Miller Electric SPW-1, MW 4200, MW 4150 User Manual

AUTO

ARCJ~

May

1991

Effective

With

FORM:OM-113

Serial

No.

336D

KA898403

MODEL:

AUTO

AUTO
SPW-1

ARCfi

ARCfi

MW
MW

4150

4200

OWNERS

IMPORTANT:

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MILLER

AMIerGroupLld..Company

Appleton,

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ELECTRIC

Box

1079

WI

414-734-9821

54912

USA

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PRINTED

IN

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Model

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No.

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1-1.

1-2.

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Description



SAFETY

Introduction

General

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1
4

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Designa

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SAFETY

2-

2-1.

2-2.

General

Safety

3SPECIFICATIONS

3-1.
3-2.
3-3.
3-4.
3-5.
3-6.
3-7.

Volt-Ampere
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Supplied

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4INSTALLATION

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.

Site

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6
6

8

8

8

8

9
10
10

10

10

11
11

12

12
14

14

14

16
16
16

18

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.
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5OPERATOR

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19

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21

22
23

24

25
26

26

27
27

28

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SECTION

SECTION

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8

Diagram

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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.

8-2.

8-3.
8-4.
8-5.

WELDING

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30

31
31

32

33

34
35
36
37
37
37

40

40
40

41

41
41

Section

No.

Page

No.

SECTION

Table

Table
Table

Table

Table

Table

11

Figure
Figure
Figure

Figure

Figure

Figure
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Figure

Chart
Chart

4-1.

6-1.

6-2.

7-1.

7-2.



PARTS

11-1.

Main

11-2.

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3-1.
3-1.

3-2.

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42

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46

47

48
50

51

52

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22
23

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29

SECTION

1

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SAFETY

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6

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Gas

Hose

Measure

source.

ameter,

thread

D.

Selection

Metal

choose

ing

ety

cated
classes

E7OS-6
flatter

wire.

E.

When

or

helmet,

eyes

safety

F.

The

distance

Obtain

S.A.E.

fittings

Wire

Spool

of

Arc

Welding

from,

thin

gauge

(AWS)

classification

the

on

recommended

provides

bead

Personal

using

fitted

the

from

glasses,

Offset/Punching

of

repair

OffsetlPunching

rotating

pose,

The

damaged

of

portion

When

small

a

steel,

set

portion.

place,

The
used

riveting

use

the

pressure

offset

cut

to

size,

The

sanded,

headofthe

as

a

punching

operations.

and

finishing

from

good

gas

both

on

For

the

correct

but

certain

sheet

label

a

more

E7OS-3.

than

Safety

this

welding

with

the

welding

and

automotive

toolisused.

head.

area

head

is

applied

in

the

is

new

filled

tool

time

gas

quality

and

hose,

endsofhose.

GMAW

welding

(GMAW).

wires

The

steel.

for

GMAW

of

the

wire

are

fluid

Obtain

Equipment

power

proper

Also

arc.

Tool

sheet

cutaway

are

placed

to

sheet

steel.

in

of

piece

body

be

can

tool.

The

use

minimum.

to

a

to

the

gloves

is

placed

with

The

cylinder

in.

5/8

install

Process

wire

There

are

American

spool.

E7OS-6

(wetter)

source,

filter

wear

prevent

(Figure

steel

This

and

over

handles,

A

position

sheet

putty,

rotated

punching

of

this

tool

to

welding

(16

mm)

5/8-18

is

important

are

many

best

suited

Welding

wires

is

usually

Two

and

E705-3.

weld

puddle

a

spool

wear

to

lens,

protective

injury.

3-4)

is

easier

tool

hasadual

the

jaws

the

sheet

the

new

piece

to

overlap

steel

is

welded

finish

and

one-half

tool

will

keep

power

outside

di

right-hand

in

Gas

types

for

weld

Soci

indi

AWS

wire

The

and

of

selected

a

welding

protect

the

clothing,

when

an

pur.

of

the

offset

steel.

tool

indents

of

sheet

the off

into

sanded.

turn

to

be

expedites

material

to

a

Hose

Gas

Figure

3-3.

Helmet

Wire

Spool

Li.

Safety

Glasses

Additional

Regulator/Flowmeter

Required

Equipment

Gloves

/

1.

I

Figure

3-4.

Offset/Punching

Tool

OM-113

336

Page

9

3-6.

The

capabilities

tions:

OPTIONAL

following

of

A.

SPW-1,

cludes

Section

B.

Spool

Gun

C.

D.

25

ft.

EQUIPMENT

equipment

the

basic

Spot,

three

spot

4-4)

gun

cable

holder

(7.6

m)

can

unit

Pulse,

power

be

obtained

to

or

Continuous

nozzles)

cord

extension.

suit

(for

special

extend

to

applica

Panel

installation

the

(in

see

3-7.

The

following

mal

use:

A.

B.

C.

D.

CONSUMABLE

parts

Contact

Nozzles

liner

Gun

Drive

rolls.

are

tubes

PARTS

subject

to

wear

or

damage

in

nor

4-1.

Select

Base

secure

1.

2.

3.

4.

5.

6.

7.

8.

mounting

SITE

an

Correct

Shielding

Adequate

No

A

Proper

or

Proper

Adequate

for
tions.

location.

SELECTION

Figure

installation

input

gas

ventilation

flammables

clean

and

temperature

cold

airflow

space

installation,

holes

the

unit

on

(Figure

4-1.

site

which

supply

power

supply

area

dry

that

around

for

maintenance,

provide

a

running

SECTION

Location

provides

and

fresh

avoids

unit

opening

the

capability

gear

4-1)

(see

side

or

4

the

unit

air

supply

extremes

access

and

in

a

INSTALLATION

SB-087

313-0

following:

nameplate)

of

heat

doors

func

repair

install

to

permanent

and

a

4-2.

This

for

the
power

4~

~.

RELOCATION

OR

WARNING:

from

placing

surfaces;

cause

internal







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used

TRANSPORTING

welding

moving

lifting

source.

WARNING:



overheating

parts.

locate

not

Do

Maintain
unrestricted

underside

keep

Do

not

place

air

take

cooling

the

eye

Do

Disconnect

intake

at

power

unit

only

not

passages

this

void

is

during

touch

at

source

deenergized

welding

FALLING

personal



Use

gear,

accessories



Use

the



If

the

power

EQUIPMENT

injury

lifting

gas

equipment

unit.

or

lifting

base,

moving

enoughtoextendbeyond

base.

lift

if

or

forks

tips

may

damage

Using

parts

base,

equipment

FIRE

OR

unit

RESTRICTED

allows

on

and

unit

overcombustible

18

least

space

free

filtering

any

unit.

if

any

air

passages.

METHODS

is

equipped

installation.

for

ELECTRIC

live

electrical

input

power

supply

source.

and

equipment

lift

to

eye

cylinders,

devices.

or

of

adequate

this

be

sure

short

too

the

cause

lift

if

of

EXPLOSION

or

over

AIRFLOW

possible

inches

all

sides

on

of

obstructions.

device

that

provide

of

type

filtering

Weight

supporting

SHOCK

parts.

conductors

line

BEFORE

can

unit

only,

or

any

with

unit

lift

that

opposite

can

forks

damage

penetrate

personal

unit

falls

can

combustible

damage

surfaces.

(457

of

over

airflow

with

a

capacity

the

can

cause

damage.

NOT

other

capacity

lift

forks

forks

sideofthe

injury

off

the

result

can

mm)

and

unit,

in

the

for

device

lifting

eye

welding

kill.

from

moving

serious

running

heavy

lift

to

under

are

long

internal

unit

the

and/or

lift

forks.

to

of

is

of

OM-113

336

Page

10

4-3.

a

1.

2.

3.

4.

RUNNING

WARNING:

TIPPING

or

equipment



Use

unit.



If

using

lift

forks

opposite



Do

unit

Place

running

Install

the

bar

onto

er

source

hardware.

Blockthe

lation

of

Slide

axle

wheel

on

each

er

on

Secure

rings.

GEAR

UNCONTROLLED

of

unit

damage.

equipment

lift

forks

are

long

side

not

place

while

it

is

blocks

under

gear.

4

in.

two

the

front

baseashown

unit

up

securely

rear

wheel/gas

through

each

end

side

of

wheels

in

INSTALLATION

result

can

of

adequate

to

handle

enough

of

the

base.

of

part

any

suspended.

frame

of

(102

mm)

corners

in

Figure

in

cylinder

cylinder

of

wheel.

place

axle

with

with

in

personal

capacity

this

unit,

extend

to

the

body

unit

before

casters

of

the

4-2

middleto

rack

rack,

a

3/4

supplied

(Figure

TILTING

to

be

sure

out

under

installing

and

spread

welding

using

ease

assembly.

and

install

in.

flat

retaining

4-2)

OR

injury

lift

the

the

of

the

the

power

in.

