Miller M-15 Gun, Spoolmate 3035 Spool Gun, M-15, Spoolmate 3035 Owner's Manual

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Page 1

OM-1322 200 070N

March 2004

Processes

MIG (GMAW) Welding Pulsed MIG (GMAW-P)

Flux Cored (FCAW) Welding

Description

Arc Welding Power Source and Wire Feeder

Millermatic Pulser

M-15 Gun And Spoolmate

3035 Spool Gun

Visit our website at

www.MillerWelds.com

Page 2

From Miller to You

Thank you and congratulations on choosing Miller. Now you can get

the job done and get it done right. We know you don’t have time to do it any other way.

That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy.

Today, the people that build and sell Miller products continue the tradition. They’re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929.

This Owner’s Manual is designed to help you get the most out of your Miller products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite.

We’ve made installation and operation quick and easy. With Miller you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, there’s a Troubleshooting section that will help you figure out what the problem is. The

Miller is the first welding equipment manufacturer in the U.S.A. to be registered to the ISO 9001:2000 Quality System Standard.

parts list will then help you to decide the exact part you may need to fix the problem. Warranty and service information for your particular model are also provided.

Working as hard as you do

− every power source from Miller is backed by the most hassle-free warranty in the business.

Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full

line catalog or individual catalog sheets. To locate your nearest

distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web.

Mil_Thank 7/03

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TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Arc Welding Hazards 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Additional Symbols For Installation, Operation, And Maintenance 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. California Proposition 65 Warnings 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Principal Safety Standards 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6. EMF Information 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT UTILISATION 5 . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Signification des symboles 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Dangers relatifs au soudage à l’arc 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. 7 . . . . . . . . . . .

2-4. Principales normes de sécurité 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5. Information sur les champs électromagnétiques 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − INSTALLATION 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Welding Power Source And MIG Gun Specifications 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Spool Gun Specifications 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Welding Power Source Duty Cycle And Overheating 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. MIG Welding Gun Duty Cycle And Overheating 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. Spool Gun Duty Cycle And Overheating 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6. Volt-Ampere Curves 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7. Installing Cylinder Rack Wheels 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8. Installing Work Clamp 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-9. Installing MIG Welding Gun 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-10. Connecting A Spool Gun 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-11. Setting MIG Gun Polarity For Wire Type 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-12. Installing Gas Supply 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-13. Installing MIG Wire Spool and Adjusting Hub Tension 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-14. Installing Spool Gun Wire Spool And Threading Welding Wire 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-15. Positioning Jumper Links 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-16. Electrical Service Guide 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-17. Selecting A Location And Connecting Input Power 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-18. Threading Welding Wire 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-19. Installing Optional Curved Or 9 in Straight Barrel On Spoolmate 3035 Spool Gun 21 . . . . . . . . . . . . . . . .

3-20. Using Gun/Cable Holder 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − OPERATION 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Controls 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Weld Parameter Chart 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Parameter Adjustment Guide 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − MAINTENANCE &TROUBLESHOOTING 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Routine Maintenance 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Circuit Breaker CB1 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Unit Overload 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Replacing Gun Contact Tip 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5. Changing Drive Roll and Wire Inlet Guide 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6. Aligning Drive Rolls and Wire Guide 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7. Removing Knob From Front Panel 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-8. Cleaning Or Replacing Gun Liner 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-9. Replacing Switch And/Or Head Tube 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-10. Changing Drive And Push Rolls On Spoolmate 3035 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-11. Changing Liner On Spoolmate 3035 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-12. Troubleshooting 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-13. Spool Gun Troubleshooting 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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TABLE OF CONTENTS

SECTION 6 − ELECTRICAL DIAGRAM 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − MIG WELDING (GMAW) GUIDELINES 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Typical MIG Process Connections 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Typical MIG Process Control Settings 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3. Holding And Positioning Welding Gun 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-4. Conditions That Affect Weld Bead Shape 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-5. Gun Movement During Welding 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-6. Poor Weld Bead Characteristics 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-7. Good Weld Bead Characteristics 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-8. Troubleshooting − Excessive Spatter 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-9. Troubleshooting − Porosity 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-10. Troubleshooting − Excessive Penetration 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-11. Troubleshooting − Lack Of Penetration 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-12. Troubleshooting − Incomplete Fusion 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-13. Troubleshooting − Burn-Through 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-14. Troubleshooting − Waviness Of Bead 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-15. Troubleshooting − Distortion 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-16. Common MIG Shielding Gases 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-17. Troubleshooting Guide For Semiautomatic Welding Equipment 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − PARTS LIST 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPTIONS AND ACCESSORIES WARRANTY

Page 5

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.

som _8/03

Y Marks a special safety message.

. Means “Note”; not safety related.

1-2. Arc Welding Hazards

Y The symbols shown below are used throughout this manual to

call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1-5. Read and follow all Safety Standards.

Y Only qualified persons should install, operate, maintain, and

repair this unit.

Y During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input

live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard.

D Do not touch live electrical parts. D Wear dry, hole-free insulating gloves and body protection. D Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work or ground.

D Do not use AC output in damp areas, if movement is confined, or if

there is a danger of falling.

D Use AC output ONLY if required for the welding process. D If AC output is required, use remote output control if present on

unit.

D Disconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards).

D Properly install and ground this equipment according to its

Owner’s Manual and national, state, and local codes.

D Always verify the supply ground − check and be sure that input

power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet.

D When making input connections, attach proper grounding conduc-

tor first − double-check connections.

D Frequently inspect input power cord for damage or bare wiring −

replace cord immediately if damaged − bare wiring can kill.

D Turn off all equipment when not in use. D Do not use worn, damaged, undersized, or poorly spliced cables. D Do not drape cables over your body.

power circuit and machine internal circuits are also

This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards.

D If earth grounding of the workpiece is required, ground it directly

with a separate cable.

D Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

D Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

D Wear a safety harness if working above floor level. D Keep all panels and covers securely in place. D Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

D Do not connect more than one electrode or work cable to any

single weld output terminal.

SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters.

D Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Section before touching any parts.

FUMES AND GASES can be hazardous.

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.

D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use exhaust at the arc to remove

welding fumes and gases.

D If ventilation is poor, use an approved air-supplied respirator. D Read the Material Safety Data Sheets (MSDSs) and the

manufacturer’s instructions for metals, consumables, coatings, cleaners, and degreasers.

D Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe.

D Do not weld in locations near degreasing, cleaning, or spraying op-

erations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.

D Do not weld on coated metals, such as galvanized, lead, or

cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

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OM-1322 Page 1

Page 6

ARC RAYS can burn eyes and skin.

BUILDUP OF GAS can injure or kill.

Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld.

D Wear a welding helmet fitted with a proper shade of filter to protect

your face and eyes when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards).

D Wear approved safety glasses with side shields under your

helmet.

D Use protective screens or barriers to protect others from flash and

glare; warn others not to watch the arc.

D Wear protective clothing made from durable, flame-resistant mate-

rial (leather and wool) and foot protection.

WELDING can cause fire or explosion.

Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot

burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding.

D Protect yourself and others from flying sparks and hot metal. D Do not weld where flying sparks can strike flammable material. D Remove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not possible, tightly cover them with approved covers.

D Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

D Watch for fire, and keep a fire extinguisher nearby. D Be aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

D Do not weld on closed containers such as tanks, drums, or pipes,

unless they are properly prepared according to AWS F4.1 (see Safety Standards).

D Connect work cable to the work as close to the welding area as

practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock and fire hazards.

D Do not use welder to thaw frozen pipes. D Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

D Wear oil-free protective garments such as leather gloves, heavy

shirt, cuffless trousers, high shoes, and a cap.

D Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

workpiece, and hot equipment can cause fires and

FLYING METAL can injure eyes.

D Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool, they can throw off slag.

D Wear approved safety glasses with side

shields even under your welding helmet.

D Shut off shielding gas supply when not in use. D Always ventilate confined spaces or use

approved air-supplied respirator.

HOT PARTS can cause severe burns.

D Do not touch hot parts bare handed. D Allow cooling period before working on gun or

torch.

MAGNETIC FIELDS can affect pacemakers.

D Pacemaker wearers keep away. D Wearers should consult their doctor before

going near arc welding, gouging, or spot welding operations.

NOISE can damage hearing.

Noise from some processes or equipment can damage hearing.

D Wear approved ear protection if noise level is

high.

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully.

D Protect compressed gas cylinders from excessive heat, mechani-

cal shocks, slag, open flames, sparks, and arcs.

D Install cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

D Keep cylinders away from any welding or other electrical circuits. D Never drape a welding torch over a gas cylinder. D Never allow a welding electrode to touch any cylinder. D Never weld on a pressurized cylinder − explosion will result. D Use only correct shielding gas cylinders, regulators, hoses, and fit-

tings designed for the specific application; maintain them and associated parts in good condition.

D Turn face away from valve outlet when opening cylinder valve. D Keep protective cap in place over valve except when cylinder is in

use or connected for use.

D Read and follow instructions on compressed gas cylinders,

associated equipment, and CGA publication P-1 listed in Safety Standards.

OM-1322 Page 2

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Page 7

1-3. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.

D Do not install or place unit on, over, or near

combustible surfaces.

D Do not install unit near flammables.

D Do not overload building wiring − be sure power supply system is

properly sized, rated, and protected to handle this unit.

FALLING UNIT can cause injury.

D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

D Use equipment of adequate capacity to lift and

support unit.

D If using lift forks to move unit, be sure forks are

long enough to extend beyond opposite side of unit.

OVERUSE can cause OVERHEATING

D Allow cooling period; follow rated duty cycle. D Reduce current or reduce duty cycle before

starting to weld again.

D Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

MOVING PARTS can cause injury.

D Keep away from moving parts such as fans. D Keep all doors, panels, covers, and guards

closed and securely in place.

H.F. RADIATION can cause interference.

D High-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and communications equipment.

D Have only qualified persons familiar with

electronic equipment perform this installation.

D The user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installation.

D If notified by the FCC about interference, stop using the

equipment at once.

D Have the installation regularly checked and maintained. D Keep high-frequency source doors and panels tightly shut, keep

spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference.

D Put on grounded wrist strap BEFORE handling

boards or parts.

D Use proper static-proof bags and boxes to

store, move, or ship PC boards.

MOVING PARTS can cause injury.

D Keep away from moving parts. D Keep away from pinch points such as drive

rolls.

WELDING WIRE can cause injury.

D Do not press gun trigger until instructed to do

so.

D Do not point gun toward any part of the body,

other people, or any metal when threading welding wire.

1-4. California Proposition 65 Warnings

Y Welding or cutting equipment 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 Section 25249.5 et seq.)

Y Battery posts, terminals and related accessories contain lead

and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.

ARC WELDING can cause interference.

D Electromagnetic energy can interfere with

sensitive electronic equipment such as computers and computer-driven equipment such as robots.

D Be sure all equipment in the welding area is

electromagnetically compatible.

D To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

D Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

D Be sure this welding machine is installed and grounded

according to this manual.

D If interference still occurs, the user must take extra measures

such as moving the welding machine, using shielded cables, using line filters, or shielding the work area.

