ESAB MIG-35 Solid/Cored Wire Feeder Troubleshooting instruction

INSTRUCTIONS for

SOLID/CORED WIRE FEEDER

F-12-786-M

March, 2001

MIG-35

P/N 953552 W/2-ROLL DRIVE

P/N 677634 W/4-ROLL DRIVE*

(*See Supplement F-12-821)

NOTE: For design changes in MIG-35 units, refer to page 23.

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe
practices for arc welding equipment, we urge you to read our booklet, Precautions and Safe Practices for Arc Welding,
Cutting and Gouging, Form 52-529. Do NOT permit untrained persons to Install, operate, or maintain this equipment. Do
NOT attempt to install or operate this equipment until you have read and fully understand these instructions. If you do not
fully understand these instructions, contact your supplier for further information. Be sure to read the Safety Precautions on
page 3 before installing or operating this equipment.

Be sure this information reaches the operator.
You can get extra copies through your supplier.

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and accompanying
labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided.
This equipment must be checked periodically. Malfunctioning equipment should not be used. Parts that are broken,
missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become
necessary, the manufacturer recommends that a telephone or written request for service advice be made to the
Authorized Distributor from whom purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The
user of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty
maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility
designated by the manufacturer.

2

SAFETY PRECAUTIONS

WARNING: These Safety Precautions are for

your protection. They summarize precaution­ary information from the references listed in

Additional Safety Information section. Before
performing any installation or operating procedures, be
sure to read and follow the safety precautions listed below
as well as all other manuals, material safety data sheets,
labels, etc. Failure to observe Safety Precautions can result
in injury or death.

PROTECT YOURSELF AND OTHERS
Some welding, cutting, and gouging
processes are noisy and require ear
protection. The arc, like the sun, emits

ultraviolet (UV) and other radiation and
can injure skin and eyes. Hot metal can cause burns.
Training in the proper use of the processes and equip­ment is essential to prevent accidents. Therefore:

1. Always wear safety glasses with side shields in any work

area, even if welding helmets, face shields, and goggles
are also required.

2. Use a face shield fitted with the correct filter and cover

plates to protect your eyes, face, neck, and ears from
sparks and rays of the arc when operating or observing
operations. Warn bystanders not to watch the arc and
not to expose themselves to the rays of the electric-arc
or hot metal.

3. Wear flameproof gauntlet type gloves, heavy long-sleeve

shirt, cuffless trousers, high-topped shoes, and a weld­ing helmet or cap for hair protection, to protect against
arc rays and hot sparks or hot metal. A flameproof apron
may also be desirable as protection against radiated
heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,

trouser cuffs, or pockets. Sleeves and collars should be
kept buttoned, and open pockets eliminated from the
front of clothing

5. Protect other personnel from arc rays and hot sparks

with a suitable non-flammable partition or curtains.

6. Use goggles over safety glasses when chipping slag or

grinding. Chipped slag may be hot and can fly far.
Bystanders should also wear goggles over safety glasses.

FIRES AND EXPLOSIONS -- Heat from
flames and arcs can start fires. Hot slag
or sparks can also cause fires and ex­plosions. Therefore:

1. Remove all combustible materials well away from the

work area or cover the materials with a protective non­flammable covering. Combustible materials include wood,
cloth, sawdust, liquid and gas fuels, solvents, paints and
coatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks or

crevices in floors or wall openings and cause a hidden
smoldering fire or fires on the floor below. Make certain
that such openings are protected from hot sparks and
metal.“

3. Do not weld, cut or perform other hot work until the

workpiece has been completely cleaned so that there
are no substances on the workpiece which might pro­duce flammable or toxic vapors. Do not do hot work on
closed containers. They may explode.

4. Have fire extinguishing equipment handy for instant use,

such as a garden hose, water pail, sand bucket, or
portable fire extinguisher. Be sure you are trained in its
use.

5. Do not use equipment beyond its ratings. For example,
overloaded welding cable can overheat and create a fire
hazard.

6. After completing operations, inspect the work area to
make certain there are no hot sparks or hot metal which
could cause a later fire. Use fire watchers when neces­sary.

7. For additional information, refer to NFPA Standard 51B,
"Fire Prevention in Use of Cutting and Welding Pro-

--

cesses", available from the National Fire Protection Asso­ciation, Batterymarch Park, Quincy, MA 02269.

ELECTRICAL SHOCK -- Contact with live
electrical parts and ground can cause
severe injury or death. DO NOT use AC
welding current in damp areas, if move­ment is confined, or if there is danger of
falling.

1. Be sure the power source frame (chassis) is connected
to the ground system of the input power.

2. Connect the workpiece to a good electrical ground.

3. Connect the work cable to the workpiece. A poor or
missing connection can expose you or others to a fatal
shock.

4. Use well-maintained equipment. Replace worn or dam­aged cables.

5. Keep everything dry, including clothing, work area, cables,
torch/electrode holder, and power source.

6. Make sure that all parts of your body are insulated from
work and from ground.

7. Do not stand directly on metal or the earth while working
in tight quarters or a damp area; stand on dry boards or
an insulating platform and wear rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the power.

9. Turn off the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on next page)
for specific grounding recommendations. Do not mistake
the work lead for a ground cable.

ELECTRIC AND MAGNETIC FIELDS —
May be dangerous. Electric current flow­ing through any conductor causes lo­calized Electric and Magnetic Fields
(EMF). Welding and cutting current cre­ates EMF around welding cables and
welding machines. Therefore:

1. Welders having pacemakers should consult their physi­cian before welding. EMF may interfere with some pace­makers.

2. Exposure to EMF may have other health effects which are
unknown.

3. Welders should use the following procedures to minimize
exposure to EMF:
A. Route the electrode and work cables together. Secure

them with tape when possible.
B. Never coil the torch or work cable around your body.
C. Do not place your body between the torch and work

cables. Route cables on the same side of your body.

D. Connect the work cable to the workpiece as close as

possible to the area being welded.
E. Keep welding power source and cables as far away

from your body as possible.

10/98

FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in confined spaces. Do
not breathe fumes and gases. Shield­ing gases can cause asphyxiation.
Therefore:

1. Always provide adequate ventilation in the work area by
natural or mechanical means. Do not weld, cut, or gouge
on materials such as galvanized steel, stainless steel,
copper, zinc, lead, beryllium, or cadmium unless positive
mechanical ventilation is provided. Do not breathe fumes
from these materials.

2. Do not operate near degreasing and spraying opera­tions. The heat or arc rays can react with chlorinated
hydrocarbon vapors to form phosgene, a highly toxic
gas, and other irritant gases.

3. If you develop momentary eye, nose, or throat irritation
while operating, this is an indication that ventilation is not
adequate. Stop work and take necessary steps to im­prove ventilation in the work area. Do not continue to
operate if physical discomfort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below)
for specific ventilation recommendations.

5. WARNING: This product, when used for welding or

cutting, produces fumes or gases which
contain chemicals known to the State of
California to cause birth defects and, in
some cases, cancer. (California Health &

Safety Code

CYLINDER HANDLING -- Cylinders, if
mishandled, can rupture and violently
release gas. Sudden rupture of cylin­der, valve, or relief device can injure or
kill. Therefore:

1. Use the proper gas for the process and use the proper
pressure reducing regulator designed to operate from
the compressed gas cylinder. Do not use adaptors.
Maintain hoses and fittings in good condition. Follow
manufacturer's operating instructions for mounting regu­lator to a compressed gas cylinder.

