Miller MW 4150 Owner's Manual

IMPORTANT

contents

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1989

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Model

No.

1

1-1.
1-2.
1-3.
1-4.

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Description



SAFETY

Introduction

General

Arc

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No._____________________________

______________________________

No.

Page

WELDING

POWER

SOURCE

1

1

3
5

Designa

The

infor

SECTION

SECTION

SECTION

2-1.
2-2.

3-1.
3-2.
3-3.
3-4.
3-5.

3-6.

3-7.

4-1.

4-2.

4-3.

4-4.

4-5.

4-6.

4-7.

4-8.
4-9.
4-10.

4-11.

4-12.

4-13.

2-

SAFETY

General

Safety

3

Alert

INTRODUCTION

Volt-Ampere

Duty

Cycle

Description

Supplied

Additional

Optional

Consumable

4

INSTALLATION

Site

Selection

Transporting

Running

Optional

Shielding

Work

Cable

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Polarity

MWG-200
Installation

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Hub

Tension

Electrical

Welding

PRECAUTIONS

Information

Symbol

Curves

Equipment

Required

Equipment

Parts

Methods

Gear

Installation

SPW-1

Gas

Panel

Installation

Assembly

Selection

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Of

Optional

Wire

Spool

Adjustment

Connections

Input

Wire

Threading

AND

And

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And

Signal

Equipment

Installation

Gun

Connections

Spool

Installation

Gun

SIGNAL

Words

WORDS

..

6

6

8

8
8
8

9

10
10

10
10

11

11

12

13

14

14

15

16

16
16
17

Section

No.

Page

No.

SECTION

SECTION

SECTION

5-1.

5-2.

5-3.

5-4.
5-5.

6-1.

6-2.

6-3

7-1.
7-2.

7-3.
7-4.
7-5.

7-6.
7-7.

7-8.
7-9.

OPERATOR

5

Power

ThicknessNolts

Fine

Switch

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SEQUENCE

6

Gas

And

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(Models

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7-

MAINTENANCE

Routine

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Drive

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CONTROLS

And

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Light

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Pulse

OF

OPERATION

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Controls

Panel

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Only)

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19
19
19
19

19

20

22

23

23

24
26

26
26
27
27

27

27

SECTION

SECTION

SECTION

8-

Diagram

Diagram

9

9-1.
9-2.

9-3.

9-4.
9-5.
9-6.

10

10-1.
10-2.

10-3.

10-4.

10-5.

10-6.

ELECTRICAL

8-1.

Circuit

8-2.

Circuit

WELDING

Gas

Metal

Gas

Metal

Gas

Metal

Welds

Plug

Skip

Welding

Troubleshooting

AUTO

Pointers

Procedure

Procedures
How

To

Prevent

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Welding

Diagram
Diagram

TECHNIQUES

Arc
Arc

Arc

BODY

For

Welding

For

For

For

Frames

DIAGRAMS

Welding
Welding

Welding

The

REPAIR

Welding

Welding

Glass

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And

SPW-1

For

&

Panel

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(GMAW)-Pulsed

(GMAW)-Spot

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Metal

Arc

Welding

APPLICATION

Auto

Mild

Door

Breakage

Fenders

High

Sheet

Body

Steels

Panels

And

And

Strength

(HSS)

Process

Metal

Spatter

Quarter

Steels

Seam

On

Panels

Windows

30

30

31

32

33
34
34

34

37

37

37
38
38

38

Section

SECTION

LIST

No.

11

Figure
Figure

Figure

Figure

Figure
Figure

Figure
Figure

OF

CHARTS

Table

Chart
Chart

Table

Table

(GMAW)

Table
Table

Table



PARTS

11-1.
11-2.
11-3.
11-4.

11-5.
11-6.

11-7.
11-8.

3-1.

3-1.
3-2.
3-2.

6-1.

6-2.
7-1.

7-2.

LIST

Main

Assembly

Baffle,

Drive

Assembly,

Panel,

Panel,

SPW

1

Circuit

Running

AND

TABLES

Specifications

Volt-Ampere
Duty

Cycle

Conductor

Input

Suggested

Checking

Maintenance

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-

Air

W/Components

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Front

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Gear

Curves

And

Parameters

Parameters

Weld

Schedule

Wire

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Fuse

For

Size

Continuous

Gas

Metal

Arc

Welding

Page

40

42

44

45

46

48
49
50

21
23
23

28

No.

7

7
7

17

SECTION

1



SAFETY

RULES

FOR

OPERATION

OF

ARC

WELDING

POWER

SOURCE

1-1.

INTRODUCTION

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trichloroethylene

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PHOSGENE,

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113336

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also

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cut

where

or

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penetrate

1

Page

to

atmospheres

trichloroethylene

C.

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113

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regulator

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detailedinCGA

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User

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F.

Close

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Rope

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staging-support

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*Trademark

1-3.

ARC

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defective

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burn.

service

statement

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113

336

Page

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or

3

Comply

Arc

careless

high
bright

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COMPLY

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4

Page

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screens

336

done,

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1-4.

STANDARDS

For

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information,

their

latest

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1.

ANSI

Standard

CUTTING

Society,

2.

NIOSH,

AND

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from

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ernment

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OSHA,

29CFR

Documents,

Washington,

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ANSI

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OCCUPATION

FACE

PROTECTION

National

NY

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ANSI

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USE

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sources

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control

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devices.

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electrically

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inspection,

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plugs.

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550

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SAFETY

obtainable

1910,

D.C.

Standards

10018.

National

York,

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high

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BOOKLET

refer

and

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AND

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currents

electronic

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SAFETY

from

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AND

of

Washington,

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HEALTH

from

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SAFE

EDUCATIONAL

obtainable

Institute,

STANDARD

Standards

10018.

FIRE

AND

WELDING

with

used

similar

and

with

welding

With

such

HOT

ON.

Never

power

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circuit

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polarity

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source,

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Always

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Electronic

can

INDEX

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American

Miami,

IN

ARC

CUTTING

Documents,

D.C.

STANDARDS,

the

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AND

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IN

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of

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obtainable

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TIBLES

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PRESSED

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550

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obtainable

Standard

Association,

02269.