For Gasoline Engines: Y Engine exhaust contains chemicals known to the State of

California to cause cancer, birth defects, or other reproductive harm.

For Diesel Engines: Y Diesel engine exhaust and some of its constituents are known

to the State of California to cause cancer, birth defects, and other reproductive harm.

Return To Table Of Contents

OM-1322 Page 3

Page 8

1-5. Principal Safety Standards

Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (phone: 305-443-9353, website: www.aws.org).

Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard

AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (phone: 305-443-9353, website: www.aws.org).

National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone: 617−770−3000, website: www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 1735 Jefferson Davis Highway, Suite 1004, Arlington, VA 22202−4102 (phone: 703−412−0900, website: www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale

1-6. EMF Information

Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields

Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon committee of the National Research Council concluded that: “The body of evidence, in the committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.” However, studies are still going forth and evidence continues to be examined. Until the final conclusions of the research are reached, you may wish to minimize your exposure to electromagnetic fields when welding or cutting.

To reduce magnetic fields in the workplace, use the following procedures:

Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone: 800−463−6727 or in Toronto 416−747−4044, website: www.csa−in- ternational.org).

Practice For Occupational And Educational Eye And Face Protection,

ANSI Standard Z87.1, from American National Standards Institute, 11 West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900, website: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, from National Fire Protection Association,

P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone: 617−770−3000, website: www.nfpa.org and www. sparky.org).

OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there are 10 Regional Offices−−phone for Region 5, Chicago, is 312−353−2220, website: www.osha.gov).

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep welding power source and cables as far away from operator as practical.

5. Connect work clamp to workpiece as close to the weld as possible.

About Pacemakers:

Pacemaker wearers consult your doctor first. If cleared by your doctor, then following the above procedures is recommended.

OM-1322 Page 4

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Page 9

SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT

UTILISATION

som_fre 8/03

2-1. Signification des symboles

Signifie « Mise en garde. Faire preuve de vigilance. » Cette procédure présente des risques identifiés par les symboles adjacents aux directives.

Ce groupe de symboles signifie « Mise en garde. Faire preuve de vigi-

Y Identifie un message de sécurité particulier.

. Signifie « NOTA » ; n’est pas relatif à la sécurité.

2-2. Dangers relatifs au soudage à l’arc

lance. » Il y a des dangers liés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Se reporter aux symboles et aux directives ci-dessous afin de connaître les mesures à prendre pour éviter tout danger.

Y Les symboles ci-après sont utilisés tout au long du présent

manuel pour attirer l’attention sur les dangers potentiels et les identifier. Lorsqu’on voit un symbole, faire preuve de vigilance et suivre les directives mentionnées afin d’éviter tout danger. Les consignes de sécurité énoncées ci-après ne font que résumer le contenu des normes de sécurité mentionnées à la section 2-4. Lire et respecter toutes ces normes.

Y L’installation, l’utilisation, l’entretien et les réparations ne doi-

vent être confiés qu’à des personnes qualifiées.

Y Pendant l’utilisation de l’appareil, tenir à l’écart toute personne,

en particulier les enfants.

LES DÉCHARGES ÉLECTRIQUES peuvent être mortelles.

Un simple contact avec des pièces sous tension peut causer une électrocution ou des blessures graves. L’électrode et le circuit de soudage sont sous tension

d’entrée et les circuits internes de l’appareil sont également sous tension. En soudage semi−automatique ou automatique, le fil, le dévidoir, le logement des galets d’entraînement et les pièces métalliques en contact avec le fil de soudage sont sous tension. Tout matériel mal installé ou mal mis à la terre présente un danger.

D Ne jamais toucher aux pièces électriques sous tension. D Porter des gants et des vêtements de protection secs et exempts de

trous.

D S’isoler de la pièce et de la terre au moyen de tapis ou autres disposi-

tifs isolants suffisamment grands pour empêcher tout contact physique avec la pièce ou la terre.

D Ne pas se servir d’une source de courant alternatif dans les zones humi-

des, les endroits confinés ou là où on risque de tomber.

D Ne se servir d’une source de courant alternatif QUE si le procédé de souda-

ge l’exige.

D Si l’utilisation d’une source de courant alternatif s’avère nécessaire, se ser-

vir de la fonction de télécommande si l’appareil en est équipé.

D Couper l’alimentation ou arrêter le moteur avant de procéder à l’instal-

lation, à la réparation ou à l’entretien de l’appareil. Couper/étiqueter l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir les normes de sécurité).

D Installer et mettre à la terre correctement l’appareil conformément à

son manuel d’utilisation et aux codes nationaux, provinciaux et municipaux.

D Toujours vérifier la terre du cordon d’alimentation − Vérifier et s’assu-

rer que le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre.

D Pour exécuter les branchements d’entrée, fixer d’abord le conducteur

de mise à la terre adéquat et contre−vérifier les connexions.

D Vérifier fréquemment le cordon d’alimentation et s’assurer qu’il n’est

ni endommagé ni dénudé ; le remplacer immédiatement s’il est endommagé − tout câble dénudé peut causer une électrocution.

D Mettre l’appareil hors tension quand on ne l’utilise pas. D Ne pas utiliser de câbles usés, endommagés, de calibre insuffisant ou

mal épissés.

D Ne pas s’enrouler les câbles autour du corps. D Si la pièce soudée doit être mise à la terre, le faire directement avec un

câble distinct.

D Ne pas toucher l’électrode quand on est en contact avec la pièce, la

terre ou une électrode d’une autre machine.

dès que l’appareil est en fonctionnement. Le circuit

D N’utiliser que du matériel en bon état. Réparer ou remplacer sur−le−

champ les pièces endommagées. Entretenir l’appareil conformément au présent manuel.

D Porter un harnais de sécurité quand on travaille en hauteur. D Maintenir solidement en place tous les panneaux et capots. D Fixer le câble de retour de façon à obtenir un bon contact métal sur

métal avec la pièce à souder ou la table de travail, le plus près possible de la soudure.

D Ne pas connecter plus d’une électrode ou plus d’un câble de masse à un

même terminal de sortie.

Il subsiste un COURANT CONTINU IMPORTANT dans les convertisseurs après la suppression de l’alimentation électrique.

D Arrêter les convertisseurs, débrancher le courant électrique et dé-

charger les condensateurs d’alimentation selon les instructions énoncées à la section Entretien avant de toucher les pièces.

D Se tenir à distance des fumées et ne pas les inhaler. D À l’intérieur, ventiler la zone et/ou utiliser un dispositif d’aspiration au

niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.

D Si la ventilation est insuffisante, utiliser un respirateur à adduction

d’air agréé.

D Lire les fiches techniques de santé−sécurité (FTSS) et les instruc-

tions du fabricant concernant les métaux, les consommables, les revêtements, les nettoyants et les dégraisseurs.

D Ne travailler dans un espace clos que s’il est bien ventilé ou porter un

respirateur à adduction d’air. Demander toujours à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de soudage peuvent se substituer à l’air, abaisser la teneur en oxygène et causer des lésions ou des accidents mortels. S’assurer que l’air est respirable.

D Ne pas souder à proximité d’opérations de dégraissage, de nettoyage

ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.

D Ne pas souder de métaux munis d’un revêtement, tels que la tôle

d’acier galvanisée, plombée ou cadmiée, à moins que le revêtement n’ait été enlevé dans la zone de soudage, que l’endroit soit bien ventilé, et si nécessaire, porter un respirateur à adduction d’air. Les revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques lorsqu’on les soude.

Revenez à la table des matières

LES FUMÉES ET LES GAZ peuvent être dangereux.

Le soudage génère des fumées et des gaz dont l’inhalation peut être dangereuse pour la santé.

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LES RAYONS DE L’ARC peuvent causer des brûlures oculaires et cutanées.

Le rayonnement de l’arc génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de causer des brûlures oculaires et cutanées. Des étincelles sont projetées pendant le soudage.

D Porter un masque de soudage muni d’un filtre de la nuance adéquate

pour se protéger le visage et les yeux pendant le soudage ou pour regarder (voir les normes de sécurité ANSI Z49.1 et Z87.1).

D Porter des lunettes de sécurité à écrans latéraux sous le masque. D Utiliser des écrans ou des barrières pour protéger les tiers de l’éclat

éblouissant ou aveuglant de l’arc ; leur demander de ne pas regarder l’arc.

D Porter des vêtements de protection en matière durable et ignifuge

(cuir ou laine) et des chaussures de sécurité.

LE SOUDAGE peut causer un incendie ou une explosion.

Le soudage effectué sur des récipients fermés tels que des réservoirs, des fûts ou des conduites peut causer leur éclatement. Des étincelles peuvent être projetées

pièces chaudes et les équipements chauds peuvent causer des incendies et des brûlures. Le contact accidentel de l’électrode avec tout objet métallique peut causer des étincelles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de danger.

D Se protéger et protéger les tiers de la projection d’étincelles et de mé-

tal chaud.

D Ne pas souder à un endroit où des étincelles peuvent tomber sur des

substances inflammables.

D Placer toutes les substances inflammables à une distance de 10,7 m

de l’arc de soudage. En cas d’impossibilité, les recouvrir soigneusement avec des protections agréées.

D Des étincelles et des matières en fusion peuvent facilement passer

même par des fissures et des ouvertures de petites dimensions.

D Surveiller tout déclenchement d’incendie et tenir un extincteur à proxi-

mité.

D Le soudage effectué sur un plafond, un plancher, une paroi ou une

cloison peut déclencher un incendie de l’autre côté.

D Ne pas souder des récipients fermés tels que des réservoirs, des fûts

ou des conduites, à moins qu’ils n’aient été préparés conformément à l’AWS F4.1 (voir les normes de sécurité).

D Brancher le câble sur la pièce le plus près possible de la zone de sou-

dage pour éviter que le courant ne circule sur une longue distance, par des chemins inconnus, et ne cause des risques d’électrocution et d’incendie.

D Ne pas utiliser le poste de soudage pour dégeler des conduites ge-

lées.

D En cas de non utilisation, enlever la baguette d’électrode du porte−

électrode ou couper le fil au raz du tube−contact.

D Porter des vêtements de protection exempts d’huile tels que des

gants en cuir, une chemise en tissu épais, des pantalons sans revers, des chaussures montantes et un masque.

D Avant de souder, retirer tout produit combustible de ses poches, tel

qu’un briquet au butane ou des allumettes.

de l’arc de soudure. La projection d’étincelles, les

LES PARTICULES PROJETÉES peuvent blesser les yeux.

D Le soudage, le burinage, le passage de la pièce à

la brosse métallique et le meulage provoquent

ques. Pendant leur refroidissement, les soudures risquent de projeter du laitier.

D Porter des lunettes de sécurité à écrans latéraux agréés, même sous le

masque de soudage.

l’émission d’étincelles et de particules métalli-

LES ACCUMULATIONS DE GAZ peuvent causer des blessures ou même la mort.

D Couper l’alimentation en gaz protecteur en cas de

non utilisation.

D Veiller toujours à bien ventiler les espaces confinés ou porter un respira-

teur à adduction d’air agréé.

