of

remov

ing

input

power

plug

from

receptacle,

pad

locking

line

disconnect

switch

in

open

position,

removing

fuses

from

fuse

box,

or

shutting

off

and

red-tagging

circuit

breaker

or

other

discon

necting

device.

A.

Electrical

Input

Requirements

Operate

the

welding

power

source

from

a

single-phase,

60

Hertz,

ac

power

supply.

The

input

voltage

must

match

one

of

the

electrical

input

voltages

shown

on

the

input

data

label

on

the

unit

nameplate.

Contact

the

local

elec

tric

utility

for

information

about

the

type of

electrical

ser

vice

available,

how

proper

connections

should

be

made,

and

inspection

required.

OM-113

336

Page

16

B.

Jumper

Link

Installation

(Figures

4-10

And

4-11)

a

WARNING:

Read

and

follow

safety

informa

tion

at

beginning

of

entire

Section

4-12

be

fore

proceeding.

Jumper

links

are

used

to

allow

the

equipment

to

operate

from

different

line

voltages.

The

jumper

links

may

be

in

a

bag

attached

to

the

input

terminal

board

or

installed

on

the

input

terminal

board

for

the

highest

voltage

shown

on

the

input

voltage

label.

1.

Remove

the

wrapper.

2.

Compare

position

of

jumper

links

on

the

input

terminal

board

(see

Figure

4-10)

to

the

voltage

link

arrangement

on

input

voltage

label

(see

Fig

ure

4-11).

Air

Baffle

a

CAUTION:

INCORRECT

INPUT

VOLTAGE

JUMPER

LINK

PLACEMENT

can

damage

unit.



Position

jumper

links

as

shown

on

the

input

voltage

label

(see

Figures

4-10

and

4.11).



Store

unused

jumper

links

across

linked

terminals.

IMPORTANT:

If

the

input

voltages

stated

on

nameplate

or

rating

label

are

different

from

those

in Figure 4-11,

check

the

input

voltage

label

in

the

unit

or

call

Factor,

Service

Department.

3.

Install

jumper

links

onto

the

input

terminal

board

to

match

the

available

input

line

voltage.

4.

Reinstall

wrapper.

C.

Wall

Receptacle

And

Power

Cable

Connections

(Figure

4-12)

WARNING:

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Install

a

fusible

line

disconnect

switch

in

the

input

circuit

to

the

welding

power

source.

Use

Table

4-1

as

a

guide

in

selecting

appropri

ate

input

conductor

and

fuse

size.



Connect

input

conductors

to

the

welding

power

source

before

connecting

to

single-

phase

input

power.



Read

and

follow

safety

information

at

begin

ning

of

entire

Section

4-12

before

proceed

ing.

The

line

disconnect

switch

provides

a

safe

and

convenient

means

to

completely

remove

all

electrical

power

from

the

welding

power

source

whenever

necessary

to

inspect

or

service

unit.

All

models

are

equipped

with

a

three-conductor

power

cable.

Models

requiring

200

or

230

volts

input

are

equipped

with

a

three-prong

polarized

plug

and

wall

re

ceptacle.

The

wail

receptacle

should

be

installed

in

a

convenient

location

by

a

competent

electrician.

Install

the

wall

receptacle

with

the

grounding

terminal

at

the

top,

allowing

the

power

cable

to

hang

downward

without

undue

bending

or

twisting.

Table

4-1.

Input

Conductor

And

Fuse

Slze*

In

put

Voltage

200 230

460

575

Input

Conductor

Size

(AWG)

10 10

14

14

Ground

Conductor

Size

(AWG)

10 10

14

14

Fuse

Size

In

Amperes

40 35

20

15

*Conductor

size

is

based

on

the

1990

Edition

of

the

National

Electrical

Code

(NEC)

specifications

for

allowable

ampacities

of

insulated

copper

conductors,

having

a

temperature

rating

of

167F

(75C),

with

not

more

than

three

single

current-carrying

conductors

in

a

raceway

(Article

310

of

NEC).

(The

ground

conductor

is

not

counted

as

a

current-carrying

conductor.)

*Fuse

size

is

based

on

not

more

than

200

percent

of

the

rated

input

amperage

of

the

welding

power

source

(Article

630

of

NEC).

S~0092/9~90

Input

Voltage

Label

Input

Terminal

Board

Figure

4-10.

Input

Terminal

Board

Location

Models

having

an

electrical

input

voltage

above

230

volts

have

prewired

power

cables

with

three

conductors.

The

black

and

white

conductors

must

be

connected

to

RefS0-072507-L

the

line

disconnect

switch,

and

the

green

conductor

must

be

connected

to

a

proper

ground

(see

Figure

4-12).

Use

a

grounding

method

that

is

acceptable

to

the

local

electrical

inspection

authority.

200V

230V

Figure

4-11.

Input

Voltage

Label

SA-117

070

OM-113

336

Page

17

a

WARNING:

ELECTRIC

SHOCK

can

kill.



Do

not

connect

an

input

(white

or

black)

con

ductor

to

the

ground

term

mal.



Do

not

connect

the

ground

(green)

conductor

to

an

input

line

terminal.

Incorrect

input

connections

can

result

in

an

electrically

energized

welding

power

source

chassis.

The

ground

terminal

is

connected

to

the

welding

power

source

chassis

and

is

for

grounding

purposes

only.

Wall

Receptacle

Figure

4-12.

Wall

Receptacle

And

Power

Cable

Connections

4-13.

WELDING

WIRE

THREADING

(Figure

4-7)

a

WARNING:

ELECTRIC

SHOCK

can

kill;

MOVING

PARTS

can

cause

serious

injury.



Do

not

touch

live

electrical

parts.



Keep

away

from

moving

parts.



Do

not

energize

welding

power

source

or

wire

feeder

until

instructed

to

do

so.

The

welding

wire

and

all

metal

parts

in

contact

with

it

are

energized

while

welding.

WELDING

WIRE

can

cause

puncture

wounds;

HOT

SURFACES

can

cause

severe

burns.



Do

not

press

gun

trigger

until

instructed

to

do

so.



Do

not

point

gun

toward

any

part

of

the

body,

any

conductive

surface,

or

other

personnel

when

threading

welding

wire.



Allow

gun

to

cool

before

touching.

1.

Open

left

side

access

door.

2.

Install

welding

wire

spool

according

to

Section

4-10.

IMPORTANT:

Spooled

wire

has

a

tendency

to

unravel

when

loosened

from

the

spool.

Maintain

a

firm

grip

on

the

wire

during

the

threading

operation.

3.

Unreel

and

straighten

approximately

6

in.

(152

mm)

of

wire

from

wire

spool.

4.

Cutoff

any

wire

that

is

bent,

and

remove

any

burrs

or

sharp edges.

5.

Release

pressure

spring

on

drive

roll

assembly,

and

pivot

upper

drive

roll

up

and

away

from

lower

drive

roll.

6.

Route

welding

wire

into

wire

inlet

guide,

along

lower

drive

roll

groove,

and

into

wire

outlet

guide

(see

Figure

4-7).

7.

Pivot

upper

drive

roll

down

onto

lower

drive

roll.

8.

Reinstall

pressure

spring.

Be

sure

that

welding

wire

is

in

groove

of

drive

rolls.

9.

Lay

gun

cable

assembly

out

as

straight

and

flat

as

possible.

10.

Energize

welding

power

source.

If

power

source

has

spot

welding

capabilities,

place

the

Selector

switch

in

the

CONTINUOUS

position.

11.

Depress

and

hold

the

gun

trigger

until

the

wire

feeds

approximately

1/4

in.

(6

mm)

out

the

gun

nozzle.

If

wire

feeds

more

than

1/4

in.

out

nozzle,

cut

wire

off

to

1/4

in.

12.

Deenergize

welding

power

source.

13.

Adjust

hub

tension

according

to

Section

4-11,

if

necessary.

14.

Close

and

secure

access

door.

IMPORTANT:

For

a

smoother

weld

start,

be

sure

weld

ing

wire

extends

1/4

in.

(6

mm)

out

of

contact

tube

and

has

a

sharp

end.

Ground

Conductor

Line

Disconnect

Switch

Li

Line

Conductor

L2

Line

Conductor

SA-112

075-A

OM-113

336

Page

18



OPTIONAL

Weld

Cable

SECTION

5

OPERATOR

CONTROLS

Fine

Tuning

Wire

Speed

Control

Gun

Trigger

Power

Switch

Figure

5-1.

Operator

Controls

5-1.

POWER

SWITCH

AND

PILOT

LIGHT

(Figure

5-1)

POWER

e

00FF

Placing

the

POWER

switch

in

the

ON

position

energizes

the

welding

power

source.

The

pilot

light

comes

on

whenever

the

POWER

switch

is

in

the

ON

position

and

indicates

that

the

unit

is

receiving

input

power.

Placing

the

POWER

switch

in

the

OFF

position

shuts

down

the

welding

power

source

and

turns

off

the

pilot

light.

IMPORTANT:

When

the

POWER

switch

is

in

the

ON

po

sition,

the

pilot

light

comes

on,

but

the

fan

motor

does

not

run

unless

the

internal

components

are

already

warm.

The

fan

motor

is

thermostatically

controlled

and

only

op

erates

when

additional

cooling

is

required

(see

Section

5-4).

5-2.

THICKNESS

VOLTS

SELECTOR

(Figure

5-1)

THICKNESS

VOLTS

a

CAUTION:

ARCING

can

damage

jack

plug

and

receptacle

contact

surfaces.



Do

not

change

THICKNESS

VOLTS

selector

plug

position

while

welding

or

under

load.

Selector

Switch



Pulse

Off

Time

Control

Positive

(+)

Weld

Receptacle

Spool

Gun

Receptacle

Pilot

Light

Thickness

Volts

Receptacles

And

Selector

Plug

Ref.

SB.087

313.D

ON

OM-113

336

Page

19

Arcing

causes

the

contact

surfaces

to

become

pitted.

Eventually

continuity

is

lost

and

the

selec

tor

plug

no

longer

works

to

select

output

range.

The

THICKNESS

VOLTS

selector

jack

plug

and

recep

tacles

provide

a

selection

of

heat

input

to

the

weld.

The

higher

the

numbered

receptacle,

the

hotter

the

weld.

IMPORTANT:

After

installing

selector

plug

into

THICK

NESS

VOLTS

receptacle,

rotate

plug

1/4

turn

clockwise

to

secure

in

place.

When

removing

plug

from

receptacle,

rotate

plug

1/4

turn

counterclockwise

while

withdrawing

it

from

receptacle.

5-3.

FINE

TUNING

WIRE

SPEED

CONTROL

(Fig

ure

5-1)

(~o

FINE

TUNING

-1

WIRE

SPEED

The

FINE

TUNING

WIRE

SPEED

control

provides

selection

of

the

speed

at

which

welding

wire

feeds

into

the

weld.

Rotating

the

FINE

TUNING

WIRE

SPEED

control

clockwise

increases

wire

feed

speed.

The

scale

around

the

FINE

TUNING

WIRE

SPEED

con

trol

is

calibrated

in

percent

and

does

not

indicate

the

ac

tual

wire

feed

speed.

IMPORTANT:

The

FINE

TUNING

WIRE

SPEED

control

may

be

adjusted

while

welding.

IMPORTANT:

In

the

PULSE

mode,

the

FINE

TUNING

WIRE

SPEED

control

must

be

set

at

50

percent

or

less

when

using

THICKNESS

VOLTS

taps

5

and

6.

5-4.

FAN-ON-DEMAND~

The

fan

motor

is

thermostatically

controlled

and

does

not

turn

on

with

the

unit

POWER

switch.

The

fan

motor

runs

when

main

transformer

Ti

and/or

rectifier

assem

bly

SR3

are

warm.

Under

normal

loading,

the fan

motor

may

not

run.

The

fan

motor

turns

off

when

Ti

and

SR3

are

cool

or

when

the

unit

POWER

switch

is

turned

off.

Normally-open

thermostats

TP1

and

TP2,

and

relay

CR2

control

the fan

motor.

5-5.

OPTIONAL

SPOT/PULSE

PANEL

CON

TROLS

(Figure

5-1)

IMPORTANT:

In

the

PULSE

mode,

the

FINE

TUNING

WIRE

SPEED

control

must

be

set

at

50

percent

or

less.

Exceeding

the

50

percent

control

setting

may

trip

the

circuit

breaker

in

the

motor

control

circuit

stopping

wire

feed.

