BUG-O Systems CW-7 User Manual

INSTRUCTIONS

AND

PARTS MANUAL

CW-7

CIRCLE WELDER

Please record your equipment identication information below for future reference. This information can be found on your machine nameplate.

Model Number

Serial Number

Date of Purchase

Whenever you request replacement parts or information on this equipment, always supply the information you have recorded above.

LIT-CW-7-IPM-0215

Bug-O Systems is guided by honesty, integrity and ethics in service to our customers and in all we do.

A DIVISION OF WELD TOOLING CORPORATION

280 TECHNOLOGY DRIVE CANONSBURG, PENNSYLVANIA 15317-9564 USA

PHONE: 412-331-1776 http://www.bugo.com FAX: 412- 331- 0383

SAFETY

PROTECT YOURSELF AND OTHERS FROM SERIOUS INJURY OR DEATH. KEEP

CHILDREN AWAY. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE

AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

ELECTRIC SHOCK can kill.

1) The equipment is not waterproof. Using the unit in a wet environment may result in serious injury. Do not touch equipment when wet or standing in a wet location.

2) The unused connectors have power on them. Always keep the unused connectors covered with the supplied protective panels. Operation of the machine without the protective panels may result in injury.

3) Never open the equipment without rst unplugging the power cord or serious injury may result.

4) Verify the customer-supplied power

connections are made in accordance

with all applicable local and national electrical safety codes. If none exist, use International Electric Code (IEC)

950.

5) Never remove or bypass the equip- ment power cord ground. Verify the

equipment is grounded in accordance

with all applicable local and national electrical safety codes. If none exist, use International Electric Code (IEC) 950.

EQUIPMENT DAMAGE

POSSIBLE.

1) Do not plug in the power cord with out rst verifying the equipment is OFF and the cord input voltage is the same as required by the machine or serious damage may result.

2) Always verify both the pinion and wheels are fully engaged before apply ing power or equipment damage may occur.

3) Do not leave the equipment unattended.

4) Remove from the worksite and store in a safe location when not in use.

FALLING EQUIPMENT can cause serious personal injury and equipment damage.

Faulty or careless user installation is possible. As a result, never stand or walk underneath equipment.

MOVING PARTS can cause serious injury.

READ INSTRUCTIONS.

Read the instruction manual before installing and using the equipment.

1) Never try to stop the pinion from moving except by removing power or by using the STOP control.

2) Do not remove any protective panels, covers or guards and operate equipment.

HIGH FREQUENCY WARNINGS

SPECIAL PRECAUTIONS ARE REQUIRED WHEN USING PLASMA,

TIG OR ANY WELDING PROCESS THAT USES HIGH FREQUENCY

TO STRIKE AN ARC.

WARNING: HIGH FREQUENCY CAN EFFECT MACHINE

OPERATION AND THEREFORE, WELD QUALITY.

Read the precautions below before installing and using the equipment.

PRECAUTIONS:

1) Some plasma or welding cables are strong sources of high frequency interference.

NEVER lay a plasma or welding cable across the controls of the machine.

2) Always physically separate the plasma or welding cable leads from the machine cables. For example, the plasma or welding cable leads should NEVER be bundled with a pendant cable or the machine power cord. Maximize the separation between any machine cables and the plasma or welding cables.

3) Strictly follow the grounding procedures specied for the plasma or welding unit. NOTE: Some plasma and welding units produce exceptionally large amounts of high frequency noise. They may require a grounding rod be driven into the earth within six feet (2 meters) of the plasma or welding unit to become compatible with an automatic cutting or welding process.

4) If the high frequency is produced using a spark gap, adjust the points so the gap is as small as possible. The larger the gap, the higher the voltage and the higher the interference.

5) Some plasma or welding units will inject high frequency interference into the AC power line. Use separate power line branches whenever possible to power the plasma or welding source and the machine. Do not plug them into the same outlet box.

6) High frequency noise may enter the machine through the plasma or welding supply remote contactor leads. Some plasma and welding sources can produce noise spikes of up to several thousand volts. These sources are not compatible with automated cutting and welding equipment. It is recommended that the remote contactor leads on these plasma or welding sources not be connected to the machine. An alternate solution is to purchase a separate remote contactor isolation box.

CW-7 CIRCLE WELDER

INSTRUCTIONS AND PARTS MANUAL

TABLE OF CONTENTS

PAGE

5-6 ...... Introduction / Features / Setup and Operation

7 ........ CWO-3332 Wire Feeder Controls

8 ........ CWO-6210 Rotation Controls

9 ........ Technical Data / Dimensions

10 ....... CWO-1700 CW-7 Circle Welder / Exploded View

11 ....... CWO-1700 CW-7 Circle Welder / Parts List

12 ....... CW-7 Circle Welder / Wiring Diagram / Electrical Component Chart

13 ....... CWO-3495 CW-7 Collector / Exploded View / Parts List

14 ....... CWO-3139 Universal Power Cable / Exploded View / Parts List

14 ....... CWO-3139-M Miller Power Cable/ Exploded View / Parts List

15 ....... CWO-1665 CW-7 Racking System / Exploded View / Parts List

15 ....... CWO-1690 Horizontal Racker / Exploded View / Parts List

16 ....... CWO-2005 Wire Feeder Guard / Exploded View / Parts List

17 ....... CWO-3027 Meter Kit Assembly / Exploded View / Parts List

17 ....... CWO-3027 Meter Kit Assembly / Wiring Diagram

18 ....... CWO-3496 Shaft Assembly / Exploded View / Parts List

18 ....... CWO-3227 Cam Shaft & Spacer Assembly / Exploded View / Parts List

19 ....... CWO-3205-11 7" Cam Assembly / Exploded View / Parts List

19 ....... CWO-3498 5" Wire Reel Mount Assembly / Exploded View / Parts List

20 ....... CWO-3063-2 Large Brush Holder and Support / Exploded View / Parts List

20 ....... CWO-3194 Housing Assembly / Exploded View / Parts List

21 ....... CWO-3361 P.M. Motor Assembly / Exploded View / Parts List

21 ....... CWO-3359 Transmission 5:1 Assembly / Exploded View / Parts List

22 ....... CWE-1530 Small Brush Holder Assembly / Exploded View / Parts List

22 ....... CWO-3461 Small Retainer Block Assembly / Detail View

23 ....... CWO-3332 GMA Wire Feeder Control / Exploded View / Parts List

24 ....... CWO-3332 GMA Wire Feeder Control / Wiring Diagram / Electrical Component Chart

25 ....... CWO-6210 Rotation Control / Exploded View / Parts List

26 ....... CWO-6210 Rotation Control / Wiring Diagram / Electrical Component Chart

27 ....... CW-7 Gun Assemblies (MIG-FLUX CORED)

28 ....... CW-7 Gun Assemblies (SUB ARC)

29 ....... CW-7 Drive Roll Kits

29 ....... CWO-3690-_ K231 Subarc Gun Assembly / Exploded View / Parts List

30 ....... CWO-3700-_ Subarc Gun Assembly / Exploded View / Parts List

30 ....... CWO-3490 CW-7 Flux Hopper Assembly / Exploded View / Parts List

31 ....... #5 Gun & Cable Assembly / Exploded View / Parts List

32 ....... 3-Jaw Expandable Chucks

33 ....... Optional Motorized Racking Equipment / CWO-1665-MV / Exploded View / Parts List

34 ....... Optional Motorized Racking Equipment / CWO-1690-MH / Exploded View / Parts List

35 ....... Optional Motorized Racking Equipment / CWP-3350 / Exploded View / Parts List

36 ....... Optional Motorized Racking Equipment / CWP-3351 / Exploded View / Parts List

37 ....... Optional Motorized Racking Equipment / PRS-1100 / Exploded View / Wiring Diagram

38 ....... Optional Motorized Racking Equipment / PRS-1100 / Parts List

39 ....... Optional Motorized Racking Equipment / CWP-3363 / Exploded View / Parts List

39 ....... Optional Motorized Racking Equipment / PRS-1075 / Exploded View / Parts List

40 ....... Preventive Maintenance / CW-7 Circle Welder

43 ....... Warranty

INTRODUCTION

The CW-7 Circle Welder is designed for welding of nozzles into vessels or domed heads utilizing SUBARC, MIG or FLUX CORED PROCESS, with gas shielding. The CW-7 mounts on a 3-Jaw Chuck welding diameter 6" to 50" O.D.