3/8

instal

a

wash

6.

7.

8.

4-4.

a

Install

5.

base

using

ciated

Remove

power

ning

gear

screws

cap

Install

cylinder

power

x

3/4

cap

Install

OPTIONAL

(Figure

WARNING:



Do



Shut

connect

ging
ing.

Lockout/tagging

input

ing
locking
removing

and

red-tagging

necting

cylinder

5/16-18

hardware

the

two

source

source

safety

handle

as

screws

chain

wrapper

shown

bracket

as

SPW-1

4-3)

ELECTRIC

touch

not

down

welding

input

procedures

power

line

disconnect

fuses

device.

rack

onto

x

3/4

(see

Figure

front

cap

onto

wrapper

in

onto

and

onto

live

power

before

in

existing

PANEL

electrical

power

shown

procedures

plug

from

fuse

circuit

welding

screws

cap

4-2).

screws

and

discard.

using

rear

4-2.

panel

Figure

Figure

holes

cylinder

INSTALLATION

SHOCK

parts.

source,

employing

inspecting

consist

from

receptacle,

in

switch

box,

breaker

or

top

source

and

of

welding

Install

power

in

1/4-20

of

using

in

rear

welding

4-2

bracket.

kill.

can

and

lockout/tag

install.

or

of

remov

position,

open

or

shutting

other

discon

asso

run

x

3/4

1/4-20

panel.

dis

pad

off

Nut

Spreader

Bar

Casters

Cylinder

Nut

Washer

Cap

Screw

Safety

chain

Washers

Flat

Washers

Flat

Cylinder

Rack

Axle

SC-049

.wheel

808-E

Figure

4-2.

Running

Gear

Installation

OM-113

336

Page

11

IMPORTANT:

during

such

the

Remove

hand

Locate

move

pull

ly

for

as

corner

wiring

capabilities

moved

tions,

for

facing

1.

2.

through
through

3.

Disconnect

4.

Connect

PLG2.

er

(see

Install

5.

front

panel,

1.

Step

SPW-

1

Spot

the

Spool

right,

of

front

harness

wiring

gun.

are

cover

in

this

procedure

left

or

front

panel.

module

wiring

harness

of

end

opening

approximately

jumpered

receptacle

Be

Figure

SPW-1

sure

and

the

connectors

4-3).

panel

secure

will

Panel

Retain

for

reinstallation.

with

respect

plate

panel.

clamped

from

first

harness

front

panel

in.

2

(51

connector

RC55

from

into

upper

using

not

all

from

to

clamp

with

mm).

from

SPW-1

are

screws

provide

hardware

the

to

upper

air

baffle.

and

connectors



will

it

plug

locked

right

removed

All

opera-

careful

PLG2.

panel

togeth

corner

spot

re

direc

right-

Re

come

to

of

in

WARNING:

a

rupture

loss

serious





causing

of

life;

injury

Keep

cylinders

electrical

allow

Never

cylinder.



Always

bracket,awall,

gear

port.

B.

Regulator/Flowmeter

ure

4-4)

With

1.

2.

the

cylinder

der

cylinder

gas

dure

cumulated

The

equipped

for

(see

cap

valve,

from

flows

rid

gets

around

regulator/flowmeter

with

with

use

cylinders.

not

A

use

gasket

IMPORTANT:

leaks.

Do

PRESSURIZED

serious

FALLING

and

away

circuits.

a

welding

fasten

cylinder

correctly

Figure

and

open

cylinder,

of

dust

any

the

a

stem,

either

CO2

should

lubricants

personal

CYLINDERS

equipment

from

electrode

securely

other

or

(Customer

installed,

Stand

4-4).

the

close

dirt

or

valve

must

nut

connectors,

cylinders

be

or

sealing

CYLINDERS

damage.

welding

stationary

Supplied)

remove

to

one

valve

slightly.

valve.

that

may

seat.

be

or

installed

agents.

can

and

injury

can

cause

other

or

touch

to

to

running

any

sup

(Fig

cylin

sideofthe

When

This

proce

have

properly

and

gasket

Argon/CO2

to

prevent

ac

Plug

PLG2

Receptacle

RC55

SPw-1

Panel

Spot

4-5.

A.

Gas

Secure

on

cylinder

chain

cylinder

the

vent

valve.

OM-113

336

_....~

._~

FIgure

SHIELDING

Cylinder

cylinder

gas

bracket.Ifthe

to

cylinder

Page

SPW-1

4-3.

GAS

(Customer

to

wall

from

12

INSTALLATION

running

running

other

or

falling

Panel

Installation

Supplied)

using

gear

gear

stationary

and

over

(Figure

safety

is

not

to

support

breaking

be

3-3)

chain

used,

to

pre

off

the

Install

3.

the

vertical

onto

A

4.

rear

connections.

this

to

10

WORK

ft.

4-6.

A

supplied

onto

plug

A.

Work

1.

Insert

lug

sleeves.

2.

Lay
clamp

3.

Align

with

cure

supplied

4.

Bend

dle

Slide

5.
the

regulator

gas

of

face

position,

cylinder.

gas

shielding

the

of

welding

fitting.

output

the

regulator/f

CABLE

cable

(3

m)

with

the

unit.

the

cable,

Clamp

end

the

it

on

through

work

the

which

smaller

the

the

hole

terminal

the

nut

the

tabs

around

the

insulating

work

clamp

onto

the

regulator/flowmeter

and

output

gas

power

Attach

Attach

lowmeter.

ASSEMBLY

with

a

To

install

one

lug

proceed

Installation

the

work

of

one

cable

inside

the

hole

work

the

lug

bolt.

the

on

cable.

work

sleeveonthe

handle.

flattest

to

end

has

in

and

the

cylinder

gas

tighten

fitting

source

end

other

attached

the

work

follows:

as

(Figure

cable

of

two

the

inner

in

work

the

cable

the

work

of

the

endofthe

supplied

stem

is

provided

for

of

the

clamp

4-5)

with

handle

surface.

clamp

terminal

clamp

work

work

valve;

gauge

nut

securely

making

hose

gas

gas

to

one

and

the

terminal

insulating

of

the

handle

lug.

with

clamp

cable

keep

in

at

hose

end

work

the

the

gas

to

is

jack

Se

the

han

over

Gas

Connection

(5/8.18

Fitting

Hose

Male

Required)

Regulator

CO2

CO2

Washer

Installation

CO2

Cylinder

Gas

Connection

(5/8-18

Fitting

Hose

Male

Required)

Argon

Installation

Argon

Argon

Mix

Or

Cylinder

SB-109

492-A

B.

6.

Step

Jack

Slide

other

4

Figure

Plug

the

remaining

work

clamp

Step

4-5.

Installation

Work

Figure

insulating

handle.

Step

Steps

Clamp

(Figure

4-4.

sleeve

6

1

and

5

Installation

4-6)

Typical

over

3

Step

Regulator/Flowmeter

the

5.

Insert

looped

Twist

6.
is

tight

Cut

Bend

(C)

Wrap

lated

Push

off

of

7.

8.

9.

10.

AU

B~

0250

Installation

in.

3/8

a

endsoftie

wire

tie

(B)

around

looped

twisted

the

uninsulated

the

portion

the

of

strip

of

jack plug

(9.5

mm)

wire.

until

entire

insulation

endsoftie

tie

wire

portion

onto

foil

and

cable

copper

cable

U

diameter

tie

of

cable.

wire.

over

of

cable.

tightly

twisted

over

wire

and

rod

is

twisted

along

around

tie

wire

copper

through

and

the

side

uninsu

(D).

foil

(E).

The

cables

onto

1.

2.

3.

4.

supplied

to

the

weld

cables

Remove
end

of

Clamp
tending

(44

mm).

Place

mately

Make

ends

of

jack

weld

3/4

each

cable

upward

steel

1/4

half

a

tie

plugs

output

follows:

as

in.

weld

in

a

tie

wire

in.

(6

turn

wire

out

used

are

receptacles.

of

mm)

(19

cable.

with

vise

the

vise

of

approximately

(itemA,Figure

from

mm)

around

cable

together.

the

jack

from

end

weld

plugs

to

connect

Install

insulation

uninsulated

1-3/4

4-6)

approxi

endofinsulation.

bringing

looped

one

ex

in.

~

FP

Figure

4-6.

Jack

Plug

Installation

OM-113

336

S~0023

Page

13

11.

12.

13.

4-7.

Insert

the

1/4-20

holes

in

cable

torn

Remove

insulating
jack

lines

Insert

hole

en.

