Miller SWINGARC SS-12 AND 16 Le manuel du propriétaire

Miller

October

1995

Form:

OM-1583J

Effective

With

Serial

No.

KF91

4926

OWNERS



Read

and

follow

these

instructions

safety

blocks

carefully.

Have

only

trained

and

qualified

inetall,

operate,

or

service

this

unit.

and

all

persons

~j,A



Give

this

manual

to

the

operator.



For

help,

call

your

distributor



Call

your

distributor

if

you

do

not

understand

I~I

U

or:

MILLER

Electric

Mtg.

Co.,

P.O.

Box

1079,

the

directions.

Appleton,

WI

54912

414-734-9821

MANUAL

c~..

~

~~~)

~

J

~

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

1pm

(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

60

Above

Horizontal



For

Options

And

Accessories,

See

Rear

Cover

cover

5194



ST-142 705-B

'

1995

MILLER

Electric

Mtg.

Co.

PRINTED

IN

USA

(a

MILLERS

TRUE

BLUETM

LIMITED

WARRANTY

Effective

January

1,1995

(Equipment

with

a

serial

number

preface

of

KD

or

newer)

This

limited

werranty

supersedes

all

warranties

and

is

exclusive

with

no

other

guarantees

or

warranties

expressed

or

implied.

1,

LIMITED

WARRANTY



Subject

to

the

terms

and

conditions

below,

MILLER

Electric

Mfg.

Co.,

Appleton.

Wisconsin.

warrants

to

its

original

retail

purchaser

that

new

MILLER

equipment

sold

after

the

effective

date

of

this

limited

warranty

is

tree

of

de

fects

in

material

and

workmanship

at

the

time

it

is

shipped

by

MILLER.

THIS

WAR

RANTY

IS

EXPRESSLY

tN

LIEU

OF

ALL

OTHER

WARRANTIES.

EXPRESS

OR

IMPLIED.

INCLUDING

THE

WARRANTIES

OF

MERCHANTABILITY

AND

FtT

NESS.

Within

the

warranty

periods

listed

below,

MILLER

will

repair

or

replace

any

war

ranted

parts

or

components

that

fait

due

to

such

defects

in

material

or

workmanship.

MILLER

must

be

notified

in

writing

within

thirty

(30)

days

of

such

defect

or

Iailure,

at

which

time

MILLER

will

provide

instructions

on

the

warranty

claim

procedures

to

be

followed.

MILLER

shall

honor

warranty

claims

on

warranted

equipment

listed

below

in

the

avant

of

such

a

lailure

within

the

warranty

time

periods.

All

warranty

lime

periods

stan

on

the

date

that

the

equipment

was

delivered

to

the

original

retail

purchaser,

or

one

year

after

the

equipment

is

sent

to

a

North

American

distributor

or

eighteen

months

after

the

equipment

is

sent

10

an

tnlamalional

distributor.

5

Years

Parts

3

Years

Labor



Original

main

power

rectifiers



tnvarters

(input

and

output

rectifiers

only)

2.

3 Years



Pans

and

Labor



Transformer/Rectifier

Power

Sources



Plasma

Arc

Cutting

Power

Sources

-

Semi-Automatic

and

Automatic

Wire

Feeders

-

Invanar

Power

Supplies



tnlallitigs



Robots

3.

2

Years



Pans

and

Labor



Engine

Driven

Welding

Generators

(NOTE:

Engines

are

warranted

separately

by

the

engine

manufacturer.)



Air

Compressors

4.

1

Yaar



Pans

and

Labor



Motor

Driven

Guns



Process

Controllers



IHPS

Power

Sources



Wafer

Coolant

Systems



HF

Units

-

Grids



Spot

Welders



Load

Banks



SDX

Transformers



Running

Gear/Trailers

-

Plasma

Cutting

Torches

(except

APT,

ZIPCUT

&

PLAZCUT

Models)

*

Tecomxeh

Enginas



Dautz

Engines

(outside

North

Amarica)

-

Field

Options

(NOTE:

Field

options

are

covered

under

True

Blua~~

br

the

remaining

warranty

period

of

the

product

Ihey

are

installad

in,

or

for

a

minimum

of

one

year



whichever

ix

greater.)

5.

6

Months



Batteries

6.

90

Days



Pans

and

Labor



MIG

Guns/FIG

Torches



APT,

ZIPCUT

&

PLAZCUT

Modal

Plasma

Cutting

Torches



Remote

Cont

rots

*

Accessory

Kits



Raplacamanf

Pans

MILLERS

True

BIuaTM

Limited

Warranty

shalt

not

apply

to:

1.

Items

furnished

by

MILLER,

but

manufactured

by

others,

such

as

engines

or

trade

accaasoriax.

Thaxa

items

are

covered

by

the

manufacturers

warranty,

if

any.

2.

Consumable

components;

such

as

contact

tips,

cutting

nozzlas,

contaclors

and

relays

or

pans

Ihal

tail

due

to

normal

wear.

3.

Equipmanl

that

has

been

modified

by

any

party

other

than

MILLER,

or

equip

ment

thaI

has

been

improperly

installed,

improperly

oparstad

or

misused

based

upon

industry

standards,

or

equipment

which

has

not

had

reasonable

and

necessary

maintenance,

or

equipment

which

has

bean

used

br

operation

outside

of

tha

specifications

for

tha

aquipmant.

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

EOUIPMENL

In

tha

avant

of

a

warranty

claim

covered

by

this

warranty,

bra

exclusive

remedies

shall

be,

at

MILLERS

option:

(1)

rapair;

or

(2)

raplacament;

or.

where

authorized

in

writing

by

MILLER

in

appropriate

caxas,

(3)

the

reasonable

coal

of

repair

or

replace

ment

alan

authorizad

MILLER

sarvica

stafion;

or

(4)

payment

of

or

cradit

for

the

pur

chase

price

(lass

reasonable

dapracialion

baxad

upon

actual

usa)

upon

ralum

of

the

goods

xl

cuxtomars

risk

and

expanse.

MILLERS

option

of

repair

or

replacement

will

be

FOB.,

