Download Miller Electric SPW-1 Technical data

September1987
Read
and
understand
the
entire
manual, with special emphasis on
the safety material throughout the manual, before
FORM: 113336
Effective With Serial No. JH159463
contents of this
installing, operating,
or
maintaining
this
~
~
equip
ment. This unit and these instructions are for use
MODEL
only by persons trained and experienced in the safe
operation of welding equipment. Do not allow un
AUTO ARC MW 4150
trained persons to install, operate, or maintain this
unit. Contact your distributor if you do not fully
SPW 1
understand these instructions.
OWN ERS
MANUAL
ill
1T(T~Fl~____
I ~f
I II %\~ r~
MILLER ELECTRIC MFG
718 S. BOUNDS ST. P.O. Box 1079
APPLETON, WI 54912 USA
NWSA CODE NO. 4579
PRJNTED IN USA.
CO.
ONE YEAR LIMITED WARRANTY
Miller Electric Mfg. Co. warrants to the buyer
for personal,
purchases this Auto Arc Welder (Welder)
that this Welder
family or household purposes (Consumer)
will be free from defects in material and workmanship for a
period of one year from the date of purchase. This warranty
covers only the original purchaser of this Welder. Miller Electric
does not authorize any party, including its authorized
distributors, to offer any other warranty on behalf of Miller
Electric. Upon expiration of the warranty period, Miller Electric
shall have no further liability related to the Welder, except on
warranty claims made during the warranty period.
COVERAGE
-
who
C4
5t~~
~
C.~*
~
THIS WARRANTY IS OFFERED IN LIEU OF ANY OTHER
Cr4
EXPRESS WARRANTY; AND, EXCEPT TO THE EXTENT
PROHIBITED BY APPLICABLE LAW, THE DURATION OF
IMPLIED
ALL
WARRANTIES, INCLUDING BUT NOT
LIMITED TO THE IMPLIED WARRANTIES OF MERCHAN-
Cs
TABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IS
LIMITED TO THE DURATION OF THIS WARRANTY.
Some
~
~
states
do not allow limitations
on
how
long
implied
an
warranty lasts, so the above limitation may not apply to you.
This warranty gives you specific legal rights, and you may also
have other
rights
which vary from state
to state.
REMEDY FOR DEFECTIVE WELDER
Upon receipt of any
defective Welder, Miller El~ctric will, at its option, repair or
replace the defective Welder at its expense, refund or credit
the purchase price (less reasonable depreciation based on ac
we) use), or reimburse the Consumer for the cost of repair or
replacement at an approved Miller Electric warranty station,
provided that the purchaser of that Welder has followed the
procedure for obtaining warranty performance set forth below.
The Welder so repaired or used as a replacement will be ship
ped to the purchaser of the defective Welder, with transporta
tion charges prepaid to any destination in the continental
United States (transportation charges on shipments to Alaska
or Hawaii will be paid only to the nearest port of export).
THE PuRCHASERS
REMEDIES
FOR A DEFECTIVE
WELDER, TO THE EXTENT PERMITTED BY APPLICABLE
LAW, ARE LIMITED TO THE REMEDY PROVIDED BY THIS
WARRANTY:
AND, TO THE EXTENT ENFORCEABLE
UNDER APPLICABLE LAW, MILLER ELECTRIC SHALL l~
NO EVENT BE LIABLE FOR
CONSEQUENTIAL, INCIDENTAL
OF, OR
OR SPECIAL DAMAGES ARISING OUT OF THE USE
INABILITY TO USE, THE WELDER, WHETHER BASED ON
BREACH OF THIS WARRANTY,
MILLER
ELECTRICS
NEGLIGENCE OR OTHER TORT, OR ON ANY THEORY OF
STRICT LIABILITY.
Except
as
specified below,
Millers
warranty does
~
~
apply
not
components having normal useful life of less than
year, such as spot welder tips, relay and contactor
to
one
Ill
points.
with the welding wire including
parts that come in contact
nozzles and nozzle insulators where failure does nOt result from
defect
in
workmanship
or
Some states do not allow the exclusion
sequential or incidental damages,
not apply to you.
so
or
limitation of
con
the above limitations may
material.
PROCEDURE FOR OBTAINING WARRANTY PERFORMANCE
Miller shall be
~
honor warranty claims
in the event of failure resulting from
required
to
Equipment
following periods from
to the original user:
ranted
within the
ment
~
1. Arc
2
the date of
on
war
defect
a
delivery of Equip-
welders, powersources, and components 1
Original
(labor
-
main power rectifiers
1 year only)
year
3 years
3. All
4.
~
welding guns, feeder/guns and plasma torches... ~
60 days
Replacement or repair parts, exclusive of labor
.
.
As
soon as
any defect in a Welder becomes known, the pur
chaser of the Welder must, within thirty (30) days, notify an
approved Warranty Station or Miller Electric in writing of the
defect, The purchaser must then, within the one year warranty
period, return the Welder to Miller Electric at the following address:
Miller Electric
Mfg.
Co.
718 South Bounds Street
P.O. Box 1079
WHAT IS NOT COVERED
to any
4
Welder
subjected
This warranty does not extend
to misuse, neglect, accident, or in
-
warranty repair by anyone except Miller Electric. Further, this
warranty only extends to those purchasing the Welder for per-
sonal, family
dustrial
or
users are
household
given
a
purposes.
Commercial
different warranty.
and
in-
Appleton, Wisconsin 54912
All
transportation charges
prepaid.
to
Warranty Station
or
Miller Electric
must be
.
~
Feb. 8,1988
ERRATA SHEET
After this manual
appearing later
was
printed, refinements
in
equipment design
occurred. This sheet lists
exceptions
FORM: 113336
to
data
in this manual.
Part
Replaced
**
No.
With
8-33
023 083
600 318
113 280
.089 120
113 129
112863
Description
CABLE, weld-stranded No. 3 (order by ft)(Eff w/JJ337881)
HOSE, air (Eff w/JH296877)(consisting of)
.cLAMP;hose3/8-.45odia
.TUBING, 1/4IDxl/16(orderbyft)
.FITTING,adapter
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
Quantity
3ft
1
2
4ft
1
TABLE OF CONTENTS
Page
Section No.
SECTION 1
1.
1
1
1
1
-
-
-
2.
3.
4.
SECTION 2
2
2
2
2
2
2
2
-
-
-
-
-
-
-
3
3
3
3
3
-
-
-
-
-
-
4.
5.
6.
7.
4
4
4
4
4
-
-
-
-
-
-
5
5
5
5
-
-
-
-
Electrical
5.
6.
9.
6
6
6
-
-
-
-
6
-
-
14
14
Welding Power Source On Running Gear
17
Input Connections
17
Spot Weld Panel
Assembly
Installation Of Welding Wire Spool
ThreadingTheWeldingWire
MWG 200 Welding Gun Connections
Installation Of The
18
Work Cable
19
Installation Of
20
20
21
22
Shielding
Gas
OPERATOR CONTROLS
-
1.
Power Switch
23
Pilot
3.
Thickness/Volts Selector
4.
5.
Fine Tuning/Wire Speed Control
Optional Spot Pulse Panel Controls
23
23
23
23
6.
Fan-On-Demand
24
Light
MAINTENANCE & TROUBLESHOOTING
-
Transformer
24
2.
Fan Motor
3.
Removal Of Drive Roll Gears
4.
Cleaning Of Drive Rolls
5.
Circuit Breakers
6.
Troubleshooting
25
25
25
25
25
-
WELDING PARAMETERS, TECHNIQUES AND SET-UP
1.
Continuous Seam Gas Metal Arc
2.
Set-Up
3.
Pulsed Gas Metal Arc
4.
6.
Spot Welding
Plug Welds
Skip Welding
7.
Weld Defects: Causes And Corrective Actions
8.
Procedures For
Welding
Welding
For Continuous Gas Metal-Arc
Welding
6-14.
Welding
Welding Door Panels
Procedures For Welding Fenders And Quarter Panels
Welding Frames And High Strength (HSS) Steels
Procedures For Welding Thin Sheet Metal
Welding Mild Steels
How To Prevent Glass Breakage And Spatter On Windows
6-15.
Shutdown Procedures
6
-
16
2.
6 -5.
6
14
INSTALLATION
-
3.
4.
13
13
13
13
Volt-Ampere Curves
Description Of Supplied Parts
Additional Supplies Required
Location
SECTION 6
6
11
INTRODUCTION
-
Installation Of The
5-1.
-
1
Standards Booklet Index
1.
SECTION 5
5
7
Welding
2.
SECTION 4
4
Arc
Receiving-Handling
Description
Duty Cycle
-
-
1
General Information And Safety
3 -7.
3
8..
3
Introduction
General Precautions
1.
SECTION 3
3
SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
-
2.
3.
6
9.
6-10.
-
6-11.
6-12.
6-13.
No.
Procedures For
30
31
32
33
33
33
33
36
36
37
37
38
38
38
38
I
I
I
SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
REGLES DE SECURITE POUR LE FONCTIONNEMENT DU POSTE DE SOUDAGE A LARC
SECTION 1
SECTION 1
-
-
We learn
by experience.
Learning safety through personal experience, like a
child touching a hot stove is harmful, wasteful, and un
wise. Let the experience of others teach you.
1-1. INTRODUCTION
Contrairement a lappren
tissage de Ia vie, Iapprentissage de Ia sØcuritØ par ox
pØrience personnelle, comme lenfant qui touche un
poŒle chaud, est dangereux, imprudent et inutile.
lnstruisez-vous donc de lexpØrience dautrui.
Safe practices developed from experience in the use of
and cutting are described in this manual.
Research, development, and field experience have
soudage
1-1. INTRODUCTION
-
welding
evolved reliable
equipment
and safe
installation,
tion, and servicing practices. Accidents
equipment is improperly used
reason for the safe practices may
Some
are
based
on common
occur
opera
when
The
or
maintained.
not
always be given.
sense, others may require
It is wiser to follow the
explain.
technical volumes to
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
observe
to
these
safe
practices may cause
safety becomes a habit,
serious
the
injury or death. When
equipment can be used with confidence.
These safe
1
-
practices
cutting; and 2
-
Arc
divided
are
General Precautions,
into two Sections:
welding
Welding (and Cutting) (only).
common
to arc
and
Reference standards: Published Standards
on safety are
complete pro
cedures than those given in this manual. They are listed
also available for additional and
more
in the Standards Index in this manual. ANSI Z49.1 is the
most
complete.
The National Electrical
Code, Occupational Safety and
Administration, local industrial codes, and local
inspection requirements also provide a basis for equip
ment installation, use, and service.
Health
-
Des mØthodes de sØcuritØ issues de lexpØrience
du
et du coupage sont dØcrites dans le manuel. La
recherche, le progres et lexpØrience dans ce domaine
ont dØveloppØ un materiel fiable et des mØthodes de
sØcuritØ pour linstallation, le fonctionnement et lentre
tien. Des accidents se produisent lorsque le materiel est
inadequatement utilisØ ou entretenu. La raison de ces
mØthodes de sØcuritØ peut ne pas Œtre toujours donnØe.
Certaines sont fondØes sur le sens commun, dautres
demanderont a Œtre expliquees par des livres techni
ques. II est plus sage de suivre les rŁgles.
Lisez et comprenez
GENERAL PRECAUTIONS
Different
arc
and fluxes
welding processes, electrode alloys,
produce different fumes, gases,
can
and radiation levels. In addition to the information
in this manual, be
sure to
consult flux and elec
trode manufacturers for
and
precautionary
specific technical data
measures
concerning their
Manquer dobserver ces mØthodes de sØcuritØ pourrait
entrainer des blessures graves ou mŁme Ia mort. Quand
Ia sØcuritØ devient une habitude, le materiel peut alors
Œtre utilisØ en toute confiance.
Ces mØthodes de sØcuritØ sont divisØes en deux sec
tions:
1
Precautions gØnØrales,
communes
au
soudage et au coupage a larc, et 2 Soudage a larc
(et coupage) (uniquement).
-
-
Normes de rØfØrence: Des publications des normes
amØricaines de sØcuritØ sont aussi a votre disposition
modes opØratoires plus complets que
pour dautres
ceux du present manuel. Elles sont donnØes dans lln
dex des Normes de ces regles de sØcuritØ. ANSI Z49-1
est Ia plus complete.
Les codes de IACNOR,
les codes provinciaux et
municipaux donnent aussi les exigences pour une in
stallation,
une
utilisation et
un
entretien srs.
PRECAUTIONS -GENERALES
Plusieurs procØdØs du soudage a larc, des lec
trodes allis,
et los flux peuvent produire des
et
niveaux
de
vapeurs,
gal,
rayonnement
diffØrents. Pour tout renseignement supplØmen
taire a ce manuel, consultez aussi los fabricants
des lectrodes
et des flux afin dobtenir
los
renseignements
de
mesures
techniques spcifiques
precaution
lee
leurs
et
concernant
matØriaux.
material.
A.
A.
mØthodes de sØcuritØ avant
dinstructions.
1-2.
1-2.
ces
dessayer dinstaller, de faire fonctionner ou de rØparer
Pour votre sØcuritØ personnelle et celle.
lappareil.
dautrui, conformez-vous a ces regles et aux manuels
Prevention des brlures
Burn Prevention
Portez des vØtements de protection des gants a crispin
pour le soudage, un casque et
des chaussures de sØcuritØ. Boutonnez le col de votre
chemise et les pattes de vos poches, et portez des pantalons sans revers pour Øviter que des Øtincelles et dii
laitier ne sy introduisent.
-
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
Wear helmet with
-
safety goggles or glasses with side
appropriate filter lenses or plates
shields underneath,
(protected by clear cover glass). This is a MUST for
welding or cutting, (and chipping) to protect the eyes
spØcialement dØsignØs
Portez un masque
Øcrans latØ-raux de
des couvre-Ientilles
soudage
ou
le
avec
lunetles de sØcuritØ
ou
avec
protection, des lunettes filtrantes
(proteges
coupage
par
(et
un verre
le
ou
clair). Pour le
burinage),
il
est
113 336 Page 1
from radiant energy and flying metal. Replace cover
glass when broken, pitted, or spattered. See 1-3A.2.
OBLIGATOIRE de protØger ses yeux contre Ienergie de
rayonnement et les Øclats de metal. Remplacez le verre
protecteur lorsquil est brisØ, piquØ ou quil a reu des
Avoid
projections.
oily
or
Hot metal
should
greasy
such
never
clothing.
A
spark may ignite them.
electrode stubs and
be handled Without gloves.
workpieces
as
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 im
mediate treatment of flash burns of the eyes and skin
burns.
plugs should
Ear
in
be
worn
when
working
overhead
on
confined space. A hard hat should be
others work overhead.
a
worn
intending
B.
Evitez de porter des habits impregnØs dhuile
graisse. Une Øtincelle pourrait Ies enflammer.
ou
de
a
Ne manipulez jamais sans gants un metal chaud tel que
des chutes dØlectrode et des piŁces a souder.
Premiers soins et traitement des yeux: Tout atelier
devrait avoir a sa disposition un poste de premiers soins
ainsi quune personne compØtente, a moms quur, ser
vice medical ne soit Ł proximitØ pour soigner immediate
ment les brlures des yeux et de Ia peau.
when
Portez des bouche-oreilles
Flammable hair preparations should not be used
sons
or
Voir 1.3A.2.
by
plafond ou dans
lorsque dautres
un
Iorsque
travaillez
vous
espace restreint. Portez
personnes travaillent
au
un
au
casque
plafond.
per
to weld or cut.
Les personnes devant souder
ou
couper
ne
employer des preparations inflammables
Toxic Fume Prevention
doivent pas
pour leurs
cheveux.
Severe discomfort,
illness
fumes,
or
heat,
or
death
result from
can
oxygen enrichment or depletion
that welding (or cutting) may produce. Prevent them
with adequate ventilation as described in ANSI Stan
vapors,
dard Z49.1 listed 1 in Standards index. NEVER ventilate
with oxygen.
B.
Prevention des gax
Les gaz, les vapeurs, Ia chaleur, un enrichissement ou
manque doxygŁne
peuvent entraIner un malaise,
une maladie ou mŒme Ia mort. Remediez-y par Ia ven
tilation dØcrite dans Ia Norme ANSI Z49.1 paragraphe 1
de Ilndex des Normes. NE ventilez JAMAIS a Iox
un
ygene.
Lead
-,
cadmium
zinc
mercury -, and beryllium
and similar materials, when welded (or cut) may
-,
-,
of toxic fumes. Ade
quate local exhaust ventilation
must be used, or each
the operator must wear an
air-supplied respirator. For beryllium, both must be us
ed.
area as
well
-
-
bearing
produce harmful concentrations
person in the
toxiques
as
En soudant
coupant, les p10mb, cadmium, zinc,
ou autres matØriaux semblables
peuvent crØer des concentrations nocives de gaz toxi
ques. On doit avoir recours a une ventilation aspirante
adequate du local, ou alors toute personne sur les lieux,
de mŒme que le soudeur, doit porter un masque a ad
duction dair.
On doit employer les deux pour le
mercure
et
ou en
beryllium
beryllium.
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 yen-
tilated,
or
the operator
wears an
air-supplied respirator.
Work in
a confined space only while it is
tilated and, if necessary, while wearing an
being ven
air-supplied
respirator.
Gas leaks in
a
confined
space
should
confined space.
Leaving
confined space, shut OFF gas
supply
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 pro
ducts. The ultraviolet (radiant) energy of the arc -can
also
decompose trichioroethylene and pervapors to form phosgene. DO NOT
where solvent vapors can be drawn into
or cutting atmosphere or where the radiant
chloroethylene
WELD
the
or cut
welding
113 336 Page 2
Ne travaillez dans un espace restreint que sil est bien
ventilØ et, si nØcessaire, portez un masque a adduction
dair.
On doit Øviter les fuites de gaz dans un espace restreint.
