AUTO ARC AASW 1510M User manual

AUTO
ARCJ
August1993
Form:
OM-118044B
Effective
With
Serial
No. JK72761
7
OWNERS
MANUAL
t~ll~
1T~G~
~T'
~
AASW
1510M
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.

For
help,
call
your
distributor,
or:
MILLER Electric
Mfg.
Co.,
P.O.
Box
1079,
Appleton,
WI
54912
414-734-9821

Manually
Operated,
1.5
kVA
Portable
Spot
Welder

For Resistance
Spot
Welding

Rated
Output
Varies
With
Tong
Length

Uses
110
V,
60
Hz,
Single-Phase
Input
Power

Equipped
With
A
lOft
(3 m)
Input
Power
Cord
With
Plug

U

Give this
manual
to
the
operator.
łutO_arC
7193
ST.145
104
'
1993
MILLER
Electric
Mtg.
Co.
PRINTED
IN
USA

1~
LIMITED WARRANTY
Effective
January
I,
1992
(Equipment
with
a
serial
number
preface
of
XC
or
newer)
This limited
wsrrsnty
supersedes
all
previous
manutacturers warranties
and
is
esclusive
with no other
guarantees
or
warranties
expressed
or
implied.
ii
LIMITED
WARRANTY

Subject
to
the
terms
and
conditions
below,
warrants
to
its
original
retail
purchaser
that
new
equipment
sold
after
the
effective
date
ot
this
lim
ited
warranty
is
tree of
detects
in
material
and
workmanship
at
the time it
iv
shipped
from
factory.
THIS
WARRANTY
IS EXPRESSLY
IN
LIEU
OF
ALL
OTHER
WAR
RANTIES.
EXPRESS OR IMPLtED.
INCLUDING THE
WARRANTtES OF MER
CHANTABILITY AND FITNESS
Within
the
warranty
periods
listed
below,
manufacturer
will
repair
or
replace
any
warranted
parts
or
components
that
fail
due
to
such defects
in
material
or
workman
ship.
Manufacturer
must
be
notified
in
writing
within
thirty
(30j
days
of
such detect
or
failure,
at
which
time
manufacturer
will
provide
instructions
on
the
warranty
claim
procedures
to
he followed.
Manufacturer
shall
honor
warranty
claims
on warranted
equipment
listed
below
in
the
event
of
such
a
failure
within
the
warranty
time
periods.
All
warranty
time
periods
start
on
the
date
that
the
equipment
was
delivered
to
the
originaf
retail
purchaser.
and
are
as
follows.
t.
5
Years Parts

3
Years Labor
Original
main
power
rectifiers
2.
3
Years

Parts
and
Labor
*
Transformer/Rectifier
Power
Sources
*
Plasma
Arc
Cutting
Power
Sources
*
Semi-Automatic
and Automatic Wire Feeders
Robots
3
2
Years

Parts
and
Labor
*
Engine
Driven
Welding
Generators
(NOTE:
Engines
are
warranted
seourstely
by
the
engine
manufacturer.j

Air
Compressors
4
t
Year

Parts and Labor
Motor Driven Guna
Frocess
Controllers
Water
Coolant
Systems
HF
Units
Grids
Spot
Welders
Load Banks
SDX
Transformers
Running
Gear/Trailers
Field
Options
(NOTE:
Field
options
sre
covered
under
the
limited
warranty
for
the
re
maining
warranty
oeriod
of
the
product
they
are
installed
in. or
for
a
mini
mum
of
one
year

