Miller HK300226 Owner's manual

Miller
Brand
Miller
Model
HK300226
Category
Welding System
Type
Owner's manual

This manual is also suitable for

January
1980
FORM:
OM-1522A
Effective
With
Serial
No.
HK300226
MODEL
SWINGARC
DIGITAL
-
1
12
SWINGARC
DIGITAL
-
1
16
OWN
ERS
MANUAL
AhuilEul
%j~
MILLER
ELECTRIC
MFG.
CO.
718
S.
BOUNDS
ST.
P.O.
Box
1079
APPLETON,
WI
54912
USA
NWSA
CODE
NO.
4579
PRINTED
IN
U.S.A.
L
~
~~
t_.
~~
~
LIMITED
WARRANTY
EFFECTIVE:
JUNE
1.
1979
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
ex-
clusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY-Subject
to
the
terms
and
conditions
As
a
matter
of
general
policy
only,
Miller
may
honor,
claims~.
hereof,
Miller
Electric
Mfg.
Co.,
Appleton,
Wisconsin
warrants
submitted
by
the
original
user
within
the
foregoing
periods.
to
its
Distributor/Dealer
that
all
new
and
unused
Equipment
(
furnished
by
Miller
is
free
from
defect
in
workmanship
?~.d
In
the
case
of
Millers
breach
of
warranty
or
any
other
duty
material
as
of
the
time
and
place
of
delivery
by
Miller.
No
war-
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedie~
ranty
is
made
by
Miller
with
respect
to
engines,
trade
ac-
therefore
shall
be,
at
Millers
option
(1)
repair
or
(21
replacement
cessories
or
other
items
manufactured
by
others.
Such
or,
where
authorized
in
writing
by
Miller
in
appropriate
cases,
(3)
.
-
engines,
trade
accessories
and
other
items
are
sold
subject
to
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
the
warranties
of
their
respective
manufacturers,
if
any
.
All
Miller
service
station
or
(4)
payment
of
or
credit
for
the
purchase
engines
are
warranted
by
their
manufacturer
for
one
year
from
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
date
of
original
purchase.
return
of
the
goods
at
Customers
risk
and
expense.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
Miller
shall
instnkt
the
cIai~
.
Except
as
specified
below,
Millers
warranty
does
not
apply
mant
on
the
warranty
claim
procedures
to
be
followed.
to
components
having
normal
useful
life
of
less
than
one
(11
.
year,
such
as
spot
welder
tips,
relay
and
contactor
points,
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
~
MILLERMATIC
parts
that
come
in
Contact
with
the
welding
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTA
wire
including
nozzles
and
nozzle
insulators
where
failure
does
lION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR.
not
result
from
defect
in
workmanship
or
material.
BREACH
OF
CONTRACT
WHICH,
BUT
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
Miller
shall
be
required
to
honor
warranty
claims
on
war-
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
INCLUDING
ranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
OF
within
the
following
periods
from
the
date
of
delivery
of
Equip-
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ment
to
the
original
user:
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EX
CLUDED
AND
DISCLAIMED
BY
MILLER.
1.
Arc
welders,
power
sources
and
components
. .
1
year
2.
Original
main
power
rectifiers
3
years
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
(labor
-
1
year
onlyl
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR.
A
3.
All
welding
guns
and
feeder/guns
90
days
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
4.
All
other
Millermatic
Feeders
1
year
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
AND
5.
Replacement
or
repair
parts,
exclusive
of
labor
.
60
days
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
OF
6.
Batteries
6
months
WELDING
EQUIPMENT
AND
NOT
FOR
CONSUMERS
OR
~s
CONSUMER
USE.
MILLER
WARRANTIES
DO
NOT
EXTEND
provided
that
Miller
is
notified
in
writing
within
thirty
1301
days
TO,
AND
NO
RESELLER
IS
AUTHORIZED
TO
EXTEND
?
of
the
date
of
such
failure.
MILLERS
WARRANTIES
TO,
ANY
CONSUMER.
t,
4~
%..~
J~
.,~
~,
J~
ERRATA
.SHEET
After
this
manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this
manual.
AMENDMENT
TO
SECTION
3
-
INSTALLATION
Amend
Section
3-6C.
Inlet
Wire
Guide
t~t.i1I~
An
extension
liner
(082
050)
and
inlet
wire
guide
(082
036)
are
provided
with
mode/s
effective
with
Serial
No.
JA420
762
for
use
with
small
diameter
wire.
The
liner
will
handle
wire
up
to
5/64
diameter.
1.
For
.030
-
5/64
wire.
a.
Insert
liner
(082
050)
into
inlet
wire
guide
(082
036)
and
secure
with
set
screw.
b.
Loosen
the
inlet
wire
guide
securing
screw
(3).
I~IsIl~
Wire
guides
should
be
installed
so
that
the
tip
of
the
guide
is
as
close
to
the
drive
roll
as
possible
without
touching.
c.
Insert
guide
assembly
into
drive
assembly.
Secure
by
tightening
screw
(3).
2.
For
3/32
-
1/8
wire.
a.
Remove
anti-wear
guide(s)
(045
233)
from
inlet
wire
guide.
b.
Loosen
the
inlet
wire
guide
securing
screw
(3).
I~sI~
I
~
Wire
guides
should
be
installed
so
that
the
tip
of
the
guide
is
as
close
to
the
drive
roll
as
possible
without
touching.
c.
Insert
the
inlet
wire
guide
(1)
into
drive
assembly
as
illustrated
in
Figure
2-4.
Secure
by
tightening
screw
(3).
d.
Install
anti-wear
guide(s)
over
inlet
wire
guide
and
secure
with
set
screw.
I~II~
Behind
the
drive
gear
are
spring
washers.
To
obtain
proper
alignment
of
the
drive
roll
on
the
drive
gear
with
the
wire
guides
rotate
the
drive
gear
securing
bolt
(11)
thereby
moving
the
drive
roll/n
or
out
to
the
desired
position.
The
drive
roll
on
the
pressure
gear
will
locate
itseff
on
the
wire
when
the
gear
cover
is
replaced
and
the
gears
mesh
together.
The
wire
drive
housing
is
made
with
mounting
ho/es
of
sufficient
clearance
to
provide
adjustment
of
the
wire
guides
up
or
down
in
relation
to
the
drive
rolls.
This
adjustment
hasbeen
factor,
set,
but
if
readjustment
becomes
necessary,
loosen
mounting
bolts
(item
17,
Figure
3-4),
weld
terminal
nut
(18)
and
bolt,
located
behind
mounting
plate
(19).
Slide
the
wire
drive
housing
upward
or
downward
until
the
wire
can
be
fed
straight
through
the
guides
while
seated
in
the
drive
roll
groove.
Tighten
mounting
bolts,
weld
terminal
bolt
and
nut.
Amend
Section
3-7.
WATER
CONTROL
KIT
Add
IMPORTANT
block
at
beginning
of
Section.
If
a
recirculating
coolant
system
is
used,
do
not
make
connections
from
the
coolant
pump
to
the
Water
valve
but
rather
connect
directly
to
the
gun
water
hoses.
Failure
to
comply
may
result
in
damage
to
the
coolant
pump
and/or
gun.
AMENDMENT
TO
SECTION
7
-
TROUBLESHOOTING
IMPORTANT:
1/8/81
OM-1522A
Page
A
0
P
.11
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901
Figure
7-1.
Circuit
Diagram
For
Models
Effective
With
S/N
JA393930
Thru
JA450102
A
kit
for
.035
U
groove
wire
044 749
is
now
available.
Drive
roll
072
000
and
inlet
guide
056
192
makŁ
up
the
kit.
tOptional
Parts.
-.
,,
.~-
BE
SURE
TO
PROVIDE
MODEL
AND
SE~IAL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
-
-~--.-~a
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Item~
No.
--I
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18
19
28
31
49
73
83
Pg
8
Pg
8
Pg
8
Pg
8
ao;328
079
878
-
079
535
049
290
039
734
081
337
026
837
045
896
031
643
035
835
.~TL
~
RECEPTACLE
W/
PINS,
free
hanging
(consisting
of)
...
TERMINAL,
female
4
080~328
079 534
Deleted
079
739
045
766
026 837
071
642
031
643
031
677
CLAMP,
cable
OPTICAL
ENCODER
DISC
(Elf
W/JA427092)
INSULATOR
(qty
chg)
CIRCUIT
CARD,
motor
speed
(Elf
W/JA393930)
CAPACITOR(qtychg)(EffW/JA450103)
CAPACITOR,
tantalum
5.6
uf
35
volts
dc
(Elf
W/JA393930)
026
202
DIODE
(qty
chg)
(Elf
W/JA393930)
026
202
035
827
D50-54,56-60
R51
,53-57,63,
67,68,74,75,
81
,82,84,89
Pg
8
R51,53-55,57,
63
,67,.68
,74,
75,81,82,84,89
R52,56,61
R64
R80
Pg
8
Pg
8
Pg
8
129
131
139
142
145
145
194
206
Pg
13
035 827
035
827
052
138
052
138
039
331
039
331
035
886
035
886
047
170
045
391
047
171
045
390
073
664 024 605
080
772
080
772
079
657
072 090
080
825 072 089
601
295
601
925
079
625
079
625
601
939
044
735
045
233
-
604612
082
036
082
050
604612
t047
945
074
125
1
2
1
12
10
15
14
3
1
2
1
1
1
1
1
2-
1~
1
1
11
-.
r,
035
827
RESISTOR
(qty
chg)
(Elf
W/JA393930
thru
JA450
102).
RESISTOR
(qtychg)(EffW/JA450103).
RESISTOR
(qty
chg)
(Elf
W/JA450103).
RESISTOR
(qtychg)(EffW/JA393930).
RESISTOR
(qtychg)
(Elf
W/JA393930).