Les fuites de gaz en grande quantitØ peuvent
transformer dangereusement Ia concentration dox
ygŁne. Namenez pas de bouteilles de gaz dans un
espace restreint.
at source
prevent possible accumulation of gases in the space
if downstream valves have been accidently opened or
left open. Check to be sure that the space is safe before
to
re-entering
ou composes de matØriaux Ømet
gaz toxiques ne doivent pas Œtre chauffØs a
moms que Ienrobage
Ia surface a
ne soit ate de
travailler, que le local ne soit bien ventilØ, ou que le
soudeur ne porte un masque a adduction dair.
be avoided.
Leaked gas in large quantities can change oxygen con
centration dangerously. Do not bring gas cylinders into
a
Les mØtaux enrobØs
tant des
En quittant un espace restreint, FERMEZ le robinet
dalimentation de gaz de Ia bouteille. Ainsi on pourra
rentrer en toute sØcuritØ dans Ia piŁce, mŒme si les
robinets aval
ont ete ouverts par accident, ou Si on es
a laissØs ouverts.
Les vapeurs de dissolvants chlorØs peuvent Œtre dØcom
(ou de Ia flamme) et
par Ia chaleur de larc
former du PHOSGENE, gaz trŁs toxique, et dautres
produits irritant les poumons et les yeux. Lenergie
ultra-violette de Iarc peut aussi decomposer Ies vapeurs
de trichtoroethylene et de perchloroØthylŁne pour
former du phosgene. NE SOUDEZ PAS ou ne coupez
pas dans des endroits oU les vapeurs de dissolvants peu
vent Œtre attirØes dans IatmosphŁre de soudage ou de
posØes
a
energy can penetrate to
of
amounts
minute
atmospheres containing even
trichloroethylene or per
chioroethylene.
Fire and
C.
coupage et ł lØnergie de rayonnement peut pØnCtrer
dans des atmospheres contenant des quantitØs mØme
de
minuscules
trichloroØthylene ou de per
chloroØthylene.
Explosion Prevention
Causes of fire and explosion
the arc, flame,
material; misuse of
by
are:
C.
combustibles reached
hot slag or heated
flying sparks,
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.
explosion:
To prevent fires and
cause
short circuits.
Sachez que les Øclats dØtincelles ou Ia chute du laitier
sinfiltrer
dans les fissures, le long des
tuyauteries, par les fenŒtres et les portes et par es
couvertures des murs ou du sol, sans que le soudeur
portant des lunettes ne les voie. Les Øtincelles et les
35 pieds.
scones peuvent voler jusqu
peuvent
spray rooms, dip tanks, storage areas, yen
If the work cannot be moved, move com
bustibles at least 35 feet away out of reach of sparks
and heat; or protect against ignition with suitable and
paint
tilators.
snug-fitting,
fire-resistant
covers or
shields.
Si des combustibles
protected by heat-resistant
covers or
shields.
standing by with suitable fire ex
tinguishing equipment during and for some time after
welding or cutting if:
Fire watcher must be
a.
appreciable combustibles (including building
b.
construction) are within 35 feet
appreciable combustibles are further than 35
d.
can be ignited by sparks
openings (concealed or visible) in floors
within
35
feet
may
expose
or
area
is free of
sparks,
b.
c.
d.
produce flammable
or
be welded on or cut, unless container has first
been cleaned as described in AWS Standard A6.O,
listed 7 in Standards index.
never
This includes:
a
solvent
or
thorough steam or caustic cleaning (or
water washing, depending on the corna
soudez
quantitØs apprØciables de combustibles
(y compris une construction en chantier) se
trouvent a moms de 35 pieds.
Des quantitØs apprØciables de combustibles
sont a plus ~e 35 pieds mais peuvent Œtre
Des
enflammØes par des Øtincelles.
Des ouvertures (cachØes ou visibles) sur les
planchers ou les murs a moms de 35 pieds
peuvent exposer des combustibles aux
Øtincelles.
Les
combustibles adjacents aux murs,
plafonds, toits ou cloisons mØtalliques peu
vent ºtre enflammØs par une chaleur rayon
nante ou transmise.
Avant de commencer, avisez le contremaItre pour quiI
sassure que les precautions adØquates soient prises.
Une fois le travail terminØ, vØrifiez quil ny ait pas
de cendres ardentes ou de flammes dans le
local.
dØtincelles,
On
combustibles, or that can
toxic vapors when heated, must
An empty container that held
ne
Un surveillant doit se tenir a proximitØ avec un materiel
de lutte contre lincendie adØquat, pendant et quelque
temps aprŁs le soudage ou Ie coupage Si:
conducted heat.
After work is done, check that
glowing embers, and flames.
proximitØ,
dolt pas souder (ou couper) le ctØ oppose des
touchant les combustibles. Les murs, plafonds et
planchers proches du travail doivent Œtre protØgØs par
des couvertures ou Øcrans protecteurs ignifugØs.
com
have been taken.
a
ne
or
permit should be obtained before operation to
supervisors approval that adequate precautions
se trouvent
murs
Hot work
ensure
ce
ignifugØs.
On
bustibles to sparks
combustibles adjacent to walls, ceilings,
roofs, or metal partitions can be ignited by
radiant
explosions: Veillez Ł
chaleur et protegez-les des Øtincelles avec des couver
tures ou des Øcrans protecteurs adØquats, bien ajustØs
feet but
walls
les
coupez pas. Si possible, dØplacez votre travail
loin des combustibles. Evitez les ateliers de peinture au
pistolet, les cuves dimmersion, les entrepts, les yen
tilateurs. Si cela nest pas possible, placez les com
bustibles a au moms 35 pieds des Øtincelles et de Ia
a.
c.
et
ne
pas,
et
Walls touching combustibles on opposite sides should
not be welded on (Or cut). Walls, ceilings, and floor near
work should be
prØvenir les incendies
que votre appareil soit propre et en Øtat de marche,
dØnuØ dhuile et de graisse, et de particules de metal sur
les piŁces electriques qui pourraient entraIner des
courts-circuits.
If combustibles are in area, do NOT weld or cut. Move
the work if practicable, to an area free of combustibles.
Avoid
explosions
sont les com
Les causes dincendie
et dexplosion
bustibles atteints par larc, Ia flamme, les Øtincelles, le
laitier chaud ou les matØriaux chauffØs, le mauvais
ernploi des gaz comprimØs et des bouteilles ainsi que les
courts-circuits.
Pour
Keep equipment clean and operable, free of oil, grease,
and (in electrical parts) of metallic particles that can
Prevention des incendies et des
dolt jamais souder ni couper
sur un recipient
combustibles, ou pouvant produire
des vapeurs inflammables ou toxiques a Ia chauffe, a
moms que le recipient nait Øte lavØ au prØalable, corndØcnit dans Ia Norme AWS A6.O, figurant au
me
paragraphe 7 do llndex des Normes.
ne
ayant
contenu des
Cela cornprend: un nettoyage a fond a Ia vapour ou au
caustique (ou un lavage avec dissolvant ou eau solon Ia
solubilitØ du combustible) suivi dune
purge et dune
113 336
inPage 3
solubility) followed by purging and inerting
or carbon dioxide, and using protective
recommended in A6.O. Waterfilling just
as
equipment
below working level may substitute for inerting.
bustibles
with nitrogen
A container with unknown contents should be cleaned
(see paragraph above). Do NOT depend on sense of
smell
or
sight
determine if it is safe to weld
to
castings or containers must be
welding or cutting. They can explode.
Hollow
or
cut.
vented before
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
GASES
IN
HANDLING
COMPRESSED
OF
CYLINDERS, listed ii in Standards index.
jection dazote ou de gaz carbonique, en utilisant un
Øquipement de protection comme recommandØ dans
lA6-O. LatmosphŁre inerte peut Œtre remplacØe par un
niveau deau
Vous devez layer un recipient dont Ia nature de contenu
est inconnue (voir paragraphe ci-dessus). NE vous fiez
PAS a lodorat ou a Ia vue pour dire si lon peut le
souder ou le couper en toute sØcuritØ.
Vous devez pratiquer un event sur les piŁces ou red
pients creux avant de les souder ou couper: us peuvent
exploser.
Atmospheres explosives: Ne soudez ni ne coupez
Iair
jamais dans des lieux o
peut contenir des
poussiŁres, gaz ou vapeurs liquides inflammables (tels
que lessence).
D.
Pressure
Regulators
Regulator relief valve is designed to protect only the
regulator from overpressure; it is not intended to pro
tect any downstream equipment. Provide such protec
tion with
one or more
Precautions gØnerales: Suivez les precautions de ce
et celles dØcrites a Ia Norme CGA P-i (PrØcau
tions de sØcuritØ pour Ia manipulation de gaz comprimes
des Normes.
en bouteilles), paragraphe 6 de lIndex
faulty regulator from service immediately for
repair (first close cylinder valve). The following symp
toms indicate a faulty regulator:
Remove
if gas leaks externally.
if delivery pressure continues to rise
Excessive Creep
with downstream valve closed.
-
-
if gauge pointer does not move off stop
Faulty Gauge
pin when pressurized, nor returns to stop pin after
-
pressure release.
Repair. Do NOT attempt repair. Send faulty regulators
repair to manufacturers designated repair center,
where special techniques and tools are used by trained
personnel.
for
2.
DØtendeurs de pression
La soupape de sretØ
dun
dØtendeur est destinØe a pro
tØger seulement le dØtendeur de Ia surpression. Elle na
pas pour but de proteger les boyaux et le chalumeau: on
protege ceux-ci par des soupapes de retenue concues
spØcialement pour cette fonction.
relief devices.
Never connect a regulator to a cylinder containing gas
other than that for which the regulator was designed.
Leaks
Gaz comprimØ
manuel,
1.
1.
arrivant au-dessous du travail a effectuer.
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 ac
cident. (See 1-3G.)
Ne montez jamais un dØtendeur sur une bouteille conte
nant un gaz different de celui pour lequel le dØtendeur a
ØtØ conu.
Enlevez immØdiatement un dØtendeur dØfectueux pour
le faire rØparer (dabord,
fermez le robinet de Ia
bouteille). Les symptmes suivants dØnotent Ia dØfec
tuositØ du dØtendeur:
Fuites Si le gaz fuit extØrieurement.
Ascension excessive si Ia pression de debit continue a
monter, le robinet du chalumeau Øtant fermØ.
ManomŁtre dØfectueux
Si laiguille du manomŁtre ne
sØcarte pas de (a goupille de butØe lors de Ia mise en
pression, ou ne revient pas sur Ia goupille aprŁs lØchap
pement de Ia pression.
-
-
-
Reparation. NESSAYEZ
Envoyez
les
dØtendeurs
PAS de rØparer vous-mŒmes.
dØfectueux a rØparer aux
ateliers de reparation agrees du fabricant, oCi des techni
ques et des outils spØciaux Sont utilisØs par un person
nel formØ.
2.
Bouteilles
Les bouteilles doivent Œtre
manipulØes avec soin pour
a leurs parois, robinets ou
systŁmes de sretØ. Evitez quun Circuit Ølectrique soit
en contact avec les bouteilles, y compris les rails de con
tact, les fils electriques ou les circuits de soudage. Gela
pourrait crØer des arcs courts-circuits pouvant entralner
prØvenir les fuites
ou
degts
des accidents graves (Voir 1.3G.).
DOT marking must be on each cylinder. It is an
assurance of safety when the cylinder is properly
ICC
or
handled.
~~~113336Page4
Chaque
bouteille doit porter les inscriptions ICC ou
DOT. Cest un gage de sØcuritØ pourvu que Ia bouteille
soit bien manipulØe.
a
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
cylinder.
alter name, number, or other
It is illegal and hazardous.
or
markings
on a
Empties: Keep valves closed, replace caps securely;
mark MI; keep them separate from FULLS and return
promptly.
Prohibited
use.
Never
cylinder
use a
or
other than its intended use, NEVER
roller.
its contents for
as
a
support
Identification du gaz: Nutilisez que les bouteilles mdi
quant Ia nature du gaz; ne vous fiez pas a Ia couleur
pour reconnaItre Ia nature du gaz. Adressez-vous a
votre fournisseur si
cela nest
pas
NEFFACEZ
modifiez
ou
ne
numØros ou autres indications
eSt
illegal
indique.
JAMAIS
sur
une
les
noms,
bouteille. Cela
dangereux.
et
Vides: Maintenez les robinets fermØs, replacez bien les
chapeaux; inscrivez Vides;
sØparez-les des Pleines
et retournez-Ies rapidement.
or
Emplol interdit: Nutilisez une bouteille ou son contenu
ce a quoi elle est destinØe, mais JAMAIS corn-
que pour
Locate
or secure
cylinders
they
so
cannot be knocked
over.
and work
Passageways
where
areas
they
areas.
Keep cylinders clear of
me
support
ou
rouleau.
Placez Ies bouteilles pour quelles ne tombent
quun dØtendeur (et un boyau) est monte
placez les ou attachez-Ies debout.
pas. Lors
sur
elles,
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
allow contents to exceed 130F. 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.
Passages et lieux de travail. Enlevez les bouteilles dun
endroit oC~ Ion pourrait Ies frapper.
Transport des bouteilles. Avec une grue, utilisez un sup
port fiable tel quune
plate-forme ou un cadre. NE
SOULEVEZ PAS des bouteilles du sol par leur robinet
ou chapeau, ou avec des chaInes, Ølingues ou aimants.
NEXPOSEZ
PAS Ies bouteilles a une chaleur excessive,
au Iaitier et aux flammes, etc., pouvant
leur rupture. Le contenant ne doit jamais
causer
dØpasser 55C. Refroidissez en pulvØrisant de leau si
nØcessaire.
Øtincelles,
aux
es bouteilles et particuliŁrement les soupapes
les chocs, les chutes, Ies chutes dobjets et Ia
temperature. Remettez bien les chapeaux lorsque vous
dØplacez les bouteilles.
ProtØgez
contre
Stuck valve. Do NOT
cylinder valve that
your supplier.
a
Mixing
use a
can not
hammer
be
or
wrench to open
opened by hand. Notify
gases. Never try to mix any gases in
Never refill any
cylinder.
Cylinder fittings
should
never
a
cylinder.
Robinet coincØ. NUTIL~SEZ PAS un marteau ou une
mØtallique pour ouvrir un robinet de bouteille que
ne peut pas ouvrir a Ia main. Avisez votre four
clØ
lon
nisseur.
be modified
or
exchang
ed.
MØlange
dans
~3
Hose
Ne
une
de gaz. Nessayez
bouteille.
jamais de mØlanger des
gaz
rechargez jamais upe bouteille. Les ØlØments de Ia
ne doivent jamais Œtre modifies ou remplaces.
bouteille
Prohibited
for the
use. Never use hose other than that designed
specified gas. A general hose identification rule
is: red for fuel gas, green for oxygen, and black for inert
gases.
clamps designed for the hose (not or
dinary wire or other substitute) as a binding to connect
hoses to fittings.
or
No copper
to
tubing splices. Use only standard brass fit
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
Boyau
Utilisation interdite.
que celui
Use ferrules
tings
3.
excess
hose to prevent kinks and
Protect hose from
sparks, slag,
tangles.
didentification
vert pour
est:
IoxygŁne,
Nutilisez
au
gaz
jamais un boyau autre
indique. La rŁgle gØnerale
rouge pour les gaz combustibles,
et noir pour les gaz inertes.
Utilisez des bagues ou colliers appropriØs au boyau (et
non du fil ordinaire ou autre substitution) pour brancher
Ies boyaux a lappareillage.
Nutilisez pas des raccords en cuivre. Nutilisez que des
accessoires standard en Iaiton pour raccorder un boyau.
UtiIisez une petite Iongueur de boyau. Cela Øvitera les
noeuds et lusure prØmaturee. Suspendez le boyau au
dessus du sol pour Øviter quil ne soit ØcrasØ, piØtine ou
eridommagØ.
damage by sharp edges, and by
and open flame.
Examine hose
appropriØ
regularly for leaks, wear, and loose con
pressured hose in water; bubbles in
Enroulez Ie surplus de boyau pour Øviter les noeuds et
emmŒlemer,ts. Evitez que le boyau ne soit endommage
par des tranchants, Øtincelles, laitier et flamme nue.
nections. Immerse
dicate leaks.
113336
Page
5
Repair leaky
ing (1-2D3).
or worn
hose
Do NOT
use
by cutting
area out
and
splic
tape.
Proper Connections
4.
Clean cylinder valve outlet of impurities that may clog
orifices and
damage
seats before
a
Reparation. Coupez Ia partie percØe ou usØe, et rac
cordez (1-2D3). NUTILISEZ JAMAIS de ruban adhØsif.
connecting regulator.
Except for hydrogen, crack valve momentarily, pointing
outlet away from people and sources of ignition. Wipe
with
VØrifiez rØguliŁrement les fuites, lusure
et les rac
cordements lches.
Plongez le boyau sous pression
dans de leau; les bulles indiqueront les fuites.
clean lintless cloth.
4.
Branchements corrects
Avant de brancher le dØtendeur, nettoyez Ia sortie du
robinet de Ia bouteille des impuretØs qui peuvent
obstruer les orifices et endommager les sieges. Sauf
ouvrez momentanØment le robinet,
pour lhydrogŁne,
regulator to cylinder. Before connecting, check
regulator label and cylinder marking agree, 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.
flammables.
Tighten connections. When assembling
cher, vØrifiez que Ia marque du dØtendeur et Ia descrip
tion de Ia bouteille concordent, et que lorif ice dentrØe
Match
that the
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.
eloignant
en
Ia sortie des personnes et des sources in
Essuyez avec un tissu propre et non
graisseux.
Appareillez le dØtendeur
a Ia bouteille. Avant de bran
du dØterideur et lorifice de sortie de Ia bouteille aillent
ensemble. NE BRANCHEZ JAMAIS un dØtendeur
conu pour un gaz special (ou des gaz spØciaux) a une
bouteille contenant dautres gaz.