whichever is
greater
5. e
Months

Batteries
6
50
Days

Farrs and Labor

MIG
unstIG
Torches

Plasms
Cutting
Torches
xw,

Remote
Controls
*
Accessory
Kits
*
Replacement
Parts
Umiled
Warranty
shall
not
apply
to:
1.
Items
furnished
by
manufacturer, but manufactured
by
others,
such
as en
gines
or
trade accessories.
These items
are
covered
by
the
manufacturers
warranty,
it
sny.
2
Consumable
components:
such as
contact
tips,
cutting
nozztes.
contactots
and
relays
or
parts
that
fail
due
to
normal
wear.
3.
Equipment
that has been modiked
by
any
party
other than
manufacturer,
or
equipment
that
has been
improperly
installed.
improperty
operated
or
misused
bused
upon
industry
standards,
or
equipment
which
has
not
had reasonable
and
necessary
maintenance,
or
equipment
which
has
been
used
for
operation
outside
of
the
specifications
for
the
equipment.
MANUFACTURERS
PRODUCTS ARE INTENDED FOR
PURCHASE
AND
USE
BY
COMMERCIAL/INDUSTRIAL
USERS
AND
PERSONS
TRAINED
AND
EXPE
RIENCED
IN
THE
USE AND MAINTENANCE OF WELDING
EGUfPMEN1I
In
the
event
of
a
warranty
claim
covered
by
this
warranty.
the
esclusive
remedies
shall
be, at manufacturers
option:
(1
(repair,
or
(21
replacement:
or.
where
autho
rized
in
writing
by
manufacturer
in
appropriate
cases.
(31
the
reasonable
cost
of
re
pair
or
replacement
at
an
authorized
service
station:
or
(4(
payment
of
or
credit for
the
purchase
price
(less
reasonable
depreciation
based
upon
actual
use(
upon
re
turn
ot
the
goods
at
customers
risk
and
espense.
manufacturers
option
of
repair
or
replacement
will
be
F.O
B..
Factory
at
Appleton,
Wisconsin.
or
FOB.
stan
autho
rized
service
facility
as
determined
by
manufacturer. Therefore
no
compensation
or
reimbursement for
transportation
cosls
of
any
kind
will
be
allowed.
TO
THE
EXTENT
PERMITTED
BY
LAW. THE
REMEDIES PROVIDED HEREf
N
ARE
THE
SOLE AND EXCLUSIVE REMEDIES.
IN
NO EVENTSHALL
MANUFAC
TURER
BE
LIABLE
FOR
DIRECT.
INDIRECt SPECIAL.
INCIDENTAL OR CON
SEGUENTIAL DAMAGES
(INCLUDING
LOSS
OF
PROFIT(,
WHETHER
BASED
ON
CONTRACT. 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
FROVISION.
MIGHT ARISE
BY
IMPLICATION.
OPERATION
OF
LAW.
CUSTOM
OF
TRADE OR
COURSE OF
DEALING.
IN
CLUDING
ANY
IMPLIED WARRANTY OF
MERCHANTABILfTY
OR FITNESS
FOR
PARTICULAR
PURPOSE.
WITH
RESPECT
TO
ANY
AND
ALL EGUIPMENT
FURNISHED
BY
MANUFACTURER IS EXCLUDED
AND
DISCLAIMED BY MAN
UFACTURER.
Some
states
in
the U.S.A.
do
not
allow
limitations
of
how
long
an
implied
warranty
lasts,
or
the
exclusion
of
incidental,
indirect,
special
or
consequential
damages,
so
the
above limitation
or
enclusion
may
not
apply
to
you.
This
warranty
provides
spe
cific
legal
rights,
and
other
rights may
be available,
but
may
vary
from
state
to
state.
In
Canada,
legislation
in
some
provinces provides
for certain
additional
warranties
or
remedies other
than as
stated
herein,
and
to
the
eutent
that
they
may
not
be
waived,
the
limitations
and
eaclusions
set
out
above
may
not
apply
This
Limited
Warranty
provides
specific legal tights,
and
other
rights
may
be
available, but
may
vary
from
province
to
province.
RECEIVING-HANDLING
Before
Unpacking
eqUipment,
check
carton
for
any
damage
that
may
have
occurred
dur(ng
sh(pment.
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
followingspaces
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
Purohase
brand_acct
5/93