Factory

at

Appleton,

Wisconsin,

or

FOB.

at

a

MILLER

authorized

ser

vice

facility

as

daterminad

by

MILLER.

Theralora

no

compensation

or

reimburse

ment

br

Iranaponaf

ion

costs

of

any

kind

will

be

allowed.

TO

THE

EXTENT

PERMITTED

BY

LAW,

THE REMEDIES

PROVIDED

HEREIN

ARE

THE

SOLE

AND

EXCLUSIVE

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

OTHER

LEGAL

THEORY

WHICH,

BUT

FOR

THIS

PROVISION,

MIGHT

ARISE

BY

IMPUCATION,

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

states

in

the

U.S.A.

do

not

allow

limitations

of

how

long

an

impliad

warranty

lasts,

or

the

exclusion

of

incidental,

indirect,

special

or

consaquantixl

damages,

so

the

above

limitation

or

exclusion

may

not

apply

lo

you.

This

warranty

provides

spe

cific

legal

rights,

and

olhar

rights

may

ba

availabla,

but

may

vary

Irom

state

to

state.

In

Canada,

legislation

in

xoma

provinces

provides

for

certain

addilional

warranties

or

ramadiax

orhar

than

ax

xtalad

herein,

and

to

the

extant

that

they

may

not

be

waived,

the

limitations

and

exclusions

sat

out

above

may

not

apply.

This

Limited

Warranty

provides

specific

legal

rights,

and

other

rights

may

be

availabfa,

but

may

from

provinca

to

province.

.}

WI,

i-u

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

Seria)

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

6/95

ERRATA

SHEET

January

17,

1996

FORM:

OM-1583J

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.

CHAN

GES

TO

SECTION

7-

PARTS

LIST

Change

Parts

List

as

follows:

**

Dia.

Part

Mkgs.

No.

Replaced

With

Description

Quantity

34-28

...

LED71

174

755

...

179

203

..

LED,

5100

2.OV

2OmA

green

(Eff

w/KG044454)

1

39-28

149

746

...

179

265

..

ADAPTER,

gun/feeder

LH

(Eff

w/KG044454)

1

39-33

149

527

...

179

263

..

COVER,

drive

roll

(Effw/KG044454)

1

39-37

149

964

...

Deleted

..

Eff

w/KG044454

**First

digit

represents

page

no



digits

following

dash

represent

item

no.

BE

SURE

TO

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

1.

;

~

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

touchin9

the

weldin9

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

big

enough

to

prevent

any

physical

contact

with

the

work

or

ground.

4.

Disconnect

input

power

or

stop

engine

before

installing

or

servicing

this

equipment.

Lockout/tagout

input

power

according

to

OSHA

29

CFR

1910.147

(see

Safety

Standards).

5.

Properly

install

and

ground

this

equipment

according

to

its

Owners

Manual

and

national,

state,

and

local

codes.

6.

Always

verify

the

supply

ground



check

and

be

sure

that

input

power

cord

ground

wire

Is

properly

connected

to

around

terminal

in

disconnect

box

or

that

cord

plug

is

connected

to

a

properly

grounded

receptacle

outlet.

7.

When

making

Input

connections,

attach

proper

grounding

conductor

first



double-check

connections.

8.

Frequently

inspect

input

power

cord

for

damage

or

bare

wiring



replace

cord

Immediately

If

damaged



bare

wiring

can

kill.

9.

Turn

off

all

equipment

when

not

In

use.

10.

Do

not

use

worn,

damaged,

undersized,

or

poorly

spliced

cables.

11.

Do

not

drape

cables

over

your

body.

12.

If

earth

grounding

of

the

workpiece

is

required,

ground

It

directly

with

a

separate

cable



do

not

use

work

clamp

or

work

cable.

13.

Do

not

touch

electrode

if

you

are

in

contact

with

the

work,

ground,

or

another

electrode

from

a

different

machine.

14.

Use

only

well-maintained

equipment.

Repair

or

replace

damaged

parts

at

once.

Maintain

unit

according

to

manual.

15.

Wear

a

safety

harness

if

working

above

floor

level.

16.

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.

Inwelding,

as

in

most

jobs,

exposure

to

certain

hazards

occurs.

Welding

is

safe

when

precautions

are

taken.

The

safety

information

9iven

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.

2.

3.

17.

Clamp

work

cable

with

good

metal-to-metal

contact

to

workpiece

or

wnrkt~hI~

as

near

the

weld

~

nr~gtlnnl

ARC

RAYS

can

burn

eyes

and

skin;

ARC

RAYS

t4~

.~

NOISE

can

damaae

hearIng;

FLYING

SLAG

OR

SPARKS

can

Injure

eyes.

Arc

rays

from

the

welding

process

produce

Intense

visible

and

invisible

(ultraviolet

and

infrared)

rays

that

can

burn

eyes

and

skin.

Noise

from

some

processes

can

damage

hearing.

Chipping,

grinding,

and

welds

cooling

throw

off

pieces

of

metal

or

slag.

2.

3.

4.

Wear

a

welding

helmet

fitted

with

a

proper

shade

of

filter

to

protectyourface

and

eyes

when

welding

orwatchlng

(see

ANSI

Z49.1

and

Z87.1

listed

In

Safety

Standards).

Wear

approved

safety

glasses

with

side

shields.

Use

protective

screens

or

barriers

to

protect

others

from

flash

and

glare;

warn

others

not

to

watch

the

arc.

NOISE

5.

Wear

protective

clothing

made

from

durable,

flame-resistant

1.

Use

appr

oved

ear

plugs

or

earmuffs

If

noise

level

is

high.

material

(wool

and