TUBING,
neoprene
3/8
ID
x
3/32
waIl
x
8
LINER,
monocoil
x
9
inches
BEARING,
ball
SPRING,
compression
BASE,
swivel
-
boom
(Elf
W/JA438933)
BASE,
swivel
-
boom
(Elf
W/JA438933)
SCREW,
cap
-
hex
hd
1/4-20
x
1/2
WASHER
(qtychg)
SCREW,
hex
hd
1/4-28
x
1-3/4
GUIDE,
anti-wear
(consisting
of)
SCREW,.set:-
socket
hd
8-32
x-1
/8
GUIDE,
inlet
-
wire
(Elf
W/JA420762)
LINER,
monocoil
-
inlet
wire
(Elf
W/JA420762)
SCREW,
set
-
socket
hd
8-32
x
1/8
(Elf
W/JA420762)
BURN
BACK
CONTROL
(consisting
of)
POTENTIOMETER,
1
turn
2
watt
1
OKohm
047
980
.
TIMER,
delay
20
mil
sec/20
sec
-
024
366~.
KNOB,
pointer
-
line
indicator
t045
506
LOCKING
COVER
1
1
OM-1522A
Page
D
TABLE
OF
CONTENTS
Section
No.
Page
No.
SECTION
1
-
SAFETY
RULES
FOR
OPERATION
OF
ARC
WELDING
POWER
SOURCE
1
-1.
Introduction
1
1
-
2.
General
Precautions
1
1
-3.
ArcWelding
3
1
-
4.
Standards
Booklet
Index
4
SECTION
2
-
INTRODUCTION
2-1.
General
5
2
-
2.
Receiving-Handling
5
2
-
3.
Description
5
2-4.
Safety
5
SECTION
3
-
INSTALLATION
3
-
1.
Location
And
Assembly
5
3
-
2.
Drive
Motor
7
3-3.
lnstallationOfWireSupport
7
3
-
4.
Reinstallation
Of
Hub
Assembly
7
3
-
5.
Installation
Of
Wire
Reel
7
3
-
6.
Drive
Roll
And
Wire
Guide
Installation
8
3
-
7.
Water
Control
Kit
(Optional)
Connections
9
3
8.
Shielding
Gas
Connections
9
3
-
9.
Welding
Gun
Connections
9
3-10.
Boom
Adjustments
9
3-11.
Motor
Control
Connection
10
3-12.
GunTriggerConnection
10
3-13.
Weld
Cable
Connection
10
3-14.
115
Volts!
Contactor
Connection
10
3-15.
Remote
Control
Connection
10
3-16.
Installation
Of
Spool-Type
Wire
10
3-17.
Installation
Of
Reel-Type
Wire
10
3-18.
Adjustment
Of
Hub
Tension
11
3-19.
WeldingWireThreading
11
SECTION
4
-
FUNCTION
OF
CONTROLS
4
-
1.
Power
Switch
11
4
-
2.
Remote
Control
Receptacle
And
Switch
11
4
-
3.
Purge
Button
11
4-4.
lnchSwitch
12
4
-
5.
Wire
Speed
Control
12
4-6.
InchesPerMinuteMeter
12
4-7.
Reset
Circuit
Breaker
12
4-8.
Burnback
Control
12
SECTOON
5
-
SEQUENCE
OF
OPERATION
5
-
1.
Gas
Metal-Arc
Welding
(GMAW)
12
5
-
2.
Shutting
Down
12
SECT~ON
6
-
MAINTENANCE
6-1.
Inspection
And
Upkeep
12
6
-
2.
Cleaning
Of
Drive
Rolls
13
6-3.
Fuse
13
6
-
4.
Brush
Inspection
&
Replacement
13
SECTION
7
-
TROUBLESHOOTING
SECTION
1-SAFETY
RULES
FOR
OPERATION
OF
ARC
WELDING
POWER
SOURCE
1-1.
INTRODUCTION
We
learn
by
experience.
Learning
safety
through
personal
experience,
like
a
child
touching
a
hot
stove
is
harmful,
wasteful,
and
unwise.
Let
the
experience
of
others
teach
you.
Safe
practices
developed
from
experience
in
the
use
of
weld
ing
and
cutting
are
described
in
this
manual.
Research,
devel
opment.
and
field
experience
have
evolved
reliable
equipment
and
safe
installation,
operation,
and
servicing
practices.
Acci
dents
occur
when
equipment
is
improperly
used
or
main
tained.
The
reason
for
the
safe
practices
may
not
always
be
given.
Some
are
based
on
common
sense,
others
may
require
technical
volumes
to
explain.
It
is
wiser
to
follow
the
rules.
Read
and
understand
these
safe
practices
before
attempting
to
install,
operate,
or
service
the
equipment.
Comply
with
these
procedures
as
applicable
to
the
particular
equipment
used
and
their
instruction
manuals,
for
personal
safety
and
for
the
safety
of
others.
Failure
to
observe
these
safe
practices
may
cause
serious
in
jury
or
death.
When
safety
becomes
a
habit,
the
equipment
can
be
used
with
confidence.
These
safe
practices
are
divided
into
two
Sections:
1
-
General
Precautions,
common
to
arc
welding
and
cutting;
and
2
-
Arc
Welding
(and
Cutting)(only).
Reference
standards:
Published
Standards
on
safety
are
also
available
for
additional
and
more
complete
procedures
than
those
given
in
this
manual.
They
are
listed
in
the
Standards
Index
in
this
manual.
ANSI
Z49.1
is
the
most
complete.
The
National
Electrical
Code,
Occupational
Safety
and
Health
Administration,
local
industrial
codes,
and
local
in
spection
requirements
also
provide
a
basis
for
equipment
in
stallation,
use,
and
service.
GENERAL
PRECAUTIONS
Burn
Prevention
Wear
protective
clothing
-
leather
(or
asbestos)
gauntlet
gloves,
hat,
and
high
safety-toe
shoes.
Button
shirt
collar
and
pocket
flaps,
and
wear
cuffless
trousers
to
avoid
entry
of
sparks
and
slag.
Wear
helmet
with
safety
goggles
or
glasses
with
side
shields
underneath,
appropriate
filter
lenses
or
plates
(protected
by
clear
cover
glass).
This
is
a
MUST
for
welding
or
cutting,
(and
chipping)
to
protect
the
eyes
from
radiant
energy
and
flying
metal.
Replace
cover
glass
when
broken,
pitted,
or
spattered.
See
1-3A.2.
Avoid
oily
or
greasy
clothing.
A
spark
may
ignite
them.
Hot
metal
such
as
electrode
stubs
and
workpieces
should
never
be
handled
without
gloves.
Medical
first
aid
and
eye
treatment.
First
aid
facilities
and
a
qualified
first
aid
person
should
be
available for
each
shift
unless
medical
facilities
are
close
by
for
immediate
treatment
of
flash
burns
of
the
eyes
and
skin
burns.
Ear
plugs
should
be
worn
when
working
on
overhead
or
in
a
confined
space.
A
hard
hat
should
be
worn
when
others
work
overhead.
Flammable
hair
preparations
should
not
be
used
by
persons
intending
to
weld
or
cut.
B.
Toxic
Fume
Prevention
Adequate
ventilation.
Severe
discomfort,
illness
or
death
can
result
from
fumes,
vapors,
heat,
or
oxygen
enrichment
or
depletion
that
welding
(or
cutting)
may
produce.
Prevent
them
with
adequate
ventilation
as
described
in
ANSI
Stan
dard
Z49.1
listed
1
in
Standards
index.
NEVER
ventilate
with
oxygen.
Lead
-,
cadmium
-,
zinc
-,
mercury
-,
and
beryllium
.
bearing
and
similar
materials,
when
welded
(or
Cut)
may
produce
harmful
concentrations
of
toxic
fumes.
Adequate
local
exhaust
ventilation
must
be
used,
or
each
person
in
the
area
as
well
as
the
operator
must
wear
an
air-supplied
respirator.
For
beryllium,
both
must
be
used.
Metals
coated
with
or
containing
materials
that
emit
toxic
fumes
should
not
be
heated
unless
coating
is
removed
from
the
work
surface,
the
area
is
well
ventilated,
or
the
operator
wears
an
air-supplied
respirator.
Work
in
a
confined
space
Only
while
it
is
being
ventilated
and,
if
necessary,
while
wearing
an
air-supplied
respirator.
Gas
leaks
in
a
confined
space
should
be
avoided.
Leaked
gas
in
large
quantities
can
change
oxygen
concentration
danger
ously.
Do
not
bring
gas
cylinders
into
a
confined
space.
Leaving
confined
space,
shut
OFF
gas
supply
at
source
to
prevent
possible
accumulation
of
gases
in
the
space
if
down
stream
valves
have
been
accidently
opened
or
left
open.
Check
to
be
sure
that
the
space
is
safe
before
re-entering
it.
Vapors
from
chlorinated
solvents
can
be
decomposed
by
the
heat
of
the
arc
(or
flame)
to
form
PHOSGENE,
a
highly
toxic
gas,
and
other
lung
and
eye
irritating
products.
The
ultra
violet
(radiant)
energy
of
the
arc
can
also
decompose
tn
chloroethylene
and
perchloroethylene
vapors
to
form
phos
gene.
DO
NOT
WELD
or
cut
where
solvent
vapors
can
be
drawn
into
the
welding
or
cutting
atmosphere
or
where
the
radiant
energy
carl
penetrate
to
atmospheres
containing
even
minute
amounts
of
trichioroethylene
or
perchloroethylene.
C.
Fire
and
Explosion
Prevention
Causes
of
fire
and
explosion
are:
combustibles
reached
by
the
arc,
flame,
flying
sparks,
hot
Slag
or
heated
material;
misuse
of
compressed
gases
and
cylinders;
and
short
circuits.
BE
AWARE
THAT
flying
sparks
or
falling
slag
can
pass
through
cracks,
along
pipes,
through
windows
or
doors,
and
through
wall
or
floor
operPngs,
Out
of
sight
of
the
goggled
operator.