Serrez les branchements. Lorsque vous assemblez des
branchements filetØs, nettoyez et polissez les sieges o
cest nØcessaire. Serrez. Si les branchements perdent,
dØmontez-les, nettoyez et resserez avec une clef adØ
quate.
Regulator outlet (or hose) connections may be iden
tified by right hand threads for oxygen and left hand
threads (with grooved hex on nut or shank) for fuel gas.
5.
regulator of residual gas through suitable vent
before opening cylinder (or manifold valve) by turning
adjusting screw in (clockwise). Draining prevents ex
cessive compression heat at high pressure seat by
allowing seat to open on pressurization. Leave adjusting
screw engaged slightly on single-stage regulators.
to side
of
regulator
while
opening cylinder
valve.
Open cylinder valve slowly so that regulator pressure in
When gauge is pressurized (gauge
creases slowly.
reaches regulator maximum) leave cylinder valve in
following 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 (capful of Ivory
Liquid* or equivalent per gallon of water). Bubbles in
dicate leak. Clean off soapy water after test; dried soap
is combustible.
E.
User
Responsibilities
Remove leaky or defective equipment from service im
mediately for repair. See User Responsibility statement
in
equipment manual.
*Trademark of Proctor & Gamble
113336 Page 6
(en
si besoin est,
un
adaptateur CGA
fournisseur) entre Ia bouteille et le
dØtendeur. Avec deux clefs, serrez ladaptateur filetØ A
vente chez votre
DROITE et A GAUCHE.
Pressurizing Steps:
Drain
Stand
Adaptateurs. Placez,
On peut reconnaltre les branchements de sortie du
dØtendeur (ou boyau) a laide du filetage a droite pour
loxygŁne et a gauche (identifiØ par un Øcrou cannelØ)
pour les gaz combustibles.
5.
DØmarches de mise
en
pression
Purgez le dØtendeur de rØsidu de gaz avant douvrir Ia
bouteille (ou le robinet de canalisation) en serrant Ia vis
de rØglage (dans le sens des aiguilles dune
montre).
Cette operation permet au siege de haute pression de
souvrir a Ia mise en pression, supprimant ainsi toute
surchauffe de compression. Maintenez Ia vis de rØglage
des dØtendeurs a simple dØtente lØgŁrement engagØe.
Avant douvrir le robinet de Ia bouteille, assurez-vous
que les boyaux sont branches et que les soupapes aval
sont fermØes.
Tenez-vous latØralement au dØtendeur en ouvrant le
robinet de Ia bouteille. Ouvrez-Ie lentement pour que Ia
pression du dØtendeur monte progressivement. Lorsque
le manomŁtre est mis sous pression (indique le max
imum) le robinet de Ia bouteille de gaz inerte ou dox
ygene devra Œtre ouvert a fond pour assurer lØtanchØitØ
et celui de Ia bouteille de gaz combustible ouvert de
moms dun tour pour pouvoir le ref ermer rapidement en
cas
durgence.
RØfØrez-vous aux tableaux de pression (distribuØs par
fOurnisseur) pour un rØglage recommandØ de
pression sCir et efficace sur les dØtendeurs. VØrifiez les
fuites a Ia premiere mise en pression puis rØguliŁrement,
brossez avec une solution savonneuse (un bouchon
dlvory Liquid* ou semblable par gallon deau). Les
bulles indiquent une fuite. Enlevez leau savonneuse
aprŁs examen; le savon sec est inflammable.
votre
*Marque de Commerce
de Proctor & Gamble
Leaving Equipment Unattended
F.
Close gas
E.
de
Iusager
Otez immØdiatement les parties percØes ou dØfec
Voir les ResponsabilitØs de lUsager du manuel
de lappareil.
at source and drain gas.
supply
ResponsabilitØs
tueuses.
G.
Rope Staging-Support
not be
Rope staging-support should
cutting operation; rope may
used for welding
F.
or
burn.
is
a
The
rise, ultraviolet and infrared energy radiates,
weldments are hot, and compressed gases may be us
fumes
ed. The wise operator avoids unnecessary risks and pro
tects himself and others from accidents. Precautions
described here and in standards referenced in index.
are
A.
Burn Protection
Comply
precautions
with
in 1-2.
arc is intense and visibly bright. Its radia
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.
The
welding
tion
can
GET
DONT
COMPLY
BURNED;
WITH
PRECAU
TIONS.
Protective
1.
sans
surveillance
de gaz a Ia
Liens et supports
source et
purgez.
temporaires
Pour vos travaux de soudage ou de coupage, nutilisez
pas de Ia corde comme soutien, eIIe est inflammable.
bright and hot. Sparks fly,
is very
arc
G.
-
safe process, but a careless operator invites trouble.
equipment carries high currents at significant
voltages. The
laissØ
Fermez Ialimentation
Comply with precautions in
1-1, 1-2, and this section. Arc Welding, properly done,
WELDING
1-3. ARC
Appareil
Clothing
long-sleeve clothing (particularly for gas-shielded
to gloves, hat, and shoes (1-2A). As
necessary, use additional protective clothing such as
leather jacket or sleeves, flame-proof apron, and f ireresistant leggings. Avoid outergarments of untreated
Wear
1-3. SOUDAGE A LARC
Confprmez-vous aux
precautions des paragraphes 1.1 et 1.2 de cette section.
bien exØcutØ est sOr, mais un
Le soudage a larc
soudeur negligent est un danger. Le paste de soudage
transporte des caurants ØlevØs saus de fortes tensions.
Larc est trŁs vif et chaud. Les Øtincelles volent, les
vapeurs mantent, lenergie ultra-violette et infrarouge
rayonnent, les soudures sont chaudes, et des gaz corn
primes peuvent Œtre utilisØs. Le soudeur prudent Øvite
les risques inutiles, se protege et protege autrul contre
Ies accidents. Les precautions sant dØcrites ici et dans
.Ies normes donnØes dans llndex.
-
A.
Protection contre les brlures
Conformez-vous aux precautions du paragraphe 1 .2.
Larc de soudage est intense et visiblernent vif. Son
rayonnement peut blesser les yeux, traverser les habits
lØgers, se rØflØchir sur les surfaces claires, et brCiler Ia
peau et les yeux. Les br~lures de Ia peau ressemblent a
un gras coup de soleil. Celles darcs
sous gaz pratecteur
NE VOUS
sont plus graves et plus douloureuses.
SUIVEZ LES PRECAUTIONS.
BRULEZ PAS
-
arc) in addition
cotton.
Bare skin
protection.
Wear
Eye
and Head Protection
Protect eyes from exposure to
electric arc without protection.
Welding
no.
over
12
helmet
or
or
shield
arc.
containing
NEVER look at
a
striking
Portez des vŒtements a manches longues (surtout pour
larc
en atmosphere inerte) avec gants,
masque et
chaussures (1.2A.).
an
plate shade
welding. Place
Si nØcessaire portez en plus une veste ou des manches
cuir, un tablier et des guŒtres ignifugØs. De
prØfØrence ne portez pas de vŒtements en coton non
traitØ.
en
Protection de Ia peau. Portez des vŁtements epais
foncØs. Boutonnez le col pour protØger Ia poitrine et le
cou, et boutonnez les poches pour prØvenir Iinfiltration
dØtincelles.
2.
Cracked
or
plate
with
a
clear
broken helmet
worn; radiation can pass
Cracked, broken,
or
or
cover
loose filter
Replace
broken, pitted,
spattered.
plate.
to cause
plates
clear
que
JAMAIS
shield should NOT be
through
IMMEDIATELY.
or
Protection des yeux
et
de Ia tŒte
arc.
Evitez
Protect filter
protection
filter
denser must be used when
face before
VŒtements de
dark, substantial clothing.
Button collar to protect chest and neck and button
pockets to prevent entry of sparks.
2.
1.
burns.
replaced
plate when
vos
yeux soient
un arc
Ølectrique
exposØs a larc. NE regardez
sans protection.
Lorsque
vous soudez, portez un Øcran ou masque avec
filtrant teintØ N 12 ou plus foncØ. Mettez-Ie sur Ic
visage avant damorcer Iarc.
verre
must be
cover
ProtØgez
le verre filtrant dun
couvre-verre clair. NE
PORTEZ PAS un masque fendu ou brisØ; le rayonne
ment peut sinfiltrer et causer des brOlures.
Les verres filtrants fendus, brisØs ou lches doivent Œtre
remplacØs IMMEDIATEMENT. Rernplacez un couvre
verre brisØ, piquØ Ou tachØ par des projections.
113336 Page 7
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
Looking at an arc momentarily with unprotected
Iparticularlya high intensity gas-shielded arc) can
struck.
eyes
retinal burn that may leave
cause a
area
a
permanent dark
in the field of vision.
Vous devez portez des lunettes a Øcrans latØraux sous Ie
masque pour protØger les yeux dans le cas oCi le masque
ne serait pas abaissØ sur le visage avant lamorcage
de
Iarc. Regarder momentanØment un arc sans protection
(principalement un arc en atmosphere inerte a haute in
tensitØ) peut brOler Ia rØtine et laisser un point sombre
permanent dans le champ de vision.
Protection du personnel a proximitØ
3.
Protection of
3.
Nearby Personnel
Local de
soudage fermØ. Pour
enclosed bay is best. In open areas,
operation with low-reflective, noncombustible screens or panels. Allow for free air circula
tion, particularly at floor level.
le soudage de produc
mieux utiliser une salle sØparØe ou une bale
fermØe. Dans les locaux ouverts, entourez les travaux
dØcrans ou panneaux peu rØflØchissnts et ininflam
mables. Laissez lair circuler librement, particuliŁrement
au niveau du sol.
the weld. Provide face shields for all persons
looking directly at the weld.
Donnez des masques aux personnes qul regarderont
directement Ia soudure.
welding
Enclosed
separate
For
area.
production welding,
a
room or
the
surround
Viewing
who will be
Others working in
flash
Before
starting
bay doors
B.
area.
See that all persons
are
wearing
goggles.
are
to
weld, make
sure
that
screen
flaps
tion, il
vaut
Autres persorines travaillant sur les lieux. Veillez a ce
que toutes les personnes portent es lunettes de protec
tion.
or
closed.
Avant dattaquer
Ia soudure, assurez-vous
rebords dØcran ou les portes soient fermØs.
que
les
Toxic Fume Prevention
B.
Comply
with
precautions
Generator engine exhaust must be vented to the outside
air. Carbon monoxide can kill.
C.
Fire and
Comply
with
Suivez les precautions du paragraphe 1.2B. LØchappe
ment du moteur de Ia gØnØratrice doit Œtre ventilØ a Iair
extØrieur. Loxyde de carbone peut tuer.
Explosion Prevention
precautions
Prevention des gaz toxiques
in 1-2B.
C.
Prevention des incendies
et
des
explosions
in 1-2C.
rated capacity. Do not overload arc
Equipments
welding equipment. It may overheat cables and cause a
Suivez les precautions 1.2C. Puissance nominale de
Ne surchargez pas le poste de soudage a
Iarc. Cela peut surchauffer les cables et causer un in
cendie.
lappareil.
fire.
Loose cable connections may overheat
cause a fire.
Never strike
an
vessel. It creates
rupture
or
arc
a
on
brittle
lead to such
a
cylinder
area
a
that
or
can
or
flash and
other pressure
cause a violent
rupture later under rough
Les branchements Iches
faire des Øtincelles et
ou
Namorcez
pient
jamais
de cable peuvent surchauffer
incendie.
causer un
un arc sur une
bouteille
ou autre
rØci
pression. Cela crØerait un point de rupture
entraInant a plus ou moms longue ØchØance lexplosion
sous
du reservoir.
handling.
D.
Compressed Gas Equipment
Comply with precautions in 1-2D.
E.
Shock Prevention
Exposed hot conductors or other bare metal in the
welding circuit, or in ungrounded, electrically-HOT
equipment can fatally shock a person whose body
a conductor. DO NOT STAND, SIT, LIE,
LEAN ON, OR TOUCH a wet surface when welding,
without suitable protection.
becomes
113 336
Page 8
D.
Gaz comprimØ
Suivez Ies precautions 1.20.
E.
Prevention des
Des conducteurs
dØcharges Ølectriques
charges
ou metal nu incorpores au cir
a un appareil chargØ sans mise a Ia
terre peuvent donner une dØcharge fatale a a personne
dont le corps devient conducteur. NE SOUDEZ PAS
DEBOUT, ASSIS, COUCHE, PENCHE sur une surface
humide ni en contact avec une telle surface sans protec
tion appropriØe.
cult de
soudage
ou
To protect
against shock:
Keep body and clothing dry. Never work in damp area
adequate insulation against electrical shock.
Stay on a dry duckboard, or rubber mat when damp
ness or sweat can not.be avoided. Sweat, sea water, or
without
electrically HOT
body surface
electrical resistance, enabling dangerous and possibly
lethal currents to flow through the body.
between
body
grounded
metal
moisture
part
or
-
and
-
an
reduces the
Pour vous proteger contre les dØcharges Ølectriques,
maintenez votre corps et vŒtements secs. Ne travaillez
jamais dans un endroit humide sans isolation adequate
contre les dØcharges electriques. Lorsque vous ne
pouvez Øviter lhumiditØ ou Ia sueur, placez-vous sur un
caillebotis sec ou un tapis en caoutchouc. La sueur,
leau de mer, ou IhumiditØ entre le corps et une piŁce
CHARGEE, ou une piŁce de metal a Ia masse, rØduisent
Ia rØsistance electrique de Ia surface du corps, permet
tant IentrØe de courants dangereux, voire mortels.
1.
Grounding
1.
the
welding equipment is grounded according to
the National Electrical Code, and the work is grounded
according to ANSI Z49.1 Safety In Welding And Cut
ting, a voltage may exist between the electrode and
any conducting object. Examples of conducting objects
include, but are not limited to, buildings, electrical
tools, work benches, welding power source cases,
workpieces, etc. Never touch the electrode and any
metal object unless the welding power source is
When
Mise a Ia
terre
de
lappareil
Equipment
arc
Lorsque Iappareil de soudage a Iarc
est mise a Ia terre
National Electrical Code, et Ia masse
est mise a Ia terre suivant Ia norme ANSI Z49.1 Safety
in Welding and Cutting, une tension peut exister entre
suivant Ia
norme
lØlectrode
et un
objet
conducteur. Certaines de
ces
ob
seulement), des
jets
par
bªtiments, des outils electriques, des Øtablis, des
chassis de postes de soudure, des piŁces douvrage,
etc. Ne jamais touchez IØlectrode ou des objets en
sont
exemple
metal avant davoir
(mais
pas
mis le poste de soudure a Iarrt.
of f.
installing, connect the frames of each unit such
as welding power source, control, work table, and
water circulator to the building ground. Conductors
must be adequate to carry ground currents safely.
Equipment made electrically HOT by stray current may
shock, possibly fatally. Do NOT GROUND to electrical
conduit, or to a pipe carrying ANY gas or a flammable li
quid such as oil or fuel.
When
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
a dangerous condi
ment will become electrically HOT
tion that can shock, possibly fatally.
-
welding, check ground for continuity. Be sure
conductors are touching bare metal of equipment
Before
frames at connections.
If
a
line cord with
equipment
ground
a
ground
for connection to
lead to the
lead is
a
provided with the
switchbox,
connect the
grounded switchbox. If
a
Electrode Holders
Fully insulated
NOT
3.
use
protruding
PRISE DE TERRE a une conduite electrique, ou a
tuyau de gaz ou de liquide inflammable tel que lhuile
un combustible.
Connexion
triphasØe.
Avant
Iinstallation
vØrifiez
un
ou
Ia
phase nØcessaire a Iappareil. Si seul le triphasØ est
disponible, ne branchez lappareil monophasØ qu deux
des fils de Ia ligne triphasØe. NE BRANCHEZ PAS le
conducteur de terre de lappareil au troisiŁme fil (sous
tension), autrement lappareil serait chargØ: condition
dangereuse pouvant donner une dØcharge fatale.
Avant le soudage, vØrifiez si Ia prise de terre est
uniforme. En branchant, assurez-vous que les con
ducteurs touchent le metal nu du chassis de Iappareil.
Lorsquun
appareil doit Œtre alimentØ a partir dun
fret dalimentation,
a celui-ci.
cof
Ie conducteur de terre doit Œtre reliØ
Si vous avez en plus une fiche a trois broches pour Ia
Ia broche
terre, ne branchez le conducteur de terre qu
de terre. Si le cordon dalimentation a une fiche a trois
broches, reliez-Ie a une prise femelle tripolaire reliØe a Ia
terre. Nenlevez jamais Ia broche de terre dune fiche ou
nutilisez jamais une fiche dont Ia broche de terre serait
brisØe.
2.
electrode holders should be used.
holders with
par les courants vagabonds peut donner une dØcharge
risquant dŒtre mortelle. NE BRANCHEZ PAS VOTRE
three-
plug is added for connection to a grounded
mating receptacle, 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 recep
tacle. Never remove the ground prong from a plug, or
use a plug with a broken off ground prong.
prong
2.
A linstallation, branchez les chassis de chaque element
(source de courant, commande, Øtabli et circuit deau) a
Ia terre. Les conducteurs doivent pouvoir conduire les
courants telluriques en toute sØcuritØ. Lappareil chargØ
Do
screws.
Pince-Ølectrodes
Utilisez des pince-Ølectrodes bien isolØes. NUTILISEZ
PAS des pince-electrodes avec vis saillantes.
Connectors
3.
Fully insulated lock-type connectors should be used
join welding cable lengths.
Connecteurs
to
Utilisez des connecteurs a verrouillage bien isolØs pour
assembler de longs cables.
113336
Page
9
4.
Cables
4.
cables for wear, cracks and damage.
IMMEDIATELY REPLACE those with excessively worn
lethal shock
or damaged insulation to avoid possibly
Frequently inspect
-
from bared cable. Cables with damaged areas may be
taped to give resistance equivalent to original cable.