A.

Selector

Switch

The

Selector

switch

enables

the

operator

to

select

con

tinuous,

spot,

or

pulsed

wire

feed

operation.

1.

Continuous

Position

CONTINUOUS

Placing

Selector

switch

in

CONTINUOUS

posi

tion

and

depressing

the

gun

trigger

feeds

welding

wire

for

as

long

as

the

gun

trigger

remains

closed.

2.

Spot

Position

SPOT

....

Placing

Selector

switch

in

SPOT

position

and

de

pressing

the

gun

trigger

feeds

welding

wire

for

the

length

of

time

set

on

the

SPOT

TIME

control.

3.

Pulse

Position

PULSE

Placing

Selector

switch

in

PULSE

position

and

depressing

the

gun

trigger

feeds

welding

wire

for

the

length

of

time

set

on

the

PULSE

ON

TIME

control.

At

the

end

of

the

pulse

on

time,

welding

wire

stops

feeding

for

the

length

of

time

set

on

the

PULSE

OFF

TIME

control.

The

welding

wire

con

tinues

to

pulse

feed

on

and

off

for

the

selected

times

until

the

gun

trigger

is

released.

The

pulse

option

provides

better

control

of

the

heat

input

to

the

weld

on

thin

gauge

metals,

thereby

decreas

ing

distortion

and

the

likelihood

of

melt-throughs.

B.

Spot

Time/Pulse

On

Time

Control

The

SPOT

TIME/PULSE

ON

TIME

control

enables

the

operator

to

select

from

0.5

to

4

seconds

of

pulse

time

for

spot

operation

or

0.25

to

2

seconds

for

pulse

operation.

Rotating

the

control

clockwise

increases

spot/pulse

on

time.

The

control

scale

is

calibrated

in

percent

and

does

not

indicate

actual

spot/pulse

on

time.

C.

Pulse

Off

Time

Control

The

PULSE

OFF

TIME

control

enables

the

operator

to

select

from

0.25

to

i

second

of

pulse

off

time

for

pulse

operation.

Rotating

the

control

clockwise

increases

pulse

off

time.

The

control

scale

is

calibrated

in

percent

and

does

not

indicate

actual

pulse

off

time.

D.

Burn

back

Time

Control

e.~.

~

BURNBACK

TIME

The

BURNBACK

TIME

control

provides

a

means

of

ad

justing

the

time

period

(up

to

a

maximum

of

0

25

sec

onds)

that

the

welding

wire

remains

electrically

ener

gized

after

the

wire

feeding

has

stopped.

By

adjusting

this

control

properly,

the

welding

wire

will

neither

freeze

in

the

weld

puddle

nor

in

the

contact

tube

of

the

gun.

If

the

welding

wire

freezes

to

the

work,

in

crease

the

burnback

time.

If

the

welding

wire

burns

back

into

the

contact

tube,

decrease

the

burnback

time

Ro

tate

the

control

clockwise

to

increase

the

burnback

time,

and

rotate

the

control

counterclockwise

to

decrease

the

burnback

time.

The

scale

surrounding

the

control

is

cali

brated

in

percent

and

does

not

represent

an

actual

burn

back

time.

OM-113

336

Page

20

SECTION

6

SEQUENCE

OF

OPERATION

f%~

WARNING:

ELECTRIC

SHOCK

can

kill;

a~

MOVING

PARTS

can

cause

serious

injury;

IMPROPER

AIRFLOW

AND

EXPOSURE

TO

ENVIRONMENT

can

damage

internal

parts.



Do

not

touch

live

electrical

parts.



Keep

away

from

moving

parts.



Keep

all

covers

and

panels

in

place

while

operating.

Warranty

is

void

if

the

welding

power

source

is

operated

with

any

portion

of

the

outer

enclosure

removed.

ARC

RAYS,

SPARKS,

AND

HOT

SURFACES

can

burn

eyes

and

skin;

NOISE

can

damage

hearing.



Wear

correct

eye,

ear,

and

body

protection.

FUMES

AND

GASES

can

seriously

harm

your

health.



Keep

your

head

out

of

the

fumes.



Ventilate to

keep

from

breathing

fumes

and

gases.



If

ventilation

is

inadequate,

use

approved

breathing

device.

WELDING

WIRE

can

cause

puncture

wounds.



Do

not

point

gun

toward

any

part

of

the

body,

any

conductive

surface,

or

other

personnel.

HOT

METAL,

SPATTER,

AND

SLAG

can

cause

fire

and

burns.



Watch

for

fire.



Keep

a

fire

extinguisher

nearby,

and

know

how

to

use

it.



Do

not

use

near

flammable

material.



Allow

work

and

equipment

to

cool

before

handling.

MAGNETIC

FIELDS

FROM

HIGH

CURRENTS

can

affect

pacemaker

operation.



Wearers

should

consult

their

doctor before

going

near

arc

welding,

gouging,

or

spot

weld

ing

operations.

See

Section

1

-

Safety

Rules

For

Operation

Of

Arc

Welding

Power

Source

for

basic

welding

safety

information.

6-1.

GAS

METAL

ARC

WELDING

(GMAW)-CON

TINUOUS

AND

GAS

METAL

ARC

WELDING-

PULSED

ARC

(GMAW-P)

IMPORTANT:

Be

sure

that

work

cable

is

installed

into

NEGATIVE

()

weld

output

receptacle

and

weld

cable

from

unit

is

installed

into

POSITIVE

(+)

weld

output

re

ceptacle (see

Section

4-7).

2.

Wear

dry

insulating

gloves

and

clothing.

3.

Thoroughly

clean

joint

area

of

workpiece.

a

CAUTION:

WELDING

CURRENT

can

dam

age

vehicle

computers

and

other

electronic

components.



Disconnect

both

battery

cables

before

weld

ing

on

a

vehicle.



Disconnect

vehicle

computer(s)

before

weld

ing

on

a

vehicle.



Place

work

clamp

as

close

to

the

weld

as

pos

sible

to

avoid

long

electrical

paths.



Be

sure

all

weld

circuit

connections

are

clean

and

tight.

4.

Connect

work

clamp

to

clean,

bare

metal

at

work-

piece.

5.

Select

and

obtain

proper

welding

wire,

and

thread

as

instructed

in

Section

4-13

of

this

Manual.

6.

If

applicable,

place

the

Selector

switch

on

the

op

tional

SPW-1

Panel

in

the

CONTINUOUS

posi

tion

if

continuous

welding,

and

place

the

switch

in

the

PULSE

position

if

pulse

welding

(see

Section

5-5).

7.

If

pulse

welding,

rotate

the

SPOT

TIME/PULSE

ON

TIME

and

PULSE

OFF

TIME

control

to

de

sired

settings

(see

Section

5-5).

8.

Set

a

voltage

condition

with

the

THICKNESS

VOLTS

selector

plug

that

is

appropriate

for

the

base

metal

thickness

and

type

of

shielding

gas

(see

Section

5-2

and

Table

6-1).

IMPORTANT:

It

is

important

that

the

selected

voltage

be

appropriate

for

type

of

weld

and

thickness

of

material.

Be

sure

that

the

weld

bead

is

thoroughly

fused

with

the

base

metal

along

the

total

length

of

the

bead.

If

the

weld

bead

does

not

penetrate

the

base

metal,

increase

the

weld

voltage.

If

the

edges

of

the

bead

cut

into

the

base

metal,

decrease

weld

voltage.

9.

Rotate

the

FINE

TUNING

WIRE

SPEED

control

to

50.

The

control

can

be

adjusted

as

required

while

welding.

10.

Turn

on

shielding

gas

at

the

source.

11.

Adjust

shielding

gas

pressure,

and

purge

shield

ing

gas

hose

as

follows:

a.

Open

left

side

access

door,

release

pressure

spring

on

drive

roll

assembly,

and

pivot

upper

drive

roll

up

and

away

from

lower

drive

roll.

a

WARNING:

Read

and

follow

safety

informa

tion

at

beginning

of

entire

Section

6

before

proceeding.

1.

Install

and

connect

unit

according

to

section

4.

OM-113

336

Page

21

Table

6-1.

Suggested

Parameters

For

Continuous

Gas

Metal

Arc

Welding

(GMAW)

Voltage

Adjustment

Receptacle

1

2

3

4

5

6

Metal

Thickness

Gauges

22-18

18-16

16-14

14-12

12-10 10

or

Heavier

Inches

.035+

.047+

.059+

.067+ .104+

.134+

Millimeters

.8+

1.2+

1.5+

1.9+

2.6+

3.4+

*Amperage

For

.030

in.

(0.8

mm)

Wire

30-55 55-85

85-105 105-130 130-150

150-180

*Amperage

for

.035

in.

(0.9

mm)

Wire

35-65

65-95

95-115

115-140

140-180 175-220

*Amperage

values

are

obtained

by

adjusting

the

FINE

TUNING

WIRE

SPEED

Control.

~

WARNING:

ELECTRIC

SHOCK

can

kill.

cracking

sounding

arc.

(When

optimum

arc

length

is



Do

not

touch

live

electrical

parts.

reached,

arc

will

sound

like

frying

bacon).



Do

nottouch

welding

wire

orany

metal

part

in

16.

If

pulse

welding,

readjust

SPOT

TIME/PULSE

contact

with

it

while

welding.

ON

TIME

and

PULSE

OFF

TIME

control

as

nec-

The

welding

wire

and

all

metal

parts

in

contact

essary.

with

it

carry

weld

current

whenever

the

gun

trig

ger

is

depressed.

6-2.

GAS

METAL

ARC

WELDING

(GMAW)-SPOT

(Models

With

Optional

SPW-1

Panel

Only)

a

WARNING:

Read

and

follow

safety

informa

b.

Energize

welding

power

source,

and

depress

tion

at

beginning

of

entire

Section

6

before

gun

trigger

for

approximately

15

seconds

to

ad-

proceeding.

just

regulator/flowmeter

and

to

purge

the

gas

hose.

1.

Install

and

connect

unit

according

to

Section

4.

IMPORTANT:

Shielding

gas

flow

rate

of

15

to

25

cfh

is

IMPORTANT:

Be

sure

the

work

cable

is

installed

into

typical.

Welding

out

of

position

at

high

wire

feed

speeds

NEGATIVE

()

weld

output

receptacle

and

weld

cable

or

welding

in

a

drafty

environment

will

require

more

from

unit

is

installed

into

POSITIVE

(.4-)

weld

output

re

shielding

gas.

ceptacle

(see

Section

4-7).

2.

Wear

dry

insulating

gloves

and

clothing.

c.

Deenergize

welding

power

source.

CAUTION:

WELDING

CURRENT

can

damage

d.

Close

drive

roll

housing

as

follows:

vehicle

computers

and

other

electronic

Pivot

upper

drive

roll

down

onto

lower

drive

roll,

components.

and

reinstall

pressure

spring.



Disconnect

both

battery

cables

before

weld

ing

on

a

vehicle.

e.

Close

and

secure

side

access

door.



Disconnect

vehicle

computer(s)

before

weld-

12.

Wear

welding

helmet

with

proper

filter

lens

ac-

ing

on

a

vehicle.

cording

to

ANSI

Z49.

1.



Place

work

clamp

as

close

to

the

weld

as

pos

13.

Energize

welding

power

source.

sible

to

avoid

long

electrical

paths.



Be

sure

all

weld

circuit

connections

are

clean

14.

Be

sure

welding

wire

extends

approximately

1/4

and

tight.

in.

(6

mm)

out

gun

nozzle,

position

gun

over

joint,

lower

welding

helmet,

and

depress

gun

trigger.

3.

Connect

work

clamp

to

clean,

bare

metal

at

work-

IMPORTANT:

The

welding

wire

is

not

energized

until

piece.

the

gun

trigger

is

pressed;

therefore,

the

operator

can

4.

Select

and

obtain

proper

welding

wire,

and

thread

accurately

position

gun

on

weld

joint

before

lowering

as

instructed

in

Section

4-13

of

this

manual.

helmet

and

pressing

gun

trigger.

5.

Set

spot

weld

parameters

(weld

voltage,

wire

feed

speed,

spot

weld

time,

burnback

time)

as

15.

Readjust

FINE

TUNING

WIRE

SPEED

control

as

follows:

necessary.

a.

Obtain

sample

piece

of

metal

the

same

type,

but

IMPORTANT:

Adjust

the

wire

speed

to

keep

weld

spat-

approximately

twice

the

thickness

of

final

work

ter

at

a

minimum

while

maintaining

a

steady,

quick-

piece,

and

clean

surface

to

be

welded.