2. Always secure cylinders in an upright position by chain
or strap to suitable hand trucks, undercarriages, benches,
walls, post, or racks. Never secure cylinders to work
tables or fixtures where they may become part of an
electrical circuit.

3. When not in use, keep cylinder valves closed. Have
valve protection cap in place if regulator is not con­nected. Secure and move cylinders by using suitable
hand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and flames.
Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1,
"Precautions for Safe Handling of Compressed Gases in
Cylinders", which is available from Compressed Gas
Association, 1235 Jefferson Davis Highway, Arlington,
VA 22202.

§25249.5 et seq.)

EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:

1. Always have qualified personnel perform the installa­tion, troubleshooting, and maintenance work. Do not
perform any electrical work unless you are qualified to
perform such work.

2. Before performing any maintenance work inside a power
source, disconnect the power source from the incoming
electrical power.

3. Maintain cables, grounding wire, connections, power
cord, and power supply in safe working order. Do not
operate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep
equipment away from heat sources such as furnaces,
wet conditions such as water puddles, oil or grease,
corrosive atmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position
and in good repair.

6. Use equipment only for its intended purpose. Do not
modify it in any manner.

ADDITIONAL SAFETY INFORMATION -- For
more information on safe practices for elec­tric arc welding and cutting equipment, ask
your supplier for a copy of "Precautions and
Safe Practices for Arc Welding, Cutting and
Gouging", Form 52-529.

The following publications, which are available from the
American Welding Society, 550 N.W. LeJuene Road, Mi­ami, FL 33126, are recommended to you:

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"

3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"

5. AWS C5.5 - "Recommended Practices for Gas Tungsten
Arc Welding“

6. AWS C5.6 - "Recommended Practices for Gas Metal Arc
Welding"“

7. AWS SP - "Safe Practices" - Reprint, Welding Hand­book.

8. ANSI/AWS F4.1, "Recommended Safe Practices for
Welding and Cutting of Containers That Have Held
Hazardous Substances."

MEANING OF SYMBOLS - As used through­out this manual: Means Attention! Be Alert!
Your safety is involved.

Means immediate hazards which, if
not avoided, will result in immediate,
serious personal injury or loss of life.

Means potential hazards which could
result in personal injury or loss of life.

Means hazards which could result in
minor personal injury.

4

SP98-10

PRÉCAUTIONS DE SÉCURITÉ

AVERTISSEMENT: Ces règles de sécurité ont pour
objet d assurer votre protection. Veillez à lire et à
observer les précautions énoncées ci-dessous avant de
monter l équipement ou de commercer à lutiliser. Tout
défaut dobservation de ces précautions risque
dentraîner des blessures graves ou mortelles.

1. PROTECTION INDIVIDUELLE-- Les brûlures de la
peau et des yeux dues au rayonnement de larc
électrique ou du métal incandescent, lors du soudage
au plasma ou à lélectrode ou lors du gougeage à
larc, peuvent savérer plus graves que celles
résultant dune exposition prolongée au soleil. Aussi
convient-il dobserver les précautions suivantes:

a. Portez un écran facial adéquat muni des plaques

protectrices et des verres filtrants appropriés afin de
vous protéger les yeux, le visage, le cou et les
oreilles des étincelles et du rayonnement de larc
électrique lorsque vous effectuez des soudures ou
des coupes ou lorsque vous en observez lexécution.

AVERTISSEZ les personnes se trouvant à proximité

de façon à ce quelles ne regardent pas larc et à ce
quelles ne sexposent pas à son rayonnement, ni à
celui du métal incandescent.

b. Portez des gants ignifugés à crispins, une tunique

épaisse à manches longues, des pantalons sans
rebord, des chaussures à embout dacier et un
casque de soudage ou une calotte de protection,
afin déviter dexposer la peau au rayonnement de
larc électrique ou du métal incandescent. ll est
également souhaitable dutiliser un tablier
ininflammable de façon à se protéger des étincelles
et du rayonnement thermique.

c. Les étincelles ou les projections de métal incandes-

cent risquent de se loger dans des manches
retroussées, des bords relevés de pantalons ou
dans des poches. Aussi convient-il de garder
boutonnés le col et les manches et de porter des
vêtements sans poches à lavant.

d. Protégez des étincelles et du rayonnement de larc

électrique les autres personnes travaillant à proximité
à laide dun écran ininflammable adéquat.

e. Ne jamais omettre de porter des lunettes de sécurité

lorsque vous vous trouvez dans un secteur où lon
effectue des opérations de soudage ou de coupage
à larc. Utilisez des lunettes de sécurité à écrans ou
verres latéraux pour piquer ou meûler le laitier. Les
piquetures incandescentes de laitier peuvent être
projetées à des distances considérables. Les
personnes se trouvant à proximité doivent également
porter des lunettes de protection.

f. Le gougeage à larc et le soudage à larc au plasma

produisent un niveau de bruit extrêmement élevé
(de 100 à 114 dB) et exigent par conséquent
lemploi de dispositifs appropriés de protection audi­tive.

2. PRÉVENTION DES INCENDES-- Les projections de
laitier incandescent ou détincelles peuvent
provoquer de graves incendies au contact de
matériaux combustibles solides, liquides ou gazeux.

Aussi faut-il observer les précautions suivantes:

a. Éloigner suffisamment tous les matériaux combus-

tibles du secteur où lon exécute des soudures ou
des coupes à larc, à moins de les recouvrir
complètement dune bâche non-inflammable. Ce
type de matériaux comprend notamment le bois, les
vêtements, la sciure, lessence, le kérosène, les
peintures, les solvants, le gaz naturel, lacétylène, le
propane et autres substances combustibles
semblables.

b. Les étincelles ou les projections de métal incandes-

cent peuvent tomber dans des fissures du plancher
ou dans des ouvertures des murs et y déclencher
une ignition lente cachée. Veiller à protéger ces
ouvertures des étincelles et des projections de
métal.

c. Nexécutez pas de soudures, de coupes, dopérations

de gougeage ou autres travaux à chaud à la surface
de barils, bidons, réservoirs ou autres contenants
usagés, avant de les avoir nettoyés de toute trace
de substance susceptible de produire des vapeurs
inflammables ou toxiques.

d. En vue dassurer la prévention des incendies, il

convient de disposer dun matériel dextinction prêt
à servir immédiatement, tel quun tuyau darrosage,
un seau à eau, un seau de sable ou un extincteur
portatif.

e. Une fois le travail à larc terminé, inspectez le

secteur de façon à vous assurer quaucune étincelle
ou projection de métal incandescent ne risque de
provoquer ultérieurement un feu.