Pamphlet

the

American

from

Broadway,

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from

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51,

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70,

from

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51B,

obtainable

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National

New

York,

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HAVE

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Miami,

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from

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NATIONAL

National

the

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from

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IN

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COMBUS

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FL

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AND

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can

New

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AND

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Rexdale

1R3.

booklet,

obtainable

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Welding

FL

33126.

Standard

PROTECTION,

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NY

York,

Gas

Suite

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from

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1900

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the

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A.

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bels,

design,

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nameplate

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The

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codes

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of

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on

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unit

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panel

section

equipment

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Rules

2-

SAFETY

AND

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manual

unit

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The

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the

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maintenance,

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PRECAUTIONS

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113336

Page

6

SECTION

Table

INTRODUCTION

3-

3-1.

SpecificatIons

Rated

Weld

Output

At

60%

Duty

Cycle

150

Amperes

At

Volts

23

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Max.

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32

Rated

At

input

Hz

60

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At

200V 230V 460V

26.5

24

12

Load

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mm)

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113

00

9-057436-1

336

90

Page

100

7

70

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adjustment

age
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determine

age.

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that

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percentage

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the

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source

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DESCRIPTION

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a

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3-4.

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B.

C.

D.

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113336

Page

Spreader

Bar

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8

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Wire

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provides

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fitted

from

glasses,

good

gas

both

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the

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correct

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of

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a

than

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this

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the

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of

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the

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welding

(GMAW).

wires

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for

of

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more

E7OS-3.

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power

the

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gloves

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sheet

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can

tool.

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E7OS-6

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(Figure

sheet

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wire

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mm)

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important

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injury.

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easier
has

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types

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a

of

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keep

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hand

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weld

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wire

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to

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be

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Figure

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

Helmet

1/~

Safety

Glasses

Additional

Wire

Spool

Regulator!

:

Required

Gloves

Equipment

Figure

3-4.

Offset/Punching

Tool

113

336

Page

9

3-6.

OPTIONAL

The

following

capabilities

tions:

A.

B.

C.

D.

of

SPW-1,

cludes

Section

Spoolgun

Gun

cable

25

ft

(7.6

EQUIPMENT

equipment

the

basic

Spot,

three

spot

4-3)

holder

m)

power

be

can

unit

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cord

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installation

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to

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Panel

the

(in

see

3-7.

The

following

mal

use:

A.

B.

C.

D.

CONSUMABLE

parts

Contact

Nozzles

Gun

liner

Drive

rolls

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PARTS

subject

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ordamage

in

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4-1.

SITE

SELECTION

Figure

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LocatIon

4-1)

SECTION

18

in.

mm)

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TB-072

4-INSTALLATION

4A

4-2.

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the

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EXPLOSION

on

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METHODS

installation.

combustible

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18

all

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type

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of

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mm)

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4.

5.

6.

7.

8.

an

Correct

Shielding

Adequate

No

flammables

A

clean

Proper

cold

Proper

Adequate

installation,

Base

mounting

336

the

Page

secure

tion.

113

installation

input

power

supply

gas

ventilation

and

dry

temperature

airflow

around

space

maintenance,

holes

unit

on

a

running

10

site

which

supply

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area

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unit

for

opening

provide

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(see

fresh

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orina

gear

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air

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side

repair

the

following:

nameplate)

supply

of

access

permanent

doors

functions.

to

install

heat

loca

for

and

WARNING:

4~

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ing

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Using

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ELECTRIC

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EQUIPMENT

injury

lifting

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and

to

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cylinders,

or

devices.

equipmentof

or

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tips

or

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of

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electrical

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line

BEFORE

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tion

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tion

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blocks

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two

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up

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end

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of

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bending

INSTALLATION

TILTING

In

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of

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part

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mm)

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rack,

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the

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OR

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capacity

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body

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the

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tour

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6.

power
gear

screws

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power

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8.

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welding

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INSTALLATION

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Figure

existing

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PANEL

electrical

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Front

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____4..~

~

_v__

~

~

Pin

Screw

Cap

Gear

Installation

Flat

Cap

Safety

Washers

Wheel

Screw

Chain

Flat

Washers

Cotter

TC-049

Pin

808-C

113

336

Page

11

IMPORTANT:

capabilities

moved

tions,

tor

facing

1.

Remove

corner

2.

Locate

move

pull

opening

mately

3.

Disconnect

4.

Connect
PLG2.

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5.

Install

panel,

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during

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front

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wiring

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end

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2

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Figure

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panel.

harness

harness

wiring

front

panel

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mm).

jumpered

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sure

4-3).

panel

secure

Spot

gun.

are

cover

from

harness

-

connector

RC55

connectors

into

using

will

Panel

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reinstallation.

for

with

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first

clamp

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to

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er

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Keep

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(Figure

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cap

der

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valve,

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the

Figure

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and

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a

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fasten

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correctly

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the

open

close

dirt

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seat.

personal

CYLINDERS

equipment

from

electrode

other

or

(Customer

installed,

to

valve

valve.

that

may

CYLINDERS

damage.

welding

any

to

securely

stationary

remove

sideofthe

one

slightly.

This

procedure

have

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and

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touch

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support.

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cylin

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RC55

SPw-1

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Spot

4-5.

SHIELDING

A.

Gas

Secure

on

cylinder

chain

cylinder

the

vent

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113336

Page

~



FIgure

Cylinder

gas

cylinder

bracket.

to

cylinder

12

4-3.

SPW-1

GAS

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to

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wall

or

from

Panel

INSTALLATION

Supplied)

running

other

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gear

running

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over

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(Figure

using

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Gas

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Figure

Hose

Male

Required)

Hose

Male

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4-4.

Installation

co2

Typical

Installation

-

TB-lOg

Regulator/Flowmeter

492

2.

The
with

either

IMPORTANT:

leaks.

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-

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the

tical

cylinder.

A

4.

shielding

of

the

tions.

fitting.

lator/flowmeter.

WORK

4-6.

