CIGWELD W4016300 User manual

Manual 0-5228 1 Spool Cover Assembly Instruction
SPOOL COVER ASSEMBLY ( W4016300 ) INSTRUCTIONS
CIGWELD Pty. Ltd
71 Gower Street
Preston, Victoria, Australia, 3072
Telephone: [phone]
www.cigweld.com.au
Manual 0-5228
Revision No.: AA
Issue Date: September 14, 2012
Spool Cover for VAF4, VAF4HD
and WeldSkill 4R Wirefeeders
Part Number: W4016300
Assembly Instructions
General Information
The Cigweld spool cover is designed to be used together with VAF4, VAF4 HD and WeldSkill 4R Wirefeeders. These
instructions will guide you through the proper assembly procedure of the spool cover.
Supplied Parts (For Transmig VAF4 and VAF4 HD Wirefeeders)
The following components are included in this kit:
Item Description Quantity
1 Bolt, M12 x 30 2
2 Star Washer, M12 2
3 Flat Washer, M12 2
4 Screw, Countersunk, M5 x 12 2
5 Spool Cover Mounting Bracket 1
6 Spool Cover 1
7 Spool Cover Mounting Bracket 1
Table 1 Spool Cover Assembly
Art # A-11347
1
2
3
4
5
6
7
Figure 1 Spool Cover Assembly (For Transmig VAF4 and VAF4 HD Wirefeeders)

Spool Cover Assembly Instruction 2 Manual 0-5228
SPOOL COVER ASSEMBLY (W4016300) INSTRUCTIONS
!
WARNING
Disconnect input power to the power source before installing or removing this control.
SAFETY INSTRUCTIONS AND WARNINGS
!
WARNING
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE
INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR
SERVICING THIS EQUIPMENT.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or
property, if the operator does not strictly observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be
learned through study and training before using this equipment. Some of these practices apply to equipment
connected to power lines; other practices apply to engine driven equipment. Anyone not having extensive
training in welding and cutting practices should not attempt to weld.
Safe practices are outlined in the Australian Standard AS1674.2-2007 entitled: Safety in welding and allied
processes Part 2: Electrical. This publication and other guides to what you should learn before operating
this equipment are listed at the end of these safety precautions. HAVE ALL INSTALLATION, OPERATION,
MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.
WARNING
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit
is electrically live whenever the output is on. The input power circuit and machine internal circuits
are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel,
drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly
installed or improperly grounded equipment is a hazard.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body protection.
3. Insulate yourself from work and ground using dry insulating mats or covers.
4. Disconnect input power or stop engine before installing or servicing this equipment. Lock input power
disconnect switch open, or remove line fuses so power cannot be turned on accidentally.
5. Properly install and ground this equipment according to its Owner’s Manual and national, state, and local
codes.
6. Turn off all equipment when not in use. Disconnect power to equipment if it will be left unattended or out of
service.
7. Use fully insulated electrode holders. Never dip holder in water to cool it or lay it down on the ground or the
work surface. Do not touch holders connected to two welding machines at the same time or touch other
people with the holder or electrode.
8. Do not use worn, damaged, undersized, or poorly spliced cables.
9. Do not wrap cables around your body.

Manual 0-5228 3 Spool Cover Assembly Instruction
SPOOL COVER ASSEMBLY ( W4016300 ) INSTRUCTIONS
10.Ground the workpiece to a good electrical (earth) ground.
11.Do not touch electrode while in contact with the work (ground) circuit.
12.Use only well-maintained equipment. Repair or replace damaged parts at once.
13.In confined spaces or damp locations, do not use a welder with AC output unless it is equipped with a volt-
age reducer. Use equipment with DC output.
14.Wear a safety harness to prevent falling if working above floor level.
15.Keep all panels and covers securely in place.
WARNING
ARC RAYS can burn eyes and skin; NOISE can damage hearing.
Arc rays from the welding process produce intense heat and strong ultraviolet rays that can burn
eyes and skin. Noise from some processes can damage hearing.
1. Use a Welding Helmet or Welding Faceshield fitted with a proper shade of filter (see ANSI Z49.1 and AS 1674
listed in Safety Standards) to protect your face and eyes when welding or watching.
2. Wear approved safety glasses. Side shields recommended.
3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc.
4. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protec-
tion.
5. Use approved ear plugs or ear muffs if noise level is high.
6. Never wear contact lenses while welding.
WARNING
FUMES AND GASES can be hazardous to your health.
Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your
health.
1. Keep your head out of the fumes. Do not breathe the fumes.
2. If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied respirator.
4. Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s instruction for metals, consumables,
coatings, and cleaners.
5. Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Shielding
gases used for welding can displace air causing injury or death. Be sure the breathing air is safe.
6. Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can
react with vapours to form highly toxic and irritating gases.
7. Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is
removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied
respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