LES PIÈCES CHAUDES peuvent causer des brûlures graves.

D Ne pas toucher les pièces chaudes à main nue. D Prévoir une période de refroidissement avant

d’utiliser le pistolet ou la torche.

LES CHAMPS MAGNÉTIQUES peuvent perturber le fonctionnement des stimulateurs cardiaques.

D Les personnes qui portent un stimulateur cardiaque

doivent se tenir à distance.

D Ils doivent consulter leur médecin avant de s’appro-

cher d’un lieu où on exécute des opérations de soudage à l’arc, de gougeage ou de soudage par points.

LE BRUIT peut affecter l’ouïe.

Le bruit de certains processus et équipements peut affecter l’ouïe.

D Porter des protecteurs d’oreille agréés si le niveau

sonore est trop élevé.

Les BOUTEILLES endommagées peuvent exploser.

Les bouteilles de gaz protecteur contiennent du gaz sous haute pression. Toute bouteille endommagée peut exploser. Comme les bouteilles de gaz font

manipuler avec précaution.

D Protéger les bouteilles de gaz comprimé de la chaleur excessive, des

chocs mécaniques, du laitier, des flammes nues, des étincelles et des arcs.

D Placer les bouteilles debout en les fixant dans un support stationnaire

ou dans un porte−bouteilles pour les empêcher de tomber ou de se renverser.

D Tenir les bouteilles éloignées des circuits de soudage ou autres cir-

cuits électriques.

D Ne jamais poser une torche de soudage sur une bouteille de gaz. D Ne jamais mettre une électrode de soudage en contact avec une bou-

teille de gaz.

D Ne jamais souder une bouteille contenant du gaz sous pression − elle

risquerait d’exploser.

D N’utiliser que les bouteilles de gaz protecteur, régulateurs, tuyaux et

raccords adéquats pour l’application envisagée ; les maintenir en bon état, ainsi que les pièces connexes.

D Détourner la tête lorsqu’on ouvre la soupape d’une bouteille. D Laisser le capuchon protecteur sur la soupape, sauf en cas d’utilisa-

tion ou de branchement de la bouteille

D Lire et suivre les instructions concernant les bouteilles de gaz compri-

mé, les équipements associés et les publications P−1 de la CGA, mentionnées dans les normes de sécurité.

normalement partie du procédé de soudage, les

OM-1322 Page 6

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Page 11

2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de

l’appareil.

Risque D’INCENDIE OU D’EXPLOSION

D Ne pas placer l’appareil sur une surface inflam-

mable, ni au−dessus ou à proximité d’elle.

D Ne pas installer l’appareil à proximité de produits inflammables. D Ne pas surcharger l’installation électrique − s’assurer que l’alimen-

tation est correctement dimensionnée et protégée avant de mettre l’appareil en service.

LA CHUTE DE L’APPAREIL peut blesser.

D N’utiliser que l’anneau de levage pour lever l’ap-

pareil. NE PAS utiliser le chariot, les bouteilles de gaz ou tout autre accessoire.

D Utiliser un engin de capacité adéquate pour lever

D Si on utilise un chariot élévateur pour déplacer l’unité, s’assurer que

les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil.

l’appareil.

L’EMPLOI EXCESSIF peut FAIRE SURCHAUFFER L’ÉQUIPEMENT.

D Prévoir une période de refroidissement ; respec-

ter le cycle opératoire nominal.

D Réduire le courant ou le cycle opératoire avant de

D Ne pas obstruer les orifices ou filtrer l’alimentation en air du poste.

reprendre le soudage.

LES ORGANES MOBILES peuvent causer des blessures.

D Se tenir à l’écart des organes mobiles comme les

ventilateurs.

D Maintenir fermés et bien fixés les portes,

panneaux, recouvrements et dispositifs de protection.

LE RAYONNEMENT HAUTE FRÉQUENCE (H. F.) risque de causer des interférences.

D Le rayonnement haute fréquence peut causer

des interférences avec les équipements de radionavigation et de communication, les services de sécurité et les ordinateurs.

D Ne demander qu’à des personnes qualifiées familiarisées avec les

équipements électroniques de faire fonctionner l’installation.

D L’utilisateur est tenu de faire corriger rapidement par un électricien

qualifié les interférences causées par l’installation.

D Si la Federal Communications Commission signale des interféren-

ces, arrêter immédiatement l’appareil.

D Faire régulièrement contrôler et entretenir l’installation. D Maintenir soigneusement fermés les panneaux et les portes des sour-

ces de haute fréquence, maintenir le jeu d’éclatement au réglage adéquat et utiliser une terre et un blindage pour réduire les interférences éventuelles.

LE SOUDAGE À L’ARC peut causer des interférences.

LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.

D Mettre un bracelet antistatique AVANT de mani-

puler des cartes ou des pièces.

D Utiliser des pochettes et des boîtes antistatiques

pour stocker, déplacer ou expédier des cartes de circuits imprimés.

LES PIÈCES MOBILES peuvent causer des blessures.

D Se tenir à l’écart des pièces mobiles. D Se tenir à l’écart des points de coincement tels

que les dévidoirs.

LES FILS DE SOUDAGE peuvent causer des blessures.

D Ne pas appuyer sur la gâchette avant d’en avoir

reçu l’instruction.

D Ne pas diriger le pistolet vers soi, vers d’autres

personnes ou vers toute pièce mécanique en engageant le fil de soudage.

D L’énergie électromagnétique peut causer des

interférences avec l’équipement électronique sensible tel que les ordinateurs et l’équipement commandé par ordinateur tel que les robots.

D Veiller à ce que tout l’équipement de la zone de soudage soit compati-

ble au point de vue électromagnétique.

D Pour réduire la possibilité d’interférence, maintenir les câbles de sou-

dage aussi courts que possible, les grouper, et les poser aussi bas que possible (par ex. : à terre).

D Veiller à souder à une distance de 100 mètres de tout équipement

électronique sensible.

D Veiller à ce que le poste de soudage soit posé et mis à la terre confor-

mément au présent manuel.

D En cas d’interférences après exécution des directives précédentes, il

incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.

LES CHAMPS MAGNÉTIQUES peuvent affecter les stimulateurs cardiaques.

D Porteurs de stimulateur cardiaque, restez à dis-

tance.

D Les porteurs d’un stimulateur cardiaque doivent

d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de gougeage ou de soudage par points.

Revenez à la table des matières

OM-1322 Page 7

Page 12

2-4. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (téléphone : (305) 443−9353, site Web : www.aws.org).

Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, norme American Welding Society AWS F4.1, de l’American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (téléphone : (305) 443−9353, site Web : www.aws.org).

National Electrical Code, norme NFPA 70, de la National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (téléphone : (617) 770−3000, sites Web : www.nfpa.org et www.sparky.org).

Safe Handling of Compressed Gases in Cylinders, brochure CGA P−1, de la Compressed Gas Association, 1735 Jefferson Davis Highway, Suite 1004, Arlington, VA 22202−4102 (téléphone : (703) 412−0900, site Web : www.cganet.com).

Code for Safety in Welding and Cutting, norme CSA W117.2, de la Canadian Standards Association, Standards Sales, 178 boulevard

Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800) 463−6727 ou à Toronto : (416) 747−4044, site Web : www.csa−international.org).

Practice For Occupational And Educational Eye And Face Protection, norme ANSI Z87.1, de l’American National Standards Institute, 11 West 42nd Street, New York, NY 10036−8002 (téléphone : (212) 642−4900, site Web : www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, norme NFPA 51B, de la National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (téléphone : (617) 770−3000, site Web : www.nfpa.org et www.sparky.org).

OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, de l’U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10 bureaux régionaux − Téléphone pour la Région 5, Chicago : (312) 353−2220, site Web : www.osha.gov).

2-5. Information sur les champs électromagnétiques

Données sur le soudage électrique et les effets des champs magnétiques basse fréquence sur l’organisme

En parcourant les câbles de soudage, le courant crée des champs électromagnétiques. Les effets potentiels de tels champs restent préoccupants. Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de recherche de 17 ans, un comité de spécialistes du National Research Council a conclu : « L’accumulation de preuves n’a pas démontré que l’exposition aux champs magnétiques et aux champs électriques à haute fréquence constitue un risque pour la santé humaine ». Toutefois, les études et l’examen des preuves se poursuivent. En attendant les conclusions finales de la recherche, il serait souhaitable de réduire l’exposition aux champs électromagnétiques pendant le soudage ou le coupage.

Afin de réduire les champs électromagnétiques en milieu de travail, respecter les consignes suivantes :

1. Garder les câbles ensemble en les torsadant ou en les fixant avec du

ruban adhésif.

2. Mettre tous les câbles du côté opposé à l’opérateur.

3. Ne pas s’enrouler les câbles autour du corps.

4. Garder le poste de soudage et les câbles le plus loin possible de soi.

5. Placer la pince de masse le plus près possible de la zone de soudage.

Consignes relatives aux stimulateurs cardiaques :

Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur médecin. Si ce dernier les déclare aptes, il leur est recommandé de respecter les consignes ci-dessus.

OM-1322 Page 8

Revenez à la table des matières

Page 13

SECTION 3 − INSTALLATION

Rated Output

3-1. Welding Power Source And MIG Gun Specifications

Max. Open Amperage Range DC

160 A at 26 VDC,

60% Duty Cycle

*While idling

Wire Type and Diameter Wire Feed

Solid Steel Stainless Steel Flux Cored 25−700 IPM

.023 − .035 in

(0.6 − 1.2 mm)

30-200 36 32

.023 − .035 in

(0.6 − 0.9 mm)

Circuit

Voltage DC

.030 − .045 in

(0.8 − 1.2 mm)

200 (208) V 230 V 240 V

2.1*

Amps Input at Rated Output, 50 or 60 Hz, Single-Phase

460 575

1.8*

Speed

(.65−17.8

m/min)

1.7*

Maximum Spool

Size

12 in (305 mm)

Diameter

33 lb (15 kg)

0.9*

Dimensions Net Weight

H: 32 in (813 mm)

W: 26 in (660 mm)

D: 46 in (1168 mm)

Operating Temperature Range − −20C to +40C Storage Temperature Range − -30C to + 50C

3-2. Spool Gun Specifications

Wire Diameter Range

.023 Thru .035 in

(0.6 Thru 0.9 mm)

Aluminum Wire

.023 Thru 035 in

(0.6 Thru 0.9 mm) Hard

Or Cored Wire

Approximate Wire

Feed Range

115 To 715 ipm (4.1

To 20.4 mpm)

Cooling

Method

Air Cooled

Maximum Spool

Size

4 in (102 mm)

Diameter

Overall Dimensions Weight

Length:

11-1/2 in (291 mm)

Width:

2-1/4 in (57 mm)

Height:

8 in (203 mm)

0.7*

KVA KW

6.36

0.51*

5.45

0.26*

225 lb

(102 kg)

9.1 lb (4.1 kg)

Gun With Cable

Return To Table Of Contents

OM-1322 Page 9

Page 14

3-3. Welding Power Source Duty Cycle And Overheating

30% Duty Cycle At 200 Amperes60% Duty Cycle At 160 Amperes

Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating.