1.
2.
RESISTANCE SPOT
WELDING
SAFETY
PRECAUTIONS
a
WARNING
SPOT 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
resistance
spot
welding,
as
in
most
jobs,
exposure
to
certain hazards
occurs.
Spot
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
next
page.
Read
and
follow
all
Safety
Standards.
HAVE ALL
INSTALLATION,
OPERATION,
MAINTENANCE,
AND REPAIR
WORK
PERFORMED
ONLY
BY
QUALIFIED
PEOPLE.
RESISTANCE SPOT
WELDING
can
5.
Watch
for
fire,
and
keep
a
fire
extinguisher
nearby.
cause
fire
or
explosion.
6.
Do
not
spot
weld
on
closed
containers
such
as
tanks
or
drums.
Sparks
can
fly
oft
from
the weld.
The
flying
sparks,
hot
workpiece,
and hot
equipment
can
cause
fires
and
burns.
7.
Do
not
weld
where
atmosphere
may
contain
flammable
dust,
gas,
or
liquid
vapors
(such
as
gasoline).
8.
Remove
any
combustibles,
such
as a
butane
lighter
or
matches,
1.
Protect
yourself
and
others
from
flying
sparks
and hot metal.
from
your
person
before
doing
any
welding.
2.
3.
Do
not
spot
weld where
flying
sparks
can
strike
flammable
material,
Remove
all
flammables
within
35
ft
(10.7
m)
of
the
weld.
If
this is
not
possible,
tightly
cover
them
with
approved
covers.
9.
10.
After
completion
of
work,
inspect
area
to
ensure
it is free of
sparks,
glowing
embers,
and
flames.
Do
not
exceed
the
equipment
rated
capacity.
4.
Be alert that
welding
sparks
can
easily
go
through
small cracks
11.
Use
only
correct
fuses
or
circuit breakers. Do
not
oversize
or
and
openings
to
adjacent
areas.
bypass
them.
ELECTRIC SHOCK
can
kill.
6. When
making
input
connections,
attach the
grounding
Touching
live
electrical
parts
can cause
fatal shocks
conductor first.
or
severe
burns.
The
input
power
circuit
and
machine
internal
circuits
are
also
live
when
power
is
on.
Incorrectly
installed
or
improperly grounded
equipment
is
a
hazard.
7.
8.
Keep
cords
dry,
free
of
oil
and
grease,
and
protect
from
hot
metal and
sparks.
Frequently
inspect
input.power
cord
and
ground
conductor
for
1.
2.
3.
Do
not
touch live
electrical
parts.
Wear
dry,
hole-free
insulating
gloves
and
body
protection.
Disconnect
input
power
before
installing
or
servicing
this
9.
damage

replace
immediately
if
damaged.
Check
ground
conductor for
continuity
Turn oft all
equipment
when
not
in
use.
equipment. Lockout/tagout
input
power
according
to
OSHA
29 10.
For
water-cooled
equipment,
check
and
repair
or
replace
any
CFR
1910.147
(see
Safety
Standards).
leaking
hoses
or
fittings.
Do
not
use
any
electrical
equipment
if
4.
Properly
install and
ground
this
equipment
according
to
this
you
are
wet
or
in
a
wet
area.
manual
and
national,
state,
and
local
codes.
11.
Use
only
well-maintained
equipment. Repair
or
replace
5.
Check
and be
sure
that
input
power
cord
ground
wire is
properly
damaged
parts
at
once.
connected
to
ground
terminal
in
disconnect
box
or
that
cord
plug
is connected
to
a
properly grounded
receptacle
outlet

always
12.
Wear
a
safety
harness
if
working
above floor level.
double-check the
supply
ground
before
applying
power.
13.
Keep
all
panels,
covers,
and
guards
securely
in
place.
HOT
METAL
can cause
burns.
Wear
gloves
or
allow
cooling
period
before
servicing
tongs
or
tips.
Wear
approved
face shield
or
safety goggles
with
side
shields.
Wear
protective
garments
such
as
oil-free,
flame-resistant
leather
gloves, heavy
shirt,
cuffless
trousers,
high
shoes,
and
a
cap.
Synthetic
material
usually
does
not
provide
such
protection.
1.
2.
Always
wear
welding-type,
insulated
gloves
when
using
this
equipment.
Do
not
touch
workpiece,
tips,
or
tongs
with
bare
hands.
3.
Protect
others
in
nearby
areas
by
using
approved
flame-resistant
or
noncombustible
fire
curtains
or
shields.
Have
all
nearby
persons
wear
safety glasses
with
side shields.
MOVING PARTS
can cause
injury.
1.
Keep
away
from
moving
parts.
2.
Keep
away
from
pinch
points.
The
tong
tips,
tongs,
and
linkages
move
during
3.
Do
not
put
hands
between
tips.
operation.
4.
Keep
all
guards
and
panels securely
in
place.
FUMES
can
be
hazardous
to
your
3.
In
confined
spaces,
use an
approved
air-supplied
respirator.
health.
4.
Do
not
weld
on
metals,
such
as
galvanized,
lead,
or
cadmium
Coatings,
cleaners,
paints,
and
platings
can
produce
fumes when welded.
Breathing
these fumes
can
be
hazardous
to
your
health.
1.
Do
not
breathe the
fumes.
2.
If
inside,
ventilate
the
area
and/or
use
exhaust
at
the
weld
to
remove
fumes.
5.
plated
steel,
unless the
coating
is
removed
from
the
weld
area,
the
area
is
well
ventilated,
or
if
necessary,
while
wearing
an
air-supplied
respirator.
The
coatings
and
any
metals
containing
these elements
can
give
off toxic
fumes
if
welded.
Read
the
Material
Safety
Data
Sheets
(MSDSs)
and
the
manufacturers
instructions
for
metals,
coatings,
and
cleaners.
SPARKS
can
cause
injury.
Very
often
sparks
fly
off from
the
)oint
area.
sr4
4/93