Keep cable dry, free of oil arfd grease, and protected
from hot metal and sparks.
5.
Terminals And Other Exposed Parts.
6.
VØrifiez frØquemment lusure, les fissures et laltØration
des cables. REMPLACEZ IMMEDIATEMENT ceux dont
lisolation serait trop usØe ou altØrØe pour prØvenir les
dØcharges mortelles provoquØes par un cable dØnudØ.
Vous pouvez enrouler les parties endommagees de
ruban adhØsif en Øpaisseur suffisante pour donner une
rØsistance de cable neuf. Maintenez les cables secs,
dØpourvus dhuile et de graisse et mettez-les a labri du
metal chaud et des Øtincelles.
5.
Terminals and other exposed parts of electrical units
should have insulating covers secured before operation.
Electrode
Tetes de cables
et autres
parties dØnudØes
Avant Ia mise en marche, les tŒtes de cables et autres
parties dØnudØes dun appareil Ølectrique doivent Œtre
munies de leurs couvrefils isolants.
6.
Equipment with output on/off
a.
Cables
Electrode
control (con
tactor)
a
Appareil
.
equipØ
dune
commande
mar
che/arrºt (contacteur)
Welding
power
sources
for
use
with the gas
En
welding (GMAW), gas tungsten
arc welding (GTAW) and similar processes
normally are equipped with devices that per
mit on-off control of the welding power out
put. When so equipped the electrode wire
becomes electrically HOT when the power
source switch is ON and the welding gun
metal
arc
Equipment without output on/oft control
b
(no contactor)
Welding
metal
power
Appareil non-equipe dune
.
sources
used with shielded
7.
touch
power
electrode
the
source
unless
the
is off.
Safety Devices
Safety devices
such
as
7.
or
shunted
Do not open power circuit
welding. If, in an emergency,
guard against shock burns, or
change polarity while
disconnected,
flash from switch arcing.
or
unattended.
Always shut OFF
Power disconnect switch must be available
113 336
Page 10
source.
ne
Avant linstallation, linspection ou Ia reparation de lap
pareil, mettez lalimentation sur ARRET et enlevez les
fusibles gØnØraux (ou verrouillez les interrupteurs) pour
Øviter une remise en MARCHE accidentelle. DØbran
chez tous les cables de Ia source de courant ainsi que les
prises des cordons dalimentation en 115 volts.
it must be
and
near
et ne
soudage, nouvrez pas le circuit dalimentation
changez pas Ia polaritØ. Sil est dØbranchØ au
cours
dune
Lors du
dØcharge
disconnect all power to equipment.
power
Dispositif de sØcuritØ
Le dispositif de sØcurite-verrouillage et coupe-circuit
doit pas Œtre dØbranchØ ou dØshuntØ.
out.
Before installation, inspection, or service, of equip
ment, 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.
welding
postes
interlocks and circuit breakers
should not be disconnected
Leaving equipment
mar
soudage a
power output on-off control devices. With
such equipment the electrode is electrically
HOT when the power switch is turned ON.
Never
commande
de soudure utilisØs pour le
electrode enrobØe
larc
avec
(SMAW) et des procŁs semblabes peuvent
commande mar
Œtre non-Øquipes dune
che/arrŒt de Ia puissance de sortie. Lorsque
linterrupteur est en position MARCHE
lØlectrode
devient chargØ.
Ne touchez
jamais lØlectrode sans couper le courant au
poste de soudure.
Les
welding (SMAW) and similar pro
may not be equipped with welding
welding
protection
che/arrŒt (sans contacteur)
arc
cesses
soudure utilisØs
sous
gazeuse avec electrode fusible (GMAW), ou
avec electrode tungstene (GTAW) et des
procŁs semblables sont equipØs dune com
mande marche/arrŒt de Ia puissance de sor
tie. Lorsque linterrupteur est en position
MARCHE
et linterrupteur du pistolet est
fermØ, le fil dØlectrode devient chargØ. Ne
touchez jamais le fil electrode ou tout autre
objet conducteur faisant contact avec le cir
cuit dØlectrode sans couper le courant au
poste de soudure.
switch is closed. Never touch the electrode
wire or any conducting object in contact
with the electrode circuit unless the welding
power source is off.
b.
general, les postes de
le soudage a larc
pour
the
urgence, faites attention
ou aux
Appareil laissØ
aux
brOlures de
jaillissements dØtincelles.
sans surveillance. Mettez
ARRET et dØbranchez lappareil.
toujours
sur
I
F.
Protection For Wearers Of Electronic Life
Linterrupteur
Support Devices (Pacemakers)
imitØ de Ia
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.
For more in
1-4. STANDARDS BOOKLET INDEX
formation, refer to the following standards or their latest
-
revisions and
1.
comply
applicable:
as
ANSI Standard Z49.1, SAFETY IN WELDING
AND CUTTING obtainable from the American
Welding Society, 550 Le Jeune Rd, P.O. Box
351040, Miami, FL 33135.
2.
F.
coour)
Inducteurs de courant ØlevØ peuvent nuire le fonction
appareil pour le rŁglement de battement
de coeur. Toute personne portant un appareil Ølec
tronique de sauvetage (appareil pour le reglement de
battement de coeur), devrait consulter un docteur avant
dapprocher toute operation de soudage a larc, a Ia
gouge ou a point.
nement dun
1-4.
OSHA, SAFETY AND HEALTH STANDARDS,
29CFR 1910, obtainable from the U.S. Govern
ment Printing Office, Washington, D.C. 20402.
ANSI Standard Z87.1, SAFE PRACTICES FOR
OCCUPATION AND EDUCATIONAL EYE AND
PROTECTION obtainable from the
FACE
American National Standards Institute, 1430
Broadway,
5.
6.
ou aux normes
9.
10
Pour
plus de
de IACNOR
amØricaines suivantes:
NORMES
-
aux normes
ANSI Standard Z49.1, SAFETY IN WELDING
AND CUTTING distribuØ par lAmerican Welding
Society, 550 Le Jeune Rd., P.O. Box 351040
Miami, FL 33135
2.
NIOSH, SAFETY AND HEALTH IN ARC
WELDING AND GAS WELDING AND CUTTING
distribuØ par le Superintendent of Documents,
U.S. Government Printing Office, Washington
D.C. 20402
New
3.
OSHA, SAFETY AND HEALTH STANDARDS,
29CFR 1910, distribuØ par U.S. Department of
Labor, Washington D.C. 20210
4.
ANSI Standard Z87.1, SAFE PRACTICES FOR
OCCUPATION AND EDUCATIONAL EYE AND
FACE PROTECTION distribuØ par IAmerican
National Standards Institute, 1430 Broadway,
New York, NY 10018
5.
ANSI Standard Z41.1, STANDARD FOR MENS
SAFETY
TOE FOOTWEAR distribuØ par lad
dresse donnee en 4.
York, NY 10018.
ANSI Standard Z41.1, STANDARD FOR MENS
SAFETY -TOE FOOTWEAR obtainable from the
American National Standards Institute, 1430
Broadway, New York, NY 10018
ANSI Standard Z49.2, FIRE PREVENTION IN
THE USE OF CUTTING AND WELDING PRO
CESSES obtainable from the American National
AWS Standard A6.0, WELDING AND CUT
TING CONTAINERS WH!CH HAVE HELD COM
BUSTIBLES obtainable from the American
-
6.
ANSI Standard Z49.2, FIRE PREVENTION IN
THE USE OF CUTTING AND WELDING PRO
CESSES distribuØ par laddresse donnee en 4.
7.
AWS Standard A6.O, WELDING AND CUT
TING CONTAINERS WHICH HAVE COM
BUSTIBLES distribuØ par laddresse donnee en
8.
Standard 51, OXYGEN
FUEL GAS
SYSTEMS FOR WELDING AND CUTTING
distribuØ par Ia National Fire Protection Associa
tion, 470 Atlantic Avenue, Boston, MA 02210
9.
NFPA Standard 70-1978, NATIONAL ELEC
TRICAL CODE distribuØ par laddresse donnØe
en 8
10.
NFPA Standard 51B, CUTTING AND WELDING
PROCESSES distribuØ par Iaddresse donnØe en
Welding Society, 550 Le Jeune Rd., P.O. Box
351040, Miami, FL 33135.
8.
DES
1.
Standards Institute, 1430 Broadway, New York,
NY 10018.
7.
INDEX
NIOSH,
Documents, U.S. Government Printing Office,
4.
trouver a prox
Protection pour toute personne portant des
renseignements, rØfØrez-vous
ARC
IN
HEALTH
SAFETY AND
CUTTING
AND
WELDING
GAS
AND
WELDING
the
obtainable from
Superintendent of
se
appareils Øloctroniquos do sauvotage (ap
pareil pour lo rŁglomont do battemont do
Washington, D.C. 20402.
3.
darrŒt doit toujours
de courant.
source
FUEL GAS
Standard 51, OXYGEN
SYSTEMS FOR WELDING AND CUTTING ob
tainable from the National Fire Protection
Association, 470 Atlantic Avenue, Boston, MA
02210.
NFPA
-
NFPA Standard 70-1978, NATIONAL ELEC
TRICAL CODE obtainable from the National Fire
Protection Association, 470 Atlantic Avenue,
Boston, MA 02210.
NFPA Standard 51 B, CUTTING AND WELDING
PROCESSES obtainable from the National Fire
Protection Association,
Boston, MA 02210.
470
Atlantic Avenue,
NFPA
-
8
113 336
Page
11
11.
CGA Pamphlet P-i, SAFE HANDLING OF COM
PRESSED GASES IN CYLINDERS obtainable
from the Compressed Gas Association, 500 Fifth
Avenue, New York, NY 10036.
11.
CGA Pamphlet P-i, SAFE HANDLING OF COM
PRESSED GASES IN CYLINDERS distribuØ par
Ia Compressed Gas Association,
500 Fifth
Avenue, New York, NY 10036.
12.
GSA Standard Wi 17.2, CODE FOR SAFETY IN
WELDING AND CUTTING obtainable from the
Canadian Standards Association, Standards
Sales, 178 Rexdale Boulevard, Rexdale, Ontario,
Canada M9W 1R3.
12.
CSA Standard W117.2, CODE FOR SAFETY IN
WELDING AND CUTTING distribuØ par Ia Cana
dian Standards Association, Standards Sales,
178
Rexdale
Boulevard, Rexdale, Ontario,
Canada M9W 1R3.
13.
NWSA
WELDING
SAFETY
booklet,
BIBLIOGRAPHY obtainable from the National
13.
NWSA
WELDING
booklet,
SAFETY
BIBLIOGRAPHY distribuØ par Ia National
Welding Supply Association, 1900 Arch Street
Philadelphia, PA 19103.
14.
American Welding Societe Standard AWSF4.1
Recommended Safe Practices for the Prepara
tion for Welding and Cutting of Containers and
Piping That Have Held Hazardous Substances,
distribuØ par lAmerican Welding Societe. 550 Le
Jeune Rd., P.O. Box 351040, Miami, FL 33135
15.
ANSI Standard Z88.2 Practice For Respiratory
Protection
distribuØ par lAmerican
National
Standards Institute, 1430 Broadway, New York,
NY 10018.
Welding Supply Association,
1900 Arch Street,
Philadelphia, PA 19103.
113336
14.
American Welding Society Standard AWSF4.1
Recommended Safe Practices for the Prepara
tion for Welding and Cutting of Containers and
Piping That Have Held Hazardous Substances,
obtainable from the American Welding Society,
550 Le Jeune Rd., P.O. Box 351040, Miami, FL
33135.
15.
ANSI Standard Z88.2 Practice for Respiratory
Protection obtainable from the American Na
tional Standards Institute, 1430 Broadway, New
York, NY 10018.
Page
12
a
SECTION 2
INTRODUCTION
-
Input At Rated Load Output
60 Hz
Amperes
Rated
Amperes Output
60% Duty Cycle
Model
208
Volts
Circuit
Voltage
230
Single-Phase
At
Weight
460
Volts
Volts
575
kva
Volts
Overall
Dimensions
kw
Without
Height:
150 Amperes
Spot Weld Panel
32
@
24
26.5
12
9.6
4.8
5.5
Spot Weld
(91 kg)
23 Volts
Panel
(93 kg)
Figure 2
2
Ship
210 lbs.
(95 kg)
Width: 13-1/2 in. (343mm1
Depth: 27 in. (686mm) 205 lbs.
.
With
30 in. (762mm)
Net
200 lbs.
-
1.
215 lbs.
(98 kg)
Specifications
1. GENERAL INFORMATION AND SAFETY
-
General
A.
When
Information
preser~ited
in this manual and
on
various
requesting information concerning
this
equip
ment, it is essential that Model Description and Serial
Number of the equipment be supplied.
labels, tags, and plates provided on this 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 equip
2
-
3.
DESCRIPTION
-
This constant
voltage
dc
arc
ment.
and wire feeder system is design
welding power
ed for the Gas Metal Arc Welding (MIG) process. Nor
The nameplate of this unit uses international symbols
labeling the front panel controls. The symbols also
appear at the appropriate section in the text.
mal operation requires the welding gun be connected to
POSITIVE weld output receptacle while the
workpiece is connected to the (-) NEGATIVE weld out
source
the 1)
for
B.
put receptacle.
Safety
The
This
installation,
operation, maintenance, and
troubleshooting of arc welding equipment requires
practices and procedures which ensure personal safety
and the safety of others. Therefore, this equipment is to
be installed, operated and maintained only by qualified
persons in accordance with this manual and all ap
as, but not limited to, those listed at
-
Safety
Rules For
Operation
Of
Safety
pear throughout
which
identify
different levels of hazard.
hl LtI
statements include
and maintenance
carefully
or
procedures
2
duty cycle of
or
followed could result in
gear,
-
4.
DUTY CYCLE
(Figure 2-2)
-
The
welding
power source is the percentage of a ten
period that a welding power source can be
operated at a given output without causing overheating
and damage to the unit. This welding power source is
rated at 60 percent duty cycle. This means that the
welding power source can be operated at rated load for
this unit ap
by the signal
to
manual_highlighted
words I~TL1;h1lli~c1 and
I~I~1
running
minute
specifically pertaining
this
single-phase welding power
quick disconnect gun
a
with all necessary interconnecting cables,
and assembly hardware. Models with the
a
Arc Welding Power Source.
instructions
consists of
with built-in wire feeder,
optional SPW
1 panel provide the controls for regulating spot weld
time/pulse on time, burnback time, and pulse off time.
plicable codes such
the end of Section 1
unit
source
six minutes out of every ten. During the remaining four
minutes, the unit should idle to permit proper cooling. If
the welding amperes are decreased, the duty cycle will
installation, operation,
practices which if not
serious personal injury
increase.
Figure 2-2 enables the operator to determine
welding power source at various duty
the output of the
loss of life.
cycles.
t~1IIli1i~I statements include
installation, operation,
and maintenance procedures or practices which if not
carefully followed could result in minor personal injury
or damage to this equipment.
200
175
A third
signal word, Il~~l~.l;If~Il highlights instruc
special emphasis to obtain the most
efficient operation of this equipment.
tions which need
a.
150
4
U
125
2
-
2.
RECEIVING-HANDLING
-
Before
installing
this
equipment, clean all packing material from around
carefully inspect for any damage that may
have occurred during shipment. Any claims for loss or
damage that may have occurred in transit must be filed
by the purchaser with the carrier. A copy of the bill
of lading will be furnished by the manufacturer on re
the unit and
quest if occasion
to
file claim arises.
100
30
35
40
50
%
DUTY
60
70
80
CYCLE
90
100
8-067 436.1
Figure 2-2. Duty Cycle Chart
113336 Page 13
L~.tU1Is1~ EXCEEDING DUTY CYCLE RATINGS
2
will
(Figure 2-4)
2
-
damage the welding power source.
Do not exceed indicated duty cycles.
5. VOLT-AMPERE CURVES
(Figure 2-3)
-
-
DESCRIPTION
6.
OF
SUPPLIED
A.
Running Gear
B.
Jack
Plugs
C.
Wall
Receptacle And Plug (208/230
PARTS
The
volt-ampere
curves are provided to show the available
output of the welding power source in each of the out
put receptacle taps with the FINE TUNING/WIRE
SPEED control at the maximum position. Different set
tings on the FINE TUNING/WIRE SPEED control will
yield different volt-ampere curves. Consult Tabe 6-1
(Range Selection Chart) for specific information to be
used in conjunction with the volt-ampere curves.
volt models
only)
2
D.
MWG 200 Gun, Nozzle, And Six Contact Tubes.
E.
Nine Feet (2.8 m) Of 3-Conductor Input Cord
F.
Work Cable And Work Cable
G.
Optional SPW
-
1
Clamp
Panel And Three Nozzles
7. ADDITIONAL SUPPLIES REQUIRED
(Figure
2-5)
UI
I-l
6 HIGH
5
0
>
V
IMPORTANT Contact
your
supplier
or
see
the
4
yellow pages of the local telephone book for the loca
3
tion of the nearest Auto Arc Distributor.
2
1 LOW
Gas Cylinder
A.
0
25
50
75
DC
100
125
150
175
200
AMPERES
B-057 436-lA
Two types of gas mixtures are generally used with MIG
welders in the repair of automotive sheet steel. A mix
ture of 75 percent argon and 25 percent carbon dioxide
will
Figure 2-3. Volt-Ampere Curves
provide
ter, and
smoother
a
a more
Welding grade
stable
welding appearance, less spat
than straight carbon dioxide.
arc
carbon dioxide will do
however, it does produce
an
acceptable job;
spatter, a more violent
and less stable arc, and it penetrates deeper and may
cause
burn
more
through problems
on
light
sheet
gauge
steel.
Axle
Casters
Wheels
Spreader
Bar
Ir
-.
-
t
I
I
Plug
Cable
Handle
Figure 2-4. Supplied Parts
113336
Page
14
Wall
Receptacle
Clamp
Brucket
Hardware
Spool Of
D.