Sparks
and
slag
can
fly
35
feet.
To
prevent
fires
and
explosion:
Keep
equipment
clean
and
operable,
free
of
oil,
grease,
and
(in
electrical
parts)
of
metallic
particles
that
can
cause
short
circuits.
If
combustibles
are
in
area,
do
NOT
weld
or
cut.
Move
the
work
if
practicable,
to
an
area
free
of
combustibles.
Avoid
paint
spray
rooms,
dip
tanks,
storage
areas,
ventilators.
If
the
work
cannot
be
moved,
move
combustibles
at
least
35
feet
away
out
of
reach
of
sparks
and
heat;
or
protect
against
ignition
with
suitable
and
snug-fitting,
fire-resistant
covers
or
shields.
Walls
touching
combustibles
on
opposite
sides
should
not
be
welded
on
(Or
cut).
Walls,
ceilings,
and
floor
near
work
should
be
protected
by
heat-resistant
covers
or
shields.
Fire
watcher
must
be
standing
by
with
suitable
fire
ex
tinguishing
equipment
during
and
for
some
time
after
weld
ing
or
cutting
if:
a.
appreciable
combustibles
(including
building
construc
tion)
are
within
35
feet
b.
appreciable
combustibles
are
further
than
35
feet
but
can
be
ignited
by
sparks
c.
openings
(concealed
or
visible)
in
floors
or
walls
within
35
feet
may
expose
combustibles
to
sparks
d.
combustibles
adjacent
to
walls,
ceilings,
roofs,
or
metal
partitions
can
be
ignited
by
radiant
or
conducted
heat.
Hot
work
permit
should
be
obtained
before
operation
to
ensure
supervisors
approval
that
adequate
precautions
have
been
taken.
After
work
is
done,
check
that
area
is
free
of
sparks,
glowing
embers,
and
flames.
An
empty
container
that
held
combustibles,
or
that
can
pro
duce
flammable
or
toxic
vapors
when
heated,
must
never
be
welded
on
or
cut,
unless
Container
has
first
been
cleaned
as
described
in
AWS
Standard
A6.O,
listed
3
in
Standards
index.
1-2.
A.
OM-1
522
Page
1
This
includes:
a
thorough
steam
or
caustic
cleaning
(or
a
solvent
or
water
washing.
depending
on
the
combustibles
solubility)
followed
by
purging
and
inerting
with
nitrogen
or
carbon
dioxide,
and
using
protective
equipment
as
recom
mended
in
A6.0.
Waterfilling
just
below
working
level
may
substitute
for
inerting.
A
container
with
unknown
contents
should
be
cleaned
(see
paragraph
above).
Do
NOT
depend
on
sense
of
smell
or
sight
to
determine
if
it
is
safe
to
weld
or
cut.
Hollow
castings
or
containers
must
be
vented
before
welding
or
cutting.
They
can
explode.
Explosive
atmospheres.
Never
weld
or
cut
where
the
air
may
contain
flammable
dust,
gas,
or
liquid
vapors
(such
as
gaso
line)
-
0.
Compressed
Gas
Equipment
Standard
precautions.
Comply
with
precautions
in
this
manual,
and
those
detailed
in
CGA
Standard
P-i,
PRECAU
TIONS
FOR
SAFE
HANDLING
OF
COMPRESSED
GASES
IN
CYLINDERS,
listed
6
in
Standards
index.
1.
Pressure
Regulators
Regulator
relief
valve
is
designed
to
protect
only
the
regula
tor
from
overpressure;
it is
not
intended
to
protect
any
downstream
equipment.
Provide
such
protection
with
one
or
more
relief
devices.
Never
connect
a
regulator
to
a
cylinder
containing
gas
other
than
that
for
which
the
regulator
was
designed.
Remove
faulty
regulator
from
service
immediately
for
repair
(first
close
cylinder
valve).
The
following
symptoms
indicate
a
faulty
regulator:
Leaks
-
if
gas
leaks
externally.
Excessive
Creep
-
if
delivery
pressure
continues
to
rise
with
downstream
valve
closed.
Faulty
Gauge
-
if
gauge
pointer
does
not
move
off
stop
pin
when
pressurized,
nor
returns
to
stop
pin
after
pressure
release.
Repair.
Do
NOT
attempt
repair.
Send
faulty
regulators
for
repair
to
manufacturers
designated
repair
center,
where
special
techniques
and
tools
are
used
by
trained
personnel.
2.
Cylinders
Cylinders
must
be
handled
carefully
to
prevent
leaks
and
damage
to
their
walls,
valves,
or
safety
devices:
Avoid
electrical
circuit
contact
with
cylinders
including
third
rails,
electrical
wires,
or
welding
circuits.
They
can
produce
short
Circuit
arcs
that
may
lead
to
a
serious
accident.
(See
1-3C.)
ICC
or
DOT
marking
must
be
on
e~h
cylinder.
It
is
an
assurance
of
safety
when
the
cylinder
is
properly
handled.
Identifying
gas
content.
Use
only
cylinders
with
name
of
gas
marked
on
them;
do
not
rely
on
color
to
identify
gas
con
tent.
Notify
supplier
if
unmarked.
NEVER
DEFACE
or
alter
name,
number,
or
other
markings
on
a
cylinder.
It
is
illegal
and
hazardous.
Empties:
Keep
valves
closed,
replace
caps
securely;
mark
MT;
keep
them
separate
from
FULLS
and
return
promptly.
Prohibited
use.
Never
use
a
cylinder
or
its
contents
for
other
than
its
intended
use,
NEVER
as
a
support
or
roller.
Locate
or
secure
cylinders
so
they
cannot
be
knocked
over.
Passageways
and
work
areas.
Keep
cylinders
clear
of
areas
where
they
may
be
struck.
Transporting
cylinders.
With
a
crane,
use
a
secure
support
such
as
a
platform
or
cradle.
Do
NOT
lift
cylinders
off
the
ground
by
their
valves
or
caps,
or
by
chains,
slings,
or
mag
nets.
Do
NOT
expose
cylinders
to
excessive
heat,
sparks,
slag,
and
flame,
etc.
that
may
cause
rupture.
Do
not
allow
contents
to
exceed
130F.
Cool
with
water
spray
where
such
exposure
exists.
Protect
cylinders
particularly
valves
from
bumps,
falls,
falling
objects,
and
weather.
Replace
caps
securely
when
moving
cylinders.
Stuck
valve.
Do
NOT
use
a
hammer
or
wrench
to
open
a
cylinder
valve
that
can
not
be
opened
by
hand.
Notify
your
supplier.
Mixing
gases.
Never
try
to
mix
any
gases
in
a
cylinder.
Never
refill
any
cylinder.
Cylinder
fi
ttin~
should
never
be
modified
or
exchanged.
-
3.
Hose
Prohibited
use.
Never
use
hose
other
than
that
designed
for
the
specified
gas.
A
general
hose
identification
rule
is:
red
for
fuel
gas,
green
for
oxygen,
and
black
for
inert
gases.
Use
ferrules
or
clamps
designed
for
the
hose
(not
ordinary
wire
or
other
substitute)
as
a
binding
to
connect
hoses
to
fittings.
No
copper
tubing
splices.
Use
only
standard
brass
fittings
to
splice
hose.
Avoid
long
runs
to
prevent
kinks
and
abuse.
Suspend
hose
off
ground
to
keep
it
from
being
run
over,
stepped
on,
or
other
wise
damaged.
Coil
excess
hose
to
prevent
kinks
and
tangles.
Protect
hose
from
damage
by
sharp
edges,
and
by
sparks,
slag,
and
open
flame.
Examine
hose
regularly
for
leaks,
wear,
and
loose
connec
tions.
Immerse
pressured
hose
in
water;
bubbles
indicate
leaks.
Repair
leaky
or
worn
hose
by
cutting
area
out
and
splicing
(l-2D3).
Do
NOT
use
tape.
4.
Proper
Connections
Clean
cylinder
valve
outlet of
impurities
that
may
clog
orifices
and
damage
seats
before
connecting
regulator.
Except
for
hydrogen,
crack
valve
momentarily,
pointing
outlet
away
from
people
and
sources
of
ignition.
Wipe
with
a
clean
lint-
less
cloth.
Match
regulator
to
cylinder.
Before
connecting,
check
that
the
regulator
label
and
cylinder
marking
agree,
and
that
the
regulator
inlet
and
cylinder
outlet
match.
NEVER
CON
NECT
a
regulator
designed
for
a
particular
gas
or
gases
to
a
cylinder
containing
any
other
gas.
Tighten
connections.
When
assembling
threaded
connections,
clean
and
smooth
seats
where
necessary.
Tighten.
If
connec
tion
leaks,
disassemble,
clean,
and
retighten
using
properly
fitting
wrench.
Adapters.
Use
a
CGA
adapter
(available
from
your
supplier)
between
cylinder
and
regulator,
if
one
is
required.
Use
two
wrenches
to
tighten
adapter
marked
RIGHT
and
LEFT
HAND
threads.
Regulator
outlet
(or
hose)
connections
may
be
identified
by
right
hand
threads
for
oxygen
and
left
hand
threads
(with
grooved
hex
on
nut
or
shank)
for
fuel
gas.
5.
Pressurizing
Steps:
Drain
regulator
of
residual
gas
through
suitable
vent
before
opening
cylinder
(or
manifold
valve)
by
turning
adjusting
screw
in
(clockwise).
Draining
prevents
excessive
compression
heat
at
high
pressure
seat
by
allowing
seat
to
open
on
pressur
ization.
Leave
adjusting
screw
engaged
slightly
on
single-stage
regulators.
Stand
to
side
of
regulator
while
opening
cylinder
valve.
Open
cylinder
valve
slowly
so
that
regulator
pressure
in
creases
slowly.
When
gauge
is
pressurized
(gauge
reaches
regu.
lator
maximum)
leave
cylinder
valve
in
following
position:
For
oxygen,
and
inert
gases,
open
fully
to
seal
stem
against
possible
leak.
