Millermatic Challenger 172 And M-10 Gun - Auburn … - Liu Lab... · Millermatic Challenger 172 And...

Millermatic Challenger 172And M-10 Gun

Processes

Description

MIG (GMAW)

Flux Cored (FCAW)

Wire Feeder

OM-1318 187923FMarch 2000

Visit our website at

www.MillerWelds.com

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local Miller distributorto receive the latest full line catalog orindividual catalog sheets. To locate your nearestdistributor or service agency call 1-800-4-A-Miller,or visit us at www.MillerWelds.com on the web.

Thank you and congratulations on choosing Miller. Nowyou can get the job done and get it done right. We knowyou dont have time to do it any other way.

Thats why when Niels Miller first started building arcwelders in 1929, he made sure his products offeredlong-lasting value and superior quality. Like you, hiscustomers couldnt afford anything less. Miller productshad to be more than the best they could be. They had tobe the best you could buy.

Today, the people that build and sell Miller products continue thetradition. Theyre just as committed to providing equipment and servicethat meets the high standards of quality and value established in 1929.

This Owners Manual is designed to help you get the most out of yourMiller products. Please take time to read the Safety precautions. They willhelp you protect yourself against potential hazards on the worksite. Weve

made installation and operation quick and easy.With Miller you can count on years of reliableservice with proper maintenance. And if forsome reason the unit needs repair, theres aTroubleshooting section that will help youfigure out what the problem is. The parts listwill then help you to decide which exact partyou may need to fix the problem. Warranty andservice information for your particular modelare also provided.

Miller is the first weldingequipment manufacturer inthe U.S.A. to be registered tothe ISO 9001 Quality SystemStandard.

Working as hard as you do every power source fromMiller is backed by the mosthassle-free warranty in thebusiness.

From Miller to You

Miller offers a TechnicalManual which providesmore detailed service andparts information for yourunit. To obtain a TechnicalManual, contact your localdistributor. Your distributorcan also supply you withWelding Process Manualssuch as SMAW, GTAW,GMAW, and GMAW-P.

The following terms areused interchangeablythroughout this manual:MIG = GMAW

TABLE OF CONTENTS

SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Additional Symbols For Installation, Operation, And Maintenance 3. . . . . . . . . . . . . . . . . . . . . . 1-4. Principal Safety Standards 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 1 CONSIGNES DE SECURITE LIRE AVANT UTILISATION 5. . . . . . . . . . . . . . . . . . . . . 1-1. Signification des symboles 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Dangers relatifs au soudage larc 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Dangers supplmentaires en relation avec linstallation, le fonctionnement

et la maintenance 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4. Principales normes de scurit 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. Information sur les champs lectromagntiques 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 SPECIFICATIONS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1. Specifications 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2. Volt-Ampere Curves 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3. Welding Power Source Duty Cycle And Overheating 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4. Welding Gun Duty Cycle And Overheating 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 INSTALLATION 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. Installing Work Clamp 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. Installing Welding Gun And Changing Polarity 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3. Installing Gas Supply 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4. Electrical Service Guide 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5. Selecting A Location And Connecting Input Power 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6. Installing Wire Spool And Adjusting Hub Tension 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7. Installing Drive Roll, Wire Guide And Threading Welding Wire 15. . . . . . . . . . . . . . . . . . . . . . . . . 3-8. Weld Parameter 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 OPERATION 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. Controls 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 MAINTENANCE &TROUBLESHOOTING 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. Routine Maintenance 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2. Drive Motor Fuse F1 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3. Short Circuit Shutdown 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4. Cleaning Or Repairing Drive Assembly 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5. Replacing Gun Contact Tip 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6. Cleaning Or Replacing Gun Liner 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7. Replacing Switch And/Or Head Tube 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8. Troubleshooting Table 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 ELECTRICAL DIAGRAM 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 7 MIG WELDING (GMAW) GUIDELINES 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Typical MIG Process Connections 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2. Typical MIG Process Control Settings 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3. Holding And Positioning Welding Gun 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4. Conditions That Affect Weld Bead Shape 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5. Gun Movement During Welding 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6. Poor Weld Bead Characteristics 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7. Good Weld Bead Characteristics 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8. Troubleshooting Excessive Spatter 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9. Troubleshooting Porosity 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10.Troubleshooting Excessive Penetration 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11.Troubleshooting Lack Of Penetration 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12.Troubleshooting Incomplete Fusion 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13.Troubleshooting Burn-Through 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14.Troubleshooting Waviness Of Bead 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15.Troubleshooting Distortion 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16.Common MIG Shielding Gases 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 PARTS LIST 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPTIONS AND ACCESSORIESWARRANTY

WARNINGThis product, when usedfor welding or cutting,produces fumes orgases which containchemicals known to theState of California tocause birth defects and,in some cases, cancer.(California Health &Safety Code Section25249.5 et seq.)

OM-1318F

OM-1318 Page 1

SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USINGsom _nd_4/98

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazardswith this procedure! The possible hazards are shown inthe adjoining symbols.

Marks a special safety message.

Means Note; not safety related.

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

1-2. Arc Welding Hazards

The symbols shown below are used throughout this manual tocall attention to and identify possible hazards. When you seethe symbol, watch out, and follow the related instructions toavoid the hazard. The safety information given below is onlya summary of the more complete safety information found inthe Safety Standards listed in Section 1-4. Read and follow allSafety Standards.

Only qualified persons should install, operate, maintain, andrepair this unit.

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocksor severe burns. The electrode and work circuit iselectrically live whenever the output is on. The inputpower circuit and machine internal circuits are also

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

Do not touch live electrical parts.

Wear dry, hole-free insulating gloves and body protection.

Insulate yourself from work and ground using dry insulating matsor covers big enough to prevent any physical contact with the workor ground.

Do not use AC output in damp areas, if movement is confined, or ifthere is a danger of falling.

Use AC output ONLY if required for the welding process.

If AC output is required, use remote output control if present onunit.

Disconnect input power or stop engine before installing orservicing this equipment. Lockout/tagout input power according toOSHA 29 CFR 1910.147 (see Safety Standards).

Properly install and ground this equipment according to itsOwners Manual and national, state, and local codes.

Always verify the supply ground check and be sure that inputpower cord ground wire is properly connected to ground terminal indisconnect box or that cord plug is connected to a properlygrounded receptacle outlet.

When making input connections, attach proper grounding conduc-tor first double-check connections.

Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill.

Turn off all equipment when not in use.

Do not use worn, damaged, undersized, or poorly spliced cables.

Do not drape cables over your body.

If earth grounding of the workpiece is required, ground it directlywith a separate cable.

Do not touch electrode if you are in contact with the work, ground,or another electrode from a different machine.

Use only well-maintained equipment. Repair or replace damagedparts at once. Maintain unit according to manual.

Wear a safety harness if working above floor level.

Keep all panels and covers securely in place.

Clamp work cable with good metal-to-metal contact to workpieceor worktable as near the weld as practical.

Insulate work clamp when not connected to workpiece to preventcontact with any metal object.

Do not connect more than one electrode or work cable to anysingle weld output terminal.

SIGNIFICANT DC VOLTAGE exists after removal ofinput power on inverters. Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Sectionbefore touching any parts.

Welding produces fumes and gases. Breathingthese fumes and gases can be hazardous to yourhealth.

FUMES AND GASES can be hazardous.

Keep your head out of the fumes. Do not breathe the fumes.

If inside, ventilate the area and/or use exhaust at the arc to removewelding fumes and gases.

If ventilation is poor, use an approved air-supplied respirator.

Read the Material Safety Data Sheets (MSDSs) and themanufacturers instructions for metals, consumables, coatings,cleaners, and degreasers.

Work in a confined space only if it is well ventilated, or whilewearing an air-supplied respirator. Always have a trained watch-person nearby. Welding fumes and gases can displace air andlower the oxygen level causing injury or death. Be sure the breath-ing air is safe.

Do not weld in locations near degreasing, cleaning, or spraying op-erations. The heat and rays of the arc can react with vapors to formhighly toxic and irritating gases.

