Download Miller MILLERMATIC 80A Specifications
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OM-1038 FORM: September 1975 Effective with Serial No. HF875171 MODEL STOCK NO. CONTROL/FEEDER MILLERMATIC 70A .030 WIRE 057 361 .035 WIRE 057 367 .045 WIRE 057 368 MILLERMATIC 80A MODEL/STOCK NO. SERIAL/STYLE NO. OWNERS .030 WIRE 058 000 .035 WIRE 058 001 .045 WIRE 058 002 DATE PURCHASED MANUAL MILLER ELECTRIC MFG. CO. APPLETON, WISCONSIN, USA 54911 ADDITIONAL COPY PRICE 35 CENTS to NWSA CODE NO. 4579 I,. 5.5. 4 ) 4 4 I H C c C) 4 ~ I C C 4 Mfg. Co.s obligation, under this warranty, is limited to replacing or repairing any defective part or correcting any manufacturing defect without charge during the warranty period if MILLERS inspection confirms the existence of such defects. MILLERS option of repair or replacement will be f.o.b. factory at Appleton, Wisconsin or f.o.b. a MILLER authorized service facility, and therefore no compensation for trans portation costs of any kind will be allowed. 4 C C ) C ) ~ C C) c C) C I ~ The warranty C ~ C) MILLER Electric C ~ is installed and C 4 , to be free from defects in new equipment Mfg. Co., Appleton, Wisconsin, factory workmanship for the periods indicated below, provided the equipment operated according to manufacturers instructions. warrants all material and C ~ C H WARRANTY MILLER Electric C c period, beginning on the date of sale to the original purchaser-user of the equipment, will be as I I follows: 1. 2. 3. Arc CD CD welders, power sources, and components main power rectifiers MHFC-L1 Feeder, MHG-35C1, 20E, 20K, 1 year 3 years and all guns and torches All other Millermatic Feeders 90 days Original 4. 5. DEL-200 (unconditionally) C C 1 year 6 months 6. C) C) 9 6 ) D to trade CD C) C) ~ MILLER Electric ~ directly or Co. will not be liable for any loss or consequential from the use of equipment covered in this warranty. Mfg. indirectly damage or expense accruing C) c C) C) ~ 3 c ~ C) C) C handled C) C I 3 Mag-Diesel engine All other engines 1 year Engine Warranties are covered by the engine manufacturers, subject to their procedures and to be through their authorized local Service Stations or agencies. No warranty will be made in respect accessories, such being subject to the warranties of their respective manufacturers. on -) CD This warranty supersedes all previous MILLER warranties and is exclusive with warranties expressed or implied. no other guarantees or C 9 C) c C) 9 C) Q Q Q Q O Q~Q~~PP QQQ Q Q~~Q p OJ Q ~OrOOTrOO~ObdooObOObThO~oo~Ob dThT~ Turntable Assembly (Stock No. 057 522) Rotates as the operator changes work positions. Eliminates cable strain and reduces wire feed friction. Quick Disconnects (Stock No. 057 459) Permits rapid connection and disconnection of welding cables. TABLE OF CONTENTS Paragraph No. SECTION 1 1 1 1 - - - Page INTRODUCTION 1. General 1 2. Receiving-Handling 1 3, Description Safety 1 1-4. SECTION 2 INSTALLATION 2-1. Location 2- 2. Swivel 2- 3. 115 Volts AC Connections 2 2 4. Contactor Control Connections 2 5. Shielding Gas 2 6. Switch Control Connections 2 7. Weld Cable Terminal And Access Hole 2 2 2 2 - - - - 1 Carrying Handle (80A Models Only) 1 Connections 2- 8. Wire Guide And Drive Roll Gear Installation 2 9. 2 Spool Type Welding Wire Installation (70A Models Only) 2-10. Four Inch Spool Type Welding Wire Installation (70A Models Only) 2-11. Installation Of Welding Wire Eight Inch And Twelve Inch Spool (BOA Only) 2-12. Hub Tension Adjustment 3 2-13. Strain Relief Installation 4 2-14. Welding Wire Threading 4 - Eight Inch . . .. SECTION 3 3 - 3 - - - 4 - - 4 Speed Control 3. Purge Button 5 4. Inch Switch 5 6. Pilot Lamp (8OA Models 5 1. 2. - 1. 5 Only) 5 SEQUENCE OF OPERATION Gas Metal-Arc Welding (GMAW) Shutting Down SECTION 5 5 3 Power Switch SECTION 4 4 3 FUNCTION OF CONTROLS 3-5. Circuit Breaker 3 3 Wire 1. 3- 2. 3 - 5 5 MAINTENANCE Inspection and Upkeep SECTION 6 PARTS LIST TROUBLESHOOTING 6 No. SECTION 1 - INTRODUCTION Weight Model Electrode Wire Electrode Wire Dia. Capability Feed Speed Control Circuit Power at (Pounds) Dimensions (Inches) Gun Net Ship 27 34 Height- 13-1/4 70A Width 50-675 24 Volts ipm AC .030.045 Depth Width Depth 1-1. 