For
fuel
gas,
open
to
less
than
one
turn
to
permit
quick
emergency
shutoff.
Page
2
Use
pressure
charts
(available
from
your
supplier)
for
safe
and
efficient,
recommended
pressure
settings
on
regulators.
Check
for
leaks
on
first
pressurization
and
regularly
there
after.
Brush
with
soap
solution
(capful
of
Ivory
Liquid
or
equivalent
per
gallon
of
water).
Bubbles
indicate
leak.
Clean
off
soapy
water
after
test;
dried
soap
is
combustible.
E.
User
Responsibilities
Remove
leaky
or
defective
equipment
from
service
immed
iately
for
repair.
See
User
Responsibility
statement
in
equip
ment
manual.
F.
Leaving
Equipment
Unattended
Close
gas
supply
at
source
and
drain
ga.
G.
Rope
Staging-Support
Rope
staging-support
should
not
be
used
for
welding
or
cut
ting
operation;
rope
may
burn.
1-3.
ARC
WELDING
Comply
with
precautions
in
1-1,
1-2,
and
this
section.
Arc
Welding,
properly
done,
is
a
safe
process,
but
a
careless
opera
tor
invites
trouble.
The
equipment
carries
high
currents
at
significant
voltages.
The
arc
is
very
bright
and
hot.
Sparks
fly,
fumes
rise,
ultraviolet
and
infrared
energy
radiates,
weld
ments
are
hot,
and
compressed
gases
may
be
used.
The
wise
operator
avoids
unnecessary
risks
and
protects
himself
and
others
from
accidents.
Precautions
are
described
here
and
in
standards
referenced
in
index.
A.
Burn
Protection
Comply
with
precautions
in
1-2.
The
welding
arc
is
intense
and
visibly
bright.
Its
radiation
can
damage
eyes,
penetrate
lightweight
clothing,
reflect
from
light-colored
surfaces,
and
burn
the
skin
and
eyes.
Skin
burns
resemble
acute
sunburn,
those
from
ga-shielded
arcs
are
more
severe
and
painful.
DONT
GET
BURNED;
COMPLY
WITH
PRECAUTIONS.
1.
Protective
Clothing
Wear
long-sleeve
clothing
(particularly
for
ga-shielded
arc)
in
addition
to
gloves,
hat,
and
shoes
(1-2A).
As
necessary,
use
additional
protective
clothing
such
a
leather
jacket
or
sleeves,
flame-proof
apron,
and
fire-resistant
leggings.
Avoid
outergarments
of
untreated
cotton.
Bare
skin
protection.
Wear
dark,
substantial
clothing.
Button
collar
to
protect
chest
and
neck
and
button
pockets
to
pre
vent
entry
of
sparks.
2.
Eye
and
Head
Protection
Protect
eyes
from
exposure
to
arc.
NEVER
look
at
an
elec
tric
arc
without
protection.
Welding
helmet
or
shield
containing
a
filter
plate
shade
no.
12
or
denser
must
be
used
when
welding.
Place
over
face
before
striking
arc.
Protect
filter
plate
with
a
clear
cover
plate.
Cracked
or
broken
helmet
or
shield
should
NOT
be
worn;
radiation
can
pass
through
to
cause
burns.
Cracked,
broken,
or
loose
filter
plates
must
be
replaced
IM
MEDIATELY.
Replace
clear
cover
plate
when
broken,
pitted,
or
spattered.
Flash
goggles
with
side
shields
MUST
be
worn
under
the
helmet
to
give
some
protection
to
the
eyes
should
the
helmet
not
be
lowered
over
the
face
before
an
arc
is
struck.
Looking
at
an
arc
momentarily
with
unprotected
eyes
(particularly
a
high
intensity
ga-shielded
arc)
can
cause
a
retinal
burn
that
may
leave
a
permanent
dark
area
in-the
field
of
vision.
3.
Protection
of
Nearby
Personnel
Enclosed
welding
area.
For
production
welding,
a
separate
room
or
enclosed
bay
is
best.
In
open
area,
surround
the
operation
with
low-reflective,
non-combustible
screens
or
panels.
Allow
for
free
air
circulation,
particularly
at
floor
level.
Viewing
the
weld.
Provide
face
shields
for
all
persons
who
will
be
looking
directly
at
the
weld.
Others
working
in
area.
See
that
all
persons
are
wearing
flash
goggles.
Before
starting
to
weld,
make
sure
that
screen
flaps
or
bay
doors
are
closed.
B.
Toxic
Fume
Prevention
Comply
with
precautions
in
1-2B.
Generator
engine
exhaust
must
be
vented
to
the
outside
air.
Carbon
monoxide
can
kill.
C.
Fire
and
Explosion
Prevention
Comply
with
precautions
in
1-2C.
Equipments
rated
capacity.
Do
not
overload
arc
welding
equipment.
It
may
overheat
cables
and
cause
a
fire.
Loose
cable
connections
may
overheat
or
flash
and
cause
a
fire.
Never
strike
an
arc
on
a
cylinder
or
other
pressure
vessel.
Is
creates
a
brittle
area
that
can
cause
a
violent
rupture
or
lead
to
such
a
rupture
later
under
rough
handling.
D.
Compressed
Gas
Equipment
Comply
with
precautions
in
1-2D.
E.
Shock
Prevention
Exposed
hot
conductors
or
other bare
metal
in
the
welding
circuit,
or
in
ungrounded,
electrically-HOT
equipment
can
fatally
shock
a
person
whose
body
becomes
a
conductor.
DO
NOT
STAND,
SIT, LIE,
LEAN
ON,
OR
TOUCH
a
wet
sur
face
when
welding,
without
suitable
protection.
To
protect
against
shock:
Keep
body
and
clothing
dry.
Never
work
in
damp
area
with
out
adequate
insulation
against
electrical
shock.
Stay
on
a
dry
duckboard,
or
rubber
mat
when
dampness
or
sweat
can
not
be
avoided.
Sweat,
sea
water,
or
moisture
between
body
and
an
electrically
HOT
part
-
or
grounded
metal
-
reduces
the
body
surface
electrical
resistance,
enabling
dangerous
and
possibly
lethal
currents
to
flow
through
the
body.
1.
Grounding
the
Equipment
When
installing,
connect
the
frames
of
each
unit
such
as
welding
power
source,
control,
work
table,
and
water
circula
tor
to
the
building
ground.
Conductors
must
be
adequate
to
carry
ground
currents
safely.
Equipment
made
electrically
HOT
by
stray
current
may
shock,
possibly
fatally.
Do
NOT
GROUND
to
electrical
conduit,
or
to
a
pipe
carrying
ANY
gas
or
a
flammable
liquid
such
as
oil
or
fuel.
Three-phase
connection.
Check
phase
requirement
of
equip
ment
before
installing.
If
only
3-phase
power
is
available,
connect
single-phase
equipment
to
only
two
wires
of
the
3-phase
line.
Do
NOT
connect
the
equipment
ground
lead
to
the
third
(live)
wire,
or
the
equipment
will
become
electri
cally
HOT
-
a
dangerous
condition
that
can
shdck,
possibly
fatally.
Before
welding,
check
ground
for
continuity.
Be
sure
conduc
tors
are
touching
bare
metal
of
equipment
frames
at
connec
tions.
If
a
line
cord
wish
a
ground
lead
is
provided
with
the
equip
ment
for
connection
to
a
switchbox,
connect
the
ground
lead
to
the
grounded
switchbox.
If
a
three-prong
plug
is
added
for
connection
to
a
grounded
mating
receptacle,
the
ground
lead
must
be
connected
to
the
ground
prong
only.
If
the
line
cord
comes
with
a
three-prong
plug,
connect
to
a
grounded
mating
receptacle.
Never
remove
the
ground
prong
from
a
plug,
or
use
a
plug
with
a
broken
off
ground
prong.
Trademark
of
Proctor
&
Gamble.
OM-1522
Page
3
2.
Electrode
Holders
Fully
insulated
electrode
holders
should
be
used.
Do
NOT
use
holders
with
protruding
screws.
3.
Connectors
Fully
insulated
lock-type
connectors
should
be
used
to
join
welding
cable
lengths.
4.
Cables
Frequently
inspect
cables
for
wear,
cracks
and
damage.
IMMEDIATELY
REPLACE
those
with
excessively
worn
or
damaged
insulation
to
avoid
possibly
-
lethal
shock
from
bared
cable.
Cables
with
damaged
areas
may
be
taped
to
give
resistance
equivalent
to
original
cable.
Keep
cable
dry,
free
of
oil
and
grease,
and
protected
from
hot
metal
and
sparks.
5.
Terminals
And
Other
Exposed
Parts
Terminals
and
other
exposed
parts
of
electrical
units
should
have
insulating
covers
secured
before
operation.
6.
Electrode
Wire
Electrode
wire
becomes
electrically
HOT
when
the
power
switch
of
gas
metal-arc
welding
equipment
is
ON
and
welding
gun
trigger
is
pressed.
Keep
hands
and
body
clear
of
wire-and
other
HOT
parts.
7.
Safety
Devices
Safety
devices
Such
as
interlocks
and
circuit
breakers
should
not
be
disconnected
or
shunted
out.
Before
installation,
inspection,
or
service,
of
equipment,
shut
OFF
all
power
and
remove
line
fuses
(or
lock
or
red-t~
switches)
to
prevent
accidental
turning
ON
of
power.
Discon
nect
all
cables
from
welding
power
source,
and
pull
all
115
volts
line-cord
pIu~.
Do
not
open
power
Circuit
or
change
polarity
while
welding.
If,
in
an
emergency,
it
must
be
disconnected,
guard
against
shock
burns,
or
flash
from
switch
arcing.
Leaving
equipment
unattended.
Always
shut
OFF
and
dis.
connect
all
power
to
equipment.
Power
disconnect
switch
must
be
available
near
the
welding
power
source.