Do not weld on coated metals, such as galvanized, lead, orcadmium plated steel, unless the coating is removed from the weldarea, the area is well ventilated, and if necessary, while wearing anair-supplied respirator. The coatings and any metals containingthese elements can give off toxic fumes if welded.

OM-1318 Page 2

Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Sparks fly off from theweld.

ARC RAYS can burn eyes and skin.

Wear a welding helmet fitted with a proper shade of filter to protectyour face and eyes when welding or watching (see ANSI Z49.1and Z87.1 listed in Safety Standards).

Wear approved safety glasses with side shields under yourhelmet.

Use protective screens or barriers to protect others from flash andglare; warn others not to watch the arc.

Wear protective clothing made from durable, flame-resistant mate-rial (leather and wool) and foot protection.

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

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

WELDING can cause fire or explosion.

Protect yourself and others from flying sparks and hot metal.

Do not weld where flying sparks can strike flammable material.

Remove all flammables within 35 ft (10.7 m) of the welding arc. Ifthis is not possible, tightly cover them with approved covers.

Be alert that welding sparks and hot materials from welding caneasily go through small cracks and openings to adjacent areas.

Watch for fire, and keep a fire extinguisher nearby.

Be aware that welding on a ceiling, floor, bulkhead, or partition cancause fire on the hidden side.

Do not weld on closed containers such as tanks, drums, or pipes,unless they are properly prepared according to AWS F4.1 (seeSafety Standards).

Connect work cable to the work as close to the welding area aspractical to prevent welding current from traveling long, possiblyunknown paths and causing electric shock and fire hazards.

Do not use welder to thaw frozen pipes.

Remove stick electrode from holder or cut off welding wire atcontact tip when not in use.

Wear oil-free protective garments such as leather gloves, heavyshirt, cuffless trousers, high shoes, and a cap.

Remove any combustibles, such as a butane lighter or matches,from your person before doing any welding.

FLYING METAL can injure eyes.

Welding, chipping, wire brushing, and grindingcause sparks and flying metal. As welds cool,they can throw off slag.

Wear approved safety glasses with sideshields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

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

approved air-supplied respirator.

HOT PARTS can cause severe burns.

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

torch.

MAGNETIC FIELDS can affect pacemakers.

Pacemaker wearers keep away. Wearers should consult their doctor before

going near arc welding, gouging, or spotwelding operations.

NOISE can damage hearing.

Noise from some processes or equipment candamage hearing.

Wear approved ear protection if noise level ishigh.

Shielding gas cylinders contain gas under highpressure. If damaged, a cylinder can explode. Sincegas cylinders are normally part of the weldingprocess, be sure to treat them carefully.

CYLINDERS can explode if damaged.

Protect compressed gas cylinders from excessive heat, mechani-cal shocks, slag, open flames, sparks, and arcs.

Install cylinders in an upright position by securing to a stationarysupport or cylinder rack to prevent falling or tipping.

Keep cylinders away from any welding or other electrical circuits.

Never drape a welding torch over a gas cylinder.

Never allow a welding electrode to touch any cylinder.

Never weld on a pressurized cylinder explosion will result.

Use only correct shielding gas cylinders, regulators, hoses, and fit-tings designed for the specific application; maintain them andassociated parts in good condition.

Turn face away from valve outlet when opening cylinder valve.

Keep protective cap in place over valve except when cylinder is inuse or connected for use.

Read and follow instructions on compressed gas cylinders,associated equipment, and CGA publication P-1 listed in SafetyStandards.

OM-1318 Page 3

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

FIRE OR EXPLOSION hazard.

Do not install or place unit on, over, or nearcombustible surfaces.

Do not install unit near flammables.

Do not overload building wiring be sure power supply system isproperly sized, rated, and protected to handle this unit.

FALLING UNIT can cause injury.

Use lifting eye to lift unit only, NOT runninggear, gas cylinders, or any other accessories.

Use equipment of adequate capacity to lift andsupport unit.

If using lift forks to move unit, be sure forks arelong enough to extend beyond opposite side ofunit.

OVERUSE can cause OVERHEATING

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

starting to weld again. Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

Put on grounded wrist strap BEFORE handlingboards or parts.

Use proper static-proof bags and boxes tostore, move, or ship PC boards.

MOVING PARTS can cause injury.

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

rolls.

WELDING WIRE can cause injury.

Do not press gun trigger until instructed to doso.

Do not point gun toward any part of the body,other people, or any metal when threadingwelding wire.

MOVING PARTS can cause injury.

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

closed and securely in place.

H.F. RADIATION can cause interference.

High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommunications equipment.

Have only qualified persons familiar withelectronic equipment perform this installation.

The user is responsible for having a qualified electrician prompt-ly correct any interference problem resulting from the installa-tion.

If notified by the FCC about interference, stop using theequipment at once.

Have the installation regularly checked and maintained.

Keep high-frequency source doors and panels tightly shut, keepspark gaps at correct setting, and use grounding and shielding tominimize the possibility of interference.

ARC WELDING can cause interference.

Electromagnetic energy can interfere withsensitive electronic equipment such ascomputers and computer-driven equipmentsuch as robots.

Be sure all equipment in the welding area iselectromagnetically compatible.

To reduce possible interference, keep weld cables as short aspossible, close together, and down low, such as on the floor.

Locate welding operation 100 meters from any sensitive elec-tronic equipment.

Be sure this welding machine is installed and groundedaccording to this manual.

If interference still occurs, the user must take extra measuressuch as moving the welding machine, using shielded cables,using line filters, or shielding the work area.

1-4. Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, from AmericanWelding Society, 550 N.W. LeJeune Rd, Miami FL 33126Safety and Health Standards, OSHA 29 CFR 1910, from Superinten-dent of Documents, U.S. Government Printing Office, Washington, D.C.20402.Recommended Safe Practices for the Preparation for Welding and Cut-ting of Containers That Have Held Hazardous Substances, AmericanWelding Society Standard AWS F4.1, from American Welding Society,550 N.W. LeJeune Rd, Miami, FL 33126National Electrical Code, NFPA Standard 70, from National Fire Protec-tion Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,from Compressed Gas Association, 1235 Jefferson Davis Highway,Suite 501, Arlington, VA 22202.Code for Safety in Welding and Cutting, CSA Standard W117.2, fromCanadian Standards Association, Standards Sales, 178 RexdaleBoulevard, Rexdale, Ontario, Canada M9W 1R3.Safe Practices For Occupation And Educational Eye And FaceProtection, ANSI Standard Z87.1, from American National StandardsInstitute, 1430 Broadway, New York, NY 10018.Cutting And Welding Processes, NFPA Standard 51B, from NationalFire Protection Association, Batterymarch Park, Quincy, MA 02269.

OM-1318 Page 4

1-5. EMF Information

Considerations About Welding And The Effects Of Low FrequencyElectric And Magnetic FieldsWelding current, as it flows through welding cables, will cause electro-magnetic fields. There has been and still is some concern about suchfields. However, after examining more than 500 studies spanning 17years of research, a special blue ribbon committee of the NationalResearch Council concluded that: The body of evidence, in thecommittees judgment, has not demonstrated that exposure to power-frequency electric and magnetic fields is a human-health hazard.However, studies are still going forth and evidence continues to beexamined. Until the final conclusions of the research are reached, youmay wish to minimize your exposure to electromagnetic fields whenwelding or cutting.To reduce magnetic fields in the workplace, use the followingprocedures:

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

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

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

4. Keep welding power source and cables as far away from opera-tor as practical.

5. Connect work clamp to workpiece as close to the weld as possi-ble.

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

OM-1318 Page 5

SECTION 1 CONSIGNES DE SECURITE LIRE AVANTUTILISATION

som _nd_fre 4/98

1-1. Signification des symboles

Signifie Mise en garde ! Soyez vigilant ! Cette procdureprsente des risques de danger ! Ceux-ci sont identifispar des symboles adjacents aux directives.

Identifie un message de scurit particulier.

Signifie NOTA ; nest pas relatif la scurit.

Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a desrisques de danger relis aux CHOCS LECTRIQUES, aux PICES ENMOUVEMENT et aux PICES CHAUDES. Reportez-vous aux symboleset aux directives ci-dessous afin de connatre les mesures prendre pourviter tout danger.