PRINCIPAL
SAFETY
STANDARDS
Safety
in
Welding
and
Cutting,
ANSI Standard
Z49.
1
from
American
Code for
Safety
in
We/ding
and
Cutting,
CSA Standard
Wi
17.2,
from
Welding
Society,
550
N.W.
LeJeune
Rd.
Miami FL
33126
Canadian Standards
Association,
Standards
Sales.
178
Rexdale
Bou
levard, Rexdale,
Ontario,
Canada
M9W
1R3.
Safety
and Health
Standards,
OSHA 29 CFR
1910,
from
Superinten
dent
of
Documents,
U.S.
Government
Printing
Office,
Washington,
D.C. 20402.
Safe Practices
For
OccupationAndEducationalEyeAnd
Face Protec
National
Electrical
Code,
NFPA
Standard
70,
from
National Fire
Pro-
tion,
ANSI Standard
Z87.1,
from American National
Standards
tection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
Institute,
1430
Broadway,
New
York,
NY
10018.
Safe
Handling
of
Compressed
Gases
in
Cylinders,
CGA
Pamphlet
P-i,
from
Compressed
Gas
Association,
1235
Jefferson Davis
High-
Cutting
And
Welding
Processes,
NFPA
Standard
51B,
from
National
way.
Suite
501,
Arlington,
VA
22202.
Fire Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
EMF
INFORMATION
N
OTE
~
Considerations
About
Welding
And
The
Effects
Of
Low
Frequency
Electric
And
_____________________
Magnetic
Fields
The
following
is
a
quotation
from the
General
Conclusions
Section
produce
changes
in,
biological
systems.
While
most
of this
work is
of
the
U.S.
Congress,
Office
of
Technology
Assessment,
Biological
of
very
high
quality,
the
results
are
complex.
Current
scientific
Effects
of
Power
Frequency
Electric &
Magnetic
Fields

understanding
does
not
yet
allow
us
to
interpret
the
evidence
in
a
Background
Paper,
OTA-BP-E-53
(Washington,
DC:
U.S.
single
coherent
framework.
Even
more
frustrating,
it does
not
yet
Government
Printing
Office,
May
1989):
.
. .
there is
now a
very
allow us
to
draw
definite
conclusions about
questions
of
possible
large
volume
of
scientific
findings
based
on
experiments
at
the risk
or
to
offer
clear
science-based
advice
on
strategies
to
minimize
cellular
level and from
studies
with
animals
and
people
which
clearly
or
avoid
potential
risks.
establish
that low
frequency
magnetic
fields
can
interact
with,
and
modlo14/93
TABLE
OF CONTENTS
SECTION
1

SAFETY INFORMATION
1
SECTION
2
SPECIFICATIONS
2-1.
Duty Cycle
..
2
SECTION
3-
INSTALLATION
3-1.
Tong
And
Tip
Installation
2
3-2.
Tong
Pressure
Adjustment
3
3-3.
Connecting
Input
Power
4
SECTION
4
OPERATION
4
SECTION
5-
MAINTENANCE
&
TROUBLESHOOTING
5-1.
Routine
Maintenance
5
5-2.
Dressing
Tips
5
5-3.
Replacing
Tips
5
5-4.
Changing
Tongs
6
5-5.
Cleaning
Tongs
6
5-6.
Troubleshooting
6
SECTION.6
-
ELECTRICAL
DIAGRAMS
7
SECTION
7
PARTS
LIST
Figure
7-1.
Main
Assembly
8
Figure
7-2.
Transformer,
Power Main
10
Figure
7-3.
Spot
Welder
Tips
10
Sr4
4/93
OM-
118
044B
8/93

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.
Resistance
Spot
Welders
modl
.24/93
Model
Output
Amperes*
Tong
Gap
6
in
(152 mm)
12
in
(305
mm)
18
in
(457 mm)
Tongs
Tongs
Tongs
1.5
kva,
110
Volts
5500 4500
3600
3-1/2
in
(89
mm)
*Calibrated
with standard
type
tongs
(see
Figure
7-3)
2
\
WARNING
2
a
CAUTION
/

Do
not
touch
hue
electrical
pans
+
~
MOVING
PARTS
can
injure.
~
ELECTRIC SHOCK
can
kill
~
~
______________________________