leather)

and

foot

protection.

FUMES

AND

GASES

can

be

hazardous



to

your

health.

fumes and

gases

can

be

hazardous

to

your

health.

Welding

produces

fumes

and

gases.

Breathing

these

£~

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.

5.

6.

7~

Work

In

a

confined

space

only

if

It

Is

well

ventilated,

or

while

wearing

an

air-supplied

respirator.

Always

have

a

trained

and

lower

the

oxygen

level

causing

injury

or

death.

Be

sure

the

watchperson

nearby.

Welding

fumes

and

gases

can

displace

air

breathing

air

is

safe.

Do

not

weld

in

locations

near

degreaslng,

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

3.

If

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

cleaners,

and

degreasers.

containing

these

elements

can

give

off

toxic

fumes

if

welded.

CYLINDERS

can

explode

If

damaged.

4.

Never

drape

a

welding

torch

over

a

gas

cylinder.

Shielding

aas

cylinders

contain

gas

under

high

pressure.

Irdamaged,

a

cylinder

can

explode.

Since

gas

cylinders

are

normally

part

of

the

welding

process,

be

sure

to

treat

them

carefully,

5.

6.

7.

Never

allow

a

welding

electrode

to

touch

any

cylinder.

Never

weld

on a

pressurized

cylinder



explosion

will

result.

Use

only

correct

shielding

gas

cylinders,

regulators,

hoses,

and

fittings

designed

for

the

specific

application;

maintain

them

and

associated

parts

in

good

condition.

1.

Protect

compressed

gas

cylinders

from

excessive

heat,

8.

Turn

face

away

from

valve

outlet

when

opening

cylinder

valve.

mechanical

shocks,

slag,

open

flames,

sparks,

and

arcs.

9.

Keep

protective

cap

in

place

over

valve

except

when

cylinder

is

2.

Install

cylinders

in

an

upright

position

by

securing

to

a

stationary

In

use

or

connected

for

use.

support

or

cylinder

rack

to

prevent

falling

or

tipping.

10.

Read

and

follow

Instructions

on

compressed

gas

cylinders,

3.

Keep

cylinders

away

from

any

welding

or

other

electrical

associated

equipment,

and

CGA

publication

P-i

listed

In

Safety

circuits.

Standards.

srl.1.I

204

WELDING

can

cause

fire

or

explosion.

Welding

on

closed

containers,

such

as

tanks,

drums,

or

pipes,

can

cause

them

to

blow

up.

Sparks

can

fly

off

from

the

welding

arc.

The

flying

sparks,

hot

workpiece,

and

hot

equipment

can

cause

fires

and

burns.

Accidental

contact

of

electrode

to

metal

objects

can

cause

sparks,

explosion,

overheating,

or

fire.

Check

and

be

sure

the

area

is

safe

before

doing

any

welding.

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.

5.

Watch

for

fire,

and

keep

a

fire

extinguisher

nearby.

6.

Be

aware

that

welding

on

a

ceiling,

floor,

bulkhead,

or

partition

can

cause

fire

on

the

hidden

side.

7.

Do

not

weld

on

closed

containers

such

as

tanks,

drums,

or

pipes,

unless

they

are

properly

prepared

according

toAWS

F4.1

(see

Safety

Standards).

8.

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

tire

hazards.

9.

Do

not

use

welder

to

thaw

frozen

pipes.

10.

Remove

stick

electrode

from

holder

or

cut

off

welding

wire

at

contact

tip

when

not

in

use.

11.

Wear

oil-free

protective

garments

such

as

leather

gloves,

heavy

shirt,

cuffless

trousers,

high

shoes,

and

a

cap.

12.

Remove

any

combustibles,

such

as

a

butane

lighteror

matches,

from

your

person

before

doing

any

weding.

1.

Stop

engine

and

~et

it

coot

oft

before

checking

or

adding

fuel.

2.

Do

not

add

fuel

while

smoking

or

if

unit

is

near

any

sparks

or

ooen

flames.

1.

Always

wear

a

face

shield

when

working

on

a

battery.

2.

Stop

engine

before

disconnecting

or

connecting

battery

cables.

3.

Do

not

allow

tools

to

cause

sparks

when

working

on

a

battery.

4.

Do

not

use

welder

to

charge

batteries

or

jump

start

vehicles.

5.

Observe

correct

polarity

(+

and

)

on

batteries.

1.

It

the

engine

is

warm

and

checking

is

needed,

follow

steps

2

and

3.

2.

Wear

safety

glasses

and

gloves

and

put

a

rag

over

cap.

3.

Tum

cap

slightly

and

let

pressure

escape

slowly

before

completely

removing

cap.

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

Sate

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.

Le.Jeune

Rd.

Miami,

FL

33126

National

Electrical

Code,

NFPA

Standard

70,

from

National

Fire

Pro

tection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

811.1.1

2/94

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

ForOccupafionAnd

Educational

Eye

And

Face

Protec

tion,

ANSI

Standard

Z87.1,

from

American

National

Standards

Institute,

1430

Broadway,

New

York,

NY

10018.

Cutting

And

Welding

Processes,

NFPA

Standard

SiB,

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.

ENGINES

can

be

hazardous.

Engines

produce

harmful

exhaust

gases.

2.

If

used

in

a

closed

area,

vent

engine

exhaust

outside

and

away

from

any

building

air

intakes.

ENGINE

FUEL

can

cause

fire

or

explosion.

I

Engine

fuel

is

highly

flammable.

3.

Do

not