Spool Cover Assembly Instruction 4 Manual 0-5228
SPOOL COVER ASSEMBLY (W4016300) INSTRUCTIONS
WARNING
WELDING can cause fire or explosion.
Sparks and spatter fly off from the welding arc. The flying sparks and hot metal, weld spatter, hot
workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode or welding
wire to metal objects can cause sparks, overheating, or fire.
1. Protect yourself and others from flying sparks and hot metal.
2. Do not weld where flying sparks can strike flammable material.
3. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them
with approved covers.
4. Be alert that welding sparks and hot materials from welding can easily go through small cracks and open-
ings 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 or drums.
8. Connect work cable to the work as close to the welding area as practical to prevent welding current from
travelling long, possibly unknown paths and causing electric shock and fire 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.
WARNING
FLYING SPARKS AND HOT METAL can cause injury.
Chipping and grinding cause flying metal. As welds cool, they can throw off slag.
1. Wear approved face shield or safety goggles. Side shields recommended.
2. Wear proper body protection to protect skin.
WARNING
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding process, be sure to treat them carefully.
1. Protect compressed gas cylinders from excessive heat, mechanical shocks, and arcs.
2. Install and secure cylinders in an upright position by chaining them to a stationary support or equipment
cylinder rack to prevent falling or tipping.
3. Keep cylinders away from any welding or other electrical circuits.
4. Never allow a welding electrode to touch any cylinder.
5. Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific
application; maintain them and associated parts in good condition.
6. Turn face away from valve outlet when opening cylinder valve.
7. Keep protective cap in place over valve except when cylinder is in use or connected for use.
8. Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1
listed in Safety Standards.

Manual 0-5228 5 Spool Cover Assembly Instruction
SPOOL COVER ASSEMBLY ( W4016300 ) INSTRUCTIONS
WARNING
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can cut fingers and hands and catch loose clothing.
1. Keep all doors, panels, covers, and guards closed and securely in place.
2. Stop engine before installing or connecting unit.
3. Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary.
4. To prevent accidental starting during servicing, disconnect negative (-) battery cable from battery.
5. Keep hands, hair, loose clothing, and tools away from moving parts.
6. Reinstall panels or guards and close doors when servicing is finished and before starting engine.
!
WARNING
This product, when used for welding or cutting, produces fumes or gases which contain chemicals
know to the State of California to cause birth defects and, in some cases, cancer. (California Health
& Safety code Sec. 25249.5 et seq.)
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 - Background Paper, OTA-BP-E-63 (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 and 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 evi-
dence in a single coherent framework. Even more frustrating, it does not yet allow us to draw definite conclu-
sions 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 cable around the body.
4. Keep welding power source and cables as far away from body as practical.
ABOUT PACEMAKERS:
The above procedures are among those also normally recommended for pacemaker wearers. Con-
sult your doctor for complete information.