13-1/4 - - 45.5 51 22-1/4 1-1. Specifications GENERAL ~~uIi.i~JuiiJ This manual has been prepared especially for use in familiar izing personnel with the design, installation, operation, main tenance, and troubleshooting of this equipment. All informa I Under this heading, installation, operating, and main procedures or practices will be found that if not carefully followed may create a safety hazard to personnel tion presented herein should be given careful consideration to assure optimum performance of this equipment. 1-2. 18 - Height- 17-1/2 80A Figure 11 - I tenance - I RECEIVING-HANDLING I Prior to installing this equipment, clean all packing material from around the unit and carefully inspect for any damage that may have occurred during shipment. Any claims for loss ~~TAN~ damage that may have occurred in transit must be filed by the purchaser with the carrier. A copy of the bill of lading and freight bill will be furnished by the carrier on request if occasion to file claim arises. or Under this heading, installation, operating, and main procedures or practices will be found that if carefully followed may result in damage to equip tenance When requesting information concerning this equipment, it is essential that Model Description and/or Stock Number and Serial (or Style) Numbers of the equipment be supplied. 1-3. not ment. I I DESCRIPTION This control/feeder is of the constant wire feed is designed to be used in conjunction with and potential welding power speed type a constant source. I 1-4. I SAFETY Under this heading, explanatory statements will be found that need special emphasis to obtain the most efficient operation of the equipment. The following definitions apply to CAUTION, IMPORTANT, and NOTE blocks found throughout this manual: SECTION 2 2- 1. LOCATION - INSTALLATION to (Figure 2-1) the portability of this unit, the unit may be located wher desired. Suitable space should be allowed for making ever necessary Connections. 2 - 2. SWIVEL CARRYING HANDLE (80A Models Only) (Figure 2-2) Handle In Normal Position For Carrying By One Person Figure 2-1. Control/Feeder Dimensions Refer to Figure 2-1 for dimensional information on the control/feeder. Lead lengths must be considered when install ing the control/feeder. If the welding power source can be located near the work area, the control/feeder can usually be installed on top of the welding power source. However, due TB-058 000-2 Figure 2-2. 80A Model Carrying Handle OM-1038 Page 1 The carrying handle facilitate two-person on the 80A model carrying. Figure may be rotated to illustrates this 2-5. SHIELDING (Figures GAS CONNECTIONS 2-4 & 3-1) 2-2 usage. Determine 2 - 3. 115 VOLTS AC CONNECtIONS (Figures Attach one end of the 115 volts power cable to the supplied prong female plug as shown in Figure 2-3. It is recom mended that a 16/3 conductor cable be used as the 115 volts power cable. After attachment of the 115 volts plug to the 3 The shielding gas hose which comes from the gun is to be attached to the output shielding gas connector, labeled GAS, on the front panel of the control/feeder. Refer to Figure 3-1 for gas output connections. This connector has right-hand 115 volts power cable is complete, insert the 115 volts plug into the 115 VOLTS AC Receptacle on the rear panel of the control/feeder and rotate the 115 volts plug as far as it will turn in a clockwise direction. This rotating action will lock the plug in the receptacle and prevent the plug from fully pulling should tension be applied to the 115 volts power cable. Connect the remaining end of the 115 volts power cable to a 115 volts ac 60 Hertz power supply. threading. out (Green Hex-Head 2-6. SWITCH CONTROL CONNECTIONS two-pole twistlock receptacle is provided on the front panel of the control/feeder for making switch control con nections. When the switch connected across this receptacle is closed, the contactor in the welding power source will energize, shielding gas will flow, and wire will begin to feed. screwr7~ ~ ~eTerm 4. CONTACTOR CABLE TERMINAL 2-4 & 3-1) terminal weld cable to the weld cable terminal, Insert the weld cable from the gun through the access hole in the front of the control/ feeder and connect the weld cable to the weld cable terminal. Refer to Figures 2-4 and 3-1, respectively, for rear Plug Installation CONTROL CONNECTIONS and front weld cable one end of the contactor control cable to the supplied 2 prong male plug. It is recommended that a 16/2 conductor cable be used for the contactor control cable. After attach ment of the contactor control plug to the contactor control cable is complete, insert the contactor control plug fully into the Contactor Control Receptacle on the rear panel of the control/feeder and rotate the contactor control plug as far as it will turn in a clockwise direction. This rotating action will lock the plug in the receptacle and prevent the plug from the should tension be applied to the contactor out cable. Attach the remaining end of the contactor cable to the contactor control connection point on welding power source. 