Be sure this information reaches the operator.
You can get extra copies through your supplier.
INSTRUCTION MANUAL
Mig 4HD
DUAL WIRE FEEDER
P/N 37544
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation
and safe practices for arc welding equipment, we urge you to read our booklet, "Precautions and Safe Practices
for Arc Welding, Cutting, and Gouging", Form 52-529. Do NOT permit untrained persons to install, operate, or
maintain this equipment. Do NOT attempt to install or operate this equipment until you have read and fully
understand these instructions. If you do not fully understand these instructions, contact your supplier for
further information. Be sure to read the Safety Precautions (Section I) before installing or operating this
equipment.
F15-483-&
-XO,
Mig 4HD Wire Feeder
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and
accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the
instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained
equipment should not be used. Parts that are broken, missing, worn, distorted or contaminated should be
replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends
that a telephone or written request for service advice be made to the Authorized Distributor from whom
purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.
The user of this equipment shall have the sole responsibility for any malfunction which results from improper
use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a
service facility designated by the manufacturer.
TABLE OF CONTENTS
SECTION TITLE PAGE
PARAGRAPH
1 SAFETY ............................................................................................................................ 3-6
2 DESCRIPTION AND SPECIFICATION ...................................................................................7
2.1 Mig 4HD Wire Feeder .............................................................................................7
2.2 Mig 4HD Wire Feeder Options ................................................................................8
3 EQUIPMENT .........................................................................................................................10
3.1 General .................................................................................................................10
3.2 Optional Equipment and Accessories....................................................................10
3.3 Accessories ..........................................................................................................10
4 INSTALLATION .....................................................................................................................11
4.1 Installation .............................................................................................................11
5 OPERATION .........................................................................................................................13
5.1 Adjustments and Operation...................................................................................13
5.2 Operating Sequence .............................................................................................13
6 SERVICE ..............................................................................................................................13
6.1 Maintenance .........................................................................................................13
7 REPLACEMENT PARTS ....................................................................................................... 16
2
3
WARNING: These Safety Precautions are for
your protection. They summarize precaution-
ary information from the references listed in
Additional Safety Information section. Before
performing any installation or operating procedures, be
sure to read and follow the safety precautions listed below
as well as all other manuals, material safety data sheets,
labels, etc. Failure to observe Safety Precautions can result
in injury or death.
PROTECT YOURSELF AND OTHERS --
Some welding, cutting, and gouging
processes are noisy and require ear
protection. The arc, like the sun, emits
ultraviolet (UV) and other radiation and
can injure skin and eyes. Hot metal can cause burns.
Training in the proper use of the processes and equip-
ment is essential to prevent accidents. Therefore:
1. Always wear safety glasses with side shields in any work
area, even if welding helmets, face shields, and goggles
are also required.
2. Use a face shield fitted with the correct filter and cover
plates to protect your eyes, face, neck, and ears from
sparks and rays of the arc when operating or observing
operations. Warn bystanders not to watch the arc and
not to expose themselves to the rays of the electric-arc
or hot metal.
3. Wear flameproof gauntlet type gloves, heavy long-sleeve
shirt, cuffless trousers, high-topped shoes, and a weld-
ing helmet or cap for hair protection, to protect against
arc rays and hot sparks or hot metal. A flameproof apron
may also be desirable as protection against radiated
heat and sparks.
4. Hot sparks or metal can lodge in rolled up sleeves,
trouser cuffs, or pockets. Sleeves and collars should be
kept buttoned, and open pockets eliminated from the
front of clothing
5. Protect other personnel from arc rays and hot sparks
with a suitable non-flammable partition or curtains.
6. Use goggles over safety glasses when chipping slag or
grinding. Chipped slag may be hot and can fly far.
Bystanders should also wear goggles over safety glasses.
FIRES AND EXPLOSIONS -- Heat from
flames and arcs can start fires. Hot slag
or sparks can also cause fires and ex-
plosions. Therefore:
1. Remove all combustible materials well away from the
work area or cover the materials with a protective non-
flammable covering. Combustible materials include wood,
cloth, sawdust, liquid and gas fuels, solvents, paints and
coatings, paper, etc.
2. Hot sparks or hot metal can fall through cracks or
crevices in floors or wall openings and cause a hidden
smoldering fire or fires on the floor below. Make certain
that such openings are protected from hot sparks and
metal.“
3. Do not weld, cut or perform other hot work until the
workpiece has been completely cleaned so that there
are no substances on the workpiece which might pro-
duce flammable or toxic vapors. Do not do hot work on
closed containers. They may explode.