Wire
important factor to consider in MIG welding is the
selection of the correct welding wire. There are many
types to choose from, but certain wires are best suited
for welding on automotive sheet steel. The American
An
Gas
Cylinder
Welding Society (AWS) classification for MIG wires is
usually indicated on the label of the wire spool. Two
AWS wire classes commonly used in the repair of
are E7OS-6 and E7OS-3. The
E7OS-6 will provide a more fluid (wetter) weld puddle
and a flatter bead; however, E7OS-3 is acceptable for
automotive sheet steel
use
with this
welding
power
source.
Helmet, Gloves, Safety Glasses
E.
using this welding power source it is important
welding helmet, fitted with the proper lens, be
worn to protect the eyes from the welding arc. Also im
portant is protective clothing, safety glasses, and gloves
to prevent injury from flying sparks.
When
that
Regulator/Flowmeter
Safety
Gas Hose
a
Glasses
Figure 2-6. Offset/ Punching Tool
Figure 2-5.
Additional
Supplies Required
F.
B.
Regulator/Flowmeter
The
Regulator/flowmeters are used to provide a constant
shielding gas pressure and flow rate to the weld area
during the welding process. Because gases have dif
ferent properties, each regulator/flowmeter is designed
to
be used with
a
specific gas
or
mixture of gases.
changed from one gas
to another unless the proper adapters are installed. Be
sure to obtain the proper regulator/flowmeter for the
type of shielding gas that will be used with this welding
Regulator/flowmeters
power
cannot be
source.
steel
Use
can
process in the
repair of automotive sheet
use of a special Off
be made easier with the
the tool will indent
a
small offset in the sheet steel. A
piece of sheet steel is then cut to size and placed in
position to overlap the offset portion. The new piece of
sheet steel is then welded into place, sanded, filled with
body putty and finished sanded. The head of the tool
new
be rotated
half turn to be used
as a punching
punching tool will expedite riveting opera
tions. The use of this tool will help keep material use
and finishing time to a minimum.
one
tool. The
Gas Hose
approximately 8
welding
set/Punching Tool. This tool has a dual purpose,
rotating head. The damaged area is cut away and the
jaws of the offset portion of the head are placed over
the sheet steel. When pressure is applied to the handles
can
C.
Offset/Punching Tool (Figure 2-6)
ft. (2.4 m) of
S.A.E. gas hose with
good quality 5/8 in.
fittings.
113336 Page 15
SECTION 3
WARNING
ELECTRIC SHOCK
Do not touch live electrical
S
can
INSTALLATION
kill.
1. INSTALLATION OF THE WELDING POWER
3
SOURCE ON RUNNING GEAR (Figure 3-2)
parts.
-
conductors
input power
deenergized supply line BEFORE moving
Disconnect
-
from
unit.
CAUTION UNCONTROLLED
TILTING
OR TIP
_________
unit
ot
l~IN~i
can
result in
personal injuryand
equipment damage.
Use equipment of adequate capacity
to lift the
unit.
If
using
forks
lift forks to handle this unit, be sure the lift
long enough to extend out of the op
are
posite side of the base.
Do not place any part of the body under the
while it is suspended.
Place blocks under frame of unit before attaching
fling gear.
1.
run-
Install the two 4 inch (102 mm) casters and the
spreader bar
on
the front
power source base
3/8 in. hardware.
2.
unit
as
corners
shown in
of the
welding
Figure 3-2 using
Block the unit up securely in middle to ease in
stallation of
rear
wheel/gas cylinder rack
assembly.
3.
Figure 3-1. Completely Assembled Unit
Cylinder
Cap Screw
Bracket
Slide axle through cylinder rack and install a
wheel on each end of axle with a 3/4 in. flat
washer on each side of wheel. Secure the wheels
in place with cotter pins by bending both legs of
cotter pin around the axle in one direction or by
bending one leg clockwise and the other leg
counterclockwise (legs should conform to con
tour of axle as tightly as possible).
~.__~.ł.E;
~~~...__-_~___
Cap
Screw
Two Front
Cotter Pin
2
Safety Chain
Flat Washers
Flat Washer
Running Gear
Cotter Pin
Nut
Washer
Wheel
Casters
TC-049 808-C
Figure 3-2. Installation Of Running Gear
113336 Page 16
Install cylinder rack on welding power source
base using 5/16-18 x 3/4 cap screws and
associated hardware (see Figure 3-2).
4.
CAUTION
_________
damage.
equipment of adequate capacity
Use
in top of
welding power source wrapper and discard. In
stall running gear handle to wrapper using
1 /4-20 x 3/4 cap screws as shown in Figure 3-2.
Remove the two front cap
5.
6.
Install
cylinder bracket
shown
3/4 cap
screws
source
1/4-20
x
rear
panel of welding
Figure 3-2 using
and existing holes in
in
panel.
using lift forks to handle this unit, be sure the lift
are long enough to extend out of the op
posite side of the base.
Using lift forks too short will expose internal com
ponents to damage should the tips of the lift forks
If
forks
penetrate the bottom of the unit.
A
lifting
device
However, if
Set gas cylinder in rack and lock in position with
safety chain. Cylinder must be scured at all
7.
to lift the
unit.
screws
to rear
as
power
IMPROPER LIFTING OF EQUIPMENT
personal injury and equipment
in
result
can
be
sure
a
is
moving the unit.
lifting the unit,
long enough to extend
provided
for
fork lift vehicle is used for
that the lift forks
are
completely under the base.
times.
3
2. LOCATION (Figure 3-3)
A proper installation
site should be selected for the welding power source if
the unit is to provide dependable service, and remain
3 -3. ELECTRICAL INPUT CONNECTIONS
-
-
relatively maintenance free.
A.
Electrical Input
Requirements
This
A proper installation site permits freedom of air move
ment into and out of the welding power source, and
welding power source is designed to be operated
from a single-phase, 60 Hertz, ac power supply which
has a line voltage rating that corresponds with one of
dust, dirt, moisture, and
input voltages shown on the nameplate or
primary data label. Consult the local electric utility if
corrosive vapors. A minimum of 18 inches (457 mm) of
unrestricted space must be maintained between the
there is any question about the type of electrical system
available at the installation site or how proper connec
welding
tions to the welding power
also least
subjects the units
to
power source front and rear
panels and the
the electrical
source are to
be made.
nearest obstruction.
Also, the underside of the welding
power source must be kept completely free of obstruc
tions. The installation site should also permit easy
removal of the welding power
for maintenance functions.
CAUTION
source outer
B.
enclosure
WARNING
RESTRICTED
AIR
and
damage
possible
FLOW
to
causes
.
Disconnect
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 intake air
passages of this welding power source.
if any type of filtering device is used.
Warranty is void
input
inspecting or servicing.
Lockout/tagging procedures
and
power
lockout! tagging procedures
kill.
can
Do not touch live electrical parts.
internal
parts.
ELECTRIC SHOCK
.
_________
overheating
Matching The Welding Power Source To
The Available Input Voltage
before
consist of
employ
internally
padlocking line
disconnect switch in open position, removing fuses
from fuse box, or shutting off and red-tagging circuit
breaker or other disconnecting device.
CAUTlO1N
INCORRECT
INPUT
VOLTAGE
________
damage unit.
Position jumper link as shown on the input voltage
label located on primary terminal block.
JUMI~K
LINK PLACEMENT
can
The input voltage jumper link provided on the primary
terminal block permits the welding power source to be
operated
from
various
line
voltages.
voltages
from which this unit may be
stated on the nameplate and on the input
See
Figure
The
various
operated are
voltage label.
3-6 for location of the
primary terminal block
input voltage jumper link is position
ed for the highest of the voltages stated on the
nameplate. If the welding power source is to be
operated from a line voltage which is lower than the
highest voltage for which the unit was designed, the
jumper link will have to be moved to the proper position
before operating the unit. Steps 1-5 below provide in
structions on repositioning the jumper link. If the
available input voltage matches the highest voltage of
the unit, skip Steps 1-5.
and this label. The
/
Figure 3-3. Location
If the unit has not been installed
holes are provided in the base for
case a
on
the
running
mounting
gear,
purposes in
permanent location is desired.
113 336
Page
17
Input Voltage Label
Ret: TD-008 084
Figure 3
6.
-
Primary Voltage
Terminal Block
Location
Figure 3
1.
Use
a
-
4.
Input Connections
3/8 in. wrench to
from the
welding
remove
power
the cap
source
Figure 3-5). Loosen the wing-headed
which
secure
screws
5.
Replace
C.
Input Conductor Connections (Figure 3-4)
outer enclosure.
wrapper (see
screws
the door.
WARNING: ELECTRIC SHOCK
2.
Lift outer enclosure upward to
3.
Locate Terminal Block where indicated in
3-6.
can
kill.
Do not touch live electrical parts.
It is recommended that a fusible line disconnect
switch be installed in the input circuit to the
remove.
Figure
we/ding power source.
provide a safe and convenient means to
completely remove all electrical power from the welding
power source whenever it is necessary to internally in
This would
This
WJa1:If..tii~
terminal block with
welding
power
source
has
one
position for the jumper fink for
each voltage listed on the nameplate. The jumper link
must be connected for the correct voltage.
4.
a
screws securing the jumper link.
jumper link in the proper position
before operating the unit. Tighten all screws
securely.
Loosen the two
Place
the
Remove
spect
or
service the unit.
Employ lockout/tagging procedures on input
fine before making input connections to the
we/ding power source.
Lockout/tagging procedures Consist of padlocking line
disconnect switch in open position, removing fuses
from fuse box, or shutting off and red-tagging circuit
breaker or other disconnecting device.
Connect unit to single-phase input power.
Connect the ground (green) lead to a proper elec
trical ground.
Use a grounding method that is acceptable to the local
electrical inspection authority. Ensure that black and
white leads
are
connected to line terminals.
Table 3-1. Recommended
Primary Wire
& Fuse Size
input conductor sizes are based on National Electrical Code specifica
ampacities of insulated copper conductors, having a
temperature of 75C, with not more than three conductors in a raceway
or cable. Numbers in I ) are equipment ground conductor sizes.
tions for allowable
All
models
are
ordinarily
conductor power cord.
volts input power are
polarized plug
and wall
equipped
with
a
Models requiring 208
equipped
with
a
threeor
230
three-prong
receptacle. The wall receptacle
should beinstalled in a convenient location by a compe
tent electrician. The wall receptacle should be installed
with the
Figure 3
113 336 Page 18
-
5. Wrapper
Cap Screw
Location
grounding terminal at the top. This would allow
hang downward without undue ben
twisting.
the power cable to
ding
or
3
INSTALLATION
4.
-
WELD
SPOT
THE
OF
A.
Installation Of Work
Clamp (Figure 3-8)
PANEL (Optional) (Figure 3-7)
Install the work
WARNING
ELECTRIC SHOCK
can
_________
Do not touch live electrical
Disconnect
input
inspecting
or
Insert the end of the work clamp with the ter
minal lug on it through one of the two supplied
insulating sleeves.
2.
Lay the work cable inside the half of the work
clamp which has the flatest inner surface.
3.
Align
employ
and
power
before internally
servicing.
consist of
Lockout/tagging procedures
padlocking
line
disconnect switch in open position, removing fuses
from fuse box, or shutting off and red-tagging circuit
breaker
or
other
disconnecting
IMPORTANT All
device.
directions, such
as
left
with respect to the operator
Remove module
hand
corner
facing
cover
of front
right,
paneL
or
_______________
1.
onto the work cable as follows:
1.
parts.
lockout! tagging procedures
clamp
kill.
the front
are
the smaller hole in the work clamp with the
hole in the work cable terminal lug. Secure the
terminal lug to the work clamp with the supplied
nut and bolt.
plate from upper rightpanel. Retain securing
screws.
I,)
Step
4
Step 2
Figure 3-8. Work Clamp Installation
4.
Bend the tabs
on
the end of the work
clamp
around the work cable.
5.
Slide the insulating sleeve
the work clamp handle.
6.
Slide the
on
the work cable
remaining insulating sleeve
over
over
the
other work clamp handle.
B.
The
Jack
Plug Installation (Figure 3-9)
jack plug, included in the parts package, must be
plain end of the work cable as follows:
attached to the
1.
Remove 1 in. (25.4 mm) of insulation from end
of cable.
Figure 3-7. Spot Weld Panel
2.
wiring harness clamped to air baffle.
wiring harness from first clamp and
carefully pull end of wiring harness with connec
it will come
tors through opening in front panel
through approximately 2 in. (51 mm).
Locate
Remove
Bd~
-
3.
Disconnect
from
4.
and
discard
jumpered
connector
plug PLG2.
Connect
PLG2.
receptacle RC2
Be
sure
the
from SPW 1
connectors
panel
are
to
DL~
locked
C~)
5.
3
-
Install SPW 1 panel into front panel
ing screws removed in Step 1.
5. WORK CABLE ASSEMBLY
work cable with
unit.
C~
---~___
together.
a
lug
on one
using
secur
FyI
A 10 foot (3 m)
end is included with this
TA.901
-
Figure 3
-
9. Jack
024-4
Plug InstallatIon
113336
Paqe 1~
2.
Clamp cable in
ding upward
a
vise with uninsulated end exten
vise approximately 1-3/4 in.
Wire
Spool Hub
out of
(44.5 mm).
3.
Place steel tie wire (item A) approximately 1/4
in. (6.4 mm) from end of insulation.
4.
Make half turn around cable bringing looped
ends of tie wire together.
5.
Insert
3/8 in. (9.5 mm) diameter rod
a
looped
through
ends of tie wire.
i/Feeder
I Connector Securing
Drive
Knob
Tension
6.
Twist tie wire (B) until entire tie wire is twisted
and is tight and around insulation of cable.
7.
Clip off looped
8.
Bend the twisted tie wire
ends of tie wire.
over
and
Compreselon
Spring
For 8 in. Spoole
\
Spring
Housing
TA-072 573
Retaining Ring
Figure 3-10. Wire Spool Installation And Welding
Wire Threading
along the side
(C) of uninuslated portion of cable.
3
-
7. THREADING THE WELDING WIRE
(Figure
3-10)
9.
10.
Wrap the strip of
copper foil tightly around unin
sulated end of cable and twisted tie wire (D).
Push the
jack plug
onto cable over copper foil
(E).
L~~U~E
ELECTRIC SHOCK can
kill;
WELDING WIRE can cause puncture wounds;
MOVING PARTS can cause injury.
Do not touch live electrical parts.
Do not
11.
other
Insert the 1/4-20 setscrews into the center and
bottom holes in jack plug and tighten (E).
point gun toward any part of the body,
personnel, or any conductive surface when
threading welding
wire.
Keep clear of pinch points.
12.
Remove cable from vise and insert
jack plug into
insulating sleeve. Slide insulating sleeve over
jack plug and cable until hole in insulating sleeve
lines up with remaining hole in jack plug (F).
The welding wire and all metal parts in contact with it
are energized when the gun trigger is pressed.
1.
Disengage tension spring
pivot the gear
13.
cover
on
open
drive
assembly and
Figure
shown in
as
3-10.
Insert the 8-32 self-tapping screw (F) through
hole in insulating sleeve into jack plug and
IMPORTANT Spooled wire has a tendency to
unravel when loosened from the spool. Maintain a firm
tighten.
_____________
14.
jack plug into the NEGATIVE weld output
receptacle on front panel of the welding power
Insert
source.
grip
Open hinged door panel on left side of welding
power source by turning the two wing-headed
screw
2.
fasteners in
Remove all
a
packing
during
the
threading operation.
Loosen end of wire from spool and cut off any
kinked or bent portion with side cutters. The cut
must be a good clean cut to avoid binding in the
drive system.
3.
Thread wire through the inlet guide, over the
drive roll, and approximately 4 inches (102 mm)
into the outlet
counterclockwise direction.
from
the wire
2.
3 -6. INSTALLATION OF WELDING WIRE SPOOL
(Figure 3-10)
1.
on
guide.
IMPORT4NT~
spool of wire.
Whenever the upper portion of the
assembly is closed, ensure that gears are properly
meshed and the wire is placed in the groove of the drive
rolls. Failure to comply with this requirement will result
in erratic wire feed and damage to the drive rolls.
_____________
drive
3.
4.
Remove
retaining ring by pressing the two spring
loaded pins inward. Remove compression spring
from the welding power source wire spool hub.
Place wire
spool
onto the
wire spool hub
so
that
4.
wire feeds from the bottom of the
inlet wire
guide
as
shown in
that small pin-of the spool hub fits into the small
hole of the wire spool.
5.
5.
113 336
Replace retaining ring on the hub. Compression
spring not required for 12 in. spools. For 8 in.
spools, use compression spring.
Page
20
Lower gear
cover
making
sure
that the gears
are
properly meshed, and that the wire is placed in
the groove of the drive roll. Reposition tension
spring into Iked~position.
spool into the
Figure 3-10. Ensure
Turn Line Disconnect Switch and welding power
source POWER switch to the ON position.
If welding power source has spot welding
capabilities, place SELECTOR SWITCH in the
CONTINUOUS WELDING position.
~
WELDING
ELECTRIC
WIRE
can
MOVING PARTS
SHOCK
cause
can cause
can
puncture
injury.
Do not touch live electrical parts.
Do not point gun toward any part of the
other
personnel,
or
kill;
wounds;
body,
any conductive surface when
threading we/ding wire.
of pinch points.
The welding wire and all metal parts in contact with
are energized when the gun trigger is pressed.
Keep c/ear
it
6.
Press gun trigger and hold in until the wire ex
tends about 1/4 in. (6 mm) out of the contact
tube.
7.
Set proper hub tension by adjusting the hex nut
(see Figure 3-10). Wire should unwind freely,
but tension should be sufficient to keep the wire
prevent backlash when the gun trigger
A.
taut and
is released.
8.
9.
Close
hinged
source
and
If
excess
door
secure
A.