Features

• Amperage & wire speed control

• Wire feeder with one set of drive rolls

• 1/12 HP P.M. motor and rotational speed control

• 500 AMP gun & cable assembly

• Gas shielding kit with 120 VAC solenoid valve

• 5/8" (16 mm) gas cup

• Burn back control

• 50 ft. (15 m) power cable

• 50 ft. (15 m) gas shielding hose

• 50 ft. (15 m) weld cable

• Quick disconnects for all cables

• Weld contact switch

• Cold wire inch switch

• Wire direction switch

• Pre and post ow controls

• Wire reel adaptor for 60 lb. (27 kg) spools

• Adjustable vertical and horizontal torch positioning system

• Rise and fall cam assembly with 7" (178 mm) of travel

• Brushes and collector rings for welding current, rated at 500 AMPS 100% duty cycle

• Brushes and collector rings for all controls, eliminates cable and hose wrap

SETUP AND OPERATION

POWER SOURCE

Use only constant voltage type power sources with this circle welder machine. If using a multiple process power source, be sure that it is set for constant voltage output as per the instructions in the manual for the power source. Set the power source polarity switch or properly connect the electrodes and work leads for the correct electrode polarity.

GUNS AND CABLES

All circle welders come equipped with a gun and cable assembly. It is our recommendation that at least once a week the liner be taken out of the cable and soaked overnight in a solvent solution. To keep the wire moving it is also recommended that a felt clip be saturated with a product like Ferro Slick and fed through the incoming tube of the wire feeder at least once a day.

SETUP AND OPERATION CONT'D.

ADDITIONAL CABLES

The circle welders are supplied with the following cables:

1. CWO-3139 50' (15 m) power cable that connects the power source to the cable connector on the top gear of the machine.

2. CWO-3040 50' (15 m) weld cable that connects the lead coming out of the top of the machine using the quick connect connector to your power supply.

3. CWO-9406 50' (15 m) gas shielding hose that connects the gas tting on the top of the shaft to your shielding gas supply.

Cam

WIRE SPEED AND VOLTAGE ADJUSTMENT

The wire speed control on the front of the CWO-3332 Wire Feed Control box has a dial that is calibrated directly in inches per minute. Set the voltage using the control on the power source.

RISE AND FALL OF THE CAM

All circle welders are equipped with a rise and fall cam assembly. The cam assembly must be aligned before any other settings can be made. To align the cam rotate the machine so the horizontal rack is parallel to the pipe, then adjust the gun holder so it is perpendicular to the horizontal rack. Position torch tip to top dead center of joint. Loosen the set screws in the brass block on the cam, and rotate the cam to the vertical position as shown. Refasten set screws.

CAM SETTING

The cam setting is equal to distance “B” subtracted from distance “A”.

Example:

Let A=3 and B=2 3-2=1 The cam setting is 1.

WHEEL ADJUSTMENT

The CW-7 Racking System CWO-1665 and the Large Vertical Racker CWO1690 are equipped with adjustable wheels. Always check these components for proper wheel adjustment before using the machine. The wheels need adjustment if you can cock or wiggle the components out of alignment. The wheels should be snug but not prohibit movement along the path of travel. The wheels with the hex stand offs are adjustable. To adjust the wheels, loosen the hex bolt (A) until the adjustable bushing (B) can be rotated. Correct the wheel alignment by rotating the adjustable bushing (B). Once adjusted, hold the adjustable bushing (B) while tightening the hex bolt (A). Recheck alignment.

Torch Holder

Horizontal Rack

Pipe

MACHINE CONTROLS

Operational parameters can be set using the two control boxes. Please refer to the sections in this manual entitled CWO-3332 Wire Feeder Control for descriptions of the various welding parameters that are available, as well as CWO-6210 Rotation Control for descriptions of the various speed and directional capabilities.

MAKING A WELD

1. Position the gun to start position using the CWO-1665 Racking System.

2. Connect the ground cable to the workpiece. The ground cable must make good electrical contact with the work.

3. Position the electrode in the joint. The end of the electrode may be lightly touching the work.

4. With manual/auto switch in the “OFF” position, set rotation direction and speed.

5. Weld process and rotation are both started by throwing the manual/auto switch to auto.

6. Weld process and rotation are stopped by throwing the manual/auto switch to “OFF”.

WARNING: When using an open arc process, it is necessary to use correct eye head and body protection.

CWO-3332 WIRE FEEDER CONTROLS

WIRE FEED SPEED

WIRE DIRECTION

PREFLOW

PURGE - UP

COLD INCH - DOWN

MANUAL / AUTOMATIC

POSTFLOW

BURNBACK

WIRE FEED SPEED CONTROL:

This control sets the feed speed of the wire feeder. Turn the knob to the left for slower speeds and to the right for higher speeds. The control is calibrated. The nameplate shows the wire speed for the given setting of the control.

WIRE DIRECTION:

Controls the direction the wire is being fed thru the feeder. Up to return wire to the spool. Down to feed the wire to the gun.

MANUAL / AUTOMATIC:

The manual position allows the operator to rotate the machine without welding to check the wire placement as well as the cam setting. The auto side will start the entire weld operation based on the operators settings, including machine rotation.

PREFLOW CONTROL:

This control, provides ow of shielding gas to the work before the arc is established. The gas solenoid valve is energized immediately when the gun trigger is closed, but the time delay before the wire feeder is energized is adjustable from 0 to 1.5 seconds. Turn the knob to the left for shorter delays and to the right for longer delays.

POSTFLOW CONTROL:

This control provides ow of shielding gas to the work after welding has stopped. Delay for the gas solenoid valve shutoff is adjustable from .5 to 4.5 seconds. Turn the knob to the left for shorter delays and to the right for longer delays.

PURGE - UP / COLD INCH - DOWN SWITCH:

This control provides control of some wire feeder functions without energizing the welding power source. The momentary up position energizes the gas solenoid but not the wire feeder or welding power source. The momentary down position energizes the wire feeder but not the gas solenoid or the welding power source.

BURNBACK CONTROL:

This control provides a precise time delay that allows the wire to be burned off at the end of the weld. This is useful for those applications where higher speed, ne wire feeding is used and there is a tendency for the electrode to overrun at the end of the weld and cause “sticking” in the crater. The delay is adjustable for optimum burnback depending on wire size, process, procedure, etc.

CWO-6210 ROTATION CONTROLS

Digital Readout

Speed Control

Travel Direction

On/Off Switch

Pilot Light

DIGITAL READOUT:

Displays reference number only.

SPEED CONTROL:

Controls the speed in which the machine travels. The depicted lines 0 to 100 should not be construed as inches per minute of travel. They should be considered as reference points only.

TRAVEL DIRECTION:

Controls the direction in which the machine will travel. Select forward for clockwise rotation, brake for stop, and reverse for counterclockwise rotation.

ON/OFF SWITCH:

The on/off switch enables/disables power to the rotation control box.

PILOT LIGHT:

The pilot light indicates whether the machine is on/off as dictated by the on/off switch.

