Miller KB100704 Owner's manual

January

1992

FORM:

OM-151

016

L

Effective

With

Serial

No.

KB1

00704

MODEL:

Auto

Arcﬁ

140

OWNERS

MANUAL

IMPORTANT:

Read

and

understand

the

entire

contents

of

this

manual,

with

special

emphasis

on

the

safety

material

throughout

the

manual,

before

installing,

operating,

or

maintaining

this

equipment.

This

unit

and

these

instructions

are

for

use

only

by

persons

trained

and

experienced

in

the

safe

operation

of

welding

equipment.

Do

not

allow

untrained

persons

to

install,

operate,

ormaintain

this

unit.

MILLER

ELECTRIC

Mfg.

Co.

A

MUter

Group

Ltd.,

Company

P.O.

Box

1079

Appleton,

WI

54912

USA

Tel.

414-734-9821

Contact

your

distributor

if

you

do

not

fully

understand

these

instructions.

auto_arc

8191



ST-I

49 628

PRINTED

IN

USA

8

ONE

YEAR

LIMITED

WARRANTY

EFFECTIVE:

FEBRUARY

17,

1989

Thiswarranty

supersedes

all

ARC

warranties

and

is

exclusive

with

no

other

guarantees

orwarranties

expressed

or

implied.

COVERAGE



MILLER

Electric

Mfg.

Co.

warrants

to

the

for

the

purchase

price

(less

reasonable

depreciation

based

~

buyer

who

purchases

this

AUTO

ARC

Welder

(Welder)

for

upon

actual

use)

upon

return

of

the

goods

at

Consumers

risk

j

personal,

family

or

household

purposes

(Consumer)

that

this

and

expense.

MILLERs

option

of

repair

or

replacement

will

be

I

Welderwillbefreefromdefectsinmaterialandworkmanshipfor

FOB.,

Factory

at

Appleton,

WI

or

F.O.B.

at

a

MILLER

autho

a

period

of

one

year

from

the

date

of

purchase.

This

warranty

rized

service

facility,

therefore,

no

compensation

for

transporta

A

covers

only

the

original

purchaser

of

this

Welder.

MILLER

Elec-

tion

costs

of

any

kind

will

be

allowed.

Upon

receipt

of

notice

of

()

tric

does

not

authorize

any

party,

including

its

authorized

dis-

apparentdefectorfailure,MlLLERshallinstructtheclaimanton

,~

tributors,

to

offer

any

other

warranty

on

behalf

of

MILLER

Elec-

the

warranty

claim

procedures

to

be

followed.

f\

tric.

Upon

expiration

of

the

warranty

period,

MILLER

Electric

V

shall

have

no

further

liability

the

Welder,

except

on

THIS

WARRANTY

IS

OFFERED

IN

LIEU

OF

ANY

OTHER

~

warranty

claims

made

during

the

warranty

period.

No

warranty

EXPRESS

WARRANTY;

AND,

EXCEPT

TO

THE

EXTENT

is

made

by

MILLER

with

respect

to

engines,

trade

accessories

PROHIBITED

BY

APPLICABLE

LAW,

THE

DURATION

OF

~

orother

items

manufactured

by

others.

Such

engines,

trade

ac-

ALL

IMPLIED

WARRANTIES,

INCLUDING

BUT

NOT

A

cessories

and

other

items

are

sold

subject

to

the

warranties

of

LIMITED

TO

THE

IMPLIED

WARRANTIES

OF

MERCHAN

~J

their

respective

manufacturers,

if

any.

All

engines

are

war-

TABIL1~Y

AND

FITNESS

FOR

A

PARTICULAR

PURPOSE,

IS

.f~

ranted

by

their

manufacturer

for

two

years

from

date

of

original

LIMITED

TO

THE

DURATION

OF

THIS

WARRANTY.

(~

purchase,

except

Deutz

engines

which

have

a

one

year,

2000

hour

warranty.

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

I

AND

ANY

IMPLIED

WARRANTY,

GUARANTY

OR.

REPRE

MILLER

shall

be

required

to

honor

warranty

claims

on

war-

SENTATION

AS

TO

PERFORMANCE,

AND

ANY

REMEDY

j

ranted

Equipment

in

the

event

of

failure

resulting

from

a

defect

FOR

BREACH

OF

CONTRACT

WHICH,

BUT

FOR

THIS

~

within

the

following

periods

from

the

date

of

delivery

of

Equip-

PROVISION,

MIGHT

ARISE

BY

IMPLICATION,

OPERATION

~

ment

to

the

original

user:

OF

LAW,

CUSTOM

OF

TRADE

OR

COURSE

OF

DEALING,

I

Arc

w

Id

rs

w

r r

and

corn

onents

1

r

INCLUDING

ANY

IMPLIED

WARRANTY

OF MERCHANT-

2

On

ml

e

,

p0

e

sauces,

p

yea

ABILITY

OR

OF

FITNESS

FOR

PARTICULAR

PURPOSE,

(labori

aunpowe

ec

tie

yea

s

WITH

RESPECT

TO

ANY

AND

ALL

EQUIPMENT

FUR-

I

3.

All

welding

guns,

feeder/guns

and

torches

90

days

NISHED

BY

MILLER

IS

EXCLUDED

AND

DISCLAIMED

BY

4.

Replacement

or

repair

parts,

exclusive

of

labor

.

60

days

LLE

5.

Batteries

6

months

Some

states

do

not

allow

limitations

on

how

long

an

implied

provided

that

MILLER

is

notified

in

writing

within

thirty

(30)

days

warranty

lasts,

so

the

above

limitation

may

not

apply

to

you.

of

such

failure.

This

warranty

gives

you

specific

legal

rights,

and

you

may

also

have

other

rights

which

vary

from

state

to

state.

WHAT

IS

NOT

COVERED



This

warranty

does

not

extend

to

any

Welder

subjected

to

misuse,

neglect,

accident,

or

in-

THE

PURCHASERS

REMEDIES

FOR

A

DEFECTIVE

warranty

repair

by

anyone

except

MILLER

Electric

or

its

autho-

WELDER,

TO

THE

EXTENT

PERMITTED

BY

APPLICABLE

rized

service

stations.

Further,

this

warranty

only

extends

to

the

LAW,

ARE

LIMITED

TO

THE

REMEDY

PROVIDED

BY

THIS

original

purchaser

of

this

Welder.

WARRANTY.

TO

THE

EXTENT

ENFORCEABLE

UNDER

APPLICABLE

LAW,

MILLER

ELECTRIC

SHALL

IN

NO

In

the

case

of

MILLERs

breach

of

warranty

or

any

other

duty

EVENT

BE

LIABLE

FOR

CONSEQUENTIAL,

INCIDENTAL

with

respect

to

the

quality

of

any

goods,

the

exclusive

remedies

OR

SPECIAL

DAMAGES

ARISING

OUT

OF

THE

USE

OF,

OR

therefore

shall

be,

at

MILLERs

option

(1)

repair

or

(2)

replace-

INABILITY

TO

USE,

THE

WELDER,

WHETHER

BASED

ON

ment

or,

where

authorized

in

writing

by

MILLER

in

appropriate

BREACH

OF

THIS

WARRANTY,

MILLER

ELECTRICS

NEG

cases,

(3)

the

reasonable

cost

of

repair

or

replacement

at

an

LIGENCE

OR

OTHER

TORT,

OR

ON

ANY

THEORY

OF

authorized

MILLER

service

station

or

(4)

payment

of

or

credit

STRICT

LIABILITY.

~

RECEIVING-HANDLING

Before

unpacking

equipment,

check

carton

for

any

damage

that

may

have

occurred

during

shipment.

File

any

claims

for

loss

or

damage

with

the

delivering

carrier.

Assistance

for

filing

or

settling

claims

may

be

obtained

from

distributor

and/or

equipment

manufacturers

Transportation

Department.

When

requesting

information

about

this

equipment,

always

provide

Model

Designation

and

Serial

or

Style

Number.

Use

the

following

spaces

to

record

Model

Designation

and

Serial

or

Style

Number

of

your

unit.

The

information

is

located

on

the

rating

label

or

nameplate.

Model

_____________________________________________________

Serial

or

Style

No.

_________________________________________

Date

of

Purchase

_________________________________________

auto_arc

8/91

ERRATA

SHEET

January

19,

1993

FORM:

OM-151

016

Use

above

FORM

number

when

ordering

extra

manuals.

After

this

manual

was

printed,

refinements

in

equipment

design

occurred.

This

sheet

lists

exceptions

to

data

appearing

later

in

this

manual.

Figure

3-7.

Installing

Safety

Chain

CHANGES

TO

SECTION

8

PARTS

LIST

Change

Parts

List

as

follows:

Dia.

Part

Replaced

Mkgs.

No.

With

Description

Quantity

.25-19

.

PCi

...

137800..

+157

044

.

25-24

.

SR2

...

147535..

.

155056

TP1

155054

026701

.

25-25

147571

. .

.

147571

.

25-27

. .

PLG1

..

088297..

.152118

.

25-36

147578..

.

152872

.

25-37

087

341

. . .

Deleted

. .

26-

.

Added..

.

156339

. .

26-

.

Added..

.

147893

. .

26-

.

Added..

.090693

.

26-

Added..

.

109318

.

26-

Added..

.602250

. .

26-

Added

.

121

614

.

26-

Added

. .

.

602 384

.

26-

Added..

.602389

.

26-

Added..

.

156340

CIRCUIT

CARD,

motor

speed

control

(Eff

w/KD352528)

..

1

RECTIFIER,

si

diode

(consisting

of)

1

THERMOSTAT,

NC

1

INSULATION,

thermostat

1

HANDLE,

(qty

chg)

(Eff

w/KC229027)

1

CORD

SET,

250V

6-50P

l2ga

3/c

l2ft

(Eff

w/KC213453)

..

1

BASE,

(Eff

w/KC229027)

1

Eff

w/KC229027

RETAINER,

bottle

(Eff

w/KC229027)

1

AXLE,

running

gear

(Eff

w/KC229027)

1

WHEEL,

rubolene

spoke

8

in

x

2.000

wide

x

.760

bore

(Eff

w/KC229027)

2

CASTER,

swvl

cushionex

2.500

x

.812

x

.312-18

x

1.000

(Eff

w/KC229027)

2

WASHER,

flat

stl

SAE

.750

(Eff

w/KC229027)

4

RING,

retaining

ext

.750

shaft

x

.O85grv

depth

(Eff

w/KC229027)

2

SNAP,

chain

(Eff

w/KC229027)

1

HOOK,

S

blunt

1.500

in

(Eff

w/KC229027)

1

CHAIN,

weldless

2/0

x

11.000

(Eff

w/KC229027)

1

**First

digit

represents

page

no



digits

following

dash

represent

item

no.

+AlI

components

remain

the

same

with

listed

exceptions.

BE

SURE

TO

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

.3

IMPORTANT:

Effective

with

Serial

No.

KC229027,

running

gear

is

standard

on

units

from

the

factoiy.

CHANGES

TO

SECTION

3

INSTALLATION

Add

Section

3-7.

Installing

Safety

Chain

1

cylinder

Bracket

2

S-Hook

crimp

between

small

hole

in

bracket

and

chain.

3

chain

4

Snap

crimp

onto

open

end

of

chain.

4

Tools

Needed:

Ref.

ST.149

255A

ARC

WELDING

SAFETY

PRECAUTIONS

ELECTRIC

SHOCK

can

kill.

Touching

live

electrical

parts

can

cause

fatal

shocks

or

severe

burns.

The

electrode

and

work

circuit

is

electrically

live

whenever

the

output

is

on.

The

input

power

circuit

and

machine

internal

circuits

are

also

live

when

power

is

on.

In

semiautomatic

or

automatic

wire

welding,

the

wire,

wire

reel,

drive

roll

housing,

and

all

metal

parts

touching

the

welding

wire

are

electrically

live.

Incorrectly

installed

or

improperly

grounded

equipment

is

a

hazard.

Do

not

touch

live

electrical

parts.

Wear

dry,

hole-free

insulating

gloves

and

body

protection.

Insulate

yourself

from

work

and

ground

using

dry

insulating

mats

or

covers.

4.

Disconnect

input

power

or

stop

engine

before

installing

or

servicing

this

equipment.

5.

Properly

install

and

ground

this

equipment

according

to

its

Owners

Manual and

national,

state,

and

local

codes.

Turn

off

all

equipment

when

not

in

use.

Do

not

use

worn,

damaged,

undersized,

or

poorly

spliced

cables.

Do

not

wrap

cables

around

your

body.

Ground

the

workpiece

to

a

good

electrical

(earth)

ground.

Do

not

touch

electrode

while

in

contact

with

the

work

(ground)

circuit.

11.

Use

only

well-maintained

equipment.

Repair

or

replace

damaged

parts

at

once.

12.

Wear

a

safety

harness

to

prevent

falling

if

working

above

floor

level.

13.

Keep

all

panels

and

covers

securely

in

place.

a

WARNING

ARC

WELDING

can

be

hazardous.

PROTECT

YOURSELF

AND

OTHERS

FROM

POSSIBLE

SERIOUS

INJURY

OR

DEATH.

KEEP

CHILDREN

AWAY.

PACEMAKER

WEARERS

KEEP

AWAY

UNTIL

CONSULTING

YOUR

DOCTOR.

In

welding,

as

in

most

jobs,

exposure

to

certain

hazards

occurs.

Welding

is

safe

when

precautions

are

taken.

The

safety

information

given

below

is

only

a

summary

of

the

more

complete

safety

information

that

will

be

found

in

the

Safety

Standards

listed

on

the

Read

and

follow

all

Safety

Standards.

HAVE

ALL

INSTALLATION,

OPERATION,

MAINTENANCE,

AND

REPAIR

WORK

PERFORMED

ONLY

BY

QUALIFIED

PEOPLE.

1.

2.

3.

6.

7.

8.

9.

10.

/)

~

ARC

RAYS

can

burn

eyes

and

skin;

1.

Wear

a

welding

helmet

fitted

with

a

proper

shade

of

filter

(see

NOISE

can

damage

hearing.

ANSIZ49.1

IistedinSafetyStandards)toprotectyourfaceand

eyes

when

welding

or

watching.

Arc

rays

from

the

welding

process

produce

intense

2.

Wear

approved

safety

glasses.

Side

shields

recommended.

heat

and

strong

ultraviolet

rays

that

can

burn

eyes

3.

Use

protective

screens

or

barriers

to

protect

others

from

flash

and

skin.

Noise

from

some

processes

can

damage

and

glare;

warn

others

not

to

watch

the

arc.

hearing.

4.

Wear

protective

clothing

made

from

durable,

flame-resistant

material

(wool

and

leather)

and

foot

protection.

5.

Use

approved

ear

plugs

or

ear

muffs

it

noise

level

is

high.

T

FUMES

AND

GASES

can

be

hazardous

5.

Work

in

a

confined

space

only

if

it

is

well

ventilated,

or

while

to

your

health.

wearing

an

air-supplied

respirator.

Shielding

gases

used

for

Weldingproducesfumesandgases.

Breathingthese

welding

can

displace

air

causing

injury

or

death.

Be

sure

the

fumes

and

gases

can

be

hazardous

to

your

health.

breathing

air

is

safe.

6.

Do

not

weld

in

locations

near

degreasing,

cleaning,

or

spraying

operations.

The

heat

and

rays

of

the

arc

can

react

with

vapors

to

1.

Keep

your

head

out

of

the

fumes.

Do

not

breath

the

fumes.

form

highly

toxic

and

irritating

gases.

2.

If

inside,

ventilate

the

area

and/or

use

exhaust

at

the

arc

to

remove

welding

fumes

and

gases.

7.

Do

not

weld

on

coated

metals,

such

as

galvanized,

lead,

or

3.

Il

ventilation

is

poor,

use

an

approved

air.supplied

respirator.

cadmium

plated

steel,

unless

the

coating

is

removed

from

the

4.

Read

the

Material

Safety

Data

Sheets

(MSDS5)

and

the

weld

area,

the

area

is

well

ventilated,

and

if

necessary,

while

manufacturers

instruction

for

metals,

consumables,

coatings,

wearing

an

air-supplied

respirator.

The

coatings

and

any

metals

and

cleaners,

containing

these

elements

can

give

off

toxic

fumes

if

welded.

WELDING

can

cause

fire

or

explosion.

5.

Watch

for

fire,

and

keep

a

fire

extinguisher

nearby.

Sparks

and

spatter

fly

off

from

the

welding

arc.

The

6.

Be

aware

that

welding

on

a

ceiling,

floor,

bulkhead,

or

partition

flying

sparks

and

hot

metal,

weld

spatter,

hot

can

cause

fire

on

the

hidden

side.

workpiece,

and

hot

equipment

can

cause

fires

and

burns.

Accidental

contact

of

electrode

or

welding

wire

7.

Do

not

weld

on

closed

containers

such

as

tanks

or

drums.

to

metal

objects

can

cause

sparks,

overheating,

or

fire.

8.

Connect

work

cable

to

the

work

as

close

to

the

welding

area as

practical

to

prevent

welding

current

from

traveling

long,

possibly

1.

Protect

yourself

and

others

from

flying

sparks

and

hot metal.

2.

Do

not

weld

where

flying

sparks

can

strike

flammable

material.

9.

unknown

paths

and

causing

electric

shock

and

fire

hazards.

Do

not

use

welder

to

thaw

frozen

pipes.

3.

Removeallflammableswithin35ft(10.7m)oftheweldingarc.lt

this

is

not

possible,

tightly

cover

them

with

approved

covers,

10.

Remove

stick

electrode

from

holder

or

cutoff

welding

wire

at

contact

tip

when

not

in

use.

4.

Be

alert

that

welding

sparks

and

hot materials

from

welding

can

11.

Wear

oil-free

protective

garments

such

as

leather

gloves,

heavy

easily

go

through

small

cracks

and

openings

to

adjacent

areas.

shirt,

cuffless

trousers,

high

shoes,

and

a

cap.

>~

FLYING

SPARKS

AND

HOT

METAL

can

cause

injury,

Chipping

and

grinding

cause

flying

metal.

As

welds

cool,

they

can

throw

off

slag.

1.

2.

Wear

approved

face

shield

or

safety

goggles.

Side

shields

recommended.

Wear

proper

body

protection

to

protect

skin.

srI

11/91

CYLINDERS

can

explode

if

damaged.

Shielding

gas

cylinders

contain

gas

under

high

pressure.

If

damaged,

a

cylinder

can

explode.

Since

gas

cylinders

are

normally

part

of

the

welding

process,

be

sure

to

treat

them

carefully.

1.

Protect

compressed

gas

cylinders

from

excessive

heat,

mechanical

shocks,

and

arcs.

2.

Install

and

secure

cylinders

in

an

upright

position

by

chaining

them

to

a

stationary

support

or

equipment

cylinder

rack

to

prevent

falling

or

tipping.

3.

Keep

cylinders

away

from

any

welding

or

other

electrical

circuits.

-

4.

Never

allow

a

welding

electrode

to

touch

any

cylinder.

5.

Use

only

correct

shielding

gas

cylinders,

regulators,

hoses,

and

fittings

designed

for

the

specific

application;

maintain

them

and

associated

parts

in

good

condition.

6.

Turn

face

away

from

valve

outlet

when

opening

cylinder

valve.

7.

Keep

protective

cap

in

place

over

valve

except

when

cylinder

is

in

use

or

connected

for

use.

6.

Read

and

follow

instructions

on

compressed

gas

cylinders,

associated

equipment,

and

CGA

publication

P-i

listed

in

Safety

Standards.

ENGINE

FUEL

can

cause

fire

or

1.

Stop

engine

before

checking

or

adding

fuel.

explosion.

2.

Do

not

add

fuel

while

smoking

or

if

unit

is

near

any

sparks

or

open

flames.

3.

Allow

engine

to

cool

before

fueling.

If

possible,

check

and add

Engine

fuel

is

highly

flammable.

fuel

to

cold

engine

before

beginning

job.

4.

Do

not

overfill

tank



allow

room

for

fuel

to

expand.

5.

Do

not

spill

fuel.

If

fuel

is

spilled,

clean

up

before

starting

encilne.

MOVING

PARTS

can

cause

injury.

3.

Have

only

qualified

people

remove

guards

or

covers

for

maintenance

and

troubleshooting

as

necessary.

SPARKS

can

cause

BATTERY

GASES

TO

EXPLODE;

BATTERY

ACID

can

burn

eyes

and

skin,

1.

2.

Always

wear

a

face

shield

when

working

on

a

battery.

Stop

engine

before

disconnecting

or

connecting

battery

cables.

Batteries

contain

acid

and

generate

explosive

gases.

3.

4.

5.

Do

not

allow

tools

to

cause

sparks

when

working

on

a

battery.

Do

not

use

welder

to

charge

batteries

or

jump

start

vehicles.

Observe

correct

polarity

(+

and

)

on

batteries.

PRINCIPAL

SAFETY

STANDARDS

Safety

in

Welding

and

Cutting,

ANSI

Standard

Z49.1,

from

American

Welding

Society,

550

N.W.

LeJeune

Rd,

Miami

FL

33126

Safety

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

Cutting

of

Containers

That

Have

Held

Hazardous

Substances,

Ameri

can

Welding

Society

Standard

AWS

F4.1,from

American

Welding

So

ciety.

550

N.W.

LeJeune

Ad,

Miami,

FL

33126

National

Electrical

Code,

NFPA

Standard

70,

from

National

Fire

Pro

tection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

Safe

Handling

of

Compressed

Gases

in

Cylinders,

CGA

Pamphlet

P-I,

from

Compressed

Gas

Association,

1235

Jefferson

Davis

High

way,

Suite

501,

Arlington,

VA

22202.

Code

for

Safety

in

Welding

and

Cutting,

CSA

Standard

Wi

17.2,

from

Canadian

Standards

Association,

Standards

Sales,

178

Rexdale

Bou

levard,

Rexdale,

Ontario,

Canada

M9W

1

R3.

Safe

Practices

For

Occupation

And

Educational

EyeAnd

Face

Protec

tion,

ANSI

Standard

Z87.1,

from

American

National

Standards

Insti

tute,

1430

Broadway,

New

York,

NY

10018.

Cuffing

And

Welding

Processes,

NFPA

Standard

51

B,

from

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

a

WARNING

ENGINE

EXHAUST

GASES

can

kill.

1.

Use

equipment

outside

in

open,

well-ventilated

areas.

2.

If

used

in

a

closed

area,

vent

engine

exhaust

outside

and

Engines

produce

harmful

exhaust

gases.

away

from

any

building

air

intakes.

ENGINES

can

be

hazardous.

Moving

parts,

such

as

fans,

rotors,

and

belts

can

cut

fingers

and

hands

and

catch loose

clothing.

1.

Keep

all

doors,

panels,

covers,

and

guards

closed

and

securely

in

place.

2.

Stop

en

ne

before

installing

or

connecting

unit.

4.

To

prevent

accidental

starting

during

servicing,

disconnect

negative

()

battery

cable

from

battery.

5.

Keep

hands,

hair,

loose

clothing,

and

tools

away

from

moving

parts.

6.

Reinstall

panels

or

guards

and

close

doors

when

servicing

is

finished

and

before

starting

engine.

~4

~

~-.

~f

~



(-





STEAM

AND

COOLANT

can

skIn.

The

coolant

in

the

r

under

pressure.

PRESSURIZED

burn

face,

eyes,

adiator

can

be

very

h

HOT

and

ot

and

1.

2.

3.

Do

not

remove

radiator

cap

when

engine

is

hot.

Allow

engine

to

cool.

Wear

gloves

and

put

a

rag

over

cap

area

when

removing

cap.

Allow

pressure

to

escape

before

completely

removing

cap.

sri

11/91

OM-151

016

2/92

TABLE

OF

CONTENTS

SECTION

1



SAFETY

SIGNAL

WORDS

.

1

SECTION

2

SPECIFICATIONS

2-1.

Volt-Ampere

Curves

2

2-2.

Duty

Cycle

2

SECTION

3

INSTALLATION

3-1.

Installing

Work

Clamp

3

3-2.

Gun

Polarity

For

Wire

Type

3

3-3.

Selecting

A

Location

And

Connecting

Input

Power

3

3-4.

Threading

Welding

Wire

5

3-5.

Feeding

Welding

Wire

5

3-6.

Installing

Gas

Supply

6

SECTION

4

OPERATION

6

SECTION

5

MAINTENANCE

&

TROUBLESHOOTING

5-1.

Routine

Maintenance

10

5-2.

Overload

Protection

10

5-3.

Cleaning

Or

Replacing

Drive

Roll

And

Replacing

Wire

Inlet

Guide

11

5-4.

Replacing

Pressure

Bearing

12

5-5.

Adjusting

Hub

Tension

12

5-6.

Installing

Wire

Spool

13

5-7.

Troubleshooting

13

SECTION

6

ELECTRICAL

DIAGRAMS

15

SECTION

7

WELDING

METHODS

&

TROUBLESHOOTING

7-1.

Flux

Cored

Arc

Welding

(FCAW)

And

Gas

Metal

Arc

Welding

(GMAW)

17

7-2.

Welding

Troubleshooting

19

SECTION

8

PARTS

LIST

Figure

8-1.

Main

Assembly

24

Figure

8-2.

Drive

Assembly,

Wire

27

SECTION

1



SAFETY

SIGNAL

WORDS

The

following

safety

alert

symbol

and

signal

words

are

used

throughout

this

manual

to

call

attention

to

and

identify

different

levels

of

hazard

and

special

instructions.

a

WARNING

statements

identify

procedures

or

practices

which

must

be

followed

to

avoid

serious

personal

injury

or

loss

of

life.

a

CAUTION

statements

identify

procedures

or

practices

which

must

be

followed

to

avoid

minor

personal

injury

or

damage

to

this

equipment.

~

IMPORTANT:

statements

identify

special

instructions

necessary

for

the

most

efficient

operation

of

this

equipment.

SECTION

2SPECIFICATIONS

Table

2-1.

Welding

Power

Source

Specifications

Description

Type

Of

Output

Rated

Weld

Output

Type

Of

Input

Amperes

At

Rated

Output

KVA

Used

At

Rated

Output

KW

Used

At

Rated

Output

Max.

Open-Circuit

Voltage

Control

Circuit

Voltage

At

Gun

Welding

Processes

Constant

Voltage

(CV)

Direct

Current

(DC)

120

Amperes,

21

Volts

DC,

30%

Duty

Cycle

(see

Section

2-2)

Single-Phase

230

Volts

AC,

60

Hertz

20

Amperes

4.7

kVA

3.9

kW

32

Volts

DC

24

Volts

DC

Wire

Feed

Speed

Range

Wire Diameter

Range

Input

Power

Cord

With

Plug

Overall

Dimensions

Weight

Gas

Metal

Arc

Welding

(GMAW)

(Uses

Solid

Or

Aluminum

Wire

And

External

Shielding

Gas)

Flux

Cored

Arc

Welding

(FCAW)

(Uses

Wire

With

Flux

Inside

And

Requires

No

External

Shielding

Gas)

47

To

690

pm

(1.2

To

17.5

mpm)

.023

To

.035

in.

(0.58

To

0.89

mm)

5

ft.

(1.5

m)

Length:

27

in.

(686

mm),

Width:

12

in.

(305

mm),

Height:

22-1/2

in.

(571

mm)

Shipping

117

lbs.

(53

kg);

Net

117

lbs.

(50

kg)

OM-151

016

Page

1

2-1.

Volt-Ampere

Curves

2-2.

Duty

Cycle

Figure

2-2.

Welding

Power

Source

Duty

Cycle

Chart

SECTION

3INSTALLATION

Table

3-1.

Items

Included

With

Welding

Power

Source

Item

Quantity

Welding

Gun



Shipped

Set

To

Feed

.030

in.

(0.8

mm)

Wire

(See

Gun

Owners

Manual

Form

112

934)

1

lOft.

(3m)

Work

Cable

And

Clamp

1

4ft.

(1.2

m)

Air

Hose

1

Contact

Tubes

(2

.030

in.,

3

.023

in.,

And

3

.035

in.)

8

Monocoil

Liner

For

.023

Thru

.030

in.

Wire

1

Figure

2-1.

Volt-Ampere

Curves

200

50

U,

uJ

0.

100

go

80

70

60

50

Duty

cycle

is

how

long

the

unit

or

gun

can

operate

within

a

ten

minute

period

without

causing

overheating

or

damage.

This

welding

power

source

is

rated

at

30%

duty

cycle

allowing

welding

3

minutes

out

of

every

10 minutes.

SB.124

624

.5

20

25

30

40

50

DUTY

CYCLE

Z

60

70

80

90

100

OM-151

016

Page

2

3-1.

Installing

Work

Clamp

3-2.

Gun

Polarity

For

Wire

Type

a

WARNING

Tools

Needed:

3/8in.

a

WARNING

Figure

3-1.

Work

Clamp

Installation

E

LECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Turn

OFF

welding

power

source,

and

disconnect

input

power

before

inspecting

or

installing.

swarnl.1

9/91

1

Polarity

Changeover

Label

2

Polarity

Jumper

Links

Always

read

and

follow

wire

man

ufacturers

recommended

polarity.

Close

door.

2

Fi

gure

3-2.

Gun

P

olarity

Jump

er

Link

Position

3-3.

Selecting

A

Location

And

Connecting

Input

Power

Ret.

5T-149631.A

~

.~

E



S



LECTRIC

SHOCK

can

kill.

Do

not

touch

live

electrical

parts.

1-lave

only

qualified

persons

install

unit.

Installation

must

meet

National

Electrical

Code

and

I

all

other

codes.

overheating

and

possible

damage

to

unit.

BLOCKED

AIRFLOW

causes

.



Do

not

block

or

filter

airflow

Warranty

is

void

if

any

type

of

filter

is

used.

OM-151

016

Page3

Figure

3-3.

Location

And

Input

Power

Connections

Table

3-2.

Electrical

Service

Requirements

230

(Amps)

20

Ia

(Amps)

lb

31

thru

41

(Amps)

30

Cop

(AWG

Or

Kcmil)

14

(feet)

(meters)

65

20

Fuse)

(AWG

Or

Kcmil)

14



These

calculations

of

Electric

Service

Requirements

are

based

on

the

1990

Edition

of

the

National

Elec

trical

Code

(NEC).

NEC

is

re-issued

every

3

years,

check

latest

edition

and

update

these

calculations,

if

required.

See

the

following

footnotes

for

specific

conductor

types,

temperatures,

exceptions,

and

etc.

I

(a)

150%

of

line

current,

1990

NEC

Article

630-12-a,

(bI

200%,

(C)

standard

fuse

size

nearest

150%

of

rating

label

line

current.

2

1990

NEC

Table

310-16-75-Cu.

with

+

note.

~

Maximum

input

conductor

length

is

based

on

not

more

than

a

3%

voltage

drop

from

the

service

entrance

panel

to

the

input

of

the

welding

unit,

Articles

210.19(a)

and

215-2(b)

of

NEC.



Ground

conductor

size

determined

by

Article

250-95

of

NEC

exception

No.

2,

ground

conductor

is

not

required

to

be

larger

than

line

conductor

and

Table

250-95-Copper.

S-0092-A

1

18

in.

(457

mm)

Open

Space

At

Front

And

Rear

2

Rating

Label

Supply

correct

input

power.

3

230

Volts

AC

Wall

Receptacle

4

Input

Conductors

Select

size

and

length

using

Table

3-2.

5

Line

Disconnect

Switch

Obtain

and

install

switch

and

wall

receptacle.

6

Grounding

Conductor

Select

size

and

length

using

Table

3-2.

Be

sure

grounding

con

ductor

goes

to

an

earth

ground.

Install

input

conductors

and

grounding

conductor

between

wall

receptacle

and

deenergized

line

disconnect

switch.

7

Line

Fuses

Select

fuses

or

circuit

breakers

using

Table

3-2.

Install

into

deenergized

line

disconnect

switch.

Connect

deenergized

supply

conductors

to

line

disconnect

switch.

8

Input

Power

Plug

Turn

OFF

unit

POWER

switch,

and

connect

plug

to

wall

receptacle.

Place

line

disconnect

switch

in

ON

position

before

using

welding

power

source.

ssb21

10/91

ST-149

630

OM-151

016

Page

4

3-4.

Threading

Welding

Wire

a

WARNING

CYLINDERS

can

explode

if

damaged.



Keep

cylinders

away

from

welding

and

other

electrical

circuits.



Never

touch

cylinder

with

welding

electrode.



Always

secure

cylinder

to

running

gear,

wall,

or

other

stationary

support.

3-5.

Feeding

Welding

Wire

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.

The

welding

wire,

drive

rolls,

drive

assembly,

and

all

metal

parts

touching

the

welding

wire

are

electrically

live

when

welding

or

feeding

wire

using

gun

trigger.

swarn2.4

9/91

I

Wire

Spool

Loosen

wire

from

spool,

cutoff

bent

wire,

and

pull

6

in.

(150mm)

of

wire

off

spool.

2

Wire

Inlet

Guide

3

Drive

Roll

4

Wire

Outlet

Guide

Thread

wire

through

wire

inlet

guide.

along

drive

roll,

and

into

wire

outlet

guide.

Be

sure

wire

is

in

correct

groove.

5

Pressure

Adjustment

Knob

And

Arm

Close

and

secure

pressure

roll

assembly.

Close

door.

Ret.

ST-150

193-A

/

Ref.

ST.149

632A

3

4

Tools

Needed:

Figure

3-4.

Threading

Welding

Wire

a

CAUTION

WELDING

WIRE

can

cause

puncture

HOT

SURF

ACES

can

burn

skin.

wounds.



Allow

gun

to

cool

before

touching.



Do

not

press

gun

trigger

until

instructed

to

do

so.



Do

not

point

gun

toward

any

part

of

the

body,

other

people,

or

any

metal

when

threading

welding

wire.

i~))l~(,,,fft,

swarn2.1

9/91

4

La

1

y

gun

cable

Out

straight.

Nozzle

5

3

Tools

Needed:

2

Contact

Tube

Remove

nozzle

and

contact

tube.

3

Gun

Trigger

Turn

ON

unit

and

feed

2

in.

(55

mm)

of

wire

out

of

gun.

Turn

OFF

unit

and

reinstall

contact

tube

and

nozzle.

4

Adjusting

Pressure

Turn

ON

unit

and

check

drive

roll

pressure

by

feeding

wire

against

a

wood

board

or

concrete

surface;

wire

should

feed

steadily

without

slipping.

5

Pressure

Knob

Tighten

pressure

knob

if

necessary.

1

Close

door.

Pet.

ST-151

288/S~O827-A

Figure

3-5.

Feeding

Welding

Wire

OM-151

016

Page

5

3-6.

Installing

Gas

Supply

a

WARNING

BUILDUP

OF

SHIELDING

GAS

can

harm

health

or

kill.



Shut

off

shielding

gas

supply

when

not

in

use.

warn4

1

9/91

Obtain

gas

cylinder

and

chain

to

running

gear,

wall,

or

other

station-

ary

support

so

cylinder

cannot

fall

and

break

off

valve.

1

Cap

2

Cylinder

Valve

Remove

cap,

stand

to

side

of

valve,

and

open

valve

slightly.

Gas

flow

blows

dust

and

dirt

from

valve.

Close

valve.

3

Cylinder

4

CO2

Washer

5

Regulator

Install

onto

gas

cylinder

so

that

face

is

vertical.

6

Flowmeter

7

Gas

Hose

Connection

Fitting

has

5/8-18

right-hand

threads.

Obtain

gas

hose

with

fittings,

and

install

between

cylin

der

and

welding

power

source.

8

Flow

Adjust

Typical

flow

rate

is

20

cfh

(cubic

feet

per

hour).

Tools

Needed:~J

~

Ret

SB-log

492

Figure

3-6.

Typical

CO2

Regulator/Flowmeter

Installation

SECTION

4OPERATION

a.

WARNING~

ELECTRIC

SHOCK

can

kill.



Always

wear

dry

insulating

gloves.



Insulate

yourself

from

work

and

ground.



Do

not

touch

live

electrical

parts.



Keep

alt

panels

and

covers

securely

in

place

FUMES

AND

GASES

can

be

hazardous

to

your

health.



Keep

your

head

out

of

the

fumes.



Ventilate

area,

or

use

breathing

device.



Read

Material

Safety

Data

Sheets

(MSDSs)

and

manufacturers

instructions

for

material

used.

WELDING

can

cause

fire

or

explosion.



Do

not

weld

near

flammable

material.



Watch

for

fire;

keep

extinguisher

nearby.



Do

not

locate

unit

over

combustible

surfaces.



Do

not

weld

on

closed

containers.



Allow

work

and

equipment

to

cool

before

handling.

I~J.

1LW

CYLINDERS

can

explode

if

damaged.



Keep

cylinders

away

from

welding

and

other

electrical

circuits.



Never

touch

cylinder

with

welding

electrode.



Always

secure

cylinder

to

running

gear,

wall,

or

other

stationary

support.

2

8

I

6

5

4

=~.

=~c?

p

~

c-

ARC

RAYS

can

burn

eyes

and

skin;

NOISE

can

damage

hearing.



Wear

welding

helmet

with

correct

shade

of

filter.



Wear

correct

eye,

ear,

and

body

protection.

Q

~

MOVING

PARTS

can

cause

injury.



Keep

away

from

pinch

points

such

as

drive

rolls.



Keep

all

doors,

panels,

covers,

and

guards

closed

and

securely

in

place.



~

I

MAGNETIC

FIELDS

FROM

HIGH

CUR

RENTS

can

affect

pacemaker

operation.



Pacemaker

wearers

keep

away.



Wearers

should

consult

their

doctor

before

going

near

arc

welding,

gouging,

or

spot

welding

opera

tions.

See

Safety

Precautions

at

beginning

of

manual

for

ba

sic

welding

safety

information.

swarn6

2

10/91

OM-151

016

Page

6

1

Fine

Tuning/Wire

Speed

Con

trol

1

Insulating

Gloves

2

Safety

Glasses

With

Side

Shields

3

Welding

Helmet

Wear

dry

insulating

gloves,

safety

glasses

with

side

shields,

and

a

welding

helmet

with

a

correct

shade

of

filter

(see

ANSI

Z49.1).

Figure

4-2.

Safety

Equipment

.

1

Work

Cable

I

2

~__

~

Tools

Needed

~

2

Work

Clamp

Use

wire

brush

or

sandpaper

to

clean

metal

at

weld

joint

area.

Connect

work

clamp

to

a

clean.

paint-free

location

on

workpiece.

as

close

to

weld

area

as

possible.

Ref.

ST-149

359

Figure

4-3.

Work

Clamp

.

1

Fine

Tuning/Wire

Speed

Control

Use

this

Control

to

select

a

wire

feed

speed.

As

THICKNESSVOLTAGE

switch

(Figure

4.5)

setting

increases,

wire

speed

range

also

increases.

The

numbers

around

the

control

are

not

a

wire

feed

speed

and

are

for

reference

only

(see

Table

4-1).

,~

i

60

~

,~

10

FiNE

TUNING

010

WIRE

SPEE

\~__________________

2

ThicknessNoltage

Switch

2

3

Power

Switch

3

>

ST-150

192

Figure

4-1.

Controls

Figure

4-4.

Wire

Speed

Control

OM-151

016

Page

7

a

CAUTION

ARCING

can

damage

switch.

Do

not

change

THICKNESSNOLTAGE

switch

position

while

welding.

Arcing

inside

switch

can

damage

contacts,

causing

switch

to

fail.

warn51

9/91

I

DO

NOT

SWITCH

2

UNDER

LOAD

,~J

~

3

THICKNESS

V

VOLTAGE

)___

1

ThicknessNoltage

Switch

Use

this

switch

to

select

an

arc

number,

the

thicker

the

material

that

can

be

welded

(see

Table

4-1).

voltage.

The

higher

the

selected

Figure

4-5.

Voltage

Switch

Figure

4-6.

Power

Switch

a

WARNING

3

Install

&

Put

On

Turn

On

\~\

Do

~~~Readjust

Contro~?\

Connect

J J

Personal

Safety

)

)Equipment

&

Gas

) j

Set

Controls

) )

Sample

Weld

) )

And

Prepare

J

Equipment

JJ

Equipment

JJ

(lfApplicable)7j

~/J

ForProduction

Figure

4-8.

Sequence

Of

Operation



BUILDUP

OF

SHIELDING

GAS

can

harm

health

S

Shut

off

shielding

gas

supply

when

not

in

use.

or

kill.

warnl

1

9/91

1

Shielding

Gas

Cylinder

2

Valve

3

Gun

Trigger

Open

valve

on

cylinder

just

before

welding.

Purge

air

from

gas

line

by

pressing

gun

trigger.

Close

valve

on

cylinder

when

fin

ished

welding.

S.0621

-c

Figure

4-7.

Shieldin

g

Gas

OM-151

016

Page

8

Table

4-1.

Suggested

Welding

Settings

Wire

Type,

Shielding

Gas,

And

Flow

Rate

Wire

Diameter

(inch)

Operator

Control

Settings

Material_Thickness

1/4

in.

(6.4

mm)

3/16

in.

(4.8

mm)

1/8

in.

(3.2

mm)

14

ga.

16

ga.

18

ga.

22

ga.

24

ga.

-

E70S6

CO

2

20

cfh+

.023

Voltage

4

3

2

1

Wire

Speed*

100%

80% 70%

60%

55%

45%

35%

.030

Voltage

4

3

2

1



Wire

Speed*

80%

75%

60%

60% 50%

40%

30%

.035

Voltage

4

3 2

1

Wire

Speed*

65%

60%

50%

40%

30%

20%

15%



E7OS-6

75%

Argon

25%

CO

2

20

cfh+

.023

Voltage

4

3 2

2

1

Wire

Speed*

100%

90%

80%

70%

60%

50%

.

40%

.030

Voltage

4

3

2

1

.



Wire

Speed*

90%

80%

70%

60%

50%

45%

30%

.035

Voltage

4

3

2

1



Wire

Speed*

75%

70%

60%

50%

40%

33%

25%



E7ITGS

Flux

Core

.030

Voltage

3

2

1 1

1

Wire

Speed*

40%

65%

45%

40%

30%

20%

.035

Voltage

3 3

2

1



Wire

Speed*

60%

50%

40%

30%

20%

10%



ER

308

Stainless

Steel

Tn-Mix

20

cfh+

.023

Voltage

4

3 3

3

2

1



Wire

Speed*

100%

90%

859o

75%

70% 60%



.030

Voltage

4

3

2



Wire

Speed*

75~

75% 65%

60%

55%

50%

.035

Voltage

4

Wire

Speed*

60% 60%

50%

Aluminum

Argon

20

cfh+

.030

Voltage

4

3

2

1

Wire

Speed*

90%

85%

80%

90%

85%



.035

Voltage

4

3

2

1



Wire

Speed*

85%

90%

80%

*

Do

not

change

THICKNESSNOLTAGE

switch

position

while

welding.

FINE

TUNING/WIRE

SPEED

value

in

Table

4-1

is

a

starting

value

only,

and

WIRE

SPEED

control

setting

can

be

fine

tuned

during

welding.

+cfh

=

cubic

ft

per

hour

OM-iSi

016

Page

9

SECTION

5

MAINTENANCE

&

TROUBLESHOOTING

___

4~

WARNING

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.

Turn

OFF

welding

power

source,

and

disconnect

input

power

before

inspecting,

maintaining,

or

servicing.

HOT

PARTS

can

cause

severe

burns.



Allow

cooling

period

before

maintaining

or

servicing.

Maintenance

to

be

performed

only

by

qualified

persons.

swarn8.2

10/91

5-1.

Routine

Maintenance

Table

5-1.

Maintenance

Schedule

Time

Maintenajice

Before

each

use.

Check

gun

parts

for

looseness,

cracks,

and

breaks;

tighten,

repair,

and

replace

parts

as

required.

Carefully

clean

weld

spatter

or

dirt

from

around

nozzle

opening

using

a

hardwood

stick,

never

a

metal

tool.

Every

month.

Above

normal

equipment

use:

Check

all

labels

(see

6

month

entry),

repair

any

damaged

insula

tion

or

replace

gun

or

work

cable,

clean

internal

parts

(see

6

month

entry),

clean

and

tighten

connections

at

gun

cable

and

work

clamp.

Every

3

months.

Repair

cable

insulation

damage

or

replace

gun

or

work

cable.

Clean

and

tighten

gun

cable

and

work

clamp

connections.

Every

6

months.

Replace

any

labels

that

are

unreadable

or

damaged

(see

Section

8

for

part

number).

Remove

unit

outer

enclosure

to

blow

out

or

vacuum

dust

and

dirt

from

inside

using

a

clean,

dry

airstream

or

vacuum

suction.

5-2.

Overload

Protection

a

WARNING

A.

Overheating

ELECTRIC

SHOCK,

HOT

PARTS,

AND

MOVING

PARTS

HAZARDS.

Read

safety

infor

mation

at

beginning

of

Section

5

before

proceeding.

Thermostat

TP1

protects

the

unit

from

damage

due

to

overheating.

If

main

rectifier

SR2

gets

too

hot,

TP1

opens

and

weld

output

stops.

The

fan

keeps

running

to

cool

the

rectifier.

Wait

several

minutes

before

trying

to

weld.

B.

Short

Circuit

Shutdown

If

contact

tube

is

shorted

and

sticks

to

workpiece,

the

unit

shuts

down,

but

fan

runs.

To

resume

operation,

release

gun

trigger,

turn

OFF

unit,

and

remove

contact

tube

from

workpiece.

Check

contact

tube

and

replace

if

damaged.

Turn

ON

unit

to

continue

operation.

C.

Fuse

Fl

a

CAUTION

STATIC

ELECTRICITY

can

damage

parts

on

circuit

boards.



Put

on

grounded

wrist

strap

BEFORE

handling

boards

or

parts.

fwarn5.1

9/91

MOVING

PARTS

can

cause

injury.



Keep

away

from

moving

parts.



Keep

away

from

pinch

points

such

as

drive

rolls.

OM-151

016

Page

10

5-3.

Cleaning

Or

Replacing

Drive

Roll

And

Replacing

Wire

Inlet

Guide

a

WARNING

ELECTRIC

SHOCK

AND

MOVING

PARTS

HAZARDS.

Read

safety

information

at

begin

ning

of

Section

5

before

proceeding.

Figure

5-2.

Removing

Drive

Roll

And

Wire

Inlet

Guide

Turn

OFF

and

unplug

unit.

Unlatch

door,

and

remove

door/wrapper.

I

Motor

Control

Board

PCi

2

Fuse

Fl

(See

Parts

List

For

Size)

Pull

fuse

from

fuse

holder

on

PCi.

To

reinstall,

push

fuse

into

fuse

holder.

3

Control

Relay

CR1

Reinstall

wrapper,

and

latch

door.

Ref.

ST150

194

/

ST-149

921-A

Figure

5-1.

Fuse

Fl

Location

3

Turn

OFF

and

unplug

unit.

I

Wire

Spool

2

Gun

Contact

Tube

Cut

welding

wire

off

atcontact

tube.

Retract

wire

onto

spool

and

se

cure.

3

Pressure

Roll

Assembly

4

Securing

Screw

5

Washers

6

Drive

Roll

Remove

drive

roll

as

shown.

Use

a

wire

brush

to

clean

drive

roll.

Push

drive

roll

onto

shaft

and

secure

with

washers

and

screw.

7

Wire

Inlet

Guide

Remove

guide

by

pressing

or

barbed

area

or

cutting

off

one

end

near

housing

and

pulling

it

out

of

hole.

Push

new

guide

into

hole

from

rear

until

it

snaps

in

place.

Thread

welding

wire

(see

Section

3-5).

Close

door.

Ref.

ST-ISO

193-A/ST-150

391-A

4

7

Tools

Needed:

5

OM-151

016

Page

ii

5-4.

Replacing

Pressure

Bearing

a

WARNING

ELECTRIC

SHOCK

AND

MOVING

PARTS

HAZARDS.

beginning

of

Section

5

before

proceeding.

Read

safety

information

at

Figure

5-3.

Replacing

Pressure

Roll/Bearing

Assembly

5-5.

Adjusting

Hub

Tension

~

WARNING

ELECTRIC

SHOCK,

HOT

PARTS,

AND

MOVING

PARTS

HAZARDS.

Read

safety

infor

mation

at

beginning

of

Section

5

before

proceeding.

~lMPORTANT:

If

hub

tension

is

too

tight,

motor

fuse

Fican

open

(see

Section

5-2).

If

hub

tension

is

too

loose,

wire

unravels

and

can

become

tangled

inside

unit.

Turn

OFF

and

unplug

unit.

1

Spool

Cut

welding

wire

off

at

contact

tube.

Retract

wire

onto

spool

and

se

cure.

2

Hub

3

Hub

Tension

Nut

Grasp

spool

in

one

hand

and

turn

while

using

a

wrench

to

adjust

hub

tension

nut.

When

a

slight

force

is

needed

to

turn

spool,

tension

is

set.

Tools

Needed:

Close

and

secure

pressure

roll

~

assembly.

Thread

welding

wire

(see

Section

3-5).

Close

door.

~

9/16

in.

pet.

sr.i~o

193-A

Turn

OFF

and

unplug

unit.

1

Wire

Spool

2

Gun

Contact

Tube

Cut

welding

wire

off

at

contact

tube.

Retract

wire

onto

spool

and

se

cure.

3

Pressure

Roll

Arm

4

Cotter

5

6

Screw

7

Bearing

Remove

bearing

as

shown.

Install

new

bearing

and

secure

with

screw.

Reinstall

arm

onto

and

secure

with

cotter

pin.

Thread

welding

wire

(see

Section

3-5).

Close

door.

Tools

Needed:

Ret.

ST-150

193-A

/

ST-153

390

3

5

Figure

5-4.

Hub

Tension

Adjustment

OM-151

016

Page

12

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