OM-113

336

Page

22

b.

Place

Selector

Switch

on

optional

SPW-1

panel

in

CONTINUOUS

position,

and

set

welding

volt

age

and

wire

feed

speed

parameters

according

to

Steps

8

thru

15

in

Section

6-1.

(Set

voltage

and

wire

feed

speed

for

metal

thickness

of

sam

ple

metal.)

IMPORTANT:

Use

in

CONTINUOUS

position

serves

as

coarse

adjustment

of

unit

for

SPOTmode

operation.

Arc

length

and

weld

puddle

can

not

be

observed

with

spot

welding

nozzle

installed

on

gun.

Several

pieces

of

double

thickness

metal

maybe

required

to

coarse

adjust

unit.

c.

After

voltage

and

wire

feed

speed

parameters

have

been

set,

deenergize

welding

power

source,

remove

continuous

welding

nozzle

from

gun,

and

replace

nozzle

with

appropriate

spot

welding

nozzle.

d.

Obtain

sample

pieces

of

metal

the

same

type

and

thickness

of

final

workpiece.

e.

Place

welding

power

source

in

SPOT

mode,

and

rotate

SPOT

TIME/PULSE

ON

TIME

and

BURNBACK

TIME

controls

to

desired

settings.

IMPORTANT:

The

correct

burnback

time

allows

the

wire

to

burn

back

just

free

of

the

weld

puddle.

If

the

weld

ing

wire

freezes

to

the

workpiece

at

the

end

of

the

weld

cycle,

increase

burnback

time.

If

the

welding

wire

burns

back

into

the

contact

tube,

decrease

burnback

time.

If

the wire

burns

back

into

the

contact

tube,

it

may

be

nec

essary

to

replace

the

contact

tube

in

the

gun.

(See

gun

Owners

Manual

for

contact

tube

replacement

proce

dure.)

f.

Make

several

practice

spot

welds

to

determine

if

weld

parameters

are

set

correctly.

(Refer

to

Table

6-2

to

check

sample

weld.)

To

spot

weld,

place

gun

nozzle

directly

on

work-

piece,

hold

gun

motionless,

and

depress

gun

trigger.

When

trigger

is

depressed,

welding

wire

and

shielding

gas

will

feed

for

the

length

of

time

set

on

the

SPOT

TIME/PULSE

ON

TIME

Control.

IMPORTANT:

The

welding

wire

is

not

energized

until

the

gun

trigger

is

pressed;

therefore,

the

operator

can

accurately

position

gun

on

weld

joint

before

lowering

helmet

and

pressing

gun

trigger.

IMPORTANT:

The

gun

trigger

must

be

held

closed

until

the

SPOT

TIME/PULSE

ON

TIME

control

has

timed

Out,

completing

the

spot

weld

cycle.

If

the

trigger

is

released

before

the

cycle

is

complete,

the

cycle

stops,

and

the

unit

resets

for

another

weld

cycle.

6.

After

all

weld

parameters

have

been

set,

prepare

weld

joint

(see

Sections

9

and

10),

and

weld

final

workpiece.

6-3.

SHUTTING

DOWN

1.

Stop

welding.

2.

Shut

down

welding

power

source.

3.

Turn

off

shielding

gas

at

the

source.

a

WARNING:

HIGH

CONCENTRATION

OF

SHIELDING

GAS

can

harm

health

or

kill.



Shut

off

gas

supply

when

not

in

use.

Table

6-2.

Checking

Weld

Parameters

Weld

Appearance

Cause

Correction

Procedure

Dark

blue

circle

or

small

protru-

sion

visible

on

reverse

side

of

weld.

Voltage

and

wire

feed

speed

parameters

are

set

correctly.

None.

Small

burn-through

on

reverse

side

of

weld.

Voltage

and

wire

feed

speed

parameters

are

set

correctly,

but

spot

time

too

long.

DecreaseSPOTTIME/PULSEONTIMEControI

setting.

Excessive

burn-through

on

re-

verse

side

of

weld.

Welding

voltage

set

too

high.

Repeat

Steps

5a

thru

f

in

Section

6-2

to

reset

voltage

and

wire

feed

speed

parameters.

No

dark

blue

circle

or

small

pro-

trusion

on

reverse

side

of

weld,

but

when

welded

pieces

are

pulled

apart,

a

small

hole

is

torn

in

bottom

piece

of

metal.

Voltage

and

wire

feed

speed

parameters

set

correctly,

but

spot

time

too

short.

Increase

SPOT

TIME/PULSE

ON

TIME

Control

setting.

No

dark

blue

circle

or

small

pro-

trusion

on

reverse

side

of

weld,

and

when

welded

pieces

are

pulled

apart,

there

is

minimal

penetration

into

lower

piece

of

metal.

Welding

voltage

set

too

low.

Repeat

Steps

5a

thru

f

in

Section

6-2

to

reset

voltage

and

wire

feed

speed

parameters.

OM-113

336

Page

23

SECTION

7

MAINTENANCE

&

TROUBLESHOOTING

7-1.

ROUTINE

MAINTENANCE

IMPORTANT:

Every

six

months

inspect

the

labels

on

this

unit

for

legibility.

All

precautionary

labels

must

be

maintained

in

a

clearly

readable

state

and

replaced

when

necessary.

See

Parts

List

for

part

number

of

precautionary

labels.

a

WARNING:

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Shutdown

welding

powersource,

and

discon

nect

input

power

employing

lockout/tagging

procedures

before

inspecting,

maintaining,

or

servicing.

Lockout/tagging

procedures

consist

of

removing

input

power

plug

from

receptacle,

padlocking

line

disconnect

switch

in

open

position,

remov

ing

fuses

from

fuse

box,

or

shutting

off

and

red-

tagging

circuit

breaker

or

other

disconnecting

device.

MOVING

PARTS

can

cause

serious

injury.



Keep

away

from

moving

parts.

HOT

SURFACES

can

cause

severe

burns.



Allow

cooling

period

before

servicing.



Do

not

depress

gun

trigger

while

performing

maintenance

on

gun.

Maintenance

to

be

performed

only

by

qualified

persons.

Table

7-1.

Maintenance

Schedule

Frequency*

Maintenance

Every

month.

Units

in

heavy

service

environ-

ments:

Check

labels,

weld

cables,

clean

internal

parts

and

drive

rolls.

Every

6

months.

Check

all

labels

(see

IMPOR

TANT

block,

Section

7-1).

In

spect

gun

and

cables

(Section

7-iC).

Clean

drive

rolls

(Section

7-iD).

*Frequency

of

service

is

based

cii

units

operated

40

hours

per

week.

Increase

frequency

of

maintenance

if

usage

exceeds

40

hours

per

week.

A.

Fan

Motor

This

unit

is

equipped

with

an

exhaust

fan

and

relies

on

forced

draft

for

adequate

cooling.

The

fan

motor

requires

no

maintenance

other

than

periodic

cleaning

according

to

Section

7-lB.

B.

Internal

Cleaning

a

WARNING:

Read

and

follow

safety

informa

tion

at

beginning

of

entire

Section

7-1

before

proceeding.

Every

six

months,

blow

out

or

vacuum

dust

and

dirt

from

the

inside

of

the

welding

power

source.

Remove

the

out

er

enclosure,

and

use

a

clean,

dry

airstream

or

vacuum

suction

for

the

cleaning

operation.

If

dusty

or

dirty

condi

tions

are

present,

clean

the

unit

monthly.

C.

Inspection

and

Upkeep

a

WARNING:

Read

and

follow

safety

informa

tion

at

beginning

of

entire

Section

7-1

before

proceeding.

Every

six

months,

inspect

the

gun,

hoses,

and

cables.

If

dusty

or

dirty

conditions

are

present,

inspect

the

unit

monthly.

Inspection

should

consist

of

the

following:

1.

Open

side

access

door.

2.

Inspect

gun

for

broken

areas,

cracks,

and

loose

parts;

tighten,

repair,

and

replace

as

required.

3.

Repair

or

replace,

as

required,

all

hose

and

cable;

give

particular

attention

to

frayed

and

cracked

in

sulation

and

areas

where

hose

and

cables enter

equipment.

4.

Remove

grease

and

grime

from

components,

moisture

from

electrical

parts

and

cable.

a

CAUTION:

FLYING

DIRT

AND

METAL

CHIPS

can

injure

personnel

and

damage

equip

ment.



Point

gun

liner

only

in

a

safe

direction

away

from

personnel

and

equipment

when

cleaning

with

compressed

air.

5.

Blow

out

the

gun

wire

guide

liner

with

com

pressed

air

when

changing

wire.

This

will

remove

any

metal

chips

and

dirt

that

may

have

accumu

lated.

6.

Close

and

secure

side

access

door.

D.

Cleaning

Of

Drive

Rolls

a

WARNING:

Read

and

follow

safety

informa

tion

at

beginning

of

entire

Section

7-1

before

proceeding.

MOVING

PARTS

can

cause

serious

injury.



Keep

away

from

moving

parts.

HIGH

ROTATIONAL

SPEED

can

cause

dam

age

to

drive

rolls

and

injure

personnel.



Do

not

allow

drive

rolls

to

rotate

at

high

speed

if

compressed

air

is

used

forcleaning

the

drive

roll

assembly.

It

is

necessary

to

remove

the

drive

rolls

for

proper

clean

ing

of

the

wire

grooves

(see

Section

7-2

for

removal

and

installation

instructions).

Use

a

wire

brush

to

clean

rolls.

IMPORTANT:

Failure

to

properly

maintain

the

drive

rolls

can

result

in

a

buildup

of

wire

particles

which

decreases

the

efficiency

of

the

wire

feeding

operation.

OM-113

336

Page

24

7-2.

REPLACING

DRIVE

ROLL

AND

WIRE

INLET

GUIDE

(Figure

7-1)

As

a

result

of

wear

or

a

change

in

wire

size,

it

may

be

necessary

to

replace

the

drive

rolls

and

wire

inlet

guide.

Proceed

as

follows:

a

WARNING:

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Shut

down

welding

powersource,

and

discon

nect

input

power

employing

lockouVtagging

procedures

before

inspecting,

maintaining,

or

seivicing.

Lockout/tagging

procedures

consist

of

removing

input

power

plug

from

receptacle,

padlocking

lir~

disconnect

switch

in

open

position,

remov

ing

fuses

from

fuse

box,

or

shutting

off

and

red-

tagging

circuit

breaker

or

other

disconnecting

device.

A.

Replacing

Upper

Drive

Roll

a

WARNING:

Read

and

follow

safety

informa

tion

at

beginning

of

entire

Section

7-2

before

proceeding.

1.

Disassembly

a.

Open

and

secure

left

side

access

door.

b.

Release

pressure

spring

from

spring

pin

on

drive

roll

cover.

c.

Remove

cotter

pin

from

drive

roll

cover

pivot

pin.

d.

Remove

pivot

pin,

thereby

freeing

drive

roll

cov

er

from

drive

assembly.

e.

Remove

retaining

ring

and

flanged bearing

from

one

end

of

drive

roll

shaft.

f.

Push

drive

roll

shaft

out

drive

roll

cover

until

drive

roll

falls

from

cover.

Be

sure

that

key

re

mains

in

slot

in

drive

roll

shaft.

Install

drive

roll

into

drive

roll

cover

with

gear

section

of

drive

roll

facing

the

rear

of

the

cover

(side

facing

motor

insulator).

Be

sure

to

align

clearance

hole

in

drive

roll

with

the

two

shaft

clearance

holes

in

drive

roll

cover.

b.

Align

key

in

drive

roll

shaft

with

keyway

in

drive

roll,

and

route

end

of

drive

roll

shaft

without

re

taining

ring

and

bearing

through

hole

in

rear

side

of

drive

roll

cover,

through

drive

roll,

and

out

front

side

of

cover.

c.

Reinstall

flanged

bearing

and

retaining

ring

re

moved

in

Step

le

onto

end

of

drive

roll

shaft.

2.

Assembly

a.

Lower

Wire

Drive

Drive

Roll

Motor

Shaft

And

Key

Wire

Inlet

Guide

Cotter

Pin

Drive

Roll

Cover

spring

Pin

Brush

(2)

Brush

Cap

(2)

Motor

Insulator

Lower

Drive

Roll

Lower

Drive

Roll

Shaft

Self-Locking

Nut

Gun/Feeder

Connector

Opening

Weld

Cable

Terminal

Nut

Drive

Roll

Retaining

Flanged

Cover

Drive

Ring

Bearing

Pivot

Pin

Roll

FIgure

7-1.