3. CHOC ÉLECTRIQUE-- Le gougeage à larc et à larc
au plasma exige lemploi de tensions à vide
relativement importantes; or, celles-ci risquent de
causer des dommages corporels graves et même
mortels en cas dutilisation inadéquate. La gravité
du choc électrique reçu dépend du chemin suivi par
le courant à travers le corps humain et de son
intensité.

a. Ne laissez jamais de surfaces métalliques sous

tension venir au contact direct de la peau ou de
vêtements humides. Veillez à porter des gants bien
secs.

b. Si vous devez effectuer un travail sur une surface

métallique ou dans un secteur humide, veillez à
assu-rer votre isolation corporelle en portant des
gants secs et des chaussures à semelles de ca­outchouc et en vous tenant sur une planche ou une
plate-forme sèche.

c. Mettez toujours à la terre le poste de soudage/

coupage en le reliant par un câble à une bonne prise
de terre.

d. Nutilisez jamais de câbles usés ou endommagés.

Ne surchargez jamais le câble. Utilisez toujours un
équipement correctement entretenu.

e. Mettez léquipement hors tension lorsquil nest pas

en service. une mise à la masse accidentelle peut
en effet provoquer une surchauffe de léquipement
et un danger dincendie. Ne pas enrouler ou passer

5

9/97

levage, des câbles de grue ou divers chemins
électriques.

g. Empêchez lapparition de toute humidité, notamment

sur vos vêtements, à la surface de lemplacement de
travail, des câbles, du porte-électrode et du poste de
soudage/coupage. Réparez immédiatement toute fuite
deau.

4. VENTILATION-- La respiration prolongée des fumées
résultant des opérations de soudage/coupage, à
lintérieur, dun local clos, peut provoquer des mal­aises et des dommages corporels. Aussi convient-il
dobserver les précautions suivantes:

a. Assurez en permanence une aération adéquate de

lemplacement de travail en maintenant une ventila­tion naturelle ou à laide de moyens mécaniques.
Neffectuez jamais de travaux de soudage ou de
coupage sur des matériaux de zinc, de plomb, de
beryllium ou de cadmium en labsence de moyens
mécaniques de ventilation capables dempêcher
linhalation des fumées dégagées par ces matériaux.

b. Neffectuez jamais de travaux de soudage ou de

coupage à proximité de vapeurs dhydrocarbure chloré
résultant dopérations voisines de dégraissage ou de
pulvérisation. La chaleur dégagée ou le rayonnement
de larc peut déclencher la formation de phosgène -­gaz particulièrement toxique -- et dautres gaz irri­tants, à partir des vapeurs de solvant.

c. Une irritation momentanée des yeux, du nez ou de la

gorge constatée au cours de lutilisation de
léquipement dénote un défaut de ventilation. Arrêtez­vous de travailler afin de prendre les mesures néces­saires à lamélioration de la ventilation. Ne poursuivez
pas lopération entreprise si le malaise persiste.

d. Certaines commandes comportent des canalisations

où circule de lhydrogène. Larmoire de commande est
munie dun ventilateur destiné à empêcher la forma­tion de poches dhydrogène, lesquelles présentent un
danger dexplosion; ce ventilateur ne fonctionne que
si linterrupteur correspondant du panneau avant se
trouve placé en position ON (Marche). Veillez à
manuvrer cette commande en vérifiant si le couvercle
est bien en place, de façon à assurer lefficacité de la
ventilation ainsi réalisée. Ne jamais débrancher le
ventilateur.

e. Les fumées produites par lopération de soudage ou

de coupage peuvent savérer toxiques. Aussi est-il
nécessaire de disposer en permanence dun dispositif
adéquat de ventilation de type aspirant, afin délimi­ner du voisinage de lopérateur tout dégagement de
fumée visible.

f. Consultez les recommandations particulières en matière

de ventilation indiquées à lalinéa 6 de la norme Z49.1
de lAWS.

5. ENTRETIEN DE LÉQUIPEMENT-- Un équipement
entretenu de façon défectueuse ou inadéquate risque
non seulement de réaliser un travail de mauvaise

qualité mais, chose plus grave encore, dentraîner
des dommages corporels graves, voire mortels en
déclenchant des incendies ou des chocs électriques.
Observez par conséquent les précautions suivantes:

a. Efforcez-vous de toujours confier à un personnel qua-

lifié linstallation, le dépannage et lentretien du poste
de soudage et de coupage. Neffectuez aucune
réparation électrique sur léquipement à moins dêtre
qua-lifié à cet effet.

b. Ne procédez jamais à une tâche dentretien

quelconque à lintérieur du poste de soudage/
coupage, avant davoir débranché lalimentation
électrique.

c. Maintenez en bon état de fonctionnement les câbles,

le câble de masse, les branchements, le cordon
dalimentation et le poste de soudage/coupage.
Nutilisez jamais le poste ou léquipement sil présente
une défectuosité quelconque.

d. Prenez soin du poste de soudage et de coupage et

des équipements accessoires. Gardez-les à lécart
des sources de charleur, notamment des fours, de
lhumidité, des flaques deau maintenez-les à labri
des traces dhuile ou de graisse, des atmosphères
corrosives et des intempéries.

e. Laissez en place tous les dispositifs de sécurité et

tous les panneaux de larmoire de commande en
veillant à les garder en bon état.

f. Utilisez le poste de soudage/coupage conformément

à son usage prévu et neffectuez aucune modifica­tion.

6. INFORMATIONS COMPLÉMENTAIRES RELATIVES
À LA SÉCURITÉ--

Pour obtenir des informations complémentaires sur

les règles de sécurité à observer pour le montage et
lutilisation déquipements de soudage et de coupage
électriques et sur les méthodes de travail
recommandées, demandez un exemplaire du livret
N° 52529 Precautions and Safe Practices for Arc
Welding, Cutting and Gouging publié par ESAB.
Nous conseillons également de consulter les publica­tions sui-vantes, tenues à votre disposition par
lAmerican Welding Society, 550 N.W. LeJuene Road,
Miami, FL 32126:

a. Safety in Welding and Cutting AWS Z49.1
b. Recommended Safe Practices for Gas-Shielded Arc

Welding AWS A6. 1.

c. Safe Practices for Welding and Cutting Containers

That Have Held Combustibles AWS-A6.0.

d. Recommended Safe Practices for Plasma Arc Cut-

ting AWS-A6. 3.

e. Recommended Safe Practices for Plasma Arc Weld-

ing AWS-C5. 1.

f. Recommended Safe Practices for Air Carbon Arc

Gouging and Cutting AWS-C5. 3.

g. Code For Safety in Welding and Cutting

CSA-Standard W117. 2.

6

9/97

SECTION 1 DESCRIPTION AND SPECIFICATIONS

I. DESCRIPTION AND SPECIFICATIONS

The MIG-35 Wire Feeder covered in this literature is de­signed for short arc, spray arc mig or cored wire welding
with a constant potential (CP) welding power source. In
short arc welding, relatively low voltages and small- di­ameter wires are used. Wire speed is set so that the
low-voltage arc actually shorts out to the weld puddle
50-200 times a second. The result is a small weld puddle,
with minimum melting of base metal and minimum trans­fer of heat into the work. Short arc welding can be done
in any position, and used to weld sheet as thin as 1/16-in.
In spray arc welding, heavier wires and higher voltages
are used, and there is no shorting out of the arc. Metal
is transferred in a stream of droplets through the arc. The
weld puddle is larger and out-of-position welding is some­what more difficult, but higher rates of metal deposition
are possible.