A

10

ft.

supplied

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plug

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clamp

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lowmeter

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cylinders

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use

regulator

of

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regulator/f

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power

one

other

CABLE

cable

the

unit.Toinstall

cable,

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end

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one

work

cable

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the

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connectors,

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fittingisprovided

source

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endofthe

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the

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supplied

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gas

lowmeter

stem

nut

for

making

gas

gas

attached

the

work

follows:

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(Figure

cable

with

the

handleofthe

inner surface.

work

terminal

with

of

the

the

on

properly

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equipped

for

use

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to

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agents.

valve;

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to

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one

at

the

onto

the

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and

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hosetothe

clamp

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terminal

the

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supplied

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cable

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insulating

clamp

the

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ver

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rear

output

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end

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lug

work

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the

nut

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supplied

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of

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cables

onto

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2.

tending

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steel

mately

4.

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of

tie

wire

5.

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looped

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6.

7.

8.

9.

10.

11

12.

tie

around

tight

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the

of

uninsulated

the

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lated

portion

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the

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the

in

holes

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sulating

and

plug

with

remaining

13.

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the

insulating

installation

jack

plugs

weld

output

follows:

as

in.

3/4

weld

cable

upward

1/4

cable.

in

tie

in.

turn

(19

a

out

wire

(6

around

mm)

mm)

vise with

of

together.

in.

(9.5

endsoftie

wire

looped

twisted

wire.

until

(B)

insulationofcable.

endsoftie

tie

wire

portion

of

strip

jack plug

1/4-20

jack

cable.from

sleeve.
cable

8-32

sleeve

copper

of

cable

onto

setscrews

and

plug,

vise,

Slide

until

hole

hole

self-tapping

into

(Figure

used

are

4-6)

to

connect

receptacles.

insulation

of

the

uninsulated

vise

approximately

A,

(item

from

mm)

entire

of

and

Figure

endofinsulation.

cable

bringing

diameter

tie

wireistwisted

wire.

and

over

cable.

foil

twisted

cable

tighten

and

along

tightly

over

into

center

(E).

insert

insulating

in

insulating

in

jack

plug

(F);

screw

(F)

plug,

and

jack

Install

from

4-6)

looped

rod

the

around

tie

wire

copper

and

jack

plug

sleeve

sleeve

through

tighten.

weld

the

jack

plugs

one

end

1-3/4

approxi

ends

through

and

side

uninsu

(D).

foil

bottom

into

over

lines

hole

end

ex

in.

is

(C)

(E).

in

jack

up

in

6.

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work

6

Step

Figure

the

clamp

4-5.

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remaining

handle.

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insulating

Installation

sleeve

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1

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TB-025

the

190-IA

other

AU

B~

Ecj~--1

F?

FIgure

4-6.

~

Jack

U

~L

Plug

Installation

113

336

~1

S-0023

Page

13

4-7.

WELD

POLARITY

4-8.

MWG-200.WELDING

GUN

CONNECTIONS

POSITIVE

WARNING:

ING

a

can

nections.



Do

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Shutdown

ing

any

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welding.

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before

IMPORTANT:

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2.

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them

Connect

TIVE

Connect

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()

jack

(+)

output

Connections,

receptacles;

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+

ELECTRIC

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burn

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in

receptacles.

weld

jack plug

For

reverse

five

welding

lock

change

twistlock

jack

on

plug

output

from

receptacle.

Electrode

cable

becomes

NEGATIVE

SHOCK

or

damage

electrical

powersource

connections.

plug

position

plug

plugs

weld

cable

of

twistlock

in

selected

1/4

from

parts.

turn

receptacle.

work

cable

NegatWe/Straight

connections

negative.

can

kill;

electrical

before

plug

receptacle

clockwise

unit

into

NEGATIVE

into

to

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ARC

con

mak

while

to

POSI

Polarity

output

WARNING:

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nect

procedures

Lockout/tagging
input

line

ing

tagging

device.

A.

Gun/Feeder

And

Figure

IMPORTANT:

assembly.

gun

1.

Open

2.

Loosen

(Figure

IMPORTANT:

the

of

tip

ble

without

Insert

3.

let

guide,

power

as

bly

4.

lighten

5.

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Do

not

Shutdown

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power

disconnect

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4-8)

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access

the

4-7).

Wire

the

guide

touching.

the

gun/feeder

through

source

illustrated

the

gun/feeder

and

secure

ELECTRIC

touch

live

electrical

welding

power

before

powersource,

employing

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procedures

from

plug

switch

from

fuse

box,

breaker

Connector

outlet

guideisprovided

door.

gun/feeder

guides

isasclosetothe

front

in

connector

should

connector,

the

access

panel

Figure

connector

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113

336

Page

15

The

socketsonthe

nated

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when

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and

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red

113

336

Page

17

CAUTION:

a

1.

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113336

Page

5-1)

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Under

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unit

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normal

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loading,

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Figure

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wire

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the

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set

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336

Page

313-C

relay

less.

cir

wire

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TIME

wire

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19

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336

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Do

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.030

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Table

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Receptacle

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values

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Inches

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For

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4

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3.4+

150180

175-220

336

Page

21

6-2.

GAS

(Models

WARNING:

4A

tion

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336

Welding

in

Page

METAL

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6-2

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6-2.

Checking

Weld

Parameters

Weld

Appearance

Dark

blue

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pulled

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lower

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piece

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spot

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voltage

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fin

thru

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ON

Section

6-2

parameters.

ON

.

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6-2

parameters.

TIME

TIME

to

to

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.

reset

~

6-3

SHUTTING

1.

Stop

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Shut

down

7-1.

ROUTINE

IMPORTANT:
this

unit for

maintained
when

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cautionary

Table

Frequency*

Month

Every

6

Every

Months

*Frequency

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if

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DOWN

welding

MAINTENANCE

six

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clearly

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7-1.

MaIntenance

Units

ments:

clean

Check

All

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legibility.

in

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drive

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months

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precautionary

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Section

state

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Schedule

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and

113

336

Page

23

A.

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This

unit

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maintenance

no

Section

to

internal

B.