Replacing

Drive

Rolls

And

Motor

Brushes

OM-113

336

Page

25

d.

Reinstall

drive

roll

cover

and

pivot

pin

into

drive

roll

assembly.

e.

Reinstall

cotter

pin

onto

pivot

pin.

f.

If

installing

or

changing

lower

drive

roll,

proceed

to

Section

7-2B;

otherwise,

reengage

pressure

spring

over

spring

pin

on

drive

roll

cover,

and

close

and

secure

access

door.

B.

Replacing

Lower

Drive

Roll

a

WARNING:

Read

and

follow

safety

informa

tion

at

beginning

of

entire

Section

7-2

before

proceeding.

1.

Disassembly

a.

If

applicable,

release

pressure

spring

from

spring

pin

on

drive

roll

cover.

b.

If

applicable,

pivot

upper

drive

roll

up,

awayfrom

lower

drive

roll.

c.

Remove

self-locking

nut

from

end

of

lower

drive

roll

shaft,

and

remove

drive

roll.

Be

sure

that

key

remains

in

slot

in

drive

roll

shaft.

2.

Assembly

a.

Install

drive

roll

onto

lower

drive

roll

shaft

align

ing

keyway

in

drive

roll

clearance

hole

with

key

in

drive

roll

shaft.

(Drive

roll

must

be

installed

with

gear

section

facing

the

motor

insulator.)

b.

Reinstall

self-locking

nut

onto

drive

roll

shaft.

c.

Adjust

horizontal

position

of

lower

drive

roll

in

or

out

as

necessary.

To

move

the

drive

roll

in

to

wards

the

motor

insulator,

rotate

the

self-lock

ing

nut

clockwise.

To

move

the

drive

roll

out

away

from

the

center

panel

of

the

unit,

rotate

the

nut

counterclockwise.

IMPORTANT:

Be

sure

that

upper

and

lower

drive

roll

gears

are

properly

meshed

and

the

drive

roll

grooves

are

aligned

when

adjusting

horizontal

position

of

lower

drive

roll.

d.

Reengage

pressure

spring

over

spring

pin

on

drive

roll

cover.

e.

If

replacing

wire

inlet

guide,

proceed

to

Section

7-20;

otherwise,

close

and

secure

side

access

door.

C.

Replacing

Wire

Inlet

Guide

1.

Loosen

wire

guide

securing

screw.

2.

Remove

wire

guide

from

drive

housing.

3.

Install

new

wire

guide

through

mounting

hole

in

left

side

of

drive

housing

(see

Figure

7-1).

IMPORTANT:

Wire

guide

should

be

installed

as

close

to

the

drive

rolls

as

possible

without

touching

them.

4.

Tighten

wire

guide

securing

setscrew.

5.

Close

and

secure

side

access

door.

7-3.

DRIVE

HOUSING

REALIGNMENT

(Figure

4-7)

a

WARNING:

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Shutdown

welding

powersource,

and

discon

nect

input

power

employing

lockout/tagging

procedures

before

inspecting,

maintaining,

or

servicing.

Lockout/tagging

procedures

consist

of

removing

input

power

plug

from

receptacle,

padlocking

line

disconnect

switch

in

open

position,

remov

ing

fuses

from

fuse

box,

or

shutting

off

and

red-

tagging

circuit

breaker

or

other

disconnecting

device.

The

wire

drive

housing

is

made

with

mounting

holes

of

sufficient

clearance

to

provide

adjustment

of

the

wire

guides

up

or

down

in

relation

to

the

drive

rolls.

This

ad

justment

has

been

factory

set,

but

if

readjustment

be

comes

necessary

proceed

as

follows:

1.

Open

access

door.

2.

Loosen

mounting

bolts

and

the

weld

terminal

nut,

securing

wire

drive

housing

to

the

air

baffle.

3.

Slide drive

housing

upward

or

downward

until

the

wire

can

be

fed

straight

through

the

guides

while

seated

in

the

drive

roll.

4.

Tighten

mounting

bolts

and

weld

terminal

nut.

5.

Close

and

secure

access

door.

7-4.

REPLACING

HUB

ASSEMBLY

(Figure

7-2)

If

it

should

become

necessary

to

replace

part

or

all

of

the

hub

assembly,

reinstall

the

new

hub

assembly

as

follows:

1.

Slide

the

following

items

onto

the

single

support

shaft

in

order

given:

a.

Fiber

Washer

b.

Brake

Washer

c.

Hub

d.

Brake

Washer

e.

Fiber

Washer

f.

Keyed

Washer

g.

Spring

h.

Flat

Washer

2.

Rotate

hex

nut

onto

support

shaft.

Hex

nut

should

be

rotated

only

until

a

slight

drag

is

felt

while

turn

ing

hub.

3.

Install

welding

wire

according

to

Section

4-13.

4.

Reinstall

retaining

ring

onto

hub.

OM-113

336

Page

26

7-5.

INSPECTING

AND

REPLACING

MOTOR

BRUSHES

(Figure

7-1)

WARNING:

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Shutdown

welding

powersource,

and

discon

nect

input

power

employing

lockout/tagging

procedures

before

inspecting,

maintaining,

or

servicing.

Lockout/tagging

procedures

Consist

of

removing

input

power

plug

from

receptacle,

padlocking

line

disconnect

switch

in

open

position,

remov

ing

fuses

from

fuse

box,

or

shutting

off

and

red-

tagging

circuit

breaker

or

other

disconnecting

device.

1.

Open

access

door.

2.

Remove

the

brush

caps

(two).

3.

Remove

brushes.

4.

Examine

brushes.

Replace

brushes

if

they

are

chipped

or

broken

or

if

less

than

1/4

in.

(6

mm)

of

brush

material

remains.

5.

Install

brushes,

and

secure

with

caps.

a

CAUTION:

DISASSEMBLY

OF

THE

MOTOR

FIELD

MAGNETS

can

result

in

personal

in

jury

and

equipment

damage.



Limit

drive

motor

repairs

to

brush

replace

ment.

The

field

magnets

are

very

strong.

If

disassem

bly

is

attempted,

injury

to

fingers

and

hands

may

result

from

the

rotor

being

drawn

back

into

the

motor.

The

field

magnets

are

matched

sets,

and

operation

may

be

affected

if

the

magnets

are

tampered

with.

Warranty

is

void

if

the

motor

is

tampered

with.

6.

Close

and

secure

access

door.

7-6.

OVERLOAD

PROTECTION

WARNING:

ELECTRIC

SHOCK

can

kill.

.

Do

not

touch

live

electrical

parts.



Shutdown

welding

powersource,

and

discon

nect

input

power

employing

lockout/tagging

procedures

before

inspecting,

maintaining,

or

servicing.

Lockout/tagging

procedures

consist

of

removing

input

power

plug

from

receptacle,

padlocking

line

disconnect

switch

in

open

position,

remov

ing

fuses

from

fuse

box,

or

shutting

off

and

red-

tagging

circuit

breaker

or

other

disconnecting

device.

A.

Circuit

Breaker

CB1

a

WARNING:

Read

and

follow

safety

informa

tion

at

beginning

of

entire

Section

7-6

before

proceeding.

The

drive

motor

is

protected

from

damage

due

to

over

load

by

circuit

breaker

CB1,

located

under

the

access

door.

Should

an

overload

on

CB1

occur,

the

contactorW

coil

would

open

thereby

stopping

all

output

from

the

welding

power

source.

If

CB1

opens,

manually

reset

the

circuit

breaker

as

fol

lows:

1.

Open

access

door.

2.

Check

for

jammed

wire

or

clogged

gun

liner,

and

correct

problem.

If

motor

overload

occurs

repeat

edly,

repair

or

replace

the

motor

or

liner.

3.

Check

for

binding

drive

gear

or

misaligned

drive

rolls,

and

correct

problem.

4.

Reset

circuit

breaker

CB1

(depress

button);

it

may

be

necessary

to

allow

a

cooling

period

before

the

breaker

can

be

reset.

5.

Close

and

secure

access

door.

6.

Resume

operation.

Hex

Nut

Keyed

Washer

Washer

Fiber

Washer

Retaining

Ring

Spring

*COmpreSsion

Spring

*

Used

With

8

In.

(203

mm)

Spools.

Hub

Brake

Washer

Fiber

Washer

Figure

7-2.

Hub

Assembly

Pef.

SD.072

509G

OM-113

336

Page

27

B.

Circuit

Breaker

CB2

a

WARNING:

Read

and

follow

safety

informa

tion

at

beginning

of

entire

Section

7-6

before

proceeding.

Circuit

breaker

CB2

protects

the

24

volts

ac

winding

of

transformer

Ti

from

overload.

CB2

is

located

under

the

access

door.

Should

CB2

open,

the

contactor

W

coil

would

open

thereby

stopping

all

output

from

the

welding

power

source.

If

CB2

opens,

manually

reset

the

breaker.

7-7.

THERMAL

OVERLOAD

PROTECTION

Rectifier

SRi

is

protected

from

overheating

by

a

normally-closed

thermostat

TP3

wired

in

series

with

relay

CR1

and

contactor

W

coil

circuit.

Should

overheat

ing

occur,

TP3

would

open

causing

CR1

and

thereby

the

contactor

to

drop

out

(deenergize)

and

the wire

drive

motor

to

stop,

thereby

stopping

all

weld

output.

If

this

condition

occurs,

it

will

be

necessary

to

allow

a

cooling

period

before

resuming

operation.

7-8.

PRINTED

CIRCUIT

BOARD

REPLACEMENT

a

WARNING:

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Shutdown

welding

powersource,

and

discon

nect

input

power

employing

lockout/tagging

procedures

before

inspecting,

maintaining,

or

servicing.

Lockout/tagging

procedures

consist

of

removing

input

power

plug

from

receptacle,

padlocking

line

disconnect

switch

in

open

position,

remov

ing

fuses

from

fuse

box,

or

shutting

off

and

red-

tagging

circuit

breaker

or

other

disconnecting

device.

CAUTION:

ELECTROSTATIC

DISCHARGE

(ESD)

can

damage

circuit

boards.



Put

on

properly

grounded

wrist

strap

BE

FORE

handling

circuit

boards.



Transport

circuit

boards

in

proper

static-

shielding

carriers

or

packages.



Perform

work

only

at

a

static-safe

work

area.

INCORRECT

INSTALLATION

or

misaligned

plugs

can

damage

circuit

board.



Be

sure

that

plugs

are

properly

installed

and

aligned.

EXCESSIVE

PRESSURE

can

break

circuit

board.



Use

only

minimal

pressure

and

gentle

move

ment

when

disconnecting

or

connecting

board

plugs

and

removing

or

installing

board.

WARNING:

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Shutdown

welding

powersource,

and

discon

nect

input

power

employing

lockout/tagging

procedures

before

inspecting,

maintaining,

or

servicing.

Lockout/tagging

procedures

consist

of

removing

input

power

plug

from

receptacle,

padlocking

line

disconnect

switch

in

open

position,

remov

ing

fuses

from

fuse

box,

or

shutting

off

and

red-

tagging

circuit

breaker

or

other

disconnecting

device.

MOVING

PARTS

can

cause

serious

injury.



Keep

away

from

moving

parts.

HOT

SURFACES

can

cause

severe

burns.



Allow

cooling

period

before

servicing.

Troubleshooting

to

be

performed

only

by

qualified

persons.

7-9.

TROUBLESHOOTING

a

a

It

is

assumed

that

the

unit

was

properly

installed

accord

ing

to

Section

4

of

this

manual,

the

operator

is

familiar

with

the

function

of

controls,

the

welding

power

source

was

working

property,

and

that

the

trouble

is

not

related

to

the

welding

process.

The

following

table

is

designed

to

diagnose

and

provide

remedies

for

some

of

the

troubles

that

may

develop

in

this

welding

power

source.

Use

this

table

in

conjunction

with

the

circuit

diagram

while

performing

troubleshoot

ing

procedures.

If

the

trouble

is

not

remedied

after

per

forming

these

procedures,

contact

the

nearest

Factory

Authorized

Service

Station.

In

all

cases

of

equipment

malfunction,

strictly

follow

the

manufacturers

proce

dures

and

instructions.

OM-113

336

Page

28

Table

7-2.

