Miller Auto Arc User manual

July
1988
FORM:
118583
OWN
ERS
MANUAL
Al
IT/VAI5F1____
I~1
1J
I
~
I~I
I
~.

MILLER
ELECTRIC MFG.
Co.
718
S.
BOUNDS
ST,
P.O.
Box
1079
APPLETON,
WI 54912 USA
ADDITIQNAL
COPY
PRICE
30
CENTS
IMPORTANT
Read and
understand
the entire
contents
of this
manual,
with
special
emphasis
on
the
safety
material
throughout
the
manual,
before
installing,
operating,
or
maintaining
this
equip
ment.
This
unit and these
instructions
are
for
use
only
by
persons
trained
and
experienced
in
the
safe
operation
of
welding equipment.
Do
not
allow
un
trained
persons
to
install,
operate,
or
maintain this
unit.
Contact
your
distributor
if
you
do
not
fully
understand
these
instructions.
Effective
With
Serial
No. JH304844
MODEL
AUTO ARC
PIN
WELDER
NWSA
CODE
NO. 4679
PRINTED IN
U.S.A.

ONE
YEAR
LIMITED
WARRANTY
COVERAGE
-
Miller Electric
Mlg.
Co.
warrants
to the
buyer
REMEDY FOR DEFECTIVE
WELDER
-
Upon
receipt
of
any
who
purchases
this
Auto
Arc
Welder
(Welder)
for
personal,
defective
Welder,
Miller
Electric
will,
at its
option,
repair
or
c~
family
or
household
purposes
(Consumer)
that
this
Welder
replace
the
defective
Welder
at
its
expense,
refund
or
credit
~
will
be
free
from
defects
in
material
and
workmanship
for
a
the
purchase price
(less
reasonable
depreciation
based
on ac
period
of
one
year
from
the
date
of
purchase.
This
warranty
tual
use),
or
reimburse
the
Consumer for the
cost
of
repair
or
,~
covers
only
the
original
purchaser
of this
Welder.
Miller
Electric
replacement
at
an
approved
Miller
Electric
warranty
station,
~
does
not
authorize
any
party,
including
its
authorized
provided
that
the
purchaser
of that Welder
has
followed
the
distributors,
to
offer
any
other
warranty
on
behalf of
Miller
procedure
for
obtaining
warranty performance
set
forth
below~