4. Have fire extinguishing equipment handy for instant use,
such as a garden hose, water pail, sand bucket, or
portable fire extinguisher. Be sure you are trained in its
use.
10/98
5. Do not use equipment beyond its ratings. For example,
overloaded welding cable can overheat and create a fire
hazard.
6. After completing operations, inspect the work area to
make certain there are no hot sparks or hot metal which
could cause a later fire. Use fire watchers when neces-
sary.
7. For additional information, refer to NFPA Standard 51B,
"Fire Prevention in Use of Cutting and Welding Pro-
cesses", available from the National Fire Protection Asso-
ciation, Batterymarch Park, Quincy, MA 02269.
ELECTRICAL SHOCK -- Contact with live
electrical parts and ground can cause
severe injury or death. DO NOT use AC
welding current in damp areas, if move-
ment is confined, or if there is danger of
falling.
1. Be sure the power source frame (chassis) is connected
to the ground system of the input power.
2. Connect the workpiece to a good electrical ground.
3. Connect the work cable to the workpiece. A poor or
missing connection can expose you or others to a fatal
shock.
4. Use well-maintained equipment. Replace worn or dam-
aged cables.
5. Keep everything dry, including clothing, work area, cables,
torch/electrode holder, and power source.
6. Make sure that all parts of your body are insulated from
work and from ground.
7. Do not stand directly on metal or the earth while working
in tight quarters or a damp area; stand on dry boards or
an insulating platform and wear rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the power.
9. Turn off the power before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on next page)
for specific grounding recommendations. Do not mistake
the work lead for a ground cable.
ELECTRIC AND MAGNETIC FIELDS —
May be dangerous. Electric current flow-
ing through any conductor causes lo-
calized Electric and Magnetic Fields
(EMF). Welding and cutting current cre-
ates EMF around welding cables and
welding machines. Therefore:
1. Welders having pacemakers should consult their physi-
cian before welding. EMF may interfere with some pace-
makers.
2. Exposure to EMF may have other health effects which are
unknown.
3. Welders should use the following procedures to minimize
exposure to EMF:
A. Route the electrode and work cables together. Secure
them with tape when possible.
B. Never coil the torch or work cable around your body.
C. Do not place your body between the torch and work
cables. Route cables on the same side of your body.
D. Connect the work cable to the workpiece as close as
possible to the area being welded.
E. Keep welding power source and cables as far away
from your body as possible.
SECTION 1 SAFETY PRECAUTIONS
4
FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in confined spaces. Do
not breathe fumes and gases. Shield-
ing gases can cause asphyxiation.
Therefore:
1. Always provide adequate ventilation in the work area by
natural or mechanical means. Do not weld, cut, or gouge
on materials such as galvanized steel, stainless steel,
copper, zinc, lead, beryllium, or cadmium unless positive
mechanical ventilation is provided. Do not breathe fumes
from these materials.
2. Do not operate near degreasing and spraying opera-
tions. The heat or arc rays can react with chlorinated
hydrocarbon vapors to form phosgene, a highly toxic
gas, and other irritant gases.
3. If you develop momentary eye, nose, or throat irritation
while operating, this is an indication that ventilation is not
adequate. Stop work and take necessary steps to im-
prove ventilation in the work area. Do not continue to
operate if physical discomfort persists.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below)
for specific ventilation recommendations.
5. WARNING: This product, when used for welding or
cutting, produces fumes or gases which
contain chemicals known to the State of
California to cause birth defects and, in
some cases, cancer. (California Health &
Safety Code
§25249.5 et seq.)
CYLINDER HANDLING -- Cylinders, if
mishandled, can rupture and violently
release gas. Sudden rupture of cylin-
der, valve, or relief device can injure or
kill. Therefore:
1. Use the proper gas for the process and use the proper
pressure reducing regulator designed to operate from
the compressed gas cylinder. Do not use adaptors.
Maintain hoses and fittings in good condition. Follow
manufacturer's operating instructions for mounting regu-
lator to a compressed gas cylinder.
2. Always secure cylinders in an upright position by chain
or strap to suitable hand trucks, undercarriages, benches,
walls, post, or racks. Never secure cylinders to work
tables or fixtures where they may become part of an
electrical circuit.