Troubleshooting

TROUBLE

PROBABLE

CAUSE

REMEDY

No

weld

output;

wire

does

not

feed.

Line

Disconnect

Switch

in

OFF

position.

Place

Line

Disconnect

Switch

in

ON

position.

.

Improper

electrical

input

con-

nections.

See

Section

4-12

for

proper

input

connections.

Input

voltage

jumper

links

not

in

proper

position.

See

Section

4-12

for

proper

jumper

link

position.

Line

fuse(s)

open.

Check

and

replace

open

line

fuses.

Main

rectifier

SRi

overheating

(thermal

shutdown).

Allow

rectifier

to

cool

down

(see

Section

7-7).

Gun

switch,

or

gun

switch

leads.

See

gun

Owners

Manual.

POWER

switch

Si.

Replace

Si.

Switch

control

relay

CR1.

Replace

CR1.

No

weld

output;

wire

feeds.

THICKNESS

VOLTS

plug

not

secure

in

receptacle.

Secure

connection.

Work

clamp

connection

loose

or

incomplete

due

to

rust,

paint,

etc.

on

surface

of

workpiece.

Check

work

connection

for

good

metal-to-metal

contact.

Contact

tube.

See

gun

Owners

Manual.

Low

weld

output.

Low

input

voltage.

Check

for

proper

input

voltage.

Input

voltage

jumper

link

in

wrong

position.

SeeSection4-i2forproperjumperlinkposition.

Electrode

wire

stops

feeding

while

welding.

~

Circuit

breaker

CB2.

Check

and

reset

CB2

if

necessary

(see

Section

7-6).

Sharp

or

excessive

bend

in

gun

cables

or

liners,

Straighten

gun

cables

and/or

replace

liners

(see

gun

Owners

Manual).

Incorrect

hub

tension.

Readjust

hub

tension

(see

Section

4-li).

Contact

tube

opening

re-

stricted;

burnback

of

wire

into

tube.

See

gun

Owners

Manual.

.

Friction

in

gun.

See

gun

Owners

Manual.

Gun

liner

dirty,

restricted.

See

gun

Owners

Manual.

Broken

or

damaged

gun

liner.

See

gun

Owners

Manual.

Worn

drive

rolls.

Replace

drive

rolls

(see

Section

7-2).

Drive

rolls

misaligned.

Realign

drive

rolls

(see

Sections

7-2

and

7-3).

Excessive

loading

of

drive

mo-

tor.

Clear

restriction

in

drive

assembly.

Drive

motor

brushes.

Check

and

replace

brushes

if

necessary

(see

Section

7-5).

Drive

Motor

M.

Check

and

replace

motor

if

necessary.

Gun

trigger

switch

inoperative

or

leads

broken.

See

gun

Owners

Manual.

Unit

shuts

down

while

welding.

Fan

motor

FM.

Check

and

replace

FM

if

necessary.

OM-113

336

Page

29

Table

7.2.

Troubleshooting

(Continued)

TROUBLE

PROBABLE

CAUSE

REMEDY

No

open-circuit

voltage.

THICKNESS

VOLTS

plug

not

secure

in

receptacle.

Secure

plug

in

receptacle.

Contactor

W

points.

Contact

nearest

Factory

Authorized

Service

Sta

tion.

Gun

switch.

See

gun

Owners

Manual.

Transformer

Ti.

Contact

nearest

Factory

Authorized

Service

Sta

tion.

Plug

PLG2

not

secure

in

recep-

tacle

RC55

(models

with

option

al

Spot

Weld

Panel

only).

Secure

PLG2

into

RC55.

Wire

does

not

feed;

open

circuit

voltage

normal.

Circuit

breaker

CB1

or

CB2.

Reset

CB1

or

CB2

(see

Section

7-6).

Rectifier

SR2.

Contact

nearest

Factory

Authorized

Service

Sta

tion.

Wire

feed

motor

M.

Replace

M.

Spot

weld

timer

does

not

time

out

(models

with

SPW-1

panel).

SPW-1

panel

or

circuit

board

PC5O.

See

Section

7-8,

and

contact

nearest

Factory

Authorized

Service

Station.

Pulsed

wire

feed

operation

not

available.

SPW-i

panel

or

circuit

board

PC5O.

See

Section

7-8,

and

contact

nearest

Factory

Authorized

Service

Station.

SECTION

8

ELECTRICAL

DIAGRAMS

230V.

3

TE

I

64-

84

q

~

POSITIVE

NEGATIVE

Circuit

Diagram

No.

SB-121

827

Diagram

8.1.

Circuit

Diagram

For

MW

4150

Models

OM-113

336

Page

30

AC

B

5C3

Diagram

8-2.

Circuit

Diagram

For

MW

4200

Models

OFF

Ti

ME

PLO

51

68f~1~69

~

S

V

CONT.

<P

S5OA

SPOT

P

UL

SE

____________________

P

Circuit

Diagram

No.

A-ago

568-A

Diagram

8-3.

Circuit

Diagram

For

SPW-i

Panel

<

SI

PLOP

230V.

:3

TE

I

4

PLG2

POSITIVE

NEGATIVE

Circuit

Diagram

No.

SB-i

37

373

NC55

56

OM.113

336

Page

31

OM113

336

Page

32

Wiring

Diagram

No.

C-090

711-B

Diagram

8-4.