TECHNICAL DATA

Amperage: 0-500 amps Input Voltage: 115 VAC Voltage: 0-50 VAC Wire Sizes: .035-3/32" (.8-2.4 mm) Rotation Speed: .2-2.2 rpm Cam Range: 0"-7" (0-175 mm) Welding Diameter: 6"-24" (150-600 mm) Shielding Gas: Solenoid Control Height: 34" (864 mm) Net Weight: 250 lbs. (113.6 kg) Shipping Weight: 380 lbs. (173.0 kg)

DIMENSIONS

34"

(850 mm)

63"

(1575 mm)

WELDING

DIAMETER

(150-600 mm)

30"

(750 mm)

6"-24"

CWO-1700 CW-7 CIRCLE WELDER / EXPLODED VIEW

1215

CWO-1700 CW-7 CIRCLE WELDER / PARTS LIST

ITEM QTY PART NO. DESCRIPTION 1 1 CWO-1665 CW-7 Racking System

2 1 CWO-1690 Large Horizontal Racker 3 1 CWO-2005 Wire Feed Guard 4 1 CWO-3027 Meter Kit Assembly 5 1 CWO-3063-2 Brush Holder & Support Assembly 6 1 CWO-3194 CW-7 Housing Assembly 7 1 CWO-3204 Slide Bar Mounting Assembly 8 1 CWO-3205-11 7" Cam Assembly 9 1 CWO-3218 Cable Support Bar 10 1 CWO-3227 Camshaft & Bar Assembly 11 1 CWO-3287 Base Plate 12 1 CWO-3288 Motor & Transmission Plate Assembly 13 1 CWO-3312 Lifting Lug Assembly 14 1 CWO-3332 GMA Wire Feed Assembly 15 1 CWO-3359 Transmission SW 5:1 Assembly 16 1 CWO-3361 P.M. Motor Assembly #147 17 1 CWE-1530 Small Brush Retainer Assembly 18 1 CWO-3468 LN-7 Wire Feeder Assembly 19 1 CWE-1050-3/0 Weld Cable 3/0 *20 1 CWO-3490 Flux Hopper Assembly (Subarc models only) 21 1 CWO-3495 CW-7 Collector 22 1 CWO-3020-3/0 Weld Cable Inlet 3/0 23 1 CWO-3496 Shaft Assembly, CW-7 AB, ABG 24 1 CWO-3498 Wire Reel Assembly 25 1 CWO-3499 CW-7 Guard Assembly 26 1 CWO-3955 Terminal Block Assembly 27 1 CWO-4088 Wire Feeder Mount Plate 28 2 CWO-4340 1-1/2" Flange Bearing 29 1 CWO-4900 33# Load Spring Assembly 30 1 CWO-5074 1-1/2" I.D. Trantorque 31 1 CWE-1048 10" Diameter Aluminum Gear 32 1 CWO-6210 Rotation Control Box 33 1 CWO-6416 Control Mount Plate 34 1 CWO-8057 Solenoid Adaptor Kit 35 1 CWO-3490 Flux Hopper

Notes: 1. See CWO-1700-WD for wiring and cable information.

2. CWO-3332 is shown with CWO-3332-K kit installed.

3. CWO-6210 is shown with CWO-6210-K kit installed.

* CWO-3490 Flux Hopper Assembly is installed on Subarc models only

CW-7 CIRCLE WELDER / WIRING DIAGRAM

IN FROM WELDER

SUPPLY

UNIT

POWER

CABLE

ELECTRICAL COMPONENT CHART

ITEM DESCRIPTION PART NO.

1 Meter Kit Assembly CWO-3027 2 Brush Holder & Support Assembly CWO-3063-2 3 Power Cable CWO-3139* 4 GMA Pigtail CWO-3331 5 GMA Wire Feed Control CWO-3332 6 P.M. Motor Assembly CWO-3361 7 Small Brush Retainer Assembly CWE-1530 8 LN-7 Wire Feeder Assembly CWO-3468

9 Weld Cable 3/0 CWO-3478 10 CW-7 Collector CWO-3495 11 Weld Cable Inlet 3/0 CWE-1050-3/0 12 CW-5 Terminal Block CWO-3955 13 Shunt Bar 500-50 CWO-6008 14 Rotation Control Box CWO-6210 15 Solenoid Adaptor Kit CWO-8057

*CWO-3139 For Universal Welders CWO-3139-M For Miller Welders.

CWO-3495 CW-7 COLLECTOR / EXPLODED VIEW / PARTS LIST

ITEM QTY PART NO. DESCRIPTION 1 6 CWO-3127 Brass Ring 4.250" Dia x .188 Thk

2 1 CWO-5741 Brass Ring 4.250" Dia x 3.000 Thk 3 7 CWO-5744 Micarta Spacer 4 1 CWO-5747 Micarta Spacer w/Notch 5 1 CWO-5748 Micarta Sleeve .500" Dia x 3.750" Lg 6 2 CWO-5806 Micarta Sleeve .500" Dia x 5.375" Lg 7 1 CWO-5752 Micarta Sleeve 1.875" Dia x 4.50" Lg 8 1 CWO-5745 Top Plate CW-5 Collector 9 1 CWO-5746 Bottom Plate CW-5 Collector 10 1 CON WTE 0383 5 Pos Box Mounting Connector Plug 11 2 TERM-5494 #8 Red Ring Connector 12 4 FAS-0215 6-32 x 1/2" Rnd Hd Scr 13 4 FAS-0455 1/4"-20 x 1/2" Soc Hd Set Scr 14 4 FAS-1310 6-32 Hex Nut 15 2 FAS-0393 Hex Hd Cap Scr 3/8-16 x 6" 16 2 WAS-0260 3/8" SAE Washer 17 4 FAS-0204 Rnd Hd Slot Scr 4-40 x 3/8 Zinc 18 4 FAS-1305 Hex Nut 4-40 19 1 BUG-1034 Panel Connector, 4-T, M

CWO-3139 UNIVERSAL POWER CABLE / EXPLODED VIEW / PARTS LIST

CWO-3139-M MILLER POWER CABLE / EXPLODED VIEW / PARTS LIST

CWO-1665 CW-7 RACKING SYSTEM / EXPLODED VIEW / PARTS LIST

ITEM QTY PART NO. DESCRIPTION 1 2 ABR-1060 V-Guide Ways 33"

2 1 CWO-1675 Vertical Racker

3 1 CWO-1695 Attachment Block 4 1 CWO-3023-1 Torch Angle Adjuster 16" 5 1 CWO-3460 24.8# Load Spring Assembly

CWO-1690 HORIZONTAL RACKER / EXPLODED VIEW / PARTS LIST

ITEM QTY PART NO. DESCRIPTION 1 1 BUG-2032 Knob, Black

2 1 CWO-1671 Racker Shield 3 1 CWO-1678 Racker Plate 4 1 CWO-1679 Pinion 11T 5 2 CWO-1680 W2 Fixed Leg & Wheel Assembly 6 2 CWO-1681 W2 Adj. Leg & Wheel Assembly 7 1 CWO-1687 Mount Plate (Large Racker) 8 2 CWO-4326 Fixed Leg & Wheel Assembly 9 2 CWO-4327 Adj. Leg & Wheel Assembly 10 2 FAS-0557 Soc Hd Cap Scr 1/4-20 x 3/4" 11 1 FAS-1307 Hex Jam Nut 3/4-16 12 1 MUG-1141 Bearing Collet 13 1 MUG-1142 Knob, Locking 14 1 MUG-1144 Shaft 15 2 MUG-1453 Stand-Off

16 1 MUG-1579 Retaining Ring 17 2 WAS-0240 1/4" SAE Washer 18 2 FAS-0559 Soc Hd Cap Scr 1/4-20 x 1"

F = FIXED WHEEL PLACEMENT

A = ADJUSTABLE WHEEL PLACEMENT

CWO-2005 WIRE FEEDER GUARD / EXPLODED VIEW / PARTS LIST

ITEM QTY PART NO. DESCRIPTION

1 1 BUG-3209 Hinge 3/4" x 2" Lg 2 1 CWO-2008 Plastic Guard 3 2 FAS-0535 Soc Hd Cap 10-24 x 1/2" 4 1 HDW-1001 Steel Hair Pin Zinc Plated 5 2 BUG-3197 Binding Post, #8-32 x 3/16 Lg

6 2 BUG-3198 Binding Post Screw, #8-32 x 3/16 Lg

CWO-3027 METER KIT ASSEMBLY / EXPLODED VIEW / PARTS LIST

ITEM QTY PART NO. DESCRIPTION 1 48" 900-4-001 2 Cond. 18 AWG. SJO Cord

2 1 CSR WTE 0187 Wire Strain Relief

3 1 CWO-4396 DC Volt Meter, 0-50 VDC 4 1 CWO-4397 DC AMP Meter, 0-500 ADC 5 1 CWO-4399 5" x 7" Front Meter Plate 6 1 CWO-6374 Alum. Box, Powder Coated 7 1 FAS-0145 Pan Hd Scr #10-32 x 1/2" 8 1 FAS-1340 Hex Nut #10-32 9 4 FAS-2935 Sheet Metal Scr #6 x 3/8" 10 5 TERM WTE 0294 #10 Ring, Red 11 3 TERM-0024 1/4" Red Ring 12 1 TERM-4162 1/4" Blue Ring