1-2. Dangers relatifs au soudage larc

Les symboles prsents ci-aprs sont utiliss tout au long duprsent manuel pour attirer votre attention et identifier les risquesde danger. Lorsque vous voyez un symbole, soyez vigilant etsuivez les directives mentionnes afin dviter tout danger. Lesconsignes de scurit prsentes ci-aprs ne font que rsumerlinformation contenue dans les normes de scurit numres la section 1-4. Veuillez lire et respecter toutes ces normes descurit.

Linstallation, lutilisation, lentretien et les rparations ne doi-vent tre confis qu des personnes qualifies.

Au cours de lutilisation, tenir toute personne lcart et plus par-ticulirement les enfants.

UN CHOC LECTRIQUE peut tuer.

Un simple contact avec des pices lectriques peutprovoquer une lectrocution ou des blessures graves.Llectrode et le circuit de soudage sont sous tensionds que lappareil est sur ON. Le circuit dentre et lescircuits internes de lappareil sont galement sous

tension ce moment-l. En soudage semi-automatique ou automatique,le fil, le dvidoir, le logement des galets dentranement et les picesmtalliques en contact avec le fil de soudage sont sous tension. Desmatriels mal installs ou mal mis la terre prsentent un danger.

Ne jamais toucher les pices lectriques sous tension. Porter des gants et des vtements de protection secs ne comportant

pas de trous. Sisoler de la pice et de la terre au moyen de tapis ou dautres

moyens isolants suffisamment grands pour empcher le contact phy-sique ventuel avec la pice ou la terre.

Ne pas se servir de source lectrique courant lectrique dans les zoneshumides, dans les endroits confins ou l o on risque de tomber.

Se servir dune source lectrique courant lectrique UNIQUEMENT si leprocd de soudage le demande.

Si lutilisation dune source lectrique courant lectrique savre nces-saire, se servir de la fonction de tlcommande si lappareil en est quip.

Couper lalimentation ou arrter le moteur avant de procder linstal-lation, la rparation ou lentretien de lappareil. Dverrouillerlalimentation selon la norme OSHA 29 CFR 1910.147 (voir normes descurit).

Installer et mettre la terre correctement cet appareil conformment son manuel dutilisation et aux codes nationaux, provinciaux etmunicipaux.

Toujours vrifier la terre du cordon dalimentation Vrifier et sassu-rer que le fil de terre du cordon dalimentation est bien raccord laborne de terre du sectionneur ou que la fiche du cordon est raccorde une prise correctement mise la terre.

En effectuant les raccordements dentre fixer dabord le conducteurde mise la terre appropri et contre-vrifier les connexions.

Vrifier frquemment le cordon dalimentation pour voir sil nest pasendommag ou dnud remplacer le cordon immdiatement sil estendommag un cble dnud peut provoquer une lectrocution.

Mettre lappareil hors tension quand on ne lutilise pas. Ne pas utiliser des cbles uss, endommags, de grosseur insuffi-

sante ou mal pisss. Ne pas enrouler les cbles autour du corps. Si la pice soude doit tre mise la terre, le faire directement avec un

cble distinct. Ne pas toucher llectrode quand on est en contact avec la pice, la

terre ou une lectrode provenant dune autre machine.

Nutiliser quun matriel en bon tat. Rparer ou remplacer sur-le-champ les pices endommages. Entretenir lappareil conformment ce manuel.

Porter un harnais de scurit quand on travaille en hauteur.

Maintenir solidement en place tous les panneaux et capots.

Fixer le cble de retour de faon obtenir un bon contact mtal-mtalavec la pice souder ou la table de travail, le plus prs possible de lasoudure.

Isoler la pince de masse quand pas mis la pice pour viter le contactavec tout objet mtallique.

Il y a DU COURANT CONTINU IMPORTANT dans lesconvertisseurs aprs la suppression de lalimenta-tion lectrique. Arrter les convertisseurs, dbrancher le courant lectrique, et d-

charger les condensateurs dalimentation selon les instructionsindiques dans la partie entretien avant de toucher les pices.

Le soudage gnre des fumes et des gaz. Leurinhalation peut tre dangereux pour votre sant.

Eloigner votre tte des fumes. Ne pas respirerles fumes.

A lintrieur, ventiler la zone et/ou utiliser un chappement au niveaude larc pour lvacuation des fumes et des gaz de soudage.

Si la ventilation est insuffisante, utiliser un respirateur alimenta-tion dair homologu.

Lire les spcifications de scurit des matriaux (MSDSs) et lesinstructions du fabricant concernant les mtaux, les consomma-bles, les revtements, les nettoyants et les dgraisseurs.

Travailler dans un espace ferm seulement sil est bien ventil ou enportant un respirateur alimentation dair. Demander toujours unsurveillant dment form de se tenir proximit. Des fumes et desgaz de soudage peuvent dplacer lair et abaisser le niveau doxy-gne provoquant des blessures ou des accidents mortels. Sassu-rer que lair de respiration ne prsente aucun danger.

Ne pas souder dans des endroits situs proximit doprations dedgraissage, de nettoyage ou de pulvrisation. La chaleur et lesrayons de larc peuvent ragir en prsence de vapeurs et former desgaz hautement toxiques et irritants.

Ne pas souder des mtaux munis dun revtement, tels que laciergalvanis, plaqu en plomb ou au cadmium moins que le revte-ment nait t enlev dans la zone de soudure, que lendroit soit bienventil, et si ncessaire, en portant un respirateur alimentationdair. Les revtements et tous les mtaux renfermant ces lmentspeuvent dgager des fumes toxiques en cas de soudage.

LES FUMES ET LES GAZ peuventtre dangereux.

OM-1318 Page 6

Le rayonnement de larc du procd de soudagegnre des rayons visibles et invisibles intenses(ultraviolets et infrarouges) susceptibles de provoquer

des brlures dans les yeux et sur la peau. Des tincelles sont projetespendant le soudage.

LES RAYONS DE LARC peuvent pro-voquer des brlures dans les yeux etsur la peau.

Porter un casque de soudage muni dun cran de filtre appropri pourprotger votre visage et vos yeux pendant le soudage ou pour regar-der (voir ANSI Z49.1 et Z87.1 numr dans les normes de scurit).

Porter des protections approuvs pour les oreilles si le niveau sondre esttrop lev.

Utiliser des crans ou des barrires pour protger des tiers de lclairet de lblouissement; demander aux autres personnes de ne pas re-garder larc.

Porter des vtements de protection constitu dans une matire dura-ble, rsistant au feu (cuir ou laine) et une protection des pieds.

Le soudage effectu sur des conteneurs ferms telsque des rservoirs, tambours ou des conduites peutprovoquer leur clatement. Des tincelles peuvent treprojetes de larc de soudure. La projection dtincel-

les, des pices chaudes et des quipements chauds peut provoquer desincendies et des brlures. Le contact accidentel de llectrode avec desobjets mtalliques peut provoquer des tincelles, une explosion, unsurchauffement ou un incendie. Avant de commencer le soudage, vrifieret sassurer que lendroit ne prsente pas de danger.

LE SOUDAGE peut provoquer unincendie ou une explosion.

Se protger et dautres personnes de la projection dtincelles et demtal chaud.

Ne pas souder dans un endroit l o des tincelles peuvent tomber surdes substances inflammables.

Dplacer toutes les substances inflammables une distance de 10,7m de larc de soudage. En cas dimpossibilit les recouvrir soigneuse-ment avec des protections homologus.

Des tincelles et des matriaux chauds du soudage peuvent facile-ment passer dans dautres zones en traversant de petites fissures etdes ouvertures.

Surveiller tout dclenchement dincendie et tenir un extincteur proxi-mit.

Le soudage effectu sur un plafond, plancher, paroi ou sparationpeut dclencher un incendie de lautre ct.

Ne pas effectuer le soudage sur des conteneurs ferms tels que desrservoirs, tambours, ou conduites, moins quils naient t prpa-rs correctement conformment AWS F4.1 (voir les normes descurit).