Wiring

Diagram

For

SPW-1

Panel

RC

SE

-

~~~~~~~1

I

I

I



I

I

I

I

I

Circuit

Diagram

No.

B-092

817-A

Diagram

8-5.

Circuit

Diagram

For

SPW-1

Panel

Dual

Timer/Pulser

Board

PC5O

OM.113

336

Page

33

SECTION

9

WELDING

TECHNIQUES

&

TROUBLESHOOTING

a

CAUTION:

WELDING

CURRENT

can

dam

age

vehicle

components

and

other

elec

tronic

components.



Disconnect

both

battery

cables

before

weld

ing

on

a

vehicle.



Place

work

clamp

as

close

to

the

weld

as

possible

to

avoid

long

electrical

paths.



Be

sure

gun

to

power

source

as

well

as

cable

connections

to

work

clamp

are

clean

and

tight.



To

be

100

percent

free

of

risk,

disconnect

the

computer(s)

from

the

vehicle.

The

ability

to

produce

a

good

bead

while

using

the

Con

tinuous

Seam

Gas

Metal

Arc

process

is

dependent

on

several

factors.

One

of

the

most

important,

after

wire

and

shielding

gas

selection,

is

the

way

the

gun

is

held.

Cradle

the

gun

in

one

hand

and

rest

the

side

of

the

hand

on

the

workpiece

(avoid

doing

this

on

hot

material);

use

other

hand

to

hold

gun

and

control

the

gun

trigger.

Posi

tion

the

gun

either

toward

or

away

from

the

body

at

a

45

to

60

degree

lead

angle

(see

Figure

9-2).

This

will

give

a

good

view

of

the

arc

and

make

it

easier

to

follow

the

seam

while

wearing

a

helmet.

Maintain

a

1/4

to

5/1

6inch

(6-8

mm)

distance

from

the

bottom

of

the

gun

nozzle

to

theworkpieceduringthearcstartingandwelding

period.

Do

not

pull

the

gun

back

from

the

seam

when

the

arc

starts,

as

this

will

create

a

long

wire

extension

and

result

in

a

poor

weld.

The

welding

wire

is

not

energized

until

the

trigger

is

pressed.

Therefore

the

welding

wire

can

be

extended

1/4

inch

(6mm)

beyond

the

gun

nozzle

and

placed

on

the

seam

before

lowering

the

helmet

and

pressing

the

gun

trigger.

The

gun

can

be

moved

along

the

seam

in

a

steady

move

ment

known

as

the

drag

technique

(see

Figure

9-3),

or

it

can

be

oscillated

a

few

degrees

beyond

each

side

of

the

seam.

The

travel

speed

will

be

regulated

by

the

type

of

weld

bead

required,

the

thickness

of

the

material,

weld

ing

current

selected

and

the

technique

used.

However,

the

average

speed

is

15

to

20

inches

per

minute

(0.4-0.5

mpm).

rn~r

Figure

9-3.

Welding

Techniques

Other

welding

techniques

that

affect

the

weld

character

istics

iii

the

GMAW

welding

process

include

the

back

hand

and

forehand

technique,

and

the

vertical

up

and

vertical

down

positions.

In

the

backhand

technique

the

gun

is

positioned

so

that

the

electrode

wire

is

feeding

in

the

opposite

direction

of

arc

travel.

The

filler

metal

is

be

ing

fed

into

the

weld

metal

previously

deposited.

In

the

forehand

technique

the

gun

is

angled

so

that

the

elec

trode

wire

is

fed

in

the

same

direction

as

the

arc

travel.

The

backhand

technique

generally

yields

a

more

stable

arc

and

less

spatter

on

the

workpiece.

9-1.

GAS

METAL

ARC

WELDING

(GMAW)

-

CONTINUOUS

SEAM

S-

04

2

1

Figure

9-2.

Gun

Position

Figure

9-1.

Continuous

Seam

S.0422

OM-113

336

Page

34

Backhand

Technique

Forehand

Technique

Figure

9-4.

Longitudinal

Gun

Positions

The

vertical

up

and/or

vertical

down

techniques

describe

the

direction

of

arc

travel

when

the

welding

must

be

done

in

the

vertical

position.

In

both

of

these

techniques

gun

positioning

is

extremely

important

because

the

arc

must

be

kept

on

the

leading

edge

of

the

puddle

to

ensure

corn-

plete

weld

penetration.

The

drag

technique

is

generally

employed

when

welding

in

the

vertical

position,

but

when

bridging

a

gap,

the

arc

can

be

oscillated

from

one

side

of

the

work

to

the

other.

Figure

9-5.

Welding

In

The

Vertical

Up

And

Vertical

Down

Position

9-2.

GAS

METAL

ARC

WELDING

(GMAW)-PULSED

In

pulsed

welding

the

filler

metal

is

transferred

to

the

work

during

the

period

of

Pulse

On

Time,

and

cools

dur

ing

the

period

of

Pulse

Off

Time.

When

the

selector

switch

is

placed

in

the

PULSE

position

and

the

gun

trig

ger

is

depressed,

the

welding

wire

feeds

through

the

gun

for

the

length

of

time

set

on

the

SPOT

TIME/PULSE

ON

TIME

control.

At

the

end

of

the

pulse

on

time

the

welding

wire

stops

feeding

for

the

length

of

time

set

on

the

PULSE

OFF

TIME

control.

This

on

and

off

sequence

continues

for

the

amount

of

time

selected

on

the

time

control

until

the

gun

trigger

is

released.

The

pulse

option

provides

better

control

of

the

heat

input

to

the

weld

on

thin

gauge

metals,

thereby

decreasing

distortion

and

the

likelihood

of

burn

throughs.

Set-up

procedures

for

pulsed

seam

welding

are

the

same

as

those

for

continuous

seam

welding

except

that

the

SELECTOR

SWITCH

is

placed

in

the

PULSE

posi

tion

and

the

SPOT

TIME/PULSE

ON

TIME

control

and

PULSE

OFF

TIME

controls

must

be

set

to

the

desired

positions.

Direction

of

Arc

Travel

Direction

of

Arc

Travel

Vertical

Up

Vertical

Down

Figure

9-6.

Pulsed

Seam

OM-113

336

Page

35

9-3.

GAS

METAL

ARC

WELDING

(GMAW)-SPOT

Instead

of

having

a

continuous

or

pulsed

weld

to

join

two

pieces

of

sheet

steel

together,

welding

in

spot

of

1

to

1-1/2

inches

(25-38

mm)

apart

can

be

done.

The

MIG

spot

welding

process

fuses

two

pieces

of

sheet

steel

to

gether

by

penetrating

entirely

through

one

of

the

pieces

into

the

other.

The

spot

process

is

designed

to

be

used

in

any

position.

Little

joint

preparation

is

required

other

than

cleaning

the

surfaces

and

ensuring

that

the

two

pieces

overlap.

Spot

welding

is

based

on

the

same

principles

as

continu

ous

seam

welding

except

that

there

is

no

travel

speed

in

volved;

instead,

there

is

a

welding

time

interval.

The

weld

is

made

by

placing

the

welding

gun

directly

on

the

top

sheet

and

holding

it

motionless

as

shown

in

Figure

9-8.

When

the

gun

trigger

is

depressed,

the

electrode

wire

and

shielding

gas

will

be

continuously

fed.

The

arc

will

be

maintained

for

the

full

length

of

time

set

on

the

SPOT

TIME/PULSE

ON

TIME

control

and

it

will

con

tinue

to

penetrate

in

one

place

until

the

top

sheet

is

welded

with

the

bottom

sheet.

After

the

preset

welding

time

has

elapsed

the

wire

will

stop

feeding,

the

contactor

will

open

and

the

arc

will

be

broken.

The

GMAW

spot

welding

process

produces

little

heat,

therefore

little

distortion

results.

Because

of

the

low

heat

characteristics

of

this

technique,

it

is

often

used

when

welds

are

made

in

close

proximity

to

upholstery,

rubber,

or

other

flammable

materials.

Figure

9-8.

Fender

Repair

With

Spot

Nozzle

Figure

9-7.

Spot

Weld

OM-113

336

Page

36

9-4.

PLUG

WELDS

Plug

welds

provide

a

means

of

joining

two

pieces

of

metal

where

the

thickness

of

the

top

sheet

is

beyond

the

normal

range

of

the

welding

power

source

or

where

sheet

metal

sections

are

too

thin

to

be

spot

welded

or

pulsed

welded

without

producing

distortion

or

burn

throughs.

The

plug

weld

is

made

by

drilling

or

punching

a

hole

in

the

top

sheet,

clamping

the

metal

sections

tightly

together,

and

filling

the

hole

with

a

weldment.

The

plug

weld

can

be

timed

using

the

spot

timer

or

untimed.

Plug

welds

should

be

spaced

1

to

1-1/2

inches

(25-38

mm)

apart.

Plug

welds

on

sample

materials

should

be

made

so

that

proper

parameters

can

be

set.

9-5.

SKIP

WELDING

Skip

welding

provides

a

means

of

making

a

series

of

short

welds,

usually

less

than

3/4

in.,

(18

mm)

in

length

each,

consistent

in

size

and

appearance.

Skip

welding

can

be

accomplished

with

this

unit

by

setting

a

spot

weld

time

and

jogging

the

gun

trigger

off

and

on

again

each

time

the

spot

timer

times

out.

Skip

welds

on

sample

material

should

be

made

so

that

proper

parameters

can

be

set.

9-6.

TROUBLESHOOTING

THE

GAS

METAL

ARC

WELDING

PROCESS

A.

Porosity

Figure

9-9.

Porosity

Remove

spatter

from

the

gun

nozzle.

Check

gas

hoses

for

leaks.

Eliminate

drafts

(from

fans,

open

doors,

etc.)

blowing

into

the

welding

arc.

Place

nozzle

1/4

to

5/16

in.

(6-8

mm)

from

workpiece.

Increase

gas

flow

to

displace

all

air

from

the

weld

zone.

Decrease

excessive

gas

flow

to

avoid

turbulence

and

the

en

trapment

of

air

in

the

weld

zone.

Hold

gun

at

end

of

weld

until

molten

metal

solidifies.

Check

for

frozen

C02

regulator/flowmeter.

2.

Wrong

gas.

Use

welding

grade

shielding

gas.

3.

Dirty

welding

wire.

Use

clean

and

dry

welding

wire.

Eliminate

pick

up

of

oil

or

lubricant

on

welding

wire

from

feeder

or

conduit.

4.

Workpiece

dirty.

Remove

all

grease,

oil,

moisture,

rust,

paint,

undercoating,

and

dirt

from

work

surface

before

welding.

Use

a

more

highly

deoxidizing

welding

wire.

5.

Welding

wire

extends

too

far

out

of

nozzle.

Welding

wire

should

extend

1/4

in.

(6

mm)

out

of

nozzle.

Possible

Causes

1.

Inadequate

shielding

gas

coverage.

Corrective

Actions

OM-113

336

Page

37

B.

Excessive

Spatter

Possible

Causes

Corrective

Actions

1.

Excessive

spatter

when

using

C02

shield-

gas.

Select

lower

voltage

range

or

adjust

FINE

TUNING

WIRE

SPEED

control.

C.

Incomplete

Fusion

(Lack

of

fusion)

Figure

9-10.

Incomplete

Fusion

Possible

Causes

Corrective

Actions

1.

Workpiece

dirty.

Clean

weld

surfaces

of

impurities

(grease,

oil,

moisture,

rust,

paint,

dirt,

etc.)

prior

to

welding.

2.

Insufficient

heat

input.

Select

higher

voltage

range

or

adjust

FINE

TUNING

WIRE

SPEED

control.

3.

Improper

welding

technique.

When

using

a

weaving

technique

dwell

momentarily

on

the

side

walls

of

the

groove.

Provide

improved

access

at

root

of

joints.

Keep

electrode

directed

at

the

leading

edge

of

the

puddle.

Provide

proper

gun

angle.

D.

Lack

of

Fusion

~

~

~

~

Figure

9-11.

Lack

of

Penetration

Possible

Causes

Corrective

Actions

1.

Improper

joint

preparation.

Material

too

thick.

Joint

preparation

and

design

must

be

ade

quate

to

provide

access

to

the

bottom

of

the

groove

while

maintaining

proper

welding

wire

extension

and

arc

characteris

tics.

2.

Improper

weld

technique.

Maintain

normal

gun

angle

to

achieve

maximum

penetration

(see

Section

9-1).

Keep

arc

on

leading

edge

of

the

puddle.

3.

Insufficient

heat

input.

Select

higher

voltage

range

and

wire

speed.

Reduce

the

travel

speed.

Be

sure

welding

wire

extends

1/4

in.

(6

mm)

out

of

nozzle.

OM-113

336

Page

38

E.

Excessive

Penetration

(Burn-Through)

Possible

Causes

Corrective

Actions

1.

Excessive

heat

input.

Select

lower

voltage

range

and

reduce

wire

speed.

Increase

travel

speed.

F.

Cracks

in

Weld

Metal

Possible

Causes

Corrective

Actions

1.

Improper

joint

preparation.

Material

too

thick.

Joint

preparation

and

design

must

be

ade

quate

to

provide

access

to

the

bottom

of

the

groove

while

maintaining

proper

welding

wire

extension

and

arc

characteris

tics.

2.

Heat

input

too

high

causing

excessive

shrinkage

and

distortion.

Select

lower

voltage

range

and

reduce

wire

speed.

Increase

travel

speed.

G.

Waviness

of

Bead

Figure

9-13.

Waviness

of

Bead

Possible

Causes

Corrective