3. When not in use, keep cylinder valves closed. Have
valve protection cap in place if regulator is not con-
nected. Secure and move cylinders by using suitable
hand trucks. Avoid rough handling of cylinders.
4. Locate cylinders away from heat, sparks, and flames.
Never strike an arc on a cylinder.
5. For additional information, refer to CGA Standard P-1,
"Precautions for Safe Handling of Compressed Gases in
Cylinders", which is available from Compressed Gas
Association, 1235 Jefferson Davis Highway, Arlington,
VA 22202.
EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:
1. Always have qualified personnel perform the installa-
tion, troubleshooting, and maintenance work. Do not
perform any electrical work unless you are qualified to
perform such work.
2. Before performing any maintenance work inside a power
source, disconnect the power source from the incoming
electrical power.
3. Maintain cables, grounding wire, connections, power
cord, and power supply in safe working order. Do not
operate any equipment in faulty condition.
4. Do not abuse any equipment or accessories. Keep
equipment away from heat sources such as furnaces,
wet conditions such as water puddles, oil or grease,
corrosive atmospheres and inclement weather.
5. Keep all safety devices and cabinet covers in position
and in good repair.
6. Use equipment only for its intended purpose. Do not
modify it in any manner.
ADDITIONAL SAFETY INFORMATION -- For
more information on safe practices for elec-
tric arc welding and cutting equipment, ask
your supplier for a copy of "Precautions and
Safe Practices for Arc Welding, Cutting and
Gouging", Form 52-529.
The following publications, which are available from the
American Welding Society, 550 N.W. LeJuene Road, Mi-
ami, FL 33126, are recommended to you:
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
5. AWS C5.5 - "Recommended Practices for Gas Tungsten
Arc Welding“
6. AWS C5.6 - "Recommended Practices for Gas Metal Arc
Welding"“
7. AWS SP - "Safe Practices" - Reprint, Welding Hand-
book.
8. ANSI/AWS F4.1, "Recommended Safe Practices for
Welding and Cutting of Containers That Have Held
Hazardous Substances."
MEANING OF SYMBOLS - As used through-
out this manual: Means Attention! Be Alert!
Your safety is involved.
Means immediate hazards which, if
not avoided, will result in immediate,
serious personal injury or loss of life.
Means potential hazards which could
result in personal injury or loss of life.
Means hazards which could result in
minor personal injury.
SP98-10
SECTION 1
SAFETY PRECAUTIONS
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SECTION 2
DESCRIPTION
7
Table 2-1. Mig 4HD Specifications
Input Power Required ..........................................42 V ac, 5A, 50/60 Hz, 1-phase
Wire Feed Speed Range ..................................... 50-750 in./min. (1.3-19 m/min.)
Wire Sizes Accommodated:
Hard/Soft ............................................... .023 thru 1/16 in. (0.6 thru 1.6 mm)
Flux Cored............................................. .035 thru 3/32-in. (0.9 thru 2.4 mm)
Length...................................................................................................................
Width ....................................................................................................................
Height*..................................................................................................................
Weight (approx**) .................................................................................................
*Add 2-3/4-in. (7 cm) for spindle and spindle arm.
**8-ft (2.4m) control cable and hose included in specified weight.
2.1 Mig 4HD Dual Wire Feeder
The Mig 4HD Dual Wire Feeder (Figure 2-1 and Table
2-1) described in this manual is designed for short
arc, spray arc or cored wire welding with a constant
potential (MIG) welding power source.
Secondary input from the Power Source can be DC
"+" or DC "-" depending on the requirements of the
wire type being used.
Mig spot welding can be done with the Mig 4HD Dual
if it is equipped with Option Kit (P/N 37799).
The Mig 4HD Dual uses drive motors designed to
feed wires from .023 to 3/32-inches diameter. Rate of
wire feed (50-750 inches per minute) is precisely
controlled by a solid-state, Pulse Width Modulated
(PWM) governor printed circuit board housed in the
control assembly. The Gun Switch is energized by 12
volts DC for operator safety.