Brancher le cble sur la pice le plus prs possible de la zone de sou-dage pour viter le transport du courant sur une longue distance pardes chemins inconnus ventuels en provoquant des risques dlec-trocution et dincendie.

Ne pas utiliser le poste de soudage pour dgeler des conduites ge-les.

En cas de non utilisation, enlever la baguette dlectrode du porte-lectrode ou couper le fil la pointe de contact.

Porter des vtements de protection dpourvus dhuile tels que desgants en cuir, une chemise en matriau lourd, des pantalons sans re-vers, des chaussures hautes et un couvre chef.

Avant de souder, retirer toute substance combustible de vos pochestelles quun allumeur au butane ou des allumettes.

DES PARTICULES VOLANTESpeuvent blesser les yeux.

Le soudage, lcaillement, le passage de la pice la brosse en fil de fer, et le meulage gnrentdes tincelles et des particules mtalliques vo-

lantes. Pendant la priode de refroidissement des soudures, elles ris-quent de projeter du laitier. Porter des lunettes de scurit avec crans latraux ou un cran facial.

LES ACCUMULATIONS DE GAZ ris-quent de provoquer des blessures oumme la mort.

Fermer lalimentation du gaz protecteur en cas denon utilisation.

Veiller toujours bien arer les espaces confins ou se servir dun respi-rateur dadduction dair homologu.

DES PICES CHAUDES peuvent pro-voquer des brlures graves.

Ne pas toucher des parties chaudes mains nues Prvoir une priode de refroidissement avant

dutiliser le pistolet ou la torche.

LES CHAMPS MAGNTIQUES peuventaffecter les stimulateurs cardiaques.

Porteurs de stimulateur cardiaque, restez distance. Les porteurs dun stimulateur cardiaque doivent

dabord consulter leur mdecin avant de sapprocherdes oprations de soudage larc, de gougeage oude soudage par points.

LE BRUIT peut affecter loue.

Le bruit des processus et des quipements peut affecterloue.

Porter des protections approuvs pour les oreilles sile niveau sondre est trop lev.

Des bouteilles de gaz protecteur contiennent du gazsous haute pression. Si une bouteille est endomma-ge, elle peut exploser. Du fait que les bouteilles de gazfont normalement partie du procd de soudage, les

manipuler avec prcaution.

Protger les bouteilles de gaz comprim dune chaleur excessive,des chocs mcaniques, du laitier, des flammes ouvertes, des tin-celles et des arcs.

Placer les bouteilles debout en les fixant dans un support stationnai-re ou dans un porte-bouteilles pour les empcher de tomber ou dese renverser.

Tenir les bouteilles loignes des circuits de soudage ou autres cir-cuits lectriques.

Ne jamais placer une torche de soudage sur une bouteille gaz. Une lectrode de soudage ne doit jamais entrer en contact avec une

bouteille. Ne jamais souder une bouteille pressurise risque dexplosion. Utiliser seulement des bouteilles de gaz protecteur, rgulateurs,

tuyaux et raccords convenables pour cette application spcifique;les maintenir ainsi que les lments associs en bon tat.

Ne pas tenir la tte en face de la sortie en ouvrant la soupape de labouteille.

Maintenir le chapeau de protection sur la soupape, sauf en cas duti-lisation ou de branchement de la bouteille.

Lire et suivre les instructions concernant les bouteilles de gaz com-prim, les quipements associs et les publications P-1 CGA nu-mres dans les normes de scurit.

Si des BOUTEILLES sont endomma-ges, elles pourront exploser.

OM-1318 Page 7

1-3. Dangers supplmentaires en relation avec linstallation, le fonctionnementet la maintenance

Risque DINCENDIE OUDEXPLOSION.

Ne pas placer lappareil sur, au-dessus ou proxi-mit de surfaces infllammables.

Ne pas installer lappareil proximit de produits inflammables Ne pas surcharger linstallation lectrique sassurer que lalimen-

tation est correctement dimensionn et protg avant de mettrelappareil en service.

LA CHUTE DE LAPPAREIL peutblesser.

Utiliser lanneau de levage uniquement pour sou-lever lappareil, NON PAS les chariot, les bouteil-les de gaz ou tout autre accessoire.

Utiliser un engin dune capacit approprie poursoulever lappareil.

En utilisant des fourches de levage pour dplacer lunit, sassurerque les fourches sont suffisamment longues pour dpasser du ctoppos de lappareil.

LEMPLOI EXCESSIF peutSURCHAUFFER LQUIPEMENT.

Prvoir une priode de refroidissement, respec-ter le cycle opratoire nominal.

Rduire le courant ou le cycle opratoire avant derecommancer le soudage.

Ne pas obstruer les passages dair du poste.

LES CHARGES LECTROSTATI-QUES peuvent endommager les cir-cuits imprims.

tablir la connexion avec la barrette de terreavant de manipuler des cartes ou des pices.

Utiliser des pochettes et des botes antistatiquespour stocker, dplacer ou expdier des cartes decircuits imprimes.

DES ORGANES MOBILES peuventprovoquer des blessures.

Ne pas sapprocher des organes mobiles. Ne pas sapprocher des points de coincement

tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuvent pro-voquer des blessures.

Ne pas appuyer sur la gachette avant den avoirreu linstruction.

Ne pas diriger le pistolet vers soi, dautres person-nes ou toute pice mcanique en engageant le filde soudage.

DES ORGANES MOBILES peuventprovoquer des blessures.

Rester lcart des organes mobiles comme leventilateur.

Maintenir ferms et fixement en place les portes,panneaux, recouvrements et dispositifs deprotection.

LE RAYONNEMENT HAUTE FR-QUENCE (H.F.) risque de provoquerdes interfrences.

Le rayonnement haute frequence peut provoquerdes interfrences avec les quipements de ra-dionavigation et de communication, les servicesde scurit et les ordinateurs.

Demander seulement des personnes qualifies familiarisesavec des quipements lectroniques de faire fonctionner linstalla-tion.

Lutilisateur est tenu de faire corriger rapidement par un lectricienqualifi les interfrences rsultant de linstallation.

Si le FCC signale des interfrences, arrter immdiatement lappa-reil.

Effectuer rgulirement le contrle et lentretien de linstallation. Maintenir soigneusement ferms les portes et les panneaux des

sources de haute frquence, maintenir les clateurs une distancecorrecte et utiliser une terre et et un blindage pour rduire les interf-rences ventuelles.

LE SOUDAGE LARC risque deprovoquer des interfrences.

Lnergie lectromagntique risque de provoquerdes interfrences pour lquipement lectroniquesensible tel que les ordinateurs et lquipementcommand par ordinateur tel que les robots.

Veiller ce que tout lquipement de la zone de soudage soit com-patible lectromagntiquement.

Pour rduire la possibilit dinterfrence, maintenir les cbles desoudage aussi courts que possible, les grouper, et les poser aussibas que possible (ex. par terre).

Veiller souder une distance de 100 mtres de tout quipementlectronique sensible.

Veiller ce que ce poste de soudage soit pos et mis la terreconformment ce mode demploi.

En cas dinterfrences aprs avoir pris les mesures prcdentes, ilincombe lutilisateur de prendre des mesures supplmentaires tel-les que le dplacement du poste, lutilisation de cbles blinds, luti-lisation de filtres de ligne ou la pose de protecteurs dans la zone detravail.

LES CHAMPS MAGNTIQUES peuventaffecter les stimulateurs cardiaques.

Porteurs de stimulateur cardiaque, restez dis-tance.

Les porteurs dun stimulateur cardiaque doiventdabord consulter leur mdecin avant de sappro-cher des oprations de soudage larc, de gou-geage ou de soudage par points.

OM-1318 Page 8

1-4. Principales normes de scurit

Safety in Welding and Cutting, norme ANSI Z49.1, de lAmerican Wel-ding Society, 550 N.W. Lejeune Rd, Miami FL 33126

Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendentof Documents, U.S. Government Printing Office, Washington, D.C.20402.