Spool Cover Assembly Instruction 6 Manual 0-5228
SPOOL COVER ASSEMBLY (W4016300) INSTRUCTIONS
Recommended Protective Filters for Electric Welding
Description of Process Approximate Range of
Welding Current in Amps
Minimum Shade Number of
Filter(s)
Manual Metal Arc Welding - covered
electrodes (MMAW)
Less than or equal to 100 8
100 to 200 10
200 to 300 11
300 to 400 12
Greater than 400 13
Gas Metal Arc Welding (GWAW)
(MIG) other than Aluminium and
Stainless Steel
Less than or equal to 150 10
150 to 250 11
250 to 300 12
300 to 400 13
Greater than 400 14
Gas Metal Arc Welding (GMAW)
(MIG) Aluminium and Stainless Steel
Less than or equal to 250 12
250 to 350 13
Gas Tungsten Arc Welding (GTAW)
(TIG)
Less than or equal to 100 10
100 to 200 11
200 to 250 12
250 to 350 13
Greater than 350 14
Flux-cored Arc Welding (FCAW) -with
or without shielding gas.
Less than or equal to 300 11
300 to 400 12
400 to 500 13
Greater than 500 14
Air - Arc Gouging Less than or equal to 400 12
Plasma - Arc Cutting
50 to 100 10
100 to 400 12
400 to 800 14
Plasma - Arc Spraying —15
Plasma - Arc Welding
Less than or equal to 20 8
20 to 100 10
100 to 400 12
400 to 800 14
Submerged - Arc Welding —2(5)
Resistance Welding —Safety Spectacles or eye
shield
Refer to standard AS/NZS 1338.1:1992 for comprehensive information regarding the above table

Manual 0-5228 7 Spool Cover Assembly Instruction
SPOOL COVER ASSEMBLY ( W4016300 ) INSTRUCTIONS
Assembly Procedure For Transmig VAF4 and VAF4 HD Wirefeeders
Spool cover is assembled in the following steps:
1. Remove the spool hub assembly.
a. Remove the clip from the spool hub.
b. Unscrew the 3-lobe screw.
c. Remove the spool hub parts and the spacer in the following sequence. Note that the spacer is not
required when fitting the spool cover.
Hexagon Nut
Spring Washer
Flat Washer,large hole
Spacer
Shaft
Friction Washer
Hub Wire Reel
Keyed Washer
Compression Spring
Flat Washer, small hole
3-lobe Screw
Retaining Clip
Art # A-11514
Figure 2 Removing Spool Hub Assembly (For Transmig VAF4 and VAF4 HD Wirefeeders)
2. Assemble the Spool Cover Mounting Brackets, one inside and one outside the spool cover, with the two
countersunk screws M5 x 12.
3. Secure the spool cover assembly to the spool support arm with M12 x 30 Bolts, Star Washers, M12, and
Flat Washers, M12 as shown in the diagram below.
Art # A-11344
Spool Cover Mounting Brackets
Spool Cover
Countersunk Screws,
M5×12
Hub Wire Reel
Keyed Washer
Compression Spring
Flat Washer, small hole
3-lobe Screw
Retaining Clip
Friction Washer
M12 x 30 Bolts;
Star Washers, M12;
Flat Washers, M12
Figure 3 Installing Spool Cover (For Transmig VAF4 and VAF4 HD Wirefeeders)

Spool Cover Assembly Instruction 8 Manual 0-5228
SPOOL COVER ASSEMBLY (W4016300) INSTRUCTIONS
3. Install the spool hub component parts over the spool hub shaft in the following sequence.
Friction Washer
Spool Hub
Keyed Washer
Spring
Flat Washer
3-lobe Screw
Retaining Clip
Art # A-11349
Figure 4 Spool Hub Assembly (For Transmig VAF4 and VAF4 HD Wirefeeders)
WARNING
Fully tighten all fasteners.

Manual 0-5228 9 Spool Cover Assembly Instruction
SPOOL COVER ASSEMBLY ( W4016300 ) INSTRUCTIONS
Refer to the figures below for the assembled spool cover:
Art # A-11356
Figure 5a Assembled Spool Cover (door opened) (For Transmig VAF4 and VAF4 HD Wirefeeders)
Art # A-11348
Figure 5b Assembled Spool Cover (For Transmig VAF4 and VAF4 HD Wirefeeders)

Spool Cover Assembly Instruction 10 Manual 0-5228
SPOOL COVER ASSEMBLY (W4016300) INSTRUCTIONS
Assembly Procedure For WeldSkill 4R Wirefeeder
1. Remove the spool hub assembly in the sequence as shown in the figure below (except for the spool hub
base).
Spool Hub Nut
Bolt
Flat Washer
Flange
Spool Hub
Art # A-11515
Spool Hub Base
Spool Cover
Fibre Washer
Spring
Figure 6 Removing Spool Hub Assembly (For WeldSkill 4R Wirefeeders)
2. Remove the spool hub base and the spool cover by loosening the M8 bolt.
M8 Bolt
Art # A-11516
Spool Hub Base
M8 Fasteners
Figure 7 Removing M8 Fasteners (For WeldSkill 4R Wirefeeders)
3. Fit the new spool cover and spool hub base using the M8 fasteners. (Please refer to Figure 7)