If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or voltage, or duty cycle before welding.

Y Exceeding duty cycle can

damage unit and void warranty.

6 Minutes Welding 4 Minutes Resting

Overheating

Minutes

3 Minutes Welding 7 Minutes Resting

A or V

Reduce Duty Cycle

3-4. MIG Welding Gun Duty Cycle And Overheating

CAUTION

WELDING LONGER THAN RATED DUTY CYCLE can damage gun and void warranty.

• Do not weld at rated load longer than shown below.

• Using gasless flux cored wire reduces gun duty cycle.

Definition .023 To .045 in (0.6 To 1.1 mm)

Minutes

Duty Cycle is percentage of 10 minutes that gun can weld at rated load without overheating.

Hard Or Flux Cored Wires

100% Duty Cycle At 150 Amperes

100% Duty Cycle At 120 Amperes

Using CO

Using Mixed Gases

.023 To .045 in (0.6 To 1.1 mm) Hard Or Flux Cored Wires

60% Duty Cycle At 200 Amperes

Using CO

60% Duty Cycle At 150 Amperes

Using Mixed Gases

duty1 4/95 − 200 060

warn7.1 8/93

OM-1322 Page 10

Continuous Welding

Return To Table Of Contents

6 Minutes Welding 4 Minutes Resting

SB1.1 8/93

Page 15

3-5. Spool Gun Duty Cycle And Overheating

CAUTION

WELDING LONGER THAN RATED DUTY CYCLE can damage gun and void warranty.

• Do not weld at rated load longer than shown below.

• Using gasless flux cored wire reduces gun duty cycle.

Definition .023 To .035 in (0.6 To 0.9 mm) Aluminum Wire

Minutes

Duty Cycle is percentage of 10 minutes that gun can weld at rated load without overheating.

3-6. Volt-Ampere Curves

.023 To .035 in (0.6 To 0.9 mm) Hard Or Flux Cored Wires

60% Duty Cycle At 150 Amperes

Using Argon Shielding Gas

6 Minutes Welding 4 Minutes Resting

Volt-ampere curves show minimum and maximum voltage and amperage output capabilities of unit. Curves of other settings fall between curves shown.

warn7.1 8/93

SB1.1 8/93

Return To Table Of Contents

va_curve1 4/95 − SB-192 436

OM-1322 Page 11

Page 16

3-7. Installing Cylinder Rack Wheels

1 Welding Power Source Block front casters to prevent movement.

Block up rear of unit. 2 Dual Cylinder Support Bracket 3 Chain

Slide Chain Into Slot

Install supplied chains onto dual bracket.

4 Dual Cylinder Rack

5 Axle

6 Wheel

Remove paint from axle grooves before installing retaining rings.

7 Washer

8 Retaining Ring

Install axle, wheel, washer, and retaining ring to both sides as shown.

803 261-A

OM-1322 Page 12

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Page 17

3-8. Installing Work Clamp

1 Work Cable 2 Boot Route cable through front panel

opening. Slide boot onto work cable.

3 Negative (−) Output Terminal Connect cable to terminal and

cover connection with boot. Close door.

MIG PULSE

3-9. Installing MIG Welding Gun

−

203006

Tools Needed:

1/2, 3/4 in

802 713-B

1 Drive Assembly 2 Gun Securing Knob 3 Gun End Loosen securing knob. Insert gun

end through opening until it bottoms against drive assembly (make sure

gun end does not touch drive rolls). Tighten knob.

4 Gun Trigger Plug Insert plug into receptacle labeled

“MIG GUN”, and tighten threaded collar.

Close door.

Ref. 802 714-B

Return To Table Of Contents

OM-1322 Page 13

Page 18

3-10. Connecting A Spool Gun

1 Barbed Fitting

.If spool gun gas hose is

equipped with a pre-installed barbed fitting, cut off fitting from end of hose.

Connect spool gun gas hose to barbed fitting.

2 Pulse Weld Terminal Connect spool gun cable to pulse

weld terminal. 3 Gun Trigger Plug Insert plug into receptacle labeled

“SPOOL GUN”, and tighten threaded collar.

4 Negative (−) Output Terminal 5 Positive (+) Output Terminal

(Non-Pulsing)

Close door.

3-11. Setting MIG Gun Polarity For Wire Type

Shown As Shipped − Set For Electrode Positive (DCEP) for Solid Steel, Stainless Steel, Aluminum or Gas Shielded Flux Core Wires.

Wire Drive Assembly

Lead To Positive (+)

Output Terminal

Work Clamp Lead

To Negative (−)

Output Terminal

Reverse MIG Lead Connections − Set for Electrode Negative (DCEN). For Gasless Flux Cored Wires (FCAW Process). Drive Assembly Becomes Negative.

Spool Gun Lead To

Positive (+) Pulse

Output Terminal

1 Polarity Changeover Information Always read and follow wire

manufacture’s recommended polarity.

.If the spool gun and standard MIG

gun are both connected to the machine, both welding wires will become energized by pulling either gun trigger. Welding wire will only feed from the gun that th e trigger i s pulled and only one gun at a time can be used for welding.

802 710-C

3/4 in

OM-1322 Page 14

Ref. 190 821-A

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Page 19

3-12. Installing Gas Supply

.DO NOT use Argon/Mixed gas regulator/flowmeter

with CO2 shielding gas. See Parts List for optional CO2 gas regulator/flowmeter.

Argon Gas Or

Mixed Gas

Obtain gas cylinders and chain to running gear, wall, or other stationary support so cylinders cannot fall and break off valve.

1 Cap 2 Cylinder Valve Remove cap, stand to side of

valve, and open valve slightly. Gas flow blows dust and dirt from valve.

Close valve. 3 Cylinder 4 Regulator/Flowmeter (2) Install so face is vertical. 5 Regulator/Flowmeter Gas

Hose Connection

6 Welding Power Source Gas

Hose Connection For Spool Gun

7 Welding Power Source Gas

Hose Connection For MIG Gun

Connect gas hoses between regulator/flowmeter gas hose connections, and fittings on rear of welding power source.

8 Gas Flow Adjustment Control Typical flow rate is 20 cfh (cubic

feet per hour). Check wire manufacturer’s recommended flow rate.

Tools Needed:

1-1/8, 5/8 in

Return To Table Of Contents

Rear

Panel

802 028-A / Ref. 802 717-C / 201 022

OM-1322 Page 15

Page 20

3-13. Installing MIG Wire Spool and Adjusting Hub Tension

Use compression spring with 8 in (200 mm) spools.

When a slight force is needed to turn spool, tension is set.

Tools Needed:

15/16 in

ST-072573-B

OM-1322 Page 16

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Page 21

3-14. Installing Spool Gun Wire Spool And Threading Welding Wire

1 Thumb Screw 2 Spool Cover

Tools Needed:

Remove thumb screw and spool cover.

3 Hub Tension Nut 4 Wire Spool Install spool so wire feeds from top.

Turn hub tension nut just so a slight drag is felt on the wire spool.

5 Push Roll/Lower Drive Roll 6 Drive Roll Pressure

7 Drive Roll Release Lever

8 Wire Inlet Guide 9 Contact Tip 10 Nozzle

Adjustment Opening

(Red)

Remove nozzle and contact tip. Push and hold red lever. Thread wire through inlet guide, past push roll/drive roll, and out end of gun 2 inches (50 mm).

Install contact tip and nozzle. Reinstall spool cover and thumb screw.

.Screw rotation clockwise decreases

drive roll pressure and counterclockwise rotation increases pressure.

Release red lever.

Turn On welding

power source power.

Wood

Press gun trigger to feed wire to check drive roll

pressure. Turn screw enough to prevent slipping.

Return To Table Of Contents

Cut off wire.

Ref. 801 891-A

OM-1322 Page 17

Page 22

3-15. Positioning Jumper Links

.Before setting jumper link, check input voltage and link

unit for voltage closest to the input voltage at the site.

200 VOL TS

230 VOL TS

240 VOL TS

203529

Check input voltage available at site and listed on the machine rating label.

1 Jumper Links Access Door Open door. 2 Jumper Link Label Check label − only one is on unit. 3 Input Voltage Jumper Links Move jumper links to match input

voltage. Close and secure access door.

Tools Needed:

3/8 in

Ref. 802 714-B

3-16. Electrical Service Guide

Input Voltage 200 230 240 460 575 Input Amperes At Rated Output 32 28 27 14 11 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes

Circuit Breaker 1, Time-Delay

Normal Operating

Min Input Conductor Size In AWG/Kcmil 10 10 10 14 14

Max Recommended Input Conductor Length In Feet (Meters)

Min Grounding Conductor Size In AWG/Kcmil 10 10 10 14 14

Reference: 1999 National Electrical Code (NEC) 1 Choose a circuit breaker with time-current curves comparable to a Time Delay Fuse. 2 “Time-Delay” fuses are UL class “RK5” .

3 “Normal Operating” (general purpose − no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and

above). OM-1322 Page 18

Return To Table Of Contents

35 30 30 15 10

45 40 40 20 15

(27)

118 (36)

128 (39)

185 (56)

289 (88)

Page 23

3-17. Selecting A Location And Connecting Input Power

18 in (457 mm) of space for airflow

Y Always connect

grounding conductor first. = GND/PE

Y Do not move or operate unit

where it could tip.

1 Rating Label Supply correct input power. 2 Plug (NEMA Type 6-50P) 3 Receptacle

(NEMA Type 6-50R) Connect plug to receptacle. 4 Input And Grounding

Conductors Connect directly to line disconnect

device if hard wiring is required. 5 Line Disconnect Device See Section 3-16.

Y Special installation may be

required where gasoline or

volatile liquids are present −

see NEC Article 511 or CEC

Section 20.

L1L2

230 VAC, 1

802 717-C

Return To Table Of Contents

OM-1322 Page 19

Page 24

3-18. Threading Welding Wire

1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Pressure Adjustment Knob

5 Drive Roll 6 Outlet Wire Guide 7 Gun Conduit Cable Lay gun cable out straight.

Tools Needed:

.Hold wire tightly to keep it

from unraveling.

6 in

(150 mm)

Open pressure assembly. Pull and hold wire; cut off end. Push wire thru guides into gun;

Tighten

.Use pressure indicator

scale to set a desired drive roll pressure.

1 2 3 4

Pressure

Indicator

Scale

continue to hold wire.

Close and tighten pressure

assembly, and let go of wire.

Press gun trigger until wire comes out of gun. Reinstall

contact tip and nozzle

OM-1322 Page 20

Remove gun nozzle and contact tip. Turn On.

Tighten

1 2 3

WOOD

Feed wire to check drive roll pressure.

Tighten knob enough to prevent slipping.

Return To Table Of Contents

Cut off wire. Close

and latch door.

Ref. 802 714-B / S-0627-A

Page 25

3-19. Installing Optional Curved Or 9 in Straight Barrel On Spoolmate 3035 Spool Gun

Y Turn Off and disconnect

input power.

1 Contact Adapter Remove existing barrel from

contact adapter. 2 Gas Hose Disconnect gas hose from gas

nipple. 3 Straight Barrel 4 Curved Barrel 5 Locking Nut

.Before tightening locking nut

on the curved barrel, the barrel

can be rotated to the desired

position.