overfill

tank



allow

room

for

fuel

to

expand.

4.

Do

not

spill

fuel.

If

fuel

is

spilled,

clean

up

before

starting

engine.

~

MOVING

PARTS

can

cause

injury.

~

Moving

parts,

such

as

tans,

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.

3.

4.

5.

6.

Have

only

qualified

people

remove

guards

or

covers

for

To

prevent

accidental

starting

during

servicing,

disconnect

maintenance

and

troubleshooting

as

necessary.

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

engine

before

installing

or

connecting

unit.

finished

and

before

starting

engine.

SPARKS

can

cause

BATTERY

GASES

TO

EXPLODE;

BATTERY

ACID

can

burn

eyes

and

skin.

Batteries

contain

acid

and

generate

explosive

gases.

STEAM

AND

PRESSURIZED

HOT

COOLANT

can

burn

face,

eyes,

and

skin.

It

is

best

to

check

coolant

level

when

engine

is

cold

to

avoid

scalding.

CONSIGNES

DE

SECURITE

POUR

LE

SOUDAGE

A

LARC

UN

CHOC

ELECTRIQuE

peut

tuer.

Un

simple

contact

avec

des

piŁces

Olectnques

peut

provoquer

une

electrocution

ou

des

blessures

graves.

LOlectrode

et

Ia

circuit

de

soudage

sont

sous

tension

des

que

lappareil

est

surON.

Le

circuit

dentrŁe

at

les

circuits

intemes

de

lappareil

sont

egalement

sous

tension

a

ce

moment-l.

En

soudage

semi-automatique

ou

automatique,

le

Id,

le

dØvidoir,

le

logement

des

galets

dentrafnement

at

las

piŁces

mOtalliques

en

contact

avec

Ia

Iii

de

soudage

sont

sous

tension.

Des

matØflels

mal

installŁs

ou

mal

mis

a

Ia

terre

prØsentent

un

danger.

1.

Ne

jamais

toucher

les

piŁces

Ølectriques

sous

tension.

2.

Porter

des

gants

at

des

vOtements

de

protection

secs

ne

comportant

pas

de

trous.

3.

Sisoler

de

Ia

piŁce

at

de

Ia

terre

au

moyen

de

tapis

ou

dautres

moyens

isolants

suffisamment

grands

pour

empŁcher

le

contact

physique

Øventuel

avec

Ia

piŁce

ou

Ia

terre.

4.

Coupar

lalimentation

ou

arrOter

le

moteur

avant

de

procØder

a

linstallation,

a

Ia

reparation

ou

a

Ientratien

de

lapparail.

DOverrouillerlalimentation

selon

Ia

norme

OSHA

29

CFA

1910.147

(voir

normes

de

sOcurite).

5.

Installer

et

maitre

a

Ia

terre

correctement

cel

appareil

conformØment

a

son

manuel

dutilisation

at

au

codes

nalionaux,

provinciaux

et

municipaux.

6.

Toujours

verifier

Ia

terre

du

cordon

dalimentation



Verifier

et

sassurer

qua

Ia

it)

de

terra

du

cordon

dalimentalion

esl

bien

raccordØ

ala

borne

de

terre

du

sectionneur

ou

qua

Ia

fiche

du

cordon

est

raccordØe

a

une

pnse

correctement

mise

~

Ia

terre.

7.

En

oft

ectuanl

las

raccordements

dentrØe

fixer

dabord

Ia

conducteur

de

mise

a

Ia

terre

appropne

at

contre-vØnfier

les

connexions.

8.

Verifier

frØquemment

le

cordon

dalirnentation

pour

voir

sil

nest

pas

endommagØ

ou

dØnudØ



remplacer

Ia

cordon

immØdiatement

sil

est

endommage



un

cable

dØnudØ

paul

provoquer

une

electrocution.

9.

Maitre

lappareil

hors

tension

quand

on ne

lutilise

pas.

10.

Ne

pas

Utiliser

des

cables

uses.

endommages,

de

grosseur

insuttisante

ou

mal

episses.

11.

Ne

pas

enrouler

las

cables

autour

du

corps.

12.

Si

Ia

piŁce

soudØe

dolt

Łtre

mise

ala

terre,

le

faire

directement

avec

tin

cable

distipct



ne

pas

utiliser

Ia

connecteur

de

piŁce

ou

le

cable

de

retour.

13.

Ne

pas

toucher

electrode

quand

on

asIan

contact

avec

Ia

piŁce,

Ia

terre

ou

une

electrode

provenant

dune

autre

machine.

14.

Nutiliser

quun

matØnel

en

bon

Øtat.

ROparer

ou

remplacer

sur-le-champ

les

piŁces

endommagees.

Entretenir

lappareil

contormØment

a

ce

manuel.

15.

Porter

un

hamais

de

sOcufltO

quand

on

travaille

en

hauteur.

16.

Maintenir

solidement

en

place

tous

las

panneaux

at

capots.

17.

Fixer

le

cable

de

retour

de

tacon

~

obtenir

un

bon

contact

mØtal-mŁtal

avec

Ia

piŁce

a

souderou

Ia

table

de

travail,

le

plus

prŁs

possible

de

Ia

soudure.

a

MISE

EN

GARDE

LE

SOUDAGE

A

LARC

peut

Œtre

dangereux.

SE

PROTEGER

El

PROTEGER

LES

AUTRES

COPITRE

LES

BLESSURES

GRAVES

VOIRE

MORTELLES.

TENIR

LES

ENFANTS

A

LECART.

L.ES

PERSONNES

QUI

PQRTENT

UN

STIMULATEUR

CARDIAQUE

NE

DOIVENT

PAS

NON

PLUS

SAPPROCHER

DU

POSTE

DE

SOUDAGE,

A

MOINS

DAVOIR

CONSULTE

UN

MEDECIN.

La

soudage,

comma

Ia

plupail

des

travaux,

prØsente

certains

dangers.

Par

contre.

Ia

soudage

peut

Otre

effectuØ

en

toute

sOcuntØ

quand

on

prend

les

mesures

qui

simposent.

Les

consignes

de

sŁcuritØ

donnØes

ci-aprŁs

ne

font

que

rØsumer

linformation

contenue

dans

las

normes

de

sØcuntO

OnumØres

a

Ia

page

suivante.

Lire

et

respecter

toutes

ces

normes

de

sØcufltØ.

DN

LLJTILISATiON,

LENTRETIEN

El

LES

R~PARATIONS

NE

DOl

VENT

ETRE

CONFIES

ouA

DES

PERSONNES

OUALIFIEES

LE

RAVONNEMENT

DE

LARC

peut

brOler

les

RAVONNEMENT

DE

LARC

yeux

et

Pa

peau.

Le

BRUIT

peut

endommager

~

IouIe;

les

PROJECTIONS

DE

LAITIER

OU

LES

ETINCELLES

peuvent

blesser

les

yeux.

2.

Porter

un

masque

a

serra-tOle

muni

dun

verre

filtrant

de