Manual 0-5228 11 Spool Cover Assembly Instruction
SPOOL COVER ASSEMBLY ( W4016300 ) INSTRUCTIONS
Assembly Procedure for WeldSkill 4R Wirefeeder Continued
4. Replace the spool hub assembly in the reverse sequence as shown in Figure 6.
WARNING
Fully tighten all fasteners.
Art # A-11517
Figure 8 Assembled Spool Cover (door opened) (For WeldSkill 4R Wirefeeders)
Art # A-11518
Figure 9 Assembled Spool Cover (For WeldSkill 4R Wirefeeders)

Spool Cover Assembly Instruction 12 Manual 0-5228
SPOOL COVER ASSEMBLY (W4016300) INSTRUCTIONS
TERMS OF WARRANTY – APRIL 2012
1. The Trade Practices Act 1974 (Commonwealth) and similar State Territory legislation relating to the supply
of goods and services, protects consumers’ interests by ensuring that consumers are entitled in certain
situations to the benefit of various conditions, warranties, guarantees, rights and remedies (including war-
ranties as to merchantability and fitness for purpose) associated with the supply of goods and services. A
consumer should seek legal advice as to the nature and extent of these protected interests. In some cir-
cumstances, the supplier of goods and services may legally stipulate that the said conditions, warranties,
guarantees, rights and remedies are limited or entirely excluded. The warranties set out in Clause 2 shall be
additional to any nonexcludable warranties to which the Customer may be entitled pursuant to any statute.
2. Subject to Clause 3. CIGWELD gives the following warranties to the Customer:
Insofar as they are manufactured or imported by CIGWELD, goods will upon delivery be of merchantable
quality and reasonably fit for the purpose for which they are supplied by CIGWELD.
CIGWELD will repair or, at its option, replace those of the goods which, upon examination, are found by
CIGWELD to be defective in workmanship and/or materials.
CIGWELD reserves the right to request documented evidence of date of purchase.
3. The Warranty in Clause 2;
Is conditional upon:
The Customer notifying CIGWELD or our Accredited Distributor in writing of its claim within seven (7) days
of becoming aware of the basis thereof, and at its own expense returning the goods which are the subject
of the claim to CIGWELD or nominated Accredited Distributor/Accredited Service Provider. The goods being
used in accordance with the Manufacturer’s Operating Manuals, and under competent supervision.
Does not apply to:
Obsolete goods sold at auction, second-hand goods and prototype goods.
Breakdown or malfunction caused by accident, misuse or normal wear and tear.
Repairs or replacement made other than by CIGWELD or Accredited Service Providers, unless by prior ar-
rangement with CIGWELD.
Replacement parts or accessories which may affect product safety or performance and which are not
manufactured, distributed or approved by CIGWELD.
4. CIGWELD declares that, to the extent permitted by law, it hereby limits its liability in respect of the supply of
goods which are not of a kind ordinarily acquired for personal, domestic or household use or consumption
to any one or more of the following (the choice of which shall be at the option of CIGWELD).
The replacement of the goods or the supply of equivalent goods.
The repair of goods.
The payment of cost of replacing the goods or acquiring equivalent goods.
The payment of the cost of having goods repaired.
5. Except as provided in Clauses 2 to 4 above, to the extent permitted by statute, CIGWELD hereby excludes all
liability for any loss, damage, death or injury of any kind whatsoever occasioned to the Customer in respect of
the supply of goods including direct, indirect, consequential or incidental loss, damage or injury of any kind.

Manual 0-5228 13 Spool Cover Assembly Instruction
SPOOL COVER ASSEMBLY ( W4016300 ) INSTRUCTIONS
WARRANTY SCHEDULE – APRIL 2012
These warranty periods relate to the warranty conditions in clause 2. All warranty periods are from date of sale
from the Accredited Distributor of the equipment. Notwithstanding the foregoing, in no event shall the warranty
period extend more than the time stated plus one year from the date CIGWELD delivered the product to the Ac-
credited Distributor. Unless otherwise stated the warranty period includes parts and labour. CIGWELD reserves
the right to request documented evidence of date of purchase.
PRODUCT WARRANTY PERIOD
SPOOL COVER (W4016300) 3 months
Please note that the information detailed in this statement supersedes any prior published data produced by
CIGWELD.