Install either straight or curved barrel onto contact adapter, and tighten locking nut.

Connect gas hose to gas nipple.

Tools Needed:

801 889-B

Return To Table Of Contents

OM-1322 Page 21

Page 26

3-20. Using Gun/Cable Holder

1 Side Panel 2 Latch 3 Cable Holder Press latch down to release and

open door. 4 Holster (2) Wrap cable around cable holder,

and place gun nozzle into holster.

802 726

OM-1322 Page 22

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Page 27

4-1. Controls

SECTION 4 − OPERATION

VOLTAGEWIRE SPEED

AMPERA GE VOLTAGE DUTY CYCLE MAX OCV

NEMA CLASS I (60)

RATED OUTPUT

160

60%

−1

−2

−3

−4

−5

ARC LENGTH

(

PULSE ONLPULSE ONLY

)

100

DO NO T SWITCH WHILE WELDING

MIG GUN SPOOL GUN

OFF

1 Voltage Control Set Voltage control according to the

parameter chart for good starting point. Turn control clockwise to increase voltage.

2 Wire Speed Control Set Wire Speed control according to the

parameter chart. Increase or decrease wire

speed to obtain desired bead profile and travel speed.

3 Arc Length Control Set Arc Length control according to the

parameter chart. Use Arc Length control (pulse width) to adjust puddle fluidity and width of bead. Shorter arc length setting will result in a narrower, cooler weld puddle.

Return To Table Of Contents

200 034-B

Longer arc length setting will result in a wider, hotter weld puddle.

4 Power Switch This switch energizes the main transformer

and control circuitry. 5 Spool Gun Receptacle 6 MIG Gun Receptacle

OM-1322 Page 23

Page 28

4-2. Weld Parameter Chart

3035

*Line voltage can affect weld output, settings on this chart are starting values only. You may need to adjust voltage and wire feed speed to optimize your settings.

Input Line

Voltage*

Higher

e.g. 240

Volts AC

230 Volts AC

Lower

e.g. 218

Volts AC

Parameter

Chart Settings

Weld Will Be

Hotter

Lower Settings

Use Parameter

Chart Inside

Door

Weld Will Be

Colder

Raise Settings

OM-1322 Page 24

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Page 29

3035

Return To Table Of Contents

200 796-A

OM-1322 Page 25

Page 30

4-3. Parameter Adjustment Guide

ld puddl

d full of

Problem Probable Cause Remedy

Erratic arc, ball at end of wire too large at time of transfer to weld puddle.

Arc Length control set too low. Increase arc length setting slightly (see Section 4-1).

Wire shorting (stubbing) into we

Wire burns back into gun tip at start of weld.

Wire burns back into gun tip while welding.

Weld bead appearance is rough an

Weld puddle too hot and wire pushes through material.

Weld puddle too cold and weld bead appearance is ropy.

Weld gun is not pulsing. Gun not connected to pulse weld terminal. Check and reconnect gun weld cable if necessary (see

porosity.

Wire speed set too high.

Voltage set too high. See parameter chart on inside of door or see Section 4-2,

Wire speed set too low. See parameter chart on inside of door or see Section 4-2,

Distance from gun tip to work is too close. Increase distance between gun tip and work to

Gun tip overheating. Increase distance between gun tip and work.

Gas coverage at weld puddle insufficient.

Incorrect parameter settings. See parameter chart on inside of door or see Section 4-2,

Decrease wire speed setting slightly (see Section 4-1).

Make fine adjustment to Arc Length control setting (see Section 4-1).

and readjust parameters.

approximately 5/8 to 3/4 in (15.9 to 19 mm).

Set gas flow to 30 cfh (14 L/min).

Use a gun push angle of 10 to 15 degrees.

and readjust parameters.

Section 3-10).

OM-1322 Page 26

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Page 31

SECTION 5 − MAINTENANCE &TROUBLESHOOTING

5-1. Routine Maintenance

3 Months

Replace unreadable labels

Clean and tighten weld terminals

6 Months

Blow out or vacuum inside.

Y Disconnect power

before maintaining.

Repair or replace cracked weld cable

Remove drive roll and carrier. Apply light coat of oil or grease to drive motor shaft.

.Maintain more often

during severe conditions.

5-2. Circuit Breaker CB1

Ref. 802 990

1 Circuit Breaker CB1 If CB1 opens, wire feeding stops. 2 Welding Gun Check gun liner for blockage or

kinks. 3 Wire Drive Assembly Check for jammed wire, binding

drive gear or misaligned drive rolls. Allow cooling period and reset

breaker. Close door.

Ref. 802 714-B

5-3. Unit Overload

Thermostats TP1 in rectifier SR1 and TP2 in stabilizer Z1 protect the unit from damage due to overheating. If TP1 and/or TP2 opens, wait several minutes before trying to weld.

Return To Table Of Contents

OM-1322 Page 27

Page 32

5-4. Replacing Gun Contact Tip

Tools Needed:

5-5. Changing Drive Roll and Wire Inlet Guide

Y Turn Off power.

1 Nozzle 2 Contact Tip Cut off welding wire at contact tip.

Remove nozzle. Remove contact tip and install new

contact tip. Reinstall nozzle.

Ref. 800 797-C

1 Securing Screw 2 Inlet Wire Guide

Loosen screw. Slide tip as close to drive rolls as possible without touching. Tighten screw.

3 Anti-Wear Guide Install guide as shown. 4 Drive Roll Install correct drive roll for wire size

and type. 5 Drive Roll Securing Nut Turn nut one click to secure drive

roll.

Tools Needed:

5/64 in

7/16 in

Ref. 802 990

OM-1322 Page 28

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Page 33

5-6. Aligning Drive Rolls and Wire Guide

Correct Incorrect

Tools Needed:

Y Turn Off power.

View is from top of drive rolls looking down with pressure assembly open.

1 Drive Roll Securing Nut 2 Drive Roll 3 Wire Guide 4 Welding Wire 5 Drive Gear

Insert screwdriver, and turn screw in or out until drive roll groove lines up with wire guide.

Close pressure roll assembly.

Ref. ST-800 412-A

5-7. Removing Knob From Front Panel

Y Turn Off power.

1 Front Panel 2 Knob 3 Slot 4 Control Shaft Rotate knob to allow access to slot.

Insert tip of screwdriver into slot, and while pushing on spring clip, pull knob off control shaft.

To reinstall, push knob fully onto

control shaft.

803 346 / 802 717-C

Return To Table Of Contents

OM-1322 Page 29

Page 34

5-8. Cleaning Or Replacing Gun Liner

Y Disconnect gun from unit first.

Head Tube

Remove nozzle, contact tip, and adapter.

5/16 in

Tools Needed:

5/16 in, 10 mm

10 mm

Lay gun cable out straight before installing new liner.

Blow out gun casing.

Remove liner.

To Reassemble Gun:

Install and tighten new liner. Cut liner off 3/4 in (20 mm) (3/8 in

[9.5 mm] for aluminum) from head tube.

Install adapter, contact tip, and nozzle.

OM-1322 Page 30

Ref. ST-800 797-C

Return To Table Of Contents

Page 35

5-9. Replacing Switch And/Or Head Tube

Y Disconnect gun first.

1 Remove handle

locking nut.

4 Secure head

tube in vice.

3 Slide handle.

2 Remove switch housing. Note: If installing new

switch, push switch lead connectors onto terminal of new switch (polarity is not important). Install switch back into handle, and secure with handle locking nut. If replacing head tube, continue to end of figure.

5 Loosen jam nut. Remove

from vice and turn head tube out by hand.

6 Install existing shock washer onto

new head tube. Hand-tighten head tube into connector cable.

8 Remove from vice. Reposition

handle and install switch housing. Secure with handle locking nut.

7 Place head tube in vice and tighten

until nuts are tight.

Tools Needed:

3/4 in

Return To Table Of Contents

Ref. ST-800 795-C

OM-1322 Page 31

Page 36

5-10. Changing Drive And Push Rolls On Spoolmate 3035

It may be necessary to remove drive roll side of gun case to change lower drive roll.

Tools Needed:

Y Turn Off power at welding

power source first.

1 Drive Roll Cover Remove cover.

Changing Push Roll:

To remove push roll: 2 Push Roll Screw 3 Washer 4 Push Roll Remove screw and washer, and lift

out push roll. To install push roll: Slide push roll onto shaft and

secure with washer and screw.

Changing Lower Drive Roll:

To remove drive roll: 5 Lower Drive Roll Screw 6 Washer 7 Lower Drive Roll 8 Drive Roll Key 9 Drive Roll Shaft Remove screw and washer, and lift

out drive roll. Note: drive roll key will come out with drive roll.

To install drive roll: Place drive roll key in slot in drive

roll shaft. Line slot in drive roll up with drive

roll key, and slide drive roll onto shaft.

Secure drive roll with washer and screw.

Reinstall gun case, if applicable. Reinstall drive roll cover.

OM-1322 Page 32

801 893-A

Return To Table Of Contents

Page 37

5-11. Changing Liner On Spoolmate 3035

Tools Needed:

Y Turn Off power at welding

power source first.

1 Nozzle 2 Contact Tip 3 Liner Remove and replace liner.

Reinstall parts as shown.

Ref. 801 891-A

5-12. Troubleshooting

Trouble Remedy

No weld output; wire does not feed. Be sure line disconnect switch is On (see Section 3-17).

Replace building line fuse or reset circuit breaker if open (see Section 3-17).

Reset circuit breaker CB1 (see Section 5-2).

Secure gun trigger connections (see Section 3-9).

Have Factory Authorized Service Agent check Power switch.

Have Factory Authorized Service Agent check all board connections and main control board.

No weld output; wire feeds. Thermostat TP1 open (overheating). Allow fan to run; the thermostat will close when the unit has cooled

(see Section 3-3).

Connect work clamp to get good metal to metal contact.

Replace contact tip (see Section 5-4).

An overload condition occurred. Release gun trigger (see Section 5-3).

Have Factory Authorized Service Agent check main control board and main rectifier.

Low weld output. Connect unit to proper input voltage or check for low line voltage (see Section 3-17).

Check input voltage jumper links and correct position if necessary (see Section 3-15).

Have Factory Authorized Service Agent check main control board.

Return To Table Of Contents

OM-1322 Page 33

Page 38

Trouble Remedy

Low, high, or erratic wire speed. Readjust front panel settings (see Section 4-1).

Change to correct size drive rolls (see Section 5-5).

Readjust drive roll pressure (see Section 3-18).

Replace inlet guide, contact tip, and/or liner if necessary (see Sections 5-4 and 5-8).

Check position of input jumper links (see Section 3-15).

Have Factory Authorized Service Agent check main control board.

No wire feed. Reset circuit breaker CB1 (see Section 5-2).

Turn Wire Speed control to higher setting (see Section 4-1).

Clear obstruction in gun contact tip or liner (see Sections 5-4 and 5-8).

Readjust drive roll pressure (see Section 3-18).

Change to correct size drive rolls (see Section 5-5).