1.
welding
on
screw
power
fasteners.
wire feeds out, cut off to 1/4 in. (6 mm)
length with side
3 -8.
panel
with
cutters.
MWG 200 WELDING GUN CONNECTIONS
Gun/Feeder Connector Installation (Figure
3-11)
Loosen
the
gun/feeder
connector
securing
knob.
IMPORTANT Wire~ guides should be installed
that the tip of the guide is as close to the drive roll
possible without touching.
so
______________
2.
Insert the
as
gun/feeder connector, which includes
guide, through the access
B.
the installed outlet
hole
in
assembly
the
as
wire feeder and into the drive
illustrated in Figure 3-1 1, Photo A.
3.
Tighten the gun/feeder connector securing knob
as illustrated in Figure 3-1 1, Photo B.
B.
Gun Switch Connection
(Figure 3-11, Photo
C)
Trigger receptacle is provided for making gun
switch control connections. Align the keyways on the
gun switch plug with the Gun Trigger receptacle keys,
insert the plug, and rotate threaded collar clockwise as
illustrated in Figure 3-11, Photo C. When the gun
switch is closed, the contactor in the welding power
A Gun
source
energizes, shielding
gas
flows,
and wire feeds.
C.
Figure 3-11. Welding Gun Connections
3
-
9. INSTALLATION OF SHIELDING GAS
4.
A
shielding
of the
A.
Cylinder
Gas
this output
hose to the
Secure the gas cylinder to the running gear with sup
plied chain. If running gear is not to be used, chain
cylinder to a wall or other stationary support to prevent
cylinder from falling
over
Ii~1~II~e~ GAS.
plosive.
Keep
from
fitting
gas output
is provided at the
welding
power source for making gas
connections. Attach one end of the gas hose to
rear
and
of the gas
off the valve.
breaking
UNDER
fitting. Attach other end
regulator/flowmeter.
PRESSURE
is
ex
Flow
open
flame and
shielding
smoking
materials away
Adjustment
gas.
cylinders in upright position.
Ensure that cylinders are chained to stationary
support or running gear
A/ways
store
B.
Regulator/Flowmeter
1.
With
the
Gas Hose
Connection
(5/8-18 Male
cylinder correctly
placed,
remove
-
Fitting Required)
C02
cylinder cap, then stand to one side of the
cylinder valve and open valve slightly. When gas
is emitted from the cylinder, close the valve. This
procedure will help to get rid of any dust that
Installation
may have accumulated around the valve seat.
Regulator/flowmeter
2.
with
with
a
must
be
properly equipped
stem, nut connectors, and gasket for use
either C02
cylinders or Argon/CO~
cylinders.
Attach gas regulator to gas cylinder valve; keep
the face of the regulator/flowmeter gauge in a
vertical position and tighten stem nut securely to
3.
gas
cylinder valve.
Fitting Required)
IMPORTANT A gasket should be installed to
pre
vent leaks. Do not use lubricants or
sealing agents.
Angon Installation
Figure
3-12.
TB-109 492
Typical Regulator/Flowmeter
Installation
SECTION 3
-
OPERATOR CONTROLS
Continuous/Spot! Pulse
Selector Switch
-Burnback Time
Pulse Off Time
Spot
Gun/FeederS
Connector
Time/
Tuning! Wire
Pilot
Light
Output Receptacle
Thickness/Volts Receptacles.
And Selector Plug
B-087 313-B
Figure 4-1. Front Panel View
113 336
Page
22
4
-
1.
Rotating the FINE TUNING/WIRE SPEED control
clockwise increases the rate of the wire feed and weld
selected
of
the
the
within
current
range
POWER SWITCH (Figure 4-1)
THICKNESS/VOLTS tap.
POWER
When the FINE TUNING/WIRE SPEED control is set at
0, wire feeds at the slowest speed and weld current is at
minimum in the selected range; when set at 100, the
wire feeds at the fastest speed and weld current is at
ION
maximum in that range.
The scale which surrounds the FINE TUNING/WIRE
SPEED control is calibrated in increments of ten ranging
from 0 to 100 percent. Due to this percentage calibra
OFF
-
uI~lgsfl~V~I~ When the POWER switch
is
placed,,,
the ON position, the pilot light will turn on but the fan
motor will not start running unless the internal com
The fan motor is ther
are already warm.
mostatically controlled and will only operate when addi
tional cooling is required (see Section 4-6).
tion, it should be noted that if this scale is being used
select
wire
a
percentage of the range in
actual wire feed speed
an
weld
and
speed
feed
use
is
being
to
current, only a
selected and not
amperage.
or
ponents
Placing the POWER switch in the ON position will
energize the welding power source and place the unit in
a ready-to-weld status. Placing the POWER switch in
the OFF position will shut the unit down.
-
-
2.
~ I ~ In the PUL SE
I I~ lg.] ~I
PANEL
WELD
mode, the FINE TUN
ING! WIRE SPEED control must be set at 50 percent
less when using THICKNESS! VOL TS taps 5 and 6.
or
Selector Switch
A.
A Pilot light is pro
PILOT LIGHT (Figure 4-1)
vided to indicate when the welding power source is
energized and in a ready-to-weld status. The Pilot light
illuminates whenever the POWER switch is in the ON
4
PULSE
5. OPTIONAL SPOT
CONTROLS (Figure 4-1)
4
-
and weld output is available. If the unit shuts
down because of overtemperature the pilot light goes
position
out.
The Selector switch enables the operator to select con
or pulsed wire feed operation. Placing the
tinuous, spot,
Selector
switch
in
the
CONTINUOUS
position and
depressing the gun trigger feeds welding wire for as
long as the gun trigger remains closed. Placing the
Selector switch in the SPOT position and depressing
trigger feeds welding wire for the length of time
the gun
4 -3. THICKNESS/VOLTS SELECTOR
(Figure 4-1)
Placing the Selector
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 pulse on
time, welding wire feeding stops for the length of time
set on the PULSE OFF TIME control. Welding wire
feeding continues to pulse on and off for the selected
times until the gun trigger is released.
set on
the SPOT TIME control.
switch in the PULSE
THICKNESS
VOLTS
The THICKNESS/VOLTS selector
jack plug and recep
provide a selection of heat input to the weld from
through 6. The higher the numbered tap the hotter
tacles
1
The
the weld.
LII~II~cr
can
ELECTRIC SHOCK
burn skin
or
damage
can
kill; ARCING
pulse option provides
better control of the heat in
metals, thereby decreas
put
to the weld on thin gauge
ing
distortion and the likelihood of
melt-throughs.
electrical connections.
Do not touch live electrical parts.
change position of TH/CKNESS/ VOL TS
B.
Spot Time/Pulse On
Time Control
Do not
The SPOT TIME/PULSE ON TIME control enables the
selector
jack plug while welding.
Be sure that jack plug is secure
before welding.
4
-
4.
FINE
TUNING/WIRE
in
SPEED
receptacle
CONTROL
(Figure 4-1)
010
operator
to select from
0.5 to 4 seconds of weld time
operation or 0.25 to 2 seconds of pulse time for
pulse operation. Rotating the control clockwise in
creases
spot/pulse on time. The control scale is
for spot
FINE TUNING
WIPE SPEED
The FINE TUNING/WIRE SPEED control provides a
means of varying both the speed of the wire feed motor
and weld current of each THICKNESS/VOLTS tap.
calibrated
in
percent
spot/pulse
on
times.
C.
and
does
not
indicate
actual
Pulse Off Time Control
The PULSE OFF TIME control enables the operator to
select from 0.25 to 1 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.
113 336
Page 23
D.
Fan motor FM is ther
controlled
to
provide fan cooling of main
mostatically
transformer Ti and rectifier assembly SRi if these com
4
Burnback Time Control
The BURNBACK TIME control enables the operator to
select the amount of time the electrode wire remains
electrically hot after the wire stops feeding. The correct
buræback time allows the wire to burn back just free of
puddle. If the burnback time is too
burn back into the contact tube.
could
wire
the weld
long the
-
6. FAN-ON-DEMAND
ponents require cooling. The fan will only run when
cooling is required. Two normally-open thermostats,
TP1 in rectifier assembly SRi and TP2 in main
transformer Ti, and relay CR2, regulate the operation
of fan motor FM. When the main transformer and/or
rectifier
Rotating
creases
the BURNBACK TIME control clockwise in
burnback time from 0 to 0.25 seconds. The
control scale is calibrated in percent and does not in-.
dicate actual burnback times.
-
assembly
warm
up
enough
to
close
thermostat(s) TP1 and/or TP2, fan relay CR2 energizes
causing fan
will
motor
continue
FM to start
running.
until
to
the
The fan motor
main transformer
operate
and/or rectifier assembly have cooled enough to permit
thermostats TP1 and TP2 to open or until the welding
power
SECTION 5
-
source
is shut down.
MAINTENANCE & TROUBLESHOOTING
456
I
15
TC-072 ~
Figure 5-1. Drive Roll Gear
Removal And
Installation
WARNING
ELECTRIC SHOCK
can
kill.
Periodically inspect the labels on the
legibility. All precautionary labels must be main
IMPORTANT
_________
______________
Do not touch live electrical parts.
Disconnect unit from input power before internal
ly inspecting
or
servicing.
MOVING PARTS can cause serious injury.
Keep clear of moving parts.
HOT SURFACES can cause severe burns.
cooling period before servicing.
Troubleshooting of internal parts to be performed only
by qualified persons.
Allow
113336 Page 24
unit for
c/early readable state and replaced when
Parts List for part number of precau
See
necessary.
tionaly labels.
tained in
5
-
a
1. TRANSFORMER
-
Occasionally blow
dust and dirt from around the transformer.
out
the
Do this
upon the location of the unit
and the amount of dust and dirt in the atmosphere. Use
a clean, dry air source for this cleaning operation.
periodically, depending
5
2. FAN MOTOR
-
exhaust fan and
an
All models are equipped with
rely on forced draft for adequate
-
cooling.
The fan motor bearings require
maintenance,
5
3.
-
no
periodic
1.
-
-
with
REMOVAL OF DRiVE ROLL GEARS (Figure
5-1)
A.
4. CLEANING OF DRIVE ROLLS
Occasionally
it will become necessary to clean the wire groove on the
drive rolls. This cleaning operation can be performed
5
a
wire brush.
Removal Of Upper Drive Roll Gear
Grasp tension spring (10) at the top and pull out
ward until it disengages from cover (6).
ROTATIONAL
WARNING HIGH
cause
5
-
damage
SPEED
may
to drive rolls.
if
Do not allow drive rolls to rotate at
high speed
compressed air is used for cleaning
assembly.
the drive roll
5. CIRCUIT BREAKERS
-
Two circuit breakers,
immediately above the drive roll assembly, are
provided to protect the welding power source in the
located
2.
Remove
pin (16) from the back side of shaft
protects the
(17).
event of an overload. Circuit breaker CB1
3.
Pull out shaft (5) from drive roll
off drive roll cover (6).
and circuit breaker CB2 protects the
welding power source control circuitry. If either circuit
breaker opens, wire feeding ceases. It would then be
4.
Pull off snap
5.
Pull out bearing (2) from drive roll
motor armature
cover
(6) and lift
(
rings (1
and 8) from shaft (5).
cover
(6).
necessary to manually
breaker to reset it.
5
-
Slide shaft (5) out of drive roll
drive roll gear (3) drops out.
7.
Ensure that key (4) remains in the slot in shaft
(5).
cover
(6) until
The following chart is
provide remedies for some of
develop in this welding power
6. TROUBLESHOOTING
designed
6.
depress the appropriate circuit
to
diagnose
-
and
the troubles that may
source and wire feeder.
When
troubleshooting this welding power source,
simplest problem and advance to
the more complicated. Use the senses of feeling, hear
ing, seeing, and smelling. Apply common sense; then
try to locate the trouble through a process of elimina
always
start with the
B.
Removal Of Lower Drive Roll Gear
1.
Remove nut (11) from drive shaft (15).
tion.
2.
Slide drive roll gear (12) off of drive shaft (15).
conjunction with the circuit diagram
performing troubleshooting procedures. If the
trouble is not remedied after performing these pro
cedures, the nearest Factory Authorized Service Sta
tion should be contacted. In all cases of equipment
recommendations
malfunction, the manufacturers
should be strictly followed.
Use this chart in
while
3.
Ensure that key (14) remains in the slot in drive
shaft (15).
C.
Installation
Reverse the
preceeding procedures
to
install the drive
roll gears.
113 336
Page 25
PROBABLE CAUSE
TROUBLE
Electrode
wire
feeding
welding.
while
stops
Sharp
REMEDY
excessive bend in
or
gun cables
or
Straighten
gun cables and/or
replace liners.
liners.
Drive roll pressure not ap-
Apply drive
roll pressure.
Loosen and
re-adjust
plied.
Spindle friction
Contact
too
great.
orifice
burnback of
tip
restricted;
nut pressure.
Replace contacttube.
electrode.
Friction in gun.
Check wire passage; clean, replace parts
as
re
quired.
Gun casing
restricted.
Broken
or
liner
dirty,
damaged casing
or
Remove liner, blow out with
Replace casing
or
liner
as
compressed air.
required.
liner.
Drive rolls worn;
Replace drive rolls.
slipping.
Drive motor burned out.
Gun trigger
operative or
replace if necessary.
in
switch
wire
Test motor;
leads
Replace switch; check connections.
broken.
Fuse blown in power
source
I
Replace fuse.
primary.
Welding
Check for 1 15V
contactor open.
applied
Circuit breaker of contactor
circuit opened.
Reset circuit breaker.
Protective circuit breaker in
Find
wire
drive
cause
to contactor.
of overload and reset circuit breaker.
circuit
motor
opened.
Excessive
loading
of drive
Clear restriction in drive assembly.
motor.
Wire drive rolls
Wire
misaligned.
control/feeder
relay
Re-align drive rolls.
Replace control relay.
inoperative.
Electrode wire feeds but is
energized. No welding
not
arc.
Work connection loose
incomplete
paint, etc.
Welding
due
cables
to
or
rust,
Make
sure
the work
clamp connection
possible.
loose
in
clamp makes g ood metal to
workpiece. M ake the work
metal contact with the
as
Check connections.
plugs.
Contact tube.
113336
Page
26
Replace
contact tube.
close to the weld
area
as
REMEDY
PROBABLE CAUSE
TROUBLE
Low output.
Primary
link
jumper
in
position.
wrong
Low
primary voltage.
Fan
motor
fan
motor
in
position for primary voltage
Place
jumper link
being
used. See Section 3-36.
Connect
welding
input voltage.
power
source to
proper
primary
-
Unit
shuts
down
while
welding.
inoperative
or
connections
Check and repair fan motor connections. Replace
fan motor.
loose.
No output.
Fan control circuit.
Replace inoperative components in fan control cir
cuitry: relay CR2, thermostat TP1 or TP2.
POWER switch Si.
Replace Si.
Line fuse open.
Check and
Loose
primary connections.
Primary
or
No
open-circuit voltage.
disconnect switch
line circuit breaker open.
replace line fuses if
tightness
Check
Replace points.
Contactor W coil.
Replace coil.
Gun switch S3.
Replace S3.
THICKNESS/VOLTS selec-
Secure
plug
primary connections.
Place primary disconnect switch
breaker in closed position.
Contactor points.
tor
of all
necessary.
plug
into
or
line circuit
receptacle.
not secure in recep-
.
tacle.
Transformer Ti.
Plug PLG2
not
Replace Ti.
secure
in
Secure PLG2 into RC2.
receptacle RC2 (Spot Pulse
Weld Models Only).
Wire does not feed. Opencircuit voltage is normal.
Circuit breaker CB1
tripped
FINE
or
or
CB2
Reset
or
replace CB1
or
CB2.
inoperative.
TUNING/WIRE
Replace rheostat R50.
SPEED control R50 open.
Spot Weld Timer and Spot
Burnback
Timer
in-
Rectifier SR2.
Replace SR2.
Wire feed motor M.
Replace
Spot Pulse Weld panel
operative.
in-
motor
M.
Replace Spot Pulse Weld panel.
operative. Wire feeds con
tinuously. Output normal
(Spot Pulse Weld Models
Only).
113 336
Page
27
a
3
4
5
6
7
8
9
PL.G2
NEGATIVE
Circuit Diagram No. A-088 808-A
POSITIvE
Figure 5-2. Circuit Diagram
For
Welding
Power Source
I
OFF
TI ME
R
66f~L
69
PLO
-
CONT.
S5OA
51
SPOT
LJLSE1
II
II
64
63
~ P
PC~o
21
I
I
SPOT
TIME
I
~
I
~
H
55
;
A
0
6<
P1050
58
611
62
56
.~c55
Circuit
Figure
113 336
Page
28
5
-
3. Circuit
Diagram
For SPW 1 Panel
Diagram
No. A-090 568-A
---
Figure
-
-
5
-
4.
Circuit
Diagram
--~~1
For SPW 1 Panel Printed Circuit Board PC5O
113 336
Page
29
SECTION 6
CAUTION WELDING
-
WELDING PARAMETERS,
CURRENT
TECHNIQUES
AND SET-UP
damage
can
_______
automotive electronic parts.
Disconnect t,oth battery cables before
a vehicle.
welding
a
on
TA-057 469-16
Figure 6-3. Welding Techniques
Figure 6-1. Continuous Seam
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
The
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.
Position the gun either toward or away from the body at
a 45 to 60 degree lead angle (see Figure 6-2). This will
give a good view of the arc and make it easier to follow
Other
welding techniques that affect the weld
characteristics in the MIG welding process include the
backhand 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
being fed into the weld metal previously
deposited. In the forehand technique the gun is angled
metal
so
is
that the electrode wire is fed in the same direction as
arc travel. The backhand technique generally yields
the
a more
stable
arc
and less spatter
on
the workpiece.
while wearing a welding helmet. Maintain a
5/16 inch (6-8 mm) distance from the bottom of
the gun nozzle to the workpiece during the arc starting
and welding period. Do not pull the gun back from the
seam when the arc starts, as this will create a long wire
the
seam
1/4
to
extension and result in
a
poor weld.
Direction of Arc Travel
Backhand
Technique
Figure 6-2. Gun Position
The
welding
wire is not energized until the trigger is
can be extended
1/4 (6 mm) inch beyond the gun nozzle and placed on
the seam, before lowering the helmet and pressing the
pressed. Therefore the welding wire
gun
trigger.
The gun
be moved
along the seam in a steady
drag technique (see Figure
6-3), 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, welding current selected and the technique us
ed. However, the average speed is 15 to 20 inches per
minute (.4-.5 mpm).
can
movement
113336
Page
30
known
as
the
Direction of Arc Travel
-
Forehand
Figure
6-4.
Technique
Longitudinal Gun Positions
and/or vertical down techniques
describe the direction of arc tavel when the welding
must be done in the vertical position. In both of these
The
vertical
up
PARTS can cause serious
internal parts.
in the
operating.
technique is generally employed when welding
vertical position, but when bridging agap, the arc
be oscillated from
one
can
side of the work to the other.
can
AND EXPOSURE TO ENVIRONMENT
extremely important
techniques gun positioning
because the arc must be kept on the leading edge of the
puddle to ensure complete weld penetration. The drag
is
kill; MOVING
OVERHEATING
injury;
ELECTRIC SHOCK
WARNING
_________
can
Do not touch live electrical parts.
Keep all covers and panels in
damage
p/ace
while
source is operated
with any portion of the outer enclosure removed.
WELDING CURRENT can damage automotive
Warranty is void if the welding power
electronic parts.
Disconnect both battery cab/es before
a vehicle.
Thoroughly clean the joint
1.
with sandpaper
or
area
we/ding
on
of the base metal
wire brush.
Ensure that the regulator flowmeter adjustment
handle is in the closed (clockwise) position, then
slowly turn the gas cylinder valve
2.
(counterclockwise) until it is completely open.
Place the Line Disconnect Switch in the On
3.
posi
tion.
ELECTRIC SHOCK
IYAYI1~Il~Itf
can
burn skin
damage
or
can
kill; ARCING
electrical connections.
Do not touch live electrical parts.
change position of TH/CKNESS/ VOL TS
Do not
Vertical
selector jack
Up
Be
sure
before
4.
plug
that
while
welding.
jack plug
is
secure
in
receptacle
we/ding.
Place
the
THICKNESS/VOLTS
selector
jack
plug in the desired receptacle.
Rotate the FINE TUNING/WIRE SPEED control
5.
to the
6.
desired
Connect the work
clamp
close to the weld
area as
Place the
7.
in the ON
In the Vertical
welding power
position.
welding power
length of time, air
shielding gas in the
If the
8.
Figure 6-5. Welding
setting.
to the work
source
source
will
Up and Vertical
has been idle for any
to displace the
begin
IMPORTANT: Gas pressure of 6
Range
THICKNESS/VOLTS Tap
1
2
3
4
5
METAL
GAUGES
22-18
18-16
16-14
14-12
12-10
THICK-
INCHES
035+
.047+
.059+
.067+
.104+
.134
NESS
MILLIMETERS
.8+
T1~
TWT
1.9+
26-s.
3.4+
30-55
55-85
85-105
105-130
130-150
150-180
35-65
65-95
95-115
115-140
140-180
175-220
6
10
Or Heavier
I.Bmml WIRE
AMPERAGE
.035
I,gmrnl WIRE
Amperage
ranges
are
obtained by
adjusting
pounds
regulator
or
flow rate
typical. We/ding out of position, we/ding
at fast travel speed or at high wire feed speeds, or
welding in a drafty environment will require more gas
shielding.
of 15 cfh
are
+
AM PER AG E
.030
POWER switch
purge the gas hose and to adjust the
flowmeter. Retighten drive rolls.
6 -2. SETUP FOR CONTINUOUS GAS METALARC WELDING
Selection Chart For Mild Steel
as
gas hose between the gas
valve and the gun. To avoid contaminating the
weld, release drive roll pressure and depress the
gun trigger for approximately fifteen seconds to
Down Position
Table 6-1.
material
possible.
the FINE TUNING/WIRE SPEED control.
IYA!:h~lhItf
RAYS
ELECTRIC
SHOCK
can
kill;
ARC
burn eyes.
Do not touch live electrical parts.
Keep the welding wire isolated from the work
can
clamp or
we/ding.
any
conductive
surface
when
not
113336 Page3l
The
welding wire is electrically energized whenever the
trigger is depressed. The difference in potential bet
ween the welding wire and the work clamp (workpiece
or table if workclamp is connected to either) will cause
12.
gun
current to flow
6
-
Lower welding helmet,
welding.
press
trigger,
and
begin
3. PULSED GAS METAL ARC WELDING
if. con~act is made.
pulsed welding the filler metal is transferred to the
during the period of Pulse On Time, and cools dur
the
period of Pulse Off Time. When the selector
ing
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
In
9.
Extend the
welding
wire 1/4 inch (6 mm)
beyond
gun nozzle.
WARNING ARC
RAYS,
SPARKS,
AND
HOT
_________
SURFACES
burn eyes and skin; NOISE
can
can
damage hearing.
Wear correct eye, ear, and body protection.
See
Section 1-Safety Rules For Operation Of Arc
Welding Power Sources for basic welding safety infor
mation.
work
time set
put
10.
Place wire
over seam.
11.
Be
hold gun nozzle 1/4 inch to 5/16 in
8 mm) from workpiece.
sure to
ches, (6
to
113336
Page
32
the PULSE OFF TIME control. This
on
and
to the weld on thin gauge
metals, thereby decreas
ing 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 position and
Figure 6-6. Pulsed Seam
6-8. Fender
on
off sequence continues until the gun trigger is released.
The pulse option provides better control of the heat in
Figure 6-7. Spot Weld
Repair
With
Spot Nozzle
2.
Cut wire from weld.
3.
Increase BURNBACK TIME
the SPOT TIME/PULSE ON TIME control and PULSE
OFF TIME controls must be set to the desired positions.
6
4.
-
Instead of
two
pieces
having
4.
Try another sample weld.
pulsed weld to join
welding in spots of 1
B.
Too Much Burnback Time
38 mm) apart can be done. The
process fuses two pieces of sheet
1.
Remove nozzle and
continuous
a
of sheet steel
1/2 inches (25
to 1
setting.
SPOT WELDING
MIG spot
or
together,
to
welding
together 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.
replace
contact tube.
steel
Spot welding is based on the same principles as con
tinuous seam welding except that there is no travel
speed involved; 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 6-8. When the gun trigger is depressed, the elec
trode 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
continue 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
tor will open and the arc will
the contac
feeding,
be broken.
Reinstall nozzle and thread wire
2.
out new contact
tube.
6
-
3.
Decrease BURNBACK TIME
4.
Try another sample weld.
Plug welds provide a means of
pieces of metal where the thickness of the
is beyond the normal range of the welding
5. PLUG WELDS
joining
setting.
-
two
top sheet
source or where sheet metal sections are too thin
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 to 38 mm) apart.
power
to be
MIG spot welding process produces little heat,
therefore little distortion results. Because of the low
Plug
heat characteristics of this
proper parameters
The
when welds
rubber,
or
are
technique, it is often used
proximity to upholstery,
welds
on
sample materials should
can
be made
so
that
be set.
made in close
other flammable materials.
6. SKIP
-
means
Wire froze in weld
~~~
A.
puddle; increase
BURNBACK TIME.
WELDING
Skip welding provides a
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
6
of
making
a
-
series of short
timer times out.
Skip welds should be made
proper parameters
can
on
sample material
so
that
be set.
SPOT NOZZLE
NUGGETJ LIE
CONTACT TUBE
6
-
7. WELD DEFECTS: CAUSES AND CORREC
TIVE ACTIONS
The following is a partial list of some
of the more common weld defects that may occur with
the Gas Metal Arc Welding process:
WIRE
Correct Burnback Time
Setting
A.
-
Porosity
Wire froze in Contact
tube; decrease
B.
BURNBACK TIME.
Hef: TD-083 575
A.
1.
Not
Enough
Burnback Time
Briefly press gun trigger
workpiece.
Figure 6-9. Porosity
to release nozzle from
113 336
Page 33
Possible Causes
1.
Corrective Actions
Inadequate shielding gas coverage.
Remove spatter from the gun nozzle.
I
Check gas hoses for leaks.
~
Eliminate drafts (from fans, open doors, etc.) blowing into the
welding
arc.
Reduce nozzle-to-work distance.
Increase gas flow to displace all air from the weld
zone.
Decrease excessive gas flow to avoid turbulence and the entrap
ment of air in the weld zone.
Hold gun at end of weld until molten metal solidifies.
Check for frozen
C02 regulator
flow meter.
2. Gas contamination.
Use
welding grade shielding
3. Electrode contamination.
Use
only clean and dry electrode.
gas.
~
Eliminate
or
4.
Workpiece contamination.
pick
up of oil
or
lubricant
Remove all grease, oil, moisture, rust,
from work surface before
Use
5.
Excess
B.
tip-to-work
on
distance.
electrode in electrode feeder
conduit.
a more
paint, undercoating, and
dirt
welding.
highly deoxidizing
electrode wire.
Reduce stick-out.
Incomplete Fusion (Lack of fusion)
Figure 6-10. Incomplete Fusion
Corrective Actions
Possible Causes
1. Weld zone surfaces
excessive oxide.
2.
Insufficient heat
not
free of film
or
input.
3. Improper weld technique.
Clean weld
zone
surfaces of
impurities prior
to
welding.
Select higher THICKNESS/VOLTS tap.
When
using
a
weaving technique
dwell
momentarily
on
the side
walls of the groove.
Provide
improved
access at root
Keep electrode directed
Provide proper gun
Improper joint design (Heavy material
only: trailer hitches, etc.)
4.
113336 Page 34
at the
of
joints.
leading edge of
the
puddle.
angle.
angle of groove joint large enough to allow access
bottom of the groove and sidewalls with proper electrode exten
sion and arc characteristics, or use a J
or U
groove.
Provide included
to
C. Lack Of Penetration
Figure 6-11. Lack Of Penetration
Corrective Action
Possible Causes
1.
Material too thick. Joint preparation and design must be adequate
provide access to the bottom of the groove while maintaining
proper electrode extension and arc characteristics.
Improper joint preparation.
to
Reduce excessively large root face.
Provide
or
increase the root gap in butt
depth of back
2.
joints and increase the
gauge.
Maintain electrode angle normal to work surface to achieve
Improper weld technique.
imum
Keep
3. Inadequate heat input.
max
penetration.
arc on
leading edge of the puddle.
Select higher THICKNESS/VOLTS tap.
Reduce the travel
speed.
Maintain proper electrode extension.
D.
Excessive Penetration
(Burn-Through)
Figure 6-12. Excessive Penetration
Possible Causes
1.
Corrective Actions
Excessive heat input.
Select lower THICKNESS/VOLTS tap.
Increase travel
2.
Improper joint preparation.
E.
Reduce
speed.
joint opening
gap.
Cracks In Weld Metal
Possible Causes
1.
or
Improper
joint
design
Corrective Actions
(Heavy
Maintain proper groove dimensions to allow deposition of ade
to weld area.
material).
quate filler metal
2.
Select lower THICKNESS/VOLTS tap.
Heat input too high causing excessive
shrinkage anddlstortion.
~
Increase travel
speed.
113 336
Page
35
F.
Waviness of Bead
Figure 6-13. Waviness Of Bead
Possible Causes
1.
Corrective Actions
Excessive electrode extension.
Reduce electrode extension.
2. Unsteady hand.
G.
Support hand
on
solid surface.
Humping
Figure 6-14. Humping
Possible Causes
1. Too much heat
Corrective Actions
input.
Select lower THICKNESS/VOLTS tap
or
increase travel
speed.
Weld in small segments and allow to cool between welds.
H.
Excessive Spatter
.
Corrective Actions
Possible Causes
1.
Excessive
shielding
6
-
when
spatter
Select lower THICKNESS/VOLTS
ING/WIRE SPEED.
using C02
gas.
8. PROCEDURES FOR WELDING
-
Before
tap
or
adjust
ensure
plete the
path.
current
proper
6
9. PROCEDURES
PANELS
-
grounding
FOR
and to
WELDING
TUN
us
ing 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
FINE
Door Skin
Damage
com
DOOR
Every experienced autobody repair
method of performing the follow
ing procedures. However, this in formation is presented
to show how, in most cases, this we/ding power source
can make the job easier and less time consuming.
IMPORTANT
man
will have his
own
Inner Door
Inner
If the door is severly
damaged,
but the
damage is
the door can be
panel, or skin,
easily repaired without necessarily installing a whole
primarily
new
113 336
in the outer
door.
Page 36
Edge
Of Skin
Crimped
Flange
Around Door
Figure 6-15. Cutaway Of Door Panel Damage
1.
and hardware. It is not
molding
Remove exterior
necessary to remove window
control mechanisms, locks or
2.
regulator,
remote
runs.
assembly and place on flat surface
edges of door extending over edges of sur
Remove door
with
face to
provide
room to
work.
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
Spot
Weld On
Outer Panel
Reinforcement
Inner
Outer Panel
Reinforcement
The
new outer panel can then be placed and held in
position by vice-grips or c-clamp. When welding, start
at the center and proceed first in one direction and then
Figure 6-16. Hem Flange Removal
3.
If door has
panel reinforcement, break
an outer
the weld.
4.
Grind off the hem
flange
and
remove
the old
panel.
5.
Repair any damage
6.
Position
end
new outer
flange
over
to the inner
panel
over
the inner
replaced, the old panel must
by cutting along the weld if welded by con
tinuous seam, or by drilling out the spot welds if it is
spdt 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 located in each case. After the old panel is
removed, the inner panels must be carefully checked,
straightened or replaced.
be removed
panel.
door and bend the
the other. In order to ensure reduced distortion due to
heat, weld only a section of 2 or 3 inches (51 to 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 section. When the weld is completed it
can be hammered down, filled with body putty and
sanded.
flange.
6
7.
Spot weld outer panel reinforcement to
door panel.
8.
Spot weld
9.
Metal finish exterior surface, paint and assemble
interior trim and hardware.
new
hem
flange
6-10. PROCEDURES FOR
AND QUARTER PANELS
to inner
WELDING
new
panel.
FENDERS
11. WELDING
FRAMES
AND
HIGH
STRENGTH (HSS) STEELS
The new HSS steels are
used on many of the new economy 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 reduction and are heat sen
sitive. As heat is applied, the strength decreases and
cracking
can
must be
kept
as small as possible. For this reason the
MIG welding process has become the preferred method
for welding HSS steels, and the oxacetylene welding or
brazing
When
a
replaced it will be
the bolts securing the panel to the
complete panel
necessary to
remove
must be
Pulsed Seam
Welds
Figure
6-17. Automotive
occur, therefore the heat affected zone
processes, with its wider heat affective area,
not recommended.
are
normally
Seam
Body Sections Assembled With Continuous Seam, Pulsed And Spot Welds
113336 Page 37
Fit
3.
a
4.
piece of sheet steel
new
which
removed. The
was
over
new
overlap the
cut away section
Clamp the
new
by
the section
material should
one
inch.
metal in place and prepare to
spot weld.
5.
Place the THICKNESS/VOLTS selector plug in
tap, the weld timer at 3 to 4,
the burnback at 4 to 5 and the selector switch to
the SPOT position.
to number 3 or 4
6.
Install the spot nozzle
7.
With the
on,
on
the gun.
shielding gas and power source turned
place the spot nozzle and press firmly against
the
new material about 1/2 to 3/4 inch (12 to 18
mm) from the edge. Fit up must be tight to
assure good, repeatable spot welds.
Begin spot welding from
8.
side. Distortion may
the corners.
the center out
occur
if
on
each
welding begins
at
to 1 1/2 inches (25 to 38
mm) apart around the repair. Spot welds should
be about 3/16 inch (5 mm) in diameter.
Space spot welds 1
9.
Figure 6-18. Application Of Body Putty
6-12. PROCEDURES FOR WELDING THIN SHEET
METAL
1.
Use
.030
a
or
.023 E7OS-6 wire and argon/car
IMPORTANT Do
not
make
continuous
welds
_____________
bon dioxide
shielding
around the
gas.
repair
as
this will promote distortion a~nd
warpage.
2.
Use direct current electrode
burn
3.
negative for reduced
through.
Insert the gun Negative/Positive weld output
plug into the NEGATIVE weld output
selector
receptacle
and
connect
the work
lead
to
10.
After welding, remove the clamp and grind spot
flush to surface.
11.
Smooth the
joints with body filler
POSITIVE weld output receptacle.
6-14. HOW
TO
PREVENT
GLASS
AND SPAUER ON WINDOWS
IMPORTANT For maximum
penetration on thicker
18 gauge (1.22 mm) and thicker,
reconnect for direct current electrode positive.
materials such
as
6-13. 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
paint
2.
a
power wire brush or sander to remove
bare metal in the area to be repaired.
to
and
body filler after welding is completed.
6-15. SHUTDOWN PROCEDURES
damaged metal using hand cutters,
or a power hand grinder equipped with a
shears
cutting
BREAKAGE
Spatter and ex
cessive 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 windows, the
windows should be covered and protected from ex
cessive heat by using wet rags. A putty like substance
which reduces heat transfer is available through your
welding supplier. If burn through and spatter become
problems, ensure that the correct voltage tap is being
used for the size material being welded. Use an argon
-
Two to three inches (51 to 76 mm) on either side
of the weld area should be cleaned for applying
Remove
and finish.
the
C02
1.
gas mixture and check travel
Place the
welding power
position.
source
speed.
POWER switch
in the OFF
wheel.
2.
Close the gas cylinder valve.
CONCENTRATION
HIGH
SHIELDING GAS can harm health or kill.
I
Shut off gas supply when not in use.