WELD

and

plug

with

up

the

in

insulating

POLARITY

NEGATIVE

setscrews

plug,

jack

from

sleeve.

cable

rernaining

8-32

self-tapping

sleeve

and

and

vise,

Slide

insulating

until

hole

hole

into

SELECTION

into

center

tighten

insert

in

insulating

in

jack

screw

jack

plug,

POSITIVE

(E).
jack

sleeve

plug

(F)

and

plug

over

sleeve

(F).

through

and

tight-

bot-

into

1.

Open

Loosen

2.

(see

IMPORTANT:

of

the

tip

without

ble

Insert

3.
outlet

ing

sembly

4.

Tighten

Close

5.

access

the

Figure

Wire

the

guide

touching.

the

guide,

power

as

the

and

door.

gun/feeder

4-7).

guides

is

as

should

closetothe

gun/feeder

through

source

illustrated

the

front

in

gun/feeder

secure

access

connector

be

drive

connector,

access

and

panel

Figures

connector

door.

securing

installed

rolls

as

which

in

the

hole

the

into

4-7

and

securing

knob

that

so

possi

includes

weld-

drive

as

4-8.

knob.

WARNING:

ING

a

can

nections.



Do



Shut

ing



Do

welding.



Secure

before

IMPORTANT:

1.

2.

them

Connect
POSITIVE

Connect

TIVE

()

secure

IMPORTANT:

Connections,

receptacles;

~

MWG-200

WARNING:



Do



Shut

connect

4-8.

ging

ing.

Lockout/tagging

input

ing

locking
removing

and

red-tagging

necting

A.

Gun/Feeder

And

4-8)

IMPORTANT:

assembly.

gun

OM-113

336

Page

ELECTRIC

burn

skin

not

touch

down

welding

twistlock

any

not

change

twistlock

welding.

Rotate

in

receptacles,

weld

For

reverse

electrode

not

down

jack

(+)

jack

Electrode

WELDING

touch

jack

plug

weld

plug

output

cable

becomes

ELECTRIC

welding

input

procedures

power

line

disconnect

fuses

device.

Connector

The

outlet

14

1

SHOCKcan

or

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OM-113

336

Page

15

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WIRE

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6

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6-1.

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METAL

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21

Table

6-1.

Suggested

Parameters

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Metal

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Dark

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into

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side

reverse

on

pro-

of

weld,

are

is

torn

pro-

of

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are

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piece

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of

parameters

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parameters

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parameters
spot

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of

Table

spot

time

6-2.

Checking

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wire

and

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and

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time

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voltage

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and

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voltage

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feed

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feed

speed

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Parameters

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Procedure

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setting.

f

in

speed

f

in

speed

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but

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voltage

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wire

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thru

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6-2

to

parameters.

ON

TIME

6-2

to

parameters.

OM-113

336

reset

Control

reset

Page

23

SECTION

7

MAINTENANCE

TROUBLESHOOTING

&

7-1.

IMPORTANT:

this

maintained
when

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unit

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precautionary

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forced

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per

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Motor

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of

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WARNING:

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a

at

proceeding.

OM-113

336

Page

MAINTENANCE

six

Every

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a

clearly

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touch

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power

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switch

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away

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depress

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to

7-1.

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Units

ments:

cables,

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spect

7-iC).
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service

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beginning

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months

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readable

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electrical

state

for

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all

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Opening

Motor

Brushes

OM-113

336

Page

25

d.

e.

f.

B.

Replacing

WARNING:

a

tion

proceeding.

1.

Disassembly

a.

b.

c.

2.

Assembly

a.

with

b.

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wards

IMPORTANT:

are

gears

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C.

IMPORTANT:

the

OM-113

when

d.

drive

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left

drive

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336

Reinstall

roll

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close

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drive

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cotter

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release

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remove

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onto

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gear

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as

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the

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them.

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a

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operation.

CIRCUIT

ELECTRIC

touch

live

welding

power

before

procedures

plug

switch

from

fuse

breaker

ELECTROSTATIC

damage

properly

handling

circuit

carriers

work

only

INSTALLATION

damage

that

plugs

PRESSURE

minimal

when

disconnecting

and

and

follow

of

entire

the24volts

CB2

open,

all

output

manually

from

TP3

coil

circuit.

causing

necessary

BOARD

electrical

powersource,

safety

Section

is

located

the

contactor

from

reset

PROTECTION

overheating

wired

Should

CR1

and

all

weld

to

REPLACEMENT

SHOCK

parts.

employing

inspecting,

consist

from

receptacle,

in

box,

circuit

grounded

circuit

boards

or

packages.

at

a

circuit

are

pressure

position,

open

or

shutting

other

or

boards.

wrist

boards.

in

static-safe

board.

properly

can

and

removingorinstalling

informa

before

7-6

ac

winding

under

W

the

welding

the

breaker.

in

series

overheat

and

thereby

the

wire

output.

allow

a

cooling

kill.

can

and

discon

lockout/tagging

maintaining,

of

removing

padlocking

remov

off

and

disconnecting

DISCHARGE

strap

proper

work

or

misaligned

installed

break

or

circuit

gentle

move

connecting

board.

of

the
coil

a

by

with

the

drive

If

this

or

red-

BE

static-

area.

and

7-9.

a

TROUBLESHOOTING

WARNING:



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

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nect

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servicing.

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line

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ing

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

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Troubleshooting

qualified

It

is

assumed

Section

to

ing

with

was

to

The

remedies

this

with

ing

forming

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malfunction,

dures

function

the

working

the

welding

following

for

welding

circuit

the

procedures.

these

and

instructions.

touch

not

input

power

disconnect

from

circuit

PARTS

away

SURFACES

cooling

persons.

the

that

this

4

of

of

controls,

property,

process.

table

is

of

some

source.

power

diagram

If

the

procedures,

Service

Station.

strictly

ELECTRIC

live

welding

power

before

SHOCK

electrical

powersource,

employing

inspecting,

procedures

from

plug

switch

fuse

breakerorother

from

period

unit

manual,

and

designed

the

while

trouble

follow

in

box,

can

cause

moving

can

cause

before

be

to

was

properly

the

that

the

to

troubles

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performing

is

contact

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the

receptacle,

open

or

the

welding

diagnose

this

not

all

manufacturers

kill.

can

parts.

and

lockout/tagging

maintaining,

consist

of

removing

padlocking

position,

off

shutting

and

disconnecting

serious

parts.

severe

injury.

burns.

servicing.

performed

installed

operator

trouble

that

table

remedied

the

nearest

cases

only

is

power

is

not

and

develop

may

in

conjunction

troubleshoot

after

of

equipment

discon

or

remov

red-

by

accord

familiar

source

related

provide

in

per

Factory

proce

OM-113

336

Page

28

Table

7-2.

Troubleshooting

No

weld

feed.

No

weld

Low

weld

Electrode

while

welding.

Unit

shuts

TROUBLE

output;

output;

output.

wire

down

wire

wire

stops

~

while

does

not

feeds.

feeding

welding.

PROBABLE

Line

Disconnect

position.

Improper

nections.

Input

proper

Line

Main

(thermal

Gun

leads.

POWER

Switch

THICKNESS

secure

Work

or

incomplete

etc.

Contact

Low

Input

wrong

Circuit

Sharp

cablesorliners,

Incorrect

Contact

stricted;

tube.

Friction

Gun

Broken

Worn

Drive

Excessive

tor.

Drive

Drive

Gun

leads

or

Fan

electrical

voltage

position.

fuse(s)

rectifier

shutdown).

switch,

switch

control

in

receptacle.

clamp

surface

on

tube.

input

voltage.

voltage

position.

breaker

excessive

or

hub

tube

burnback

in

gun.

liner

dirty,

or

damaged

drive

rolls

misaligned.

motor

Motor

trigger

broken.

motor

jumper

open.

SRi

VOLTS

connection

due

tension.

rolls.

loading

brushes.

M.

switch

FM.

CAUSE

Switch

input

links

overheating

or

gun

Si.

CR1.

relay

plug

to

rust,

of

workpiece.

jumper

CB2.

bend

opening

of

wire

restricted.

gun

of

drive

inoperative

in

OFF

con-

not

switch

not

loose

paint,

link

in

gun

into

liner.

mo-

REMEDY

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.

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Section

in

See

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gun

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Replace

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voltage.

if

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input

jumper

line

fuses.

(see

for

good

necessary

ON

position.

connections.

link

position.

Section

metal-to-metal

(see

7-7).

Section

7-6).

Straighten

gun

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re-

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tension

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in

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and/or

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(see

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Sections

assembly.

if

necessary.

if

necessary.

replace

if

liners

4-li).

.

7-2).

7-2

and

necessary

(see

7-3).

(see

OM-113

336

Page

29

Table

7.2.

