Taylor DA4 User manual

V-21A
OPERATING GUIDE
FOR TYPES
DA4, DA5 & DA6
HI-LIFT
DRAWN ARC PISTOL
TAYLOR STUDWELDING
SYSTEMS LIMITED
A TAYLORMADE DRAWN ARC STUDWELDING PISTOL

V-21A
INDEX
2
PAGE No. CONTENT
3USEFUL INFORMATION.
5IMPORTANT SAFETY INFORMATION.
7INTRODUCTION TO STUDWELDING.
8SETTING UP AND WELDING.
11 EXPLODED DIAGRAMS AND PARTS LISTINGS.
18 ACCESSORIES.
21 EC DECLARATION OF CONFORMITY.

V-21A
USEFUL INFORMATION
3
MANUFACTURERS DETAILS
TAYLOR STUDWELDING SYSTEMS LIMITED
COMMERCIAL ROAD
DEWSBURY
WEST YORKSHIRE
WF13 2BD
ENGLAND
TELEPHONE :[phone]
FACSIMILE :[phone]
email :[e-mail]
WEB :www.taylor-studwelding.com
SALES DIRECT TEL :[phone]
TECHNICAL HELPLINE :[phone]
You may wish to record the details of your controller below as this informaon will help
with any technical assistance you may require:
PURPOSE AND CONTENT OF THIS GUIDE
This guide has been wrien for :
• The personnel of the end-user responsible for the installaon and maintenance of the
pistol.
• The operator of the welding pistol.
This guide contains informaon relang to :
• Installaon and connecon.
• Operaon.
• Technical specicaons and parameters.
• Spare parts.
PISTOL SERIAL No.
DATE PURCHASED.

V-21A
USEFUL INFORMATION
4
FURTHER INFORMATION
Should you require addional technical informaon, please contact us directly (details
on previous page) or our local agent / distributor (details of agents etc. can be obtained
from us).
This guide contains important informaon which is a pre-requisite for safe Operaon
of the equipment. The operang personnel must be able to consult this guide when
necessary. In the interests of safety, make this guide available to your personnel in good
me.
If the equipment is sold / passed on, please hand over this manual to the new owner
and if possible please inform us of the name and address of the new owner, in case we
need to contact him regarding the safety of the machine.
PLEASE READ THIS GUIDE CAREFULLY BEFORE INSTALLING OR OPERATING THE
PISTOL.
PLEASE OBSERVE CAREFULLY ALL SAFETY PROCEDURES/INSTRUCTIONS.
DUE TO THE POWER REQUIREMENTS AND ELECTROMAGNETIC EMISSIONS
PRODUCED DURING NORMAL USE, THIS PISTOL MUST ONLY BE OPERATED IN
AN INDUSTRIAL ENVIRONMENT.
NEVER REMOVE ANY PORTION OF THE PISTOL HOUSING WITHOUT FIRST
ISOLATING THE PISTOL FROM THE CONTROLLER.
Taylor Studwelding Systems Limited reserves the right to amend the contents of this guide without nocaon.

V-21A
IMPORTANT SAFETY INFORMATION !
5
PROTECT YOURSELF AND OTHERS !
Read and understand these safety notes.
1. ELECTRICAL
No poron of the outer cover of the welding controller should be removed by anyone other
than suitably qualied personnel and never whilst mains power is connected.
ALWAYS DISCONNECT THE MAINS LEAD BEFORE ATTEMPTING ANY
MAINTENANCE.
BEWARE - RISK OF ELECTRIC SHOCK !
Do not use any uids to clean electrical components as these may penetrate into the
electrical system.
Installaon must be according to the seng up procedure detailed on page 8 of this guide
and must be in line with naonal, regional and local safety codes.
2. FIRE
During welding small parcles of very hot metal are expelled. Ensure that no combusble
materials can be ignited by these.
3. PERSONNEL SAFETY
Arc rays can burn your eyes and skin and noise can damage your hearing. Operators and
personnel working in close proximity must wear suitable eye, ear and body protecon.
Fumes and gases can seriously harm your health. Use the equipment only in a suitably
venlated area. If venlaon is inadequate, then appropriate fume extracon equipment
must be used.
Hot metal spaer can cause re and burns. Appropriate clothing must be worn. Clothing
made from, or soiled with, combusble materials must NOT be worn.
Have a re exnguisher nearby and know how to use it.
Magnec elds from high currents can aect heart pacemakers or other electronically
controlled medical devices. It is imperave that all personnel likely to come into the vicinity
of any welding plant are warned of the possible risks before entering the area.
4. MAINTENANCE
All cables must be inspected regularly to ensure that no danger exists from worn or
damaged insulaon or from unsound electrical connecons. Special note should be made
of the cables close to the pistol, where maximum wear occurs. As well as producing
inconsistent welds, worn cables can overheat or spark, giving rise to the risk of re.