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tion

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113

336

Page

Motor

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WARNING:

SRi

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BOARD

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employing

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ELECTROSTATIC

damage

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INSTALLATION

damage

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PRESSURE

minimal

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grounded

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boards

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at

only

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boards;

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removing

ELECTRIC

touch

welding

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or

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elect

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the

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series

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occur,

out

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be

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REPLACEMENT

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can

parts.

wersource,

locko

ut/tagging

maintaining,

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or

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DISCHARGE

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wrist

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or

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rica!

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or

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coil

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of

and

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kill.

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pro

orserv

removing

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remov

off

and

red

a

113

336

Page

27

MOVING



HOT



Troubleshooting

fied

itisassumed

Section

to

ing

with

the

function

Keep

SURFACES

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persons.

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4

PARTS

from

away

cooling

the

unit

this

of

of

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moving

can

period

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to

was

properly

manual,

the

cause

serious

parts.

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servicing.

performed

installed

the

operator

welding

only

power

Table

Injury.

burns.

quali

by

accord

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source

7-2.

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to

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following

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the

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output;

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to

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metal

link

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liners

4-11).

Section

Section

7-2.

7-2

to

(see

and/or

metal

7-6).

gun

113

336

Page

28

Table

7-2.

TroubleshootIng

(Continued)

TROUBLE

I

Electrode

while

ing

Unit

shuts

welding.

No

open-circuit

Wire

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circuit

voltage

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time

SPW-1

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wire

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7-6).

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Section

113

336

Page

29

SECTION

ELECTRICAL

8

DIAGRAMS

A

B

C

54

2

3

4

NEGATIVE

Circuit

CircuIt

DIagram

CONT.

SPOT

7,

9

8

8-1.

Diagram

PC5O

Diagram

No.

B-121

827

113336

Page

62

For

56

SPW-1

Circuit

Panel

Diagram

No.

A-090

568-A



8-2.

DIagram

30

CircuIt

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SECTION

9

WELDING

TECHNIQUES

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CONTINUOUS

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techniques

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in

the

113

336

Page

31

Direction

of

Arc

Travel

DirectionofArc

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The

vertical

the

direction

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the

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kept

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techniques

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ing

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ger

for

the

113

336

during

GAS

METAL

Figure

welding

the

period

placed

of

in

period

is

depressed,

of

length

Page

time

32

Vertical

ARC

9-6.

the

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the

the

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Figure

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in

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FIgure

9-8.

Fender

RepaIr

WIth

Spot

Nozzle

113

336

Page

33

PLUG

9-4.

welds

Plug

where

metal

normal

sheet

pulsed

throughs.

hole

together,

weld
welds

metal

in

the

can

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thickness

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made

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time

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9-6.

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TROUBLESHOOTING

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each

that

ARC

1.

inadequate

2.

Wrong

3.

Dirty

Possible

shielding

gas.

welding

wire.

Causes

gas

coverage.

~

Figure

Remove

Check

Eiminate

welding

Place

Increase

Decrease

entrapment

Hold

Check

Use

Use

9-9.

PorosIty

gas

arc.

nozzle

gun

for

welding

clean

spatter

hoses

drafts

1/4

flow

gas

excessive

air

of

end

at

frozen

grade

and

dry

Corrective

from

the

for

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fans,

(from

5/16

to

to

displace

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in

the

of

weld

C02

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shielding

welding

Actions

nozzle.

gun

open

in.

flowtoavoid

weld

until

(6-8

all

zone.

molten

gas.

wire.

mm)

air

lowmeter.

doors,

from

from

turbulence

metal

etc.)

blowing

workpiece.

weld

the

solidifies.

zone.

and

into

the

the

113

4.

5.

336

Workpiece

Welding

Page

wire

34

dirty.

extends

too

tar

out

of

nozzle.

Eliminate

conduit.

or

Remove

dirt

from

Use

more

a

Welding

pick

all

work

wire

up

grease,

surface

highly

should

of

oilorlubricant

moisture,

oil,

before

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extend

1/4

on

rust,

welding.

welding

in.

(6

welding

paint,

wire.

out

mm)

wire

from

feeder

undercoating,

of

nozzle.

and

B.

1.

Excessive

Excessive

shielding

Spatter

Possi

ble

tter

spa

gas.

Causes

when

using

C02

Select
SPEED

lower

control.

voltage

Corrective

or

range

Actions

adjust

FINE

TUNING/WIRE

C.

incomplete

1.

2.

3.

Fus

Poss

Workpiece

Insufficient

improper

weld

ion

ible

dirty.

he

at

input.

ing

(Lackoffusion)

?

Figure

Causes

technique.

..

~

~

9-10.

Clean

paint,

Select

SPEED

When
side

Provide

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Provide

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surfaces

dirt,

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higher

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using

walls

of

the

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~

.~

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Corrective

of

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voltage

weaving

range

technique

groove.

access

directedatthe

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or

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(grease,

FINE

dwell

momentarily

of

joints.

edge

oil,

moisture,

TUNING/WIRE

of

the

puddle.

rust,

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on

D.

Lack

1.

Improper

2.

Improper

3.

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of

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Poss

joint

weld

ibie

Causes

preparation.

technique.

he

at

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Figure

~

Lack

9.11.

Material

adequate

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istics.

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(see

Keep

Select

Reduce

Be

sure

~

of

too

to

normal

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arc

on

higher

the

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thick.

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provide

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gun

9-1).

leading

voltage

travel

speed.

wire

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preparation

of

range

extends

to

wire

to

and

access

angle

edge

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the

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and

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speed.

in.

(6

design

of

and

maximum

mm)

must

the

groove

character

arc

penetration

out

of

nozzle.

be

while

113

336

Page

35

E.

Excessive

Penetration

(Burn-Through)

1.

F.

1.

2.

G.

Excessive

Cracks

Improper

Heat

shrinkage

Waviness

Possible

In

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Possible

joint

input

of

Causes

heat

input.

Metal

Causes

preparation.

~

too

high

causing

distortion.

and

Bead

Figure

excessive

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9-12.

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increase

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adequate
maintaining

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lower

travel

too

to

lower

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speed.