The Mig 4HD Dual Wire Feeder is designed to sit on
flat surfaces such as the top of the Power Source or
Cart. The standard features of the Mig 4HD Dual Wire
Feeder include:
• 4-roll drive stands, each with two driven rolls
and two pressure rolls
• 2 Internal gas solenoids
• 8-foot (2.4m) control cable w/19-pin amphenol
style plug (factory installed)
• "Euro" style torch connections
• Power ON/OFF switch
• 2 Weld Schedules per gun
• 2 Wire feed speed potentiometers per gun
• 2 Voltage control potentiometers per gun
• Gas purge/Jog switch
• Remote power source voltage control
• Right/Left side "Active" lights
• Push-Pull Torch Control Receptacle
SECTION 2
DESCRIPTION
8
2.2 Optional Accessories. The following
options are available from ESAB or your sup-
plier.
• Spot/Burnback/Pre-postflow/Trigger Lock
Module (P/N 37799). Easy to install kit permits
the operator to set times for spot welding (0-5
sec), wire burnback (0-0.6 sec), gas preflow
(0-1.5 sec) and gas postflow (0-7.5 sec). This
module also includes trigger lock which allows
the welder to make long welds without continu-
ously depressing the gun trigger. Includes
module and current detector.
• Digital Meter/Preset Module (P/N 34180).
Easy to install kit provides a digital display of
wire feed speed (ipm or m/min) and voltage.
This option also enables the welder to preset
wire feed speed. The meter automatically dis-
plays the setting for the "Active" side of the
feeder.
• Remote Schedule Selector Switch
12-1/2 ft. .............................. P/N 23102185
25 ft. .................................... P/N 23102187
Torch mounted, two position switch provides
remote schedule selection (A or B). Feeder "A/
B Switch" must be in the "B" position for remote
switch to operate.
• Water Kit (P/N 37801). Convenient way of
using water cooled guns. Kit consists of inlet/
outlet fittings, mounting hardware, quick action
connectors for the gun hoses with "B" size
water fittings for connecting to the Cooler/
Recirculator.
SECTION 2
DESCRIPTION
9
FRONT VIEW
REAR VIEW
Figure 2-1. Mig 4HD Dual Wire Feeder
JOG PURGE
SCHEDULE
SCHEDULE
A
A
BB
VOLTS VOLTS
POWER
1
0
LEFT RIGHT
POWER INDICATOR
OPTIONAL
DIGITAL
METER
KIT
PUSH
PULL
GUN
REMOTE
SELECT
B
REMOTE
SELECT
B
GUN
CONNECTOR
WATER
KIT
OPTION
SPINDLE
ASSEMBLY
4 ROLL
DRIVE STAND
POWER BLOCK
WATER
KIT
OPTION
WATER
KIT
OPTION
S/N PLATE RATING LABEL
IPM IPM
REMOTE SCHEDULE
A - B SELECT
WELD SCHEDULE
SELECT SWITCH
RIGHT/LEFT
WIRE FEED SPEED CONTROL
RIGHT SIDE SCHEDULE A & B
WIRE FEED SPEED CONTROL
LEFT SIDE SCHEDULE A & B
OUTPUT VOLTAGE CONTROL
LEFT SIDE SCHEDULE A & B
OUTPUT VOLTAGE CONTROL
RIGHT SIDE SCHEDULE A & B
WATER
KIT
OPTION
POWER
ON/OFF
(Has to be in "B" Position
to Operate Remotely)
LOCATION FOR
OPTIONAL PANEL
SECTION 3
EQUIPMENT
10
3.1 General
This section describes the Mig 4HD Dual Wire Feeder
and recommended equipment and accessories.
3.2 Equipment and Accessories
A. Constant potential Mig power source. Use the
Mig 4HD with power sources such as: 352cv,
452cv, SVI-450i cvcc, 652 cvcc, 350mpi, MTS-
3500i.
B. Extension Cables. Multi-conductor cable with
19-pin amphenol plug and receptacle. Used to
extend 8-ft (2.4m) cable supplied with wire feeder.
• 30-foot (9.1 m) P/N 34378
• 60-foot (18.3 m) P/N 34377
C. Shielding gas regulator/flowmeter and fitted hose
is supplied to bring gas from flowmeter to wire
feeder. Such as:
Regulator/Flowmeters:
R-5007 Argon/Helium/Nitrogen, P/N 998124.
R-5008 CO
2
, P/N 998125.
D. Drive Roll and Guide Tube. (Refer to Table 1):
The Mig 4HD wire feeder comes equipped with
a drive roll and a guide tube for wire sizes .035
to .045 (0.9 to 1.2 mm). Select other size drive
rolls from Table 1 for the wire size and type to be
used.