70A Model Page holes. Ensure that the weld cable terminal is kept clean at all Also ensure that the nut on this terminal is If either one of the above conditions is not secure. times. met, erratic weld current could result. 2-8. WIRE GUIDE & DRIVE LATION (Figure 2-5) Upon initial installation, ROLL GEAR INSTAL as a result of wire size changes, it required drive rolls and wire guides particular wire size. Having selected the related parts, proceed to the following or is necessary to install the accommodate the desired wire size and installation instructions: to TB-004 526 80A Model Figure 2-4. Rear Panel Views 2 access ETANr1 (Figure Attach pulling is connect the 2-4) control control AND ACCESS HOLE provided behind the left access door of the to serve as a junction point for joining to gether the weld cables from the welding power source and the gun. Insert the weld cable from the welding power source through the access hole in the rear of the control/ feeder and A TA-056 17g-1s - 7. WELD control/feeder (Gold & Silver Round Screws) Volts AC . (Figures i nals Figure 2-3. 115 (Figure 3-1) A 2 2 the distance the control/feeder is to be located welding power source and then connect a hose from the shielding gas regulator-flowmeter on the shielding gas supply to the gas input connection on the rear of the con trol/feeder. Refer to Figure 2-4 for gas input connections. This connection has a right-hand thread. from the 2-3 & 2-4) TB-004 452 1. Loosen adjustment wing pressure nut 2-5) and pull downward. Lift gear in an upright position. 2. 3. cover (item 11, Figure (2) up until it is Using a 1/8 inch allen wrench, remove shoulder and then pull Out drive roll gear (1). Insert replacement drive roll gear (1) into gear place with shoulder screw (3). screw (3) Remove nylon hex-nut 4. cover (2) Install shaft 6. (6) and drive roll gear (7) from 7. securing making 1. (item 1, Remove bolt IN Figure 2-6) from spool support shaft (9). replacement lower drive roll gear (7) onto drive (8) and secure in place with nylon hex-nut (6). Loosen Place the spool retaining spring (6) on the hub (7) that it seats tightly against the wire spool. 2-10. FOUR INCH SPOOL TYPE WELDING WIRE STALLATION (70A Models Only) (Figure 2-6) drive shaft (8). 5. Rotate the spool until the guide hole in it aligns with the on the hub (7). Slide the spool onto the hub (7) until it seats against the back side of the hub (7). guide pin sure and secure in 4. 3. screw (9) and pull Install replacement inlet secure with securing and out inlet guide (10) screw 2. Pull off washer (2). spring (3), collar assembly (4), fiber washer (5) and hub (7) from the spool support shaft (9). guide (10). in drive roll NOTE assembly (9). Ensure that the fiber washer (8) support shaft (9). is left the on ~ I Ensure that the inlet guide (10) is given approximately 1/16 inch of clearance from the drive roll gears (1 & 7) and that the flat side of the inlet guide (10) is facing screw (5). 8. Loosen securing screw (5) and pull out outlet guide (4). Insert proper size outlet guide (4) into drive roll assembly and secure with securing screw (5). th at o uti at guide (4) clears the dr ive roll gea rs & 7) by 1/16 inch and that the flat side of the outlet guide (4) is facing screw (9). (1 i TB-057 361-5 Figure 3. 2-6. Installation of Place Welding Wire Spool four inch spool of welding wire Onto the spool so that the wire will pay off from the bottom of the spool in a counterclockwise direction. a support shaft (9) 4. (5), collar assembly (4), and spring (3) spool support shaft (9). Install fiber washer Onto the 5. Place washer (2) onto bolt (1) and turn bolt (1) into spooi support shaft (9) until a significant pressure is felt. 6. Place the hub (7) and spool venient place. retaining spring (6) in a con 2-11. INSTALLATION OF WELDING WIRE EIGHT INCH & TWELVE INCH SPOOL (80A Models Only) 1. 