Rethread welding wire (see Section 3-18).

Check gun trigger and leads. Repair or replace gun if necessary.

Have Factory Authorized Service Agent check main control board.

5-13. Spool Gun Troubleshooting

Trouble Remedy

Gun tube assembly loose. Tighten nut at base of gun tube assembly.

No weld output; gun/feeder does not work.

Erratic weld output. Tighten and clean all connections.

Pressing gun/feeder trigger does not energize welding power source; welding wire is not energized; shielding gas does not flow.

Wire feeds, shielding gas flows, but welding wire is not energized.

Wire feeds erratically. Check and correct drive roll pressure (see Section 3-14).

Place Power switch on welding power source in the On position (see welding power source Owner’s Manual).

Secure plug from gun/feeder trigger cord into 4-socket receptacle on welding power source (see Section 3-10).

Secure control cable leads in welding power source (see Section 3-10).

See Troubleshooting section in welding power source Owner’s Manual.

Clean or replace drive roll; clean or replace liner (see Sections 5-10 and 5-11).

OM-1322 Page 34

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Page 39

SECTION 6 − ELECTRICAL DIAGRAM

Figure 6-1. Welding Power Source Circuit Diagram

Return To Table Of Contents

203 535-B

OM-1322 Page 35

Page 40

Figure 6-2. Spool Gun Circuit Diagram

186 451

OM-1322 Page 36

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Page 41

SECTION 7 − MIG WELDING (GMAW) GUIDELINES

7-1. Typical MIG Process Connections

Regulator/ Flowmeter

Shielding

Gas

Supply

Wire Feeder/

Gas

Hose

Power Source

Y Weld current can damage

electronic parts in vehicles.

Disconnect both battery

cables before welding on a

vehicle. Place work clamp as

close to the weld as possible.

Gun

Work Clamp

Workpiece

light mig 5/967 / Ref. 802 714-B / Ref. 802 064-B

Return To Table Of Contents

OM-1322 Page 37

Page 42

7-2. Typical MIG Process Control Settings

NOTE

These settings are guidelines only. Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. Test welds to be sure they comply to specifications.

Material thickness determines weld parameters.

.035 in

Wire Size Amperage Range

.023 in .030 in .035 in

1/8 or

.125 in

30 − 90 A 40 − 145 A 50 − 180 A

Convert Material

Thickness to

Amperage (A)

(.001 in = 1 ampere)

.125 in = 125 A

Select Wire Size

Wire

Size (Approx.)

.023 in .030 in .035 in

Recommendation

3.5 in per ampere 2 in per ampere

1.6 in per ampere

Low voltage: wire stubs into work

High voltage: arc is unstable (spatter)

Set voltage midway between high/low voltage.

Wire speed (amperage) controls weld penetration (wire speed = burn-off rate)

Wire Speed

3.5 x 125 A = 437 ipm 2 x 125 A = 250 ipm

1.6 x 125 A = 200 ipm

Select Wire Speed

(Amperage)

125 A based on 1/8 in

material thickness

ipm = inch per minute

Select Voltage

Voltage controls height and width of weld bead.

OM-1322 Page 38

Ref. 802 717-C

Return To Table Of Contents

Page 43

7-3. Holding And Positioning Welding Gun

NOTE

Welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trigger, be sure wire is no more than 1/2 in (13 mm) past end of nozzle, and tip of wire is positioned correctly on seam.

0°-15°

90° 90°

End View Of Work Angle Side View Of Gun Angle

GROOVE WELDS

1 Hold Gun and Control Gun

Trigger

2 Workpiece

3 Work Clamp 4 Electrode Extension (Stickout)

1/4 to 1/2 in (6 To 13 mm)

5 Cradle Gun and Rest Hand on

Workpiece

45°

End View Of Work Angle Side View Of Gun Angle

FILLET WELDS

0°-15°

S-0421-A

Return To Table Of Contents

OM-1322 Page 39

Page 44

7-4. Conditions That Affect Weld Bead Shape

NOTE

Weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed (weld current), and voltage.

10°

Push

Perpendicular Drag

GUN ANGLES AND WELD BEAD PROFILES

Short Normal Long

10°

ELECTRODE EXTENSIONS (STICKOUT)

Short Normal Long

FILLET WELD ELECTRODE EXTENSIONS (STICKOUT)

Slow Normal Fast

GUN TRAVEL SPEED

S-0634

OM-1322 Page 40

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Page 45

7-5. Gun Movement During Welding

NOTE

Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads works better.

1 2

7-6. Poor Weld Bead Characteristics

1 Stringer Bead − Steady

Movement Along Seam

2 Weave Bead − Side To Side

Movement Along Seam 3 Weave Patterns Use weave patterns to cover a wide

area in one pass of the electrode.

S-0054-A

7-7. Good Weld Bead Characteristics

1 Large Spatter Deposits

2 Rough, Uneven Bead 3 Slight Crater During Welding 4 Bad Overlap 5 Poor Penetration

S-0053-A

1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During

Welding Weld a new bead or layer for each

1/8 in (3.2 mm) thickness in metals being welded.

4 No Overlap 5 Good Penetration into Base

Metal

Return To Table Of Contents

S-0052-B

OM-1322 Page 41

Page 46

7-8. Troubleshooting − Excessive Spatter

Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead.

S-0636

Possible Causes Corrective Actions

Wire feed speed too high. Select lower wire feed speed.

Voltage too high. Select lower voltage range.

Electrode extension (stickout) too long. Use shorter electrode extension (stickout).

Workpiece dirty. Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.

Insufficient shielding gas at welding arc. Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.

Dirty welding wire. Use clean, dry welding wire.

Eliminate pickup of oil or lubricant on welding wire from feeder or liner.

7-9. Troubleshooting − Porosity

Porosity − small cavities or holes resulting from gas pockets in weld metal.

S-0635

Possible Causes Corrective Actions

Insufficient shielding gas at welding arc. Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.

Remove spatter from gun nozzle.

Check gas hoses for leaks.

Place nozzle 1/4 to 1/2 in (6-13 mm) from workpiece.

Hold gun near bead at end of weld until molten metal solidifies.

Wrong gas. Use welding grade shielding gas; change to different gas.

Dirty welding wire. Use clean, dry welding wire.

Eliminate pick up of oil or lubricant on welding wire from feeder or liner.

Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, and dirt from work surface before welding.

Use a more highly deoxidizing welding wire (contact supplier).

Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.

7-10. Troubleshooting − Excessive Penetration

Excessive Penetration − weld metal melting through base metal and hanging underneath weld.

Excessive Penetration

Possible Causes Corrective Actions

Excessive heat input. Select lower voltage range and reduce wire feed speed.

OM-1322 Page 42

Good Penetration

S-0639

Increase travel speed.

Return To Table Of Contents

Page 47

7-11. Troubleshooting − Lack Of Penetration

Lack Of Penetration − shallow fusion between weld metal and base metal.

Lack of Penetration Good Penetration

Possible Causes Corrective Actions

S-0638

Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove while

maintaining proper welding wire extension and arc characteristics.

Improper weld technique. Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.

Keep arc on leading edge of weld puddle.

Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.

Insufficient heat input. Select higher wire feed speed and/or select higher voltage range.

Reduce travel speed.

7-12. Troubleshooting − Incomplete Fusion

Incomplete Fusion − failure of weld metal to fuse completely with base metal or a preceeding weld bead.

Possible Causes Corrective Actions

Workpiece dirty. Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before

welding.

Insufficient heat input. Select higher voltage range and/or adjust wire feed speed.

S-0637

Improper welding technique. Place stringer bead in proper location(s) at joint during welding.

Adjust work angle or widen groove to access bottom during welding.

Momentarily hold arc on groove side walls when using weaving technique.

Keep arc on leading edge of weld puddle.

Use correct gun angle of 0 to 15 degrees.

7-13. Troubleshooting − Burn-Through

Burn-Through − weld metal melting completely through base metal resulting in holes where no metal remains.

Possible Causes Corrective Actions

Excessive heat input. Select lower voltage range and reduce wire feed speed.

Increase and/or maintain steady travel speed.

S-0640

Return To Table Of Contents

OM-1322 Page 43

Page 48

7-14. Troubleshooting − Waviness Of Bead

Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal.

Possible Causes Corrective Actions

Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.

Unsteady hand. Support hand on solid surface or use two hands.

7-15. Troubleshooting − Distortion

Distortion − contraction of weld metal during welding that forces base metal to move.

Base metal moves

in the direction of

the weld bead.

Possible Causes Corrective Actions

Excessive heat input. Use restraint (clamp) to hold base metal in position.

S-0641

S-0642

Make tack welds along joint before starting welding operation.

Select lower voltage range and/or reduce wire feed speed.

Increase travel speed.

Weld in small segments and allow cooling between welds.

OM-1322 Page 44

Return To Table Of Contents

Page 49

7-16. Common MIG Shielding Gases

t feed

(bird

This is a general chart for common gases and where they are used. Many different combinations (mixtures) of shielding gases have been developed over the years. The most commonly used shielding gases are listed in the following table.

Application

Gas

Argon X

Argon + 25% CO

80% or greater Argon +

balance CO2 or Oxygen

100% CO

Tri-Mix

1 Limited short circuiting use 2 90% HE + 7-1/2% AR + 2-1/2% CO

Spray Arc Steel Short Circuiting Steel

X X

Short Circuiting

Stainless Steel

7-17. Troubleshooting Guide For Semiautomatic Welding Equipment

Problem Probable Cause Remedy

Wire feed motor operates, but wire does no

Too little pressure on wire feed rolls. Increase pressure setting on wire feed rolls.

Incorrect wire feed rolls. Check size stamped on wire feed rolls, replace to match

wire size and type if necessary.

Wire spool brake pressure too high. Decrease brake pressure on wire spool.

Restriction in the gun and/or assembly. Check and replace cable, gun, and contact tip if

damaged. Check size of contact tip and cable liner, replace if necessary.

Aluminum

Wire curling up in front of the wire feed rolls

Wire feeds, but no gas flows.

nesting).

Too much pressure on wire feed rolls. Decrease pressure setting on wire feed rolls.

Incorrect cable liner or gun contact tip size. Check size of contact tip and check cable liner length

Gun end not inserted into drive housing properly. Loosen gun securing bolt in drive housing and push gun

Dirty or damaged (kinked) liner. Replace liner.

Gas cylinder empty. Replace empty gas cylinder.

Gas nozzle plugged. Clean or replace gas nozzle.

Gas cylinder valve not open or flowmeter not adjusted. Open gas valve at cylinder and adjust flow rate.

Restriction in gas line. Check gas hose between flowmeter and wire feeder, and

Loose or broken wires to gas solenoid. Have Factory Authorized Service Agent repair wiring.

Gas solenoid valve not operating. Have Factory Authorized Service Agent replace gas

Incorrect primary voltage connected to welding power source.

and diameter, replace if necessary.

end into housing just enough so it does not touch wire feed rolls.

gas hose in gun and cable assembly.

solenoid valve.

Check primary voltage and relink welding power source for correct voltage.

Return To Table Of Contents

OM-1322 Page 45

Page 50

Problem RemedyProbable Cause

Welding arc not stable.