Electric.
Upon
expiration
of the
warranty
period,
Miller
Electric
The Welder
so
repaired
or
used
as a
replacement
will
be
ship-
,~
~
shall have
no
further
liability
related
to
the
Welder,
except
on
ped
to
the
purchaser
of the
defective
Welder,
with
transporta
warranty
claims
made
during
the
warranty
period.
tion
charges
prepaid
to
any
destination
in
the
continental
United States
(transportation
charges
on
shipments
to Alaska
~
THIS
WARRANTY IS OFFERED
IN
LIEU OF
ANY
OTHER
or
Hawaii
will
be
paid only
to
the
nearest
port
of
export).
~
EXPRESS
WARRANTY;
AND,
EXCEPT
TO
THE
EXTENT
~
PROHIBITED
BY
APPLICABLE
LAW,
THE
DURATION OF
ALL
IMPLIED
WARRANTIES,
INCLUDING
BUT NOT
THE
PURCHASERS
REMEDIES
FOR
A
DEFECTIVE
i*~
LIMITED
TO
THE
IMPLIED WARRANTIES
OF MERCHAN-
WELDER,
TO
THE
EXTENT PERMITTED
BY
APPLICABLE
TABILITY
AND
FITNESS FOR
A
PARTICULAR
PURPOSE,
IS
LAW,
ARE
LIMITED
TO
THE
REMEDY
PROVIDED
BY
THIS
LIMITED
TO
THE
DURATION
OF
THIS WARRANTY.
WARRANTY:
AND,
TO
THE
EXTENT
ENFORCEABLE
UNDER APPLICABLE
LAW,
MILLER
ELECTRIC SHALL
IN
Some states
do
not
allow
limitations
on
how
long
an
implied
NO
EVENT BE LIABLE
FOR
CONSEQUENTIAL,
INCIDENTAL
~
warranty
lasts,
so
the above
limitation
may
not
apply
to
you.
OR
SPECIAL DAMAGES ARISING OUT
OF THE USE
OF,
OR
~
This
warranty
gives
you
specific
legal
rights,
and
you
may
also
INABILITY TO
USE,
THE
WELDER,
WHETHER
BASED
ON
have other
rights
which
vary
from
state
to
state.
BREACH
OF THIS
WARRANTY,
MILLER
ELECTRICS
NEGLIGENCE
OR
OTHER
TORT,
OR
ON
ANY
THEORY
OF
STRICT LIABILITY.
Except
as
specified
below,
Millers
warranty
does
not
apply
on-
to
components
having
normal
useful
life of less
than
one (1)
year.
such
as
spot
welder
tips, relay
and
contactor
points,
Some
states
do
not
allow the
exclusion
or
limitation
of
c
parts
that
come
in
contact
with
the
welding
wire
including
sequential
or
incidental
damages,
so
the
above
limitations
may
not
apply
to
you.
nozzles and
nozzle insulators
where
failure
does not
result
from
-
defect
in
workmanship
or
material.
PROCEDURE FOR
OBTAINING
WARRANTY
PERFORMANCE
~
Miller
shall
be
required
to
honor
warranty
claims
on
war
~
ranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
As
soon
as
any
defect
in
a
Welder becomes
known,
the
pur
within the
following periods
from
the
date
of
delivery
of
Equip-
chaser of
the
Welder
must,
within
thirty
(30)
days,
notify
an
ment to
the
original
user:
approved Warranty
Station
or
Miller
Electric
in
writing
of
the
1.
Arc
welders,
power
sources,
and
components
1
defect.
The
purchaser
must
then,
within
the
one
year
warranty
year
period,
return
the
Welder
to
Miller
Electric
at
the
following
ad-
2.
Original
main
power
rectifiers
3
years
dress:
(labor~
1
year
only)
3.
All
welding
guns,
feeder/guns
and
plasma
torches
90
ClayS
Miller
Electric
Mt
g.
Co.
4.
Replacement
or
repair
parts,
exclusive of labor 60
days
718 South
Bounds Street
P.O. Box
1079
WHAT
IS NOT COVERED
-
This
warranty
does
not extend
Appleton,
Wisconsin
54912
~A.
to
any
Welder
subjected
to
misuse,
neglect,
accident,
or
in-
warranty
repair by
anyone
except
Miller
Electric. Further,
this
All
transportation
charges
to
Warranty
Station
or
Miller
Electric
~4
warranty
only
extends to those
purchasing
the
Welder for
per-
must
be
prepaid.
sonal,
family
or
household
purposes.
Commercial
and
in
dustrial
users
are
given
a
different
warranty.

TABLE
OF CONTENTS
Section
No.
Page
No.
SECTION
1

SAFETY
RULES
FOR
OPERATION
OF PORTABLE RESISTANCE
SPOT
WELDING
EQUIPMENT
1-1.
Introduction
1
1-2.
Installation
1
1-3.
Safety
Devices
1
1-4.
Personal
Safety
1
1-5.
Burn
Prevention
1
1-6.
Fumes
1
1-7.
Fire
Prevention
1
1-8.
Protection
Of Others
1
1-9.
Cords
1
1-10.
Hoses
1
1-11.
Maintenance
1
1-12.
Standards
Index
1
SECTION
2
INTRODUCTION
2-1.
General Information
And
Safety
2
2-2.
Receiving-Handling
3
2-3.
Description
3
SECTION
3
INSTALLATION
3-1.
Electrode
Installation
3
3-2.
Electrical
Input
Connections
4
SECTION
4
SEQUENCE
OF
OPERATION
4-1.
Operator
Controls
4
4-2.
Pin
Welding
4
4-3.
Clip Welding
4
4-4.
Shrinking/Expanding
5
4-5.
Shutting
Down
5
SECTION
5-
MAINTENANCE
&
TROUBLESHOOTING
5-1. Routine Maintenance
5
5-2.
Troubleshooting
5