3.3 Accessories
A. Wire Reel Adapter (P/N 34323). Use with 60 or
65-lbs. (27 or 30 kg) coils.
B. Spool Spacer (P/N 34330). For adapting 10-in
(25.4 cm) spools.
Table 1. Drive Roll & Guide Tube Selection
Upper Outlet Center Inlet
Wire Type / Lower Pressure Guide Guide Guide
Diameter Drive Roll Roll Tube Tube Tube
Hard Wires (“V” groove)
.023 in.(0.6mm) 21155 2361 2397 21163 34612 34615
.030 in.(0.8mm) 21155 2361 2397 21164 34612 34615
.035 in.(0.9mm) 21156 2361 2397 21165 34612 34615
.040 in.(1.0mm) 21156 2361 2397 21165 34612 34615
.045 in.(1.2mm) 21156 2361 2397 21165 34612 34615
.052 in.(1.4mm) 21157 2361 2397 21166 34612 34615
1/16 in.(1.6mm) 21157 2361 2397 21166 34612 34615
Soft (aluminum) Wires (“U” groove)
.030 in.(0.8mm) 21158 2361 2397 21167
34612 34615
.035 in.(0.9mm) 21158 2361 2397 21168
34612 34615
3/64 in.(1.2mm) 21159 2361 2397 21168
34612 34615
1/16 in.(1.6mm) 21159 2361 2397
34612 34615
Top and Bottom Grooved- Aluminum
.035 in.(0.9mm) 36860 36860 21167 34612 34615
3/64 in.(1.2mm) 36860 36860 21168 34612 34615
1/16 in.(1.6mm) 36861 36861
34612 34615
Cored Wires (Serrated “V” groove)
.030 in.(0.8mm) 21160 2361 2369 21164 34612 34615
.035 in.(0.9mm) 21160 2361 2369 21165 34612 34615
.040 in.(1.0mm) 21161 2361 2369 21165 34612 34615
.045 in.(1.2mm) 21161 2361 2369 21165 34612 34615
.045 in.(1.2mm)† 37319 37319 21165 34612 34615
.052 in.(1.4mm) 21161 2361 2369 21166 34612 34615
.052 in.(1.4mm)† 37319 37319 21166 34612 34615
1/16 in.(1.6mm) 21161 2361 2369 21166 34612 34615
1/16 in.(1.6mm)† 37320 37320 21166 34612 34615
5/64 in.(2.0mm) 21162 2361 2369 21166 34613 34616
5/64 in.(2.0mm)† 37320 37320 21166 34613 34616
† Recommended for use with soft cored wires that are easy to flat-
ten. Order both lower drive roll and upper pressure roll.
Requires Support Tube, P/N 21169.
Call Factory for current recommendation.
SECTION 4
INSTALLATION
11
4.1 Installation
A. Connect the 19 pin control cable to the Power
Source.
B. Hose and Electrical Connections. Connect
shielding gas supply hose. Connect secondary
power cable to power block and power supply.
C. Attach a Mig Gun with "EURO" style connector
to the mating receptacles on the feeder front
panel.
D. Wire Spool.
As with any work area, make sure safety glasses
with side shields are worn when handling or
changing wire or clipping wire off at the spool or
at the end of the torch. Hold onto the wire coming
off the spool with one hand before clipping.
Serious eye injury can result due to the resilience
of the wire which can quickly unravel, or a cut
wire end which may shoot across the room.
Install a spool of welding wire on the hub as follows:
1. Remove "hairpin" clip from spindle.
2. Position the spool of wire so that when it is
placed on the spindle, wire will be drawn to
the feed roll from the bottom of the spool.
The spool should be held so that the index
hole on the back will engage the lug on the
spindle.
3. Slide the spool onto the spindle until it
engages the lug. Lock in place with the
hairpin clip.
4. When wire coils are to be used instead of
spools, reposition the spindle to the highest
position and mount wire reel on spindle as
though it were a spool (see 1 and 3 above).
Remove thumbnuts and cover plate from
reel. Remove coil from its package, but do
not remove its binding wires. Slide coil onto
reel so that wire will be drawn from bottom
of coil (starting end for a coil is always the
outer end). Replace reel cover plate and
thumbnuts. Cut off coil tie wires and any
kinked wire.