Wire slipping in drive rolls. Adjust pressure setting on wire feed rolls. Replace worn

Wrong size gun liner or contact tip. Match liner and contact tip to wire size and type.

Incorrect voltage setting for selected wire feed speed on welding power source.

Loose connections at the gun weld cable or work cable. Check and tighten all connections.

Gun in poor shape or loose connection inside gun. Repair or replace gun as necessary.

drive rolls if necessary.

Readjust welding parameters.

OM-1322 Page 46

Return To Table Of Contents

Page 51

Notes

Return To Table Of Contents

OM-1322 Page 47

Page 52

. Hardware is common and

not available unless listed.

SECTION 8 − PARTS LIST

2 − Fig 8-3

1 − Fig 8-2

19 − Fig 8-4

20 − Fig 8-5

21 − Fig 8-7

802 718-B

Figure 8-1. Main Assembly

OM-1322 Page 48

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Page 53

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 8-1. Main Assembly

1 Fig 8-2 BAFFLE,CENTER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Fig 8-3 PANEL,REAR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 605227 NUT, 750−14 KNURLED1.68DIA .41H NYL 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 188911 CORD SET,250V 6−50P 8−10GA 3/C 12FT ST JKT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 187255 CORD SET,250V T TNG 8−10GA 3/C 12FT ST JKT (460/575) 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

5 604102 CONN,CLAMP CABLE 1.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 152215 RACK,CYLINDER DUAL 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 135418 AXLE,RUNNING GEAR .750 DIA X 25.745 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 186758 WHEEL 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 602250 WASHER,FLAT STL SAE .750 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 121614 RING,RTNG EXT .750 SHAFT X .085 THK E STYLE 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 203482 +WRAPPER, 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 201019 LABEL,WARNING ELECTRIC SHOCK EXCESS WEIGHT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 193328 LABEL,WARNING ELECTRIC SHOCK AND INCORRECT INPUT P 1. . . . . . . . . . . . . . . . . . . . .

14 134464 LABEL,WARNING GENERAL PRECAUTIONARY STATIC&WIRE FE 1. . . . . . . . . . . . . . . . . . . .

15 200923 GUN/CABLE HOLDER,(INCLUDING) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 200921 HOLSTER,GUN/CABLE HOLDER 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 146161 BASE, 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 209870 CASTER,SWVL 4.00 IN X 1.250 IN POLY−OLEFIN 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 Fig 8-4 PANEL,FRONT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 Fig 8-5 M-15 GUN 10 FT .030-.035 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 Fig 8-7 SPOOL GUN 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 196328 CABLE,WORK 10’ NO 3 W/CLAMP (INCLUDING) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

130750 CLAMP,WORK 300 AMP 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

600318 CABLE,WELD COP STRD NO 3 EPDM JKT (ORDER BY FT) 10FT. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

196318 COVER,CABLE BTRY POST BLK .75 ID 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 091685 RESISTOR,WW FXD 50 W 25 OHM FASTON TE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 192376 STABILIZER (INCLUDING) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TP2 213414 THERMOSTAT,NC OPEN 150C 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 199399 RECTIFIER,SI 1PH 200 AMP 200 PIV 30%. . . . . . . . . . . . . . .

W/BLOCK DIODE (INCLUDING) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TP1 190284 THERMOSTAT,NC OPEN 105C CLOSE 65C FLANGE FASTON 1. . . . . . . . . . . . . . . . . . . . . . .

200158 LEAD ASSY,TWISTED PAIR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 199988 THYRISTOR,SCR MODULE 50A 400V SINGLE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C16 031688 CAPACITOR,CER DISC .01 UF 1000 VDC W/TERMS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 203531 XFMR,POWER MAIN 200(208)/230/240 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 208388 XFMR,POWER MAIN 460/575 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 203481 PANEL,SIDE LH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 151187 LATCH,SLIDE FLUSH STYLE SERIES 40 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 203480 WRAPPER,HINGED 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

200796 LABEL,PARAMETER/CONSUMABLES 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

209123 REGULATOR/FLOWMETER, 10−50 CFH ARGON/MIXED 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

144108 HOSE, GAS 5FT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦212492 REGULATOR/FLOWMETER, 10−50 CFH CO

1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+When ordering a component originally displaying a precautionary label, the label should also be ordered. ♦OPTIONAL

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.

Return To Table Of Contents

OM-1322 Page 49

Page 54

. Hardware is common and

not available unless listed.

21 22

OM-1322 Page 50

25 − Fig 8-6

Figure 8-2. Baffle, Center w/Components

Return To Table Of Contents

802 719

Page 55

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 8-2. Baffle, Center w/Components (Fig 8-1 Item 1)

SPOOL HUB ASSEMBLY,(INCLUDING) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 058427 RING,RETAINING SPOOL 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 085980 NUT,STL HEX FULL .625-11 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 605941 WASHER,FLAT STL .640 ID X 1.000 OD X 14GA THK 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 186437 SPRING,CPRSN .845 OD X .110 WIRE X 1.500 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 057971 WASHER,FLAT STL KEYED 1.500DIA X .125THK 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 057745 SPRING,CPRSN 2.430 OD X .090 WIRE X 2.500 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 186435 HUB,SPOOL 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 186436 WASHER,BRAKE PLASTIC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 177307 REEL SUPPORT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

198425 CAP,FINISHING 1.19 X .37 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

198426 WASHER,CAP 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 +199895 BAFFLE,CENTER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 CR2 000770 RELAY,ENCL 24VDC 3PDT 10A/120VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

144425 VARISTOR, 430V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 196894 BRACKET,CONSUMABLE/TOOL TRAY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 196600 CONTACTOR,DEF PRP 60A 3P 24VAC COIL W/LINKS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

114786 LINK,CONNECTING CONTACTOR TERMINAL 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 C6 185644 CAPACITOR ASSY,(INCLUDING) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 184584 CAPACITOR,ELCTLT 15000UF 45VDC 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 185643 BUSS BAR,CAPACITOR 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 082902 STRIP,MTG CENTER CAPACITOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

083147 GROMMET,SCR NO. 8/10 PANEL HOLE .312SQ .500 HIGH 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187752 STRIP,INSULATOR CAPACITOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 PC1 192067 CIRCUIT CARD ASSY,CONTROL 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG4 131056 HOUSING RECEPTACLE & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG6 115092 HOUSING PLUG & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

134201 STAND−OFF SUPPORT,PC CARD .312/.375W/POST&LOCK .43 4. . . . . . . . . . . . . . . . . . . . . . . . . .

19 TE1 192907 TERM ASSY,PRI 1PH 3V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

203529 LABEL,LINK 200/230/240 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 TE1 188910 TERM ASSY, PRI 1PH 2V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

203529 LABEL,LINK 460/575 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 038618 LINK,JUMPER TERM BD PRI as req.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 097416 TERMINAL,PWR OUTPUT BLACK 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 097421 TERMINAL,PWR OUTPUT RED 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 C11,12,13 128750 CAPACITOR,CER DISC .1 UF 500 VDC W/TERMS 3. . . . . . . . . . . . . . . . . . . . . . . . . .

24 CB1 180912 CIRCUIT BREAKER,MAN RESET 1P 5A 250VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 Fig 8-6 DRIVE ASSY,WIRE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 021469 LABEL,WARNING HIGH VOLTAGE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 +188917 DOOR,ACCESS CHANGEOVER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 199824 LABEL,WARNING ELECTRIC SHOCK AND PINCH POINTS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 197555 TRAY,CONSUMABLE/TOOL W/BUMPER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

172171 FTG,HOSE BRS BARBED COUPLER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

010493 BUSHING,SNAP−IN NYL .625 ID X .875 MTG HOLE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

+When ordering a component originally displaying a precautionary label, the label should also be ordered.

Return To Table Of Contents

OM-1322 Page 51

Page 56

. Hardware is common and

not available unless listed.

Item

No.

Dia.

Mkgs.

Part

No.

802 728-B

Figure 8-3. Panel, Rear w/Components

Description

Quantity

Figure 8-3. Panel, Rear w/Components (Fig 8-1 Item 2)

1 049399 NUT, 312−18 PUSH ON .63D .07H STL 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 148809 BLADE,FAN 9.000 5WG 34DEG .312 BORE CCW PLSTC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 188706 MOTOR,FAN 230V 50/60HZ 1550 RPM .312 DIA SHAFT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 203711 WINDTUNNEL,9.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 216607 VALVE, 24VDC 2WAY CUSTOM PORT 1/8 ORF W/FRICT 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 204770 PANEL,REAR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201022 LABEL,GAS IN SPOOLGUN/MIG GUN 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 +046575 BRACKET,SUPPORT CYL CRM 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

200285 LABEL,WARNING CYLINDER MAY EXPLODE IF DAMAGED 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 188441 CHAIN,WELDLESS 2/0 X 31 LG 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 137 761 NUT, 750NPT 1.31HEX .27H NYL BLK 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-1322 Page 52

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Page 57

. Hardware is common and

not available unless listed.

Figure 8-4. Panel, Front w/Components

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 8-4. Panel, Front w/Components (Fig 8-1 Item 19)

1 208475 LABEL,NAMEPLATE MILLERMATIC PULSER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 208164 PANEL,FRONT BEZEL 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 208165 PANEL,FRONT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 R3 208207 POT,CP FLAT 1T 2. W 1K LINEAR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 R2 198087 POTENTIOMETER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 196801 BRACKET,MTG 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 S2 192373 SWITCH,SELECTOR 7 POSITION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

136343 SCREW,K50X 20 PAN HD−PHL STL PLD PT THREAD FORMING 4. . . . . . . . . . . . . . . . . . . . . . . . . .

8 S1 128755 SWITCH,TGL DPST 40A 600VAC SCR TERM WIDE TGL 1. . . . . . . . . . . . . . . . . . . . . . . . . .

9 C7,8,9,10,. . .

14,15 136735 CAPACITOR,CER DISC .1UF 500VDC STRIP 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 048282 RECEPTACLE W/SOCKETS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 129524 TERM,FRICT 250X032 UNINSUL MALE .130 STUD MTG 3PR1 1. . . . . . . . . . . . . . . . . . . . . . . . .

12 209305 LABEL 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 207074 HANDLE,SWITCH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 207076 KNOB, .868 DIAMETER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 207077 KNOB,POINTER 1.625 DIA PUSH ON 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

802 720-A

Quantity

+When ordering a component originally displaying a precautionary label, the label should also be ordered.

Return To Table Of Contents

OM-1322 Page 53

Page 58

Item

No.

Part

No.