1-4.
STANDARDS
BOOKLET
INDEX
For
more.
information,
refer
to
the
following
standards
or
their
latest
revisions
and
comply
as
applicable:
1.
ANSI
Standard
Z49.1,
SAFETY
IN
WELDING
AND
CUTTING
obtainable
from
the
American
Welding
Society,
2501
NW
7th
St.,
Miami,
Fla.
33125.
2.
ANSI
Standard
Z87.1,
SAFE
PRACTICE
FOR
OCCUPA
TION
AND
EDUCATIONAL
EYE
AND
FACE
PROTEC
TION,
obtainable
from
American
National
Standards
Institute,
1430
Broadway,
New
York,
N.Y.
10018.
3.
American
Welding
Society
Standard
A6.0,
WELDING
AND
CUTTING
CONTAINERS
WHICH
HAVE
HELD
COMBUSTIBLES,
obtainable
same
as
item
1.
4.
NFPA
Standard
51,
OXYGEN-FUEL
GAS
SYSTEMS
FOR
WELDING
AND
CUTTING,
obtainable
from
the
National
Fire
Protection
Association,
470
AtlantIc
Avenue,
Boston.
Mass.
02210.
5.
NFPA
Standard
516,
CUTTING
AND
WELDING
PRO
CESSES,
obtainable
same
as
item
4.
6.
CGA
Pamphlet
P-i.
SAFE
HANDLING
OF
COM
PRESSED
GASES
IN
CYLINDERS,
obtainable
from
the
Compressed
Gas
Association,
500
Fifth
Avenue,
New
York,
N.
Y.
10036.
7.
OSHA
Standard
29
CFR,
Part
1910,
Subpart
0,
WELD
ING,
CUTTING
AND
BRAZING.
Page
4
SECTION
2-
INTRODUCTION
Model
Single
12
I
Single
16
Speed
Range
50-785
1P.M.
Boom
Length
12
ft.
I
16
ft.
Swing
3600
Vertical
Lift
Horizontal
To
600
Above
Maximum
Height
(With
4
Ft
Post)
At
Full
Lift
Of
Boom
17ft
21ft.
Counterbalance
(Patented)
Compression
Spring
Is
Designed
To
Balance
Boom
At
Any
Angle.
Pressure
Adjustment
Is
Provided
To
Hold
The
Boom
At
Any
Desired
Angle
Or
To
Limit
The
Vertical
Lift
At
40,
50.
or
60.
Weight
(Pounds)
Net
Ship
Net
Ship
160
280
210 350
Figure
2-1.
Specifications
2
-
1.
GENERAL
-
This
manual
has
been
prepared
especially
for
use
in
familiarizing
personnel
with
the
design,
installation,
operation,
maintenance,
and
troubleshooting
of
this
equipment.
All
information
presented
herein
should
be
given
careful
consideration
to
assure
optimum
performance
of
this
equipment.
2
-
2.
RECEIVING-HANDLING
-
Prior
to
installing
this
equipment,
clean
all
packing
material
from
around
the
unit
and
carefully
inspect
for
any
damage
that
may
have
occurred
during
shipment.
Any
claims
for
loss
or
damage
that
may
have
occured
in
transit
must
be
filed
by
the
purchaser
with
the
carrier.
A
copy
of
the
bill
of
_____________
lading
and
freight
bill
will
be
furnished
by
the
carrier
on
____________
request
if
occasion
to
file
claim
arises.
When
requesting
information
concerning
this
equip
ment,
it
is
essential
that
Model
Description
and
Serial
(or
Style)
Numbers
of
the
equipment
be
supplied.
2
-
3.
DESCRIPTION
-
This
unit
is
a
boom
mounted
digital
wire
control/feeder.
The
control/feeder
is
of
the
constant
wire
feed
speed
type
and
is
designed
to
be
used
in
conjunction
with
a
constant
potential
welding
_______
power
source.
The
boom
is
a
patented
design
allowing
both
vertical
lift
and
swing.
Cables
are
routed
through
SECTION
3
-
INSTALLATION
3
-
1.
LOCATION
AND
ASSEMBLY
(Figure
3-1)
A.
Location
A
suitable
location
for
this
unit
will
allow
room
for
the
boom
to
swing
horizontally
in
the
desired
arc,
and
to
pivot
upward
to
the
desired
angle.
Proper
placement
will
also
provide
sufficient
clearance
from
obstruction
at
the
wire
support
end
of
the
unit
when
the
boom
swings.
The
structure
to
which
the
unit
is
being
installed
should
be
of
sufficient
construction
to
support
the
weight
of
the
unit
when
the
boom
is
in
the
horizontal
position.
1.
Existing
Support
(Customer
Supplied).
IMPORTANT
______________
In
selecting
the
pipe
used
to
support
the
unit
the
model
utilizing
a
12
foot
boom
requires
a
2-1/2
inch
diameter,
Schedule
40
pipe
(wall
thickness
of
.203
inches).
The
model
with
a
16
foot
boom
re
quires
a
5
inch
diameter,
Schedule
40
pipe
(wall
thickness
of
.258
inches).
a.
Uncrate
and
remove
all
packing
material
from
the
unit.
the
boom
from
the
feeder
control
to
the
weld
head
assembly.
The
control/feeder
is
a
heavy
duty
wire
feeding
unit
combining
both
the
wire
feeder
and
the
digital
control.
It
contains
all
the
controls
and
equipment
needed
to
supply
welding
wire
and
shielding
gas
to
the
welding
gun.
2
-
4.
SAFETY
-
Before
the
equipment
is
put
into
operation,
the
safety
section
at
the
front
of
this
manual
should
be
read
completely.
This
will
help
avoid
possible
injury
due
to
misuse
or
improper
welding
applications.
CAUTION
___________
Under
this
heading,
installation,
operating,
and
maintenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
may
create
a
hazard
to
personnel.
IMPORTANT
______________
Under
this
heading,
installation,
operating,
and
maintenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
may
result
in
damage
to
equipment.
LII,)
t~
Under
this
heading,
explanatory
statements
will
be
found
that
need
special
emphasis
to
obtain
the
most
efficient
operation
of
the
equipment.
B.
Assembly
OM-1522
Page
5
CAUTION
Do
not
remove
safety
collar
(11)
until
in-
structed
to
do
so.
The
swivel
base
(8)
contains
high
pressure
springs
to
counter
balance
the
weight
at
the
weld
head.
d.
Place
bearing
(13)
on
top
of
post
(14)
and
in
sert
swivel
(8)
into
post
(14).
e.
Place
the
boom
base
plate
(19)
in
between
the
two
swivel
plates.
f.
Slide
washer
(17)
onto
bolt
(18)
and
insert
bolt
(18)
through
hole
(15).
Slide
washer
(9)
onto
bolt
(18)
and
install
nut
(10)
onto
bolt
(18).
Tighten
nut
(10);
then
back
off
nut
(10)
1/2
turn.
g.
Insert
pin
(1)
through
yoke
(3),
hole
(2),
and
install
cotter
pin
(4)
through
pin
(1).
h.
Connect
the
welding
gun
to
the
drive
assembly
as
instructed
in
the
Owners
Manual
for
the
desired
welding
gun.
i.
Grasp
bar
(20),
and
pull
boom
down
slightly.
The
boom
should
be
pulled
down
only
far
enough
to
remove
the
pressure
which
is
ap
plied
to
the
safety
collar
(11).
j.
Remove
the
safety
collar
(11)
and
retain
for
future
adjustments.
k.
The
boom
should
now
balance
in
any
posi
tion
from
horizontal
to
60
degrees
above
horizontal.
If
the
boom
does
not
balance
properly,
proceed
to
Section
3-10.
1S1l~
The
post
support
(14)/s
provided
with
a
fit
ting
for
lubricating
the
swivel
periodically,
to
prevent
premature
wear
and
to
ease
turning
during
operation.
Excessive
greasing
of
support
fitting
is
not
required
or
recommended.
3.
Base
Support
(Optional)
I~IsIl~
If
an
optional
base
support
was
purchased
with
the
unit,
mounting
holes
are
provided
for
fastening
the
base
support
to
the
floor.
2.
Post
Support
(Optional)
a.
Uncrate
and
remove
all
packing
material
from
the
unit.
b.
Mount
post
support
(14)
to
the
desired
structure.
CAUTION
___________
The
structure
to
which
the
post
support
is
mounted
must
be
of
sufficient
construction
to
sup
port
the
weight
of
the
unit
when
the
boom
is
in
the
horizontal
position.
c.
Remove
yoke
pin
(1),
nut
(10),
washers
(9
&
17),
and
bolt
(18)
from
the
yoke
(3)
and
swivel
plates
(16).
IMPORTANT
_____________
When
an
optional
base
support
is
used,
the
base
must
be
securely
mounted
to
the
floor.
As
a
minimum,
1/2
dia.,
S.A.E.
grade
5
bolts,
with
adequate
corrosion
protection
should
be
used
to
secure
the
base.
If
the
unit
is
to
be
mounted
in
an
extremely
damp
environment,
mounting
bolts
made
of
a
non-
corrosive
material
with
a
strength
equivalent
to
S.A.
E.
grade
5
steel
should
be
used.
a.
Uncrate
and
remove
all
packing
material
from
the
unit.
b.
Fasten
base
support
to
the
floor.
c.
Complete
Steps
c
through
k,
Subsection
B2.
TB-080
040
Figure
3-1.
Base
And
Boom
Assembly
b.
Mount
pipe
post
(14)
to
the
desired
struc
ture.
CAUTION
___________
The
structure
to
which
the
pipe
post
is
mounted
must
be
of
sufficient
construction
to
support
the
weight
of
the
unit
when
the
boom
is
in
the
horizon-
ta/position.
c.
Proceed
to
Subsection
B2,
Steps
c
through
k.
Page
6
i~isII~
The
base
support
is
provided
with
a
fitting
for
lubricating
the
swivel
periodically,
to
prevent
premature
wear
and
to
ease
turning
during
operation.