Troubleshooting

(Continued)

No

open-circuit

Wire

does

voltage

Spot

out

Pulsed
available.

normal.

weld

(models

wire

TROUBLE

not

feed;

timer

with

feed

voltage.

open

does

not

SPW-1

panel).

operation

circuit

time

not

PROBABLE

THICKNESS

secure

in

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switch.

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PLG2

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RC55

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al

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SPW-1

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feed

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breaker

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panel

PC5O.

SPW-i

panel

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receptacle.

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points.

Ti.

not

secure

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or

or

with

only).

or

circuit

circuit

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motor

plug

in

recep-

option

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board

board

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plug

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gun

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in

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Section

Authorized

Factory

Factory

into

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Service

7-6).

Service

nearest

nearest

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Sta

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Factory

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230V.

SECTION

I

TE

ELECTRICAL

8

DIAGRAMS

3

64-

84

q

~

OM-113

336

Page

POSITIVE

NEGATIVE

Circuit

Circuit

Diagram

30

8.1.

Diagram

For

MW

4150

Models

Diagram

No.

SB-121

827

AC

B

5C3

:3

4

PLOP

<

SI

230V.

I

TE

PLG2

POSITIVE

NEGATIVE

Diagram

SPOT

P

UL

CONT.

SE

8-2.

S5OA

Circuit

____________________

Diagram

PLO

~

<P

Circuit

MW

For

OFF

ME

Ti

51

68f~1~69

V

S

P

4200

Models

Diagram

No.

SB-i

37

373

NC55

Diagram

8-3.

Circuit

Diagram

For

56

SPW-i

Circuit

Panel

Diagram

No.

OM.113

A-ago

336

568-A

Page

31

RC

SE

711-B

C-090

Wiring

Diagram

No.

OM113

336

Page

SPW-1

8-4.