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thick.

provide

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and

and

bottom

the

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reduce

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design

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and

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speed.

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the

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speed.

be

while

character

H.

113

1.

2.

1.

336

Welding

Unsteady

Humping

Excessive

Page

36

Possible

wire

extends

hand.

Possible

heat

Causes

too

Causes

input.

far

out

Figure

of

nozzle.

-13.

9

Welding

Figure

Waviness

Support

.

9-14.

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lower

in

wire

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small

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of

should

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on

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extend

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range

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allow

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in.

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to

mm)

travel

cool

of

out

speed.

between

nozzle.

welds.

SECTION.

10

AUTO

BODY

REPAIR

APPLICATION

CAUTION:

vehicle

a

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components.

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sible

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POINTERS

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SHEET

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of

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plete

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clamp

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to

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leadtothe

IMPORTANT:

terials

nect

negative,

10-2.

The

used

or

1.

2.

3.

output

RECEPTACLE

POSITIVE

such

as

for

direct

electrode

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following

when

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high strength

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powerwire

bare

metal
inches
should

ing

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ting

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be

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away

vehicle.

a

work

avoid

to

sure

guntopower

be

100

this

equipment

same

be

to

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path.

dioxide

lead

selector

For

18

gauge

current

are

this

steels:

in

the

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damaged

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piece

section

WELDING

computers

both

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long

work

to

percent

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the

FOR

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as

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learn.

to

and

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attached

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shielding

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reverse

wire

to

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basic

some

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brush

area

on

mm)

for

applying

metal

hand

of

sheet

The

new

one

by

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as

electrical

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cables

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source

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of

vehicle.

weld

to

welds

on

flat

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sure

of

paint

the

to

paths.

are

risk,

on

finished

position

that

and

pails

grounding

0.6

or

mm)

gas.

polarity

polarity

the

place

in

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connect

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penetration

and

mm)

polarity

positive).

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guidelines

source

power

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to

repaired.

either

side

body

using

grinder

steel

material

inch

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can

electronic

other

before

weld

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a

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workpiece.

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thicker

on

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STEELS

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to

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to

of

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hand

with

the

section

should

overlap

mm).

dam

weld

pos

cable

tight.

the

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piece

of

this

is

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and

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to

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ma

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which

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4.

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at40to

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Install

6.

7.

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the

place

material

new

the

edge.

peatable

8.

Begin

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ners.

9.

Space

around

(5

mm)

IMPORTANT:

the

repair

10.

Afterwelding,

surface.

to

11.

Smooth

PROCEDURES

10-3.

IMPORTANT:

will

have

his

cedures.

how,

the

If

the

marily
repai

1.

in

most

job

door

in

red

Remove

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easier

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without

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trol

mechanisms,

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with

edges

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FIgure

the

new

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50

percent

position.

the

spot

shielding

the

spot

spot

repair.

in

as

spot

about

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up

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spot

welding

may

welds

diameter.

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will

this

remove

the

joints

nozzle

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not

Every

method

own

this

cases,

and

less

is

severely

outer

panel,

necessarily

exterior

remove

door

assembly,

of

door

room

Inner

Flange

10-1.

Cutaway

metal

in

place,

and

the

nozzleonthe

and

gas

must

from

occur

1

make

promote

with

FOR

and

1/2

be

if

to

welds

the

body

power

3/4

to

tight

the

welding

1/2

should

continuous

distortion

clamp

WELDING

experienced

of

performing

information

this

welding

time

consuming.

damaged,

or

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molding

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lock

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and

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work.

to

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Edge

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and

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percent,

selector

gun.

source

firmly

press

in.

(12-18

to

assure

center

out

begins

in.

(25-38

be

about

welds

and

and

grind

filler

and

DOOR

autobody

the

ispresentedto

powersource

but

the

the

and

damage

door

whole

a

hardware.

regulator,

on

place

over

edges

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Damage

Door

InneT

Skin

Of

Crimped

Door

Panel

to

spot

the

burnback

switchtothe

turned

against

mm),

on,

the

from

good,

each

at

mm)

side.

the

apart

3/16

around

cor

on

warpage.

spotflush

finish.

PANELS

repairman

following

can

remote

flat

Flange

can

be

new

It

surface

of

surface

TA-087

pro

show

make

is

pri

easily

door.

is

con

Damage

113

336

Page

re

in.

not

297

37

3.

4.

5.

6.

7.

8.

9.

door

if

weld.

Grind

Repair

Position

end

flange

weld

Spot

panel.

weld

Spot

Metal

trim

terior

has

off

the

any

the

finish

and

outer

an

hem

damage

new

over

outer

hem

new

exterior

hardware.

panel

flange

to

outer

inner

the

panel

flange

surface,

reinforcement,

and

remove

inner

the

panel

panel.

overdoor

flange.

reinforcement

inner

to

paint

the

and

to

panel.

and

assembly

break

old

bend

new

the

panel.

the

door

in

each

in

cated

inner

panels

replaced.

Welds

case.

must

After

be

carefully

Spot

the

Welds

old

panel

checked,

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is

removed,

the

straightened

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Welds

TA-087

or

2gB

Hem

Flange

Strip

Figure

HOW

10-4.

SPATTER

Spatter

when

keeping

zone

nearwindows,

tected

like

substance

through

ter

become

is

tap

an

argon

10-5.

QUARTER

When

essary

of

the

panel

bolted

be

spot

of

front

often

are

fender

other

If

the

removed

ous

welded

panels

to

inspect

113336

ON

and

welding

them

as

possible.

from

yourwelding

used

being

and

PROCEDU

a

complete

to

remove

structure,

is

welded

in

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fenders

elongated

be

can

panels

whole

panel

by

in

place.

welded

the

Page

or

38

seam,

Outer

Reinforcement

10-2.