13 1 WAS-0231 #10 Internal Star Washer

CWO-3027 METER KIT ASSEMBLY / WIRING DIAGRAM

CWO-3496 SHAFT ASSEMBLY / EXPLODED VIEW / PARTS LIST

3 2

ITEM QTY PART NO. DESCRIPTION 1 1 BUG-9096 Outlet Bushing, Oxygen

2 2 CWO-4049 O-Ring, Oxygen, Fuel 3 1 CWO-5778 Shaft CW-7AG / CW-7ABG

CWO-3227 CAM SHAFT & SPACER ASSEMBLY / EXPLODED VIEW / PARTS LIST

ITEM QTY PART NO. DESCRIPTION 1 1 CWO-4352 Ball Joint Rod End 3/8-24 RH

2 1 CWO-5042 Ball Joint Rod End 3/8-24 LH 3 1 CWO-9081 Spacer 4 1 CWO-9355 Pipe / Cam Shaft 5 1 FAS-0399 Hex Hd Cap Scr 3/8-16 x 1" 6 1 FAS-1395 3/8-24 Hex Jam Nut - RH 7 1 FAS-1396 3/8-24 Hex Jam Nut - LH 8 1 FAS-2396 Hex Hd Cap Scr 3/8-16 x 2-1/4" 9 3 WAS-0260 3/8" SAE Washer

CWO-3205-11 7" CAM ASSEMBLY / EXPLODED VIEW / PARTS LIST

ITEM QTY PART NO. DESCRIPTION 1 2 BUG-2098 Delrin Washer 3/8"

2 1 BUG-9012 Locking Collar 3 2 CWO-4027 End Plate

4 1 CWO-4028 Center Plate 5 1 CWO-4032 Knob 6 1 CWO-4328 Base Plate 7 1 CWO-4331 Screw 8 2 CWO-4332 Rod 9 1 CWO-5199 Scale 10 4 FAS-0434 Set Scr #10-24 x 3/8" 11 1 FAS-0444 Set Scr #10-32 x 3/8" 12 2 FAS-0495 Set Scr 3/8"-16 x 1/2" 13 4 FAS-0534 Soc Hd Cap Scr #10-24 x 3/8"

CWO-3498 5" WIRE REEL MOUNT ASSEMBLY / EXPLODED VIEW / PARTS LIST

ITEM QTY PART NO. DESCRIPTION

1 1 BUG-3293 Reel, 60 lbs.

2 1 CWO-3217 Wire Reel Support Assembly 3 2 FAS-1301 Hex Nut 1/2-13 4 2 FAS-2305 Hex Hd Cap Scr 1/2-13 x 1-3/4" 5 2 WAS-0281 1/2" Lock Washer

CWO-3063-2 LARGE BRUSH HOLDER AND SUPPORT / EXPLODED VIEW / PARTS LIST

ITEM QTY PART NO. DESCRIPTION

1 1 CWE-1536 Large Brush Holder Support 2 1 CWO-4339 Attachment Bar 3 2 CWO-3263 Large Brush Holder 4 4 CWO-3264 Spring Clip 5 4 CWO-4337 Large Brush 1-1/2" x 3/4" x 2" 6 2 CWO-5548 Micarta Spacer 7 1 CWO-5549 Micarta Bushing 8 1 FAS-0304 Hex Hd Cap Scr 1/2-13 x 3.5" 9 1 FAS-0305 Hex Hd Cap Scr 1/2-13 x 2" 10 1 FAS-0309 Hex Hd Cap Scr 1/2-13 x 1" 11 1 FAS-0357 Hex Hd Cap Scr 1/4-20 x 3/4 12 2 FAS-0359 Hed Hd Cap Scr 1/4-20 x 1" 13 3 WAS-0243 1/4" Split Lock Washer 14 2 WAS-0280 1/2" SAE Flat Washer 15 3 WAS-0281 1/2" Split Lock Washer

CWO-3194 HOUSING ASSEMBLY / EXPLODED VIEW / PARTS LIST

ITEM QTY PART NO. DESCRIPTION 1 1 CWO-4133 1/4-18 x 1/2" NPSM Hex HD Plug, Brass

2 1 CWO-5841 Center Tube Housing 3 1 CWO-5844 Top Housing Plate 4 1 CWO-5847 Lower Housing Plate 5 2 CWO-5973 Plastic Bushing 6 3 CWO-9339 Angle For Guard 7 3 FAS-0535 Soc Hd Cap Scr 10-24 x 1/2" 8 8 FAS-0548 Soc Hd Cap Scr 10-32 x 3/4"

CWO-3361 P.M. MOTOR ASSEMBLY / EXPLODED VIEW / PARTS LIST

ITEM QTY PART NO. DESCRIPTION 1 1 CWO-4067 P.M. Motor 1072

2 1 CWO-4147 P.M. Motor Bracket #970 3 1 CWO-5767 Gear, P.M. Motor 4 1 FAS-0454 Set Scr 1/4-20 x 3/8" 5 3 TER-WTE-1508 #8 Fork Blue 14RB-8FL-T&B

CWO-3359 TRANSMISSION 5:1 ASSEMBLY / EXPLODED VIEW / PARTS LIST

ITEM QTY PART NO. DESCRIPTION 1 1 CWO-4347 Transmission 5:1

2 4 FAS-0359 Hex Hd Cap Scr 1/4-20x1" 3 4 FAS-1351 1/4-20 Hex Nut 4 4 WAS-0240 1/4" SAE Washer 5 4 WAS-0243 1/4" Lock Washer 6 1 UNI-1024 Slave Pinion

CWE-1530 SMALL BRUSH HOLDER ASSEMBLY / EXPLODED VIEW / PARTS LIST

ITEM QTY PART NO. DESCRIPTION 1 1 CWE-1531 Retainer Support Small

2 1 CWE-1532 6 Pos Small Ret. Block Assembly 3 2 FAS-2351 Soc Hd Cap Scr 10-24x1" 4 1 FAS-0539 Hex Hd Cap Scr 1/4-20x1 1/4" 5 1 WAS-0240 1/4" SAE Flat 6 1 WAS-0243 1/4" Split Lock Washer

CWO-3461 SMALL RETAINER BLOCK ASSEMBLY / DETAIL VIEW / PARTS LIST

WHITE 10"

BLACK 10"

RED 10"

ORANGE 10"

2,3,4,5

ITEM QTY PART NO. DESCRIPTION 1 1 CWO-5626 Small Brush Retainer Blk

2 4 CWO-5831 Brush 1/8" x 1/8" x 7/8" 3 4 CWO-5874 Brush Holder 4 4 CWO-5875 Cap 5 4 CWO-5876 Clip 6 4 TERM WTE 0602 #6 Fork Blue

CWO-3332 GMA WIRE FEEDER CONTROL / EXPLODED VIEW / PARTS LIST

25,26

ITEM QTY PART NO. DESCRIPTION 1 1 BUG-2255 Toggle Switch

2 2 BUG-2287 Power Receptacle 3 1 CON-1202S Panel Connector, 2T F 4 1 CWO-6759 Panel Connector, 6T M 5 1 CWO-5461 Wire Feed Control Case 6 1 CWO-5462 Wire Feed Control Cover 7 1 CWO-5533A Wire Feed Front Panel 8 1 CWO-5533B Wire Feed Rear Panel 9 1 CWO-6335 Toggle Switch 10 12 FAS-0205 Rnd Hd Scr 4-40 x 1/2" 11 2 FAS-0215 Rnd Hd Scr #6-32 x 1/2" 12 12 FAS-1305 Hex Nut 4-40 13 6 FAS-1310 Hex Nut #6-32 14 1 LN7 WTE 1351 Motor Control Board 15 1 PCB-1350 Timing Control Board 16 10 SCW WTE 0264 #6 x 1/4 Pan Hd 17 4 SCW WTE 0481 Pan Hd Scr #6-32 x 1/2" 18 4 STOF-2009 Stand Off #6-32 19 12 WAS-0201 #4 Internal Star Lock Washer 20 2 WAS-0211 #6 Internal Star Lock Washer 21 1 MUG-1589 Hole Plug .522" 22 1 MS-2A18-11S Panel Connector, 5T M 23 1 ABP-1069 Toggle Switch 24 1 BUG-9884 On-Off Switch Plate 25 1 LDC-1113 Plain Washer for LN-7 26 2 LDC-1114 Hex Nut 10-24 for LN-7 27 1 LDC-1104 Knob for LN-7 28 1 LDC-1103 Potentiometer for LN-7 29 1 LDC-1107 Transformer & Lead Assembly 30 1 LDC-1109 Resistor for LN-7 31 1 LDC-1108 Switch for LN-7 32 1 LN7 WTE 1352 Circuit Breaker 250V 2.5A 33 1 LDC-1101 Reed Switch Assembly for LN-7