Recommended Safe Practice for the Preparation for Welding and Cut-ting of Containers That Have Held Hazardous Substances, norme AWSF4.1, de lAmerican Welding Society, 550 N.W. Lejeune Rd, Miami FL33126

National Electrical Code, NFPA Standard 70, de la National Fire Protec-tion Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,de la Compressed Gas Association, 1235 Jefferson Davis Highway,Suite 501, Arlington, VA 22202.

Rgles de scurit en soudage, coupage et procds connexes, normeCSA W117.2, de lAssociation canadienne de normalisation, vente denormes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.

Safe Practices For Occupation And Educational Eye And Face Protec-tion, norme ANSI Z87.1, de lAmerican National Standards Institute,1430 Broadway, New York, NY 10018.

Cutting and Welding Processes, norme NFPA 51B, de la National FireProtection Association, Batterymarch Park, Quincy, MA 02269.

1-5. Information sur les champs lectromagntiques

Donnes sur le soudage lectrique et sur les effets, pour lorganisme,des champs magntiques basse frquence

Le courant de soudage, pendant son passage dans les cbles de sou-dage, causera des champs lectromagntiques. Il y a eu et il y a encoreun certain souci propos de tels champs. Cependant, aprs avoir ex-amin plus de 500 tudes qui ont t faites pendant une priode derecherche de 17 ans, un comit spcial ruban bleu du National Re-search Council a conclu: Laccumulation de preuves, suivant lejugement du comit, na pas dmontr que lexposition aux champsmagntiques et champs lectriques haute frquence reprsente unrisque la sant humaine. Toutefois, des tudes sont toujours en courset les preuves continuent tre examines. En attendant que les con-clusions finales de la recherche soient tablies, il vous seraitsouhaitable de rduire votre exposition aux champs lectromagnti-ques pendant le soudage ou le coupage.

Afin de rduire les champs lectromagntiques dans lenvironnementde travail, respecter les consignes suivantes :

1 Garder les cbles ensembles en les torsadant ou en lesattachant avec du ruban adhsif.

2 Mettre tous les cbles du ct oppos de loprateur.

3 Ne pas courber pas et ne pas entourer pas les cbles autour devotre corps.

4 Garder le poste de soudage et les cbles le plus loin possible devous.

5 Relier la pince de masse le plus prs possible de la zone desoudure.

Consignes relatives aux stimulateurs cardiaques :

Les personnes qui portent un stimulateur cardiaque doivent avant toutconsulter leur docteur. Si vous tes dclar apte par votre docteur, il estalors recommand de respecter les consignes cidessus.

OM-1318 Page 9

SECTION 2 SPECIFICATIONS2-1. Specifications

Rated WeldingOutput

AmperageRange

Maximum Open-Circuit Voltage

DC

Amperes Input atRated Load Output

230 V, 60 Hz,Single-Phase

KVA KWWeightW/ Gun

Overall Dimensions

130 A @ 20 VoltsDC, 30% Duty Cycle 40 170 30 19.4 (0.28)*

4.490.86*

3.830.043*

80 lb(36 kg)

Length: 17 in(432 mm)

Width: 10 in(254 mm)

Height: 15-1/2 in(394 mm)

Wire TypeAnd Dia

Solid/Stainless

Flux Cored Aluminum Wire Feed Speed Range At No Load

.023 .035 in(0.6 0.9 mm)

.030 .045 in(0.8 1.2 mm)

.030 .035 in(0.8 0.9 mm)

220 700 IPM (5.6 18 m/min)

* While idling

2-2. Volt-Ampere Curves

The volt-ampere curves show theminimum and maximum voltageand amperage output capabilities ofthe welding power source. Curvesof other settings fall between thecurves shown.

ssb1.1 10/91 SB-187 997

OM-1318 Page 10

2-3. Welding Power Source Duty Cycle And Overheating

Duty Cycle is percentage of 10 min-utes that unit can weld at rated loadwithout overheating.

If unit overheats, thermostat(s)opens, output stops, and coolingfan runs. Wait fifteen minutes forunit to cool. Reduce amperage orduty cycle before welding.

Exceeding duty cycle candamage unit or gun and voidwarranty.

30% Duty Cycle At 130 Amperes

Overheating

0

15

A or V

ORReduce Duty Cycle

Minutes

duty1 4/95 SB-180 844

300

250

200

150

100

75

50

10 15 20 25 30 40 50 60 70 80 100

DC

AM

PE

RE

S

% DUTY CYCLE

3 Minutes Welding 7 Minutes Resting

2-4. Welding Gun Duty Cycle And Overheating

CAUTIONWELDING LONGER THAN RATED DUTY CYCLE can damage gun and void warranty. Do not weld at rated load longer than shown below. Using gasless flux cored wire reduces gun duty cycle. warn7.1 8/93

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

Continuous WeldingSB1.1 8/93

0

10Minutes

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

100% Duty Cycle At 100 AmperesUsing CO2

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

60% Duty Cycle At 100 AmperesUsing Mixed Gases

6 Minutes Welding 4 Minutes Resting

OM-1318 Page 11

SECTION 3 INSTALLATION

3-1. Installing Work Clamp

1 Insulator

2 Bolt

3 Smaller Hole

4 Work Clamp Tabs

Bend tabs around work cable.

5 Work Cable From Unit6 Nut

1

2

3

4

5

6

Ref. ST-025 190-D

Tools Needed:

3/8, 7/16 in

3-2. Installing Welding Gun And Changing Polarity

1 Drive Assembly

2 Gun Securing Bolt

3 Gun End

Loosen securing bolt. Insert gunend through opening until it bottomsagainst drive assembly. Tightenbolt.

4 Gun Trigger Plug

Insert plug into receptacle, andtighten threaded collar.

5 Jumper Links

Place jumper links in positionshown for desired polarity.

Close door.

Tools Needed:

2

1 34

Ref. ST-801 987

5/16 in

Straight PolarityDCEN

Reverse PolarityDCEP

Flux Cored Wires(FCAWWithout Gas)

Solid Steel OrAluminum Wires

(GMAWWith Gas)

Follow wire manufacturers recommendation.

5

OM-1318 Page 12

3-3. Installing Gas Supply

Obtain gas cylinder and chain torunning gear, wall, or other station-ary support so cylinder cannot falland break off valve.

1 Cap

2 Cylinder Valve

Remove cap, stand to side of valve,and open valve slightly. Gas flowblows dust and dirt from valve.Close valve.

3 Cylinder

4 Regulator/Flowmeter

Install so face is vertical.

5 Gas Hose Connection

Fitting has 5/8-18 right-handthreads.

6 Gas Fitting

Install gas hose between gas hoseconnction on regulator/flowmeterand gas fitting on rear of weldingpower source.

7 Flow Adjust

Typical flow rate is 20 cfh (cubic feetper hour). Check wire manufactur-ers recommended flow rate.

8 CO2 Adapter

9 O-Ring

Install adapter with O-ring betweenregulator/flowmeter and CO2cylinder.

Tools Needed:

CO2 Gas

8 9

3

1

2

45

7

1

2

3

Argon Gas

OR

ssb3.1* 12/92 ST-158 697-A / ST-801 986

5/8, 1-1/8 in

6

OM-1318 Page 13

3-4. Electrical Service Guide

Input Voltage 230

Input Amperes At Rated Output 20

Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes

Circuit Breaker 1, Time-Delay 2 20

Normal Operating 3 30

Min Input Conductor Size In AWG/Kcmil 14

Max Recommended Input Conductor Length In Feet (Meters)66

(20)

Min Grounding Conductor Size In AWG/Kcmil 14

Reference: 1999 National Electrical Code (NEC)

1 Choose a circuit breaker with time-current curves comparable to a Time Delay Fuse.

2 Time-Delay fuses are UL class RK5 .3 Normal Operating (general purpose no intentional delay) fuses are UL class K5 (up to and including 60 amp), and UL class H ( 65 amp and

above). Caution: Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard.

3-5. Selecting A Location And Connecting Input Power

1 Rating Label

Supply correct input power.

2 Plug

3 Receptacle

Connect plug to receptacle.

4 Line Disconnect Device

See Section 3-4.