PREVENT

TO

WINDOWS

excessive

windows.

near

covered

When

the

windows

excessive

which

supplier.

problems,

forthe

CO

gas

RES

PANELS

panel

the

to

or

in

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while

place,

continuous

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and

and

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heat

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by

reduces

ensure

size

material

mixture

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bolts

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cut

through

In

most

the

seam

simple

that

the

correctly

into

be

replaced,

the

out

body

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determine

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BREAKAGE

become

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using

heat

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that

away

must

be

transfer

burn

the

covered

wet

through

the

correct

being

and

check

FENDERS

be

replaced

the

panel

the

spot

afrontfenderwill

cases

other

panels

welded.

because

position

aligned.

place.

the

old

weldifwelded

the

welds

spot

manufacturers

it

will

so

where

the

problems

windows

from

the

be

performed

and

rags.

is

available

and

welded.

travel

it

will

to

weldsifthe

will

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The

alignment

the

bolt

the

of

new

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panel

continu

by

if

it

have

be

necessary

welds

TA-087

296

AND

by

heat

pro

A

putty

spat

voltage

Use

speed.

AND

be

nec

the

rest

either

holes

front

all

be

must

is

spot

the

lo

are

Figure

bled

The
tion

center

other.Inorder
weld

important

the
this

will

tion.

down,

10-6.

(HSS)

The

omy

gussets,

these
duction

strength

the
ble.

come

the
wider

mended.

10-3.

With

outer

new

vice-grips

by

and

proceed

section

a

only

to

sheet

steel

concentrated

When

filled

WELDING

STEELS

new

Leave

the

HSS

begin.

compact

brackets,

models.

new

and

decreases

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affected

For

this

the

preferred

oxacetylene

heat

Figure

AutomotIve

Continuous

can

panel

or

c-clamp.

first

to

ensure

of

2

constantly

around

weld

with

steels

cars.

are

reason

the

heat

area

a

gap

is

body

putty

FRAMES

are

HSS

floor

HSS

heat

sensitive.Asheat

and

zone

the

method

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affective

10-4.

area,

Application

Body

Seam,

Welds

be

then

When

in

one

reduced

in.

cr3

check

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the

welding

that

and

then

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completed

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AND

used

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and

pans,

steels

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must

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welding

forwelding

or

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are

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all

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STRENGTH

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members

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has

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the

the

heat,

itis

of

in

is

sec

steel

of

re

the

be

and

its

SECTION

11

-

PARTS

LIST

113

336

Page

39

9

10

11

12

16

TD-072507-J

6

Figll-4

5

Figll-2

13

17

Assembly

MaIn

11-1.

Figure

22

1

JFI-~

Gun

934

of

112

33

List

Form

Parts

See

For

23

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Item

No.

Dia.

Mkgs.

Part

No.

Descnption

Quantity

FIgure

1
2

3

4

5
6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28
29

30
31
32
33

11-1

PLG2

GS1

PLG1

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R2

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113

112

112
113
113

113

WRAPPER

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120

785

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210

290

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901
160
978
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178
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899

11-8

120

129
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605
606

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PANEL,
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1
1

1
1
1

1

1

6

1
1
i
1

2

1
1

2

1

i
1
1

i

2

1

1

1
1

2

1

1

4

4ft

1

1

1
1
1

++For

BE

SURE

Parts

ListofGun

TO

PROVIDE

see

MODEL

Form:112

AND

934

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

113

336

Page

41

FIgure

11-2.

Baffle,

-

Air

W/Components

TD-072

509-F

113336

Page

42

item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure

1

2
3

4

5

6

7

8
9

10

11

12
13
14

15
16

17
18
19

20

21
22

23

24

25

26
27

28
29
30

11-2

.

CR2,3

CR1

C6

W

TEl

VR2

SR2

CB1

R3

R5

,2

427

058

980

085

605

941

057

543
745

057

971

057

010191

058

628

428

058

837

026
006393

995

044
072817

083147

907

082

728

031

902

082

875

082

260

034
035 519

024

493

620

038
026

189

685

046

704

035

431

083

122192

741

605
059

642

145

010
006

537

704

052

-

Baffle,

RING,
NUT,
WASHER,

SPRING,
SPRING,
WASHER,

Air

W/Components

retaining

stl

hex

full

flat

cprsn
cprsn

flat

spool

fnsh

stl

.640

.845

2.430

stl

keyed

.625-11

ID

OD

x

OD

1.500

.091

x

(Fig

.090

wire

wire

dia

WASHER,fbrgd265.6561D

brake

term

24VAC

stl

nylon

DPDT

WASHER,

HUB,

spool

INSULATOR,

RELAY,

BAFFLE,

end

air

RELAY,enc124VACDPDT

GROMMET,scr8/10

ANGLE,

CAPACITOR,
STRIP,
ANGLE,

LINK,

connecting

CONTACTOR,

COIL,

LINK,

jumper

BLOCK,

VARISTOR,

RECTIFIER,

CIRCUIT

RH

mtg

elctIt

center

mtg

LH

mtg

cntor

24VAC

term

term

30A

.6W

integ

BREAKERS,

capacitor

20000uf

capacitor

capacitor

contactor

def

175

prp

blk

3P

30A

40A

40A

30A

VDC

600V

man

35VDC

terminal

24V

3P

1

reset

DRIVEASSEMBLY,wire(Figll-3)

CLIP,

RESISTOR,

CLAMP,

RESISTOR,

CLIP,

resistor

mtg

nylon

spring

WWfxd

.500

WW

mtg

25W

fxd

12W

resistor

10

.51

ohm

ohm

11-1

Item

5)

(consisting

P

5A

250V

of)