CWO-3332 GMA WIRE FEEDER CONTROL / WIRING DIAGRAM

1 2 3 4 5 6

POT

BLK

YEL YEL RED RED

MAN/AUTO

BLU BLU

BLU

BLU BLU BLU

RESET

PROTECTOR

LEAD

GROUND

RED RED

WHT/BLU

BLK

RED

GRN

BLU

INPUT

POWER SOURCE

BREAKER

CIRCUIT

RESET

LIGHT

OUTPUT

527

526

SWITCH

GLP REED

541

539

WIRE

BLK

WHT/RED

WHT

BLK

WHT/RED

BLK

SOLENOID

MOTOR

WHT

BLU

RED

GRN

WHT

BLU

1 2 3 4 5 6 7 8

9 10 11 12

RED RED RED RED

WHT/RED

BLU BLU BLU

BOARD

TIMER

J5B

B S1 S B1 T2 P

T1 C

GOF-3037

GOF-3036

BLU

WHT

C119

ABP-1069

CAP WTE 1506

WHT

CBO-1013 X 2

ELECTRICAL COMPONENT CHART

ITEM DESCRIPTION PART NO.

1 Toggle Switch ON-Off-ON BUG-2255 2 Power Receptacle BUG-2287 3 Panel Connector 2T-F CON-0384 4 Toggle Switch ON-NONE-ON CWO-6335 5 Timer Board PCB-1350 6 Panel Connector 5T, F MS-2A18-11S 7 Panel Connector, 6T, Male CWO-6759

= INDICATES CONTROL BOARD ITEMS THAT ARE NOT USER REPLACEABLE.

CWO-6210 ROTATION CONTROL / EXPLODED VIEW / PARTS LIST

15,17

13,14,21

15,16

21,14,13

ITEM QTY PART NO. DESCRIPTION

1 1 ARM-2279 Toggle Switch 2 1 BUG-9445 Power Cord 3 1 CON-PS04M Plug, Straight 4-Pin Male 4 1 BUG-9687 Knob Fluted 5 1 BUG-9694 Knob 6 2 CSR-WTE-1597 Cord Strain Relief 7 1 CWO-6216 Rotation Box Front Panel 8 1 CWO-5547B Rotation Box Rear Panel 9 1 CWO-6206 Indicator Light 10 1 CWO-6527 0-90V Spd Ctrl w/Isolator 11 1 CWO-6839 Rotation Control Case 12 1 CWO-6802 Rotation Box Cover 13 6 FAS-0115 #6-32 x 1/2" Pan Head Zinc 14 6 FAS-1310 Hex Nut 6-32 15 2 FHO-0188 Fuse Holder 16 1 MPD-1026 Fuse 2 Amp 17 1 FUS-0257 Fuse 3 Amp 18 1 MUG-1258-1 Rotary Switch Assembly 19 10 SCW-WTE-0264 #6-32 x 1/4" Sht Mt Scr 20 3 TERM-WTE-0197 #6 Red Fork 21 6 WAS-0211 #6 Internal Star Washer 22 42" WRE-WTE-0501 18/3 SJO 300V Cord 23 1 MUG-1589 Hole Plug .500" 24 1 BUG-1562 Multi-turn Potentiometer 25 4 FAS-0104 #4-40 x 3/8" Pan Hd 26 4 SCF-1001 #4-40 Self Clinching Nut 27 1 BUG-1764 Meter Display Board 28 1 MDS-1011 Display Bezel 29 6 BUG-3331 Hole Plug 1/4"

25,26

CWO-6210 ROTATION CONTROL / WIRING DIAGRAM / ELECTRICAL COMPONENT CHART

= INDICATES ITEMS THAT ARE SUPPLIED TOGETHER.

ELECTRICAL COMPONENT CHART

ITEM DESCRIPTION PART NO.

1 Toggle Switch ARM-2279 2 Red Neon Lamp CWO-6206 3 Speed Control Board w/Resistor CWO-6525 4 Fuse 2 amp MPD-1026 5 Fuse 3 amp FUS-0257 6 Rotary Switch MUG-1258-1

CW-7 GUN ASSEMBLIES (MIG/FLUX-CORED)

CWO-1560-A #5 .035 GUN ASSEMBLY MIG/FLUX .035 WIRE SIZE

CWO-8027 15H-35 CONTACT TIP 10 CWO-8034 25CT-75 NOZZLE 1 CWO-8035 35CT NOZZLE INSULATOR 1 CWO-8036 55 SW GAS DIFFUSER 1 CWO-8039 45-3545-15 CABLE LINER 1 CWO-8524 50394 500 AMP CABLE 1

CWO-1560-B #5 .045 GUN ASSEMBLY MIG/FLUX .045 WIRE SIZE

CWO-8028 15H-45 CONTACT TIP 10 CWO-8034 25CT-75 NOZZLE 1 CWO-8035 35CT NOZZLE INSULATOR 1 CWO-8036 55 SW GAS DIFFUSER 1 CWO-8039 45-3545-15 CABLE LINER 1 CWO-8524 50394 500 AMP CABLE 1

CWO-1560-C #5 1/16 GUN ASSEMBLY MIG/FLUX 1/16 WIRE SIZE

CWO-8029 15H-116 CONTACT TIP 10 CWO-8034 25CT-75 NOZZLE 1 CWO-8035 35CT NOZZLE INSULATOR 1 CWO-8037 55 GAS DIFFUSER 1 CWO-8041 45-116-15 CABLE LINER 1 CWO-8524 50394 500 AMP CABLE 1

CWO-1560-D #5 5/64 GUN ASSEMBLY MIG/FLUX 5/64 WIRE SIZE

CWO-8031 15H-564 CONTACT TIP 10 CWO-8034 25CT-75 NOZZLE 1 CWO-8035 35CT NOZZLE INSULATOR 1 CWO-8038 55 GAS DIFFUSER 1 CWO-8085 45-564-15 CABLE LINER 1 CWO-8524 50394 500 AMP CABLE 1

CWO-1560-E #5 3/32 GUN ASSEMBLY MIG/FLUX 3/32 WIRE SIZE

CWO-8032 15H-332 CONTACT TIP 10 CWO-8034 25CT-75-NOZZLE 1

CWO-8035 35CT NOZZLE INSULATOR 1 CWO-8042 45H-332-15 CABLE LINER 1

CWO-8038 55H-GAS DIFFUSER 1 CWO-8524 50394 500 AMP CABLE 1

CWO-1560-G #5 .052 GUN ASSEMBLY MIG/FLUX .052 WIRE SIZE

CWO-8024 15H-52 CONTACT TIP 10 CWO-8034 25CT-75 NOZZLE 1 CWO-8035 35CT NOZZLE INSULATOR 1 CWO-8036 55 SW GAS DIFFUSER 1 CWO-8041 45-116-15 CABLE LINER 1 CWO-8524 50394 500 AMP CABLE 1

CW-7 GUN ASSEMBLIES (SUB ARC)

CWO-1700-A #5 .035 GUN ASSEMBLY SUB ARC .035 WIRE SIZE

CWO-8027 15H-35 CONTACT TIP 10 CWO-8036 55 SW GAS DIFFUSER 1 CWO-8039 45-3545-15 CABLE LINER 1 CWO-8054 25-SA NOZZLE FLUX CONE 1 CWO-8524 50394 500 AMP CABLE 1