2. Slide the spool of wire Onto the spindle assembly so that the wire will pay off from the bottom of the spool in a counterclockwise direction. Rotate the spool until the hole in the Spool aligns with pin in the spindle assembly. Slide the spool Onto the the spindle assembly until it 3. the spindle. For eight stored seats against the back flange of inch spools only: Slide the supplied spring, beside the spindle assembly, onto the spindle assembly. *Shjpped With Gun TB-057 361-4 4. Figure 2-5. Wire Guide & Drive Roll Installation Depress the two spring loaded stops on the retaining ring retaining ring onto the spindle. When retain in position, release the two stops. and slide the ing ring is 2-12. HUB TENSION ADJUSTMENT 2-9. EIGHT INCH SPOOL TYPE WELDING WIRE INSTALLATION (70A Models Only) (Figure 2-6) Figure 2-6). 1. Remove the spooi retaining spring (item 6, 2. Slide the spool of wire onto the hub (7) so that the wire will pay off from the bottom of the spool in a counter clockwise direction. For 70A Models Figure 2-61 Only: only until Rotate the a adjustment slight drag is felt screw (item 1, while turning spindle. For 80A Models Only: Rotate the hex nut, located on the spindle support shaft, only until a slight drag is felt while turning spindle. end of the OMi 038 Page 3 Step 2 Step 1 Gun Cable TC-057 361-6A Figure 2-7. Strain 2-13. STRAIN RELIEF INSTALLATION Relief Installation (Figure 2-7) 1. Loosen the wing nut on the drive roll pressure ad just ment, pivot the drive roll pressure adjustment down ward, and lift the pressure gear assembly upward until it is in an upright position. 2. Cut off any portion of the free end of the welding wire which is not straight. Feed the welding wire through the inlet wire guide in the drive roll assembly. NOTE The following steps apply strain reliefs. The for both the front and rear only difference being that the rear I gas and weld cables should not be run underneath the handle on the rear of the control/feeder. 1. Loosen the two in the the end run screws clamp. Ensure which secure that the two of the cable that does it. the strain relief cable not 3. Continue to feed the wire loosened are on have the hose clamp screws through 4. welding wire through the outlet guide. Pivot the pressure gear assembly downward making the teeth on the upper gear mesh with lower drive gear. The welding wire must also be in the grooves of the upper and lower drive rolls. sure 2. Pull out the short end of strain relief cable and loop it the eyelet on the control/feeder. through 3. Insert the cable back into the clamp and secure the two 5. screws. 4. 5. Loosen the hose Group strain Pivot the drive roll pressure adjustment upward into on the pressure gear assembly making sure the lower flat washer is above the pressure gear casing. the slot clamp until it comes apart. all cables together (except the gun cable), pull the relief tight and secure the cables with the hose 6. Turn the wing nut on the drive roll pressure adjust ment in a clockwise direction until the drive rolls are tight against the welding wire. Do not overtighten. Further adjustment can be made after the welding clamp. power ation. Ensure that some slack is left in the cables between clamp and the feeder. Also do not tighten the hose clamp too securely as this may cut off gas flow. 2-14. and control/feeder are put into oper the gun to the control/feeder according to the instructions in the Gun Instruction Manual. 7. Connect 8. Energize 9. Place the L source the welding power source. WELDING WIRE THREADING If an external welding wire supply is used, remove the welding wire access hole plug and insert the welding wire through the welding wire access hole. Refer to Figure 2-4 for welding wire access hole location I SECTION 3-FUNCTION 3.1. POWER SWITCH the control/feeder Power Switch in the 10. Depress the INCH switch. This will run the welding through the gun without placing weld current on the welding wire. Release the INCH switch after the end of the welding wire is approximately one inch from the end of the gun tip. wire OF CONTROLS (Figure 3-1) CAUTION Placing the Power Switch on the control/feeder in the On position will apply 115 volts ac to the unit and thereby place it in an operational condition, ready to feed wire and permit