1

1

I
1
1

1

2

2

1
1
2

1
1

6

1

6

1

1
2
1

1

I
1
1

1

2

1

6

1

2

1

2

BE

SURE

TO

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

113336

Page

43

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

FIgure

1

2

3
4

5

6

7

8
9

10

11

12

13

14

15

16
17
18

19

20

21

22
23
24

25

26

11-3

roll

roll

inlet

hex

roil

sti

motor

.375-16

drive

hair

8

assy

V

.062

roll

assy

no

PM

hexhd

stl

brs

.042

Wire

groove

x

drive

thin

groove

12V

split

barbed

roll

feeder

x

1

.250

122

192

605
072
057

605

058 360
058

072

010918
057
058

605

058

010929

M



119

130820
057432
079
602

010910
044
601

079

120

079

058359
604

23456

1

Drive

Assembly,

854

649

590

287

363

585

RING,
BEARING,
GEAR,

KEY,

SHAFT,
COVER,
BEARING,

retaining

drive

drive

woodruff

drive

drive

drive

PIN,springCS.156x1.500

551
549

525

553

SPRING,
GUIDE,

NUT,

GEAR,

wire

stl

drive

pressure

sit

1kg

WASHER,fiatstlspr.375

040

MOTOR,

gear

~BRUSH&SPRlNG

SCREW

624
213

SCREW,
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cap

lock

WASHER,flatstlSAE.375

994

INSULATOR,

838
633

370

772

brs

NUT,

FITTING,
HOUSING,
KNOB,

plstc

hex

hose

PIN,pivot

741

PIN,

cotter

7

(Fig

wire

.030-.035

wire

rofl

.312-24

1/25hp

slflkg

.375

.937

9

11-2

item

.024 wire

(consisting

.375-16

3/16TBG

nipple

wire

25)

of)

2

1
1

2

1

1

1

1
I
1

1
1
1
1
2
2
1
2

1

1

1

1

1

1

1

1

BE

113

SURE

336

Page

26

TO

44

25

24

PROVIDE

23

22

MODEL

21

AND

18

FIgure

SERIAL

20

11-3.

NUMBER

DrIve

18

17

Assembly,

WHEN

ORDERING

Wire

3

REPLACEMENT

PARTS.

TC-072

511

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure

1

2

3
4

5
6

7

8

9

10

11-4

FM

SRi

TP3

Cl

TP1

-4

032678

032

662

125947

089

733

057

496

037

306

086

323

037 305

080

894

604515

-

Panel,

Rear

W/Components

MOTOR,1/5Ohp23OVAC1500RPM

fan

rect

rect

2

lOin

si

mtg

150A

150A

5wg

diode

fan

NO

cer

NC

motor

300V

300V

disc

3

(consisting

RP

SP

.01

ufI000

BLADE,

PANEL,rear

RECTIFIER,

BRACKET,

DIODE,

THERMOSTAT,

DIODE,

CAPACITOR,

THERMOSTAT,

(FIg

of)

VDC

11-1

Item

6)

1

1

1

1

1

2

1

2

4

1

1

TD-072

508-B

Figure

11-4.

Panel,

Rear

-

W/Components

BE

SURE

TO

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

113

336

Page

45

113

336

Page

TB-131

148

Figure

46

11-5.

Panel,

Front

-

W/Components

Item

No.

FIgure

Mkgs.

11-5

Dia.

Part

No.

Panel,

Front

Description

-

W/Components

(Fig

11-1

Item

Quantity

20)

1
2

3

4

5

6

7

8

9

10

11
12

13

14

15

16
17 Ri
18

19

20

21

22

23

24

25

26
27
28

29

30

31

32

33
34

35

36

37
38

39

40

41

42

43

44

RC3

RC1

PL1

Si

039

091

010

604

605

601

+119

113

119191

113

073
052
039

010291

604
605
601

091 541
605828
048

079

090328

097

057

601
605 787
604

010

072
023
039

602
026

101

602

019

600

048
010
044

600

039
019833

602

101

602
602

801

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542

291

668

787

881

543

604

RECEPTACLE

WASHER,

sti

NUT,

WASHER,

.

stl

NUT,

NAMEPLATE,
LABEL,

Auto

PANEL,front

472

COVER,

383

RECEPTACLE,

236
800

PLUG,
RECEPTACLE,

3

WASHER,flatnyiafil.6251D

668
787

681

sti

NUT,

WASHER,

sti

NUT,

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RHEOSTAT,WW5OW1.5ohm

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282

534

TERMINAL,

SWITCH,tgl

924

608
881

668
291

334

084
878
160

975

219
178
833
318

573

325

943
318

608

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.

.

.

.

CABLE

.

LIGHT,
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PLUG,

pointer

stl

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WASHER,

stl slf

NUT,

WASHER,

RECEPTACLE

&

PLUG

ASSEMBLY

SCREW,
INSULATOR,

PLUG,

.

SCREW,
STRIP,

CABLE,

md

jack

CABLE,

PLUG

ASSEMBLY,

STRIP,

178
219

814

160

.

SCREW,
PLUG,

.

INSULATOR,

. .

SCREW,

jack

&

NUT,

flat

nylafil

slf

hex

1kg

lock

sti

hex

jam

.500-20

(order

Arc

warning

Auto

Arc

open

3skt

MS-3106A-14S-IP

pin

jack

slf

hex

1kg

lock

stl

hex

jam

.500-20

&

NUT,

W/SOCKET,

female

DPST4OA600VAC

jack

hex

PLUG,

jam

lock

stl

hex

1kg

flat

nylafil

&

jack

slftpg

.500-20

NUT,

8-32

jack

5/8x2-5/8

jack

set

sch

sti

.010

cop

weld

red

strain

red

weld

cop

set

jack

x

strd

cop

lens

relief

(consisting

strd

cop

.010x2.500x.750

stl

sch

5/8

x

jack

8-32

slftpg

blk

plug

med

intl

by

(consisting

jack

plug

.625

ID

fnsh

.500-20

.500

tooth

model&serial

module

MS-3102A-14S-1S

red

plug

med
intl

(consisting

fnsh

tooth

.500

jack

plug

.500-20

(consisting

plug

Intl
med

yellow

tooth

fnsh

.625

jack

(consisting

.500

.500-20

ID

plug

(consisting

(consisting

.250

x

plug

.250-20

2.500x.750
No.

28V

.840

of)

(yellow)

3

(order

ID

of)

No.

3

(order

(consisting

.250-20

2-5/8

plug

.250

x

of)

(red)

blk

red

yellow

of)

by

by

of)

number)

of)

of)

of)

ft)

ft)

1

1

1
1

1

1

1

1
1

1

1

1

1

2
1
1
1

1
1
4

1
1

6

1

1

2

1
1

i
1
1

I

1

2

1

3ft

1
2

1

2ft

1
1

2

1

1

1

+When
BE

SURE

ordering

TO

PROVIDE

a

component

originally

MODEL

AND

displaying

SERIAL

NUMBER

a

precautionary

WHEN

the

label,

ORDERING

label

should

REPLACEMENT

also

be

ordered.