CWO-1700-B #5 .045 GUN ASSEMBLY SUB ARC .045 WIRE SIZE

CWO-8028 15H-45 CONTACT TIP 10 CWO-8036 55 SW GAS DIFFUSER 1 CWO-8039 45-3545-15 CABLE LINER 1 CWO-8054 25-SA NOZZLE FLUX CONE 1 CWO-8524 50394 500 AMP CABLE 1

CWO-1700-C #5 1/16 GUN ASSEMBLY SUB ARC 1/16 WIRE SIZE

CWO-8029 15H-116 CONTACT TIP 10 CWO-8037 55 GAS DIFFUSER 1 CWO-8041 45-116-15 CABLE LINER 1 CWO-8054 25-SA NOZZLE FLUX CONE 1 CWO-8524 50394 500 AMP CABLE 1

CWO-1700-D #5 5/64 GUN ASSEMBLY SUB ARC 5/64 WIRE SIZE

CWO-8031 15H-564 CONTACT TIP 10 CWO-8038 55 GAS DIFFUSER 1 CWO-8042 45-116-15 CABLE LINER 1 CWO-8054 25-SA NOZZLE FLUX CONE 1 CWO-8524 50394 500 AMP CABLE 1

CWO-1700-E #5 3/32 GUN ASSEMBLY SUB ARC 3/32 WIRE SIZE

CWO-8032 15H-332 CONTACT TIP 10 CWO-8038 55H-GASS DIFFUSER 1 CWO-8042 45-332-15 LINER 1

CWO-8054 25-SA NOZZLE FLUX CONE 1 CWO-8524 50394 500 AMP CABLE 1

CWO-1700-G #5 .052 GUN ASSEMBLY SUB ARC .052 WIRE SIZE

CWO-8024 15H-52 CONTACT TIP 10 CWO-8036 55 SW GAS DIFFUSER 1 CWO-8041 45-116-15 CABLE LINER 1 CWO-8054 25-SA NOZZLE FLUX CONE 1 CWO-8524 50394 500 AMP CABLE 1

CW-7 DRIVE ROLL KITS

PART NO. DESCRIPTION

CWO-7026-.035 DRIVE ROLL KIT .035 (0.9mm) SOLID WIRE

CWO-7026-.035C DRIVE ROLL KIT .035 (0.9mm) CORED WIRE

CWO-7026-.052 DRIVE ROLL KIT .045-.052 (1.0-1.3mm) SOLID WIRE

CWO-7026-.052C DRIVE ROLL KIT .045-.052 (1.0-1.3mm) CORED WIRE

CWO-7026-1/16 DRIVE ROLL KIT 1/16 (1.6mm) SOLID/CORED WIRE

CWO-7026-3/32 DRIVE ROLL KIT .068-3/32 (1.7-2.4mm) SOLID/CORED WIRE

CWO-3690-_ K231 SUBARC GUN ASSEMBLY / EXPLODED VIEW / PARTS LIST

11a

ITEM QTY PART NO. DESCRIPTION

1 1 PXS-15106-3/32 Nozzle Insert 2 1 PXT-10570 Socket Head Screw 3 1 PXS-10493-1 Nozzle Insulator 4 1 PXS-121312 Hex Hd Scr 1 1/2" & Nut 1/2"-13 5 1 PXT-9967-10 Nozzle Body Roll Pin 6 1 CWO-8052 Nozzle Body *7 1 PXS-10125-_ Contact Tip (Specify Wire Size*) 8 1 PXS-10138 Flux Cone Plug (Insulator) 9 1 PXT-9078-1 Thumb Screw 10 1 PXT-9967-30 Flux Cone Roll Pin 11 1 PXT-13835 3/4" x 7" Flux Hose W/Fbr Ins 11A 1 PXT-3835-IN Fiber Insulator 12 1 BUG-3161-P Cone Body Assembly 13 1 BUG-3163 Locking Ferrule 14 1 BUG-3164 Flux Cone (Kp2085-1) 15 1 BUG-3165 Retaining Nut

*WIRE SIZES AVAILABLE:

PART NO. WIRE SIZE

CWO-3690-1/16 1/16" (1.6 mm) CWO-3690-5/64 5/64" (2.0 mm) CWO-3690-3/32 3/32" (2.4 mm)

*REPLACEMENT CONTACT TIPS AVAILABLE:

PART NO. WIRE SIZE

AFW-2291 1/16" (1.5 mm) CWO-8048 5/64" (2.0 mm) CWO-8049 3/32" (2.4 mm)

CWO-3700-_ SUBARC GUN ASSEMBLY / EXPLODED VIEW / PARTS LIST

ITEM QTY PART NO. DESCRIPTION 1 1 CWO-3698 Adaptor-LN7

2 2 CWO-1817 Bulk Head Connector QCB 3 1 CWO-3697 QCC 72" (1829 mm) Liner 4 1 CWO-3695-1/2 Adaptor K231 1/2" 5 1 CWO-3670-72 Weld Cable 4/0 Assembly 72" (1829 mm) Lg 6 1 CWO-3690-1/16 Sub-Arc Nozzle 1/16" 1 CWO-3690-5/64 Sub-Arc Nozzle 5/64" 1 CWO-3690-3/32 Sub-Arc Nozzle 3/32" 7 1 FAS-0452 Set Scr 1/4-20 x 1/4

CWO-3490 CW-7 FLUX HOPPER ASSEMBLY / EXPLODED VIEW / PARTS LIST

ITEM QTY PART NO. DESCRIPTION 1 1 CWO-3757 Hopper Support Rod

2 1 CWO-3760 Clamp Block 1/2" 3 1 CWO-3478 3/4" Hose Barb 4 1 CWO-3769 Flux Hopper Steel 12" 5 1 GOF-3019 Handle w/Bolts N/S 48" 1000-4-001 3/4" ID x 1" OD Clear Hose

#5 GUN AND CABLE ASSEMBLY / EXPLODED VIEW / PARTS LIST

PARTS LIST WIRE SIZE

ITEM QTY PART # DESCRIPTION .035 .045 .052 1/16 5/64 3/32

1 1 CWO-8024 15H-52 Contact tip X

1 1 CWO-8027 15H-35 Contact Tip X

1 1 CWO-8028 15H-45 Contact Tip X

1 1 CWO-8029 15H-116 Contact Tip X

1 1 CWO-8031 15H-564 Contact Tip X

1 1 CWO-8032 15H-332 Contact Tip X

2 1 CWO-8034 25CT-75 Nozzle Insulator X X X X X X

3 1 CWO-8035 35CT Nozzle Insulator X X X X X X

4 1 CWO-8036 55SW Gas Diffuser X X X

4 1 CWO-8037 55 Gas Diffuser X

4 1 CWO-8038 55H Gas Diffuser X X

5 1 CWO-8045 65-60 Conductor Tube X X X X X X

6 2 CWO-8017 185 Case w/Binder Screws X X X X X X

7 2 CWO-8018 104 Cable Connector Block X X X X X X

8 1 CWO-8052 Cable Hose Support X X X X X X

9 1 CWO-8053 175 Connector Plug w/O-Rings X X X X X X

10 1 CWO-8054 25-SA Nozzle Flux Cone X X X X X X

11 1 CWO-8524 50394 500 AMP Cable X X X X X X

* 1 CWO-8039 45-4535-15 Cable Liner X X

* 1 CWO-8041 45-116-15 Cable Liner X X

* 1 CWO-8042 45-332-15 Cable Liner X

* 1 CWO-8085 45-564-15 Cable Liner X

* ITEMS NOT SHOWN

3-JAW EXPANDABLE CHUCKS

CWO-3660

CWO-3661

3-Jaw Expandable Chucks

Mounts and automatically centers the Circle Welder on nozzles with or without anges. As shown below.