nuance

appropflØa

pour

protOger

le

visage

et

las

yeux

quand

on

souda

ou

Lam

de

soudage

produit

des

rayons

visibles

at

invisibles

observe

(a

travail

de

soudaga

(voir

les

normes

ANSI

Z49.

1

at

Z87.

1

intenses

(ultraviolets

at

intrarouges)

qui

peuvent

brOler

donnØes

sous

Ia

rubnque

Principalos

normes

de

sØcufllØ).



les

yeux

at

Ia

peau.

La

bruit

produit

par

certains

procŁdOs

pout

endommager

louie.

Des

projections

de

metal

ou

de

3.

Porter

des

lunettes

de

sØcuritØ

approuvØes

avec

Øcrans

IatØraux.

laitier

sont

produites

par

le

piquage

Ia

meulage

ou

Ia

refroidissement

des

soudures.

4.

Utiliser

des

paravents

ou

des

barnŁres

de

protection

pour

prolØger

les

parsonnes

a

proximitØ

contre

les

coups

darc

et

lblouissemenl;

BRUiT

avertar

les

autres

personnes

de

ne

pas

regarder

lam.

1.

Utiliser

des

bouche-oreillas

ou

des

serre-tOte

antibruit

approuvØs

si

5.

Porter

des

vØtaments

de

protection

en

tissu

ignifuge

durable

(lame

et

le

niveau

de

bruit

as)

ØlevØ.

cuir)

at

des

chaussures

de

sØcuntØ.

dangereuses

pour

Ia

sante.

portant

un

apparail

respiratoire

a

adduction

dair

pur.

Demander

a

un

observateur

ayant

recu

Ia

bonne

formation

do

toujours

se

tenir

a

~

~I

LES

VAPEURS

El

LES

FUMEES

peuvent

Œtre

5.

Ne

travailler

dans

un

aspace

confine

qua

siI

as)

bien

ventilØ,

ou

en

Le

soudage

produit

des

vapeurs

el

des

fumØes

quil

est

proximitØ.

Las

vapeurs

at

fumØos

de

soudage

peuvent

dØplacer

lair

dangereux

de

respirar.

at

abaisser

le

niveau

doxygŁne

at

causer

des

blessuras

graves

voire

mortelles.

Sassurer

qua

lair

est

propre

Ł

Ia

respiration.

1.

Garder

Ia

tŒte

a

lextØneur

des

vapeurs

et

des

fumØes

at

ne

pas

las

6.

Ne

pas

souder

a

proximitØ

dopŁrations

do

dOgraissage.

de

respirer.

nettoyage

ou

de

pulvØrisation.

La

chaleur

et

les

rayons

do

larc

peuvent

rØagir

avec

les

vapeurs

pour

former

des

gaz

hautement

2.

A

IintOnaur

ventiler

le

poste

de

travail

ou

utilisar

tin

dispositit

place

toxiques

at

irritants.

au

niveati

do

(arc

pour

Ovacuer

las

vapeurs

et

fumØes

de

soudage.

7.

Ne

pas

souder

sur

des

mOtaux

revØtus

comme

lacier

galvanisO,

au

3.

Si

Ia

ventilation

est

mauvaise

utiliser

un

appareil

respiratoire

a

plombou

cadmiØ

a

moms

qua

(a

piŁce

nail

ØtØ

entiŁrement

dØcapØe,

adduction

dair

pur

approuve.

qua

Ia

paste

do

travail

soil

bien

ventilØ.

Sil

y

a

lieu,

porter

un

appareil

4.

Consulter

los

fiches

signalØtiques

of

les

consignes

du

fabncant

respiratoire

a

adduction

dair

pur.

Los

revOlements

et

los

mØtaux

qui

relatives

au

mØtaux,

produits

dapport.

revOtoments.

nettoyants

at

contiennentde

telsØlØments

peuventdØgagerdes

vapeurs

toxiques

dOgraissants.

lors

du

soudage.

LES

BOUTEILLES

peuvent

exploser

si

elles

4.

Ne

jamais

poser

un

chalumeau

soudeur

sur

une

bouteille

do

gaz.

Les

bouteilles

contenant

des

gaz

de

protection

sont

a

6.

Ne

jamais

souder

stir

tine

bouteille

sous

pression

:

elle

expioseralt.

sont

endommagØes.

5.

Ne

jamais

laisser

tine

electrode

do

soudage

toucher

une

bouteille.

~.

haute

pression.

Une

bouteitle

endommageo

pout

7.

Nutiliser

quo

des

bouteilles

do

gaz

do

protection,

des

dØtendeurs,

exploser.

Etant

donnØ

qua

les

bouteilles

de

gaz

font

dos

tuyaux

souples

et

des

raccords

appropriØs

conus

pour

normalement

partie

du

materiel

do

soudage,

les

trailer

Iapplication

particuliŁra;

conserver

ces

materials

et

leurs

piŁces

en

avec

le

plus

grand

soin.

bon

Otat.

1.

ProtOger

las

bouteilles

do

gaz

compnme

contre

Ia

chaleur

intense,

8.

Eloignor

le

visage

de

Ia

Sortie

du

robinet

de

Ia

bouteille

quand

on

los

chocs,

le

laitier,

les

flammes

nues

las

Øtincelles

et

larc.

louvre.

2

Placer

las

bouteillos

a

Ia

verticale

en

los

fixant

a

tin

support

fixo

ou

a

9.

Replacer

le

chapeau

stir

Ia

bouteille

apres

utilisation.

tin

chariot

pour

Øviter

quelles

ne

tombont

ou

na

basculent.

10.

Lire

et

suivre

las

consignes

relatives

aux

bouteilles

do

gaz

compnmO,

3.

Tenir

los

bouteities

a

IØcart

du

paste

do

soudage

oti

dautres

circuits

au

matØrial

connexe

ainsi

quo

Ia

publication

P-i

de

Ia

CGA

donnØe

electnques.

sous

Ia

rtibnqtie

Principales

normes

de

sOcuritØ.

srl.1.1

2/94

LE

SOUDAGE

peut

causer

un

incendle

ou

une

explosion.

Ne

pas

souder

sur

des

recipients

fermØs

comme

des

reservoirs,

des

fOts

ou

des

tuyaux

its

peuvent

oxplosor.

Lam

do

soudage

pout

produire

des

Øtincelles.

Des

Øtincelles.

une

piŁce

chaude

et

un

materiel

chaud

peuvent

provoquer

des

incendios

et

des

blessures.

Le

contact

accidentel

de

lØlectrode

sur

des

objets

mOtalliques

pout

produire

des

Øtincelles

lexplosion,

Ia

surchaufto

ou

un

incendie.

Sassurer

quo

le

lieu

ne

prØsente

pas

de

danger

avant

deffectuer

le

soudage.

1.

Se

proteger

et

protØger

los

personnes

a

proximitO

desØtincellesetdu

metal

chaud.

2.

Ne

pas

souder

dans