V-21A
IMPORTANT SAFETY INFORMATION !
6
5. TRAINING
Use of the equipment must be limited to authorised personnel only who must be suitably
trained and must have read and understood this manual. This manual must be made
available to all operators at all mes. Further copies of this manual may be purchased from
the manufacturer. Measures must be taken to prevent the use of this equipment by
unauthorised personnel.
6. INSTALLATION
Ensure that the site chosen for the equipment is able to support the weight of the
equipment and that it will not fall or cause a danger in the course of its normal operaon.
Do not hang connecng cables over sharp edges and do not install connecng cables near
heat sources or via trac routes where people may trip over them or they may be
damaged by the passage of vehicles (forklis etc).
7. INTERFERENCE
During welding operaons, intense magnec and electrical elds are unavoidably produced
which may interfere with other sensive Electronic equipment.
All Taylor Studwelding equipment is designed, manufactured and tested to conform the
current appropriate European standards and direcves regarding electromagnec
emissions and immunity and as such is safe to use in any normal environment.
8. DISPOSAL
The equipment either wholly or any of its component parts may be disposed of as part of
general industrial waste or passed to a scrap merchant. None of the components used in
the manufacture are toxic, carcinogenic or harmful to health in their “as supplied”
condion.

V-21A
INTRODUCTION TO STUDWELDING
7
The Taylor Studwelding DA6 HI-LIFT studwelding pistol when matched with an appropriate
controller and earth cables is intended for accurate stud welding up to 30 mm diameter
studs. The pistol is lightweight, ergonomic and has been designed to operate with a
minimum amount of maintenance. The DA6 HI-LIFT has been specically designed to have
an increased li capacity especially when welding with increased protrusion e.g. When
welding shear connectors (concrete anchors) thru-deck.
The energy required to carry out the welding operaon is derived from an appropriate
studwelding controller.
Taylor Studwelding Systems Ltd controllers are modern, robustly designed and oer
maximum reliability combined with an easy to understand operator interface.
THE PROCESS
The process of drawn arc studwelding is long established and well proven. The basic steps
are as follows :
• A measured amount of weld stud protrusion is set at the welding pistol.
• Once in posion, the pistol lis the stud away from the work-piece, simultaneously
striking an arc between the two.
• Both the p of the weld stud and the surface of the work-piece melt as the arc is
sustained for a pre-determined interval.
• At the compleon of the pre-determined interval, the pistol returns the weld stud to
the molten pool on the work-piece, thus forming a weld.
The most common and tradional drawn arc welds have a weld duraon greater than
100ms and employ the use of a single use ceramic arc shield, commonly referred to as a
ferrule. This ferrule helps to protect the arc during the weld and assists in formaon of the
nal llet. Post welding the ferrule is removed and disposed of.

V-21A
SETTING UP AND WELDING
8
Select the type and size of stud you wish to weld and obtain the correct chuck and foot
arrangement (see below and the accessories secon of this guide for a list of available
sizes).
Standard shear connector chucks screw directly
onto the thread on the pistol sha. The chucks
normally have a cross drilled hole in order that a
bar can be inserted for ghtening or have
machined ats to take a wrench.
IMPORTANT! Make sure the chuck is ed
securely. Failure to do so may result in damage to both the chuck and the pistol sha
during welding.
IMPORTANT! Ensure that when ng the chuck that the cable aachment to the sha is
not loosened, as this also may result in damage
during welding.
An assortment of front end opons are available
(see g.1 - 3 right) and which of these would be
preferable is down to customer choice when
ordering. All three opons shown perform the
same task but are beer suited to parcular
applicaons.
Fig.1 shows an extended foot arrangement which
is favoured by many when performing thru-deck
welding. This foot arrangement allows studs and
ferrules to be placed in areas with limited access.
Fig.2 shows an arrangement more suited in “to
beam” welding where condions and access are
generally easier.
Fig.3 shows a budget arrangement which is
available for lower volume work.
This pistol is commonly referred to as a “ring li”
pistol. This is because the li mechanism in the
pistol includes a clutch assembly with a lng ring. What this means in praccal terms is
that not only can the li can be adjusted within its operaonal limits, should certain
parameters change from weld to weld, for example the studs being welded varying in
length slightly, the pistol will be able to allow for this without aecng the li that has been
set. Even so, we recommend that only properly manufactured weld studs be used to ensure
repeatable weld quality.
1
2
3