Do
not
put
hands between
tips

Keep
away
from
pinch
points

Disconnect
input power
beforeJj

Keep
guards
n
place
nstalhng
or
servicing.
5
I
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
4
Safety
Instructions
To
Avoid
Hazard
READ
SAFETY
BLOCKS
at start
of
Section
3-I
before
proceeding.
N
OTE
~
Turn
Off switch before
checking
pressure.
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
related
to
safety.
Specification
Description
Welding
Process
Type
Of
Input
Power
Input
Power Cord
Overall Dimensions
Work
Capacity
Combined
Thickness
Mild
Steel
Weight
Options
Resistance
Spot
Welding
Single-Phase:
110 Volts
AC,
60Hz.
And 50%
Duty Cycle
lOft
(3
m)
Length:
16
in
(406
mm):
Width:
4-1/2
in
(114 mm):
Height:
6
in
(152 mm)
1/8
in
(3.2
mm)
Net: 22 lb
(10
kg)
Ship:
26
lb
(12
kg)
See Rear Cover
OM-118 044
Page
1

2-1.
Duty
Cycle
a
CAUTION
EXCEEDING
DUTY
CYCLE
RATINGS
will
damage
unit.

Do
not
exceed
50%
duty cycle.
The
duty
cycle
of
a
resistance
spot
welder
is
the
percentage
of
a one
minute
period
that
a
resistance
spot
welder
can
be
operated
without
causing overheating
or
damage
to
the
unit.
These
resistance
spot
welders
are
rated
at
50%
duty
cycle,
which
means
that
they
can
be
operated
for
thirty
seconds
out
of
every
minute.
SECTION
3INSTALLATION
3-1.
Tong
And
Tip
Installation
10
Keep
tips
dressed
down
to
within
a
1/8
in
(3.2
mm)
diameter
or
less
(see
Section
5-2).
1
Tip
2
Tip
Threads
3
Tong
Coat
tip
threads
with
supplied
heat
sink
compound,
thread
tip
into
tong,
and
tighten.
Do
not
overtigh
ten.
Repeat
procedure
for
remain
ing
tip.
Bottom
Tong
Installation:
4 Bottom
Tong
5
Hole
In
Spatter
Guard
6
Insulator
Plug
7
Bottom
Tong
Securing
Screw
Loosen the
four
(4)
screws.
Slide
tong
through
hole
in
spatter
guard.
and into
bottom
tong
holder
as
far
as
possible,
and
position
tong
so
that
tip
is
pointing straight
up.
Tighten
screws
to
lock
tong
in
place.
Top
Tong
Installation:
8
Top
Tong
9
Top
Tong
Holder/Pivot
Casting
10
Top
Tong
Securing
Screw
Loosen
the four
(4)
screws.
Slide
tong
into
pivot
casting
as
far
as
necessary,
so
that
tip
mates
with
bottom
tip
when
tongs
are
closed.
Tighten
screws
to
lock
tong
in
place.
ST-800
154
/
5T-800 155-A
warn71
a
WARNING
NOTE
~
~

E
LECTRIC
SHOCK
can
kill.

Do
not
touch live electrical
parts.

Turn
Off
unit,
and
disconnect
input
power
cord
plug
from
receptacle
before
inspecting
or
installing.
I
Allow
tongs
and
tips
to
cool
before
touching.
Be
sure
ends
of
tongs
are
clean and
free of corrosion before
installing.
Tools Needed:
3/16
in
~:i-
~
9/l6in
Figure
3-1.
Tong
And
Tip
Installation
OM-118
044
Page
2

3-2.
Tong
Pressure
Adjustment
a
WARNING
ELECTRIC SHOCK
can
kill.

Do
not
touch
live
electrical
parts.

Turn
Off
unit,
and disconnect
input
power
cord
plug
from
receptacle
before
inspecting
or
installing.

Allow
tongs
and
tips
to
cool
before
touching.
EXCESSIVE
TONG
PRESSURE
can
damage tips.