un

endroit

o

les

Øtincelles

peuvent

atteindre

des

matØnaux

initammables.

3.

Enlevertoutes

les

matiŁres

inflammables

dans

un

rayon

de

moms

de

10

m

do

lam.

Si

cola

nest

pas

possible.

bien

les

recouvnren

uhlisant

des

bAches

approuvŁes.

4.

Prendre

garde

quo

los

Otincelles

et

los

projections

no

penetrent

dans

des

zones

adjacenles

en

sinfiltrant

dans

dos

petites

fissures

et

ouvertures.

5.

Prendre

garde

aux

incondies

ot

toujours

avoir

un

oxtincteur

a

proximitO.

6.

Se

rappeler

quo

si

lon

soude

sur

un

plafond.

un

plancher,

une

cloison

ou

autre,

le

teu

pout

prondre

do

lautre

cØtØ.

7.

Ne

pas

soudor

sur

des

recipients

termØs

camme

des

reservoirs,

des

lOts

ou

des

tuyaux

a

moms

quils

no

soient

prØparØs

do

taon

approprlee

conforrnØmont

ala

norme

F4.1

de

IAWS

(voir

Ia

rubflquo

Pnncipales

normes

do

sØcuritO).

8.

Raccorder

le

cable

do

rotour

a

Ia

piŁce.

le

plus

prØs

possible

de

Ia

zone

do

soudage,

pour

empecher

quo

Ia

courant

do

soudago

no

suive

une

trajectoire

tongue

ot

Øventuellement

inconnue

et

quil

no

provoque

des

risques

dØlectrocution

et

dincendie.

9.

No

pas

utiliser

le

chalumeau

soudeur

pour

degeler

des

tuyaux.

10.

Enlever

lØtectrode

enrobØe

du

porte.Ølectrode

ou

couper

Ia

SI

do

soudage

au

ras

du

bec

contact

quand

on

ne

lutilise

pas.

11.

Porter

des

vOtements

do

protection

non

huileux

comme

des

gants

en

cuir,

une

chemise

epaisse,

des

pantalons

sans

revers,

des

chaussures

montantes

et

un

casque.

12.

Ne

pas

porter

des

matiŁres

combustibles

sur

soi

comme

un

bnquet

a

aaz

ou

des

allumettes

quand

on

soude.

ji

~

LE

CARBURANT

peut

provoquer

un

Incendie

r

~

ou

une

explosion.

La

carburant

est

hautement

inflammable.

1.

ArrØter

to

moteur

et

le

laisser

ref roidir

avant

de

verifier

le

niveau

do

carburant

ou

de

refaire

le

plein.

LES

PIECES

EN

MOUVEMENT

peuvent

causer

des

blessures.

Los

piŁces

en

mouvement

comme

las

ventilateurs,

los

rotors

at

los

courroies

peuvent

couper

los

doigts

et

los

mains

et

happer

los

vØtemants

amples.

1.

Sassurer

quo

los

portes,

los

panneaux,

los

capots

et

les

protecteurs

sont

bien

fermØs

et

bien

a

lour

place.

2.

ArrŁtor

10

moleur

avant

do

mettro

en

place

ou

do

raccorder

un

LES

ETINCELLES

peuvent

faire

EXPLOSER

LE

GAZ

DES

BATrERIES;

LELECTROLYTE

peut

brUler

Ia

peau

et

Ies

yeux.

Los

batteries

contiennent

un

produit

acide

et

dogagent

dos

vapeurs

explosives.

~ofler

un

Øcran

facial

quand

on

travaillo

sur

une

battefle.

LES

MOTEURS

peuvent

presenter

un

danger.

2.

Ne

pas

turner

en

faisant

le

plein

ou

SI

lappareil

so

trouvo

a

proximite

dØtmncelles

ou

de

flammes

flues.

3.

Ne

pas

remplir

Ia

reservoir

Ł

ras

bord

:

prØvoir

de

lespace

pour

Ia

dilatation

du

combustible.

4.

No

pas

renverser

du

carburant.

Si

on

ranverso

du

carburant,

nettoyer

los

lieux

avant

do

faire

dØmarrer

to

moteur.

3.

Seules

des

personnes

qualiliØes

doivent

dØrnontar

los

protectours

ou

los

capots

pour

faire

lentrotien

ou

les

reparations

nØcessaires.

4.

Pour

empØcher

un

dØmarrage

accidental

dun

systŁme

pendant

lentretien

ou

los

reparations,

dØbrancher

te

cable

negatif

()

de

Ia

battene.

5.

Eloigner

los

mains,

les

cheveux,

los

vOternonts

amplos

et

los

outils

des

piŁces

en

mouvement.

6.

Replacer

los

capots

ou

los

prolocteurs

ot

reformer

los

portes

une

fois

lentretien

01

los

reparations

terminØs

et

avant

do

faire

dØrnarrar

le

--

rnotour.

ArrŁter

le

moteur

avant

de

brancher

ou

do

dØbrancher

los

cables

do

Ia

battene.

No

pas

faire

des

Øtincelles

avac

les

outils

quand

on

travaille

sur

une

battene.

Ne

pas

uliliser

Ia

source

do

courant

do

soudage

pour

charger

los

batteries

ou

pour

fairo

dØmarrer

un

vØhicule.

No

pas

intervertir

Ia

polantØ

des

batteries.

a

MISE

EN

GARDE

LES

GAZ

DECHAPPEMENT

DES

MOTEURS

1.

Utiliser

le

materiel

Ł

lextØfleur,

dans

des

lieux

ouverts

et

bien

peuvent

Œtre

mortels.

ventilOs.

Los

moteurs

produisent

des

gaz

dec

happ

ement

nocits.

2.

Si

on

utilise

un

moteur

dans

un

local

fermØ,

Øvacuer

los

gaz

dØchappement

a

lextØneur

et

loin

des

pflses

dair

du

btiment.

1.

Touioursi

2.

3.

4.

5.

*

4~

~

~.

~

W.LUJ

LA

VAPEUR

El

LE

LIQUIDE

DE

REFROIDISSEMENT

BRULANT

SOUS

PRESSION

peuvent

brUler

Ia

peau

et

lee

yeux.

II

vaut

mieux

verifier

le

niveau

du

liquide

do

ref

roidissement

quand

le

motour

est

froid

atm

dØvitor

los

brUlures.

1.

2.

3.

Si

Ion

doit

verifier

to

niveau

quand

10

moteur

est

chaud,

suivre

les

Øtapes

2

at

3.

Porter

des

lunettes

do

sØcuritØ

et

des

gants

et

placer

un

chiffon

sur

10

bouchon.

Toumer

lenternont

le

bouchon

at

laisser

Ia

prossion

sechapper

lenternent

avant

denlOver

complØtement

le

bouchon.

PRINCIPALES

NORMES

DE

SECURITE

Safety

in

Welding

and

Cutting,

norme

ANSI

Z49.

1,

do

lAmerican

Welding

Safe

Handling

of

Compressed

Gases

in