Special installation may berequired where gasoline orvolatile liquids are present see NEC Article 511 or CECSection 20.

ssb2.2* 1/94 ST-801 988 / 802 401

1

18 in (457 mm) ofspace for airflow

L1L2

L1

L2

2

230 VAC, 1

Always connectgroundingconductor first.

= GND/PE

4

3

Do not move or operate unitwhere it could tip.

OM-1318 Page 14

3-6. Installing Wire Spool And Adjusting Hub Tension

S-0499

15/16 in

Standard Wire Spool 1 Lb Wire Spool

When a slight force is neededto turn spool, tension is set.

Tools Needed:

Standard Wire Reel

Part No. 183 312 Part No. 135 615

OM-1318 Page 15

3-7. Installing Drive Roll, Wire Guide And Threading Welding Wire

1 Drive roll

Choose correct drive roll for wiretype, and align drive roll with flatspot on shaft. Slide drive roll ontoshaft and secure with screw.

2 Inlet Wire Guide

Remove guide by pressing onbarbed area or cutting off one endnear housing and pulling it out ofhole. Push new guide into hole fromrear until it snaps in place.

Tools Needed:

1

2

WOOD

6 in(150 mm)

Pull and hold wire; cut off end.

4 in(102 mm)

Open pressure assembly. Push wire thru guides into gun;continue to hold wire.

Close and tighten pressureassembly, and let go of wire.

Remove gun nozzle and contact tip. Turn power on.

Press gun trigger until wirecomes out of gun.

Reinstall contact tip, and nozzle. Feed wire to check drive rollpressure. Tighten knob

enough to prevent slipping.Cut off wire. Close door.

Ref. ST-801 987 / Ref. ST-801 872 / Ref. 802 399-A / S-0627-A

OM-1318 Page 16

3-8. Weld Parameter

Material ThicknessWire Type,

Shielding Gas,And Flow Rate

WireDiameter

(inch)

OperatorControls 1/4 in

(6.4mm)

3/16 in(4.8mm)

1/8 in (3.2mm)

14 ga 16 ga 18 ga 20 ga 22 ga

Voltage Tap* 3 3 2 2 1 1.023

Wire Speed 65 60 55 50 50 40

E70S-6 Voltage Tap* 4 3 3 3 2 2 1 1CO2

20 cfh+.030

Wire Speed 60 55 50 40 35 30 25 20

Voltage Tap* 4 3 3 2 2 2 .035

Wire Speed 50 50 50 45 40 30

Voltage Tap* 3 3 2 2 1 1.023

Wire Speed 80 70 60 55 50 40

E70S-675% Argon

Voltage Tap* 4 4 3 3 2 2 1 175% Argon25% CO220 cfh+

.030Wire Speed 75 70 60 55 50 40 35 3020 cfh+

Voltage Tap* 4 3 3 2 2 2 1 .035

Wire Speed 55 55 50 45 40 35 25

Voltage Tap* 4 4 3 3 2 2 .030

Wire Speed 70 60 50 40 40 35

E71T-GSVoltage Tap* 4 4 3 2 1

E71T-GSFlux Core .035

Wire Speed 60 50 40 40 40

Voltage Tap* 4 4 3 .045

Wire Speed 50 45 40

Voltage Tap* 4 3 3 3 2 2 .023

Wire Speed 100 90 80 75 35 30

ER 308Stainless Steel

Voltage Tap* 4 3 3 2 4 2 Stainless Steel

Tri-Mix20 cfh+

.030Wire Speed 80 70 65 60 50 40 20 cfh+

Voltage Tap* 4 3 3 .035

Wire Speed 75 68 60

Voltage Tap* 4 3 2 1

Aluminum 5356.030**

Wire Speed 100 100 100 100 100% Argon

20 cfh Voltage Tap* 4 3 .035**

Wire Speed 100 100

*Do not change Voltage switch position while welding. Wire Speed value in Table is a starting value only, and Wire Speed control setting can be finetuned during welding.

** When welding aluminum, for best results, use .023.035 v-knurled drive roll and a contact tip one size larger than wire diameter... Ref. S-187 939

OM-1318 Page 17

SECTION 4 OPERATION4-1. Controls

1 Wire Speed Control

Use control to select a wire feedspeed. As Voltage switch setting in-creases, wire speed range also in-creases (see weld setting label inwelding power source).

Ref. ST-187 921

2

4

1

3

2 Voltage Switch

Switch must click into detentposition 1, 2, 3, or 4 for propercontact.

The higher the selected number,the thicker the material that can bewelded (see weld setting label inwelding power source). Do notswitch under load.

3 Voltage Switch - Fan OnlyPosition

In Fan Only position, fan runs butthere is no weld output.

4 Power Switch

OM-1318 Page 18

SECTION 5 MAINTENANCE &TROUBLESHOOTING5-1. Routine Maintenance

Disconnect power before maintaining.

3 Months

Replaceunreadablelabels.

Repair orreplacecrackedweld cable.

Clean andtighten weldterminals.

6 Months

Blow out orvacuum inside.during heavyservice, cleanmonthly.

Or

Remove drive rolland apply light coatof oil or grease todrive motor shaft.

5-2. Drive Motor Fuse F1

Turn Off power, unlatch doorand remove wrapper.

1 Circuit Board PC1

2 Fuse F1 (See Parts List ForRating)

If drive motor is inoperative, pullfuse from fuse holder on PC1. Re-place fuse if necessary. To reinstall,push fuse into fuse holder.

Reinstall wrapper, and latch door.

ST-801 867

3/8 in

Tools Needed:

1 2

5-3. Short Circuit Shutdown

If contact tip is shorted and sticks to workpiece, the unit shuts down, but fan runs. To resume operation, release guntrigger, turn Off unit, and remove contact tip from workpiece. Check contact tip and replace if damaged. Turn On unit tocontinue operation.

OM-1318 Page 19

5-4. Cleaning Or Repairing Drive Assembly

Turn Off power beforecleaning or repairing driveassembly.

1 Wire Spool

2 Nozzle

Cut welding wire off at nozzle. Re-tract wire onto spool and secure.

3 Pressure Roll Arm

4 Cotter Pin

5 Pin

6 Screw

7 Bearing

Remove bearing. Install new bear-ing and secure with screw. Reinstallarm onto pin and secure with cotterpin.

8 Screw

9 Drive Roll

Remove drive roll.

Align drive roll with flat spot onshaft. Slide drive roll onto shaft andsecure with screw.

10 Wire Inlet Guide

Remove guide by pressing onbarbed area or cutting off one endnear housing and pulling it out ofhole. Push new guide into hole fromrear until it snaps in place.

Close door.

2

6 7

8

10

3

49

1

5

Ref. ST-801 987 / Ref. ST-801 872

Tools Needed:

5/64 in

5-5. Replacing Gun Contact Tip

Ref. 802 399-A

Turn Off power beforereplacing contact tip.

1 Nozzle

2 Contact Tip

Cut off welding wire at contact tip.Remove nozzle.

Remove contact tip and install newcontact tip. Reinstall nozzle.

1

2Tools Needed:

OM-1318 Page 20

5-6. Cleaning Or Replacing Gun Liner

Ref. ST-802 399-A

3/8 in

Disconnect gun from unit.Tools Needed:

To Reassemble Gun:

Insert new liner.

Install wire outlet guide so that 1/8in (3 mm) of liner sticks out. Handtighten outlet guide, and then tight-en two full turns more.

Cut liner off so that 3/4 in (19 mm)sticks out of head tube.

Install gas diffuser, adapter, contacttip, and nozzle.

Lay gun cable out straightbefore installing new liner.

Head Tube

1/2 in

Remove liner.

Remove nozzle, contact tip,adapter, gas diffuser, and wireoutlet guide.

Blow out gun casing.

OM-1318 Page 21

5-7. Replacing Switch And/Or Head Tube

Ref. ST-800 795-C

1 Remove handlelocking nut.

2 Remove switch housing. Note: If installing newswitch, push switch lead connectors onto terminal ofnew switch (polarity is not important). Install switchback into handle, and secure with handle locking nut.If replacing head tube, continue to end of figure.