E. Drive Rolls. The drive roll has two grooves; the
smaller groove feeds 0.035 in. diameter wire,
the larger groove feeds 0.045 in. wire. The
groove nearer the gear motor feeds the wire. If
the required groove is not correctly positioned,
perform the following:
1. Release the pressure drive roll levers and
lift the assemblies upward.
2. Remove shoulder screw holding each drive
roll to the gear.
3. Reverse the drive roll on the drive roll shaft.
4. Replace the shoulder screws and tighten.
5. Secure the pressure drive roll assembly.
E. Threading Wire.
1. Release pressure drive roll assembly and
lift upward. Check that proper wire diam-
eter groove is in the inner position.
Before threading welding wire through liner, make
sure chisel point and burrs have been removed
from wire end to prevent wire from jamming in
gun or liner.
2. Feed the wire from the spool through the
inlet guide, across the drive roll groove and
into gun outlet guide.
Make sure that the proper "outlet guide
tube" is inserted into the front-panel gun
fitting for the size and type of wire being
used.
3. Lower pressure roll assembly and secure.
Apply power to the feeder. Momentarily
depress and release the torch trigger for
the desired "Active" side (Left/Right).
4. Feed wire through to gun tip using the JOG
switch located on the front panel.
5. To ensure proper wire feeding, it is impor-
tant that the wire be kept clean and that the
drive rolls be periodically cleaned of any
chips or scale that might be carried into the
gun liner and cause clogging.
F. Brake Drag Adjustment. Loosen the brake
screw in the center of the spindle hub, then
tighten it just enough to prevent coasting of the
spool when wire is drawn from it. Too much
pressure will load the wire feed motor unneces-
sarily. Too little pressure will permit the spool to
overrun, causing the wire to kink and tangle.
SECTION 5
OPERATION
12
5.1 Adjustments and Operation
A. Selecting the "Active" side (Left/Right).
1. Apply power to wire feeder by turning on
the power source and the power switch on
the 4HD front panel.
2. When power is applied to the feeder the
default "Active" side is the right side (as
viewed from the front of the feeder). This
should be indicated by the right "Active"
pilot light being illuminated. If the desired
active side is the Left, momentarily depress
and released the Left gun trigger. The Right
"Active" light will extinguish and the Left
"Active" light will be illuminated. The Left
side will remain the "Active" side until the
Right gun trigger is depressed. When ei-
ther gun trigger is depressed that side
automatically becomes the "Active" side
and the gun trigger for the opposite side is
disabled until the "Activated" gun trigger is
released.
B. Control Setting.
1. Set the wire feed rate and voltage by ad-
justing the WIRE FEED SPEED and VOLTS
control knobs on the front panel.
2. Optional BURNBACK control: sets to the
desired setting (0-0.6 seconds), depend-
ing on the amount of burnback desired.
The higher the setting, the greater the
amount of time that the contactor is held in
to allow the wire to burn back out of the
puddle, after releasing the torch switch.
If spot welding is to be performed, set rear-
panel switch to "SPOT" position, set spot-
welding potentiometer for time period
(range: 0 to 5 seconds).
C. Feeding Wire. Thread wire through torch and
contact tip as directed in Section 4, cut off wire,
so that the wire extends about 1/2-inch beyond
the end of the torch nozzle.
D. Shielding Gas Flow Rate. Operate PURGE
switch and set desired gas flow rate at the
shielding gas regulator-flowmeter. Activate
switch for at least 15 seconds to insure ad-
equate purging of gas hose and torch.
Optional Spot/Burnback/Pre-Postlfow/Trigger
Lock Module: set pre and postflow potentiom-
eters for the desired preflow interval (range: 0 -
1.5 seconds) and postflow interval (range: 0 to
7.5 seconds).
E. Making the Weld. Start to weld by pressing the
gun switch lever to actuate the torch switch.
This closes the welding contactor, and starts
wire feed and gas flow. The trigger must be
depressed for the duration of the weld. Welding
action will be stopped and all services discontin-
ued when the lever is released and returned to
its original position. If the gun is withdrawn from
the workpiece during welding, the arc will be
interrupted, but shielding gas flow and welding
wire feed will continue until the trigger lever is
released.
Do not allow metal-to-metal contact between the
wire feeder chassis and a metal surface con-
nected in any way to a welding ground.
5.2 Operating Sequence.
A. Normal.
1. Close Gun switch.
-- Gas solenoid opens, weld contactor
closes, wire feed motor runs.