Actions

.

1.

Welding

wire

extends

too

far

out

of

nozzle.

Welding

wire

should

extend

1/4

in.

(6

mm)

out

of

nozzle.

2.

Unsteady

hand.

Support

hand

on

solid

surface.

H.

Humping

.

Figure

9-14.

Humping

Possible

Causes

Corrective

Actions

1.

Excessive

heat

input.

Select

lower

voltage

range

or

increase

travel

speed.

Weld

in

small

segments

and

allow

to

cool

between

welds.

Figure

9-12.

Excessive

Penetration

OM-113

336

Page

39

SECTION

10

AUTO

BODY

REPAIR

APPLICATION

CAUTION:

WELDING

CURRENT

can

dam

age

vehicle

computers

and

other

electronic

components.



Disconnect

both

battery

cables

before

weld

ing

on

a

vehicle.



Place

work

clamp

as

close

to

the

weld

as

pos

sible

to

avoid

long

electrical

paths.



Be

sure

gun

to

power

source

as

well

as

cable

connections

to

work

clamp

are

clean

and

tight.



To

minimize

risk,

disconnect

the

computer(s)

from

the

vehicle.

10-1.

POINTERS

FOR

WELDING

AUTO

BODY

SHEET

METAL

Before

using

this

equipment

to

weld

on

a

finished

piece

of

work,

make

a

few

practice

welds

on

a

sample

piece

of

material

the

same

as

that

of

the

finished

workpiece.

Whenever

possible,

weld

in

the

flat

position

since

this

is

the

easiest

position

to

learn.

Be

sure

that

the

material

to

be

welded

is

clean

and

free

of

paint

and

rust.

The

work

cable

clamp

must

be

attached

to

the

parts

being

welded.

Clean

surface

to

ensure

proper

grounding

and

to

com

plete

the

current

path.

Use

a

.030

or

.023

in.

(0.8

or

0.6

mm)

E7OS-6

wire

and

argon/carbon

dioxide

shielding

gas.

Use

direct

current

straight

polarity

for

reduced

burn

through.

To

obtain

straight

polarity

(electrode

wire

to

negative-work

lead

to

positive),

place

the

Negative/

Positive

weld

output

selector

plug

in

the

NEGATIVE

WELD

OUTPUT

RECEPTACLE

and

connect

the

work

(ground)

lead

to

the

POSITIVE

WELD

OUTPUT

RE-

CE

PTACLE.

IMPORTANT:

For

maximum

penetration

on

thicker

ma

terials

such

as

18

gauge

(1.22

mm)

and

thicker,

recon

nect

for

direct

current

reverse

polarity

(work

lead

to

negative,

electrode

wire

to

positive).

10-2.

PROCEDURE

FOR

WELDING

MILD

STEELS

The

following

are

some

basic

guidelines

that

can

be

used

when

using

this

welding

power

source

to

weld

mild

or

high

strength

steels:

1.

Use

a

power

wire

brush

or

sander

to

remove

paint

to

bare

metal

in

the

area

to

be

repaired.

Two

to

three

inches

(51-76mm)

on

either

side

of

the

weld

area

should

be

cleaned

for

applying

body

filler

af

ter

welding

is

completed.

2.

Remove

damaged

metal

using

hand

cutters,

shears,

or

a

power

hand

grinder

equipped

with

a

cutting

wheel.

3. Fit

a

new

piece

of

sheet

steel

over

the

section

which

was

removed.

The

new

material

should

overlap

the

cut

away

section

by

one

inch

(25

mm).

4.

Clamp

the

new

metal

in

place,

and

prepare

to

spot

weld.

5.

Rotate

the

FINE

TUNING

WIRE

SPEED

control

to

50%,

the

weld

timer

at

30

to

40

percent,

the

burnback

at

40

to

50

percent

and

the

selector

switch

to

the

SPOT

position.

6.

Install

the

spot

nozzle

on

the

gun.

7.

With

the

shielding

gas

and

power

source

turned

on,

place

the

spot

nozzle

and

press

firmly

against

the

new

material

about

1/2

to

3/4

in.

(12-18

mm),

from

the

edge.

Fit

up

must

be

tight

to

assure

good,

repeatable

spot

welds.

8.

Begin

spot

welding

from

the

center

Out

on

each

side.

Distortion

may

occur

if

welding

begins

at

the

corners.

9.

Space

spot

welds

1

to

1/2

in.

(25-38

mm)

apart

around

repair.

Spot

welds

should

be

about

3/16

in.

(5

mm)

in

diameter.

IMPORTANT:

Do

not

make

continuous

welds

around

the

repair

as

this

will

promote

distortion

and

warpage.

10.

After

welding,

remove

the

clamp

and

grind

spot

flush

to

surface.

11.

Smooth

the

joints

with

body

filler

and

finish.

10-3.

PROCEDURES

FOR

WELDING

DOOR

PAN

ELS

IMPORTANT:

Every

experienced

autobody

repairman

will

ha

ye

his

own

methodofperforming

the

following

pro

cedures.

However,

this

in

formation

is

presented

to

show

how,

in

most

cases,

this

welding

powersource

can

make

the

job

easier

and

less

time

consuming.

If

the

door

is

severely

damaged,

but

the

damage

is

pri

marily

in

the

outer

panel,

or

skin,

the

door

can

be

easily

repaired

without

necessarily

installing

a

whole

new

door.

1.

Remove

exterior

molding

and

hardware.

It

is

not

necessary

to

remove

window

regulator,

remote

control

mechanisms,

lock

or

runs.

2.

Remove

door

assembly,

and

place

on

flat

surface

with

edges

of

door

extending

over

edges

of

sur

face

to

provide

room

to

work.

a

Door

Skin

Damage

Inner

Door

Inner

Door

Flange

Figure

10-1.

Cutaway

Of

Door

Panel

Damage

S

.~J4

18

OM-113

336

Page

40

0

4,

9

C,,

1~

SECTION

11



PARTS

LIST

\

\

4

cOa~~

C)

(I)

(I)

(5

1~

U..

OM-113

336

Page

42

3.

If

door

has

an

outer

panel

reinforcement,

break

the

weld.

4.

Grind

off

the

hem

flange

and

remove

the

old

panel.

5.

Repair

any

damage

to

the

inner

panel.

6.

Position

the

new

outer

panel

over

door

and

bend

the

end

flange

over

the

inner

flange.

7.

Spot

weld

outer

panel

reinforcement

to

new

door

panel.

Spot

weld

new

hem

flange

to

inner

panel.

Metal

finish

exterior

surface,

paint

and

assembly

interior

trim

and

hardware.

10-4.

HOW

TO

PREVENT

GLASS

BREAKAGE

AND

SPATTER

ON

WINDOWS

Spatter

and

excessive

heat

can

become

problems

when

welding

near

windows.

Protect

the

windows

by

keeping

them

covered

and

as

far

away

from

the

heat

zone

as

possible.

When

welding

must

be

performed

near

win

dows,

the

windows

should

be

covered

and

protected

from

excessive

heat

by

using

wet

rags.

A

putty

like

sub

stance

which

reduces

heat

transfer

is

available

through

your

welding

supplier,

If

burn

through

and

spatter

be

come

problems,

ensure

that

the

correct

voltage

tap

is

being

used

for

the

size

material

being

welded.

Use

an

ar

gon

and

002

gas

mixture

and

check

travel

speed.

10-5.

PROCEDURES

FOR

WELDING FENDERS

AND

QUARTER

PANELS

When

a

complete

panel

must

be

replaced

it

will

be

nec

essary

to

remove

the

bolts

securing

the

panel

to

the

rest

of

the

structure,

or

to

cut

through

the

spot

welds

if

the

panel

is

welded

in

place.

In

most

cases

a

front

fender

will

be

bolted

in

place,

while

the

other

panels

will

be

either

spot

welded

or

continuous

seam

welded.

The

alignment

of

front

fenders

is

usually

simple

because

the

bolt

holes

are

often

elongated

so

that

the

position

of

the

new

front

fender

can

be

shifted

and

correctly

aligned.

Generally

all

other

panels

are

welded

into

place.

If

the

whole

panel

is

to

be

replaced,

the

old

panel

must

be

removed

by

cutting

along

the

weld

if

welded

by

continu

ous

seam,

or

by

drilling

out

the

spot

welds

if

it

is

spot

welded

in

place.

Car

and

body

manufacturers

have

the

panels

welded

in

different

places,

so

it

will

be

necessary

to

inspect

the

body

to

determine

where

the

welds

are

lo

cated

in

each

case.

After

the

old

panel

is

removed,

the

inner

panels

must

be

carefully

checked,

straightened

or

replaced.

Figure

10-3.

Automotive

Body

Sections

Assembled

With

Continuous

Seam,

Pulsed,

And

Spot

Welds

S

-04

20

The

new

outer

panel

can

then

be

placed

and

held

in

posi

tion

by

vice-grips

or

c-clamp.

When

welding,

start

at

the

center

and

proceed

first

in

one

direction

and

then

the

other.

In

order

to

ensure

reduced

distortion

due

to

heat,

weld

only

a

section

of

2

or

3

in.

(51-76

mm)

at

a

time.

It

is

important

to

constantly

check

the

over

all

temperature

of

the

sheet

steel

around

the

welding

area,

because

it

is

in

this

concentrated

heat

area

that

warpage

and

distortion

will

begin.

Leave

a

gap

and

then

weld

another

short

sec

tion.

When

the

weld

is

completed

it

can

be

hammered

down,

filled

with

body

putty

and

sanded.

10-6.

WELDING

FRAMES

AND

HIGH

STRENGTH

(HSS)

STEELS

The

new

HSS

steels

are

used

on

many

of

the

new

econ

omy

compact

cars.

HSS

steels

can

be

found

in

the

steel

gussets,

brackets,

floor

pans,

and

support

members

of

these

new

models.

HSS

steels

are

thinner

for

weight

re

duction

and

are

heat

sensitive.

As

heat

is

applied,

the

strength

decreases

and

cracking

can

occur,

therefore

the

heat

affected

zone

must

be

kept

as

small

as

possi

ble.

For

this

reason

the

MIG

welding

process

has

be

come

the

preferred

method

for

welding

HSS

steels,

and

the

oxyacetylene

welding

or

brazing

processes,

with

its

wider

heat

affective

area,

are

normally

not

recom

mended.

8.

9.

Continuous

Seam

Weld

Pulsed

Seam

Welds

Spot

Weld

On

Outer

Panel

Reinforcement

Spot

Welds

Inner

Figure

10-2.

Hem

Flange

Removal

S

.04

19

Figure

10-4.

Application

Of

Body

Putty

OM-113

336

Page

41

Quantity

Model

Item

Dia.

Part

MW

MW

No.

Mkgs.

No.

Description

4150

4200

Figure

11-1.

Main

Assembly

1

115521

WRAPPER

11

2

008 072

HOUSING

PLUG

&

PINS,

(consisting

of)

11

058

791

.

TERMINAL,

male

1

pin

88

3

PLG2

008

073

HOUSING

RECEPTACLES

&

SOCKETS,

(consisting

of)

11

058

972

TERMINAL,

female

iskt

88

4

Fig

11-2

BAFFLE,

air

w/components

1

1

5

Fig

11-4

PANEL,

rear

w/components

1

1

6

039

778

RECEPTACLE,

str

2P3W

50A

250V

11

7

PLG1

023 210

CABLE

SET,

pwr

250V

lOga

3/c

9ft

1

1

8

083

175

SKID,

base

2

2

9

605

741

CLIP,

mtg

resistor

.312

ID

core

2

2

10

R2

079

781

RESISTOR,

WW

fxd

25W

50

ohm

1

1

ii

Z

083912

STABILIZER

1

1

12

TP2

089276

THERMOSTAT,

NO

1

1

13

Ti

093

173

TRANSFORMER,

power

main

(200(208)/230)

(consisting

of)

1

1

14

092 028

.

COIL,

pri/sec

1

1

15

Fig

11-5

PANEL,

front

w/components

1

1

16

023

100

CABLE,

interconnecting

grd

11

17

026

843

INSULATOR,

vinyl

blk-43

2

18

010

368

CLAMP,

grd

200A

1

18

130750

CLAMP,grd35OA

19

039

901 PLUG,

jack

blk

(consisting

of)

1

1

20

602

160

SCREW,

slftpg

type

F

filh

8-32

x

.250

11

21

026 978

INSULATOR,

jack

plug

bik

11

22

101

219

.

PLUG,

jack

5/8

x

2-5/8

1

1

23

602

178

SCREW,

set

stl

sch

.250-20

x

.375

knr

cup

point

2

2

24

010521

WIRE,tiebagl6gax5in

1

1

25

019

833

.

STRIP,

cop

.010

x

2.500

x

.750

11

602

171

.

WRENCH,

hex

.125

11

26

++

MWG-i60

GUN

1

26

++

MWG-200

GUN

1

27

115

522

PANEL,

side

1

1

122

679

LABEL,

instruction

1

135

358

LABEL,

instruction

28

089

899

LATCH,

slide

flush

style

2

2

Fig

11-8

RUNNINGGEAR

1

1

113

280

HOSE,

air

4ft

(consisting

of)

11

089

120

CLAMP,

hose .375-450

44

113

129

TUBING,

PVC

.250

ID

x

.062

wall

(order

by

ft)

4ft

4ft

112

863

FITTING,

adapter

hose

kit

1

1

112

811

LABEL,

Auto

Arc

emblem

(rear

panel)

1

1

113

603

LABEL,

Auto

Arc

MW-4150

(top

of

front

panel)

1

113

605

LABEL,

Auto

Arc

MW-4150

(left

side

panel)

113

606

LABEL,

Auto

Arc

MW-4150

(right

side

panel)

1

134

874

LABEL,

Auto

Arc

MW-4200

(top

of

front

panel)

1

134

875

LABEL,

Auto

Arc

MW-4200

(left

side

panel)

1

134

876

LABEL,

Auto

Arc

MW-4200

(right

side

panel)

1

120

714

LINER,

monocoif

.030-035

wire

(consisting

of)

1

120

715

COLLET,

liner

.035

wire

1

087 299

TUBE,

cont