shielding gas to flow. Placing the Power Switch in the Off position will shut the control/feeder down. Page 4 ON position. NOTE ~f Even though the Power Switch is in position the unit is apparently shutdown, 115 volts will still be present at the input terminals of the Power Switch for as long as the 115 volts cable is connected to its activated source. and TB -004 452 TB-004 526 iDA Model 80A Model Figure 3-1. Front 3-2. WIRE SPEED CONTROL (Figure 3-1) The WIRE SPEED Control provides a means of determining the rate at which welding wire will be fed into the weld. Rotating the WIRE SPEED Control in a clockwise direction will increase the rate of the wire feed. When the WIRE SPEED Control is set at 0, wire will feed at a rate of 50 1PM, when set at 100, the wire will feed at a rate of 675 1PM. 3- 3. PURGE BUTTON (Figure 3-1) The PURGE Button, located Panel Views on ated it completes the circuit to the motor without having to depress the gun trigger switch. This switch will permit inching of the wire at whatever setting the WIRE SPEED control is at, without energizing the welding circuit or the shielding gas valve. A circuit the front panel of the con trol/feeder, is a momentary contact switch. This switch will energize the gas solenoid and purge the shielding gas line of the gun. The PURGE Button also allows the shielding gas regulator to be adjusted without energizing the welding (Figure 3-1) 3-5. CIRCUIT BREAKER breaker, located on the upper portion of the con trol/feeder front panel, provides protection to the control/ feeder motor. In the event the motor should be placed in an overload condition, the breaker would trip and suspend all output. Should this breaker trip, the RESET Button would have to be manually depressed in order to reset the circuit breaker. circuit. 3-4. INCH SWITCH 3-6. PILOT LAMP (80A Models (Figure 3-1) INCH Switch, located on the front panel of the control/feeder, is a spring loaded toggle switch. When actu The SECTION 4 - 6. Make all connections 2. Rotate the WIRE SPEED Control to the desired 3. Place the Power Switch 7. on Depress the PURGE Button for 5. Energize power one Depress it is on the gun handle. Gas will start to to feed if drive roll pressure is start CAUTION source. The welding wire and all metal parts in contact are energized while welding. Do not touch the welding wire welding, trigger minute. CAUTION to the properly adjusted to prevent slippage. If wire slippage is noticed, tighten the drive roll pressure adjustment wing nut 1/2 turn clockwise. Repeat until slippage stops. Do not tighten wing nut too much. the control/feeder in the On 4. welding approximately 1/2 inch from the the gun flow and wire will setting. position. the Hold the tip of workpiece. instructed in Section 2. 1. as The pilot lamp, when illuminated, indicates that the control/ feeder is in a ready-to.weld state. SEQUENCE OF OPERATION (GMAW) 4-1. GAS METAL-ARC WELDING Only) (Figure 3-1) imperative that proper or any metal part making contact with it. protective protection clothing (welding coat and gloves) and eye (glasses and/or welding helmet) be put on. Failure to comply may result in serious or permanent bodily damage. 4-2. SHUTTING DOWN 1. Turn off the shielding gas at the source. OM-1038 Page 5 2. Place the Power Switch position and the control/feeder in the Off 115 Volts AC plug from the on the remove CAUTION__j source. 3. If is performed in a confinedfailureto the shielding gas supply could result in a buildup of gas fumes, thereby endangering personnel reentering the welding area. Turn off all associated equipment. welding off turn SECTION 5- MAINTENANCE 5- 1. INSPECTION AND UPKEEP 4. Usage and shop conditions will determine the type of maintenance. Inspect equipment 1. Make 2. Inspect sure welding frequency and and follows: as tighten, repair, 3. areas where it as to power source is shut down. 5. for gun required, all hose and cable; give frayed and cracked insulation and enters equipment. Repair or replace, particular attention broken and replace cracks and areas, as loose parts: 6. remove any weld spatter or foreign matter which may accumulate around the nozzle orifice. Use a hardwood stick, never a metal tool, SECTION 6 some moisture components; required. Carefully The data collected here, discusses Remove grease and grime from from electrical parts and cable. of the