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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