Do
not
use
tongs
as a
clamp
or
vice
to
hold
workpiece
together.
If
the
two
pieces
of material
to
be welded do
not
make
good
contact
at
the
point
of the
intended
weld,
clamp
material
to
provide
good
contact
between
surfaces.
NOTE
~
Tong
pressure
is
adjustable,
and
must
be
checked
and/or
set
before
operation.
Correct
tong
pressure
is
necessary
to
create
a
quality
weld
and
to
prevent
damage
to
tips.
Too
much
tong
pressure
causes
the
weld
nugget
to
dimple
and
material
to
splash
out
around the
nugget
area.
If
tong
pressure
is
too
weak,
parts
are
loose
when the
tongs
are
closed,
severe
arcing
occurs
between
workpieces,
and
no
weld
can
be made.
6
1
Front
Nut
2
Rear Nut
3
Pivot
Casting
4
Hand
Lever
5
Tongs
To increase
tong
pressure,
loosen
front
nut.
The
farther
the
front
nut
is
turned
out,
the
greater
the
pres
sure on
the
tips
when the
hand
le
ver
is closed.
Turn the
rear nut
up
to
the
pivot
casting
to
lock the
posi
tion.
To decrease
tong
pressure,
loosen
the
rear
nut
and
turn
thefront
nut
up
to
the
pivot
casting.
6
Machine
Screw
The farther
down the
screw
is
turned,
the
farther
the hand
lever
will
close.
Adjustment
of this
screw
will
determine
if
the
tongs
lock
on
the
material, or
just pull
up
tight.
Adjust
screw to
allow lever
to
be
raised
easily
after the
weld
has
been
completed.
Rel.
ST-800
156
Tools
Needed:
~:====z~
11/16
in
Figure
3-2.
Tong
Pressure
Adjustment
OM-lIB
044
Page
3

3-3.
Connecting
Input
Power
a
WARNING
.,

ELECTRIC
SHOCK
can
kill.
~\

Do
not
touch
live
electrical
parts.

Do
not cut
ground
terminal
oft
plug.

Input
supply
wiring
and
receptacle
must meet
National
Electrical Code
and all other codes.
Operate
spot
welder
from
a
sepa
rately
fused
or
circuit
breaker
pro
tected
circuit,
and
use
correct
size
input
conductors
(see
Tablefor
cor
rect
size).
1
Rating
Label
2
Cord
3
Plug
Do
not cut
ground
terminal
off
plug.
4 Grounded
Receptacle
Connect
plug
to
matching
grounded
receptacle.
Figure
3-3.
I
npu
t
P
ower
Connections
SECTION
4
-
OPERATION
a
WARNING

Always
wear
dry insulating gloves.
ELECTRIC SHOCK
can
kill.
~\

Insulate
yourself
from
work and
ground.

Do
not
touch live electrical
parts.

Keep
all
panels
and
covers
securely
in
place.
FUMES
AND
GASES
can
be hazardous
to
your
health.

Keep
your
head
out
of the fumes.

Ventilate
area,
or
use
suction device
at
weld
area.
manufacturers
instructions
for
metals,
coatings,
and cleaners.

Read Material
Safety
Data
Sheets
(MSDS5)
and
WELDING
can cause
fire
or
explosion.

Do
not
weld
near
flammable
material.

Watch
for
fire;
keep
extinguisher nearby.

Allow work and
equipment
to
cool before
handling.

Do
not
locate
unit
over
combustible
surfaces.
-
-.

Wear
face shield
or
safety
goggles.
SPARKS
AND
HOT
METAL
can
injure.

Wear
body
protection.

Allow
tips
and work
to
cool
before
handling.
MOVING PARTS
can
injure.

Do
not
put
hands between
tips.

Keep
away
from
pinch points.

Keep
guards
in
place.

.
~__..
RENTS
can
affect
pacemaker operation.
MAGNETIC FIELDS FROM HIGH CUR-

Pacemakerwearerskeepaway.

Wearers
should
consult their doctor
before
going
near
resistance
spot
welding
operations.
See
Safety
Precautions
at
beginning
of
manual
for
ba
sic
welding
safety
information.

Protect
area
and
persons
from
flying
sparks.
swarn6.1
10/91
1
Hand
Lever
Use
lever
to
open
and close
tongs.
See Section
3-2
for
tong
pressure
adjustment.
Closing
the hand
lever
compresses
the material between
the
tips
during
the
welding
process.
2
Start Switch
,....~
((
~
\~
~
Use
switch
to turn
weld
current
On
and
Oft.
Move switch
sideways
in
either direction
to start
weld
cur
rent.
Release
switch
to
stop
weld
current.
ST-I
45 104
2
swarn3.1*
2/93
Ref.
ST-800
156
Figure
4-1.
Hand
Lever
And
Start Switch
OM-118
044
Page
4

Connect
Personal
Safety
)
Install &
))
Put
On
Equipment Equipment
1
1
Begin
Weldin~)
~\
),J
Figure
4-2.
Sequence
Of Resistance
Spot
Welding
SECTION
5
MAINTENANCE
&
TROUBLESHOOTING
a
WARNING
ELECTRIC SHOCK
can
kill.

Do
not
touch live electrical
parts.