2. Release Gun switch.
-- Wire feed motor deenergized, brake
circuit effective.
-- Burnback circuit energized.
3. Burnback circuit times out (delay deter-
mined by setting of Burnback potentio-
meter).
-- Weld contactor opens.
-- Gas solenoid valve closes.
B. Spot Weld.
1. Close Gun switch.
-- Gas solenoid, weld contactor, wire feed
motor energized.
-- Spotweld timing circuit energized.
SECTION 5
OPERATION
13
2. Spotweld circuit times out (interval estab-
lished by setting of spotweld potentiom-
eter).
-- Wire feed motor deenergized, brake
circuit effective.
-- Burnback circuit energized.
3. Burnback circuit times out (interval estab-
lished by setting of burnback potentiom-
eter).
-- Weld contactor opens.
4. Release torch switch.
-- Gas solenoid valve closes.
C. Pre-flow/Post-Flow Options. Contactor and wire
feed motor are energized only after interval
established by setting of preflow potentiometer.
When torch switch is opened, gas solenoid
valve remains energized until interval estab-
lished by setting of postflow potentiometer has
elapsed.
SECTION 6
SERVICE
If it should become necessary to replace the 5
amp wire feeder circuit breaker or any other
circuit breaker/fuse in the welding machine, en-
sure that the proper size is used as a replace-
ment.
The 42-volt circuit is protected by a 5 amp circuit
breaker located at the rear of the wire feeder.
Failure of this circuit breaker will shut off the
contactor, shielding gas, and wire feeder. The
circuit breaker must cool before it can be reset.
If the breaker trips, wait before resetting.
B. Wire Feeder. As soft wire is fed, the drive rolls
may pick up metal from the wire surface. Accu-
mulation on the rolls may score the wire with
resulting unwanted friction and improper feed-
ing.
Inspect the rolls regularly and clean them with a
fine-wire power brush. Avoid roughening, or
removing the hardness of groove surfaces in
grooved rolls. Any roughening may score the
wire, just as the accumulation being removed
may do.
6.1 Maintenance.
If this equipment does not operate properly, stop
work immediately and investigate the cause of
the malfunction. Maintenance work must be per-
formed by an experienced person, and electrical
work by a trained electrician. Do not permit un-
trained persons to inspect, clean, or repair this
equipment. Use only recommended replacement
parts.
Little maintenance is required to keep the wire feeder
in top operating condition. It is important, however,
that moving parts such as feed and pressure rolls,
wire feed motor, etc., be kept clean and free of dust
or dirt. Cleaning is best accomplished by regularly
blowing off these parts with dry compressed air. This
should be done once for every eight hours of operat-
ing time, more often if necessary.
A. 42 Volt Wire Feeder and Control Circuits.
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SECTION 7
REPLACEMENT PARTS
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17
SECTION 7
REPLACEMENT PARTS
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SECTION 7
REPLACEMENT PARTS
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20
SECTION 7
REPLACEMENT PARTS
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SECTION 7
REPLACEMENT PARTS
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22
SECTION 7
REPLACEMENT PARTS
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23
SECTION 7
REPLACEMENT PARTS
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24
SECTION 7
REPLACEMENT PARTS
View 12 of 37544 Bill of Materials
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26
SECTION 7
REPLACEMENT PARTS
62 2062161 1 CIRCUIT BREAKER 5A
63 92040101 2 SCR RND HD .375-16 X .75
65 99512203 4 SPACER .26 ID X .5 OD X .13 L PLST
66 04S04010 4 SCR RND HD M04-.70 X 10
67 04W01044 4 WASHER FLAT M4
68 04W10041 4 WASHER LOCK M4
70 32300GY 1 PANEL FRONT
71 34141GY 1 PANEL COVER FRONT
72 37638GY 1 BASE
73 37639YL 1 DOOR ASSY LEFT
74 37640YL 1 DOOR ASSY RIGHT
75 37641GY 1 PANEL REAR
76 37642GY 1 PANEL CENTER
77 37644GY 1 PAN LOWER
78 37795YL 1 TOP COVER
79 37796GY 2 PANEL BLANKING
80 37797GY 1 REEL STAND
81 96W85 1 STRAIN RELIEF
ITEM PART OR
NO. CODE NO. QTY. DESCRIPTION
37544 - Bill of Materials
4HD Dual Wire Feeder (Cont'd)
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