3 Slide handle.

4 Secure headtube in vice.

5 Loosen jam nut. Removefrom vice and turn headtube out by hand.

6 Install existing shock washer ontonew head tube. Hand-tighten headtube into connector cable.

7 Place head tube in vice and tightenuntil nuts are tight.

8 Remove from vice. Repositionhandle and install switch housing.Secure with handle locking nut.

Disconnect gun first.

3/4 in

Tools Needed:

OM-1318 Page 22

5-8. Troubleshooting Table

Trouble Remedy

No weld output; wire does not feed; fan Secure power cord plug in receptacle (see Section 3-5).does not run.

Replace building line fuse or reset circuit breaker if open (see Section 3-5).

Secure gun trigger plug in receptacle (see Section 3-2).

Place Power switch in On position (see Section 4-1).

No weld output; wire does not feed; fanmotor continues to run.

Check Voltage control knob. Switch must click into detent position 1, 2, 3, or 4 for proper contact (seeSection 4-1).

Thermostat TP1 open (overheating). Allow fan to run; thermostat closes when unit has cooled (seeSection 2-3).

Check and replace motor fuse F1, if necessary (see Section 5-2).

Have Factory Authorized Service Agent check all board connections and shut down PC1 board.

No weld output; wire feeds. Connect work clamp to get good metal to metal contact.

Replace contact tip (see Section 5-5).

Check for proper connections at polarity changeover board (see Section 3-2).

Low weld output. Connect unit to proper input voltage or check for low line voltage.

Place voltage switch in desired position (see Section 4-1).

Electrode wire feeding stops during Straighten gun cable and/or replace damaged parts (see Section 5-6).welding.

Adjust drive roll pressure (see Section 3-7).

Change to proper drive roll groove (see Section 3-7).

Readjust hub tension (see Section 3-6).

Replace contact tip if blocked (see Section 5-5).

Clean or replace wire inlet guide or liner if dirty or plugged (see Section 5-4 and/or 5-6).

Replace drive roll or pressure bearing if worn or slipping (see Section 5-4).

Secure gun trigger plug in receptacle or repair leads, or replace trigger switch (see Section 3-2).

Check motor fuse F1, and replace if necessary (see Section 5-2).

Check and clear any restrictions at drive assembly and liner (see Section 5-4 and/or 5-6).

Have nearest Factory Authorized Service Agent check drive motor.

OM-1316 Page 23

SECTION 6 ELECTRICAL DIAGRAM

SB-210 034

Figure 6-1. Circuit Diagram

OM-1318 Page 24

SECTION 7 MIG WELDING (GMAW) GUIDELINES

7-1. Typical MIG Process Connections

Weld current can damageelectronic parts in vehicles.Disconnect both batterycables before welding on avehicle. Place work clamp asclose to the weld as possible.

Wire Feeder/Power Source

Workpiece

Gun

Regulator/Flowmeter

Gas

Shielding Gas

Work Clamp

light mig 5/967 / ST-801 909

OM-1318 Page 25

7-2. Typical MIG Process Control Settings

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

NOTE

1/8 or.125 in

Material thickness determines weldparameters.

Convert Material

(.001 in = 1 ampere).125 in = 125 A

Select Wire Size

Wire Size Amperage Range

.030 in

.035 in

.023 in

40 145 A

50 180 A

30 90 A

.035 in

Select Wire Speed

Select Voltage

Wire Recommendation

.030 in

.035 in

.023 in2 in per ampere

1.6 in per ampere

3.5 in per ampere

Wire Speed

2 x 125 A = 250 ipm

1.6 x 125 A = 200 ipm

3.5 x 125 A = 437 ipm

Set voltage midway between high/low voltage.

Low voltage: wire stubs into work

High voltage: arc is unstable (spatter)

125 A based on 1/8 in

Thickness to

(Amperage)

material thickness

Size (Approx.)

Amperage (A)

ipm = inch per minute

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

Voltage controls height and width ofweld bead.

Ref. ST-801 865

OM-1318 Page 26

7-3. Holding And Positioning Welding Gun

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

NOTE

1 Hold Gun and Control GunTrigger

2 Workpiece

3 Work Clamp

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

5 Cradle Gun and Rest Hand onWorkpiece

23

5

4

90 90

0-15

45

45

GROOVE WELDS

FILLET WELDS

End View Of Work Angle Side View Of Gun Angle

End View Of Work Angle Side View Of Gun Angle

1

0-15

S-0421-A

OM-1318 Page 27

7-4. Conditions That Affect Weld Bead Shape

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

NOTE

Short Normal Long

Short Normal Long

10

10

GUN ANGLES AND WELD BEAD PROFILES

ELECTRODE EXTENSIONS (STICKOUT)

FILLET WELD ELECTRODE EXTENSIONS (STICKOUT)

Push

Perpendicular Drag

GUN TRAVEL SPEED

Slow Normal Fast

S-0634

OM-1318 Page 28

7-5. Gun Movement During Welding

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

NOTE

1 Stringer Bead SteadyMovement Along Seam

2 Weave Bead Side To SideMovement Along Seam

3 Weave Patterns

Use weave patterns to cover a widearea in one pass of the electrode.

S-0054-A

3

1 2

7-6. Poor Weld Bead Characteristics

1 Large Spatter Deposits

2 Rough, Uneven Bead

3 Slight Crater During Welding

4 Bad Overlap

5 Poor Penetration

5

42 3

1

S-0053-A

7-7. Good Weld Bead Characteristics

1 Fine Spatter

2 Uniform Bead

3 Moderate Crater DuringWelding

Weld a new bead or layer for each1/8 in (3.2 mm) thickness in metalsbeing welded.

4 No Overlap

5 Good Penetration into BaseMetal

S-0052-B

2 3

1

4

5

OM-1318 Page 29

7-8. Troubleshooting Excessive Spatter

Excessive Spatter scattering of molten metal particles thatcool to solid form near weld bead.

S-0636

Possible Causes Corrective Actions

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

Voltage too high. Select lower voltage range.

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

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

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

Dirty welding wire. Use clean, dry welding wire.

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

7-9. Troubleshooting Porosity

Porosity small cavities or holes resulting from gas pocketsin weld metal.

S-0635


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

Remove spatter from gun nozzle.

Check gas hoses for leaks.

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

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

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

Dirty welding wire. Use clean, dry welding wire.

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

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

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

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

7-10. Troubleshooting Excessive Penetration

Good Penetration

Excessive Penetration weld metal melting through base metaland hanging underneath weld.

Excessive PenetrationS-0639


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

Increase travel speed.

OM-1318 Page 30

7-11. Troubleshooting Lack Of Penetration

Lack Of Penetration shallowfusion between weld metal andbase metal.

Lack of Penetration Good PenetrationS-0638


Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove whilemaintaining proper welding wire extension and arc characteristics.

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

Keep arc on leading edge of weld puddle.

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

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

Reduce travel speed.

7-12. Troubleshooting Incomplete Fusion

Incomplete Fusion failure of weld metal to fuse completely withbase metal or a preceeding weld bead.

S-0637


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

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

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

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

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

Keep arc on leading edge of weld puddle.

Use correct gun angle of 0 to 15 degrees.

7-13. Troubleshooting Burn-Through

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

S-0640


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

Increase and/or maintain steady travel speed.

OM-1318 Page 31

7-14. Troubleshooting Waviness Of Bead

Waviness Of Bead weld metal that is not parallel and does not coverjoint formed by base metal.

S-0641


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

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

7-15. Troubleshooting Distortion

Distortion contraction of weld metal during welding that forcesbase metal to move.

Base metal movesin the direction of

the weld bead.S-0642


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

Make tack welds along joint before starting welding operation.

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

Increase travel speed.

Weld in small segments and allow cooling between welds.

OM-1318 Page 32

7-16. Common MIG Shielding Gases

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

Application

GasSpray Arc Steel Short Circuiting Steel

Short CircuitingStainless Steel

Short CircuitingAluminum

Argon All Positions

Argon + 25% CO2 Flat & Horizontal1 Fillet All Positions All Positions2

CO2 Flat & Horizontal1 Fillet All Positions

Tri-Mix3 All Positions

1 Globular Transfer

2 Single Pass Welding Only

3 90% HE + 7-1/2% AR + 2-1/2% CO2

OM-1318 Page 33

Notes

OM-1318 Page 34

SECTION 8 PARTS LIST Hardware is common and

not available unless listed.