SPECIFICATIONS

Input Power Required ...115 volts, 60 hz, single phase

Wire Feed Speed Range .... 0- 1000 in./min. (0-423

mm/sec)
Wire Sizes Accommodated:

Hard/Soft . . . ..... . 023 thru 1/8-in.(.6 thru 3.2 min)

Flux Cored .... 045-in. thru 1/8-in.(1.2 thru 3.2 mm)

Length ....................................... 18.5-in. (470 mm)

Width ............................................13-in. (330 min)

Height .........................................16.5-in (419 min)

Weight (less wire) ........................43-lbs. (19.5 kg)

The MIG-35 uses a heavy duty EH-10A wire drive motor
designed to feed wires from .023-in. to 1/8-in. in diam­eter. Rate of wire feed (0-1000 inches per minute) is pre­cisely controlled by a solid-state governor printed circuit
board housed in the control assembly. For operator safety,
the torch switch is energized by 12 volts supplied by the
control. All interconnecting cable and hose are quickly
detachable to provide maximum portability of the wire
feeder.

A water kit may be purchased (as an optional accessory)
for use with the MIG-35 when used with water cooled
torches.

FEATURES:

 Permanent-magnet motor with high starting torque:

6000 rpm at full load with 40:1 gear reduction.

 Quick release pressure roll assembly; no readjust-

ment of pressure required when loading fresh spool
of wire.

 All control circuits incorporated on two solid-state

printed boards, mounted for easy access and re­moval.

 Gas purge pushbutton switch to actuate gas sole-

noid only, permit purging of hose and torch.

 Inch switch for inching wire without energizing

power source contactor.

 Anti-stick circuit for precise adjustment of amount

of wire burnback after wire feed stops, to eliminate
freezing of wire in weld puddle.

 Low voltage circuit (12v) for torch switch, to as-

sure operator safety.
 All cable and hose connections quickly detachable.
 Ground Fault Interrupt Circuit.

CONTROLS:

On front panel: Wire Speed potentiometer, wire speed
range switch, wire inch switch, gas purge pushbutton,
ground fault indicator lamp.
On rear panel: Main power switch, anti-stick potenti­ometer.

CONNECTIONS:

On front panel: Torch switch cable receptacle.
On rear panel: Power source control cable receptacle.
On machine base: Shielding gas hose, welding power
cable, torch wire conduit, provision for optional water
connections.

7

SECTION 2 EQUIPMENT

WIRE SPEED

EH-10 MOTOR-GEAR UNIT

WIRE SPEED
RANGE SW.

ACCY. SUPPORT

ASSEMBLY

TORCH SWITCH

RECEPTACLE

POTENTIOMETER

WIRE INCH
SWITCH

POWER CABLE
ADAPTABLE BLOCK

GAS PURGE
PUSHBUTTON

TORCH GAS

CONNECTION

Fig. 1 - MIG-35 Wire Feeder (front and rear view)

II. REQUIRED COMPANION EQUIPMENT AND AC-

CESSORIES

A. Constant potential power source, such as:

SVI-450i, 452cv, 652cvcc, etc.

B. Control cable assembly. For connection of the

MIG 35 to ESAB power sources with a 19-pin Amp
receptacle, the following control cable assemblies
are available:
6-foot/(1.8m), P/N 31829
30-foot/(9. I m), P/N 31830
60-foot/(18.3m), P/N 31831

C. Mig welding torch, with contact tip, wire conduit

and outlet guide for wire size/type to be employed.
A suitable air or water cooled torch may be used
with the MIG-35.

When using a water-cooled torch it will be neces­sary to connect the torch water hose to a continu­ous water supply or to the wire feeder base by us­ing an optional water kit (see Section I I I -D/E).

With the mig torch, you must have a wire feed acces­sory kit appropriate to the size and type of wire to be
used. The kit will normally include the feed roll (see
Section II-E).

D. Feed Roll: See Table 1. The MIG-35 comes

equipped with a pressure roll but NOT feed roll.
Select the proper feed roll and Outlet Guide from
Table I for the wire size and type to be used.

MAIN LINE SWITCH

ANTI-STICK

POTENTIOMETER

CONTROL

GAS SOLENOID

VALV E

(Ref.) OPENING FOR POWER
SOURCE LIFTING RING

CABLE RECEPTACLE

Table I

Wire Size/ Two Roll Drive Four RollDrive Outlet***

Type In. Feed Roll Feed Roll Kit* Guide

Hard

.023 17998 (V)  999745n

.030 2075300(V) 999325(V) 993860(a)

.035 2075303(V) 999326(V) 993860(a)

.045 2075302(V) 999327(V) 39N15(b)

.052 2075330(V) 999328(V) 39N15(b)

1/16 2075299(V) 999329(V) 39N15(b)

Cored/Hard

.035 19761 (Serr.)  993860(a)

.045 19761 Serr.) 999330 (Serr.) 39N15(b)

.052 2075261 (Serr.) 999331 (Serr.) 39N15(b)

1/16 2075261 (Serr.) 999332 (Serr.) 39N15(b)

5/64 2075261 (Serr.) 999333 (Serr.) 62N17(c)

3/32 2075257 (Serr.) 999334 (Serr.) 62N17(c)

7/64 2075257 (Serr.) 999335 (Serr.) 39N16

1/8 2075255 (Serr.) 999336 (Serr.) 39N17

Soft

.030 2075304(U) 999320(U) 29N13**

.035 2075304(U) 999321(U) 29N13**

3/64 2075301(U) 999322(U) 29N13**

1/16 2075298(U) 999323(U) 29N13**

3/32 2075297(U) 999324(U) 29N13**

n Requires Guide Bushing, P/N 17997.
* Includes a center wire guide and 2 upper and 2 lower feed rolls.
** Required outlet insert as follows: For .030/.035 wire use 993902, For 3/64 wire

use 05N57, For 1/16 wire use 12N75, For 3/32 wire use 05N58.
*** Outlet Guides must be ordered separately.
 Recommended U-Groove Pressure Roll 2075346 be used.
(a) Includes replaceable sleeve (995651).
(b) Includes replaceable sleeve (995692).
(c) Includes replaceable sleeve (995693).

SPINDLE ASSY.

CIRCUIT
BREAKER

POWER SOURCE

8

SECTION 2 EQUIPMENT

E. Shielding Gas Regulator/Flowmeter and fitted

hose to bring gas from flowmeter to wire feeder.
Such as:
Regulator/Flowmeters:
R-5007 Argon/Helium/Nitrogen, P/N 998124.
R-5008 CO2 P/N 998125.
Gas Hoses:
Argon/Helium, Nitrogen, P/N 40V77 (12-1/2-ft.) or
P/N 34V38 (25-ft.)
Heavy Duty, P/N 19416 (12-1/2-ft.)* or P/N 19415
(25ft.)*

* Must be used for CO2 and can also be used for Argon/Helium/

Nitrogen.

III. OPTIONAL ACCESSORIES

*A. Lock-In Circuit Kit (P/N 996959). Allows opera-

tor to release torch switch after arc has been struck.
Includes small circuit board, mounting bracket, and
pre-lugged leads. Instructions (F- 12-336) supplied
with kit. (Circuit connections are shown on sche­matic diagram in this booklet.)