scr

.023

wire

x

1.125

2

000

067

TUBE,

cont

scr

.030

wire

x

1.125

2

000 068

TUBE,

cont

scr

.035

wire

x

1.125

2

087 332

ADAPTER,

tube

contact

1

++For

Parts

List

of

MWG-160

GUN

See

Form

No.

112

934

And

For

MWG-200

GUN

See

Form

No.

113

337.

BE

SURE

TO

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

OM-113

336

Page

43

10

11

Figure

11-2.

Baffle,

Air

w/Components

24

25







SC-132

243

6

31

17

18

19

20

21

Fig

11-3

15

14

28

27

11

OM-113

336

Page

44

Figure

11-2.

Baffle,

Air

w/Components

(Fig

11-1

Item

4)

058

427

085

980

605

941

057 543

057

971

010

191

058628

057

745

058428

026

837

044

995

006

393

083

147

082

907

C6

031

728

082

902

082

875

CR1

072817

052 704

R5

006

537

605

741

R3

059

642

038

620

TEl

026189

034

260

W

035519

024 493

046

685

035

704

083

431

010

145

122

192

031

773

RING,

retaining

spool

NUT,

stl

hex

full

fnsh

.625-11

WASHER,

flat

stl

.640

ID

x

1.000

OD

x

l4ga

thk

SPRING,

cprsn

.845

OD

x

.091

wire

x

1.500

WASHER,

flat

stl

keyed

1.500

dia

x

.l25thk

WASHER,

fbr

.656

ID

x

1.500

OD

x

.l25thk

WASHER,

brake

stl

SPRING,

cprsn

2.430

OD

x

.090

wire

x

2.500

HUB,

spool

INSULATOR,

term

nylon

BAFFLE,

air

RELAY,

end

24VAC

DPDT

GROMMET,

scr

No.

8/10

panel

hole

.312sq

.500

high.

ANGLE,

mtg

RH

capacitor

CAPACITOR,

elctlt

20000uf

35VDC

STRIP,

mtg

center

capacitor

ANGLE,

mtg

LH

capacitor

RELAY,

end

24VAC

DPDT

CLIP,

spring

mtg

resistor

RESISTOR,

WW

fxd

12W

.51

ohm

CLIP,

mtg

resistor

.312

ID

core

RESISTOR,

WW

fxd

25W

10

ohm

LINK,

jumper

term

bik

30A

BLOCK,

term

30A

3P

LINK,

connecting

contactor

terminal

CONTACTOR,

def prp

40A

3P

24V

(consisting

of)

COIL,

cntor

24VAC

40A

VARISTOR,

.6W

175VDC

RECTIFIER,

integ

40A

800V

CIRCUIT

BREAKERS,

man

reset

1

P

5A

250V

CLAMP,

nylon

.500

clamp

dia

DRIVE

ASSEMBLY,

wire

(Fig

11-3)

LABEL,

important

whenever

the

upper

1

1

1

1

1

2

2

1

1

2

6

6

2

2

2

2

2

BE

SURE

TO

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

Item

Dia.

No.

Mkgs.

Part

No.

Description

Quantity

CR2,3

2

3

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

30

31

VR2

SR2

CB1,2

OM-113

336

Page

45

122

192

Figure

11-3.

Drive

Assembly,

Wire

(Fig

11-2

Item

30)

Figure

11-3.

Drive

Assembly,

Wire

BE

SURE

TO

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

Item

Dia.

No.

Mkgs.

Part

No.

Description

Quantity

1

057

551

SPRING,

pressure

drive

roll

1

2

058

549

GUIDE,

wire

inlet

1/16

1

2

087

331

GUIDE,

wire

outlet

.025

1

3

120

370

HOUSING,

drive

roll

feeder

..

1

4

604

741

PIN,

cotter

hair

.042

x

.937

1

5

605

525

NUT,

stl

slflkg

hex

thin

.312-24

1

6

057

590

GEAR,

drive

roll

V

groove

.030-.035

wire

keyed

(top)

1

7

010

929

WASHER,

flat

stl

spr

.375

1

8

044

994

INSULATOR,

motor

1

9

605

287

KEY,

woodruff

.062

x

.250

2

10

M

119

040

MOTOR,

gear

PM

12V

1/25hp

3550RPM

(consisting

of)

1

11

130

820

BRUSH

&

SPRING

2

12

057

432

SCREW,

cap

holder

brush

2

13

079

624

SCREW,

cap

stl

hex

hd

slflkg

.375-16

x

2.250

1

14

602

213

WASHER,

lock

sti

split

.375

2

15

010

910

WASHER,

flat

stl

SAE

.375

1

16

079

633

FITTING,

hose

brs

barbed

nipple

3/l6tbg

1

17

079

772

KNOB,

plstc

T

1.500

Ig

x

.312-18

x

2.000

bar

1

18

601

838

NUT,

brs

hex

.375-16

jam

hvy

1

19

058

553

GEAR,

drive

roll

no

groove

.024

wire

keyed

(bottom)

1

20

058 359

PIN,

pivot

.

1

21

605

854

RING,

retaining

2

22

072 649

BEARING,

drive

assy

wire

1

23

058

360

SHAFT,

drive

roll

1

24

058

363

COVER,

drive

roll

1

25

010 918

PIN,

spring

CS

.156

x

1.500

1

26

072 585

BEARING,

drive

assy

wire

1

8 9

_~

2

21

26

3

10

25

24

9,

23

22

I

13

14

15

20

16

19

18

14

17

SC-072

511-0

OM-113

336

Page

46

Item

Dia.

No.

Mkgs.

Part

No.

Quantity

Mqdel

MWMW

4150

4200

BE

SURE

TO

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

Description

Figure

11-4.

Panel,

Rear

w/Components

(Fig

11-1

Item

5)

1

SRi

137

914

RECTIFIERiWINDTUNNEL,

si

diode

(consisting

of)

1

1

SRi

137

913

RECTIFIERiWINDTUNNEL,

si

diode

(consisting

of)

1

2

TP1

604515

THERMOSTAT,NC

1

2

TP2

006

334

THERMOSTAT,

NC

1

3

D3,4

037 306

DIODE,

rect

1

50A

300V

RP

2

3

D7,9

037 957

DIODE,

rect

275A

300V

RP

2

605

886

WASHER,

lock

stl

intl

tooth

.750

4

605 884

NUT,

stl

hex

half

.750-16

4

4

C1-4

031

689

CAPACITOR,

rectifier

4

4

C14-17

031

689

CAPACITOR,

rectifier

4

5

Dl

,2

037

305

DIODE,

rect

1

50A

300V

SP

2

5

D6,8

037 956

DIODE,

rect

275A 300V

SP

2

6

TP3

086

323

THERMOSTAT,

NO

1

1

7

137

912

BRACKET,

mtg

fan

motor

1 1

8

032

662

BLADE,

fan

lOin

5wg

1

1

9

134982

PANEL,rear

1 1

10

605

227

NUT,

nyl

hex

jam

.750

1

1

11

010290

BUSHING,

strain

relief

1.030

ID

1

1

12

GS1

125

785

VALVE,

24VAC

2

way

custom

port

1/8

orf

1 1

13

089

120

CLAMP,

hose .375-450

1

1

14

604

550

HOSE,

nprn

brd

No.1

x

.187

ID

(order

by

ft)

3ft 3ft

15

FM

032

678

MOTOR,

i/5Ohp

23OVAC

1500RPM

1

1

9

10

11

1

12

13

14

Figure

11-4.

Panel,

Rear

w/Components

SC.072

5O8~D

OM-113

336

Page

47

12

13

)

14

15

SC-131

148-A

2

Figure

11-5.

Panel,

Front

w/Components

OM-113

336

Page

46

Item

Dia.

Part

No.

Mkgs.

No.

Description

Quantity

Figure

11-5.

Panel,

Front

w/Components

(Fig

11-1

Item

15)

1

039

801

RECEPTACLE,

jack

plug

blk

(consisting

of)

1

1

039

800

RECEPTACLE,

jack

plug

red

(consisting

of)

1

1

057

608

RECEPTACLE,

jack

plug

yellow

(consisting

of)

6

2

072

334

.

RECEPTACLE

&

NUT,

jack plug

yellow

1

3

091

542

RECEPTACLE

&

NUT,

jack plug

blk

1

4

091

541

.

RECEPTACLE

&

NUT,

jack plug

red

1

5

010

291

.

WASHER,

flat

nylafil

.625

ID

x

1.250

OD

x

.i25thk

1

6

604

668

.

NUT,

stl

slflkg

hex

med

fnsh

.500-20

1

7

605 787

.

WASHER,

lock

sti intl

tooth

.500

1

8

601 881

.

NUT,

sti

hex

jam

.500-20

1

9

+119

543

NAMEPLATE,

(order

by

model

and

serial

number)

1

113

604

LABEL,

Auto

Arc

warning

1

10

119

191

PANEL,

front

1

11

RC3

073 383

RECEPTACLE,

3

skt

MS-3102A-14S-1S

1

052 236

PLUG,

3

pin

MS-3106A-14S-1P

Amphenol

12

113

742

COVER,

Auto

Arc

open

module

1

13

RC1

048 282

RECEPTACLE

W/SOCKET,

(consisting

of)

1

079

534

TERMINAL,

female

lskt

18-14

wire

4

14

Ri

605828

RHEOSTAT,WW5OW1.5ohm

1

15

51

124

511

SWITCH,

tgl

DPST

40A

600VAC

1

16

PL1

048

573

LIGHT,

md

red

lens

28V

17

023

084

CABLE

&

PLUG,

jack

(consisting

of)

1

17

044

943

CABLE

&

PLUG,

jack

(consisting

of)

1

18

600 318

.

CABLE,

weld

cop

strd

No. 3

(order

by

ft)

As

Reqd

19

039

878

PLUG,

jack

yellow

(consisting

of)

1

19

039

608

PLUG,

jack

red

(consisting

of)

1

20

010

521

.

WIRE,

tie

bag

l6ga

x

5

in

1

21

019833

.

~STRIP,

cop

.010x2.500x.750

1

22

602

178

.

SCREW,

set

stl

sch

.250-20

x

.375

knr

cup

point

2

23

101

219

. .

PLUG,

jack

5/8

x

2-5/8

1

24

026 975

.

INSULATOR,

jack

plug

(yellow)

1

24

602 814

.

INSULATOR,

jack

plug

(red)

1

25

602

160

SCREW,

slftpg

filh

8-32

x

.250

1

26

010

325

BUSHING,

strain

relief

.840

ID

x

.875mtg

hole

2

27

097 824

KNOB,

pointer

1

+When

ordering

a

component

originally

displaying

a

precautionary

label,

the

label

should

also

be

ordered.

BE

SURE

TO

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

OM-113

336

Page

49

Figure

11-6.

SPW

1

Spot

Panel

(Optional)

Figure

11-6.

SPW

I

Spot

Panel

(Optional)

BE

SURE

TO

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

Item

Dia.

No.

Mkgs.

Part

No.

Description

Quantity

1

R50

028

769

POTENTIOMETER,

C

sltd

sft

lIT

2W

750K

ohm

2

3

R51

R52

028

770

028

768

POTENTIOMETER,

C

sltd

sft

l/T

2W

1

meg

ohm

POTENTIOMETER,

C

sltd

sft

liT

2W

350K

ohm

4

5

6

S50

R53

086

895

073

914

605

890

SWITCH,

rotary

3

posn

WASHER,

centering

.437

dia

RESISTOR,

WW

fxd

15W

.25

ohm

7

8

9

10

11

12

13

14

PLG51

PLG

50

PC5O

RC55

080

509

135

560

079

747

079

798

079

747

097

897

008 072

058

971

086

650

113

471

097

922

GROMMET,

scr

No.

8/10

panel

hole

.312sq

.375

high

HOUSING

PLUG

&

SOCKETS,

(consisting

of)

.

TERMINAL,

contact

hdr

24-18

wire

HOUSING,

term

hdr

13

pin

TERMINAL,

contact

hdr

24-18

wire

CIRCUIT

CARD,

dual

timer/pulser

(Fig

11-7)

HOUSING

PLUG

&

PINS,

(consisting

of)

TERMINAL,

male

I

pin

PANEL,

spot

timer

SKP-35

NAMEPLATE,

(order

by

model

and

serial

number)

KNOB,

pointer

1

1

1

2

3

1

9

13

8

4

1

10

Fig

11-7

2

7



~

1

12

SC

Ot~

924D

13

OM-113

336

Page

50

Figure

11-7.

Circuit

Card,

Dual

Tlmer/Pulser

PC5O

BE

SURE

TO

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

Dia.

Part

Mkgs.

No.

Description

Quantity

PC5O

097 897

Figure

11-7.

Circuit

Card,

Dual

Timer/Pulser

(Fig

11-6

Item

10)

A50,51

C50

C51,53,55

C52,56

C54,57,58

C59

CR50

CR51

CR52

D50-53,55,57-66

D56

050,51

Q52

R50

R51

R52,71

R53,57,61

,68,70

R54,56,59

60,62,66,67

R55,58

R63

R64,69

R65

RC5O

RC51

IC,

linear

358

CAPACITOR,

elctlt

lOOuf

35VDC

CAPACITOR

tantlm

2.2uf

35VDC

CAPACITOR

tantim

.22uf

35V

CAPACITOR

cer

mono

.1

uf

5OVDC

CAPACITOR,

elctlt

lOuf

50V

RELAY,

end

24VDC

4PDT

RELAY,

end

24VDC

SPST

RELAY,

end

24VDC

SPDT

SPRING,

hold

down

relay

SOCKET,

relay

l4skt

DIODE,

rect

1A

400V

SP

DIODE,

zener

15V

1W

SP

TRANSISTOR,

NPN

200MA

40V

TRANSISTOR,

NPN

100MA6OV

RESISTOR,

C

1W

820

ohm

RESISTOR,

CF

.25W

100

ohm

RESISTOR,

CF

.25W

lOOK

ohm

RESISTOR,

CF

.25W

4.7K

ohm

009

159

039482

032

820

073

714

073

739

090

573

027

810

099

019

099018

079

844

091

861

026

202

037

449

037

200

073 535

030 018

035 823

035 884

039

331

035

827

035

886

039

333

039

327

035 887

092

648

079

795

072

670

RESISTOR,

CF

.25W

10K

ohm

RESISTOR,

CF

.25W

22K

ohm

RESISTOR,

CF

.25W 18K

ohm

RESISTOR,

CF

.25W

220

ohm

RESISTOR,

CF

.25W

3.3K

ohm

RESISTOR,

WW

fxd

zero

ohm...

TERMINAL,

hdr

13

pin

TERMINAL,

hdr

9

pin

2

1

3

2

3

1

1

1

1

1

1

15

1

2

1

1

1

2

5

7

2

1

2

1

1

1

1

SB~O97

696~A

0>

C)

>~

H~

I

o

Z

a)

a)

Co

-J

IC))

+1

C



(31C~U1C7I

~

-J

O~

Ox

0

Iflg~

Wa)

R69

~O

~

D

0)0)0)

0)0)0)

0)

~

a)-J

N)

OM-113

336

Page

51

Figure

11-8.

Running

Gear

Figure

11-8.

Running

Gear

BE

SURE

TO

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

Dia.

Mkgs.

Part

No.

Description

Quantity

1

108940

2

025193

3

604

423

4

057478

5

022617

6

602389

7

602387

8

602384

9

070 799

10

602250

11

052693

12

052692

13

121

614

14

601

944

15

602211

16

601

869

17

008999

18

052691

19

602213

20

601

871

SCREW,

cap

stl

hexwhd

.250-20

x

.750

HANDLE,

running

gear

GRIP,

handle

.875

ID

x

4.500

BRACKET,

support

tank

CHAIN,

cyl

racks

(consisting

of)

HOOK,

S

blunt

1.500

in

CHAIN,

weldless

2/0

x

27

in

SNAP,

chain

WHEEL,

rubolene

10

in

dia

WASHER,

flat

stl

SAE

.750

RACK,

cylinder

AXLE,

running

gear

(consisting

of)

RING,

retaining

ext

.750

shaft

x

.082

SCREW,

cap

sti

hexhd

.312-18

x

.750

WASHER,

lock

stl

split

.312

NUT,

stl

hex

jam

312-18

CASTER,

plastic

swvl

4

in

dia

ANGLE,

spreader

cyl

rack

WASHER,

lock

stl

split

.375

NUT,

stl

hex

jam

.375-16

4

1

2

1

1

1

I

1

1

4

1

1

2

4

4

4

2122

1

5

11

14

~~15

~17

SC-049

808-E

OM-113

336

Page

52

I