Diagram

32

Wiring

Diagram

For

Panel

-

I

I



I

I

~~~~~~~1

I

I

I
I

Diagram

8-5.

Circuit

Diagram

For

SPW-1

Panel

Dual

Timer/Pulser

Circuit

Diagram

Board

PC5O

No.

B-092

817-A

OM.113

336

Page

33

SECTION

9

WELDING

TECHNIQUES

&

TROUBLESHOOTING

CURRENT

battery

as

electrical

long

source

work

clamp

cables

close

and

to

as

are

can

other

before

the

weld

paths.

well

as

clean

dam

elec

weld

as

cable

and

a

CAUTION:

vehicle

age

tronic



Disconnect

on

ing



Place

possible



Be

sure

connections

WELDING

components

components.

both

vehicle.

a

work

clamp

avoid

to

to

power

gun

to

tight.



To

be

100

percent

from

ARC

SEAM

Continuous

9-1.

a

good

Metal

of

One

selection,

hand

one

(avoid

and

gun

toward

(see

angle

and

arc

helmet.

a

from

the

Arc

the

doing

or

9-1.

The

ability

tinuous

several
and

shielding

Cradle

the

on

other

tion

the

60

to

good

seam

(6-8

mm)

computer(s)

GAS

CONTINUOUS

Figure

to

produce

Seam

factors.

gas

the

gun

workpiece

hand

degree

viewofthe
while

to

gun

wearing

distance

hold

either

lead

METAL

Gas

in

theworkpieceduringthearcstartingandwelding

Do

not

starts,

in

a

poor

The

welding

pressed.

inch

1/4

seam

pull

this

as

weld.

Therefore

(6mm)

before

the

gun

will

create

wire

beyond

lowering

is

back

not

the

from

a

long

energized

welding

the

the

helmet

of

free

risk,

vehicle.

the

WELDING

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bead

while

process

most

is

the

and

rest

this

control

away

Figure

is

important,

way

the

hot

on

the

gun

from

9-2).

makeiteasier

Maintain

bottomofthe

the

wire

nozzle

gun

seam

extension

until

wire

and

a

can

and

pressing

disconnect

(GMAW)

the

using

dependent

after

the

gun

sideofthe

material);

trigger.

the

body

will

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follow

to

to

5/1

1/4

nozzle

gun

when

and

the

trigger

extended

be

placed

the

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on

wire

is

held.

hand

use

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at

45

a

give

the

6inch

to

period.

the

arc

result

the

on

the

gun

trigger.

is

1

S-

2

-

Gun

Position

the

seam

beyond

be

regulated

technique

inches

20

(see

per

in

a

steady

Figure

each

by

material,

used.

minute

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ment

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the

can

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known

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be

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bead

current

average

Figure

moved

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the

as

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few

a

travel

speed

required,

selected

speed

the

is

9-2.

along

technique

degrees

will

thicknessofthe

and

the

15

to

04

move

or

9-3),

sideofthe

the

type

weld

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(0.4-0.5

it

of

mpm).

rn~r

S.0422

9-3.

a

Other

istics

hand
vertical

gun

the

ing

forehand

trode
The

arc

Figure

welding

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iii

forehand

and

down

is

positioned

opposite

fed

into

the

technique

wire

is

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less

and

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GMAW

positions.

direction

weld

fed

technique

spatter

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welding

technique,

that

so

of

metal

the

in

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same

the

on

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the

arc

gun

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affect

that

process

and

backhand

the

electrode

travel.

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previously

is

angled

directionasthe

generally

yields

workpiece.

weld

the

include

the

verticalupand

technique

wire

is

filler

metal

deposited.

that

so

a

more

character

the

back

the

feeding

is

be

In

the

the

elec

travel.

arc

stable

in

OM-113

336

Page

34

DirectionofArc

Travel

DirectionofArc

Travel

Backhand

The

direction

the

in

the

vertical

vertical

up

of

position.

and/or

travel

arc

vertical

positioningisextremely

be

kept

on

the

leading

edge

Technique

down

when

the

In

both

of

important

of

the

Figure

techniques

welding

these

because

puddle

must

techniques

to

9-4.

Longitudinal

describe

be

the

arc

ensure

done

gun

must

corn-

Gun

Positions

weld

plete

employed

when

bridging

sideofthe

Forehand

welding

the

the

to

The

other.

penetration.

when

a

gap,

work

arc

drag

in

can

Technique

technique

the

vertical

be

oscillated

is

generally

position,

from

but

one

9-2.

In

pulsed

work

the

ing

switch

is

ger

GAS

METAL

Figure

welding

during

the

period

is

placed

depressed,

Vertical

ARC

the

period

of

Pulse

in

the

the

welding

Figure

WELDING

9-6.

Pulsed

filler

of

Pulse

Off

PULSE

Up

9-5.

metal

On

Time.

position

wire

Welding

In

(GMAW)-PULSED

Seam

transferred

is

cools

and

Time,

When

feeds

the

and

the

through

The

VerticalUpAnd

the

to

dur

selector

trig

gun

the

gun

Vertical

the

for

TIME

wire

length

control.

stops

OFF

until

better

gauge

of

procedures

those

as

SELECTOR

the

and

OFF

PULSE

continues
control

provides

thin

likelihood

Set-up

same

the

tion

PULSE

positions.

time

of

At

the

feeding

TIME

the

for

the

gun

control

metals,

burn

for

SPOT

TIME

Vertical

Down

set

end

for

control.

amount

Position

on

of

the

trigger

of

thereby

throughs.

for

pulsed

continuous

SWITCH

TIME/PULSE

controls

Down

the

SPOT

the

length

This

time

of

is

released.

the

pulse

on

heat

on

of

selected

input

decreasing

seam

seam

welding

is

placed

must

in

ON

be

TIME/PULSE

time

the

time

set

off

and

on

The

pulse

the

to

distortion

welding

except

PULSE

the

TIME

control

the

to

set

OM-113

336

welding

on

sequence

the

option

weld

and

are

posi

desired

Page

ON

the

time

on

the

the

that

and

35

9-3.

Instead

pieces

1-1/2

spot

welding

gether

into

the

position.

any

than

cleaning

pieces

GAS

METAL

of

having

of

sheet

inches

(25-38

process

by

penetrating

other.

The

overlap.

Figure

a

steel

spot

Little

the

ARC

WELDING

9-7.

continuous

together,

mm)

apart

fuses

entirely

process

joint

preparation

surfaces

Spot

or

welding

can

two

pieces

through

is

and

(GMAW)-SPOT

Weld

be

done.

of

one

weld

in

sheet

pulsed

designed

is

required

ensuring

spot

of

to

that

to

The

the

be

join

of

MIG

steel

pieces

used

other

the

two

1

two

to

to

in

is

Spot

welding

ous

seam

volved;

weld

top

9-8.
wire
will

SPOT

tinue

welded

time

will

The
therefore

characteristicsofthis
welds

or

is

sheet

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and

be

maintained

TIME/PULSE

to

has

open

GMAW

are

other

instead,

made

with

flammable

based

welding

there

by

placing

and

holding

the

gun

shielding

penetrate

the

bottom

the

spot

distortion

made

the

arc

welding

in

elapsed

and

little

except

gas

for

in

close

materials.

the

same

on

that

is

a

welding

the

welding

motionless

it

will

the

ON

one

wire

will

is

be

full

TIME

place

sheet.

will

be

process

results.

trigger

technique,

proximity

principles

is

there

time

gun

as

no

travel

shown

depressed,

continuously

of

length

control

After

stop

broken.

time

and

until

the

the

preset

feeding,

produces

Because

it

is

often

to

upholstery,

continu

as

speed

interval.

in

electrode

fed.

set
it

will

top

on

Figure

The

on

sheet

directly

the

welding

the

contactor

little

of

the

low

used

rubber,

in

The

the

arc

the

con

is

heat,

heat

when

OM-113

336

Page

9-8.

Figure

36

Fender

Repair

With

Spot

Nozzle

9-4.

PLUG

WELDS

9-5.

SKIP

WELDING

welds

Plug

metal

where

normal

sheet

pulsed

range

metal

welded

throughs.

holeinthe

together,

weld

can

welds

should

apart.

welds

Plug

proper

parameters

provide

the

sections

The

top

and

be

timed

on

a

thickness

of

the

without

weld

plug

sheet,

clamping

the

filling

using

be

spaced

sample

can

means

of

the

welding

too

are

producing

is

made

hole

with

the

spot

1

to

materials

be

set.

of

top

power

thin

by

the

timer

1-1/2

should

joining

sheet

source

to

be

spot

distortion

drilling

metal

sections

weldment.

a

or

inches

be

two

pieces

is

beyond

or

welded

or

or

punching

The

untimed.

(25-38

made

of

the

where

or

burn