*B. Preflow/Postflow Kit (P/N 994853). Provides

timed preflow and postflow of shielding gas. In­cludes printed circuit board, miniature pots for set­ting the preflow and postflow intervals (from 0. 1 to
3 sec.), mounting brackets, pre-lugged leads. Sup­plied with instructions for mounting and wiring
(F-12-508).

*NOTE: Lock-in and preflow/postflow may be used to-

gether after a capacitor is removed from the
lock-in printed circuit board. For installation,
refer to the lock-in kit instruction literature
(Form 12- 336).

D. Water Kit (P/N 994466).

Permits the convenient connection of a
water-cooled torch and continuous water supply
to the wire feeder. The kit consists of a coupling,

two adaptors and a fitting. A dependable cooling
water supply, delivery and return water hoses (P/N
40V76, 2 required) will also be required. Note that
Fig. 2 illustrates the use of power cable adaptor
P/N 634693, in addition to the kit. If adaptor
(634693) is not used, adaptor (45VII supplied with
kit) can be connected to the output terminal of the
power source. Install the kit in accordance with Fig.
9 and Sec. IV-F. Connect the water-cooled torch
as shown in Fig. 2.

E. Lifting Bracket (P/N 634287; see Fig. 1). Mounts

on the wire feeder spool support between the sup­port and the spindle assembly. Enables you to
mount the wire feeder overhead on a boom.

F. Spool Enclosure Kit (P/N 600240). Provides pro-

tection of spool of wire against dust and dirt. For
installation instructions refer to Form 12-824.

G. Reel Assembly (P/N 995570). Reel slips over

spindle to allow use of coiled wire.

H. Wire Straightener (P/N 34V74). Reduces wire cast

to improve feedability and increase service life of
torch liners and contact tips (see Fig. 7). Mounts
to the EH-10 accessory support inlet guide, P/N
11N53. This Guide is required to complete the in­stallation on the wire inlet side of the straightener.

I. Wire Spool Spacer (P/N 17511). Enables the use

of a 8-in. diameter spool of welding wire with spindle
assembly on the MIG-35 wire feeder.

J. Four Roll Drive Accessory Support Assembly

(P/N 600216). Refer to booklet F- 12-821 for de-

scription.

K. Wire Feeder Rotary Turntable, P/N 678940. Al-

lows rotation of feeder as operator changes work
positions. This reduces strain and bending of torch
cables - see F- 12-984.

L. Wire Feeder Mobile Undercarriage Kit, P/N

680005. This kit includes a mounting plate and

caster type wheels to provide complete mobility for
wire feeder (see F-14322).

9

SECTION 4 INSTALLATION

*WATER KIT -994466

TORCH CONDUIT

TORCH SWITCH

*TORCH WATER HOSE

TORCH GAS HOSE

WORK

GROUND

*WATER DRAIN HOSE - 40V76 (12-1/2 Ft.)

FRONT VIEW

*ADAPTOR

- 45V11

TORCH
POWER
CABLE

WELDING WORK CABLE

(4/O, Customer Supplied)

*WATER IN HOSE - 40V76 (12-1/2 Ft.)

REAR VIEW

REGULATOR/
FLOWMETER

POWER
CABLE
ADAPTOR - 634693

ELECTRODE WELDING
CABLE

(4/O, Customer Supplied)

C.P. POWER SOURCE

*Parts required when

using a Water Kit & Water
Cooled Torch.

Fig. 2 - Interconnection Diagram

IV. INSTALLATION

After checking to be sure you have all required com­ponents and accessories (see Section 11), proceed as
follows (with reference to Fig. 2, Interconnection Dia­gram):

A. HOSE AND ELECTRICAL CONNECTIONS

Connect shielding gas supply hose. Connect con­trol cable to rear panel of unit and to power supply.
(If power supply is not new, check to make certain
that no wiring changes have been made which per­mit actuation of contactor by some means other
than power received through the welding control
cable receptacle. Any such modifications must be
removed before attaching control cable to power
supply.)

NOTE: When using a water-cooled torch, the water

connections shown in Figure 2 must also be
made.

B. TORCH CONNECTIONS

Attach torch gas hose to connection. Plug in torch
switch cable and lock by twisting. After inserting con­duit liner (if used) and attaching wire outlet guide of
correct size, connect wire feed conduit to welding head
clamp and lock in place. Connect torch power cable to
power cable adaptor (with a second cable from that
stud to the power source).

C. INSTALLING FEED ROLL

1. Release the clapper on the accessory support as­sembly (Figure 6) by disengaging the retainer from
the clapper fork.

2. Remove thumbscrew, bell washer and flat washer
from the feed roll shaft.

3. Slip the feed roll on the shaft, engaging the key.
Be sure to observe the THIS SIDE OUT marking
on the feed roll.

4. Replace flat washer, bell washer and thumbscrew,
tightening screw sufficiently to eliminate all end play
from the feed roll.

D. INSTALLING SPOOL OF WIRE

Make sure safety glasses with side shields are worn
when handling or changing wire, or clipping wire
off at the spool or at the end of the torch-serious
eye injury can result due to the springiness of the
wire which quickly unravels, or a cut wire end which
may shoot across the room.

1. Remove hairpin clip from spindle.

2. Position the spool of wire so that when it is placed
on the spindle, wire will be drawn to the feed roll
from the bottom of the spool. The spool should be
held so that the index hole on the back will engage
the lug on the spindle.

10

SECTION 4 INSTALLATION

3. Slide the spool onto the spindle until it engages
the lug. Lock in place with the hairpin clip.

4. Loosen the brake screw in the center of the spindle
hub, then tighten it just enough to prevent coast­ing of the spool when wire is drawn from it. Too
much pressure will load the wire feed motor un­necessarily. Too little pressure will permit the spool
to overrun, causing the wire to kink and tangle.

5. Thread wire to torch as follows:
a. Round off the free end of the welding wire with

a file.

b. Raise the clapper to relieve pressure on the

feed roll.

c. Thread the wire through the inlet guide, over

the groove in the feed roll, and into the outlet

guide.
d. Replace the pressure roll clapper.
e. Remove nozzle and contact tip from torch. Inch

the wire until it emerges from the front end of

torch. Slide the contact tube over the end of

the wire and secure it in place. Replace torch

nozzle.

6. When wire coils are to be used instead of spools,
mount wire reel on spindle as though it were a spool
(see 1 and 3 above). Remove thumbnuts and cover
plate from reel. Remove coil from its package, but
do not remove its binding wires. Slide coil onto reel
so that wire will be drawn from bottom of coil (start­ing end for a coil is always the outer end). Replace
reel cover plate and thumbnuts. Cut off coil tie wires
and any kinked wire. Then adjust brake screw and
thread wire to torch as covered in 4 and 5 above.