PART NO. FOR NOZZLE I.D.’S WEIGHT

CWO-3660 2 "- 10" (51mm-254mm) 69.3 lbs. (31.3 kg) CWO-3661 8"-16" (204-405 mm) 36 lbs. (16 kg) CWO-3362 10"-24" (255-610 mm) 51 lbs. (23 kg) CWO-3663 15.75"-47.25" (400-1200 mm) 64 lbs. (29 kg)

CWO-3662

CWO-3663

OPTIONAL MOTORIZED RACKING EQUIPMENT / CWO-1665-MV / EXPLODED VIEW / PARTS LIST

ITEM QTY PART NO. DESCRIPTION 1 1 ABR-1060-MH Motorized Horizontal

V-Guide Ways 33" 2 2 ABR-1060-MV Motorized Vertical V-Guide Ways 33" 3 1 CWO-1675-MV Motorized Vertical Racker 4 1 CWO-1695 Attachment Block 5 1 CWO-3023-1 Torch Angle Adjuster 16" 6 1 CWO-3460 33# Load Spring Assembly

OPTIONAL MOTORIZED RACKING EQUIPMENT / CWO-1690-MH / EXPLODED VIEW / PARTS LIST

ITEM QTY PART NO. DESCRIPTION 1 1 BUG-1550 Gear Motor (150:1)

2 2 CWO-1680 W2 Fixed Leg & Wheel 3 2 CWO-1681 W2 Adj. Leg & Wheel 4 1 CWO-1687 Mount Plt Large Racker 5 1 CWO-1693 Racker Motor MT Plt 6 2 CWO-1694 Stand-Off 7 2 CWO-4326 Fixed Leg & Wheel 8 2 CWO-4327 Adj. Leg & Wheel 9 4 FAS-0527 Soc Hd Cap 8-32 x 3/4" 10 2 FAS-0557 Soc Hd Cap 1/4-20 x 3/4" 11 2 FAS-0559 Soc Hd Cap 1/4-20 x 1" 12 1 GOF-3014 Drive Pinion w/ Key 13 2 WAS-0240 1/4" SAE Washer 14 1 CWO-1696 Motor Enclosure 15 1 BUG-9486 Panel Connector 2-T, M 16 2 GOF-3036 QD Female 17 4 FAS-0504 Soc Hd Cap 4-40 x 3/8" 18 4 FAS-0525 Soc Hd Cap 8-32 x 1/2" 19 4 FAS-1305 Hex Nut 4-40

OPTIONAL RACKING MOTORIZED RACKING / CWP-3350 / EXPLODED VIEW / PARTS LIST

ITEM QTY PART NO. DESCRIPTION 1 1 CWP-3351 Motorized Vertical Heavy Duty Rack Assembly

2 1 CWP-3352 Motorized Vertical Heavy Duty Rack Assembly 3 1 CWP-3360 Vertical Racker for Heavy Duty 4 3 WAS-0243 1/4 Split Lock Washer 5 3 FAS-2353 Hex Hd Cap Scr 1/4-20 x 1-1/2 6 1 CWP-3363 Horizontal Racker for Heavy Duty *7 1 CWO-3976 Power Racker Cable

*Not shown in drawing

OPTIONAL RACKING MOTORIZED RACKING / CWP-3351 / EXPLODED VIEW / PARTS LIST

11 12

13,11

ITEM QTY PART NO. DESCRIPTION 1 1 CWP-3355 Hvy Duty Rack 150:1 No Mounting Bracket

2 1 CWO-5933 Jaw Coupling 3/8" & 5/8" Bores With Spider 3 2 CWO-5565 5/8" Pillow Block 4 1 CWP-3354 Screw for Mtrzd Hrz Hvy Duty Rack 5 1 CWP-3353 Mtrzd Hrz Slide Hvy Duty Rack 6 2 CWP-3362 Stud 1/2-13 All Thread 7 1 CWO-3865 1"-6 Acme Nut and Bar Assembly 8 5 CWO-9038 Hold Down Clip 9 2 CWO-9065 T-3 Track 36" Lg 10 1 CWP-3356 Horiz P.M. Motor Bracket #970 Mod 11 6 FAS-1301 Hex Nut 1/2-13 12 2 WAS-0281 1/2 Split Lock Washer Zinc Plated 13 4 WAS-0280 1/2 SAE Flat 14 4 FAS-2591-SS Soc Hd Cap Scr 3/8-16 x 1-1/4 Stainless Steel 15 4 FAS-1444-SS Phil Pan Hd Scr 10/32 x 3/8" Stainless Steel 16 10 FAS-0359-SS Hex Hd Cap Scr 1/4-20 x 1" Stainless Steel 17 1 FAS-0399 Hex Hd Cap Scr 3/8-16 x 1" 18 1 WAS-0262 3/8" Split Lock Washer Zinc Plated 19 1 WAS-0260 3/8 Washer Zinc Plated 20 4 FAS-0555 Soc Hd Cap Scr 1/4-20 x 1/2 21 4 WAS-0243 1/4" Split Lock Washer Zinc Plated

OPTIONAL MOTORIZED RACKING EQUIPMENT / PRS-1100/ EXPLODED VIEW / WIRING DIAGRAM

OPTIONAL MOTORIZED RACKING EQUIPMENT / PRS-1100 / PARTS LIST

ITEM COMPONENT ITEM DESCRIPTION 120VAC 240VAC 42VAC

1 PRS-1111

2 BUG-2923

BUG-2952

BUG-2933

3 BUG-2924

4 BUG-5001

BUG-5002

BUG-5003

5 PRS-1110

6 PRS-1112

7 MUG-1156

8 BUG-1404

9 BUG-1411

10 BUG-1384

11 BUG-1383

BUG-1551

BUG-9636

12 BUG-9902

13 CAS-1770

14 BUG-9446

15 BUG-9445

GOF-3115

16 BUG-9628

17 FAS-0124

18 FAS-1320

19 WAS-0221

20 SCW WTE 0514

21 FAS-0204

22 FAS-1305

23 WAS-0201

24 FAS-0112

N/S SFX-1292

Input End Panel .7 Amp Circuit Breaker .5 Amp Circuit Breaker 2 Amp Circuit Breaker “Reset Seal, Transparent” Transformer 115VAC Transformer 240VAC Transformer 42VAC Enclosure Output End Panel Panel Connector, 4-T, F Relay Bracket Hold Down Spring Relay Socket & Spring Relay, 4Pdt, 3A 120V, Plug In Relay 3A, 240VAC Relay 48VAC Panel Connector, 6-T, F Speed Control (Iron Rotor) Cord Grip Power Cord (120VAC Shown) Line Cord 240VAC Cap & Chain Assembly 8/32 x 3/8 Pan Hd, Di-Chrome Hex Nut 8-32 #8 Internal Star Lockwasher #8-32 x 3/8" Pan Head, Zinc Rnd Hd Slt Scr 4-40 x 3/8 Zinc Hex Nut 4-40 #4 Internal Star Lockwasher Pan Hd Slt 6-32 x 1/4 Black Bumper, Cylindrical .14 x .50"

1 1

OPTIONAL MOTORIZED RACKING EQUIPMENT / CWP-3363 / EXPLODED VIEW / PARTS LIST

ITEM QTY PART NO. DESCRIPTION

1 1 CWO-1687 Plate 2 4 CWO-4326 Wheel & Leg Assembly, Fixed 3 4 CWO-4327 Wheel & Leg Assembly, Adjustable

OPTIONAL MOTORIZED RACKING EQUIPMENT / PRS-1075 / EXPLODED VIEW / PARTS LIST

PREVENTIVE MAINTENANCE / CW-7 CIRCLE WELDER

IMPORTANT: Make sure the input power at the power source is turned off and the 50' weld cable is

disconnected from the circle welder prior to working inside the circle welder.

AFTER DAILY USE:

Refer to CW-7 Exploded View Parts List. (Pg. 10, 11)

Racking System Item #1:

Inspect gear rack, hardened ways and wheels (remove all dirt, grease, weld spatter and rust). Check hardened ways for nicks and replace if necessary. Lubricate with a dry teon or graphite spray lubricant. Adjust wheels for snug t and smooth operation. Lubricate racker pinion with a dry teon or graphite spray lubricant.

Large Horizontal Racker Item #2:

Inspect wheels (remove all dirt, grease, weld spatter and rust). Adjust wheels for snug t and smooth operation. Lubricate racker pinion and wheels with a dry teon or graphite spray lubricant.