SECTION 1

SAFETY
RULES
FOR
OPERATION OF
PORTABLE
RESISTANCE SPOT
WELDING
EQUIPMENT
1-1. INTRODUCTION
The
following safety
rules
cover
general
safe
practices
which
as a
minimum
should
be
employed
when
using
resistance
spot
welding
equipment.
Establishment
of
an
attitude
of
safety
consciousness is
necessary
for
the
protection
of
personnel
and
property.
Do
not
install,
operate,
or
maintain this
equipment
be
fore
reading
this
manual.
1-2.
INSTALLATION
All
equipment
should
be
installed
by
qualified
personnel
in
conformance
with
local,
state,
and
federal codes.
1-3.
SAFETY
DEVICES
Safety
devices
such
as
fuses
should
not
be discon
nected
or
shunted
out.
1-4.
PERSONAL SAFETY
Before
installation,
inspection,
or
service of
equipment,
disconnect
input
power
and
employ lockout/tagging
pro
cedures
to
prevent
accidental
turning
on
of
power.
Always
shut off
power
when
leaving
equipment
unat
tended.
Disconnect
provisions
must
be
available nearthe
equip
ment.
1-5.
BURN
PREVENTION
Wear
long-sleeve
shirt
and
cuff-less
trousers
in
addition
to
gloves,
hat,
and
high
top
shoes. Button shirt
collar,
pocket flaps,
and
sleeve
cuffs
to
avoid
entry
of
sparks.
Woolen
clothing
is
preferable
to cotton
because it is
not
so
readily ignited.
Cotton
clothing
if
used should be
chemically
treated
to
reduce
its
combustibility.
Clothing
treated with nondurable
flame-retardent matenals
should be retreated after
each
wetting
or
cleaning.
Wear
safety goggles
or
glasses
with
side
shields. Use
a
face shield for
severe
exposure
to
flying sparks.
Avoid oils
or
greases
on
clothing
which
could be
ignited
by sparks
and
do
not
use
flammable
hair
preparations.
Do
not
handle hot metal
such
as
tong
tips
or
workpiece
without
wearing gloves.
1-6.
FUMES
Severe
discomfort
or
illness
can
result
from
fumes and
vapors
produced by
welding.
Use
adequate
ventilation
as
described
in
ANSI
Z49.1.
Lead-, cadmium-, zinc-,
mercury-,
and
beryllium-bear
ing
and similar materials
when
welded
may
produce
harmful concentrations
of
toxic fumes.
Adequate
local
exhaust
ventilation
must
be
used for each
person
in
the
area as
well
as
the
operator
must
wear an
air-supplied
respirator.
Both
must
be used when
beryllium
is
in
volved.
Metals
coated
with
materials
that emit
toxic
fumes
should
not
be heated unless the
coating
is
removed
from
the
surface,
the
area
is
adequately
ventilated,
or
the
operator
wears an
air
respirator.
1-7.
FIRE
PREVENTION
Flying
sparks
can
pass
through
cracks, windows,
doors,
wall and
floor
openings,
and
along pipes.
If
combustibles
are
nearby,
do
not
weld. Move
work if
practicable
to
an area
free
of
combustibles.
If
work
can
not
be
moved,
move
combustibles
to
a
safe
location
or
protect
against ignition
with suitable and
snug-fitting
fire
resistant
covers or
shield.
Walls,
ceilings,
and floors
near
the
work
area should
be
fire
resistant
or
protected
by
fire resistant
covers
or
shields.
Do
not
weld where
atmosphere
may
contain
flammable
dust,
gas,
or
liquid
vapors
(such
as
gasoline).
Do
not
exceed
the
equipment
rated
capacity.
After
completion
of
work
inspect
area
to
ensure
it is
free
of
sparks,
glowing
embers,
and flames.
1-8.
PROTECTION OF OTHERS
Workers
or
other
persons
adjacent
to
the
welding
area
should
be
protected by
noncombustible
or
flame-resis
tant
screens
or
shields
or
should be
required
to
wear
suitable
eye
protection.
Booths
and
screens
should
per
mit
circulation
of air
at
floor level.
1-9.
CORDS
Frequently
inspect
for
wear,
cracks,
and
damage.
Im
mediately
replace
cords with
excessively
worn or dam
age
insulation
to
avoid
possibly
lethal
shock from
bared
conductors.
Keep
cords
dry,
free of oil
and
grease
and
protect
from
hot metal and
sparks.
1-10.
HOSES
On
water
cooled
equipment
examine
hoses and
fittings
regularly
for leaks and loose
connections.
Repair
or
re
place
leaky
hoses and
fittings.
Do
not
use
tape
to
repair
leaky
hoses.
1-11.
MAINTENANCE
Remove
leaky orfaulty equipment
from
service
immedi
ately
for
repair.
Keep
equipment
clean and
properly
ad
justed.
1-12.
STANDARDS
INDEX
1. ANSI
Standard Z49.1
Safety
In
Welding
And
Cut
ting,
obtainable from the American
Welding
Soci
ety,
550
Le
Jeune
Rd.,
P.O. Box
351040,
Miami,
FL
33135.
118583
Page
1

2.
NFPA
Standard
70-1978,
National Electrical
Code,
obtainable
from
the National
Fire
Protection
Association,
470 Atlantic
Avenue,
Boston,
MA
02210.
3.
OSHA
Safety
And
Hea~h
Standards,
29
CFR
1910,
obtainable
from the
Superintendent
of Docu
ments,
U.S.
Government
Printing
Office,
Washing
ton,
D.C.
20402
4.
ANSI
Standard Z87.i
Safe
Practices
For
Occupa
tion And Educational
Eye
And
Face
Protection,
ob
tainable
from the
American National
Standards
In
stitute,
1430
Broadway,
New
York,
NY
10018.
5.
ANSI
Standard
Z41.1
Standard
For
Mens
Safety
Toe
Footwear,
obtainable
from
the
American
Na-
tional Standard
Institute,
1430
Broadway,
New
York,
NY
10018.
6.
ANSI
Standard
Z49.2
Fire
Prevention
In
The Use
Of
Cutting
And
Welding
Processes,
obtainable
from
the American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
7. NFPA
Standard
51B,
Cutting
And
Welding
Pro
cesses,
obtainable from
the
National
Fire
Protec
tion
Association,
470
Atlantic
Avenue, Boston,
MA
02210.
8.
NWSA
booklet,
Welding
Safety Bibliography,
ob
tainable
from
the
National
Welding
Supply
Associa
tion,
1900 Arch
Street,
Philadelphia,
PA
19103.
9.
Code
for
Safety
in
Welding
And
Cutting,
GSA
Stan
dard
Wi
17.2-1974.
SECTION 2-INTRODUCTION
Gun
Weight:
9
lb.
9
Oz.
(4.3
kg)
115
Volt
AC,
15
Ampere Input
Power
Required
loft.
(3m)
Power
Cord
lB-i
18775
FIgure
2-1.
DImensIonal
VIew
2-1.
GENERAL
INFORMATION
AND SAFETY
A.
General
Information
presented
in
this
manual
and
on
various
la
bels,
tags,
and
plates
on
the unit
pertains
to
equipment
design,
installation,
operation,
maintenance,
and
trou
bleshooting
which
should be
read, understood,
and
fol
lowed
for the safe
and
effective
use
of this
equipment.
B.
Safety
The
installation;
operation,
maintenance,
and
trou
bleshooting
of
resistance
spot
welding equipment
re
quires
practices
and
procedures
which
ensure
personal
safety
and
the
safety
of
others.
Therefore,
this
equip
ment
is
to
be
installed,
operated,
and maintained
only
by
qualified
persons
in
accordance
with this
manual and
all
applicable
codes
such
as,
but
not
limited
to,
those listed
11-314
In.
4-1/4
In.
mm)
(222
mm)
118583
Page
2

at
the
end
of
Section
1

Safety
Rules For
Operation
Of
Portable Resistance
Spot
Welding Equipment.
Safety
instructions
specifically
pertaining
to
this
unit
ap
pear
throughout
this
manual
highlighted
by
the
signal
words
WARNING
and
CAUTION
which
identify
differ
ent
levels of
hazard.
WARNING
statements
include
installation,
operation,
and
maintenance
procedures
or
practices
which
if
not
carefully
followed
could
result
in
serious
personal
injury
or
loss
of
life.
CAUTION
statements
include
installation,
operation,
and maintenance
procedures
or
practices
which
if
not
carefully
followed
could
result
in
minor
personal injury
or
damage
to
this
equipment.
A
third
signal
word,
IMPORTANT
highlights
instn.ic
tions
which need
special
emphasis
to
obtain the
most
ef
ficient
operation
of
this
equipment.
2-2.
RECEIVING-HANDLING
Before
installing
this
equipment,
clean all
packing
mate
rial
from
around the
unit,
and
carefully inspect
for
any
damage
that
may
have
occurred
during shipment.
Any
claim
for
loss
or
damage
that
may
have
occurred
in
tran
sit
must
be
filed
by
the
purchaser
with the carrier.
A
copy
of the
bill of
lading
will
be
furnished
by
the
manu
facturer
on
request
if
occasion
to
file claim
arises.
When
requesting
information
concerning
this
equip
ment,
it is
essential
that
Model
Description
and
Serial
Number
of
the
equipment
be
supplied.
2-3.
DESCRIPTION
This unit
is
a
hand-held resistance
welding
unit
de
signed
for
use
in
auto
body repair.
The
unit
can
be used
for
pin
welding,
welding
trim
moulding clips,
and shrink
ing/expanding.
Welding
time is
determined
by
the
op
erator.
The
unit is
protected by
a
circuit
breaker
which
opens
when
an
overload condition
exists.
Equipment
supplied
includes:
Pin
Welder,
pin
elec
trode,
clip
electrode,
shrinking
electrode,
pins,
clips,
slide
hammer,
and tool box for
storage
of
equipment.
3-1.
ELECTRODE
INSTALLATION
(Figure
3-1)
a
WARNING:
ELECTRIC
SHOCK
can
kill;
HOT
SURFACES
can
burn
skin.

Do
not
touch live
electrical
parts.

Disconnect
input
powercord
from
po
wersup
ply receptacle
before
installing
electrode.

Allow electrode
to
coo/before
touching.
2.
Pull
electrode from electrode holder
assembly,
if
necessary.
3.
Push
desired
electrode into electrode
holder
as
sembly.
These electrodes
are
tapered
and need
not
be
twisted
or
keyed.
SECTION
3-INSTALLATION
Electrode
Pln
Electrode
Illustrated
Start
Switch
Outer
Electrode
Circuit
Breaker
115
VAC
Power
Cord
And
Plug
FIgure
3-1.
ResIstance
Welder
Components
1.
Select
electrode
according
to
application.
TB-118
775
118583
Page
3

3-2.
ELECTRICAL
INPUT
CONNECTIONS
dards
and
any
additional
state
and
local
codes.
A
cord with
plug
attached
is
provided
on
this unit. Check
nameplate
for
input
voltage
requirement,
and
connect
the
plug
to
a
properly grounded
and
protected
(fuses
or
circuit
breakers)
115
volt
ac
receptacle
capable
of
sup
plying
15
amperes.
Be
sure
that the
building
supply
and
receptacle comply
with National Electrical
Code
stan-
IMPORTANT: The
supply
wiring
for
the resistance
welder
must
be
capable
of
handling
a
15
ampere
load.
The
resistance
welder
must
be
the
only
load
connected
to
the
supply
circuit. Poorunit
performance
or
frequently
opening
line
fuses
or
circuit
breakers
can
result
from
an
inadequate
or
improper supply.
SECTION
4
SEQUENCE
OF
OPERATION
a
WARNING:
ELECTRIC
SHOCK
can
kill.

Do
not
touch
live electrical
parts.

Keep
all covers
in
place
while
operating.
Warranty
is void
if
resistance
welder is
operated
with
any
portion
of the
outer
enclosure
removed.
HOT
METAL AND
SPARKS
can
cause
fire
and
burns.

Wear
correct
eye,
ear,
and
body
protection.

Allow
equipment
and
work
to
cool
before han
dling.

Watch
for
fire.

Have
a
fire
extinguisher
nearby,
and know
how
to
use
it.
FUMES
AND
GASES
can
seriously
harm
your
health.

Ventilate
to
keep
from
breathing
fumes
and
gases.

If
ventilation
is
inadequate,
use
approved
breathing
apparatus.
MOVING
PARTS
can
cause
serious
Injury.

Keep
clear of
pinch points.
MAGNETIC
FIELDS FROM
HIGH
CURRENTS
can
affect
pacemaker
operatIon.

Wearers should
consult
with
their
doctor
be
fore
going
near
welding operations.
See
Section
1

Safety
Rules For
Operation
Of
Portable
Resistance
Spot
Welders
for
basic
welding
safety
information.
4-1.
OPERATOR
CONTROLS
A.
Start Switch
(FIgure
3-1)
The Start switch
is
a
spring-loaded,
momentary-contact
push
button
which
provides
on/off control of
the
weld
output.
Push
in
and
hold switch
for
desired
weld time.
Releasing
the switch
shuts
off
weld
output.
B.
Circuit Breaker
The circuit
breaker
provides
overload
protection.
When
the unit is
operated
at
a
rate
that
exceeds
its
capacity,
the
circuit breaker
opens,
shutting
off
weld
output.
Allow
a
brief
cooling period
before
resetting
the circuit break-
er.
4-2. PIN
WELDING
Pins
are
welded
onto auto
body
sheet metal dents. The
supplied
slide
hammer
is
used
to
pull
on
the
pin, thereby
pulling
out
the dent
in
the
auto
body
sheet metal.
a
WARNING:
Read
and follow
safety
Informa
tion
at
beginning
of
entire
Section
4
before
proceedIng.
1.
Install
pin
electrode
(see
Section
3-1).
2.
Insert
pin
into electrode.
3.
Plug
in
unit.
4.
Be
sure
that
surface where
pin
is
to
be
welded is
clean,
bare
metal. Push
resistance
welder
against
surface
until
electrode
outer
ring
is
seated
against
clean,
bare
metal.
5. Press
Start
switch for 0.5
to
1.0
seconds.
There
should
be
no
more
than
1/8
to
1/4
in.
(3.1
to
6.3
mm)
discoloration
around
weld.
6.
Slip
slide hammer
over
pin
and
tighten.
7.
To
remove
dents,
pull
slide
hammer with
a
constant
force and
tap
damaged
area
with
body
hammer.
If
necessary,
use
force
on
slide hammer
to
pull
dent
out.
8.
Afterdentispulledout,cutoff
pin
and
grind
off
head.
IMPORTANT:
For
larger
indents,
several
pins
can
be
welded
onto
the
body
at
1/2
in.
(13 mm)
interials
and
clamped
together.
Clamped
pins
can
be
pulled
using
a
come-along
or
body
and
frame
straightening
equip
ment.
4-3. CLIP
WELDING
Trim
moulding clips
can
be welded
onto
auto
body
sheet
metal
using
the resistance welder.
a
WARNING:
Read
and
follow
safety
informa
tlon
at
beginning
of
entire
Section
4
before
proceedIng.
1.
Install
clip
electrode
(see
Section
3-1).
2.
Insert
clip
into
electrode.
3.
Plug
in
unit.
118583
Page
4

4.
Be
sure
that
surface
where
clip
is
to
be welded is
clean,
bare
metal.
Push
resistance
welder
against
surface
until
electrode
outer
ring
is seated
against
clean,
bare
metal.
5. Press
Start switch
for 0.5
to
1.0
seconds. There
should be
no
more
than
1/8 to
1/4
in.
(3.1
to
6.3
mm)
discoloration
around
weld.
4-4.
SHRINKING/EXPANDING
High
spots
and
small
dents
can
be
smoothed
by using
the
shrink electrode
to
apply
heat
to
these
areas.
a
WARNING:
Read
and follow
safety
Informa
tion
at
beginning
of entire
Section
4
before
proceedIng.
1.
Install
shrinking
electrode
(see
Section
3-1),
and
plug
in
unit.
2.
Be
sure
that
surface
to
be
worked
on
is
clean,
bare
metal.
Push resistance
welder
against
surface
until
electrode
outer
ring
is
seated
against
clean,
bare
metal.
3.
Press
Start switch
for 0.5
seconds
two
or
three
times
to
heat
metal.
4.
If
a
high
spot
does
not
shrink,
tap
lightly
with
body
hammer.
If
a
dent does
not
expand, carefuIIy~apply
a
damp
cloth
to
the heated
metal.
4-5.
SHUTTING
DOWN
Disconnect
input
power
cord
from
receptacle.
SECTION
5-
MAINTENANCE
&
TROUBLESHOOTING
5-1.
ROUTINE
MAINTENANCE
IMPORTANT:
Every
six months
inspect
the
labels
on
this unit
for
legibility.
Al!
precautionary
labels
must
be
maintained
in
a
clearly
readable
state
and
replaced
when
necessary.
See
Parts List
for
part
number
of
pre
cautionary
labels.
4~
WARNING:
ELECTRIC
SHOCK
can
kill.

Do
not
touch live
electrical
parts.

Disconnect
input
power
cord from
power
sup
ply
receptacle
before
inspecting, maintaining,
or
servicing.
HOT
SURFACES
can
cause severe
burns.

Allow
cooling period
before
servicing.
Troubleshooting
of internal
parts
to
be
per
formed
only
by qualified
persons.
A.
Power
Cord
Every
three
months
inspect
cord
for
breaks
in
insulation.
Repair
or
replace
cord
if
insulation breaks
are
present.
Clean
grease
and
moisture from
cord
at
each
inspec
tion.
B.
Electrode MaIntenance
Keep
electrodes clean
and
free
of
grease
and moisture.
Fine steel
wool
can
be
used
to
keep
electrode
parts
clean.
A
fine
metal
file
can
be used
to
keep
the
outer
electrode flat.
5-2.
TROUBLESHOOTING
a
WARNING:
ELECTRIC
SHOCK
can
kIll.

Do
not
touch
live
electrical
parts.

Disconnect
input
power
cord from
power sup
ply
receptacle
before
inspecting,
maintaining,
or
servicing.
HOT SURFACES
can
cause severe
burns.

Allow
cooling
period
before
servicing.
MOVING
PARTS
can
cause
serIous
Injury.

Keep
clear of
pinch
points.
Troubleshooting
of
internal
parts
to
be
per
formed
only by qualified
persons.
It is
assumed
that the
unit
was
properly
installed accord
ing
to
Section
3
of this
manual,
the
operator
is familiar
with the function
of
controls,
the resistance welder
was
working properly,
and
that the
trouble is
not
related
to
the
process.
The
following
chart
is
designed
to
diagnose
and
provide
remedies
for
some
of the troubles that
may
develop
in
this
resistance
welder.
If
the trouble
is
not
remedied
after
performing
these
pro
cedures,
contact
the
nearest
Factory
Authorized
Ser
vice
Station.
In all
cases
of
equipment
malfunction,
the
manufacturers
recommendations
should be
strictly
fol
lowed.
118583
Page
5

TROUBLE PROBABLE CAUSE REMEDY
No
weld
output.
Open
line
fuse
or circuit
breaker.
Replace
line fuse
or
reset
line
circuit
breaker.
Circuit
breaker.
Reset circuit breaker.
Weld circuit
not
complete.
Press
outer
electrode
firmly
against
clean,
bare
metal.
Start
switch.
Replace
Start
switch.
Longer
than normal
weld
time.
Electrode.
Clean
or
replace
electrode.
Material to
be welded
dirty.
Clean material
to
be
welded.
Burn
through
at
point
of
weld.
Weld
time
too
long.
Shorten
weld time.
Electrode.
Use
correct,
clean
electrode.
118583
Page
6

July
1988
FORM: 118583
PARTS
LIST
Effective With
Serial No.
JH304844

10
11
6
8
2
9
2
28
27~
18~~
TC-116
992
Figure
A
-
Complete
Assembly

Item
Part
No.
No.
Description
Quantity
1
118206
2
118200
3
118199
4
601
865
5
602207
6
118188
7
117921
8
118189
9
+118 186
10 602241
11 601927
12
118190
13
118205
14
601 862
15
+118
187
16
117083
17
117902
18
118193
19 118192
20 118201
21
602020
22
118191
23 118194
24
118198
25
118246
26
118195
27
118196
28
118197
118
247
118 248
117957
117958
117960
117959
042
164
042 165
TRIGGER
BOOT
SCREW,
pan
hd-phillips
6-32
x
3/8
PIN,
electrode
SLIDING,
electrode
SPRING,
return
ELECTRODE
ASSEMBLY,
copper
CLIP
ELECTRODE
SHRINKING
ELECTRODE
SLIDE HAMMER
TOOL
BOX
DRAW
PINS,
2.0
mm
(500
per
pkg)
MOLDING CLIPS
(500
per
pkg)
MANUAL
PULL
CLAMP
POWER
PULL
CLAMP
1
2
2
2
2
_1
1
6
1
2
2
1
1
1
1
1
1
1
1
1
2
Optional Equipment
+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.
Figure
A
Complete
Assembly
INSULATOR
SLEEVE
NUT,
brass
5/16-18
WASHER,
flat-brass 5/16
NUT,
hex-full
1/4-20
WASHER,
lock-split
1/4
WIRE,
braided
LABEL,
Auto
Arc
SCREW,
cap-socket
hd 10-32
x
1-3/4
CASE,
right
hand
WASHER,
flat-SAE
1/4
SCREW,
cap-hex
hd 1/4-20
x
3/4
TRANSFORMER
INSULATOR
PAPER
NUT,
hex
10-32
CASE,
left hand
LABEL,
Auto Arc
Pin
Welder
LABEL,
warning
AA
Pin Welder
AC
LINE
CARD,
115
volts
w/strain relief & terminal
TRIGGER
SWITCH,
480 volts
ac
20
amp
SCREW,
cap-socket
hd
10-32
x
3/4
CIRCUIT
BREAKER,
25 volts
ac
10
amp
TEFLON INSULATOR
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
118583
Page
2