Spool Cover Assembly Instruction 14 Manual 0-5228
SPOOL COVER ASSEMBLY (W4016300) INSTRUCTIONS
CIGWELD Pty Ltd
ABN: 56 007 226 815
A Victor Technologies Company
71 Gower Street
Preston VIC 3072 Australia
T: [phone]
F: [phone]
[e-mail]
www.cigweld.com.au
CIGWELD Terms of Warranty - 2012
Effective 1st January 2012, all warranties against defects (also known as a manufacturer’s
warranty) supplied with goods or services must comply with the mandatory requirements in
the new Australian Consumer Law and the Trade Practices (Australian Consumer Law)
Amendment Regulations (2010) (No.1).
This Warranty Statement should be read in conjunction with the Warranty Schedule contained
in the operating instructions of the product. This schedule contains the warranty period
applicable to the product
Any claim under this warranty must be made within the warranty period which commences on
the date of purchase of the product. To make a claim under the warranty, take the product
(with proof of purchase from a Cigweld Accredited Seller) to the store where you purchased
the product or contact Cigweld Customer Care 1300 654 674 for advice on your nearest
Service Provider.
All costs associated with lodging the warranty claim including the return of goods to Cigweld
or our Nominated Accredited Distributor / Accredited Service Provider are the responsibility of
the consumer.
This warranty is given.
Cigweld Pty Ltd
A.B.N. 56007226815
71 Gower Street, Preston
Victoria, Australia, 3072
Phone: [phone]
Email: [e-mail]
Website: www.cigweld.com.au
This warranty is provided in addition to other rights and remedies you have under law:
Our goods come with guarantees which cannot be excluded under the Australian Consumer
Law. You are entitled to replacement or refund for a major failure and to compensation for
other reasonably foreseeable loss or damage. You are also entitled to have the goods
repaired or replaced if the goods fail to be of acceptable quality and the failure does not
amount to a major failure.
Failures due to incorrect use are not covered by this warranty and consumers are reminded to
only use the product in accordance with the Operating Instruction supplied with the product.
Additional copies of Operating Instructions are available from Cigweld Customer Care
1300 654 674 or the Website.

Manual 0-5228 15 Spool Cover Assembly Instruction
SPOOL COVER ASSEMBLY ( W4016300 ) INSTRUCTIONS
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION
Cigweld, Australia
71 Gower Street
Preston, Victoria
Australia, 3072
Telephone: [phone]
Fax: [phone]
Email: [email protected]
Victor Technologies USA
2800 Airport Road
Denton, Tx 76207 USA
Telephone: [phone]
800-426-1888
Fax: [phone]
Email: [email protected]
Victor Technologies Canada
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: [phone]
Fax: [phone]
Victor Technologies Europe
Europe Building
Chorley North Industrial Park
Chorley, Lancashire
England, PR6 7Bx
Telephone: [phone]
Fax: [phone]
PT. Victor Technologies Utama Indonesia
Jl. Angsana II Blok AE No. 28
Delta Silicon I, Cikarang - Sukaresmi
Bekasi, 17550
Indonesia
Tel: [phone]
Fax: [phone] / 1867
http://www.victortechnologies.com
Victor Technologies, China
100 Old Hongjing Rd
Minhang District
Shanghai, PR, 200052
Telephone: [phone]
Fax: [phone]
Victor Technologies Asia Sdn Bhd
Lot 151, Jalan Industri 3/5A
Rawang Integrated Industrial Park - Jln Batu Arang
48000 Rawang Selangor Darul Ehsan
West Malaysia
Telephone: 603+ 6092 2988
Fax : 603+ 6092 1085
Victor Technologies Italy
OCIM, S.r.L.
Via Benaco, 3
20098 S. Giuliano
Milan, Italy
Tel: [phone]
Fax: [phone]
Victor Technologies International
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: [phone]
Fax: [phone]

Asia Pacific Regional Headquarters
71 Gower Street
Preston, Victoria, Australia, 3072
Telephone: [phone]
FAX: [phone]
Email: [email protected]
www.cigweld.com.au