common the gun wire guide liner with compressed air wire. This will remove any metal chips and Blow out when changing dirt that may have accumulated. TROUBLESHOOTING - problems which may occur in this control/feeder. The assumption of this data is that a proper welding condition has been achieved and has been used until trouble developed. In all the manufacturers recommendations should be strictly adhered to and followed. cases equipment malfunction, If after performing the following procedures It is recommended that the circuit diagram the trouble is still not be used for reference TROUBLE remedied, it is recommended that a servicemen be called. during the troubleshooting. PROBABLE CAUSE Depressing gun switch will not energize control/feeder. Electrode wire is not energized and shielding Power Switch in wrong position or REMEDY defective. Place switch to On position. , Replace defective Power Switch. gas does not flow. Circuit breaker CB1 tripped. Manually circuit breaker by depressing the the front panel of the on control/feeder labeled RESET. red Plug from gun switch is not secure in Switch Control Receptacle on control/feeder. 115 volts ac input plug is not secure in receptacle, 115 volts Wire feeds, but electrode shielding gas wire flows, is not 115 vac Fl or Insert receptacle on plug fully into 115 vac receptacle and plug 1/2 turn clockwise. Replace fuse(s). F2 open. Contactor Control contactor Insert plug fully into Switch Control Receptacle and rotate plug 1/2 turn clockwise. rotate input fuse(s) reset button plug is not secure in welding power source. Insert 1/2 plug fully into receptacle end rotate plug turn clockwise. energized. Control Contactor contactor cable leads not secure on Secure leads to Defect in welding power See source. troubleshooting source Wire feeds erratically. Pressure plug terminals. plug terminals. on drive rolls is insufficient. section in is too Worn drive roll. Page 6 large for wire size power Rotate pressure adjustment wing nut clockwise 1/4 turn increments until wire slippage stops. in Drive roll welding instruction manual. being used. Change to proper size drive roll. Replace drive roll. of ~QI NCR E~~Q2 LINIJUNCTION LEAD END VIEW Circuit Diagram No. CB-057 361-lA Figure 6-1. Circuit Diagram For 70A Model ~RD RC7 I - -~ I CIRCUrt ~Q1 NCR E'Q2 END VIEW Circuit 6-2. Circuit Diagram I UNIJUNCTION LEAD Figure BOARD Diagram No. CB.058 000.1B For 80A Model OM-1038 Page 7 September 1975 FORM: OM-1038 Effective with Serial No. HF87517I MODEL STOCK NO. CONTROL/FEEDER MILLERMATIC bA .030 WIRE 057 361 .035 WIRE 057 367 .045 WIRE 057 368 MILLERMATIC 80A MODEL/STOCK NO. SERIAL/STYLE NO. .030 WIRE 058 000 .035 WIRE 058 001 .045 WIRE 058 002 DATE PURCHASED PARTS LIST MILLER ELECTRIC MFG. CO. APPLETON, WISCONSIN, USA 54911 ,.INT(Q NWSA CODE NO. 4579 1 TD-057 361-A Figure A OM-1038 Page 1 Main Assembly 2 1 Quantity Item Dia. Factory No. Mkgs. Part No Figure Model Main A 1 032 389 2 057 430 3 010233 4 057971 5 010191 058 628 70A180A Description Assembly SCREW, machine steel round hd 1/4-20 WASHER, centering No. 18 SPRING, compression WASHER, flat steel keyed 1-1/2 dia WASHER,fiber5/8IDx i-1/2ODxl/8 - x 1 - 9 026 837 10 057401 11 057402 12 057399 12 025210 WASHER, steel brake SPRING, retaining RING, retaining spool SPINDLE, spool HUB, spool SPRING, compression CLIP, jiffy 1/4 inch (attaching hardware A, J & T) CIRCUIT BREAKER, manual reset 0.7 amp 0-RING, 3/8 x 1/2 (circuit breaker) INSULATOR, terminal nylon CATCH, door (attaching hardware A, J & 1) BUTTON, door nylon DOOR, side left hand (attaching hardware W) DOOR, side left hand (attaching hardware W) 13 057376 CHASSIS 13 025197 CHASSIS 14 003795 14 025213 HANDLE, carrying (attaching hardware H, R, S & V) HANDLE, carrying WASHER, flat steel standard 5/8 (mounting handle) SPRING, compression (mounting handle) PIN, spring 1/4 x 1 (mounting handle) BUSHING, snap 15/16 ID 1.12 mounting hole NIPPLE, galvanized 1/4 NPT x 8 inches lg COUPLING, galvanized 1/4 FPT ADAPTER, brass gas 1/4-18 NPT 5/8-18 female NIPPLE, brass ball & barbed stem 1/4 NUT, brass swivel 5/8-18 right hand BUSHING, snap 1 inch ID 1-3/8 mounting hole BUSHING, snap 1-5/8 ID 2 inch mounting hole BOLT, eye (attaching hardware P, Q & U) 6 057 408 6 058427 7 057 405 7 058428 057 745 601 115 8 CB1 *011 002 035 629 010911 057 543 605 369 15 057357 16 004213 