E. ADJUSTING THE PRESSURE ROLL ASSEMBLY

When a new wire size or type is to be used, set the
pressure roll adjustment as follows:

1. Release the clapper and unscrew the pressure ad­justing knob until the pressure spring is free.

2. Thread the wire through the inlet and outlet guides
of the accessory support.

3. Engage the clapper making sure the wire is held in
the feed roll groove.

4. Alternately press and release the torch switch (see
Caution note in Para. D above) while slowly tight­ening the pressure adjusting knob until the wire
begins to feed without slipping. The spring pres­sure applied should be the minimum required to
provide positive, nonslip wire feed. Too little pres­sure will result in wire slippage while excessive
pressure will scar and deform the wire. Note that a
light spring (1 82W55) is installed on the acces­sory support for use with soft and small diameter
hard wire. For large diameter hard wire, replace
this spring with a heavy spring (182W54) supplied
with the unit.

F. WATER KITS (Optional see Fig. 9)

Mount bulkhead adaptor (58V75) behind opening pro­vided in vertical base plate, above gas connection, and
secure with screws (No. 8-32 x 3/8-in.) and lockwashers
provided. Attach coupling and adaptor (11N16) behind
bulkhead adaptor. Mount torch cable adaptor (45V11)
on welding power stud. Connect water drain hose to
this adaptor, and water inlet hose to adaptor 11N16.

Power source contactor becomes energized the
moment the torch trigger is depressed. Arcing can
occur if the wire is brought to a ground. Keep the
torch awayfrom ground until welding is to begin.

11

SECTION 5 OPERATIONS

V. ADJUSTMENTS AND OPERATION.

A. CONTROL SETTINGS

1. Turn the Main Power Switch on the rear control
panel to the ON position.

2. Set the dual Range wire speed switch to the High
or Low range desired. The Low range provides wire
speeds from 0-500 ipm, and the High range al­lows speeds from 400 through Maximum ipm.

3. Set the wire feed rate by adjusting the WIRE
SPEED control knob on the front panel. The wire
feed rate, in turn, controls the current furnished by
the CP power source.

IMPORTANT

If the factory-set acceleration time feature
does not satisfy your welding requirements, a
trim pot on the logic board can be adjusted to
provide the exact acceleration (time) charac­teristics you desire, as follows:
(1) If stumbling arc starts occur, the accel-

eration time may be too short and the trim
pot (R23) should be adjusted counter­clockwise to increase the time.

(2) If burnbacks or near burnbacks occur, the

acceleration time may be too long and the
trim pot (R23) should be adjusted clock­wise to decrease the time.

4. Set the ANTI-STICK control on the rear panel to
the desired setting depending on the amount of
burnback desired. The higher the setting, the
greater the amount of time that the contactor is
held in to allow the wire to burnback out of the
puddle, after releasing the torch switch.

B. FEEDING WIRE

If wire has been threaded through torch and contact tip
as directed in Sec. IV-D-5, simply operate the inch
switch or cut off wire, as required, so that the wire ex­tends about 1/2 in. beyond the end of the torch nozzle.

C. SHIELDING GAS FLOW RATE

Hold gas purge pushbutton in and set desired gas
flow rate at the shielding gas regulator-flowmeter. Hold
push-button in at least 15 seconds to insure adequate
purging of gas hose and torch.

If preflow/postflow kit has been installed (inside the
control box) set its potentiometer for the desired preflow
and postflow intervals (range: 0. 1 to 3 seconds).

D. MAKING THE WELD

Start to weld by pressing the torch switch lever to actu­ate the torch switch. This closes the welding contactor,
and starts wire feed and gas flow. Then touch the end
of the welding wire to the workpiece to establish the
arc. The switch lever must be depressed for the dura­tion of the weld. Welding action will be stopped and all
services discontinued when the lever is released and
returns to its original position. If the torch is withdrawn
from the workpiece during welding, the arc will be in­terrupted, but shielding gas flow and welding wire feed
will continue until the switch lever is released.

Do not allow metal-to-metal contact between the
wire feeder chassis and a metal surface connected
in any way to a welding ground. With such con­tact, a poor welding ground connection may cre­ate a difference in potential that sends part of the
welding current through the safety ground wiring
in the control cable and wire feeder, resulting in
burnout of that wiring and/or damage to wire feeder
circuitry. If the safety ground burns out, the opera­tor may be exposed to 115V. shock hazard.

NOTE: If lock-in circuit (optional) has been installed,

switch lever can be released as soon as arc
has been struck. When weld is complete, ser­vices are discontinued by closing torch switch
again.

12

SECTION 6 OPERATIONS

VI. OPERATING SEQUENCE

NORMAL
1 . Close torch switch.

 Gas solenoid opens, weld contactor closes,

wire feed motor runs.

2. Release torch switch.

 Wire feed motor deenergized, brake circuit ef-

fective.

 Anti-stick circuit energized.

3. Anti-stick circuit times out (delay determined
by setting of anti-stick potentiometer).

 Weld contactor opens.

4. Release torch switch.

 Gas solenoid valve closes.

PREFLOW/POSTFLOW

Same as NORMAL except that when torch switch is
closed, only gas solenoid valve is immediately ener­gized. Contactor and wire feed motor are energized

only after interval established by setting of preflow po­tentiometer. When torch switch is opened, gas sole­noid valve remains energized until interval established
by setting of postflow potentiometer has elapsed.

LOCK-IN

Same as NORMAL except that closing of torch switch
energizes a parallel switch in lock-in circuit, so torch
switch lever can be released immediately. At end of
weld, momentary closing of the torch switch initiates
the sequence that normally follows opening of that
switch.

NOTE: Lock-in and preflow1postflow may be used to-

gether after a capacitor is removed from the
lock-in printed circuit board. For installation, re­fer to the lock-in kit instruction literature (form
12-335).

13

SECTION 7 TROUBLESHOOTING

VII. TROUBLESHOOTING

Listed below are a number of trouble symptoms,
each followed by the checks or action suggested
to determine the cause. Listing of checks and/or
actions is inmost probable order, but is not nec­essarily 100% exhaustive. Always follow this gen­eral rule. Do not replace a printed circuit (PC) board
until you have made all the preceding checks. Al­ways put the main power switch in OFFposition
before removing or installing a PC board. To avoid
damage, take great care not to grasp or pull on
components when removing a PC board. If a
printed circuit (PC) board is determined to be the
problem, check with your ESAB supplier for a
trade-in on a new PC board. Supply the distributor
with the part number of the PC board as well as
the serial number of the wire feeder Do not attempt
to repair the PC board yourself. Warranty on a PC
board will be null and void if repaired by customer
or an unauthorized repair shop.

A. SYMPTOM: Wire Feeder totally inoperative.

1. Check for 110-115 VAC between black and
white wires on main line switch (rear panel). If
not present, trouble lies in power input source.

2. If power is present at main line switch, check
for 110-115 VAC between P4-15 and P4-16. If
not present, reset circuit breaker.

B. SYMPTOM: Circuit breaker blows repeatedly as

soon as main line switch is turned ON.

1. Check wiring for short.

2. If no short can be found, replace J Governor
board.

C. SYMPTOM: Circuit breaker blows when torch

switch is closed.

1. Check for jammed or defective wire feed mo­tor/drive unit.

2. If motor/drive unit is OK, replace logic board.

D. SYMPTOM: With torch switch closed, wire feed

motor runs, and weld contactor closes, but gas
solenoid is not energized.

1 . Check for missing (or loose) jumper between

TB1-5 and TB1-6.