Excessive
greasing
of
support
fitting
is
not
required
or
recom
mended.
4.
Swingpak
Base
(Optional)
a.
Uncrate
and
remove
all
packing
material
from
the
Swingpak
base.
IMPORTANT
______________
The
installation
of
the
we/ding
power
source
onto
the
Swingpak
base
should
precede
mount
ing
of
the
Swingarc
unit
in
order
to
prevent
tipping
of
the
frame
under
the
weight
of
the
boom.
b.
Uncrate
and
remove
all
packing
materiai
from
the
Swingarc
unit.
c.
Complete
Steps
c
through
k,
Subsection
B2.
I~IsII~
The
Swingpak
base
is
provided
with
a
fitting
for
lubricating
the
swivel
periodically,
to
prevent
premature
wear
and
to
ease
turning
during
operation.
Excessive
greasing
of
support
fitting
is
not
required
or
recommended.
3
-
2.
DRIVE
MOTOR
-
The
drive
motor
is
provided
with
a
vent
screw
which
must
be
removed
prior
to
the
operation
of
the
control/feeder.
The
vent
screw
can
be
removed
through
the
hole
(21)
provided
in
the
motor
shroud
(see
Figure
3-1).
3
-
3.
3-1)
INSTALLATION
OF
WIRE
SUPPORT
(Figure
1.
Remove
the
securing
screws
(5)
and
lock
washers
(6)
from
the
swivel
base
(8).
2.
Lift
the
wire
support
(7)
in
place
over
the
holes
in
the
swivel
base
(8).
3.
Insert
securing
screws
(5)
with
lock
washers
(6)
and
tighten.
3
-
4.
REINSTALLATION
OF
HUB
ASSEMBLY
(Figure
3-2)
-
If
it
should
become
necessary
to
replace
the
hub
assembly,
install
the
new
hub
assembly
as
follows:
1.
Slide
the
following
items
onto
the
spindle
sup
port
shaft
(1)
in
order
given:
A.
Fiber
Washer
(2)
B.
Flat
Washer
(3)
C.
Hub
(4)
D.
Flat
Washer
(5)
E.
Fiber
Washer
(6)
F.
Keyed
Washer
(7)
G.
Spring
(8)
H.
Flat
Washer
(9)
2.
Rotate
hex
nut
(10)
onto
support
shaft
(1).
Hex
nut
should
be
rotated
only
until
a
slight
drag
is
felt
while
turning
hub
(4).
3.
Depress
the
two
spring
loaded
stops
(11)
on
the
retaining
ring
(12)
and
slide
the
retaining
ring
(12)
into
proper
position
on
the
hub
(4).
Release
the
two
stops
(11).
1.
Remove
the
retaining
ring
(5).
WIRE
REEL
(Optional)
TB-080
038
2.
Slide
the
wire
reel
(1)
onto
the
hub
(6).
Rotate
the
wire
reel
(1)
until
the
hub
guide
pin
(7)
is
seated
in
the
reel
(1).
3.
Depress
the
two
spring-loaded
stops
(4)
on
the
retaining
ring
(5)
and
slide
the
retaining
ring
(5)
into
proper
position
on
the
hub
(6).
Release
the
two
stops
(4).
67
9
10
11
12
TB-080
037
Figure
3-2.
Wire
Support
And
Hub
Assembly
3
-5.
INSTALLATION
OF
(FIgure
3-3)
1
2 3
7
6
Figure
3-3.
Reel
Installation
OM-1522
Page7
3
-6.
DRIVE
ROLL
AND
WIRE
GUIDE
INSTALLA
TION
(FIgure
3-4)
-
Upon
initial
installation,
or
as
a
result
of
changes
in
wire
size
and
type,
it
is
necessary
to
install
the
required
drive
rolls
and
wire
guides.
S
Base
selection
of
drive
rolls
upon
the
follow
ing
recommended
usages:
1.
V-Groove
rolls
for
hard
wire.
2.
U-Groove
rolls
for
soft
and
soft
shelled
cored
wires.
3.
U-Cog
rolls
for
extremely
soft
shelled
wires
(usually
hard
surfacing
types).
4.
Split
V-Knurled
rolls
for
hard
shelle?i
cored
wires
(seff-shie/ding
and
C02
shielded
types).
5.
Drive
roll
types
may
be
mixed
to
suit
particular
re
quirements
(example:
V-knurled
roll
in
combination
with
U-groove).
Having
selected
the
appropriate
drive
rolls
and
wire
guides,
proceed
to
the
following
installation
instruc
tions:
A.
One
Piece
Drive
Roll
(Figure
3-4)
S
Drive
rolls
(8
&
13)
are
of
the
double
usage
type.
When
the
grooves
become
worn,
reverse
e8ch
drive
roll,
locating
the
unused
groove
in
position
to
feed
the
wire.
1.
Loosen
the
pressure
adjustment
wing
nut
(item
2,
Figure
3-4)
and
pivot
it
free
of
the
cover.
2.
Pivot
gear
cover
(4)
away
until
it
is
in
an
open
position.
3.
Loosen
and
remove
the
three
securing
screws
(7
&
12)
on
each
gear
(5
&
9).
4.
Slide
one
drive
roll
(13)
onto
drive
gear
(9)
with
holes
aligned.
Insert
securing
screws
(12)
and
tighten.
5.
Slide
remaining
drive
roll
(8)
onto
pressure
gear
(5)
with
holes
aligned.
Insert
securing
screws
(7)
and
tighten.
B.
Split
Drive
Roll
(Figure
3-4)
I~SI1~
Drive
rolls
(6
&
10)
are
of
the
double
usage
type.
When
the
knurled
groove
of
the
drive
rolls
becomes
worn,
the
split
halves
may
be
reversed
so
that
the
unused
edges
will
now
provide
a
new
knurled
groove.
1.
Loosen
the
pressure
adjustment
wing
nut
(item
2,
Figure
3-4)
and
pivot
it
free
of
the
cover.
2.
Pivot
gear
cover
(4)
away
until
it
is
in
an
open
position.
3.
Loosen
and
remove
the
three
securing
screws
(7
&
12)
on
each
gear
(5
&
9).
4.
Separately
align
the
holes
on
each
pair
of
split
drive
rolls
(6
&
10)
and
insert
a
securing
screw
(7
&
12).
5.
Slide
remaining
drive
rolls
(10)
with
securing
screw
(12)
onto
drive
gear
(9)
in
line
with
one
of
the
threaded
holes.
6.
Insert
remaining
screws
and
tighten.
7.
Repeat
steps
4
through
6
for
installation
of drive
rolls
onto
the
pressure
gear
(5).
C.
Inlet
Wire
Guide
(Figure
3-4)
1.
Loosen
the
inlet
wire
guide
securing
screw
(3).
I~SI1~
Wire
guides
should
be
installed
so
that
the
tip
of
the
guide
is
as
close
to
the
drive
roll
as
possible
without
touching.
2.
Insert
the
inlet
wire
guide
(1)
into
drive
assembly
as
illustrated
in
Figure
3-4.
Secure
by
tightening
screw
(3).
Drive
Gear
U-Cog
Roll
1-Igure
3-5.
U-Cog
Drive
Rolls
Installation
14
13
12
Figure
3-4.
Drive
Roll
Installation
Ii~SIi~
To
ensure
proper
gripping
action
of
U-Cog
drive
rolls,
both
rolls
should
be
installed
showing
slots
on
the
side
or
both
should
show
the
side
without
slots.
Also,
it/s
necessary
to
line
up
the
blunted
teeth
on
the
pressure
gear
roll
directly
over
the
spaces
between
the
teeth
on
the
drive
gear
roll
as
illustrated
in
Figure
3-5.
Page
8
I~IsI
I
~
Behind
the
drive
gear
is
a
spring
washer(s).
To
obtain
proper
alignment
of
the
drive
roll
on
the
drive
gear
with
the
wire
guides
rotate
the
drive
gear
securing
bolt
(11)
thereby
moving
the
drive
roll
in
or
out
to
the
desired
position.
The
drive
roll
on
the
pressure
gear
will
locate
itseff
on
the
wire
when
the
gear
cover
is
replaced
and
the
gears
mesh
together.
The
wire
drive
housing
is
made
with
mounting
holes
of
sufficient
clearance
to
provide
adjustment
of
the
wire
guides
up
or
down
in
relation
to
the
drive
rolls.
This
ad
justment
has
been
facto,y
set,
but
if
readjustment
becomes
necessaiy,
loosen
mounting
bolts
(item
17,
Figure
3-4),
weld
terminal
nut
(18)
and
bolt,
located
behind
mounting
plate
(19).
Slide
the
wire
drive
hous
ing
upward
or
downward
until
the
wire
can
be
fed
straight
through
the
guides
while
seated
in
the
drive
ruil
groove.
Tighten
mounting
bolts,
weld
terminal
bolt
and
nut.
3
-
7.
WATER
CONTROL
KIT
(Optional)
CON
NECTIONS
-
When
a
water-cooled
gun
is
to
be
used,
connect
a
hose
from
the
water
supply
to
the
Water
in
put
fitting
at
the
rear
of
the
control.
This
fitting
has
a
left-hand
thread.
The
water
output
hose
routed
through
the
boom
is
to
be
connected
to
the
Water
output
fitting
at
the
front
of
the
control.
A
water
drain
hose
connects
to
the
adapter
at
the
weld
terminal
on
the
drive
assembly
and
is
routed
through
the
boom
to
an
appropriate
disposal.
3
-8.
SHIELDING
GAS
CONNECTIONS
-
A
hose
is
supplied
with
the
unit
for
making
connections
from
the
shielding
gas
source
to
the
Shielding
Gas
input
fitting
at
the
rear
of
the
control.
These
fittings
have
right-hand
threads.
The
gas
hose
routed
through
the
boom
connects
to
the
Shielding
Gas
output
fitting
at
the
front
of
the
control.