Cylinders.

CGA

Pamphlet

P-ide

Society,

550

N.W.

Lejeuno

Ad,

Miami

FL

33126

Ia

Compressed

Gas

Association,

1235

Jefferson

Davis

Highway.

Suite

501,

Arlington,

VA

22202.

Safety

and

Health

Sandards,

OSHA

29

CFR

1910,

du

Supanntendent

of

Regles

do

securitd

en

soudage,

coupage

et

procØdØs

connexes,

norme

Documents,

U.S.

Government

Printing

Office,

Washington,

D.C.

20402.

CSA

Wi17.2,

do

tAssociation

canadionne

do

normalisation.

yenta

do

normes,

178 Rexdale

Boulevard,

Aexdate

(Ontario)

Canada

M9W

1

R3.

Recommended

Safe

Practice

for

the

Preparation

for

Welding

and

Cutting

of

Containers

That

Have

Held

Hazardous

Substances,

norma

AWS

F4.1.

Safe

Practices

For

Occupation

And

Educational

Eye

And

Face

Protection,

do

IAmencan

Welding

Society,

550

N.W.

Lojeuno

Ad,

Miami

FL

33126

norme

ANSI

Z87.1,

do IAmencan

National

Standards

Institute,

1430

Broadway,

New

York,

NY

10018.

NationalElectncal

Code,

NFPA

Standard

70,

do

Ia

National

Fire

Protection

Cutting

and

Welding

Processes,

norme

NFPA

51

B,

do

Ia

National

Fire

Association,

Batterymarch

Park,

Quincy,

MA

02269.

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

srl.1.1

2194

EMF

INFORMATION

TABLE

OF

CONTENTS

SECTION

1



SAFETY

INFORMATION

SECTION

2

SPECIFICATIONS

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.

Adjusting

Control

Tilt

Bracket

3-17.

Threading

Welding

Wire

SECTION

4-OPERATION

17

SECTION

5

MAINTENANCE

&

TROUBLESHOOTING

5-1.

Routine

Maintenance

5-2.

Replacing

The

Hub

Assembly

5-3.

Overload

Protection

5-4.

TroubleshootIng

NOTE

~

Considerations

About

Welding

And

The

Effects

Of

Low

Frequency

Electric

And

Magnetic

Fields

The

following

is

a

quotation

from

the

General

Conclusions

Section

of

the

U.S.

Congress,

Office

of

Technology

Assessment,

Biological

Effects

of

Power

Frequency

Electric

&

Magnetic

Fields



Backg

round

Paper,

OTA-BP-E-53

(Washington,

DC:

U.S.

Government

Printing

Office,

May

1989):

.

. .

there

is

now

a

very

large

volume

of

scientific

findings

based

on

experiments

at

the

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

single

coherent

framework.

Even

more

frustrating,

it

does

not

yet

allow

us

to

draw

definite

conclusions

about

questions

of

possible

risk

or

to

offer

clear

science-based

advice

on

strategies

to

minimize

or

avoid

potential

risks.

To

reduce

magnetic

fields

in

the

workplace,

use

the

following

procedures:

1.

Keep

cables

close

together

by

twisting

or

taping

them.

2.

Arrange

cables

to

one

side

and

away

from

the

operator.

3.

Do

not

coil

or

drape

cables

around

the

body.

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.

About

Pacemakers:

The

above

procedures

are

among

those

also

normally

recommended

for

pacemaker

wearers.

Consult

your

doctor

for

complete

infOrmation.

modlO.1

4/93

2

3

4

5

6

7

8

10

11

14

15

23

24

25

SECTION

6-

ELECTRICAL

DIAGRAMS

27

OM-1583J

-

10/95

SECTION

7

PARTS

LIST

30

Figure

7-1.

Main

Assembly

30

Figure

7-2.

Control

Box

32

Figure

7-3.

Support,

Hub

&

Reel

35

Figure

7-4.

Boom

Assembly

36

Figure

7-5.

Drive

Assembly,

Wire

38

Figure

7-6.

Control

Panel

40

Table

7-1.

Drive

Roll

And

Wire

Guide

Kits

42

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

V~~AI

h~II~LC

2

\

3

ELECTRIC

SHOCK

can

kIII.~



Do

not

touch

live

electrical

parts.



Disconnect

input

power

before

b

~

Installing

or

servicing.

-r

a

CAUTION

/

5

MOVING

PARTS

can

Injure.

~



Keep

away

from

moving

parts.

I

S

Keep

all

panels

and

covers

closed

I

when

operating.

1

Safety

Alert

Symbol

2

Signal

Word

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.

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

In

put

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

1pm

(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

(3.7

m)

Boom

17ft(5.2m)

Vertical

Lift

Of

Boom

16

ft

(4.9

m)

Boom

21

ft

(6.4

m)

Net:

160

lb

(73

kg)

Ship:

280

lb

(127

kg)

Horizontal

To

60

Above

Horizontal

Net:

210

lb

(95

kg)

Ship:

350

lb

(159

kg)

Horizontal

To

60

Above

Horizontal

OM-1583

Page

1

SECTION

3-INSTALLATION

3-1.

Equipment

Connection

Diagrams

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.

HOT

SURFACES

can

burn

skin.



Allow

gun

to

cool

before

touching.

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Turn

Off

wire

feederand

welding

powersource,

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.

Have

only

qualified

persons

install

this

unit.

wfwam9.1

2/93

2

3

13

4

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

Figure

3-1.

Typical

System

Connections

OM-1

583

Page

2

3-2.

Installing

Swivel

Into

Pipe

Post

a

WARNING

I.

RELEASE

OF

SPRING

PRESSURE

WITHOUT

BOOM

ATTACHED

can

cause

serious

personal

injury.



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

READ

SAFETY

BLOCKS

at

start

of

Section

3-2

before

proceeding.

5

4

3

Tools

Needed:

~

3/4in

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