Turn Off
unit,
and
disconnect
input
power
cord
plug
from
receptacle
before
inspecting, maintaining,
or
servicing.
HOT
PARTS
can cause severe
burns.

Allow
cooling
period
before
maintaining
or
servicing.
5-1.
Routine
Maintenance

M

Do
not
put
hands
between
tips.
OVING
PARTS
can
injure.
Keep
away
from
pinch points.
Maintenance
to
be
performed
only by
qualified
persons.
swarn8.1 2/93
____
READ SAFETY
BLOCKS
at start
of
7
Section
5
before
proceeding.
Use
a
tip
dresser
according
to
its instructions. Do
not
file
tips
unless
qualified.
Incorrect
filing
methods
can
result
in
mismatched
tips
and
poor
quality
welds.
A
file
can
be
used
to
remove
the mushroom from the
tips
if
filing
is confined
to
the
tapered
sides
of
the
tips.
5-3.
Replacing
Tips
a
WARNING
To
replace tip,
remove
present
tip
and
go
to Section
3-1
a
Turn
Off
all
power
before
maintaining.
I
Figure
5-1.
Maintenance
Schedule
5-2.
Dressing
Tips
:::~4
~
READ
Sectio
SAFETY BLOCKS
at
start
of
n 5
before
proceeding.
OM-118
044
Page
5

5-4.
Changing
Tongs
For
changing
resistance
spot
welder
tongs,
see
Section
3-1.
5-5.
Cleaning Tongs
~Hd~
READ
SAFETY
BLOCKS
at start
of
Section
5
before
proceeding.
Wipe
both
tongs
and
tong
holders clean. Bends
or
nicks
near
the
tong
ends
that insert
into the
tong
holders
may
reduce
the
maximum
efficiency
and
capacity
of
the
spot
welder.
If
corroded,
polish
tongs
with
crocus
cloth.
5-6.
Troubleshooting
a
WARNING
ELECTRIC SHOCK
can
kill.

Do
not
touch live
electrical
parts.
.
Turn
Off
unit,
and disconnect
input
power
cord
plug
from
receptacle
before
inspecting,
maintaining,
or
servicing.
HOT PARTS
can
cause
severe
burns.

Allow
cooling
period
before
servicing.
I
M
I
Do
not
put
hands between
tips.
OVING PARTS
can
injure.
Keep
away
from
pinch points.
Troubleshooting
to
be
performed
only by qualified
persons.
swarn9
1*4/92
Table
5-1.
Welding
Trouble
Trouble
No weld
output.
Low weld
output.
Remedy

-.~
Check
line
fuses,
and
replace
if
necessary.
Section
1H
-
Check
start
switch
Si
contacts
for
pitting
and
wear.
Replace
if
nec
essary.
Check
tip
threads.
Replace
tips
if
necessary.
Replace
or
dress
tips.
Longer
than
normal
Weld
Time
re-


-~
quired.
Remove
tongs.
Remove
insulator
plugs
from
front
housing,
and
blow
out
tong
clamps
with
compressed
air.
Replace
or
dress
tips.
Check
input
tine
voltage.
Clean
work
pieces.
Adjust
tong
pressure.
Burn
through
at
point
of
weld.
Shorten weld time.
Adjust
tong
pressure.
Replace
or
dress
tips.
Realign
tips.
Figure
4-I
-..
3-2
-~
5-2,5-3
-~
3-1
OM-118
044
Page
6

SECTION
6 ELECTRICAL
DIAGRAMS
Figure
6-1.
Circuit
Diagram
For
Spot
Welders
SA-162
467
aM-us
044
Page
7