a

tightly

plug

Plug

mm)

that

so

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welding

short

welds,

consistent

each,

be

can

time

time

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proper

9-6.

accomplished

and

the

welds

parameters

TROUBLESHOOTING

WELDING

A.

Porosity

provides

usually

jogging

timer

spot

on

sample

less

in

size

with

the

gun

times

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PROCESS

means

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than

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set.

of

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appearance.

unit

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off

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THE

GAS

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mm)

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on

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series

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3.

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welding

wire.

Causes

gas

coverage.

Figure

Remove

Check

Eliminate

welding

Place

Increase

Decrease

trapment

Hold

Check

Use

Use

Eliminate

or

9-9.

gas

arc.

nozzle

gun

for

welding

clean

conduit.

Porosity

hoses

drafts

(from

1/4

flow

excessive

in

air

end

at

frozen

from

of

spatter

gas

of

grade

and

dry

pick

up

open

(6-8

zone.

molten

gas.

wire.

Actions

nozzle.

doors,

mm)

all

air

on

Corrective

the

gun

for

leaks.

fans,

to

the

C02

in.

5/16

to

displace

flowtoavoid

gas

weld

until

weld

regulator/flowmeter.

shielding

welding

oil

lubricant

or

of

etc.)

from

the

from

turbulence

metal

welding

blowing

workpiece.

weld

zone.

and

solidifies.

from

wire

into

the

the

en

feeder

4.

Workpiece

5.

Welding

dirty.

wire

extends

too

far

out

of

nozzle.

Remove

from

dirt

Use

a

more

Welding

all

work

wire

grease,

surface

highly

should

moisture,

oil,

before

welding.

deoxidizing

extend

1/4

rust,

welding

in.

(6

paint,

wire.

mm)

undercoating,

of

nozzle.

out

OM-113

336

and

Page

37

B.

Excessive

Spatter

1.

Excessive

gas.

C.

Incomplete

1.

Workpiece

2.

Insufficient

3.

Improper

Possible

spatter

Fusion

Possible

dirty.

heat

welding

Causes

when

using

(Lack

Causes

input.

technique.

C02

of

fusion)

shield-

Figure

Select

SPEED

9-10.

Clean

paint,

Select

SPEED

When
side

lower

voltage

control.

Incomplete

weld

surfaces

dirt,

etc.)

prior

higher

voltage

control.

usingaweaving

of

walls

the

Corrective

range

Fusion

Corrective

of

to

range

groove.

or

adjust

impurities

welding.

or

adjust

technique

Actions

FINE

Actions

(grease,

FINE

dwell

momentarily

TUNING

oil,

moisture,

TUNING

WIRE

WIRE

on

rust,

the

D.

1.

2.

Lack

of

Improper

Improper

Fusion

Possible

joint

weld

Causes

preparation.

technique.

~

~

~

~

Figure

Provide

electrode

Keep

Provide

9-11.

Lack

Material

to

quate

maintaining

tics.

Maintain

Section

(see

improved

directed

proper

too

gun

of

Penetration

thick.

provide

proper

normal

9-1).

access

angle.

Joint

access

welding

angle

gun

at

root

the

at

leading

Corrective

preparation

the

bottomofthe

to

wire

achieve

to

of

joints.

edge

Actions

and

extension

maximum

of

design

groove

and

the

puddle.

be

must

arc

ade

while

characteris

penetration

3.

Insufficient

OM-113

336

Page

38

heat

input.

Keep

Select

Reduce

Be

sure

on

arc

higher

the

welding

leading

voltage

travel

speed.

wire

edge

range

extends

of

the

and

1/4

puddle.

wire

speed.

in.

(6

mm)

out

of

nozzle.

E.

Excessive

Penetration

(Burn-Through)

Figure

9-12.

Excessive

Penetration

1.

Excessive

F.

Cracks

1.

Improper

2.

Heat

shrinkage

G.

Waviness

in

input

and

Possible

heat

input.

Weld

Metal

Possible

joint

preparation.

too

high

distortion.

of

Bead

Causes

Causes

causing

excessive

Select

Increase

Material

quate

lower

travel

too

to

provide

maintaining

tics.

Select

Increase

lower

travel

voltage

speed.

thick.

Joint

access

proper

voltage

speed.

Corrective

range

Corrective

preparation

to

welding

range

Actions

and

reduce

Actions

the

bottomofthe

extension

wire

and

reduce

and

wire

design

and

wire

speed.

must

groove

arc

speed.

be

ade

while

characteris

1.

2.

H.

1.

Welding

Unsteady

Humping

.

Excessive

Possible

wire

extends

hand.

Possible

heat

Causes

Causes

input.

too

far

out

of

nozzle.

Figure

Figure

Waviness

9-13.

9-14.

lower

wire

hand

Humping

Welding

Support

Select

Weldinsmall

of

should

solid

on

voltage

segments

Bead

Corrective

extend

surface.

Corrective

range

and

Actions

in.

1/4

Actions

increase

or

allowtocool

(6

mm)

travel

between

of

out

speed.

OM-113

.

nozzle.

welds.

336

Page

39

SECTION

10

AUTO

BODY

REPAIR

APPLICATION

CAUTION:

vehicle

a

age

components.



Disconnect

on

ing



Place

sible



Be

sure

connections

tight.



To

minimize

from

10-1.

POINTERS
SHEET

Before
of

work,

material

Whenever

the

easiest

be

welded

cable

clamp

Clean

the

plete

Usea.030

using

make

the

possible,

position

is

surface

current

or

this

same

clean

must

argon/carbon

Use

direct

current

To

through.

obtain

negative-work

Positive

WELD

(ground)

CE

IMPORTANT:

terials

nect

negative,

10-2.

The

used

or

1.

2.

3. Fit

weld

OUTPUT

leadtothe

PTACLE.

such

for

direct

electrode

PROCEDURE

following

when

high

strength

Use

bare

to

three

area

ter

welding

Remove

shears,

cutting

a

which

as

using

a

power

inches

should

wheel.

new

was

overlap

OM-113

336

Page

WELDING

computers

both

vehicle.

a

work

clamp

to

avoid

to

gun

risk,

the

vehicle.

FOR

METAL

equipment

few

a

practice

as

weldinthe

learn.

to

and

be

attached

to

ensure

path.

in.

.023

dioxide

(0.8

shielding

straight

straight

lead

to

output

selector

RECEPTACLE

POSITIVE

For

maximum

18

gauge

current

wire

FOR

are

some

this

welding

steels:

wire

metalinthe

(51-76mm)

be

cleaned

is

completed.

damaged

or

a

power

piece

removed.

the

cut

away

40

CURRENT

battery

close

as

electrical

long

source

power

to

work

disconnect

WELDING

weld

to

welds

of

Be

of

proper

0.6

or

the

flat

sure

paint

the

to

grounding

that

free

gas.

polarity

polarity

positive),

plug

penetration

mm)

(1.22

reverse

to

basic

brush

of

polarity

positive).

WELDING

guidelines

power

sander

or

to

area

on

for

metal

hand

grinder

sheet

The

section

and

other

cables

the

to

paths.

as

on

on

a

are

the

AUTO

a

sample

clamp

finished

position

that

and

parts

E7OS-6

mm)

for

(electrode

place

in

the

and

connect

WELD

and

MILD

source

to

be

repaired.

either

side

applying

using

equipped

steel

over

material

new

one

by

dam

can

electronic

before

weld

well

as

clean

weld

as

cable

computer(s)

BODY

finished

piece

piece

workpiece.

since

this

the

material

The

rust.

being

and

reduced

the

OUTPUT

on

thicker,

(work

that

remove

body

hand

inch

work

welded.

to

com

wire

wire

Negative/

NEGATIVE

the

work

thicker

recon

lead

STEELS

can

weld

to

paint

Two

of

the

weld

filler

cutters,

with

the

section

should

(25

mm).

pos

and

and

burn

RE-

ma

mild

af

be

of

to

to

to

to

is

a

4.

Clamp

weld.

Rotate

5.

to

burnback
switch

Install

6.

With

7.
on,

the
from

repeatable

8.

Begin

side.

corners.

9.

Space

around

in.

IMPORTANT:

the

repair

After

10.

flush

11.

Smooth

10-3.

PROCEDURES
ELS

IMPORTANT:

will

hayehis

cedures.

in

the

job

most

easier

door

in

how,

the

If

marily

repaired

1.

Remove

necessary

control

2.

Remove

with

face

Figure

the

the

the

50%,

to

the

the

place

material

new

the

edge.

spot

Distortion

spot

repair.

mm)

(5

this

as

welding,

surface.

to

the

Every

own

However,

cases,

and

is

severely

outer

the
without

mechanisms,

edges

to

provide

Door

Inner

Flange

10-1.

new

FINE

weld

at40to

SPOT

the

nozzle

spot

shielding

the

spot

Fit

spot

welding

may

welds

Spot

in

diameter.

Do

not

will

promote

remove

joints

experienced

TUNING

timer

50

position.

gas

nozzle

about

must

up

welds.

from

occur

1

to

welds

make

with

FOR

place,

WIRE

at

30

percent

the

on

and

power

and

1/2to3/4

be

tight

the

if

welding

in.

1/2

should

continuous

distortion

the

clamp

filler

body

WELDING

autobody

in

metal

methodofperforming

in

this

formation

this

welding

less

time

damaged,

or

panel,

necessarily

exterior

door

molding

to

remove

assembly,

of

door

room

extending

Cutaway

skin,

Of

is

powersource