PARTS.

113336

Page

47

item

No.

Figure

1

2

3

4

5

6

7
8

9

10

11

12

13

14

Mkgs.

11-6

PLG5I
PLG5O

Dia.

R50

R51
R52

550

R53

PC5O
RC55

Part

No.

028

769

028

770

768

028
086

895

073

914

605 890
080509
072

669

079

798

097

897

008

072

058

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086650

471

113

097

922

Description

1

SPW

POTENTIOMETER,
POTENTIOMETER,

POTENTIOMETER,
SWITCH,
WASHER,

RESISTOR,

Panel

Spot

rotary

centering

WW

(Optional)

C

sitd

C

sltd

C

sitd

3

position

.437

fxd

15W

GROMMET,scrNo.8/10

HOUSING,

HOUSING,

CIRCUIT

HOUSING

TERMINAL,

term

term

CARD,

PLUG

male

header

header

dual

9

13

timer/pulser

&

PINS,

PANEL,spottimerSKP-35

NAMEPLATE,

KNOB,

pointer

(order

by

model

lIT

2W

750K

lIT

l/T

ohm

2W
2W

sft

sft

dia

.25

pin

pin

(Fig

(consisting

&

serial

9

8

ohm

1

meg

350K

11-7)

of)

number)

ohm

ohm

Quantity

1
1

1

I

2

I

3

1
1
I

1

8

I

1

4

1.

10

3

2

14

4

7

5

1

12

FIg

11-7

BE

113336

SURE

Page

TO

48

PROVIDE

MODEL

Figure

AND

11-6.

SERIAL

SPW

NUMBER

1

Spot

WHEN

Panel

ORDERING

(Optional)

REPLACEMENT

PARTS.

TC-086

924-

Dia.

Mkgs.

Part

No.

Description

Quantity

FIgure

11-7

PC5O

A50

,51

C50

C51

,53,55

C52,56

C54,57,58

C59

CR50

CR51
CR52

D50-54,57-66

D56

050,51

052

R50
R51

R52,71

R53,57,61

,68,70

R54,56,59,

60,62,66,67

R55,58

R63

R64,69

R65

RC5O

RC51

PLG5O

097

009
039482
032
073
073

090

027810

099
099
079844

091

026202
037449
037200
073

030018
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035884

039331

035
035

039 333
039

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092
079

072

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897

159

820

714

739

573

019
018

861

535

827
886

327

648
795
670

798

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Card,

(Fig

IC,Iinear358

end
end

end

holddown

relay

rect

zener

elctit
tantim
tantlm

cer

eictlt

24VDC

24VDC

24VDC

1

A

15V

CAPACITOR,
CAPACITOR,
CAPACITOR,
CAPACITOR,
CAPACITOR,

RELAY,
RELAY,

RELAY,

SPRING,

SOCKET,

DIODE,

DIODE,

TRANSISTOR,

TRANSISTOR,

RESISTOR,

RESISTOR,
RESISTOR,

RESISTOR,

RESISTOR,

RESISTOR,

RESISTOR,

RESISTOR,
RESISTOR,

C

CF
CF
CF

CF
CF

CF
CF
CF

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TERMINAL,
TERMINAL,

HOUSING,

header

header

term

l4skt

400V

NPN

NPN

1W

.25W
.25W

.25W

.25W
.25W

.25W

.25W
.25W

header

11-6

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mono

lOut

1W

820

item

2.2uf

.22uf

.luf

50V

4PDT

SPST
SPDT

relay

SP

SP-55

200MA

100MA

ohm

100
lOOK

4.7K

10K

22K

18K

220

3.3K

zero

13

pin

9

pin

35VDC

35VDC
35V

ohm

ohm.
ohm.

ohm.

ohm

ohm..

13

10)

5OVDC

40V

60V

ohm

ohm

ohm

pin

2

1

3

2

3

1
1
1

1

1

1

15

1

2

1

1

2

5

7
2

1

2

1
1
1
1

1

+Not

BE

part

SURE

of

circuit

TO

card

PROVIDE

MODEL

AND

0

CD

CDCD

00

_____

055
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AS~Y

11-7.

NUMBER

Q51



r

~

~

1+

R53

CIrcuit

-,osolli

C53

R64

-

PRSTUVWXY

097897

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CD

I

~

PC5O

ORDERING

I

RC5I

C52

R56

R57

D58

~

D60

+

I

0

C-097

896

REPLACEMENT

PARTS.

113336

Page

49

Item

No.

Part

No.

Description

Quantity

FIgure

1

2
3
4

5

6

7

8

9

10

11

12

13

14

15
16

17
18

19
20

11-8

108

940

025

193

604423

057

478

022

617

602389
602

387

602

384

052

693

602

250
032524
070

799

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692

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211

601

869

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999

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HANDLE,

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sti

cap

running

hexwhd

gear

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BRACKET,

CHAIN,

support

cyl

racks

tank

(consisting

HOOK,Sbluntl-1/2in
CHAIN,
SNAP,

RACK,

WASHER,

cotter

PIN,
WHEEL,
AXLE,

SCREW,
WASHER,

sti

NUT,

CASTER,
ANGLE,
WASHER,

stl

NUT,

weldless

chain

cylinder

flat

stl

.187x

rubolene

running

cap

hex

gear

stl

lock

jam

plastic

spreader

lock

hex

jam

hexhd

stl

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stl

.375-16

2/0

SAE

1.500
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split

swvl

cyl

split

27in

x

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dia

.312-18

.312

4in

rack

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of)

4

1

2

1
1
1
1
1
1

4

2

2
1

4

4

4

2

1

2

2

BE

113

19

SURE

336

Page

TO

50

PROVIDE

MODEL

AND

/

Figure

SERIAL

11-8.

NUMBER

RunnIng

WHEN

Gear

ORDERING

REPLACEMENT

PARTS.

10

TC-049

808-

p1

1%