3
-9.
WELDING
GUN
CONNECTIONS
A.
Out~cst
Wire
Guide
(Figure
3-4)
L~IIS1t~
The
outlet
guide
is
provided
as
part
of
the
gun
assembly.
1.
Loosen
the
outlet
guide
adjustable
knob
(16).
~
Wire
guides
should
be
installed
so
that
the
tip.
of
the
guide
is
as
close
to
the
drive
roll
as
possible
without
touching.
2.
Insert
the
adapter
(14)
which
includes
the
install
ed
outlet
guide
(15)
into
the
drive
assembly
op
posite
the
inlet
wire
guide
as
illustrated
in
Figure
3-4.
3.
Tighten
the
outlet
guide
adjustable
knob
(16).
B.
Weld
Cable
(Figure
3-4)
A
terminal
is
provided
on
the
lower
portion
of
the
drive
assembly
to
serve
as
a
junction
point
for
joining
together
the
weld
cables
from
the
welding
power
source
and
the
gun
(if
so
equipped).
Remove
weld
ter
minal
nut
(18),
lock
washer,
and
flat
washer;
slide
the
weld
cable
from
the
gun
onto
weld
terminal;
replace
flat
washer,
lock
washer,
nut
(18)
and
tighten.
C.
Shielding
Gas
The
shielding
gas
hose
from
the
gun
is
to
be
connected
to
the
gas
hose
which
protrudes
from
the
motor
end
of
the
boom.
L~SI
I
~
An
integral
gas
input
fitting
is
provided
on
the
weld
head
for
guns
utilizing
this
type
of
connection.
See
the
appropriate
welding
gun
Owners
Manual
for
in
structions
on
making
this
connection.
If
the
hose
is
pro
vided
with
a
fitting,
cut
the
fitting
off,
and
push
the
hose
onto
the
barbed
fitting
on
the
drive
assembly.
D.
Gun
Trigger
The
plug
from
the
gun
switch
is
to
be
inserted
~fully
into
the
switch
control
cable
and
the
locking
ring
rotated.
When
the
switch
connected
across
this
receptacle
is
closed,
the
contactor
in
the
welding
power
source
will
energize,
shielding
gas
will
flow
and
wire
will
begin
to
feed.
E.
Water
(If
Applicable)
Connect
the
water
input
hose
from
the
gun
to
the
water
output
hose
from
the
control.
Connect
the
water
return
hose
from
the
gun
to
the
adapter
at
the
weld
terminal
on
the
drive
assembly.
A
reducing
bushing
is
provided
to
accept
a
5/8-18
L.H.
fitting.
If
the
bushing
is
removed,
a
7/8-14
L.H.
fitting
can
be
accomodated.
3-10.
BOOM
ADJUSTMENTS
(Figure
3-6)
A.
Weight
Lift
Adjustment
Yoke
Jam
Nut
T8-003
409.A
Figure
3-6.
Boom
Adjustments
OM-1522
Page
9
CAUTION
___________
Ensure
that
during
all
adjustment
pro
cedures,
full
threads
on
the
adjustment
rod
are
main
tained
through
the
yoke.
If
full
threads
are
not
maintain
ed,
the
boom
may
suddenly
drop
down
and
cause
injury
to
personnel
or
damage
to
equipment.
The
amount
of
weight
which
the
boom
can
retract
into
the
upright
position
when
released
can
be
varied
by
ad
justing
the
jam
nut
and
adjustment
rod
located
at
the
base
of
the
boom.
lf.a
heavier
gun
is
installed
on
the
end
of
the
boom
thereby
making
it
necessary
to
increase
the
amount
of
weight
that
the
boom
can
lift,
loosen
the
jam
nut
and
rotate
the
adjustment
rod
so
that
the
adjust
ment
rod
threads
into
the
yoke.
When
the
proper
align
ment
is
obtained,
tighten
the
jam
nut
against
the
base
of
the
yoke.
If
a
lighter
gun
is
used
with
the
Swingarc,
rotate
the
adjustment
rod
so
that
the
adjustment
rod
threads
out
of
the
yoke.
B.
Locking
Knob
By
rotating
the
Locking
Knob
in
a
clockwise
direction,
the
boom
may
be
held
in
any
desired
position.
Rotating
the
Locking
Knob
in
a
counterclockwise
direction
will
permit
the
boom
to
free
travel.
Changing
the
position
of
the
Locking
Knob
to
the
other
threaded
holes
provided
along
the
side of
the
swivel
plate,
limits
the
lift
of
the
boom
to
50
degrees
or
40
degrees
respectively
during
free
travel.
3-11.
MOTOR
CONTROL
CONNECTION
(Figure
3-7)
I~I~l~
Examine
the
motor
control
plug
and
connec
tor
carefully
to
determine
proper
alignment
of
the
pin
ar
rangement
with
the
contacts.
TA-049
731
A
receptacle
is
provided
for
connecting
the
motor
con
trol
plug
to
the
control.
Align
keyways
and
insert
the
plug
from
the
control
end
of
the
boom
into
the
recep
tacle
and
rotate
the
plug
threaded
collar
clockwise
as
far
as
possible.
3-12.
GUN
TRIGGER
CONNECTION
(Figure
4-1)
-
A
receptacle,
labeled
TRIGGER,
is
provided
for
making
switch
control
connections.
Align
keyways
and
insert
the
plug
from
the
control
end
of
the
boom
into
the
receptacle
and
rotate
the
plug
threaded
collar
clockwise
as
far
as
possible.
3-13.
WELD
CABLE
CONNECTION
-
A
weld
cable
extends
out
of
the
wire
support
end
of
the
boom
for
making
secondary
connections
to
the
welding
power
source.
The
end
of
the
weld
cable
is
equipped
with
a
terminal
for
a
1/2
stud.
3-14.
115
VOLT/CONTACTOR
CONNECTION
(Figure
3-7)
-
A
10
ft.
cable
is
provided
for
115
volts
ac
power
and
contactor
control
connections
between
con
trol
and
welding
power
source.
Align
keyways
and
in
sert
the
plug
into
receptacle
on
the
control
and
rotate
the
threaded
collar
clockwise
as
far
as
possible.
Insert
the
115
volts
power
plug
into
the
115
volts
ac
recep
tacle
on
the
welding
power
source
and
rotate
clockwise
to
lock
in
place.
Insert
contactor
control
plug
into
the
contactor
control
receptacle
on
the
welding
power
source
and
rotate
clockwise
to
lock
in
place.
CAUTION
___________
The
control
will
be
electrically
hot
inter
nally
and
ready
to
operate
as
soon
as
the
115
volts
power
plug
is
connected
to
the
115
volts
ac source
and
the
welding
power
source
is
energized.
IMPORTANT
______________
The
contactor
control
circuitry
that
is
to
be
used/n
conjunction
with
this
control/feeder
must
be
of
the
type
that
operates
on
115
volts
60
Hertz
power.
This
is
necessary
because
the
control
will
supply
115
volts
ac
through
the
contactor
control
cable
whenever
the
gun
switch
is
closed.
3-15.
REMOTE
CONTROL
CONNECTION
(Figure
4-1)
-
A
receptacle
is
provided
for
connecting
a
remote
control
to
the
unit.
Align
keyways
and
insert
the
plug
from
the
remote
control
into
the
receptacle
and
rotate
the
threaded
collar
clockwise
as
far
as
possible.
3-16.
INSTALLATION
OF
SPOOL-TYPE
WIRE
(Figure
3-2)
1.
Remove
the
retaining
ring
(12).
2.
Slide
the
spool
of
wire
onto
the
hub
(4)
so
that
the
wire
will
feed
off
the
top
of
the
spool.
The
spool
turns
in
a
clockwise
direction.
3.
Rotate
the
spool
until
the
hole
in
the
spool
aligns
with
the
pin
in
the
hub
(4).Slide
the
spool
onto
the
hub
until
it
seats
against
the
back
flange
of
the
hub.
4.
Depress
the
two
spring-loaded
stops
(11)
on
the
retaining
ring
(12)
and
slide
the
retaining
ring
(12)
into
proper
position
on
the
hub
(4).
Release
the
two
stops
(11).
3-17.
INSTALLATION
OF
REEL-TYPE
WIRE
(Figure
3-3)
1.
Loosen
the
four
wing
nuts
(3)
on
the
fingers
(2)
of
the
wire
reel
(1).
2.
Pull
the
four
fingers
(2)
out
until
they
can
be
rotated
toward
the
center
of
the
reel
(1).
3.
Install
the
wire
onto
the
reel
(1)
over
the
four
fingers
(2).
Ensure
that
the
wire
feeds
off
the
top
of
the
reel
(1).
The
reel
(1)
turns
in
a
clockwise
direction.
Figure
3-7.
Rear
Panel
Connections
Page
10
4.
Rotate
the
four
fingers
(2)
back
to
their
proper
position.
Tighten
the
four
wing
nuts
(3).
3-18.
ADJUSTMENT
OF
HUB
TENSION
(Figure
3-2)
-
Check
the
hub
tension
by
slowly
pulling
the
wire
toward
the
feed
roll.
The
wire
should
unwind
freely,
but
the
hub
tension
should
be
sufficient
to
keep
the
wire
taut
and
prevent
backlash
when
the
wire
feeding
ceases.
If
adjustment
is
required,
loosen
or
tighten
the
hex
nut
(10)
on
the
end
of
the
spindle
support
shaft
(1)
accordingly.
3-19.
WELDING
WIRE
THREADING
CAUTION
___________
Prior
to
threading
the
welding
wire
through
the
gun,
ensure
that
weld
power
is
not
available
at
the
weld
head.
1.
Install
the
wire
(reel-type
or
spool-type)
as
in
structed
in
Section
3-16
or
3-17.
2.
Cut
off
any
portion
of
the
free
end
of
the
wire
which
is
not
straight.
Ensure
that
the
cut
end
is
free
from
rough
surfaces
to
permit
proper
feeding.
Feed
approximately
4
inches
of
wire
into
the
outlet
wire
guide.
I~IsIl~
If
when
the
gear
cover
is
closed
the
U-Cog
drive
rolls
are
not
aligned
properly
(see
Section
3-6),
pivot
the
gear
cover
away
from
the
drive
gear
and
rotate
the
pressure
gear
one
tooth.
6.
Pivot
the
gear
cover
closed
making
sure
the
teeth
on
the
pressure
gear
mesh
with
the
teeth
on
the
drive
gear.
The
welding
wire
must
also
be
in
the
grooves
of
the
drive
rolls.
7.
Pivot
the
pressure
adjustment
wing
nut
until
the
washer
on
the
pressure
adjustment
is
seated
on
top
of
the
gear
cover.
8.
Turn
the
pressure
adjustment
wing
nut
in
a
clockwise
direction
until
the
drive
rolls
are
tight
against
the
welding
wire.
Do
not
overtighten.
Further
adjustment
to
attain
desired
clamping
pressure
can
be
made
after
the
welding
power
source
and
the
control/feeder
are
put
into
opera
tion.
9.
Draw
the
gun
cable
out
straight.
3.
Route
the
wire
through
the
wire
guide
tube
on
the
side
of
the
boom,
over
the
wire
pulley,
and
to
the
drive
assembly.
4.
Loosen
the
wing
nut
on
the
drive
roll
pressure
adjustment,
pivot
the
pressure
adjustment
free
of
the
cover,
and
pivot
the
pressure
gear
assembly
away
until
it
is
in
an
open
position.
5.
Feed
the
wire
through
the
inlet
wire
guide,
past
the
drive
rolls,
and
on
into
the
outlet
wire
guide.
10.
Energize
the
welding
power
source.
11.
Place
the
control
POWER
switch
in
the
ON
posi
tion.
12.
Depress
the
INCH
switch.
This
will
run
the
welding
wire
through
the
gun
without
placing
weld
current
on
the
welding
wire.
Release
the
INCH
switch
when
the
welding
wire
extends
ap
proximately
one
inch
out
of
the
gun
tip.
SECTION
4-
FUNCTION
OF
CONTROLS
Trigger
Control
Receptacle
Figure
4-1.
Control
Components
4
-
1.
POWER
SWITCH
(Figure
4-1)
-
Placing
the
POWER
switch
on
the
control
in
the
ON
position
will
apply
115
volts
ac
to
the
unit
and
thereby
place
it
in
an
operational
condition,
ready
to
feed
wire
and
permit
shielding
gas
to
flow.
Placing
the
POWER
switch
in
the
OFF
position
will
shut
the
control/feeder
down.
4
-2.
REMOTE
CONTROL
RECEPTACLE
AND
SWITCH
(Figure
4-1)
-
The
remote
control
receptacle
is
providced
for
use
in
conjunction
with
certain
optional
controls.
If
a
remote
control
is
to
be
used,
make
con
TA-049732
nections
as
instructed
in
Section
3-15
and
place
the
Remote
Control
switch
in
the
REMOTE
position.
When
changing
the
position
of
the
switch
it
is
necessary
to
pull
out
on
the
toggle.
If
a
remote
control
is
not
to
be
used,
place
the
Remote
Control
switch
in
the
STAN
DARD
position.
4
-
3.
PURGE
BUTTON
(Figure
4-1)
-
The
PURGE
button
is
a
momentary
contact
switch.
This
switch
will
energize
the
gas
solenoid
and
purge
the
shielding
gas
Fuse
Inches
Per
Minute
Purge
Meter
Button
Inch
Switch
Circuit
Breaker
Power
Switch
CAUTION
__________
Placing
the
POWER
switch
in
the
OFF
position
does
not
remove
power
from
all
of
the
controls
internal
circuitry.
Completely
terminate
all
electrical
power
to
the
control
by
removing
the
115
volts
ac
plug
from
its
power
supply,
and
ensure
that
machinery
lockout
procedures
have
been
employed
on
the
we/ding
power
sources
input
line
(see
Instruction
Manual
on
we/ding
power
source)
before
attempting
any
inspection
or
work
inside
the
unit.
Remote
Control
Receptacle
OM-1522
Page
11
line
of
the
gun.
The
PURGE
button
also
allows
the
shielding
gas
regulator
to
be
adjusted
without
energiz
ing
the
welding
circuit.
4
-
4.
INCH
SWITCH
(Figure
4-1)
-
The
INCH
switch
is
a
spring
loaded
toggle
switch.
When
actuated
it
completes
the
circuit
to
the
motor
without
having
to
depress
the
gun
trigger
switch.
This
switch
will
permit
inching
of
the
wire
at
whatever
setting
the
WIRE
SPEED
control
is
at,
without
energizing
the
welding
cir
cuit
or
the
shielding
gas
valve.
4
-
5.
WIRE
SPEED
CONTROL
(Figure
4-1)
-
A
ten
turn
WIRE
SPEED
control
provides
a
means
of
deter
mining
the
rate
at
which
welding
wire
will
be
fed
into
the
weld.
Rotating
the
WIRE
SPEED
control
in
~
clockwise
direction
will
increase
the
rate
of
the
wire
feed.
4
-
6.
INCHES
PER
MINUTE
METER
(Figure
4-1)
-
This
meter
displays
the
wire
speed
in
inches
per
minute.
Before
the
gun
trigger
is
depressed,
the
meter
displays
wire
speed
as
set
by
the
WIRE
SPEED
control.
During
welding
the
meter
displays
actual
wire
speed
as
set
by
the
WIRE
SPEED
control.
4
-
7.
RESET
CIRCUIT
BREAKER
(Figure
4-1)
-
A
circuit
breaker
provides
protection
to
the
feeder
motor.
In
the
event
the
motor
should
be
placed
in
an
overload
condition,
the
breaker
would
trip
and
suspend
all
out
put.
Should
this
breaker
trip,
the
RESET
button
would
have
to
be
manually
depressed
in
order
to
reset
the
cir
cuit
breaker.
4
-
8.
BURNBACK
CONTROL
(Optional)
-
The
burnback
circuitry
in
this
control
provides
a
means
of
keeping
the
welding
wirefrom
sticking
to
the
workpiece
after
the
gun
switch
is
released.
The
burnback
capabili
ty
in
this
control/feeder
will,
depending
upon
the
set
ting
of
the
BURNBACK
control,
keep
weld
current
pre
sent
on
the
welding
wire
from
0
to
15
cycles
after
the
wire
has
stopped
feeding.
This
delay
action
will
permit
the
welding
wire
to
burn
back
to
a
point
where
it
will
neither
stick
to
the
workpiece
nor
the
contact
tube.
If
the
welding
wire
sticks
to
the
contact
tube,
rotate
the
BURNBACK
control
to
a
more
counterclockwise
posi
tion.
If
the
welding
wire
sticks
to
the
workpiece,
rotate
the
BURNBACK
control
to
a
more
clockwise
position.
SECTION
5
-
SEQUENCE
OF
OPERATION
5
-
1.
GAS
METAL-ARC
WELDING
(GMAW)
1.
Make
all
necessary
connections
as
instructed
in
Section
3.
2.
Place
the
control
unit
Remote
Control
switch
in
the
STANDARD
position.
9.
Depress
the
trigger
on
the
gun
handle.
Gas
will
start
to
flow
and
wire
will
start
to
feed
if
drive
roll
pressure
is
properly
adjusted
to
prevent
slippage.
If
wire
slippage
is
noticed,
tighten
the
drive
roll
pressure
adjustment
wing
nut
1/2
turn
clockwise.
Repeat
until
slippage
stops.
Do
not
overtighten
wing
nut.
3.
Energize
the
welding
power
source.
4.
Place
the
POWER
switch
on
the
control
in
the
ON
position.
5.
Rotate
the
WIRE
SPEED
control
until
the
desired
wire
speed
is
displayed
on
the
INCHES
PER
MINUTE
meter.
6.
Turn
on
the
shielding
gas
at
the
source.
7.
Depress
the
PURGE
button
for
one
minute.
CAUTION:
The
welding
wire
and
all
metal
parts
in
contact
with
it
are
energized
while
welding.
Do
not
touch
the
welding
wire
or
any
metal
part
making
con-
tact
with
it.
5
-2.
SHUTFING
DOWN
1.
Turn
off
the
shielding
gas
at
the
source.
2.
Place
the
POWER
switch
on
the
control
in
the
OFF
position.
CAUTION
____________
Prior
to
welding,
it
is
imperative
that
pro
per
protective
clothing
(welding
coat
and
gloves)
and
eye
protection
(glasses
and
welding
he/met)
be
put
on.
Failure
to
comply
may
result
in
serious
or
permanent
bodily
damage.
8.
Hold
the
tip
of
the
gun
approximately
1/2
inch
from
the
workpiece.
3.
Turn
off
all
associated
equipment.
CAUTION
___________
If
welding
is
performed
in
a
confined
area,
failure
to
turn
off
the
shielding
gas
supply
could
result
in
a
build-up
of
gas
fumes,
thereby
endangering
personnel
reentering
the
welding
area.
SECTION
6-
MAINTENANCE
6
-
1.
INSPECTION
AND
UPKEEP
-
Usage
and
shop
conditions
will
determine
the
frequency
and
type
of
maintenance.
Inspect
equipment
as
follows:
1.
Make
sure
welding
power
source
is
shut
down.
2.
Inspect
gun
for
broken
areas,
cracks
and
loose
parts:
tighten,
repair,
and
replace
as
required.
3.
Carefully
remove
any
weld
spatter
or
foreign
matter
which
may
accumulate
around
the
nozzle
orifice.
Use
a
hardwood
stick,
never
a
metal
tool.
Page
12
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Miller HK300226 Owner's manual

Miller
Brand
Miller
Model
HK300226
Category
Welding System
Type
Owner's manual
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