consuming.

but

the

installing

and

window

lock

or

and

place

work.

to

Door

and

prepare

SPEED

40

to

percent,

and

the

gun.

source

firmly

press

in.

(12-18

to

assure

center

Out

begins

(25-38

be

about

welds

and

and

and

DOOR

the

following

presented

the

damage

door

can

whole

a

hardware.

regulator,

runs.

flat

on

over

edges

Door

Skin

Damage

Inner

Door

Panel

Damage

to

spot

control

the

selector

turned

against

mm),

good,

each

on

the

at

mm)

apart

3/16

around

warpage.

spot

grind

finish.

PAN

repairman

pro

to

show

make

can

is

pri

be

easily

door.

new

It

is

not

remote

surface

of

sur

S

.~J4

18

SECTION

\



11

PARTS

\

LIST

0
4,

9

C,,

4

C)

cOa~~

(I)
(I)

(5

1~

U..

OM-113

336

Page

1~

42

3.

4.

5.

6.

7.

8.

9.

If

door

the

weld.

Grind

panel.

Repair

Position

the

end

weld

Spot

panel.

weld

Spot

Metal

finish

interior

has

off

the

any

the

flange

outer

new

trim

outer

an

hem

damage

outer

new

over

panel

hem

exterior

and

hardware.

reinforcement,

panel

the

inner

panel

inner

and

over

flange.

flange

to

the

reinforcement

to

flange

surface,

paint

remove

panel.

door

inner

panel.

and

Spot

Outer

Reinforcement

the

and

to

new

assembly

Weld

On

Panel

break

old

bend

door

panels

to

catedineach

inner

welded

inspect

panels

the

replaced.

Pulsed

Seam

Welds

Figure

Assembled

in

body

case.

must

10-3.

different

determine

to

After

be

carefully

Automotive

With

Continuous

And

places,

the

Welds

Spot

Spot

so

where

old

panel

checked,

Continuous

Body

Seam,

Welds

it

will

be

necessary

the

welds

is

removed,

straightened

Seam

Weld

Sections

Pulsed,

are

lo

the

or

S

-04

20

10-4.

HOW

SPATTER

Spatter

and

welding

them

covered

possible.

and

the

bolted

front

often

the

seam,

excessive

welding

welded

whole

the

which

problems,

used

PROCEDURES

AND

a

complete

to

structure,

is

welded

fenders

can

panels

in

dows,

from

stance

your

come

being

gon

10-5.

When

essary

of

panel

be

spot

of

are

fender
other

If

removed

ous

welded

Figure

10-2.

TO

excessive

windows.

near

and

When

welding

windows

heat

reduces

supplier,

ensure

for

the

002

gas

QUARTER

remove

or

in

in

place,

or

continuous

is

elongated

be

shifted

welded

are

panel

by

cutting

or

by

Car

place.

Hem

PREVENT

ON

WINDOWS

heat

Protect

far

as

must

should

by

using

heat

If

burn

that

size

material

mixture

FOR

PANELS

must

panel

the

bolts

to

cut

In

place.

while

the

so

that

and

simple

correctly

usually

into

is

be

to

replaced,

the

along

and

out

body

drilling

Flange

GLASS

become

can

the

from

away

be

be

covered

wet

rags.

transfer

through

the

correct

being

and

check

WELDING

be

replaced

securing

through

most

cases

other

welded.

seam

because

the

position

place.

weld

the

spot

manufacturers

Removal

BREAKAGE

problems

windows

the

heat

performed

and

A

putty

is

available

and

voltage

welded.

travel

it

the

panel

the

spot

front

a

of

old

welded

welds

will

The

the

the

Generally

panel

panels

aligned.

the

if

Inner

S

AND

when

by

keeping

zone

win

near

protected

like

sub

through

spatter

tap

Use

an

speed.

FENDERS

will

be

nec

the

to

if

welds

fender

be

either

alignment

bolt

holes

front

new

must

continu

by

if

it

is

spot

have

.04

as

be

ar

rest

the

will

all

be

the

is

19

The

tion

center

other.

weld

outer

new

by

vice-grips

and

In

order

only

important

the

sheet

this

concentrated

will

begin.

tion.

When

filled

down,

10-6.

WELDING

(HSS)

The
omy

gussets,

these

duction

strength

the

ble.

come

the

wider
mended.

HSS

new

compact

new

and

decreases

affected

heat

For

this

the

oxyacetylene

heat

Figure

panel

or

proceed

to

ensure

section

a

to

constantly

steel

around

heat

Leave

a

the

weld

with

body

STEELS

steels

cars.

brackets,

models.

heat

are

zone

reason

preferred

welding

affective

10-4.

then

in

be

When

one

can

c-clamp.

first

reduced

2

of

gap

FRAMES

are

HSS

floor

HSS

and

the

method

in.

3

or

check

the

welding

that

area

and

then

is

completed

and

putty

used

steels

pans,

steels

sensitive.

cracking

must

MIG

for

or

brazing

area,

the

on

be

welding

are

Application

placed

welding,

direction

distortion

(51-76

over

area,

warpage

weld

it

sanded.

AND

HIGH

many

be

can

and

support

thinner

are

As

heat

can

kept

welding

normally

Of

Body

and

held

start

and

due

at

mm)

all

a

temperature

because

and

another

be

can

hammered

STRENGTH

of

the

new

in

found

members

for

is

applied,

occur,

small

as

process

HSS

steels,

processes,

not

Putty

OM-113

336

in

posi

at

the

then

the

to

heat,

It

time.

it

is

distortion

short

sec

econ

the

steel

weight

re

the

therefore

as

possi

has

be

and

with

recom

41

Page

is

of

in

of

its

Item

No.

1

2

3

4

5

6

7

8
9

10

ii

12

13

14

15
16

17

18
18
19
20

21
22

23

24

25

26

26
27

28

Dia.

Mkgs.

PLG2

PLG1

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Description

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Figure

WRAPPER

HOUSING

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1.125

x

1.125

x

wall

panel)

of

side

side

of

side

side

(consisting

x

of)

(consisting

.250

knr

cup

(orderbyft)

front

panel)

panel)

panel)

front

panel)

panel)

panel)

of)

of)

(consisting

point

of)

Quantity

Model

MW

4150

4200

1
1

8

1

8

1

1

1

1
2
2

1

1

1

1

1

1

1
2

1

1

1

1

1

2

1

1

1

1

1

1

2

1

1

4

4ft

1
1

1

1

MW

1
1

8

1

8

1
1

1
1

2

2

1

1

1

1

1
1

1

1

1
1
1

2

1
1
1

1
1

2

1

1

4

4ft

1
1

1
1
1
1
1

2

2

2

1

++For

BE

SURE

Parts

TO

List

PROVIDE

of

MWG-160

MODEL

GUN

AND

See

Form

SERIAL

No.

NUMBER

112

934

And

WHEN

MWG-200

For

ORDERING

GUN

See

REPLACEMENT

Form

No.

PARTS.

OM-113

113

337.

336

Page

43

31

6

10





11



17

18

19

20

21

Fig

11-3

Figure

28

11-2.

11

Baffle,

27

Air

w/Components

24

25

15

14

SC-132

243

OM-113

336

Page

44

2

Item

No.

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

Dia.

Mkgs.

CR2,3

C6

CR1

R5

R3

TEl

W

VR2

SR2

CB1,2

Part

No.

427

058
085

980

605

941

057 543
057

971

010

191

058628

057

745

058428
026

837

044

995

006

393

147

083

082

907

031

728

082

902
875

082
072817
052 704

006

537

741

605

059

642

038

620

026189

034

260

035519
024 493
046

685

035

704

083

431

145

010

122

192

031

773

Figure

RING,

NUT,

11-2.

retaining

stl

hex

WASHER,

SPRING,

WASHER,

WASHER,

WASHER,

SPRING,

HUB,

spool

INSULATOR,
BAFFLE,
RELAY,

end

GROMMET,

ANGLE,

mtg

CAPACITOR,

STRIP,

ANGLE,

RELAY,
CLIP,

mtg

mtg

end

spring

RESISTOR,

CLIP,

mtg

RESISTOR,

LINK,

jumper

BLOCK,
LINK,

term

connecting

CONTACTOR,

cntor

COIL,

VARISTOR,

RECTIFIER,

CIRCUIT

CLAMP,

DRIVE

LABEL,

nylon

ASSEMBLY,

important

Description

Baffle,

spool

full

fnsh

flat

stl

.640

.845

cprsn

flat

stl

keyed

fbr

.656

brake

stl

2.430

cprsn

term

air

24VAC

No.

scr

RH

capacitor

elctlt

center

LH

capacitor

24VAC

resistor

mtg

WW

fxd

resistor

WW

fxd

term

30A

contactor

def

24VAC

175VDC

.6W

integ

BREAKERS,

.500

whenever

Air

w/Components

.625-11

ID

x

.091

OD

x

1.500

IDx1.500

OD

x

nylon

DPDT

8/10

panel

20000uf

capacitor

DPDT

12W

.51

ID

.312

bik

3P

prp

40A

25W

30A

40A

40A

800V

man

clamp

wire

core

10

dia

(Fig

1.000

wirex1.500

dia

OD

wirex2.500

.090

hole

35VDC

ohm

ohm

terminal

24V

3P

reset

11-3)

the

upper

(Fig

OD

x

l4ga

.l25thk

x

.l25thk

x

.312sq

(consisting

P

1

250V

5A

thk

.500

11-1

of)

Item

high.

Quantity

4)

1
1
1

1

1

2

2

1

1

2
6

6

2

2

2

2

BE

SURE

TO

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

OM-113

336

Page

45

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

20

21

22

23

24

25
26

10

12

13

14

15

16

17

18
19

11

122

192

1

2

2

3

4

5

6

7

8
9

M

057
058
087
120

604

605

057

010

044
605

119
130
057

079

602

010

079
079

601

058

058 359

605
072 649

058

058

010 918

072

551
549

331
370

741

525

590

929
994
287
040

820

432
624

213

910
633

772

838
553

854

360
363

585

Figure

SPRING,

GUIDE,

GUIDE,

HOUSING,

cotter

PIN,

stl

NUT,

GEAR,
WASHER,

INSULATOR,

woodruff

KEY,
MOTOR,

BRUSH

SCREW,

SCREW,

WASHER,

WASHER,

FITTING,
KNOB,

brs

NUT,

GEAR,

PIN,

pivot

RING,
BEARING,

SHAFT,
COVER,

PIN,

spring

BEARING,

Drive

11-3.

pressure

inlet

wire
wire

outlet

drive

hair

hex

slflkg

drive

roll

flat

stl

motor

.062