Tools

Needed:

~

_,~

3/4,3/8

in

1

Swivel

Plates

2

Yoke

Remove

hardware

from

swivel

7

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

ReelSupport

Install

reel

support.

Ref.

ST-142

596-C

FIgure

3-3.

Boom

Installation

OM-1

583

Page

3

3-4.

Installing

Wire

Guide

Extension

Figure

3-4.

Wire

Guide

Extension

Installation

3-5.

Wire

Guide

And

Drive

Roll

Installation

READ

SAFETY

BLOCKS

at

start

of

Section

3-1

before

proceeding.

A.

Wire

Guide

Installation

1

Wire

Guide

Fitting

2

Bolt

4

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:

c:::::=::i=n

3/8

in

ST-152

323

Figure

3-5.

Wire

Guide

Installation

OM-1

583

Page

4

B.

Drive

Roll

Installation

Figure

3-6.

Drive

Roll

Installation

3-6.

Welding

Gun

Connections

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Turn

Off

wire

feeder

and

welding

power

source,

and

disconnect

input

power

before

inspecting

or

installing.

wtwaml.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

a

WARNING

4

3

1

Drive

Assembly

Cover

2

Gun

Securing

Knob

3

Gun

Connector

Loosen

securing

knob.

Insert

gun

connector

until

it

bottoms

against

drive

assembly.

Tighten

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

tighten

threaded

collar.

Ret.

ST-153

072

/

ST-152

321

/

Ret.

5T-142 708-B

Figure

3-7.

Gun

And

Trigger

Lead

Connections

OM-1

583

Page

5

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

Pin*

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.

Figure

3-8.

Boom

Connections

eQ

~oo~

2

1

Plug

PLG1O

2

Keyway

3

Threaded

Collar

Connect

14-pin

plug

PLG1O

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

1

OM-1583

Page

6

3-9.

Shielding

Gas

And

Weld

Cable

Connections

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,

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.



Shutoff

shielding

gas

supply

when

not

in

use.

wam4.1

2193

The

weld

cable

and

shielding

gas

hose

extend

10

ft

(3

m)

from

the

boom.

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.

.



Tools

Needed:

5/Bin

Figure

3-10.

Shielding

Gas

And

Weld

Cable

Connections

sT-I

52

800-A

OM-1

583

Page

7

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i).

3-11.

Removing

Safety

Collar

And

Adjusting

Boom

a

WARNING

L

RELEASE

OF

SPRING

P________

WITHOUT

BOOM

ATTACHED

can

cause

serious

personal

injury.

S

Do

not

remove

safety

collar

until

instructed

to

do

so.

FALLING

personal

in



Adjustment

yoke.

BOOM

jury

and

rod

must

can

cause

serious

equipment

damage.

be

threaded

fully

through

4

3

1

Tool

s

Needed:

-~

1-1/8

in

.

1

Locking

Knob

Tighten

knob

to

prevent

boom

movement.

Loosen

knob

to

allow

boom

movement.

Change

knob

position

to

limit

upward

movement.

cD

~

kh

~

~h

Ti

~

3

2

Increasing

Spring

Decreasing

Spring

Pressure

ForA

Pressure

ForA

Heavy

Gun

Light

Gun

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

2

Threaded

Rod

JamNut

Loosen

jam

nut

and

turn

threaded

rod

until

boom

balances.

Tighten

jam

nut.

Be

sure

several

full

threads

are

through

yoke

to

pre

vent

boom

falling.

Retain

safety

collar

for

use

in

dis

assembling

or

moving

boom.

Ret.

ST-152

380-A

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

648-A

~?c

Figure

3-12.

Installation

Of

Spool-Type

Wire

OM-1583

Page

8

B.

Installation

Of

Optional

Wire

Reel

And

Reel

Type

Wire

C.

Adjusting

Hub

Tension

Figure

3-13.

Installation

Of

Optional

Wire

Reel

And

Reel

Type

Wire

Figure

3-14.

Adjusting

Hub

Tension

5

4

1

Retaining

Ring

2

Spanner

Nut

3

Lock

4

Wire

Retainer

5

Wire

Reel

6

Hub

7

Hub

8

Reel

Support

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

turn

assembly

until

hub

is

seated

in

hole

in

reel.

Reinstall

re

taining

ring.

ST.143

478-A

/

ST-152

463

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:

~r

5/8

in

ST-152

649

OM-1583

Page

9

3-13.

Motor

Start

Control

a

WARNING

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



TurnOffwirefeederandweldingpowersource,

and

disconnect

input

power

before

inspecting

or

installing.

STATIC

ELECTRICITY

can

damage

parts

on

circuit

boards.



Put

on

grounded

wrist

strap

BEFORE

handling

boards

or

parts.

wfwaml.r

2/93

non-conductive

ST-152

378

/

SB-146

862-D

Figure

3-15.

Motor

Start

Control

On

Motor

Control

Board

PCi

To

change

wire

feed

starting

speed

proceed

as

follows:

Turn

Off

unit

and

welding

power

source.

Remove

wrapper.

1

Front

Panel

Remove

screw

from

upper

left

cor

ner,

and

open

hinged

front

panel.

2

Motor

Board

PCi

3

Motor

Start

Control

Poten

tiometer

A70

Turn

potentiometer

clockwise

to

in

crease

time

it

takes

the

motor

to

ramp

up

to

speed.

Remove

protec

tive

white

rubber

cap

before

making

adjustment.

Adjust

poten

tiometer

R70

using

a

small

non-

conductive

screwdriver.

Close

and

secure

front

panel,

and

reinstall

wrapper.

Tools

Needed:

1/4

in

OM-1

583

Page

10

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