44
SECTION
7
PARTS
LIST
Figure
7-1.
Main
Assembly
ST-145
048
3
2
23
2~
24
OM-118
044
Page
8

*Recommended
Spare
Parts.
Figure
7-1.
Main
Assembly
+When
ordering
a
component
originally
displaying
a
precautionary
label,
the
label
should also
be
ordered.
BE
SURE TO PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
Item
Dia.
No.
Mkgs.
Part
No.
Description
Quantity
1
2
019 643
..
HANDLE,
carrying
601 865
..
NUT,
sti hex
full
fnsh
.250-20
1
1
3
602 009
..
SCREW,
cap
stl sch .250-20
x
1.250
7
4
023
659
..
WIRING
HARNESS,
switch
1
5
6
7
8
9
10
11
023 199
..
LEVER,
operating
010
714
..
PIN,
spring
CS
.312
x
1.750
010
712
..
LINK,
tgl connecting
010 713
..
PIN,
spring
CS
.312
x
1.250
010
715
..
BOLT,
pressure
adjustment
601 876
..
NUT,
stl hex
jam
.437-20
010 668
..
SCREW,
cap
stl sch .250-20
x
1.500
1
1
2
1
1
2
2
12
13
14
15
16
017668..
010709..
010
623
.
010 716
.
602 008
.
HOLDER,tongtop
CLAMP,tongtop
.
BRAID,
tong
set
of four
.
CLAMP,
connecting
top
tong
braid
.
SCREW,
.250-20
x
1
.000soc
hexhd
1
1
1
1
4
17
601 854
. .
NUT,
al
hex
.375-24
2
18
095
297
..
STUD,
stl
.375-24
x
3.750
1
19
20
026 607
.
128 237
.
.
GUARD,
spatter
.
SCREW,
10-32
x
.500hexwhd
sIt sti
1
2
21
602 262
. .
HANDLE,
wood
1
..
..
22
23
601
778
.
070 017
.
.
BOLT,
crg
stl .250-20
x
4.500
.
INSULATION,
switch
1
1
..
24
.. . .
Si
...
.
*011 746
.
011 291
.
023 987
.
.
SWITCH,
control
(consisting
of)
...
CONTACT,
assembly
switch
.. .
CONTACT,
switch
1
1
1
011 292
. . . .
TOGGLE,
switch
1
070035
....
BASE
1
..
25
122 210
.
.
SCREW,
10-32
x
.62shexwhd sit sti
2
26
27
28
026 759
.
010
711
.
017
667
.
.
INSULATOR,
plug
sec scr
.
PIN,
spring
.375-3.00
.
HOUSING,
front
2
1
1
29
30
602 024
.
NAMEPLATE
(order
by
model and
style
number)
.
SCREW,
drive
U
2
x
3/16
1
4
31
32
33
010708
.
026 605
.
026 606
.
.
RETAINER,
clamp
tong
.
INSULATION,
bottom
clamp
.
TUBING,
fbr vulc
.250
ID
x
.375
00
x
.500
1
1
4
34
026
604
. .
INSULATION,
fbr
1/32
in 2
35
36
37
38
. . .
39
.
Ti
...
602
004
.
010707
.
039 052
.
+095
345
.
143 140
.
600 675
.
.
SCREW,
cap
stl sch
.250-20
x
.750
.
CLAMP,
bottomtong
.
CLAMP,
threaded
connecting
tong
braid
(included
w/Item
5,
Fig
7-2)
.
TRANSFORMER,
pwr
main
(Fig
7-2)
..
.
LABEL,
warning general precautionary
.
.
SPLICE,
butt
16-14 wire
2
1
1
1
1
1
40
lii
630
. .
SCREW,
10-32
x
.250hexwhd sit sti
...
1
602 205
. .
WASHER,
lock sti
intl
tooth No. 10
. . . .
1
41
019642
. .
COVER
1
42
43
44
45
46
601
847
.
115 104
.
094 503
.
026
763
.
128 237
.
.
NUT,
stl
slflkg
hex
mscr
10-32
.
CONNECTOR,
clamp
cable
1/2
in
.
CABLE,
pwr
lOft
iGga
3/C
.
TUBING,
gl
acrylic
No.
7
x
2.500
.
SCREW,
10-32
x
.500hexwhd
sit
stl
4
1
1
3
2
OM-118
044
Page
9

Replace
Coils
At
Factory
Or
Factory
Authorized
Service
Station
Description
Quantity
095 347
Figure
7-2.
Transformer,
Power
Main
(Fig
7-1
Item
38)
026601
095312
.010157
137943
+033 123
INSULATION
COIL,
pri
11OV
STUD,
sti
No.
10-32
x
8.125
NUT,
core
stud
BAR,sec
4
4
+Item
37
on
Figure
7-1
is
included
when
ordering
these items
as
replacement
parts.
BE
SURE
TO
PROVIDE MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING REPLACEMENT
PARTS.
3-1/2
~
(89~
6
(152
mm)
040
197
12
(305 mm)
040198
STANDARD
18
(457 mm)
040 199
Standard
Flat
040211 040212
6-1/2
(165
12
(305 mm)
040 203
18
(457 mm)
040204
TT-6
Standard
Flat
040211
040212
8
(203 mm)
040
207
G-7
Standard
Flat
040211
040212
Figure
7-3.
Spot
Welder
Tongs
And
Tips
Item
No.
Part
No.
2..
3..
4..
5..
2
3
5
Figure
7-2.
Transformer,
Power Main
ST-14~
482-A
Ret.
S-0550
OM-liB
044
Page
10