2

. Check solenoid for defect.

3. Check for defective contact (NC) on gas
pushbutton switch.

E. SYMPTOM: With torch switch closed, weld

contactor closes and gas solenoid is energized,
but wire feed motor does not run.

1. Check for defect in cable to wire feed motor.

2. Check for excessively-worn motor brushes, or
other motor defect.

3. Check DC voltage across C7 on J Governor
board and turn WFS from min. to max. Volt-

age should adjust 0 to 10V. If voltage is there
but motor still does not run, replace J Gover­nor board. If no voltage, replace J Governor or
logic board.

F. SYMPTOM: Wire feed motor does not run

when wire inch switch is activated.

1. Check switch for defect.

2. Check wiring beyond switch for break.

3. Replace J governor board.

4. Replace logic board.

G. SYMPTOM: No control over motor speed by

wire feed speed potentiometer.

1. Check wire speed potentiometer circuit across
P1 pins 9 and 10 with an ohmmeter. Resis­tance should range from 150 K to 50 K ohms
(max. to min.) in the High range, and from 110
K to 10 K ohms (max. to min.) in the Low range.
Replace potentiometer if defective.

2. Replace J governor board.

H. SYMPTOM: No control over anti-stick time.

1. Check anti-stick potentiometer with ohmme­ter. Resistance should range from 0- 100 K
ohms. Replace potentiometer if defective.

2. Replace logic board.

I. SYMPTOM: Erratic or pulsing wire feed rate.

1. Replace J governor board.

J. SYMPTOM: Brake resistor (R2) burns out.

1. Replace resistor.

2. Replace logic board if R2 bums out again.

K. SYMPTOM: Motor runs as soon as main line

switch is closed.

1. If contactor and solenoid are also energized:
a. Check for defective torch switch or short

in switch cable.

b. Replace logic board.

2. If contactor and solenoid are not simulta­neously energized:
a. Replace J governor board.
b. Replace logic board.

L. SYMPTOM: With torch switch closed, wire

feed motor runs, but welding contactor and
gas solenoid are not activated.

1. Check for break in wiring.

2. Check for blown fuse on logic board.

3. Replace logic board.

M. SYMPTOM: Ground Fault Light is ON and

torch trigger does not activate feeder.

1. Check or contact between the welding circuit
and the feeder chassis and clear any short
circuits.

2. Turn power OFF and back ON and
ground fault should reset.

3. Replace logic board.

4. Replace ground fault detector (sensor).

14

SECTION 8 MAINTENANCE

VIll. MAINTENANCE

If this equipment does not operate properly, stop
work immediately and investigate the cause of the
malfunction. Maintenance work must be performed
by an experienced person, and electrical work by
a trained electrician. Do not permit untrained per­sons to inspect, clean, or repair this equipment.
Use only recommended replacement parts.

A. GENERAL MAINTENANCE

Little maintenance is required to keep the wire feeder
in top operating condition. It is important, however, that
moving parts such as feed and pressure rolls, wire feed
motor, etc., be kept clean and free of dust or dirt. Clean­ing is best accomplished by regularly blowing off these
parts with dry compressed air. This should be done
once for every eight hours of operating time, more of­ten if necessary.

B. LUBRICATION OF MOTOR-GEAR UNIT

The EH-10A motor-gear unit is lubricated with a heavy
duty grease when assembled at the factory and should
not require further lubrication unless disassembled. If
disassembled, relubricate with Texaco Multifak grease.

C. CHECKING OR REPLACEMENT OF MOTOR

BRUSHES

Motor brushes should be checked periodically. If a
brush is broken, or worn down to less than 3/8-in.
length, it must be replaced. Brushes can be inspected
by unscrewing the brushholder plug and withdrawing
the brush assembly. Never remove a brush without
matchmarking it and its holder, so that it can be re­placed in the same holder in its original position.

15

SECTION 9 REPLACEMENT PARTS

IX. REPLACEMENT PARTS DATA

1. All replacement parts are keyed on the illustrations which follow. Order replacement parts by part number and
part name, as shown on illustrations.

2. Many of the parts on the illustrations, particularly electronic parts, are vendor items. This means that they are
standard commercial parts made by and purchased from other manufacturers. If you order from these outside
sources, use the manufacturers part number or designation as shown in the Electrical Parts List.

3. Always state the series or serial number of the machine on which the parts are to be used. The serial number is
stamped on the unit nameplate.

ELECTRICAL PARTS LIST

Symbol Part No. Description and Vendor

ASP 92W64 Potentiometer 100K ohm, 2W - Allen Bradley No. J5054OD-J
WSP
C1 993716 Capacitor - I mfd. 600V
C2, C3 672348 Capacitor - .0 1 mfd. 1000V
GS 951125 Switch - Pushbutton - Switchcraft, No. 203 Littleswitch
GSV 2062305 Solenoid Valve - ASCO, P/N JS82611 0
IS 97W10 Switch - DPDT, Cutler Hammer 8906K1453
MLS, SWS 97W64 Switch - DPST 15A/125V, (Cutler Hammer No. 7560K5)
P3 182W64 Connector 2 POLE/2 Wire - Pass and Seymour No. 7468
P4 674569 Connector P/C - AMP Incorp. P/N 583617-3
P5 634772 Receptacle - Amphenol No. MS-3102A-18-12P
R2 17240003 Resistor - 3 Ohm, 25W, Ohmite Type 270-25. No. L25J3RO
TB-1 95W12 Terminal Block - Cinch - Jones No. 8-140
TB-2 92W11 Terminal Block - Jones No. 354-11-04-001
TR1 994303 Transformer, Prim. 117, 50-60 Cy. - Stancor No. P8362

SPINDLE ASSY.
948259 (See Fig. 8)

SPEED RANGE (H/LS)
SWITCH - 950629

(P3) RECEPTACLE - 182W64

EH-10A MOTOR-GEAR UNIT
ASSY. - 679773 (See Fig. 5)

ACCESSORY SUPPORT
(ASSY. - 49V51
See Fig. 6)

Not Illustrated

INSULATOR RING­60N90
KEY - 28N33
THUMBSCREW­61351087
FLAT WASHER - 64309431
BELL WASHER - 950783

n RECOMMENDED SPARE PARTS

GAS CONNECTION ­58V58
(GSV) GAS SOLENOID
VALVE - 2062305n

INLET CONNECTION
74S76

POWER CABLE ADAPTOR BLOCK
ASSY. - 674156

WARNING DECAL - 954440*

CONTROL ASSY. - 37911
(See Fig. 4)

(WSP) - See Fig. 4

(GS) PUSHBUTTON PURGE SW. ­951125

(IS) - INCH SWITCH - 97W10

WARNING DECAL - 995204

GROUND FAULT INDICATOR LAMP

(Ref.) OPENING FOR ESAB
POWER SOURCE LIFTING RING

BASE/FRAME
2075554

(2) SKID - 999629**

* Replace Decal if it Becomes Exces-

sively Worn or Lost

** Earlier wire feeder bases only con-

tained 2-skid mfg. holes. To install 3­hole skids, use skid as a template and
redrill new holes in wire feeder base.