Description Quantity

169591

Figure 8-5. M-15 Gun (Fig 8-1 Item 36)

1 169715 NOZZLE,SLIP TYPE .500 ORF FLUSH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ♦087299 TIP,CONTACT SCR .023 WIRE X 1.125 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ♦000067 TIP,CONTACT SCR .030 WIRE X 1.125 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ♦000068 TIP,CONTACT SCR .035 WIRE X 1.125 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ♦000069 TIP,CONTACT SCR .045 WIRE X 1.125 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 169716 ADAPTER,CONTACT TIP 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 170470 RING,RETAINING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 169718 TUBE,HEAD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 169738 NUT,LOCKING HANDLE 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 169719 NUT,JAM 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 169737 HANDLE 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 169741 STRAIN RELIEF,CABLE 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 180433 CORD,TRIGGER ASSEMBLY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 209486 CONNECTOR, FEEDER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 079974 O-RING,.500 ID x .103CS rbr 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 ♦194010 LINER,MONOCOIL .023/.025 WIRE X 15FT (INCLUDING) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 ♦194011 LINER,MONOCOIL .030/.035 WIRE X 15FT (INCLUDING) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 ♦194012 LINER,MONOCOIL .035/.045 WIRE X 15FT (INCLUDING) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 079975 O-RING,.187 ID x .103CS rbr 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 196255 SWITCH,TRIGGER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ref. 800 792-B / Ref. 800 792-C

Figure 8-5. M-15 Gun

♦OPTIONAL

OM-1322 Page 54

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Page 59

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

197633

Figure 8-6. Wire Drive And Gears (Fig 8-2 Item 25)

1 602009 SCREW,.250-20 x 1.25 soc hd gr 8 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 172075 CARRIER,DRIVE ROLL W/COMPONENTS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 166072 SPACER,GEAR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 010224 PIN,SPRING CS .187 X 1.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 182788 HOUSING,ADAPTER GUN/FEEDER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 085242 FASTENER,PINNED 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 085 244 WASHER, cupped stl .328 ID x .812 OD x .125 lip 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 196896 CUP,SPRING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 196897 SPRING,CPRSN .695 OD X .095 WIRE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 196895 KNOB,TENSION ADJ 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 166071 LEVER,MTG PRESSURE GEAR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 204510 PIN,HINGE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 151828 PIN,COTTER HAIR .054 X .750 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 173616 COVER,RIGHT ANGLE MOTOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 173435 MOTOR,GEAR 24VDC 122RPM 20:1 RATIO (INCLUDING) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

193633 KEY,WOODRUFF .118 X .380 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

193634 WASHER,WAVE .405 ID X .740 OD 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

193635 RING,RTNG EXT .394 SHAFT X 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 079633 FITTING,HOSE BRS BARBED M 3/16TBG 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 601966 SCREW,.375−16 X 1.25HEXHD 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 604538 WASHER,FLAT STL SAE .312 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 204585 KNOB 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 173619 CARRIER,DRIVE ROLL W/COMPONENTS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 174609 SCREW,M 4−.7 x 12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 174610 SCREW,M 6−1.0 X 20 SOC HD 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 192029 WASHER,FLAT .250 ID X .437 OD 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 173620 BUSHING,MOTOR MTG 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 602243 WASHER,FLAT .438 ID X 1.00 OD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 602213 WASHER,LOCK .380 ID X .683 OD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

203526 ROLL,DRIVE V GROOVE .030/.035 COMB WIRE 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

056192 GUIDE,WIRE INLET 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*045127 GUIDE,WIRE INLET ANTI−WEAR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Roll & Wire Guide Kits.

. Hardware is common and

See Section 8-9

not available unless listed.

*Recommended Spare Parts.

Figure 8-6. Wire Drive And Gears

Return To Table Of Contents

802 986-A

OM-1322 Page 55

Page 60

. Hardware is common and

not available unless listed.

OM-1322 Page 56

801 900-C

Figure 8-7. Spool Gun Assembly

Return To Table Of Contents

Page 61

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

195 016

Figure 8-7. Spool Gun Assembly (Fig 8-1 Item 19)

1 PB1 186416 TRIGGER SWITCH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 186418 PLASTIC HANDLE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 196966 SPOOL COVER ASSY (INCLUDING) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 194622 SPOOL DEFENCE SHELL 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 194623 SPOOL SHAFT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 194624 BUSHING RESISTANCE RUBBER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 194625 LOCATION BUSHING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 194626 ADJUSTING NUT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 RING,RTNG C-CLIP .140 SHAFT X .015 THICK 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 194627 LOCKING SCREW 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 187239 COVER,DRIVE ROLL 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 186489 CABLE/GAS HOSE ASSEMBLY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 193999 SPRING,CPRSN .310 OD X .040 WIRE X 1.380 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 186415 PRESS ARM W/SHAFT,C-CLIP WASHER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 187238 BEARING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 186414 PUSH ROLL 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 186413 DRIVE ROLL 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 186488 KEY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 186410 INLET GUIDE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 048834 CLAMP,CIRC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 079878 CONNECTOR W/SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 194631 NUT,BRASS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 186412 GEARBOX ASSEMBLY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 B2 186417 MOTOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 196398 BUSS BAR,INTERCONNECTING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 197570 ANTI-ROTATION PIN 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 196848 CONTACT ADAPTER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 196827 GUN TUBE ASSEMBLY (INCLUDING) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 196849 HEAD TUBE ASSY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 186747 LINER (GUIDE SPIRAL) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 196847 LOCKING NUT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 194633 BARREL (RADIATOR TUBE) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 SCREW,M4 X 0.7 X 5 MM 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 186408 GAS NIPPLE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 186409 GAS DIFFUSER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 ♦186419 CONTACT TIP .030 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 186406 CONTACT TIP .035 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 186405 NOZZLE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

195539 GAS DIVERTER VALVE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦OPTIONAL

Return To Table Of Contents

OM-1322 Page 57

Page 62

802 532

Figure 8-8. Optional Barrel Assembly

Quantity

Item

No.

Part

No.

Description

Curved 198 371 198 372

Straight

Figure 8-8. Optional Barrel Assembly

1 197570 PIN,ANTIROTATION .078 DIA X 3/16 LG 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 194631 NUT,BRASS 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 196848 CONTACT ADAPTER 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 186408 GAS NIPPLE 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 198417 LINER 9 IN (229 MM) (GUIDE SPIRAL) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 196847 LOCKING NUT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 186409 GAS DIFFUSER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 ♦186406 CONTACT TIP .035 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 ♦186419 CONTACT TIP .030 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 186405 NOZZLE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 198416 GAS DIFFUSER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 198430 SPRING,RETAINER NOZZLE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 198415 LINER,CURVED (GUIDE SPIRAL) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 198429 NOZZLE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦OPTIONAL

OM-1322 Page 58

Return To Table Of Contents

Page 63

8-9. Drive Roll And Wire Guide Kits

Note

.023/.025 in.

.030/.035 in .030/.035 in 0.8/0.9 mm 204 579 203 526 V-Grooved 056 192

Base selection of drive rolls upon the following recommended usages: 1 V-Grooved rolls for hard wire. 2 U-Grooved rolls for soft and soft shelled cored wires. 3 U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types). 4 V-Knurled rolls for hard shelled cored wires. 5 Drive roll types may be mixed to suit particular requirements (example: V-Knurled roll in combination

with U-Grooved).

Wire Diameter

Fraction Decimal Metric

.023/.025 in.

.030 in. .035 in.

.045 in.

.052 in. .052 1.3 mm 079 597 053 698 V-Grooved 056 193

1/16 in. .062 1.6 mm 079 598 053 699 V-Grooved 056 195

.030 in. .035 in.

.045 in.

0.6 mm

0.8 mm

0.9 mm

1.2 mm

Kit No.

087 131

079 594 079 595

079 596

Drive Roll

Part No. Type

087 130

053 695 053 700

053 697

V-Grooved

V-Grooved V-Grooved

V-Grooved

Inlet

Wire Guide

056 192

056 192 056 192

056 193

Ref. S-0026-B/7-91

Return To Table Of Contents

OM-1322 Page 59

Page 64

Notes

Page 65

Notes

Page 66

Notes

Page 67

Warranty Questions?

Call 1-800-4-A-MILLER for your local Miller distributor.

Your distributor also gives you ...

Service

You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.

Support

Need fast answers to the tough welding questions? Contact your distributor. The expertise of the distributor and Miller is there to help you, every step of the way.

Effective January 1, 2003

(Equipment with a serial number preface of “LC” or newer)

This limited warranty supersedes all previous Miller warranties and is exclusive with no other

LIMITED WARRANTY − Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Miller must be notified in writing within thirty (30) days of such defect or failure, at which time Miller will provide instructions on the warranty claim procedures to be followed.

Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the date that the equipment was delivered to the original retail purchaser, or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor.

1. 5 Years Parts — 3 Years Labor

* Original main power rectifiers * Inverters (input and output rectifiers only)

2. 3 Years — Parts and Labor

* Transformer/Rectifier Power Sources * Plasma Arc Cutting Power Sources * Semi-Automatic and Automatic Wire Feeders * Inverter Power Supplies * Intellitig * Maxstar 150 * Engine Driven Welding Generators

(NOTE: Engines are warranted separately by the engine manufacturer.)

3. 1 Year — Parts and Labor Unless Specified

* DS-2 Wire Feeder * Motor Driven Guns (w/exception of Spoolmate

Spoolguns) * Process Controllers * Positioners and Controllers * Automatic Motion Devices * RFCS Foot Controls * Induction Heating Power Sources * Water Coolant Systems * Flowgauge and Flowmeter Regulators (No Labor) * HF Units * Grids * Maxstar 85, 140 * Spot Welders * Load Banks * Racks * Running Gear/Trailers * Plasma Cutting Torches (except APT & SAF

Models) * Field Options

(NOTE: Field options are covered under True

Blue for the remaining warranty period of the

product they are installed in, or for a minimum of

one year — whichever is greater.)

4. 6 Months — Batteries

5. 90 Days — Parts

* MIG Guns/TIG Torches

guarantees or warranties expressed or implied.

* Induction Heating Coils and Blankets * APT & SAF Model Plasma Cutting Torches * Remote Controls * Accessory Kits * Replacement Parts (No labor) * Spoolmate Spoolguns * Canvas Covers

Miller’s True Blue Limited Warranty shall not apply to:

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, slip rings, relays or parts that fail due to normal wear. (Exception: brushes, slip rings, and relays are covered on Bobcat, Trailblazer, and Legend models.)

2. Items furnished by Miller, but manufactured by others, such as engines or trade accessories. These items are covered by the manufacturer’s warranty, if any.

3. Equipment that has been modified by any party other than Miller, or equipment that has been improperly installed, improperly operated or misused based upon industry standards, or equipment which has not had reasonable and necessary maintenance, or equipment which has been used for operation outside of the specifications for the equipment.

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Miller’s option: (1) repair; or (2) replacement; or, where authorized in writing by Miller in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Miller service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customer’s risk and expense. Miller’s option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility as determined by Miller. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER.

Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state.

In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province.

miller_warr 8/03

Page 68

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

For Service

Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:

Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training (Schools, Videos, Books) Technical Manuals (Servicing Information

and Parts) Circuit Diagrams Welding Process Handbooks

Miller Electric Mfg. Co.

An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA

International Headquarters−USA

USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125

European Headquarters − United Kingdom

Phone: 44 (0) 1204-593493 FAX: 44 (0) 1204-598066

www.MillerWelds.com

Contact the Delivering Carrier to:

PRINTED IN USA  2004 Miller Electric Mfg. Co. 1/03

File a claim for loss or damage during shipment.

For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department.