V-21A
SETTING UP AND WELDING
9
Fit the stud and ferrule in place and set the
required burn o protrusion. This is achieved
by using a 5mm hex key to loosen the leg
clamps in the front end cap.
Aer loosening the clamps, slide the legs in or
out unl the desired stud protrusion is
achieved (this amount will vary from stud size
to stud size and is generally proporonal to the
stud diameter).
NOTE! In the BS EN ISO standard covering the
manufacture of drawn arc weld studs, the
length prior to welding (this is the length aer
welding plus the burn o allowance) is at the
discreon of the stud manufacturer.
Dierences in this length would impact on the
burn o protrusion value.
As a general rule of thumb, we would suggest that the burn o protrusion distance should
be approximately 8 to 10mm, but never less than 7mm.
Once the correct protrusion is set, you must
ensure that the movement of the stud inside
the ferrule is smooth, as any binding between
the stud and ferrule will result in poor or bad
welds. As can be seen in the accompanying
illustraon where the foot piece is shown with
some of the fasteners missing, the holes in the
foot piece are a lot bigger than the screws
fastening the foot piece to the legs. This allows
the foot piece to be adjusted to remove any binding between the stud and ferrule. Once
these condions are sased, you are now
ready to set the li.
IMPORTANT!
It is necessary to check/reset the protrusion
and posioning of the foot adaptor when
changing stud lengths/diameters.
SETTING THE LIFT
Adjustment of the pistol li is achieved by removing the rear end cap of the pistol. Inside is
an adjuster with a large slot. Use a coin to twist the adjuster. Clockwise rotaon reduces li
and conversely an-clockwise rotaon increases li. The adjuster has a “click” detent, each
click is approximately equal to a 0.25mm change in li.
Li should be set between 1mm and 8mm depending on the size of stud being welded and
other applicaon specic factors e.g. material, site condions etc.
BURN OFF PROTRUSION

V-21A
SETTING UP AND WELDING
10
Once the required li has been set, the pistol is now ready to weld and can be connected to
the controller. Consult your appropriate controller operang guide for assistance in seng
up the controller.
Other useful informaon including stud welding techniques, weld tesng and inspecon
can also be found in the controller operang guide.
PLEASE NOTE. Informaon contained in this operang guide is intended to assist in seng
up and using the pistol. All the suggested sengs are intended as a starng point only. Fine
tuning the sengs to achieve the most sasfactory results is essenal and is the
responsibility of the user of the pistol.

V-21A
EXPLODED DIAGRAMS & PARTS LISTINGS
11
ITEM No. OFF PART No. DESCRIPTION
13/5 71-300-016 4 CORE CONTROL CABLE (m)
2371-300-015 120mm² WELDING CABLE (m) - DA6
or 571-300-006 95mm² WELDING CABLE (m) - DA5
or 571-300-005 70mm² WELDING CABLE (m) - DA4
3171-101-030 4 PIN CONTROL PLUG
4181-101-163 WELDING PLUG - DA6
or 181-101-149 WELDING PLUG - DA4 & DA5
5571-101-032 CABLE CLIP (NOT SHOWN)
SHAFT FRONT END
COMPONENTS COMPONENTS
PAGE 14 PAGE 13
COIL & LIFT
ADJUSTMENT
COMPONENTS
PAGE 17
BODY
COMPONENTS
PAGE 16
LIFT
COMPONENTS HANDLE
PAGE 15 COMPONENTS
PAGE 12
12
34

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EXPLODED DIAGRAMS & PARTS LISTINGS
12
12345
6
7
8910
11
12
13
14
15
16
17
ITEM QTY PART No. DESCRIPTION
1181-101-031 SWITCH
2181-101-401 SLING SHAFT
32Z200-03-016 SCREW
41Z305-14-012 SCREW
5181-101-045 HANDLE COVER
ITEM QTY PART No. DESCRIPTION
61Z120-05-025 SCREW
72Z120-05-020 SCREW
8181-101-125 PUSHBUTTON
9181-101-030 SPRING
10 181-101-089 ACTUATOR
11 181-101-054 CABLE SLEEVE
12 1Z615-10-000 WASHER
13 181-101-205 MOUNT DA4 & 5
or 181-101-402 MOUNT DA6
14 1Z120-10-030 SCREW
15 181-101-204 CLAMP DA4 & 5
or 181-101-403 CLAMP DA6
16 2Z615-05-000 WASHER
17 2Z100-05-020 SCREW

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EXPLODED DIAGRAMS & PARTS LISTINGS
13
ITEM No. OFF PART No. DESCRIPTION
1181-101-201 CHUCK ADAPTOR
21Z700-10-095 TERMINAL - DA5 & DA6
or 1Z700-10-070 TERMINAL - DA4
32Z105-05-035 SCREW
42Z615-05-000 WASHER
5181-111-052 CLIP BEARING
6181-101-399 FRONT END CAP
7181-101-398 SPRING
8181-101-168 O RING
9181-101-006 BELLOWS
10 181-101-212 DAMPER CAP
11 181-111-054 DAMPER
12 2Z600-06-000 WASHER
13 2Z100-06-012 SCREW
14 281-101-387 LEG GRIP INSERT
15 1Z505-08-032 NUT
7
56
34
12
15
14
12 13
10 11
89

V-21A
EXPLODED DIAGRAMS & PARTS LISTINGS
14
567
34
12
12 13
10 11
89
COMPLETE SHAFT IS AVAILABLE UNDER PART NUMBER : 81-101-400
ITEM No. OFF PART No. DESCRIPTION
1181-101-208 SHAFT FRONT
2181-101-065 INSULATOR
31Z105-05-055 SCREW
4181-101-391 INSULATOR
5181-101-394 SHAFT BLOCK
6181-101-071 INSULATOR
7181-101-073 LIFTING SLEEVE
8181-101-066 INSULATOR
9181-101-193 INSULATOR
10 4Z205-03-008 SCREW
11 181-101-392 DAMPER BRACKET
12 181-101-072 INSULATOR
13 181-101-396 GUIDE SHAFT

V-21A
EXPLODED DIAGRAMS & PARTS LISTINGS
15
6
45
23
1
ITEM No. OFF PART No. DESCRIPTION
14Z220-04-010 SCREW
2181-101-014 RETAINING PLATE
3181-101-015 LIFTING RING
4181-101-018 SPRING
5281-101-250 BEARING BUSH
6181-101-395 LIFTING HOOK

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EXPLODED DIAGRAMS & PARTS LISTINGS
16
ITEM No. OFF PART No. DESCRIPTION
1181-101-023 PISTOL HALF MOULDING
2181-101-397 BODY CLAMPING RING
3181-101-101 REAR END CAP
4181-101-024 PISTOL HALF MOULDING
51Z100-04-025 SCREW
62Z800-03-006 PIN
71Z100-04-016 SCREW
123
4
5
6
7

V-21A
EXPLODED DIAGRAMS & PARTS LISTINGS
17
ITEM No. OFF PART No. DESCRIPTION
1181-101-390 COIL HOUSING
2181-101-389 LIFT COIL
3181-101-039 WAVE SPRING
4181-101-043 DETENT HOUSING
5181-101-104 COIL LOCKING RING
64Z410-05-020 SET SCREW
7181-101-376 SPRING
8181-101-082 DETENT BALL
9181-101-393 BACKSTOP
56
34
12
9
78

V-21A
ACCESSORIES - BUDGET FOOT ASSEMBLY & CHUCKS
1818
PART No. DESCRIPTION
87-101-012 12mm SHEAR CONNECTOR CHUCK
87-101-016 16mm SHEAR CONNECTOR CHUCK
87-101-019 19mm SHEAR CONNECTOR CHUCK
87-101-022 22mm SHEAR CONNECTOR CHUCK
87-101-025 25mm SHEAR CONNECTOR CHUCK
PART No. DESCRIPTION
89-101-270 12mm FOOT PIECE
89-101-257 16mm FOOT PIECE
89-101-258 19mm FOOT PIECE
89-101-250 22mm FOOT PIECE
89-101-238 25mm FOOT PIECE
TOOL PART No.
METRIC KEY SET 98-100-003
ITEM No. OFF PART No. DESCRIPTION
12Z305-06-030 SCREW
24Z600-06-025 WASHER
31SEE BELOW FOOT PIECE
4281-111-029 LEG
34
12

V-21A
ACCESSORIES - EXTENDED FOOT ASSEMBLY
ITEM No. OFF PART No. DESCRIPTION
12Z305-06-030 SCREW
24Z600-06-025 WASHER
31SEE BELOW “C” PIECE
41SEE BELOW STEM/BUTTERFLY ASSEMBLY
5281-111-029 LEG
62Z105-05-016 SCREW
5
34
12
6
19
PART No. DESCRIPTION
89-101-800 STEM/BUTTERFLY ASSEMBLY
PART No. DESCRIPTION
89-101-123 19mm “C” PIECE FOR EXT. ASSY
89-101-137 22mm “C” PIECE FOR EXT. ASSY
89-101-138 25mm “C” PIECE FOR EXT. ASSY

V-21A
ITEM No. OFF PART No. DESCRIPTION
12Z305-06-030 SCREW
24Z600-06-025 WASHER
31SEE BELOW “C” PIECE
4189-101-342 FOOT ADAPTOR
5281-111-029 LEG
62Z410-05-010 SET SCREW
5
34
12
6
ACCESSORIES - “TO BEAM” FOOT ASSEMBLY
20
PART No. DESCRIPTION
87-101-026 19mm TO BEAM FOOT ASSEMBLY
87-101-027 22mm TO BEAM FOOT ASSEMBLY
87-101-028 25mm TO BEAM FOOT ASSEMBLY
PART No. DESCRIPTION
89-101-343 19mm “C” PIECE
89-101-351 22mm “C” PIECE
89-101-352 25mm “C” PIECE