Slide Bar Mounting Assembly Item #6:

Inspect hardened ways (remove all dirt, grease and weld spatter). Check hardened ways for nicks and replace if necessary. Lubricate with a dry teon or graphite spray lubricant.

Refer to CW-7 Electrical Component Chart. (Pg. 12) Power Cable Item #4:

Inspect cable connector to make sure threads are not stripped and that the connector is not cracked. Check the cable for cuts, missing insulation and burn spots, replace if necessary.

CW-7 Collector Ring Item #11:

Inspect cable connector to make sure threads are not stripped and that the connector is not cracked. Ensure that the connector is fastened properly to the large aluminum gear item #27 on the CW-5 Exploded View Parts List.

EVERY SIX MONTHS:

Refer to CW-7 Exploded View Parts List. (Pg. 10, 11)

Aluminum Gear Item #29

Do not grease this gear. Inspect gear teeth (remove all dirt, grease and weld spatter). Lubricate with a dry teon or graphite spray lubricant. Replace gear if excessively worn.

P.M. Motor Assembly Item #17:

Do not grease this pinion. Inspect the drive pinion (remove all dirt, grease and weld spatter). Lubricate with a dry teon or graphite spray lubricant. Replace pinion if excessively worn. Check set screw and tighten if necessary. Adjust motor assembly using the four adjustable mounting fasteners so that proper gear mesh is achieved between the aluminum gear item #29 and the motor drive pinion.

5" Cam Assembly Item #7:

Inspect the slide rails and the cam pinion (remove all dirt, grease and weld spatter0. Do not grease slide rails or cam pinion. Lubricate with a dry teon or graphite spray lubricant. Replace cam pinion if excessively worn. Tighten all fasteners as needed.

Wire Reel Assembly Item #22:

Periodically coat the wire wheel shaft with a thin layer of grease as needed. Inspect the shoe assembly and replace if excessively worn.

PREVENTIVE MAINTENANCE / CW-7 CIRCLE WELDER

Refer to CW-7 Electrical Component Chart. (Pg. 12)

GMA Wire Feed Control Item #6:

Open control box, use an air hose to blow out dust and dirt. Check all wires for breaks and replace if necessary. Check all electrical connectors and plugs. If an electrical component fails refer to CWO-3332 Wire Feeder Control electrical component chart for replacement parts or return for service.

M-14 Rotation Control Item #15:

Open control box use an air hose to blow out dust and dirt. Check all wires for breaks and replace if necessary. Check all electrical connectors and plugs. If an electrical component fails refer to CWO-6210 Rotation Control electrical component chart for replacement parts or return or service.

LN-7 Wire Feeder Assembly Item #9:

Check brushes for wear. Brushes should be replaced when their length is less than 1/4 inch. Replace strain relief on wire if pulled out of motor housing.

Brush Holder & Support Item #3:

Inspect brush holder. Make sure constant tension is being applied on the brushes. Brushes should move freely within the brush holder. Check brushes for arc build-up. If brushes are pitted they will need replaced. Remove the brushes and sand them to ensure a smooth contact surface. Make sure all fasteners are tight.

Small Brush Retainer Assembly Item #8:

Inspect black brush holders for cracks and replace if needed. Check and make sure all wires are soldered properly to the holders. Replace the brushes when their length is less than 1/2 inch long. Remove the brushes and sand them to ensure a smooth contact surface. Make sure all fasteners are tight.

Terminal Block Item #13:

Inspect the plastic terminal strip and make sure it is not cracked, replace if necessary. Make sure all terminal connections are tight. Make sure all ground wires are connected to the mounting screws of the terminal strip.

EVERY TWELVE MONTHS:

Refer to CW-7 Exploded View Parts List. (Pg. 10, 11)

1-1/2" Bearing With Fasteners Item #26:

Do not grease the bearing, it is greased for life by the manufacturer. If the grease tting has not been removed and plugged we suggest that you do so now. Earlier models may not have been plugged at time of assembly.

P.M. Motor Assembly Item #15:

Bodine gear motor lubrication. Fill gear motor to oil level indicator with worm gear oil conforming to AGMA#5EP compounded (SAE#90) oil or Bodine lubricant (#L-23). Do not overll.

LN-7 Wire Feeder Assembly Item #17:

Apply graphite grease to the gear teeth. Inspect the drive roll portion of the assembly, clean as necessary. Do not use solvents on the idle roll because it may wash the lubricant out of the bearings. Do not apply grease to the drive rolls.

Transmission 5:1 Assembly Item #14:

Inspect for excessive wear and tear. Keep the transmission assembly clean and lubricate with Lubriplate #630-AA.

PREVENTIVE MAINTENANCE / CW-7 CIRCLE WELDER

Refer to CW-7 Electrical Component Chart. (Pg. 12)

CW-7 Collector Item #11:

The collector ring should be sanded once a year. If the collector ring is pitted too badly it should be replaced. Inspect all wires coming out of the collector ring for cut or missing insulation. All wires should be fastened to the center shaft with a nylon cable tie. Tighten four set screws if needed.

Weld Cable Inlet 3/0 Item #12:

Ensure that the cable is fastened tightly to the collector ring. Inspect the cable for cut or missing insulation. Make sure the micarta insulation tube on the cable is in good condition. Replace the cable if necessary.

Solenoid Adaptor Kit Item #16:

Inspect for damage. Replace if necessary.

GMA Pigtail Item #5:

Inspect the cable for cuts or missing insulation. Ensure that the elbow connector is not damaged. Ensure that all terminal ends are snug. Replace cable if necessary.

WARRANTY

Model _____________________________

Limited 3-Year Warranty*

For a period ending one (1) year from the date of invoice, Manufacturer warrants that any new machine or part is free from defects in materials and workmanship and Manufacturer agrees to repair or replace at its option, any defective part or machine. HOWEVER, if the invoiced customer registers the Product Warranty by returning the Warranty Registration Card supplied with the product within 90 days of the invoice date, or by registering on-line at www.bugo.com, Manufacturer will extend the warranty period an additional two (2) years which will provide three (3) total years from the date of original invoice to customer. This warranty does not apply to machines which, after Manufacture’s inspection are determined by Manufacturer to have been damaged due to neglect, abuse, overloading, accident or improper usage. All shipping and handling charges will be paid by the customer.

The foregoing express warranty is exclusive and Manufacturer makes no representation or warranty (either express or implied) other than as set forth expressly in the preceding sentence. Specifically, Manufacturer makes no express or implied warranty of merchantability or fitness for any particular purpose with respect to any goods. Manufacturer shall not be subject to any other obligations or liabilities whatsoever with respect to machines or parts furnished by Manufacturer.

Manufacturer shall not in any event be liable to Distributor or any customer for any loss of profits, incidental or consequential damages or special damages of any kind. Distributor’s or customer’s sole and exclusive remedy against Manufacturer for any breach of warranty, negligence, strict liability or any other claim relating to goods delivered pursuant hereto shall be for repair or replacement (at Manufacturer’s option) of the machines or parts affected by such breach.

Serial No. __________________________ Date Purchased: ____________________ Where Purchased:___________________

Distributor’s Warranty:

In no event shall Manufacturer be liable to Distributor or to any customer thereof for any warranties, representations or promises, express or implied, extended by Distributor without the advance written consent of Manufacturer, including but not limited to any and all warranties of merchantability or fitness for a particular purpose and all warranties, representations or promises which exceed or are different from the express limited warranty set forth above. Distributor agrees to indemnify and hold Manufacturer harmless from any claim by a customer based upon any express or implied warranty by Distributor which exceeds or differs from Manufacturer’s express limited warranty set forth above.

HOW TO OBTAIN SERVICE: If you think this machine is not operating properly, re-read the instruction manual carefully, then call your Authorized BUG-O dealer/distributor. If they cannot give you the necessary service, write or phone us to

tell us exactly what difculty you have experienced. BE SURE to mention the MODEL and SERIAL numbers.

*Bug-O System’s warranty applies to Bug-O components only. Where other brands of power sources, wire feeders or sub components are a part of Bug-O Equipment, please refer to that specific Manufacturer’s manual for warranty specifications on their components.

BUG-O Systems CW-7 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual