Miller KE621826 Owner's manual

Miller

April

1994

Form:

OM-1583D

Effective

With

Serial

No.

KE621

826

~11c~

~''

c~r~1

OWNERS

MANUAL

Read

and

follow

these

instructions

and

all

safety

blocks

carefully.

Have

only

trained

and

qualified

persons

install,

operate,

or

service

this

unit.

Call

your

distributor

if

you

do

not

understand

the

directions.

SWINGARCTM

SS-12

And

SS-16



24

Volts,

10

Amperes,

50/60

Hertz

Boom

Mounted

Wire

Feeder



For

Use

With

CV/DC

Welding

Power

Source

With

Contactor



For

GMAW

And

FCAW

Welding



Rated

At

100

Volts,

750

Amperes,

100%

Duty

Cycle



Wire

Feed

Speed

Range:

50

To

780

ipm

(1.3

To

19.8

mpm)



Wire

Diameter

Range:

.023

To

1/8

in

(0.6

To

3.2

mm)



Vertical

Lift

Of

Boom:

Horizontal

To

600

Above

Horizontal



See

Rear

Cover

For

Options

And

Accessories



U

Give

this

manual

to

the

operator.



For

help,

call

your

distributor



or:

MILLER

Electric

Mfg.

Co.,

P.O.

Box

1079,

Appleton,

WI

54912

414-734-9821

cover

1/94



ST-142

705-B

'

1994

MILLER

Electflc

Mfg.

Co.

PRINTED

IN

USA

Ui___________________

---

________________

I

MILLERS

TRUE

BLUETM

LIMITED

WARRANTY

Effective

January

1,

1992

(Equipment

with

a

serial

number

preface

of

KC

or

newer)

This

limited

warranty

supersedes

att

warrenties

and

is

exclusive

with

no

other

guarantees

or

wsrranties

espressed

or

implied.

LIMITED

WARRANTY



Subject

to

the

terms

end

conditions

betow,

MILLER

Electric

Mtg.

Co.,

Appleton,

Wisconsin,

werrents

to

its

original

retsil

purcheser

thet

new

MILLER

equipment

sold

after

the

effective

date

ot

this

limited

warranty

is

free

of

de

fects

in

material

snd

workmanship

et

the

time

it

is

shipped

by

MtLLER.

THIS

WAR

RANTY

IS

EXPRESSLY

IN

LIEU

OF

ALL

OTHER

WARRANTIES,

EXPRESS

OR

IMPLIED,

INCLUDING

THE

WARRANTIES

OF

MERCHANTABILITY

AND

FIT

NESS.

Within

the

wsrranty

periods

listed

below,

MILLER

wilt

repair

or

replace

any

war

ranted

parta

or

components

that

tail

due

to

auch

defects

in

material

orwoilimanahip.

MILLER

must

be

notified

in

writing

within

thirty

(30)

days

of

such

detect

or

failure,

at

which

time

MILLER

wilt

provide

instructions

on

the

warranty

claim

procedurea

to

be

followed.

MILLER

shalt

honor

warranty

claims

on

warranted

equipment

hated

below

in

the

event

ot

such

a

failure

within

the

warranty

time

periods.

All

warranty

time

perioda

alan

on

the

date

that

the

equipment

was

delivered

to

the

originst

retail

purchaser,

or

one

year

efter

the

equipment

is

sent

to

the

distributor.

5

Years

Parts

3

Years

Labor

Original

main

power

rectifiers

2.

3 Years



Parts

and

Labor



Transformer/Rectifier

Power

Sources



Plasma

Arc

Cuning

Power

Sources



Semi-Automatic

and

Automatic

Wire

Feeders



Robots

3.

2

Years



Parts

and

Labor



Engine

Driven

Welding

Generators

(NOTE:

Engines

are

warranted

aeparalely

by

the

engine

manufacturer

for

a

period

of

two

years.)



Air

Compreaaors

4.

1

Year



Parts

and

Labor

*

Motor

Driven

Guns



Process

Controllers



Water

Coolant

Syatema



HF

Units



Grids



Spot

Welders



Load

Banks



SDX

Transformers

Running

Gear/Trailera



Field

Options

(NOTE:

Field

options

are

covered

under

True

BIueTM

for

the

remaining

warranty

period

of

the

product

they

are

metalled

in,

or

fore

minimum

of

one

year



whichever

is

greater.)

6

Months



Batteries

90

Days



Perle

end

Labor



MIG

Guns/TIG

Torches



Plasma

Cutting

Torches



Remote

Controls



Accessory

Kits



Replacement

Parts

MILLERS

True

BIueTM

Limited

Warranty

shell

not

apply

to:

1.

Items

tumished

by

MILLER,

but

menutectured

by

others,

such

as

engines

or

trade

ecceesoriee.

These

items

are

covered

by

the

manufacturers

warranty,

it

any.

2.

Consumable

components;

such

as

contact

tips,

cutting

nozzes,

contactors

end

relays

or

parts

that

fail

due

to

normel

wear.

3.

Equipment

that

has

been

modified

by

any

party

other

than

MILLER,

or

equip

ment

that

has

been

improperly

installed,

improperty

operated

or

misused

based

upon

industry

standards,

or

equipment

which

has

not

had

reasonable

end

necesasry

maintenance,

or

equipment

which

has

been

used

for

operation

outside

of

the

specifications

for

I

he

equipment.

MILLER

PRODUCTS

ARE

INTENDED

FOR

PURCHASE

AND

USE

BY

COMMER

CIAL/INDUSTRIAL

USERS

AND

PERSONS

TRAINED

AND

EXPERIENCED

IN

THE USE

AND

MAINTENANCE

OF

WELDING

EOUIPMENT.

In

the

event

of

e

warranty

claim

covered

by

this

werranty,

the

exclusive

remsdies

shell

be,

at

MILLERS

option:

(1)

repair;

or

(2)

replacement;

or,

where

authorized

in

writing

by

MtLLER

in

eppropriale

cases,

(3)

the

reasonable

coal

of

repair

or

replace

ment

stan

authorized

MILLER

seivice

elation;

or

(4)

payment

of

or

ci

edit

for

the

pur

chase

price

(less

reasonable

depreciation

based

upon

actual

use)

upon

return

of

the

goods

el

customers

risk

and

expense.

MILLERS

option

of

repair

or

replacement

wilt

be

FOB.,

Feclory

at

Appleton,

Wisconsin,

or

FOB.

eta

MILLER

authorized

ser

vice

facility

as

determined

by

MILLER.

Therefore

no

compensation

or

reimburse

ment

for

Irensportetion

costs

ot

any

kind

will

be

allowed.

TO

THE

EXTENT

PERMtTTED

BY

LAW,

THE

REMEDIES

PROV:DED

HEREIN

ARE

THE

SOLE

AND

EXCLUStVE

REMEDIES.

IN

NO

EVENT

SHALL

MILLER

BE

LIABLE

FOR

DIRECT

INDIRECT,

SPECIAL,

INCIDENTAL

OR

CONSEOUENTIAL

DAMAGES

(INCLUDING

LOSS

OF

PROFIT),

WHETHER

BASED

ON

CON

TRACT,

TORT

OR

ANY

OTHER

LEGAL

THEORY.

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

ANY

IMPLIED

WAR

RANTY,

GUARANTY

OR

REPRESENTATION

AS

TO

PERFORMANCE,

AND

ANY

REMEDY

FOR

BREACH

OF

CONTRACT

TORT

OR

ANY

0

IHER

LEGAL

THEORY

WHICH,

BUT

FOR

THIS

PROVISION,

MIGHT

ARISE

BY

IMPLICATION,

OPERATION

OF

LAW,

CUSTOM

OF

TRADE

OR

COURSE

OF

DEALING,

IN

CLUDING

ANY

IMPLIED

WARRANTY

OF

MERCHANTABILITY

OR

FITNESS

FOR

PARTICULAR

PURPOSE,

WITH

RESPECT

TO

ANY

AND

ALL

EOUIPMENT

FURNISHED

BY

MILLER

IS

EXCLUDED

AND

DISCLAIMED

BY

MILLER.

Some

stales

in

the

U.S.A.

do

not

ellow

limitations

of

how

long

an

implied

warranty

lasts,

or

the

exclusion

of

incidental,

indirect,

special

or

consequential

damages,

so

the

ebove

limitation

or

exclusion

may

not

apply

to

you.

This

warranty

provides

ape

citic

legal

rights,

end

other

rights

may

be

available,

but

may

very

from

stale

to

stale.

In

Canada,

legislation

in

some

provinces

provides

for

certain

additional

warranties

or

remedies

other

than

as

staled

herein,

end

to

the

extent

that

they

may

not

be

waived,

the

limitations

end

exclusions

set

out

above

mey

not

eppiy.

This

Limited

Warrenty

provides

specific

legal

rights,

end

other

rights

may

be

available,

but

may

vary

from

province

to

province.

Li

5.

6.

~~1

xwd,

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

miller

9/93

ERRATA

SHEET

-

June

1,

1994

FORM:

OM-1583D

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.

CHANGES

TO

SECTION

7

PARTS

LIST

Change

Parts

List

as

follows:

Part

Replaced

**

No.

With

Description

Quantity



43-16

..

133

603

...

165

934

..

SPRING,

cprsn

.573

OD

x

.088

wire

x

1.062

Ig

(Eff

w/KE644333)

..

1

43-

Added

...

165

799

..

WASHER,

flat

.257

ID

stl

(Elf

w/KE644333)

1

43-

Added

...

165

798

..

SPRING,

pressure

arm

retaining

(Elf

w/KE644333)

1

43-

Added

...

.163

282

..

NUT,

.250-28

stl

(Elf

w/KE644333)

1

**First

digit

represents

page

no



digits

following

dash

represent

item

no.

BE

SURE

TO

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

F~LE

COPY

~E1U~

TO

~OLOER

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.

1.

Do

not

touch

live

electrical

parts.

2.

Wear

dry,

hole-free

insulating

gloves

and

body

protection.

3.

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.

6.

When

making

input

connections,

attach

proper

grounding

conductor

first.

7.

Turn

off

all

equipment

when

not

in

use.

8.

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.

11.

Do

not

touch

electrode

if

in

contact

with

the

work

or

ground.

12.

Use

only

well-maintained

equipment.

Repair

or

replace

damaged

parts

at

once.

13.

Wear

a

safety

harness

if

working

above

floor

level.

14.

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.

-

9.

10.

ARC

RAYS

can

burn

eyes

and

skin;

~

NOISE

can

damage

hearing.

Arc

rays

from

the

welding

process

produce

intense

heat

and

strong

ultraviolet

rays

that

can

burn

eyes

and

skin.

Noise

from

some

processes

can

damage

hearing.

NOISE

1.

Use

approved

ear

plugs

or

ear

muffs

if

noise

level

is

high.

ARC

RAYS

2.

Wear

a

welding

helmet

fitted

with

a

proper

shade

of

filter

(see

ANSI

Z49.

I

listed

in

Safety

Standards)

to

protect

your

face

and

eyes

when

welding

or

watching.

3.

Wear

approved

safety

glasses.

Side

shields

recommended.

4.

Use

protective

screens

or

barriers

to

protect

others

from

flash

and

glare;

warn

others

not

to

watch

the

arc.

5.

Wear

protective

clothing

made

from

durable,

flame-resistant

material

(wool

and

leather)

and

foot

protection.

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

fumes

and

gases

can

be

hazardous

to

your

health.

welding

can

displace

air

causing

injury

or

death.

Be

sure

the

breathing

air

is

safe.

1.

Keep

your

head

out

of

the

fumes.

Do

not

breathe

the

fumes.

2.

If

inside,

ventilate

the

area

and/or

use

exhaust

at

the

arc

to

remove

welding

fumes

and

gases.

3.

If

ventilation

is

poor,

use

an

approved

air-supplied

respirator.

4.

Read

the

Material

Safety

Data

Sheets

(MSDS5)

and

the

manufacturers

instruction

for

metals,

consumables,

coatings,

and

cleaners,

WELDING

can

cause

fire

or

explosion.

Sparks

and

spatter

fly

off

from

the

welding

arc.

The

flying

sparks

and

hot

metal,

weld

spatter,

hot

workpiece,

and

hot

equipment

can

cause

fires

and

burns.

Accidental

contact

of

electrode

orwelding

wire

to

metal

objects

can

cause

sparks,

overheating,

or

fire.

1.

Protect

yourself

and

others

from

flying

sparks

and

hot

metal,

2.

Do

not

weld

where

flying

sparks

can

strike

flammable

material.

3.

Remove

all

flammables

within

35

ft

(10.7

m)

of

the

welding

arc.

If

this

is

not

possible,

tightly

cover

them

with

approved

covers,

4.

Be

alert

that

welding

sparks

and

hot

materials

from

welding

can

easily

go

through

small

cracks

and

openings

to

adjacent

areas.

6.

7.

5.

6.

7.

8.

9.

10.

11.

Do

not

weld

in

locations

near

degreasirig,

cleaning,

or

spraying

operations.

The

heat

and

rays

of

the

arc

can

react

with

vapors

to

form

highly

toxic

and

irritating

gases.

Do

not

weld

on

coated

metals,

such

as

galvanized,

lead,

or

cadmium

plated

steel,

unless

the

coating

is

removed

from

the

weld

area,

the

area

is

well

ventilated,

and

if

necessary,

while

wearing

an

air-supplied

respirator.

The

coatings

and

any

metals

containing

these

elements

can

give

off

toxic

fumes

if

welded.

Watch

for

fire,

and

keep

a

fire

extinguisher

nearby.

Be

aware

that

welding

on

a

ceiling,

floor,

bulkhead,

or

partition

can

cause

fire

on

the

hidden

side.

Do

not

weld

on

closed

containers

such

as

tanks

or

drums.

Connect

work

cable

to

the

work

as

close

to

the

welding

area

as

practical

to

prevent

welding

current

from

traveling

long,

possibly

unknown

paths

and

causing

electric

shock

and

fire

hazards.

Do

not

use

welder

to

thaw

frozen

pipes.

Remove

stick

electrode

from

holder

or

cut

off

welding

wire

at

contact

tip

when

not

in

use.

Wearoil.free

protective

garments

such

as

leather

gloves,

heavy

shirt,

cuffless

trousers,

high

shoes,

and

a

cap.



FLYING

SPARKS

AND

HOT

METAL

can

I

cause

injury,

I

I

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

9/92

.

1.

J

CYLINDERS

can

explode

if

damaged.

..

~

~

Shielding

gas

cylinders

contain

gas

under

high

~.z

pressure.

If

damaged,

a

cylinder

can

explode.

Since

~

gas

cylinders

are

normally

part

of

the

welding

process,

be

sure

to

treat

them

carefully,

Protect

compressed

gas

cylinders

from

excessive

heat,

mechanical

shocks,

and

arcs.

3.

4.

5.

6.

7.

Keep

cylinders

away

from

any

welding

or

other

electrical

circuits.

Never

allow

a

welding

electrode

to

touch

any

cylinder.

Use

only

correct

shielding

gas

cylinders,

regulators,

hoses,

and

fittings

designed

for

the

specific

application;

maintain

them

and

associated

parts

in

good

condition.

Turn

face

away

from

valve

outlet

when

opening

cylinder

valve.

Keep

protective

cap

in

place

over

valve

except

when

cylinder

is

in

use

or

connected

for

use.

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.

8.

Read

and

follow

instructions

on

compressed

gas

cylinders,

associated

equipment,

and

CGA

publication

P-i

listed

in

Safety

Standards.

a

WARNING

A

ENGINE

EXHAUST

GASES

can

kill.

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.i

,from

American

Welding

So

ciety,

550

N.W.

LeJeune

Rd, 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,

GSA

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

EducationalEyeAnd

Face

Protec

tion,

ANSI

Standard

Z87.1,

from

American

National

Standards

Institute,

1430

Broadway,

New

York,

NY

10018.

Cutting

And

Welding

Processes,

NFPA

Standard

51

B,

from

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

ENGINES

can

be

hazardous.

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.

ENGINE

FUEL

can

cause

fire

or

1.

Stop

engine

before

checking

or

adding

fuel.



~1

I

explosion.

Engine

fuel

is

highly

flammable.

2.

3.

4.

5.

Do

not

add

fuel

while

smoking

or

if

unit

is

near

any

sparks

or

open

flames.

Allow

engine

to

cool

belore

fueling.

If

possible,

check

and add

fuel

to

cold

engine

before

beginning

job.

Do

not

overfill

tank



allow

room

for

fuel

to

expand.

Do

not

spill

fuel.

If

fuel

is

spilled,

clean

up

before

starting

engine.

1.

MOVING

PARTS

can

cause

injury.

Moving

parts,

such

as

fans,

rotors,

and

belts

can

cut

fingers

and

hands

and

catch

loose

clothing.

Keep

all

doors,

panels,

covers,

and

guards

closed

and

securely

in

place.

3.

4.

5.

6.

Have

only

qualified

people

remove

guards

or

covers

for

maintenance

and

troubleshooting

as

necessary.

To

prevent

accidental

starting

during

servicing,

disconnect

negative

()

battery

cable

from

battery.

Keep

hands,

hair,

loose

clothing,

and

tools

away

from

moving

parts.

Reinstall

panels

or

guards

and

close

doors

when

servicing

is

2.

Stop

eng

ne

before

installing

or

connecting

unit,

finished

and

before

starting

engine.

SPARKS

can

cause

BATTERY

GASES

1.

Always

wear

a

face

shield

when

working

on

a

battery.

TO

EXPLODE;

BATTERY

ACID

can

2.

Stop engine

before

disconnecting

or

connecting

battery

burn

eyes

and

skin,

cables.

Batteries

contain

acid

and

generate

explosive

ases.

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.

ff1..

),

.

Y

-.

/

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

tocool.

Wear

gloves

and

put

a

rag

over

cap

area

when

removing

cap.

Allow

pressure

to

escape

before

completely

removing

cap.

srI

9/92

PRECAUTIONS

DE

SECURITE

EN

SOUDAGE

A

LARC

LELECTROCUTION

peut

Œtre

mortelle.

Une

dØcharge

Ølectrique

pout

vous

tuer

ou

vous

brler

gravement.

LØlectrode

et

le

circuit

de

soudage

sont

sous

tension

au

dØmarrage.

Le

circuit

dentrØe

et

les

circuits

internes

des

matØriels

sont

aussi

sous

tension

des

Ia

mise

en

marche.

En

soudage

automatique

ou

semi-automatique

avec

fil,

ce

dernier,

le

support

de

roquette,

le

logement

des

galets

dentrainement

et

toutes

los

piŁces

mØtalliques

en

contact

avec

le

tilde

soudage

sont

sous

tension.

Des

matØriels

mal

installØs

ou

mal

mis

a

Ia

terre

sont

dangereux.

1.

Ne

touchez

pas

a

des

piŁces

sous

tension.

2.

Portez

des

gants

et

des

vŒtements

isolants,

secs

et

non

trouØs.

3.

lsolez-vous

de

Ia

fob

a

souder

et

de

Ia

mise

ala

terre

au

moyen

de

petits

tapis

isolants

ou

autres.

4.

DØconnectez

Ia

prise

dentrØe

des

matØriels

ou

arrŒtez

leur

moteur

avant

de

les

installer

ou

den

faire

lentretien.

LE

SOUDAGE

A

LARC

est

dangereux.

5.

Veillez

a

installer

ces

matØriels

eta

les

mettre

a

Ia

terre

solon

le

manuel

dutilisation

et

los

codes

nationaux,

provinciaux

et

bocaux

applicables.

6.

ArrŒtez

tous

les

matØriels

aprŁs

utilisation.

7.

Nutilisez

pas

de

cables

uses,

endommages,

mal

ØpissØs

ou

do

calibre

trop

petits.

8.

Nenroulez

pas

de

cables

autour

de

votre

corps.

9.

Mettez ala

terre

Ia

tOte

a

souder

au

moyen

dune

bonne

priso

do

terre.

10.

Ne

touchez

pas

a

lØlectrode

Si

vous

Œtes

en

contact

avec

10

circuit

de

soudage

(terre).

11.

Nutilisez

que

des

matØriels

en

bon

Øtat.

RØparez

ou

remplacez

sur-le-champ

los

piŁces

endommagees.

12.

Portez

un

harnais

do

sØcuritØ

si

vous

travaillez

en

hauteur.

13.

Fermez

solidemont

tous

los

panneaux

of

les

capots.

C~

Le

RAYONNEMENT

DE

LARC

peut

brUler

les

yeux

et

Ia

peau;

le

BRUIT

peut

endommager

I

ouIe.

Larc

de

soudage

produit

une

chaleur

et

des

rayons

ultraviolets

intenses,

susceptibles

de

brOler

es

yeux

et

Ia

peau.

Le

bruit

cause

par

certains

procedØs

peut

endommager

loule.

1.

Portez

un

casque

de

soudeur

avec

Øcran

filtrant

de

teinte

appropnee

(consultez

Ia

norme

ANSI

Z49

indiquee

ci-aprØs),

pour

vous

proteger

le

visage

et

los

yeux

lorsque

vous

soudez

ou

I

Les

VAPEURS

ET

LES

FUMEES

sont

1

dangereuses

pour

Ia

sante.

I

Le

soudage

dØgage

des

vapeurs

et

des

fumØes

quil

9..

est

dangereux

de

respirer.

1.

Ecartez

le

visage

pour

Øviter

de

respirer

les

fumØes.

2.

A

lintØrieur,

assurez-vous

quo

lairo

de

soudage

eSt

bien

ventilØe

ou

que

les

fumØes

et

les

vapeurs

sont

aspirØes

a

larc.

3.

Si

Ia

ventilation

est

mauvaise,

portez

un

respirateur

a

adduction

dair

approuve.

4.

Lisez

les

fiches

signalØtiques

et

les

consignes

du

fabricant

relatives

aux

mØtaux,

aux

produits

consummables,

aux

revŒtements

et

aux

produits

nettoyants.

Le

SOUDAGE

peut

causer

un

incendie

ou

une

explosion.

Larc

produit

des

Øtincelles

of

des

projections.

Avec

Ia

chaleur

intense

dŁgagee

par

Ia

tle

et

los

matØriels,

elles

peuvent

causer

un

incendie

et

des

brOlures.

Lo

contact

accidontol

de

electrode

avoc

un

objet

metallique

pout

provoquer

des

Øtincelles,

un

Øchauffement

ou

un

incendie.

1.

Protegez-vous,

ainsi

quo

les

autres,

contre

les

Øtincelles

et

los

projections.

2.

Ne

soudez

pas

dans

un

endroit

o des

Øtincelles

peuvent

attoindro

des

matØnaux

inflammables.

3.

Enlevez

toutes

les

matiŁres

inflammables

dans

un

rayon

de

10,7

metres

autourde

larc,

ou

couvrez-les

soigneusement

avec

des

bches

approuvØes.

4.

MØfiez-vous

des

Øtincelles

et

des

Øclats

brUlants,

susceptibles

de

penetrer

dans

des

aires

adjacentes

par

de

petites

ouvertures

ou

fissures.

-______________________________________

que

vous

observez

lexØcution

dune

soudure.

2.

Portezdeslunettesdesecuriteapprouvees.

DesØcranslatØraux

sont

recommandØes.

3.

Entourez

laire

de

soudage

do

ridoaux

ou

do

cloisons

de

protection

contre

los

coups

darc

ou

leblouissement;

avertissez

les

observateurs

de

ne

pas

regarder

arc.

4.

Portez

des

vØtements

en

tissus

ignifuge

durable

(lame

of

cuir)

et

des

chaussures

de

sØcuritØ.

5.

Portez

un

casque

antibruit

ou

des

bouchons

doreillo

approuvØs

si

le

niveau

de

bruit

est

ØlevØ.



5.

Ne

travaillez

dans

un

espace

confine

quo

sil

est

bien

ventilØ;

sinon,

portez

un

respirateur

a

adduction

dair.

Los

gaz

protecteurs

de

soudage

peuvent

dØplacer

loxygene

de

lair

of

causer

des

blessures

ou

Ia

mort.

Assurez-vous

quo

lair

ost

propre

a

Ia

respiration.

6.

Ne

soudez

pas

a

proximitØ

doperations

de

degraissage,

do

nettoyage

ou

de

pulvØrisation.

La

chaleur

et

les

rayons

do

Iarc

peuvent

reagir

avec

des

vapeurs

et

former

des

gaz

hautement

toxiques

et

irritants.

7.

Ne

soudoz

pas

de

tOles

galvanisØes

ou

plaquØes

en

p10mb

ou

en

cadmium

sans

los

avoir

grattØes

a

fond,

car

ces

mØtaux,

et

tout

revŒtement

qui

en

contient,

peuvent

alors

dØgager

des

fumØes

toxiques.

Assuroz-vous

dune

bonne

ventilation

et

portez

un

respiratour

a

adduction

dair

si

cost

nØcessaire.

5.

MØfiez-vous

des

incendies

et

gardez

un

extincteur

a

portØe

do

Ia

main.

6.

Noubliez

pas

quune

soudure

sur

un

plafond,

un

plancher,

une

cloison

ou

uno

paroi

pout

on

enflammer

Iautre

cOtØ.

7.

Ne

soudez

pas

un

recipient

fermØ,

comme

un

reservoir

ou un

tonnoau.

8.

Connectez

le

cable

de

soudage

le

plus

prŁs

possible

de

Ia

tOle

do

soudage

pour

empecher

le

courant

do

suivre

un

parcours

long

et

inconnu,

et

prØvenir

ainsi

los

risques

dØlectrocution

et

dincendie.

9.

Ne

faites

pas

dØgoler

dos

tuyaux

avoc

un

chalumeau.

10.

Videz

votre

carquois

porte-electrodes

ou

coupez

le

f

ii

au

tube-

contact

apres

le

soudage.

11.

Portez

des

vØtements

protecteurs

non

huileux,

tels

des

gants

on

cuir,

une

chemise

Øpaisso,

un

pantalon

sans

revers,

des

chaussures

montantes

et

un

casque.

MISE

EN

GARDE

PROTEGEZ-VOUS,

AINSI

QUE

LES

AUTRES,

CONTRE

LES

BLESSURES

GRAVES

POSSIBLES

OU

LA

MORT.

NE

LAISSEZ

PAS

LES

ENFANTS

SAPPROCHER,

NI

LES

PORTEURS

DE

STIMULATEtJR

CARDIAQUE

(A

MOINS

QUILS

NAIENT

CONSULTE

UN

MEDECIN).

Le

soudage,

comme

a

plupart

des

activitØs

industrielles,

expose

a

certains

nsques.

Le

soudage

nest

pas

dangereux

lorsquon

prend

des

precautions.

Les

consignes

de

sOcuritØ

suivantes

ne

font

que

rØsumer

linformation

contenue

dans

es

normes

ØnumØrØes

ci-apres.

Lisez

et

respectez

toutes

ces

normes.

SEULES

DES

PERSONNES

QUALIFIEES

DOIVENT

FAIRE

DES

TRAVAUX

DINSTALLATION,

DE

REPARATION,

DENTRETIEN

El

DESSAI.

Les

BOUTEILLES

endommagees

peuvent

exploser.

Les

bouteilles

contiennent

des

gaz

protecteurs

sous

haute

pression.

Des

bouteilles

endommagees

peuvent

exploser.

Comme

les

bouteilles

font

normalement

partie

du

procede

de

soudage,

traitez-les

avec

soin.

1.

Les

bouteilles

doivent

Œtre

protegees

contre

es

sources

de

chaleur

intense,

les

chocs

et

les

arcs

de

soudage.

2.

EnchaInez

verticalement

es

bouteilles

a

un

support

ou

.a

un

cadre

fixe

pour

les

empŒcher

de tomber

ou

dŒtre

renversØes.

3.

Eloignez

les

bouteilles

de

tout

circuit

electrique

ou

de

soudage.

4.

EmpŒchez

tout

contact

entre

une

bouteille

et

une

electrode.

5.

Nutilisez

que

des

bouteilles

de

gaz

protecteur,

des

detendeurs,

des

flexibles

et

des

raccords

concus

pour

chaque

application

spŁcifique;

ces

matØriels

et

les

piŁces

connexes

doivent

Œtre

en

bon

Øtat.

6.

Ne

mettez

pas

le

visage

devant

le

robinet

de

bouteille

en

louvrant.

7.

Remettez

le

chapeau

de

bouteille

aprŁs

utilisation.

8.

Lisez

et

respectez

les

consignes

relatives

aux

bouteilles

de

gaz

comprimØ

et

aux

matØriels

connexes,

ainsi

que

Ia

publication

P-i

de

Ia

CGA,

ŁnumØrŁes

dans

les

normes

ci-dessous.

Le

CARBURANT

peut

causer

un

incendie

ou

une

explosion.

Le

carburant

est

hautement

inflammable.

1.

ArrŒtez

le

moteur

avant

de

verifier

le

niveau

de

carburant

ou

de

faire

le

plein.

2.

Ne

faites

pas

le

plein

en

fumant

ou

proche

dune

source

Des

PIECES

EN

MOUVEMENT

peuvent

causer

des

blessures.

Des

piŁces

en

mouvement,

telles

des

ventilateurs,

des

rotors

et

des

courroies

peuvent

couper

les

doigts

et

les

mains,

ou

accrocher

des

vŒtements

amples.

1.

Assurez-vous

que

les

portes,

es

panneaux,

es

capots

et

les

protecteurs

sont

bien

fermes.

2.

Avant

dinstaller

ou

de

connecter

un

systŁme,

arrŒtez-en

le

moteur.

3.

Seules

des

personnes

qualifiØes

doivent

dŁmonter

des

Les

MOTEURS

peuvent

Œtre

dangereux.

dØtincelles

ou

dune

flamme

nue.

3.

Si

cest

possible,

laissez

le

moteur

refroidir

avant

de

faire

le

plein

de

carburant

ou

den

verifier

le

niveau

au

debut

du

soudage.

4.

Ne

faites

pas

le

plein

de

carburant

a

ras

bord

:

prØvoyez

de

Iespace

pour

son

expansion.

5.

Faites

attention

de

ne

pas

renverserde

carburant.

Nettoyez

tout

carburant

renversŁ

avant

de

faire

dŁmarrer

le

moteur.

protecteurs

ou

des

capots

pourfaire

Ientretien

ou

le

dØpannage

nØcessaire.

4.

Pour

empŒcher

un

demarrage

accidentel

dun

systŁme

pendant

lentretien,

dØbranchez

le

cable

daccumulateur

a

Ia

borne

negative.

5.

Napprochez

pas

les

mains

ou

les

cheveux

de

piŁces

en

mouvement;

elles

peuvent

aussi

accrocher

des

vŒtements

amples

et

des

outils.

6.

RØinstallez

les

capots

ou

les

protecteurs

et

fermez

les

portes

aprŁs

des

travaux

dentretien

et

avant

de

faire

dØmarrer

le

moteur.

Safety

in

Welding

and

Cutting

norme

ANSI

Z49.

1,

American

Welding

Society,

550,

N.W.

LeJeune

Rd.,

Miami

FL

33128.

Safety

and

Health

Standards

OSHA

29

CFR

1910,

Superintendent

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,

norme

AWS

F4.1,

American

Welding

Society,

550,

N.W.

LeJeune

Rd.,

Miami

FL

33128.

Safe

Handling

of

Comoressed

Gases

in

Cylinders

document

P-i,

Compressed

Gas

Association,

1235

Jefferson

Davis

Highway,

Suite

501,

Arlington,

Va

22202.

Code

for

Safety

in

Welding

and

Cutting

norme

GSA

Wi

17.2,

Asso

ciation

canadienne

de

normalisation,

Standards

Sales,

176

Rexdale

Boulevard,

Rexdale,

Ontario,

Canada

M9W

1

R3.

Safe

Practices

for

Occuoation

and

Educational

Eye

and

Face

Protec

~

norme

ANSI

Z87.

1,

American

National

Standards

Institute,

1430

Broadway,

New

York,

NY

10018.

National

Electrical

Code

norme

70

NFPA,

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

srlf

9/91

Cutting

and

Welding

Processes

norme

51

B

NFPA,

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

LES

ETINCELLES

ET

LES

metal.

En

retroidissant,

Ia

soudure

peut

projeter

du

laitier.

PROJECTIONS

BRULANTES

peuvent

causer

des

blessures.

Le

piquage

et

le

meulage

produiserit

des

Øclats

de

1.

2.

Portez

un

Øcran

facial

ou

des

lunettes

a

coques

approuvØes.

Des

Øcrans

lat~raux

sont

recommandØs.

Portez

des vŒtements

de

protection

individuelle

appropriØs.

MISE

EN

GARDE

Les

GAZ

DECHAPPEMENT

D

ES

MOTEURS

1.

Utilisez

des

machines

a

lextØrieur

dans

des

aires

ouvertes

et

PEUVENT

ETRE

MORTELS.

Les

moteurs

produisent

des

gaz

nocifs.

dØchappement

2.

bien

ventilØes.

Si

vous

utilisez

des

machines

dans

un

endroit

confine,

les

fumØes

dØchappement

doivent

Œtre

envoyees

a

lextØneur,

loin

des

prises

dair

du

btiment.

Des

ETINCELLES

peuvent

FAIRE

EXPLOSER

UNACCUMULATEUR;

LELECTROLYTE

DUN

ACCUMULATEUR

peut

brUler

Ia

peau

et

les

2.

~

un

accumulateur.

ArrŒtez

le

moteur

avant

de

connecter

ou

de

dŁconnecter

des

cables

daccumulateur.

Nutilisez

que

des

outils

anti-Łtincelles

pour

travailler

sur

un

yeux.

accumulateur.

Les

accumulateurs

contiennent

de

IØlectrolyte

et

4.

Nutilisezpasunpostedesoudagepourchargerunaccumulateur

degagent

des

vapeurs

explosives.

ou

connecter

provisoirement

un

vŁhicule.

1.

Portez

toujours

un

Łcran

facial

en

travaillant

sur

5.

Utilisez

Ia

polaritØ

correcte

(+

et

-)

de

laccumulateur.

La

VAPEUR

ET

LE

LIQUIDE

DE

1.

Ntez

pas

le

bouchon

de

radiateurtantque

le

moteur

na

pas

REFROIDISSEMENT

BRULANT

sous

refroidi.

PRESSION

peuvent

brUler

Ia

peau

et

les

yeux.

Le

liquide

de

refroidissement

dun

radiateur

peut

Œtre

2.

3.

Mettez

des

gants

et

posez

un

torchon

sur

le

bouchon

pour

lter.

Laissez

Ia

pression

sechapper

avant

dter

complŁtement

le

bouchon.

brUlant

et

sous

pression.

PRINCIPALES

NORMES

DE

SECURITE

EMF

INFORMATION

TABLE

OF

CONTENTS

SECTION

1



SAFETY

INFORMATION

SECTION

2-

SPECIFICATIONS

1

3

4

5

6

7

8

9

11

12

15

16

18

NOTE

~

Considerations

About

I

Magnetic

Fields

The

following

is

a

quotation

from

the

General

Conclusions

Section

Welding

And

The

Effects

Of

Low

Frequency

Electric

And

To

reduce

magnetic

fields

in

the

workplace,

use

the

following

of

the

U.S.

Congress,

Office

of

Technology

Assessment,

Biological

procedures:

Effects

of

Power

Frequency

Electric

&

Magnetic

Fields



Background

Paper,

OTA-BP-E-53

(Washington,

DC:

U.S.

Government

Printing

Office,

May

1989):.

. .

there

is

now

a

very

1.

Keep

cables

close

together

by

twisting

or

taping

them.

2.

Arrange

cables

to

one

side

and

away

from

the

cperator.

large

volume

of

scientific

findings

based

on

experiments

at

the

3.

Do

not

coil

or

drape

cables

around

the

body.

cellular

level

and

from

studies

with

animals

and

people

which

clearly

establish

that

low

frequency

magnetic

fields

can

interact

with,

and

produce

changes

in,

biological

systems.

While

most

of

this

work

is

of

very

high

quality,

the

results

are

complex.

Current

scientific

understanding

does

not

yet

allow

us

to

interpret

the

evidence

in

a

4.

Keep

welding

power

source

and

cables

as

far

away

as

practical.

5.

Connect

work

clamp

to

workpiece

as

close

to

the

weld

as

possible.

single

coherent

framework.

Even

more

frustrating,

it

does

not

yet

About

Pacemakers:

allow

us

to

draw

definite

conclusions

about

questions

of

possible

risk

or

to

offer

clear

science-based

advice

on

strategies

to

minimize

The

above

procedures

are

among

those

also

normally

recommended

for

pacemaker

wearers.

Consult

your

doctor

for

or

avoid

potential

risks.

complete

information.

modlo.1

4/93

SECTION

3

INSTALLATION

3-1.

Equipment

Connection

Diagrams

3-2.

Installing

Swivel

Into

Pipe

Post

3-3.

Installing

Boom

And

Reel

Support

3-4.

Installing

Wire

Guide

Extension

3-5.

Wire

Guide

And

Drive

Roll

Installation

3-6.

Welding

Gun

Connections

3-7.

Wire

Feed

Motor

And

Gas

Valve

Control

Connections

3-8.

14-Pin

Plug

Connection

3-9.

Shielding

Gas

And

Weld

Cable

Connections

3-10.

Voltage

Sensing

Lead

(Optional)

3-11.

Removing

Safety

Collar

And

Adjusting

Boom

3-12.

Welding

Wire

Installation

3-13.

Motor

Start

Control

3-14.

Dip

Switches

Options

3-15.

Changing

Optional

Digital

Voltage

Control

For

Use

With

A

MILLER

Inverter-Type

Power

Source

3-16.

Threading

Welding

Wire

SECTION

4OPERATION

SECTION

5

MAINTENANCE

&

TROUBLESHOOTING

5-1.

Routine

Maintenance

5-2.

Replacing

The

Hub

Assembly

5-3.

Overload

Protection

5-4.

Troubleshooting

SECTION

6

ELECTRICAL

DIAGRAMS

SECTION

7

PARTS

LIST

Figure

7-1.

Main

Assembly

Figure

7-2.

Support,

Hub

&

Reel

Figure

7-3.

Control

Box

Figure

7-4.

Control

Panel

Figure

7-5.

Boom

Assembly

Figure

7-6.

Drive

Assembly,

Wire

Table

7-1.

Drive

Roll

And

Wire

Guide

Kits

24

25

26

27

32353639404245

OM-1583D

-

4/94

SECTION

1

-

SAFETY

INFORMATION



Read

all

safety

messages

throughout

this

manual.



Obey

all

safety

messages

to

avoid

injury.



Learn

the

meaning

of

WARNING

and

CAUTION.

Figure

1-1.

Safety

Information

SECTION

2-

SPECIFICATIONS

Table

2-1.

Wire

Feeder

modl.1

2/93

1

2

_______

:

2

\

3

ELECTRIC

SHOCK

can

kiIl.~



Do

not

touch

live

electncal

parts.



Disconnect

input

power

before

installing

or

servicing.

a

CAUTION

r

5

MOVING

PARTS

can

Injure.



Keep

away

from

moving

parts.

I



Keep

alt

panels

and

covers

closed

I

when

operating.

1

Safety

Alert

Symbol

2

SignalWord

WARNING

means

possible

death

or

serious

injury

can

happen.

CAUTION

means

possible

minor

injury

or

equipment

damage

can

happen.

3

Statement

Of

Hazard

And

Result

6

a

WARNING

READ

SAFETY

BLOCKS

at

start

of

SectIon

3-1

before

proceedIng.

7H

NOTE

~

Turn

Off

switch

when

using

high

frequency.

4

Safety

Instructions

To

Avoid

Hazard

5

Hazard

Symbol

(If

Available)

6

Safety

Banner

Read

safety

blocks

for

each

sym

bol

shown.

7

NOTE

Special

instructions

for

best

oper

ation



not

safety.

Specification

Type

Of

Input

Power

From

Welding

Power

Source

Maximum

Weld

Circuit

Rating

Welding

Power

Source

Type

Wire

Feed

Speed

Range

Description

Wire

Diameter

Range

Welding

Process

Input

Power

Cord

Single-Phase

24

Volts

AC,

10

Amperes,

50/60

Hertz.

(If

115

Volts

AC

Is

The

Only

Power

Available,

Use

Optional

Power

Supply

Adapter

Model

PSA-2.)

100

Volts,

750

Amperes,

100%

Duty

Cycle

Constant

Voltage

(CV)

DC,

With

Contactor

50

To

780

ipm

(1.3

To

19.8

mpm);

Standard

Motor

14

To

213

ipm

(0.6

To

5.4

mpm);

Low

Speed

Motor

90

To

1400

ipm

(2.3

To

35.6

mpm);

High

Speed

Motor

.023

To

1/8

in

(0.6

To

3.2

mm)

Gas

Metal

Arc

(GMAW)

Or

Flux

Cored

Arc

Welding

(FCAW)

lOft(3.1

m)

Maximum

Height

With

4

ft

(1.2

m)

Post

Weight

12

ft

(37

m)

Boom

17ft(5.2m)

Vertical

Lift

Of

Boom

Net:

160

lb

(73

kg)

Ship:

280

lb

(127

kg)

16

ft

(4.9

m)

Boom

21

ft

(6.4

m)

Horizontal

To

60

Above

Horizontal

Net:

210

lb

(95

kg)

Ship:

350

lb

(159

kg)

Horizontal

To

60

Above

Horizontal

OM-1583

Page

1

Table

2-2.

Options

The

table

below

should

be

used

to

determine

the

options

that

can

be

used

together

on

a

wire

feeder.

Use

the

column

on

the

left

side

of

the

table

to

choose

the

desired

option

and

follow

the

line

across

to

see

which

options

are

compatible.

Desired

Option

Burn-

back

Control

4-In-i

Control

Digital

Meter(s)

Tech

Feed-

back

Digital

Voltage

Control

Voltage

Control

Run-In

Control

Digital

Dual

Schedule

Dual

Schedule

Control

Remote

Pendant

Control

Cord

#137

552

(For

RCSP-45)

Burnback

Control



No

Yes

4-in-i

Control

(includes

preflow/post

flow,

spotlburnback,

and

trigger

hold

control)

No



Yes

Yes Yes Yes Yes Yes Yes

Digital

Meter(s)/Tach

Feedback

(one

ortwo

meter

option)

Yes



Yes

Yes Yes Yes

No

Yes

Digital

Voltage

Control

(DVC)

Yes

Reqd



No

Yes Yes

No

Yes Yes

Voltage

Control

Yes Yes

Yes

No



Yes

No

Yes

Run-In

Control

(Option

Interface

Required)

Yes Yes Yes Yes

Yes



Yes

Yes Yes

Yes

Digital

Dual

Schedule

(Option

Interface

Required)

Yes

Reqd

No

Yes



No

Dual

Schedule

Control

(Option

Interface

Required)

Yes

No No

No

Yes

No



No No

Remote

Pendant

Control

(Option

Interface

Required)

Yes

No

Yes

No



No

Cord

#137

552

(For

RCSP-45)

(Option

Interface

Required)

Yes

No



OM-1583

Page

2

SECTION

3-

INSTALLATION

3-1.

Equipment

Connection

Diagrams

a

WARNING

CYLINDERS

can

explode

it

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.

HOT

SURFACES

can

burn

skin.



Allow

gun

to

cool

before

touching.

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



TurnOffwirefeederandwelding

power

source,

and

disconnect

input

power

before

making

connections.

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.

Figure

3-1.

Typical

System

Connections

Have

only

qualified

persons

install

this

unit.

wfwam9.1

2/93

13

1

Welding

Power

Source

2

Remote

14

Connection

3

Positive

(+)

Weld

Output

Cable

4

Negative

()

Weld

Output

Cable

5

Workpiece

6

Voltage

Sensing

Clamp

7

Weld

Control

8

Boom

9

Gun

10

Swivel

11

Pipe

Post

And

Base

12

Gas

Hose

13

Gas

Supply

ST.152

324

11

9

OM.1583

Page

3

3-2.

Installing

Swivel

Into

Pipe

Post

AA

WARNING

1

RELEASE

OF

SPRING

PRESSURE

WITHOUT

BOOM

ATTACHED

can

cause

serious

personal

Injury.

S

Do

not

remove

safety

collar

until

instructed

to

do

so.

FALLING

BOOM

can

cause

serious

personal

injury

and

equipment

damage.



Securely

mount

pipe

post

to

base

that

can

support

weight

of

unit

with

boom

in

horizontal

position.



Use

proper

equipment

for

lifting

swivel

and

boom

into

place.

3-3.

Installing

Boom

And

Reel

Support

Tools

Needed:

~

3/4,

3/8

in

1

Swivel

Plates

2

Yoke

Remove

hardware

from

swivel

plates

and

yoke.

3

Boom

Set

boom

into

swivel

as

shown.

4

Yoke

Install

through

yoke.

Install

cot

ter

and

spread

ends.

5

Bolt

Install

bolt,

tighten

hardware,

and

back

bolt

off

one

half

turn.

6

Locking

Knob

Install

locking

knob

but

do

not

tighten.

7

Reel

Support

Install

reel

support.

Ret.

ST-i

42

596.C

Tools

Needed:

~

3/4

in

1

Swingpak

Base

or

CBC

Cart

2

Pipe

Post

With

Base

3

Steel

Bolt

Secure

as

shown

using

as

a

mini

mum

1/2

in

diameter

SAE

grade

5

steel

bolts.

4

Swivel

Assembly

Insert

into

pipe

post.

Lubricate

swivel.

5

Safety

Collar

Do

not

remove

until

instructed

to.

ST-152

268

Figure

3-2.

Swivel

Installation

READ

SAFETY

BLOCKS

at

start

of

Section

3-2

before

proceeding.

1

Figure

3-3.

Boom

Installation

OM-1

583

Page

4

3-4.

Installing

Wire

Guide

Extension

Figure

3-4.

Wire

Guide

Extension

Installation

3-5.

Wire

Guide

And

Drive

Roll

Installation

I

4.~

~

READ

SAFETY

BLOCKS

at

start

of

7



I

Section

3-1

before

proceeding.

A.

Wire

Guide

Installation

When

changing

wire

size

or

type,

check

guide

size.

See

Table

7-1.

1

Drive

Rolls

Remove

drive

rolls

before

installing

wire

guides

(see

Figure

3-6).

2

Wire

Guide

Securing

Screws

Loosen

wire

guide

screws.

3

Inlet

Wire

Guide

4

Intermediate

Wire

Guide

Insert

intermediate

guide

until

flange

on

guide

rests

against

cast~

ing,

and

secure

with

guide

screw.

Install

drive

rolls

(see

Figure

3.6).

4

1

Wire

Guide

Fitting

2

Bolt

3

Monocoil

Liner

4

Wire

Guide

Extension

Tighten

bolt

to

secure

liner

in

wire

guide

fitting.

Do

not

overtighten

bolt

and

crush

liner.

Tools

Needed:

~

3/B

in

ST-152

323

Tools

Needed:

1

Ref.

ST~137

391-FISI-142

597-A

Figure

3-5.

Wire

Guide

Installation

OM-1583

Page

5

B.

Drive

Roll

~nstaIlation

a

WARNING

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Turn

Ott

wire

feeder

and

welding

power

source,

and

disconnect

input

power

before

inspecting

or

installing.

wfwami.1

2/93

4

~



When

changing

wire

size

or

type,

check

drive

roll

size.

See

Table

7-1.

1

Spring

Shaft

Carrier

Close

spring

shaft

carrier.

2

Drive

Roll

Nut

3

Drive

Roll

Carrier

Turn

all

nuts

one

click

until

lobes

of

nut

line

up

with

lobes

of

drive

roll

carrier.

Open

spring

shaft

carrier.

4

Drive

Roll

Slide

drive

rolls

onto

drive

roll

carri

ers.

Close

spring

shaft

carrier.

Turn

nut

one

click.

5

Drive

Assembly

Cover

Close

cover.

ST-142

597-A

2

3

Figure

3-6.

Drive

Roll

Installation

3-6.

Welding

Gun

Connections

3

1

Drive

Assembly

Cover

2

Gun

Securing

Knob

3

Gun

Connector

Loosen

securing

knob.

Insert

gun

connector

until

it

bottoms

against

drive

assembly.

lighten

knob.

4

Gun

Trigger

Plug

5

Gun

Trigger

Receptacle

Insert

plug

into

free-hanging

recep

tacle

and

tighten

threaded

collar.

6

Trigger

Cord

7

Trigger

Plug

8

Weld

Control

Trigger

Receptacle

Insert

plug

into

receptacle

and

4

tighten

threaded

collar.

Ret.

ST-i

53

072

/

ST-i

52

321

I

Ref.

5T-142

708-B

Figure

3-7.

Gun

And

Trigger

Lead

Connections

OM-1

583

Page

6

3-7.

Wire

Feed

Motor

And

Gas

Valve

Control

Connections

3-8.

14-Pin

Plug

Connection

Figure

3-9.

14-Pin

Plug

Connection

Table

3-1.

Remote

14

Information

~j~*

Information

A

24

volts

ac.

B

Contact

closure

to

A

completes

24

volts

ac

contactor

control

circuit.

G

Circuit

common

for

24

volts

ac

circuit.

C

+10

volts

dc

input

to

remote

control.

D

Remote

control

circuit

common.

E

0

to

+10

volts

dc

output

command

signal

from

remote

control.

F

Current

feedback;

0

to

+10

volts

dc,

1

volt

per

100

amperes.

H

Voltage

feedback;

0

to

+10

volts

dc,

1

volt

per

10

arc

volts.

The

remaining

pins

are

not

used.

1

Wire

Feed

Motor

And

Gas

Valve

Control

Receptacle

2

Plug

From

Boom

3

Cord

From

Boom

Insert

plug

from

boom

cord

into

re

ceptacle

on

rear

of

control,

and

tighten

threaded

collar.

Ref.

ST-142

708-B

Figure

3-8.

Boom

Connections

1

Plug

PLG1O

2

Keyway

3

Threaded

Collar

Connect

14-pin

plug

PLGIO

to

matching

receptacle

on

welding

power

source

as

follows:

align

key

ways,

insert

plug,

and

tighten

threaded

collar.

ST-162

179

/

Ref.

S-0512

3

OM-1

583

Page

7

3-9.

Shielding

Gas

And

Weld

Cable

Connections

£~

WARNING

CYLiNDERS

can

explode

it

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.

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.

BUILDUP

OF

SHIELDING

GAS

can

harm

health

or

kill.



Shut

oft

shielding

gas

supply

when

not

in

use.

wam4.1

2/93

If

the

welding

power

source

or

gas

supply

are

further

from

the

boom,

extend

cable

or

hose

as

follows:

1

Weld

Cable

2

Insulated

Sleeving

Bolt

together

weld

cables

from

welding

power

source

and

boom.

Use

electrical

tape

and

insulated

sleeving

to

cover

connection.

3

Shielding

Gas

Hose

Connect

hose

to

gas

supply

or

ex

tension

hose.

The

hose

from

the

boom

has

5/8-18

right-hand

threads.

81-152

800-A

The

weld

cable

and

shielding

gas

hose

extend

10

ft

(3

m)

from

the

boom.

Tools

Needed:

5/8in

Figure

3-10.

Shielding

Gas

And

Weld

Cable

Connections

OM-1583

Page

8

3-10.

Voltage

Sensing

Lead

(Optional)

A

35

ft

(10.6

m)

voltage

sensing

lead

is

provided

with

several

options.

Connect

voltage

sensing

lead

to

workpiece

(see

Figure

3-1).

3-11.

Removing

Safety

Collar

And

Adjusting

Boom

1

Locking

Knob

Tighten

knob

to

prevent

boom

movement.

Loosen

knob

to

allow

boom

movement.

Change

knob

position

to

limit

upward

movement.

Tools

Needed:

~

1-1/8

in

Pull

boom

down

slightly

and

re

move

safety

collar.

Boom

should

balance

in

any

position

from hori

zontal

to

60

degrees

above

hori

zontal.

If

necessary,

adjust

boom

as

follows:

2

Threaded

Rod

3

Jam

Nut

4

Yoke

Loosen

jam

nut

and

turn

threaded

rod

until

boom

balances.

Tighten

3

jam

nut.

Be

sure

several

full

threads

are

through

yoke

to

pre

~~

2

vent

boom

falling.

Retain

safety

collar

for

use

In

dis

Increasing

Spring

Decreasing

Spring

assembling

or

moving

boom.

Pressure

ForA

Pressure

ForA

Heavy

Gun

Light

Gun

Ret.

ST-152

380-A

4

3

Figure

3-11.

Boom

Adjustments

3-12.

Welding

Wire

Installation

A.

Installation

Of

Spool-Type

Wire

1

Retaining

Ring

2

Wire

Spool

3

Hub

Remove

retaining

ring

and

slide

spool

onto

hub.

4

Hub

Turn

spool

until

hub

fits

hole

in

spool.

Reinstall

retaining

ring.

E

ST-152

~8-A

~

4~

WARNING

RELEASE

OF

SPRING

PRESSURE

FALLING

BOOM

can

cause

serious

WITHOUT

BOOM

ATTACHED

can

cause

serious

personal

injury.

personal

in



Adjustment

jury

and

rod

must

equipment

damage.

be

threaded

fully

through



Do

not

remove

safety

collar

until

instructed

to

do

so.

yoke.

Figure

3-12.

Installation

Of

Spool-Type

Wire

OM-1

583

Page

9

B. Installation

Of

Optional

Wire

Reel

And

Reel

Type

Wire

C.

Adjusting

Hub

Tension

Figure

3-14.

Adjusting

Hub

Tension

7

5

4

1

Retaining

Ring

2

Spanner

Nut

3

Lock

4

Wire

Retainer

5

Wire

Reel

6

Hub

7

Hub

8

ReelSupport

Remove

retaining

ring.

Pull

lock

and

turn.

Remove

spanner

nut,

wire

retainer,

and

wire

reel

from

hub.

Lay

wire

reel

assembly

on

flat

sur

face,

and

install

wire

as

shown.

Tighten

spanner

nut

until

lock

is

in

position

over

hole

in

wire

retainer.

Pull

lock

and

turn

to

insert

locking

into

wire

retainer.

Slide

wire

reel

assembly

onto

hub,

and

tum

assembly

until

hub

is

seated

in

hole

in

reel.

Reinstall

re

taining

ring.

ST-143

478-A

/

ST-152

463

_____________

4

Iii

I

~

Figure

3-13.

Installation

Of

Optional

Wire

Reel

And

Reel

Type

Wire

1

Turn

Off

unit

and

welding

power

source.

1

Hex

Nut

2

Spool

Grasp

spool

in

one

hand

and

turn

while

using

a

wrench

to

adjust

hex

nut.

When

a

slight

force

is

needed

to

turn

spool,

tension

is

set.

2

E

Tools

Needed:

~

5/8in

ST-152

649

OM-1

583

Page

10

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