
Rev A: May 2010
iii Pro-Wedge 3XL Operator’s Manual Pro-Wedge 3XL Manual
Table of Contents
Safety Precautions............................................................................................................v
1. General Safety & Maintenance Information ................................................1
1.1. Intended Use ........................................................................................................1
1.2. Maintenance.........................................................................................................2
2. General Product Data......................................................................................3
3. Operating Environment ..................................................................................3
4. Site Preparation ...............................................................................................4
5. Unpacking & Installation Instructions ..........................................................4
5.1. Unpacking and Preparation..................................................................................5
5.2. Electrical Plug Connection ..................................................................................6
5.3. Electrical Extension Cords...................................................................................7
5.4. Generator Recommendations...............................................................................7
6. Welder Set-Up ..................................................................................................8
6.1. Set-Up Preparation...............................................................................................8
6.2. Adjustment #1: Wedge Centering........................................................................10
6.3. Adjustment #2: Wedge Engagement Position .....................................................14
6.4. Adjustment #3: Upper and Lower Contour Rollers.............................................17
6.5. Wedge Timing Definition ....................................................................................19
6.6. Wedge Re-Timing................................................................................................19
6.7. Wedge Removal...................................................................................................21
7. Factory Servicing .............................................................................................23
8. Welder Wiring Diagram .................................................................................23
9. Service/Spare Parts ID ....................................................................................25
9.1. 500-0100/3XL/A, Assembly, Pro-Wedge 3XL (Front).......................................26
9.2. 500-0100/3XL/A, Assembly, Pro-Wedge 3XL (Rear) ........................................27
9.3. 500-0100/3XL/A, Assy, Pro-Wedge 3XL (Parts List, Items 1-44) .....................28
9.4. 500-0100/3XL/A, Assy, Pro-Wedge 3XL (Parts List, Items 45-87) ...................29
9.5. 500-1005XL/A, Assembly, Pro-Wedge XL Controller Housing ........................31
9.6. 500-1005XL/A, Assy, Pro-Wedge XL Cntrlr Housing (Parts List) ....................32
9.7. 500-1006/3XL/A, Assembly, Pro-Wedge 3XL Control Panel ............................34
9.8. 500-1006/3XL/A, Assy, Pro-Wedge 3XL Cntrl Panel (Parts List) .....................35
9.9. 500-101/3XL/A, Assembly, Main Frame ............................................................36
9.10. 500-101/3XL/A, Assembly, Main Frame (Parts List) .........................................37