Fig. 3 - MIG-35 Wire Feeder, P/N 953552

16

SECTION 9 REPLACEMENT PARTS

WARNING LABEL ­995164

(WSP)
KNOB ­13730611

(R2) RESISTOR ­17240003

WARNING LABEL

- 954440

SIDE PANEL - 37912YL

SWITCH, TOGGLE ­97W64

SWITCH, TOGGLE ­97W10

PC BOARD BRACKET - 37914

CHASSIS - 32305GY

FILTER
NETWORK

- 996918

POTENTIOMETER

- - 92W64

TERMINAL BLOCK
6 POS 20 AMP- 93W21

TERMINAL BLOCK 8 POS 15 AMP- 93W21

(WSP) POTENTIOMETER - 92W64

SWITCH, TOGGLE - 634518

PC BOARD ASSY.
LOGIC (P2) - 38178

COVER - 994309YL

WARNING LABEL

- 995204 (Electrical Shock)

PC BOARD ASSY. (P1)
J GOV. - 994236

SWITCH SEAL, BLACK

- 951474

CIRCUIT
BREAKER

- 2062161

STRAIN
RELIEF

- 96W85

KNOB - 951502

(P5) RECEPTACLE - 634722

Fig. 4 - Control Assembly, P/N 37911

8 - 32 UNC 2B
.25 DEEP - 2 PLCS

8 - 32 UNC 2B
.60 DEEP ON
ARMATURE SHAFT

(4) HEX, HD. SCREWS 5/16 - 18x3/4
(4) FLAT WASHER 5/16
(4) LOCKWASHER 5/16

5/16 - 18 UNC 2B
.63 MIN. DEPTH
(11 full threads)

VIEW A-A

Do not use old existing hardware to mount the motor. Only use the
5/16 hardware supplied.

.19 STRIP
LENGTH

Fig. 5 - EH-10A Motor-Gear Unit Assembly (40:1, 0-1000 ipm) P/N 679773

17

SECTION 9 REPLACEMENT PARTS

OUTPUT SHAFT ASSY.
(Part of 19734 ­OUTPUT GEAR CASE

OUTPUT GEAR CASE
19734 - (Includes
Output Shaft Assy.
Shown Above)

FEED ROLL LOCATING
COLLAR -599877

GEAR ASSY. B - 20293

OUTPUT SHAFT SEALl

GEAR ASSY. A - 20292

MAGNET ASSY. - 19730

ARMATURE SHAFT SEALl

OUTPUT GEAR CASE GASKET*

llBRUSH END BELL - 19732
(Includes TWO-BRUSH
HOLDER ASSYS.)

ARMATURE & BEARINGS ­19726

Includes:
ARMATURE BEARING - 20288

MOTOR CORD LEAD - 19731

BRUSH HOLDERll

BRUSH

CAP

(2) CARBON BRUSH
REPLACEMENT KIT - 679784
Includes:
(2) BRUSH CAP
(2) CARBON BRUSH

SCREW 10-24 X 1/2

Fig. 5A - EH-10A Motor-Gear Unit Parts Breakdown

CLAPPER - 60N98

ROLL PIN 1/4 x 1-3/4 LG

INLET

INLET WIRE GUIDE

29N13

INLET GUIDE INSERT

05N58

SETSCREW #6-32 x 1/4 LG

(2) LOCKING HANDLE

BOLT 1/4 x 1-5/8 LG

SUPPLIED

HEAVY SPRING - 182W54 (FOR LARGE DIA. HARD WIRE)

(61330849)

ASSEM. - 49V44

(Includes)

SPACER - 60N79

PRESSURE ROLL

28V52

NUT - 5/16-18

SHAFT - 60N65

KNOB - 60N68

LIGHT SPRING - 182W55 (FOR SOFT &

SMALL DIA. HARD WIRE)

RETAINER - 58N24

FORK - 49V43

WIRE OUTLET GUIDE/INSERT*

(SEE TABLE 1)

CONDUIT

OUTLET

WIRE OUTLET*

GUIDE

CLAMP - 61N02

ROLLPIN - 3/16 x 1-3/4 LG

SCREW - 5/16 - 18 x 2 LG

* Outlet Guide Not Included in Assembly Part No.

49V51.

Fig. 6 - Accessory Support Assembly, P/N 49V51 - 2 Roll Drive

(4 Roll Drive - See Supplement F-12-821)

18

SECTION 9 REPLACEMENT PARTS

11N53

Fig. 7 - Optional Wire Straightener, P/N 34V74

WIRE REEL - 995570

Includes:

REEL - 995568
COVER - 995569
(4) WING NUT, 1/213
63398183

REEL

(4) .359 DIA. HOLE ON 3 DIA. D.C.

SPINDLE - 948258

SUPPORT ­948257

(2) BRAKE PAD - 948255

(Ref. Hair Pin Clip)

D TYPE WASHER ­948254

SPRING - 948253

SCREW
5/1618 x 2

HAIR PIN
CLIP
634347

WASHER ­948256

WATER

CONNECTION

58V75

(OUTLET)

5/8 - LH

COUPLING - 68121075

ADAPTOR - 11N16
(INLET)

5/8 - 18LH

1/4N.P.T.

Fig. 8 - Spindle Assembly, P/N 948259,

Optional Wire Reel, P/N 995570

Fig. 9 - Water Kit, 994466

19

Fig. 11 - Schematic Diagram

20

Fig. 12 - Wiring Diagram

21

NOTES

22

DESIGN CHANGES

The E edition of this booklet include the following:

1. Changed control fuse (F1) from 5 to 6-1/4 amps.

2. Changed logic board from 994239 to 675473.

3. Changed mother board from 994281 to 675475.

4. Add information on page 16 regarding interchangeability of logic/mother boards.

The F edition of this booklet includes the following:

1. Corrected J Gov. p.c. P/N from 999741 to 994236.

2. Corrected Spotweld Kit P/N from 994396 to 999741.

3. Added information to Table 1.

4. Added note regarding bypassing WSV if installed when water recirculator is used.

The G edition of this booklet includes the following: 1. Added parts breakdown for EH- 10A motor.

2. Added optional Dual Range Wire Speed Kit & related information.

The H edition includes the following for serial numbered units beginning with M89P - - - - - (for P/N

953552) and M89N - - - - - (for P/N 677634):

1. Added wire speed Range (Hi-Low) Switch to front panel.

2. Revised front panel component locations.

3. Changed resistor R2 from 50W, 5 ohm to 25W, 3 ohm.

4. Changed fuse (F1, 6-1/4 amps.) to circuit breaker (CB, 7 amps.)

The J edition covers part number change of Gas Purge switch (GS) 994925 to 951125.

The K edition covers change in control cables for connecting wire feeder to latest power sources and to delete the

discontinued water kit with solenoid valve (2075760) and wire wiper accessories.

The L edition covers changes in controls, optional accessories, operating sequences and troubleshooting.

The L edition was edited to change the part number for the Control Assembly from 953549 which was incorrect to

37911. The date was updated, but there was not a revision change.

The M edition updates Table 1, removes information on the Wire Wiper Holder which is no longer used and
updates call outs and/or part numbers on Fig. 3, Fig. 4, Fig. 5A, Fig. 6 and Fig. 7.

23

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