113336
Page 38
OF
September1987
FORM: 113336
Effective With Serial No. JH159463
PARTS
LIST
10
15 16
18
507-F
TD-072
1
89
19
7
234
Asembly
21
Main
-
A
Figure
23
~25
List 337
See 113
Parts Gun
FoE Of
(.0 C0 (a) a
0C
Form:
26
Replace Coils
Item
Dia.
Part
No.
Mkgs.
No.
Figure
at
Factory
or
Factory Authorized Service Station
Description
Quantity
Main Assembly
A
+007 778
1
1
WRAPPER
LABEL, general precautionary
057 506 PANEL, side
008 040 CONNECTOR, jumper
1
008 073 HOUSING RECEPTACLE & SOCKETS(consisting of)
058 972
TERMINAL, female
8
1
047 497
2
3
4
PLG2
1
1
.
Figure B BAFFLE, air-w/components (Pg 4)
Figure C PANEL, rear-w/components (Pg 6)
604 550 HOSE, No.1 x3/161D(orderbyft)
5
6
7
010 290
1
083912
STABILIZER
1
605 741
1
035 630
GS1
9
010 296
10
010 678
11
073 433
12
13
PLG1
039 778
023 210
13
PLG1
085 986
14
15
Z
16
1
1
1
1
1
1
1
21
092 028
083 175
22
Figure
23
023 100
24
026 843
25
010368
26
039 901
27
28
026 978
101 219
29
019833
.STRIP,copper
1
30
010521
31
.WIRE,tie
.SCREW,setl/4-20x3/8
SCREW, self-tapping 8-32
2
17
R2
079 781
18
TP2
19
Ti
092 239
093 173
0
1
1
1
1
.
2
1
1
2
1
1
1
.
1
.
1
32
602 178
602 160
33
++
34
010 357
NUT, speed No.2
RETAINER, screw No. 2
LABEL, instructions
605 217 FASTENER, screw-wing head No. 2
2
35
010 855
113 227
2
041 288
1
36
37
+
1
BRACKET, mounting-resistor
RESISTOR,WWfixed25watt50 ohm
THERMOSTAT, NO
TRANSFORMER, power-main (208/230) (consisting of)
COIL, pri/sec
SKID, base
PANEL, front-w/components (Pg 8)
CABLE, interconnecting-ground
INSULATOR, vinyl
CLAMP, ground iOOamp
PLUG, jack-black (consisting of)
INSULATOR, jack plug-black
PLUG, jack
20
+
1
3 ft
CLAMP, hose3/16
VALVE, 24 volts ac/6 volts dc 2 way 1/4 IPS port 1/8 orifice
FITTING, hose-elbowM 1/4 NPTx 5/8-18 RH
FITTING, pipe-elbowstreetl/4NPTLH
FITTING,barbedmale3/16TBGx1/4NPT
RECEPTACLE, straight 3 pole 50 amp 250 volts
CABLE, powerl0/39ft 50 amp cap (230 voltsand under)
CORDSET, powerl0/39ft600voIts(over230volts)
BUSHING, strain relief 1.09 x 1.03 hole
089 120
8
1
When
ordering
a
.
x
1/4
1
GUN
No. lOB
1
1
2
RunningGear(FigFPgll)
component originally
displaying
a
precautionary label, the label should also be ordered.
+For Parts List of Gun See FORM: 113 337
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
113336
Page2
4
7
11
10
7
12
13
14
21
22
TD-072 509-0
Figure B
113336 Page 3
-
Baffle. Air
-
W/Components
Item
Dia.
Part
No.
Mkgs.
No.
Figure
B
Description
Baffle, Air
-
W/Components (Fig
A
1
058 427
2
8
085 980 NUT, hex-full 5 /8-1 1
605941 WASHER,flat-41/64IDx1 ODxl4ga
057 543 SPRING, compression
057 971 WASHER, fIat-keyed 1-1/2 dia
010 191 WASHER,fiber5/8lDxl-1/2ODxl/8
058 628 WASHER, steel-brake
058428 HUB,spool
9
026 837
3
4
5
6
7
10
CR1
072 817
11
044 995
12
16
083 147
082 907
031 728
082 902
082 875
17
057 511
13
14
C6
15
18
18
W
W
19
20
21
VR1,2
22
CR2
TEl
23 SR2,3
24 .CB1 ,2
25
26
27
R3
28
29
30
R5
035 519
024 493
034 893
024 493
038 620
026 189
082 722
006 393
035 914
083 431
044 988
605 741
059 642
010014
006 537
052 704
Quantity
Pg 2 Item 5)
RING, retaining-spool
INSULATOR, terminal-nylon
RELAY, enclosed 24 voltsac DPDT flanged
BAFFLE, air
GROMMET, push in
ANGLE, mtg-RH capacitor
CAPACITOR, electrolytic 20,000 uf 35 volts dc
STRIP, mtg-center capacitor
ANGLE, mtg-LH capacitor
LINK, connector-contactor
CONTACTOR, 40 amp3 pole 24 volts (consisting of)or
COIL, 24 volts
CONTACTOR, 40 amp 3 pole 24 volts (consisting of)
COIL, 24 volts
LINK,jumper
BLOCK, terminal3oamp3 pole
VARISTOR,0.6wattl75voltsdc
RELAY, enclosed 24 volts ac DPDT flanged
RECTIFIER, integrated 25 amp 400 volts
CIRCUIT BREAKER, manually reset 5 amp 250 volts
DRIVE ASSEMBLY, wire (Fig B1 Pg 5)
BRACKET, mtg-resistor
RESISTOR, WWfixed25wattl0 ohm
CLAMP,3/4x13/64hole
RESISTOR, WWfixed 12 watt 0.5 ohm
CLIP, spring-mtg resistor
.
1
1
1
1
1
2
2
1
1
1
1
6
1
6
1
1
2
1
1
1
1
.
1
1
2
1
2
2
1
1
1
2
1
2
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
113336
Page4
Item
Dia.
Part
No.
Mkgs.
No.
Figure
044 988
Bi
Description
Drive
Assembly, Wire (Fig
B
Quantity
Pg 4 Item 25)
2
4
RING, retainer
BEARING, flanged
909 GEAR, drive .030-.035 wire
907 GEAR, drive .024 (top gear)
605 287 KEY,1/16x1/4
5
058 360
SHAFT
1
6
058 363
COVER
1
605
072
112
ti 12
2
3
7
8
9
10
11
12
13
14
M
15
16
17
18
19
20
21
22
23
24
25
854
649
1
2
1
2
072 585 BEARING, flanged 5/16x7/16x3/8
010 918 PIN, spring5/32x1-1/2
057 551 SPRING, pressure
056 081 LINER, monocoil
605 525 NUT, self-locking hex 5/16-24
010 929 WASHER, fIat-spring 3/8
093 153 MOTOR, gear(consisting of)
*031 595.
BRUSH, w/spring
057 432
SCREW, brush holder cap
079 624 SCREW, cap-hexhd3/8-16x2-1/4
602 213 WASHER, lock-split 3/8
010 910 WASHER, flat-SAE 3/8
044 994 INSULATOR, motor
601 838 NUT, brass-hex jam 3/8-16
079 633 FITTING, hose-barbed nipple 3/16 TBG
1
1
1
1
1
1
1
2
2
1
2
1
1
1
1
044 954
079 772
HOUSING, drive-roll feeder
1
KNOB
1
058 359
604 741
PIN, pivot
PIN, cotter-hair 0.042
1
x
1
15/16
1
9
10
11
12
4
20
17
Figure
Bi
-
Drive Assembly, Wire
13
*Recommended Spare Parts.
tOptional Parts
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
113 336
Page 5
TC-072 511
Item
Dia.
Part
No.
Mkgs.
No.
FM
032 678
2
032 662
3
083 916
4
SRi
6
7
037 306
TP3
8
9
10
089 733
057 496
5
Quantity
Panel, Rear-W/Components (Fig A Pg 2 Item 6)
Figure C
1
Description
086 323
037 305
C1-4
031 689
TP1
604 515
MOTOR, fan 230 volts ac
BLADE, fan 60 Hz 10 inch 6 wing
PANEL,rear
RECTIFIER, silicon diode (consisting of)
BRACKET, mtg-rectifier & fan motor
DIODE, lSOamp300voItsRP
THERMOSTAT, NO
DIODE, 150 amp300voltsSP
.CAPACITOR,ceramico.01 ufsoovoltsdc
THERMOSTAT, NC
1
1
1
1
.
1
.
2
.
1
.
2
.
4
1
3
2
4
TD-072 508-B
Figure C
-
Panel, Rear-W/Components
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
113 336
Page6
Figure D
113336
Pagel
-
Panel, Front-W/Components
Item
Dia.
Part
No.
Mkgs.
No.
Figure
Panel. Front
D
1
039 801
2
091 542
010291
604 668
605 787
601 881
3
4
5
6
7
+
Quantity
Description
-
W/ Components
RECEPTACLE ASSEMBLY,
.RECEPTACLE&NUT
(Fig
A
Pg 2
Item 22)
1
.WASHER,flat-nylafil5/8IDx1-1/4ODxl/8
.
.
.
1
NUT, self-locking hex 1 /2-20
WASHER, lock-internal tooth 1/2
NUT, hex-jam 1/2-20
1
1
1
112 552
NAMEPLATE(order by model & serial number)
1
004 948
LABEL, warning the hazard of contact
PANEL,front
COVER, open-module
RECEPTACLE ASSEMBLY, jack-red(consisting of)
PANEL,front
COVER, open-module
RECEPTACLE ASSEMBLY, jack-red(consisting of)
1
8
083917
9
087 274
10
039 800
083917
9
113 472
10
039 800
11
38
010291 .WASHER,flat-nylafil5/8lDxl-1/4ODxl/8
604 668
NUT, self-locking hex 1/2-20
605 787
WASHER, lock-internal tooth 1/2
601 881
NUT, hex-jam 1/2-20
091 541 .RECEPTACLE&NUT
605 828 RHEOSTAT, WW 50 watt 1.5 ohm
048 282 RECEPTACLEW/SOCKET(consistingof)
079 534
TERMINAL, female
090 328 SWITCH, toggle2PST4O amp 600 volts ac
097 924 KNOB, pointer
057 608 RECEPTACLE ASSEMBLY, jack-yellow(consisting of)
601 881 .NUT,hex-jaml/2-13
605 787
WASHER, lock-internal tooth 1/2
604 668
NUT, self-locking hex 1/2-20
010 291
WASHER, flat-nylafil 5/8 ID x 1-1/4 OD x 1/8
072 334
RECEPTACLE & NUT
023 084 CABLE & PLUG ASSEMBLY, jack (consisting of)
039 878
PLUG ASSEMBLY, jack-yellow (consisting of)
602 160
SCREW, self-tapping 8-32 x 1/4
026 975
INSULATOR, jack plug-yellow
101 219
PLUG
602 178
SCREW, set 1/4-20 x3/8
019833 ..STRIP,copper
023 083
CABLE
048 573 LIGHT, indicator-red lens 28 volts
010 325 BUSHING, strain-relief
044 943 CABLE & PLUG ASSEMBLY, jack (consisting of)
600 318
CABLE, weld-No. 3 (order byft)
039 608
PLUG ASSEMBLY, jack-red (consisting of)
39
019 833
..
40
602 178
..
12
1
jack-black(consisting of)
1
1
1
1
1
1
1
2
.
13
1
.
14
1
.
15
16
Ri
17
RC1
18
Si
1
1
1
4
.
19
20
21
22
26
27
28
29
30
31
37
1
2
.
1
.
1
.
1
..
1
1
..
1
..
1
2
..
32
36
1
.
25
35
6
.
23
24
33
34
1
1
1
i
.
PL1
1
2
1
2 ft
.
1
.
41
101 219
42
602 814
..
43
602 160
..
..
STRIP, copper
SCREW, setl/4-20x3/8
2
PLUG
1
INSULATOR, jack plug-red
SCREW, self-tapping 8-32x1/4
1
1
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
113336
Page8
Item
Dia.
Part
No.
Mkgs.
No.
Figure
R50
028 769
R51
028 770
3
R52
2
R51
028 768
028 770
3
R52
028 768
4
S50
086 895
5
R53
7
8
PLG51
9
PLG5O
10
11
Quantity
SPW 1 Spot Panel
E
2
6
Description
PC5O
RC55
12
13
14
POTENTIOMETER, carbon 1 turn2watt 750K ohm
POTENTIOMETER, carbon 1 turn 2 watt 1 meg ohm
POTENTIOMETER, carbon 1 turS 2 watt 350K o
POTENTIOMETER, carbon 1 turn 2 watt 1 meg ohm
POTENTIOMETER, carbon 1 turn 2 watt 350K ohm
SWITCH, rotary 3 position
WASHER, centering 7/16 dia
RESISTOR, WWfixed 15 watt 0.25 ohm
GROMMET, SCR No. 8/10
HOUSING, terminal 9 position
HOUSING, terminal 13 position
073914
605 890
080 509
072 669
079 798
097 897
008 072
058 971
086650
113471
097922
112770
112772
112768
CIRCUIT CARD
1
1
1
1
1
2
1
3
1
1
El
(Fig
HOUSING PLUG &
1
Pg 10)
PINS (consisting of)
1
1
TERMINAL, male
8
PANEL
1
NAMEPLATE (order by model & serial number)
1
KNOB, pointer
NOZZLE, spot-outside corner
NOZZLE, spot-inside corner
NOZZLE, spot-flat
4
1
1
1
El
1
3
5
~~~~~~11
12
.74
TC-086 924-B
1:
Figure E
-
SPW 1
Spot Panel (Optional)
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
113336
Page9
Dia.
Part
Mkgs.
No.
Figure
El
A50,51
C50
C51 .53,55
C52 ,56
C54,57,58
C59
CR50
CR51
CR52
D50-54,57-66
056
Q50 .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
PLG5O
Description
E
(Fig
Quantity
9 Item 10)
Pg
097 897
Circuit Card
009
039
032
073
073
1C, linear
CAPACITOR, electrolyte 100 uf 35 volts dc
CAPACITOR, tantalum 2.2 uf 35 volts dc
CAPACITOR, tantalum 0.22 uf 35 volts
CAPACITOR, ceramic 0.1 uf 50 voltsdc
CAPACITOR, electrolyte 10 uf 50 volts
RELAY, enclosed 24 volts dc 4PDT
RELAY, enclosed 24 volts dc SPDT
RELAY, enclosed 24 volts dc SPDT
SPRING, holddown-relay
SOCKET, relay
DIODE, 1 amp400voltsSP
DIODE, zener 15 volts 1 watt SP
TRANSISTOR, 200MA 40 volts NPN
TRANSISTOR, 100MA3O volts NPN
RESISTOR, carbon 1 watt 820 ohm
RESISTOR, carbon film 0.25 watt 100 ohm
RESISTOR, carbon film 0.25 watt 100K ohm
RESISTOR, carbon film 0.25 watt 4.7K ohm
159
482
820
714
739
090 573
027 810
099 019
099 018
079 844
091 861
026 202
037 449
037 200
073 535
030 018
035 823
035 884.
039 331
035
035
039
039
035
092
079
072
+079
827
886
333
327
887
648
795
670
798
2
1
3
2
3
1
1
1
1
1
1
15
1
2
1
1
1
2
5
RESISTOR, carbon film 0.25 watt 10K ohm
RESISTOR, carbon film 0.25 watt 22K ohm
RESISTOR,carbonfilm0.25wattl8Kohm
RESISTOR, carbon film 0.25 watt 220 ohm
RESISTOR, carbon film 0.25 watt 220 ohm
RESISTOR, carbon film 0.25 watt zero ohm
TERMINAL, head 13 pin
TERMINAL, header 9 pin
HOUSING, terminal header 13 pin
~0
0
~0
00
~ ~~~0531~
I
DS2~fl
DSP
5~4(Th
I
050
o
<
CR51
~
________
J
~J--
4~.
R67
~
LJ~
58
~
1~J
~ CDEFGHJKL~
Q
I~0
R5~~C~5iIj]~60
~
R
I~J
1
58
0050
R 52
1
R65
R62
_____
CR50
1
R70
~5b~
i
1
1
1~
~R5l t~j~~~_
-1~-D6I
c~J~,)
055
L,.~.J
~
CR52
1
2
-~
~
C55
____________
7
2
R511
058
c:j
R71
re
1
1
PR
ST
U V
WX
RC5O
ASSY 097897
V
0
Ret: C-097 895
COMPONENTS TO BE
REPLACED BY QUALIFIED
PERSONNEL ONLY
Circuit Card
Figure El
Not part of circuit card.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
-
+
113 336
Page
10
Item
Part
No.
Mkgs.
Figure F
1
601 954
2
3
4
025 193
604 423
057 478
022617
602 389
602 387
602 384
052 693
602250
032524
070799
052692
601 944
602211
601 869
008999
052691
5
6
7
8
9
10
Description
Quantity
No. lOB Running Gear
SCREW, cap hex hd 1/4-20
HANDLE, running gear
-
x
4
3/4
1
GRIP, handle
BRACKET, support tank
CHAIN, cylinder rack
2
HOOK
.CHAIN
.SNAP
1
1
-
1
1
1
1
RACK, cylinder
WASHER, flat SAE 3/4 in
PIN, cotter3/16x1-1/2
WHEEL, rubber, 3/4 bore 10 x2-3/4
AXLE, running gear
SCREW, cap-hex hd5/16-18x3/4
WASHER, lock-split 5/16
NUT, hex-jam 5/16-18
CASTER, swivel 4 inch dia
BAR, spreader cylinder rack
602213 WASHER, lock-split 3/8
601 871 NUT, hex jam 3/8-16
11
12
13
14
15
16
17
18
19
20
4
2
2
1
4
4
4
2
1
2
2
.1
5
9
ftp
10
20
19
1:
TC-049 808-B
Figure
F
-
No. 108
Running Gear
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
113 336
Page
11