Figure 8-1.Complete Assembly

23

4

56

Incl

udes

Item

s

712

1

13

14

7

8 9 10

11

12 15

17

16

18 19

20

21

2223

2425

27

26

2829

30

31

32

33 34 35

36

37

383940

41

42

4344

45

46

47

48

49 50

51

52

53

54

44

55

56

57

58

59

60

61

ST-801 996-A

63

63

62

OM-1318 Page 35

DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 8-1. Complete Assembly

Quantity

1 126 838 DRIVE ASSEMBLY, wire (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 090 416 PIN, hinge 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 124 817 HOUSING, wire drive 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 151 828 PIN, cotter hair .054 x .750 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 112 031 LEVER, pressure roll 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 090 443 BEARING, ball rdl sgl row .866 OD x .447 width x .315 bore. . . . . . . . . . . . . . . . . . .

(consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 622 SPACER, bearing .196 ID x .310 OD x .500 collar 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 092 237 KNOB, adj tension 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 090 415 SPRING, cprsn .720 OD x .070 wire x 1.250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 085 244 WASHER, cupped stl .328 ID x .812 OD x .125 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 085 242 FASTENER, pinned 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 010 224 PIN, spring CS .187 x 1.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 058 549 GUIDE, wire inlet 1/16 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 174 609 SCREW, M-.7 x 12 sochd 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 165 603 ROLL, drive vk groove .030.035 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 186 205 HOUSING, drive motor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 122 385 TERMINAL ASSEMBLY, changeover (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 174 504 LINK, jumper 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 186 212 MOTOR, gear 24VDC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 SR1 180 791 RECTIFIER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 175 994 SPACER, nylon .750 OD x .390 ID 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 210 036 BAFFLE, center 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 073 355 SPRING, cprsn 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 111 998 PIN, cotter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 111 929 HUB, spool 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 134 201 STAND-OFF SUPPORT, PC card 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 PC1 119 539 CIRCUIT CARD, shutdown (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 F1 073 426 FUSE, mintr gl slo-blo 5A 250V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

165 745 CONNECTOR & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 CR2 108 358 CONTACTOR, def prp 25A 2P 24V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 120 675 BRACKET, mtg motor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 FM 210 124 MOTOR, fan 230V 50/60Hz 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 005 656 BLADE, fan 6.000 4wg 30deg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 CR1 006 393 RELAY, encl 24VAC DPDT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 R1 210 067 RHEOSTAT, WW 25W 12 ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 S2 409 477 SWITCH, rotary 25A 5pos 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 048 282 RECEPTACLE w/SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 147 560 PANEL, side lower 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 T1 205 419 TRANSFORMER, pwr main 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 +147 563 WRAPPER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 089 899 LATCH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 204 036 LABEL, warning general precautionary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 126 415 CLAMP, saddle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 126 416 HANDLE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 147 462 PANEL, rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 146 753 BEZEL, 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 152 118 CORD SET, 250V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 111 443 BUSHING, strain relief .240/.510 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 605 227 NUT, .750-14 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 GS1 128 751 VALVE, 230VAC 2way 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 181 649 RESISTOR, WW fxd 40W 25 ohm 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 C1 210 033 CAPACITOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 022 160 CLAMP, capacitor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 147 566 BASE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Z1 204 506 STABILIZER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 147 461 PANEL, front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 010 368 CLAMP, work 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-1318 Page 36

DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 8-1. Complete Assembly

Quantity

56 026 843 INSULATOR, vinyl 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 111 644 BUSHING, strain relief .370/.430 ID 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 S1 116 830 SWITCH, rocker DPST 10A 250VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 186 217 KNOB, pointer 1.250dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 097 922 KNOB, pointer .875dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 NAMEPLATE, (order by model and serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

183 312 ADAPTER RING, wire spool (used w/1lb spool adapter) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 615 BUSHING, nylon 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 010 287 WRENCH, hex 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

62 010 909 NUT, 375-16 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 010 910 WASHER, flat .406 ID x .812 OD 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*Recommend Spare Parts.+When ordering a component originally displaying a precautionary label, the label should also be ordered.To maintain the factory original performance of your equipment, use only Manufacturers SuggestedReplacement Parts. Model and serial number required when ordering parts from your local distributor.

1

ST-802 388-A

2 3 45

6

7

9

12

8

10

11

Figure 8-2.M-10 Gun

OM-1318 Page 37

QuantityDescriptionPartNo.

ItemNo.

Figure Figure 8-2. M-10 Gun

1 169 715 NOZZLE, slip type .500 orf flush 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 087 299 TIP, contact scr .023 wire x 1.125. . . . . . . . 2 000 067 TIP, contact scr .030 wire x 1.125. . . . . . . . 2 000 068 TIP, contact scr .035 wire x 1.125. . . . . . . . 2 000 069 TIP, contact scr .045 wire x 1.125. . . . . . . . 3 169 716 ADAPTER, contact tip 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 170 470 RING, retaining 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 169 718 TUBE, head 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 169 738 NUT, locking handle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 194 524 NUT, jam 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 180 433 CORD, trigger assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 079 974 O-RING, .500 ID x .103CS rbr 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 194 010 LINER, monocoil .023/.025 wire x 15ft (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 194 011 LINER, monocoil .030/.035 wire x 15ft (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 194 012 LINER, monocoil .035/.045 wire x 15ft (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 079 975 O-RING, .187 ID x .103CS rbr 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 196 255 SWITCH, trigger 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPTIONALTo maintain the factory original performance of your equipment, use only Manufacturers SuggestedReplacement Parts. Model and serial number required when ordering parts from your local distributor.

Warranty Questions?

Call1-800-4-A-MILLERfor your localMiller distributor.

miller_warr 7/00

Your distributor also givesyou ...

ServiceYou always get the fast,reliable response youneed. Most replacementparts can be in yourhands in 24 hours.

SupportNeed fast answers to thetough welding questions?Contact your distributor.The expertise of thedistributor and Miller isthere to help you, everystep of the way.

Effective January 1, 2000(Equipment with a serial number preface of LA or newer)This limited warranty supersedes all previous Miller warranties and is exclusive with no other

guarantees or warranties expressed or implied.

LIMITED WARRANTY Subject to the terms and conditionsbelow, Miller Electric Mfg. Co., Appleton, Wisconsin, warrantsto its original retail purchaser that new Miller equipment soldafter the effective date of this limited warranty is free of defectsin material and workmanship at the time it is shipped by Miller.THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHERWARRANTIES, EXPRESS OR IMPLIED, INCLUDING THEWARRANTIES OF MERCHANTABILITY AND FITNESS.

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

Miller shall honor warranty claims on warranted equipmentlisted below in the event of such a failure within the warrantytime periods. All warranty time periods start on the date thatthe equipment was delivered to the original retail purchaser, orone year after the equipment is sent to a North Americandistributor or eighteen months after the equipment is sent to anInternational distributor.

1. 5 Years Parts 3 Years Labor

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

2. 3 Years Parts and Labor

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

(NOTE: Engines are warranted separately bythe engine manufacturer.)

3. 1 Year Parts and Labor

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

185 & Spoolmate 250)* Process Controllers* Positioners and Controllers* Automatic Motion Devices* RFCS Foot Controls* Induction Heating Power Sources* Water Coolant Systems* HF Units* Grids* Maxstar 140* Spot Welders* Load Banks* Miller Cyclomatic Equipment* Running Gear/Trailers* Plasma Cutting Torches (except APT & SAF

Models)* Field Options

(NOTE: Field options are covered under TrueBlue for the remaining warranty period of theproduct they are installed in, or for a minimum ofone year whichever is greater.)

4. 6 Months Batteries

5. 90 Days Parts

* MIG Guns/TIG Torches* Induction Heating Coils and Blankets

* APT, ZIPCUT & PLAZCUT Model Plasma CuttingTorches

* Remote Controls

* Accessory Kits

* Replacement Parts (N

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