17 602934 18 010604 010 603 010 606 057358 19 004 214 1 1 - 1 - . . - - 1 - 3 - - - 010860 23 057318 24 057327 .CABLE 25 057 359 26 057 360 BLANK, snap-in nylon 3/8 mouting hole BLANK, snap-in nylon 1-3/8 mounting hole RECEPTACLE, male flange grounded twistlock 2P3W (attaching hardware A, J & T) BODY, connector grounded twistlock 2P3W (RC7) CIRCUIT CARD ASSEMBLY (See Fig. B Page 4)(attaching hardware K, M & T) PANEL, control with components (See Page 5)(attaching hardware A, J & T) 29 Figure 30 31 GS1 RC3 C 33 S4 34 S5 36 Si 2 2 2 1 1 1 1 1 1 2 2 2 1 2 1 1 1 - 1 1 1 - 2 way 1/4 IPS port 1/8 orifice (attaching hardware C D & L) (consisting of) 1 .COIL 1 025 212 MOUNTING PAD, solenoid 039855 RECEPTACLE, twistlock 2P2W (attaching hardware A) CAP, twistlock 2P2W (RC3) MOUNT, resilient (attaching hardware B) SWITCH, toggle DPDT 6 amp 125 volts KEY, woodruff 3/32~x 1/2 SWITCH, push button SPDT SWITCH, toggle DPST 6 amp 125 volts *011 043 *011 232 *011 020 1 - 033 050 605136 35 1 2 VALVE, 115 volts 025 590 32 2 1 035601 039 618 5 5 - 22 057314 2 1 RELIEF, strain (consisting of) CLAMP, hose 13/l6to 1-3/4 clamp dia CLAMP, tiller line 1/8 to 1/4 cable 28 1 2 1 057 331 056 442 1 1 - 057 429 056 665 1 1 2 21 RC7 1 1 - 20 27 1 ac or 1 1 1 1 1 1 4 4 1 1 1 1 1 1 1 1 OM-1038 Page 2 13 3 1 9 11 2 4 Quantity Item Dia. Factory No. Mkgs. Part No. Figure Main A 37 602 222 38 057 412 39 057413 40 026 587 40 026 586 41 *057431 42 057 432 43 057 363 44 038 912 45 038 885 46 602 250 47 038 913 48 601 839 49 602344 50 602 341 602 347 51 057 403 51 025 209 52 53 RC2 039759 54 010929 55 019609 56 F1,2 *012618 012617 57 PL1 Model *027 629 027 639 027 631 58 605127 58 004213 59 057410 60 057411 61 057892 010 350 Assembly (Contd) WASHER, lock steel internal tooth 7/16 NUT, nylon 7/16-20 NUT,nylon 1/2-20 MOTOR, gear 1/20 hp (consisting of) MOTOR, gear 1/20 hp (consisting of) 3 3 .BRUSH&SPRING 2 2 SCREW, cap brush holder TERMINAL, power output (attaching hardware G, P & U)(consisting of) BOLT, shoulder round hd sq neck 1/2-13 x 1-11/16 2 2 - - . - . . TERMINAL BOARD WASHER, flat steel SAE 3/4 NUT, brass hex special 1/2-13 NUT, brass hex full 1/2-13 RETAINER,screw FASTENER, screw oval hd No. 5 RECEPTACLE, rivet type screw 1/4 turn (attaching hardware X) DOOR, side right hand (attaching hardware W) DOOR, side right hand (attaching hardware W) NAMEPLATE (order by stock, model, and serial numbers) RECEPTACLE, female flange midget twistlock 2P2W (attaching hardware A, WASHER, flat steel spring 3/8 KNOB, pointer FUSE, miniature glass 5 amp HOLDER, fuse miniature BULB, slide base 120 volts LENS, red jeweled HOUSING, indicator light NIPPLE, galvanized 1/4 NPT x 4-1/2 inches Ig NIPPLE, galvanized 1/4 NPT x 8 inches Ig INSULATOR, motor mount (attaching hardware F) BUSHING, nylon-flanged 3-iF DRIVE ASSEMBLY, wire (See Fig. D Page 6)(attaching hardware E & N) WRENCH,hex - . - . * 602 070 B 605 472 C 602 080 D 602 085 E 605 130 F 601 925 G 601 927 H 079 241 J 602 199 K 602 198 L 602 200 M 603 586 N 604 772 P 602 207 a 602 241 R 602 211 1 1 1 1 1 1 1 1 1 1 4 4 2 2 2 2 - . - - - - - - - - 1 J & T) 1 1 1 2 2 2 2 - Attaching A 70A180A Description S 602 242 601 859 U 601 865 V 604 537 W 601 892 X 601 905 Recommended Spare Parts 1 4 .1 11 - 4 - - 2 - 4 - 4 - 2 - - 9 - 2 - 1 - 4 - 4 - 3 . - - 13 - 4 - 10 14 4 4 BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. Page 3 4 1 Hardware SCREW, machine steel truss hd 6-32 x 3/8 SCREW, machine steel flat hd 6-32 x 1/2 SCREW, machine steel round hd 8-32 x 3/8 SCREW, machine steel round hd 8-32 x 3/4 SCREW, machine steel truss hd 10-32 x 1 SCREW, cap steel hex hd 1/4-20 x 1/2 SCR EW, cap steel hex hd 1/4-20 x 3/4 SCREW, machine steel flat hd 5/16-18 x 3/4 WASHER, lock steel external tooth No. 6 WASHER, lock -steel split No. 6 WASHER, lock steel split No. 8 WASHER, flat steel SAE No. 6 WASHER, flat steel SAE No. 8 WASHER, lock steel split 1/4 WASHER, flat steel SAE 1/4 WASHER, lock steel split 5/16 WASHER, flat steel standard 5/16 NUT, steel hex 6-32 NUT, steel hex full 1/4-20 NUT, steel hex full 5/16-18 RIVET, blind 1/8 dia 1/4 grip RIVET, drive~ steel 1/8 dia 7/32 grip T 1 Dia. Factory Mkgs. Part No. Description Quantity 28) 057 314 Circuit Card Assembly (See C2,3 C4,8,9 031 694 C7 031 693 ClO 031 633 C12 031 721 01-4 026 202 D5 037 250 01 037 824 601 867 CAPACITOR, mylar 0.47 uf 200 volts