PM

gear

&

SPRING

holder

cap

stl

cap

lock

stl

flat

hose

T

hex

1.500

.375-16

roll

plstc

drive

retaining

drive

roll

drive

roll

drive

CS

drive

Assembly,

drive

1/16

.025

roll

feeder

.042

x

thin

V

groove

spr

x

12V

hex

hd

sti

split

SAE

brs

barbed

Ig

no

groove

assy

.156

x

assy

roll

.937

.312-24

.375

.250

1/25hp

brush

slflkg

.375

.375

x

jam

wire

1.500

wire

Wire

.030-.035

3550RPM

.375-16

nipple

.312-18

hvy

.024

(Fig

wire

x

3/l6tbg

2.000

x

wire

keyed

2.250

Item

11-2

keyed

(consisting

bar

30)

(top)

of)

(bottom)

1
1

1

..

1

1
1

1
1

1

2

1

2

2
1
2
1

1
1
1

1

1

.

2
1

1

1

1

1

26

25

24

23

22

9,

21

20

19

_~

18

8 9

10

2

3

15

16

14

17

14

13

SC-072

I

511-0

BE

OM-113

SURE

336

TO

Page

PROVIDE

46

MODEL

AND

Figure

SERIAL

11-3.

NUMBER

Drive

Assembly,

WHEN

ORDERING

Wire

REPLACEMENT

PARTS.

Item

No.

10

11

12

13

14

15

Quantity

Dia.

Mkgs.

1

SRi

1

SRi

2

TP1

2

TP2

3

D3,4

3

D7,9

4

C1-4

4

C14-17

Dl

5
5
6

7

8

9

,2

D6,8

TP3

GS1

FM

Part

No.

137

914

137

913
604515
006

334

037 306
037 957
605

886

605 884
031

689

031

689

037

305

037 956

086

323

137

912

032

662

134982

227

605
010290

125

785

089

120

604

550

032

678

Description

Figure

11-4.

Panel,

Rear

RECTIFIERiWINDTUNNEL,

RECTIFIERiWINDTUNNEL,

THERMOSTAT,NC

THERMOSTAT,

DIODE,
DIODE,

rect
rect

WASHER,

stl

NUT,

hex

CAPACITOR,

CAPACITOR,

DIODE,

DIODE,

rect

rect

THERMOSTAT,

BRACKET,

BLADE,

fan

NC

1

50A

275A

lock

stl

half

.750-16

rectifier

rectifier

1

50A

275A 300V

NO

fan

mtg

lOin

5wg

300V
300V

intl

300V

motor

tooth

PANEL,rear
NUT,

nyl

BUSHING,
VALVE,

CLAMP,

HOSE,

MOTOR,

hex

24VAC

hose .375-450

nprn

i/5Ohp

jam

strain

brd

.750

relief

1.030

2

custom

way

No.1x.187

23OVAC

w/Components

diode

si
si

RP
RP

.750

SP

SP

ID

port

ID

1500RPM

diode

1/8

(order

(consisting

(consisting

orf

by

ft)

(Fig

11-1

of)

of)

Item

5)

Mqdel

MWMW

4150

1

1

2

4

2

1

1 1

1
1 1
1
1
1 1

1

3ft

1

4200

1

1

2

4

4

4

2

1

1

1
1

1

3ft

1

9

10

11

1

12

13

14

SC.072

5O8~D

BE

SURE

TO

PROVIDE

MODEL

Figure

AND

SERIAL

11-4.

Panel,

NUMBER

Rear

w/Components

WHEN

ORDERING

REPLACEMENT

PARTS.

OM-113

336

Page

47

12

13

14

)

15

OM-113

336

Page

2

148-A

SC-131

11-5.

Figure

46

Panel,

Front

w/Components

Item

No.

Dia.

Mkgs.

Part

No.

Figure

11-5.

Description

Panel,

Front

w/Components

(Fig

11-1

Item

Quantity

15)

17

18
19

20

21
22

23

24

24

25
26

27

10

11

12

13

14

15
16

17

19

1

1

1

2

3

4

5
6

7

8

9

RC3

RC1

Ri

51

PL1

039

039
057

072
091
091

010
604

605 787
601 881

+119

113
119

073 383

052 236

113

048 282

079
605828

124

048

023

044

600 318
039
039
010
019833
602

101

026 975
602 814

602

010

097 824

801

RECEPTACLE,

800

RECEPTACLE,

608

RECEPTACLE,

.

334

542

541

291

668

543

604

191

RECEPTACLE
RECEPTACLE

.

RECEPTACLE

.

WASHER,

.

stl

NUT,

.

WASHER,

.

sti

NUT,

NAMEPLATE,

LABEL,

PANEL,
RECEPTACLE,

3

TERMINAL,

742

534

PLUG,

COVER,

RECEPTACLE

RHEOSTAT,WW5OW1.5ohm

511

SWITCH,

573

084

943

878
608
521

178

219

160

325

LIGHT,

CABLE
CABLE

.

.

.

. .

BUSHING,

KNOB,

md

CABLE,

PLUG,

PLUG,

.

WIRE,

~STRIP,

SCREW,

PLUG,

.

INSULATOR,

.

INSULATOR,

SCREW,

pointer

jack

jack
jack

flat

nylafil

hex

slflkg

lock

hex

jam

(order

Arc

Auto

front

3

MS-3106A-14S-1P

pin

Auto

Arc

W/SOCKET,

female

DPST

tgl

red

lens

&

PLUG,

&

PLUG,

weld

cop

yellow

jack

red

jack

tie

bag

.010x2.500x.750

cop

stl

set

5/8

jack

jack

jack

slftpg

strain

&
&
&

sti

.500-20

warning

skt

open

jack
jack

(consisting

l6ga

sch

x

filh

relief

blk

red

yellow

jack plug
jack plug
jack plug

IDx1.250

.625

fnsh

tooth

model

(consisting

(consisting

.500-20

.500

plug

plug

plug

NUT,

NUT,
NUT,

med
intl

by

MS-3102A-14S-1S

module

(consisting

lskt

18-14

600VAC

40A

28V

(consisting
(consisting

strd

No.

3

(consisting

of)

in

5

x

.250-20x.375

2-5/8

(yellow)

plug

(red)

plug

8-32

.840

x

.250

ID

(consisting

yellow

blk

red

OD

and

serial

Amphenol

wire

of)

of)

(order

by

of)

knr

x

.875mtg

of)

of)

of)

.i25thk

x

number)

of)

ft)

cup

hole

point

As

1
1

6

1
1
1
1
1
1
1

1

1
1

1

1

1

4

1

1

1

1

Reqd

1
1

1

1

2

1

1

1
1

2

1

+When

BE

SURE

ordering

TO

PROVIDE

a

component

MODEL

originally

AND

displaying

SERIAL

a

precautionary

NUMBER

WHEN

label,

ORDERING

the

label

should

REPLACEMENT

also

be

ordered.

PARTS.

OM-113

336

Page

49

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

13

14

10

11

12

Figure

1

R50

2

R51

3

4

5
6

8

9

R52

S50

R53

7

PLG51

PLG

50

PC5O
RC55

769

028

028

770

768

028

086

895

073

914

605

890

080

509

135

560

747

079

798

079

747

079
097

897

008 072
058

971

086

650

471

113

097

922

POTENTIOMETER,

POTENTIOMETER,

POTENTIOMETER,

SWITCH,

WASHER,

RESISTOR,
GROMMET,

HOUSING

.

HOUSING,

TERMINAL,

CIRCUIT

HOUSING

PANEL,

NAMEPLATE,
KNOB,

11-6.

TERMINAL,

TERMINAL,

spot

pointer

3

rotary

centering

WW

fxd

No.

scr

PLUG

&

contact

hdr

term

contact

PLUG

timer

dual

&

male

CARD,

(order

posn

SOCKETS,

I

SKP-35

1

SPW

Panel

Spot

C

sft

sltd

C

sltd

C

sltd

.437

15W

8/10

hdr

13

hdr

dia

panel

24-18

pin

24-18

sft
sft

.25

lIT

l/T
liT

ohm

timer/pulser

PINS,

(consisting

pin

model

by

(Optional)

2W

750K

1

2W

meg

2W

350K

hole

.312sq

(consisting

wire

wire

11-7)

(Fig

of)

and

serial

ohm

ohm

ohm

.375

of)

number)

high

Fig

1

1

1

2

3

1

9

13

8

4

10

11-7

1

2

7

1

~



12

13

SC

Ot~

924D

BE

OM-113

SURE

336

TO

Page

PROVIDE

50

MODEL

Figure

AND

11-6.

SERIAL

SPW

NUMBER

I

Spot

WHEN

Panel

ORDERING

(Optional)

REPLACEMENT

PARTS.

Dia.

Mkgs.

PC5O

A50,51

C50

C51,53,55

C52,56

C54,57,58

C59
CR50
CR51
CR52

D50-53,55,57-66

D56

050,51

Q52

R50

R51

R52,71

R53,57,61

,68,70

R54,56,59

60,62,66,67

R55,58

R63

R64,69

R65

RC5O

RC51

Part

No.

097 897

009

159

039482

032

820

714

073
073

739

090

573

027

810

099

019

099018

079

844

091

861

026

202

449

037

037

200

073 535
030 018

823

035
035 884
039

331

827

035

035

886

039

333

039

327

035 887

648

092
079

795

072

670

linear

11-7.

358

Figure

IC,

CAPACITOR,

CAPACITOR

CAPACITOR
CAPACITOR

CAPACITOR,

RELAY,
RELAY,
RELAY,

SPRING,
SOCKET,

DIODE,
DIODE,

end
end

end

hold

relay

rect

zener

TRANSISTOR,
TRANSISTOR,

RESISTOR,

RESISTOR,
RESISTOR,
RESISTOR,

RESISTOR,

RESISTOR,
RESISTOR,

RESISTOR,
RESISTOR,

RESISTOR,

TERMINAL,
TERMINAL,

Description

Circuit

elctlt

tantlm

tantim

cer

mono

elctlt

24VDC
24VDC
24VDC

down

l4skt

1A

400V

15V

NPN

NPN

1W

C

.25W

CF

CF

.25W

CF

.25W

.25W

CF

CF

.25W
.25W

CF

CF

.25W
.25W

CF

WW

fxd

hdr

13

hdr

9

Card,

lOOuf

2.2uf

.22uf

lOuf

4PDT

SPST

SPDT

relay

1W

200MA

100MA6OV

820

zero

pin

pin

.1

SP

SP

ohm
100
lOOK

4.7K

10K

22K

18K

220

3.3K

35VDC

35VDC

35V

uf

50V

ohm...

Dual

5OVDC

40V

ohm

ohm

ohm

ohm

ohm
ohm

ohm

ohm

Timer/Pulser

(Fig

11-6

Item

Quantity

10)

2

1

3

2

3

1

1

1
1

1

1

15

1

2

1

1

1

2

5

7

2

1

2

1

1
1
1

BE

SURE

TO

0>

>~

o

a)
Co

-J

IC))

C

Ox

PROVIDE

C)

H~

I

Z

0

Iflg~

Wa)

PARTS.

OM-113

336

SB~O97

Page

696~A

51



MODEL

(31C~U1C7I

~

-J

Figure

AND

a)

O~

+1

11-7.

SERIAL

Circuit

NUMBER

Card,

R69

~O

0)0)0)
~

Dual

Tlmer/Pulser

WHEN

ORDERING

~

0)0)0)

a)-J

PC5O

REPLACEMENT

D

0)
N)

2122

Dia.

Mkgs.

1

2
3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18
19
20

Part

No.

108940

025193

604

057478

022617

602389
602387

602384

070

602250

052693

052692

121

601

602211

601

008999

052691
602213

601

423

799

614

944

869

871

Figure

SCREW,
HANDLE,

handle

GRIP,

BRACKET,

CHAIN,

HOOK,

CHAIN,
SNAP,

WHEEL,

WASHER,

RACK,
AXLE,

SCREW,

WASHER,

NUT,

CASTER,

ANGLE,

WASHER,

NUT,

cylinder

running

RING,

stl

stl

11-8.

Running

stl

cap

hexwhd

running

.875

support

racks

cyl

S

blunt

1.500

weldless

chain

rubolene

flat

stl

gear

lock

jam

sti

ext

hexhd

stl

swvl

retaining

cap

hex

plastic

spreader

lock

stl

hex

jam

.375-16

Description

Gear

.250-20

gear

ID

4.500

x

tank

in

27

x

dia

.750

of)

in

(consisting

2/0

in

10

SAE

(consisting

shaft

.750

.312-18

.312

split

312-18

in

4

dia

rack

cyl

.375

split

of)

x

x

.750

x

.082

.750

Quantity

4

1

2

1
1

1
I
1

1

4

1

1

2

4
4

4

~~15

1

5

11

14

BE

OM-113

SURE

336

TO

Page

PROVIDE

52

MODEL

~17

11-8.

NUMBER

AND

Figure

SERIAL

Running

WHEN

Gear

ORDERING

REPLACEMENT

PARTS.

SC-049

808-E

I