dc CAPACITOR, ceramic 0.01 uf 500 volts dc CAPACITOR, mylar 0.33 uf 75 volts dc CAPACITOR, electrolytic 80 uf 25 volts dc CAPACITOR, mylar 0.2 uf 200 volts dc DIODE, 1 amp 400 volts straight polarity DIODE, zener 24 volts 1 watt THYRISTOR, 7.4 amp 200 volts WASHER, flat brass 1/4 (mounting 01) WASHER, lock steel external tooth 1/4 (mounting 01) NUT, steel hex jam 1/4-20 (mounting 01) 037261 HEATSINK 1 02 037 289 030 937 R4 030 854 R6 030945 R7 030 940 R8 030 944 R9 030 936 RiO 030 853 Ri 1 030 938 R12 030 934 R20 030 090 12 036 143 TRANSISTOR, unijunction 5OMA 35 volts RESISTOR, carbon 0.5 watt 10 ohm RESISTOR, carbon 0.5 watt 18K ohm RESISTOR,carbon 2 watt 4700 ohm RESISTOR, carbon 0.5 watt 2000 ohm POTENTIOMETER, WW 1 turn 2 watt 5000 ohm RESISTOR, carbon 0.5 watt 33K ohm RESISTOR, carbon 0.5 watt 2200 ohm RESISTOR, carbon 0.5 watt 1200 ohm RESISTOR, carbon 0.5 watt 6800 ohm RESISTOR, carbon 0.5 watt 47 ohm TRANSFORMER, pulse WASHER, lock steel internal tooth No.4 (mountingT2) NUT, steel hex 4-40 (mounting T2) MOUNTING PAD, semi conductor 1 R3 Figure B 031 643 010 915 602 208 602 196 601 858 026 750 Fig. A Page 4 Item 2 3 1 1 1 4 1 1 1 - 1 - 1 - 1 1 1 1 1 1 1 1 1 1 1 1 - 1 - 1 COMPONENTS TO BE REPLACED BY QUALIFIED PERSONNEL ONLY TA-057 314 Figure BE SURE TO PROVIDE B Circuit Card Assembly STOCK, MODEL. AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. OM-1038 Page 4 Item Dia. Factory No. Mkgs. Part No. Figure C 71 72 Panel, Control 026 837 CR1 *034 841 73 004 255 74 010 301 75 031 251 76 RC5 038784 77 78 039 756 R21 030 940 601 375 79 80 Cl 81 Ti 82 Ri 83 SRi 84 R2 85 R5 *031 698 *036 135 *030 942 035 914 *030 941 *030 943 604 632 BB 602 070 CC 602 072 DD 604 850 EE 602 196 FF 602 199 GG 602 198 HH 601 858 JJ 601 859 KK 604 470 - With Components (See Fig. A Page 2 Item 29) INSULATOR, terminal nylon RELAY, 24 volts ac DPDT (attaching hardware BB, FF & JJ) PANEL, mounting components BUSHING, brass 0.106 ID x 1/40D x 5/16 (attaching hardware DD, FF & JJ) BRACKET, mounting RC5 (attaching hardware KK) CONNECTOR,edge 10 pin (attaching hardware AA, EE & HH) STRIP,terminal 1 pole RESISTOR, carbon 0.5 watt 2000 ohm RING, mounting capacitor (attaching hardware BB, FF & JJ) 3 CAPACITOR,electrolytic250uf ll5voltsdc TRANSFORMER, SNC P6930 115/24 volts ac (attaching hardware BB, FF & JJ) RESISTOR, WW fixed 12 watt 10 ohm (attaching hardware BB, FF & JJ) RECTIFIER, integrated 25 amp 400 volts (attaching hardware CC, GG & JJ) RESISTOR, WW fixed 100 watt 5 ohm (attaching hardware BB, FF & JJ) 1 - 1 1 - 1 1 - 1 1 1 1 - POTENTIOMETER, carbon 1 Attaching AA Quantity Description . 1 .. 1 1 1 1 turn 2 watt 15K ohm Hardware SCREW, machine steel round hd 4-40 x 1/2 SCREW, machine steel truss hd 6-32 x 3/8 SCREW, machine steel truss hd 6-32 x 5/8 SCREW, machine steel round hd 6-32 x 3/4 WASHER, lock steel internal tooth No. 4 WASHER, lock steel external tooth No. 6 WASHER, lock steel split No. 6. NUT, steel hex 4-40 NUT, steel hex 6-32 RIVET, blind 1/8 dia 1/16 grip 2 - 10 - 1 - 1 - . ... 2 - 11 - 1 . 2 - 12 - 2 .. 71 73 72 74 75 .76 79 84 80 83 82 81 TA-057 364-A Figure C * Panel, Control - With Components Recommended Spare Parts BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. Page 5 Item Factory No. Part No. 057 892 Drive Assembly, Wire (See 101 056 663 102 010 285 103 056 164 104 601 888 105 602 242 106 010 231 107 010 910 108 056 350 109 057 409 110 604 741 111 604 624 112 010 661 PIN, machined SCREW, thumb 1/4-20x 1/2 COVER, gear NUT, steel wing 5/16-18 WASHER, flat steel standard 5/16 SPRING, compression WASHER, flat steel SAE 3/8 FASTENER, pinned HOUSING, drive roll PIN, cotter hair 0.042 x 15/16 SCREW, machine steel fillister hd 1/4-20 PIN, spring 1/8 x 5/8 Figure D Quantity Description Fig. A Page 3 Item 61) 1 - 1 - 1 - 1 - - x 2 1/2 103 Gear, Drive 108 Wire Guide TB-057 361-4 Tc-o57 362-B Figure D Figure E Drive Assembly, Wire Wire Diameter Fraction Gear, Drive &_Type Decimal Metric Kit No. Part No. 057 775 .030 hard .030 .8MM 057 908 .035 hard .035 .9MM 057 909 .045 hard .045 1.2MM 057 910 Wire Guide Nos. Type Inlet V-groove 056 182 V-groove 056 182 V-groove 056 184 (Upper) 057 762 (Lower) 057 776 Assembly (Upper) 057 772 (Lower) 057 759 BE SURE TO PROVIDE STOCK, Wire Guide And Drive Gear (Upper) 057 771 (Lower) MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. OM-1038 Page 6