Taylor DA7-B User manual

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OPERATING GUIDE
FOR
TYPE DA7-B
DRAWN ARC PISTOL
TAYLOR STUDWELDING
SYSTEMS LIMITED

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INDEX
PAGE No. CONTENT
3USEFUL INFORMATION.
5IMPORTANT SAFETY INFORMATION.
7INTRODUCTION TO STUDWELDING.
8SETTING UP AND WELDING.
11 EXPLODED DIAGRAMS AND PARTS LISTINGS.
17 ACCESSORIES - STANDARD FOOT ASSEMBLIES
19 ACCESSORIES - GAS FOOT ASSEMBLY
20 ACCESSORIES - CHUCKS - EUROPEAN SCREW-ON TYPE
21 ACCESSORIES - CHUCKS - EUROPEAN SCREW-ON GAS TYPE
UK TAPER FIT - ADJUSTABLE
22 ACCESSORIES - FERRULE GRIPS
BENDING BAR
23 EC DECLARATION OF CONFORMITY

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USEFUL INFORMATION
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.

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USEFUL INFORMATION
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 pistol. 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 pistol 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 UNIT 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.

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IMPORTANT SAFETY INFORMATION !
PROTECT YOURSELF AND OTHERS !
Read and understand these safety notes.
1. ELECTRICAL
No poron of the outer cover of the welding pistol 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.

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IMPORTANT SAFETY INFORMATION !
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
and these may interfere with other sensive Electronic equipment.
All Taylor Studwelding equipment is designed, manufactured and tested to conform to 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.

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INTRODUCTION TO STUDWELDING
The Taylor Studwelding DA7-B studwelding pistol when matched with an appropriate
controller and earth cables is intended for precision stud welding up to 12 mm diameter full
base studs. The pistol is lightweight, ergonomic and has been designed to operate with a
minimum amount of maintenance.
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.
It is possible to stud weld without a ferrule. When using this method it is recommended
pracce to employ a suitable shielding gas to reduce the amount of porosity in the
completed weld and improve weld quality.

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SETTING UP AND WELDING
As standard, the DA7 pistol comes ed with standard legs
and a standard foot adaptor. The pistol has an M10 thread on
the weld sha. This enables the use of European type screw-
on chucks, enabling studs up to 12mm in diameter to be
welded (see g.1).
Other arrangements are available as shown in gs. 2 & 3.
In g.2 an adapter is ed to the weld sha to enable standard
UK and American taper ng drawn arc chucks to be used,
enabling studs up to 12mm in diameter to be welded.
In g.3 a 35mm gas foot arrangement using long legs and an
extended form of screw-on chuck allows for welding, with or
without gas.
Please refer to the accessories secon of this guide for
informaon regarding chucks and other accessories for the
pistol.
The DA7-B pistol is commonly referred to as a “ring li” pistol. This means the pistol has an
internal clutch, allowing for moderate inconsistencies in the length of the studs being
welded, without aecng weld quality.
1
2
3

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SETTING UP AND WELDING
Once you have selected the type and size of
stud you wish to weld and obtained the
correct chuck (see the accessories secon of
this guide for a list of available sizes), you will
need to set up the chuck and t it to the pistol.
On the page “An introducon to studwelding”,
under the heading “The Process” it explains
that a measured amount of stud protrusion is
set at the welding pistol.
To ensure that the correct amount of
protrusion will be available once the chuck is
ed to the pistol, it is important to set the
chuck correctly in the rst place. Some chucks
have a pre-determined depth (see right) which
will only allow a certain amount of the stud to
be inserted.
Other chucks have a backstop arrangement
that allows the depth of engagement to be
adjusted.
Regardless of which type of chuck is employed,
when welding with ceramic ferrules, it is
important that sucient stud length is
exposed to allow more than the “burn-o”
allowance of the stud to pass completely
through the ferrule. Insucient allowance may
result in the leading edge of the chuck hing
the back of the ferrule during welding. This
would result in failed welds.
In non-ferrule welding it is only necessary to
set the chuck so that sucient stud length is
exposed to prevent damage to the leading
edge of the chuck during welding.

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SETTING UP AND WELDING
Fit the chuck to the pistol (g.1) using the
appropriate wrench. Secure the chuck in posion
using a 17mm A/F wrench on the front locknut.
Failure to do so may result in damage to the
pistol.
Fit the ferrule grip into the foot adapter (g.2)
and secure in place with the set screws in the foot
adapter. Do not over-ghten the set screws as
this will result in damage to the ferrule grip.
Adjust the posion of the foot adapter using the
hex head screw on the underside of the front end
cap (g.3) to set the required stud protrusion
(g.4).
IMPORTANT ! It is necessary to check/reset the
protrusion when changing stud length/diameter.
Adjustment of the pistol li is achieved by turning
the rear end cap of the pistol (g.5) which has a
“click” detent. Clockwise rotaon reduces li and
one “click” is approx’ equal to a 0.25mm change
in li.
NOTE! It is possible to use UK type taper chucks.
The pistol will require an adapter (g.6) to take
the chucks and this will need to be ed to the
pistol sha in the same fashion as the Euro chuck.
Once the adapter is ed, chucks may be
inserted (g.7) and secured by gently tapping into
place. Chucks can then be removed using a twist
dri through the cross-drilled holes.
PLEASE NOTE! Informaon contained in this operang guide is
intended to assist in seng up the pistol. 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.
12
3
4
5
6
7
2 - 3mm

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EXPLODED DIAGRAMS & PARTS LISTINGS
SEE PAGES 12 TO 17 FOR COMPLETE BREAKDOWN OF PISTOL.
ITEM QTY. PART No. DESCRIPTION
1471-300-003 WELDING CABLE
24½ 71-300-009 CONTROL CABLE
3181-101-051 WELDING PLUG
4171-101-030 CONTROL PLUG
5971-101-032 CABLE TIE (NOT SHOWN)
13
24

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ITEM QTY PART No. DESCRIPTION
12Z400-05-006 SET SCREW
2181-101-370 FOOT ADAPTER
31Z510-10-000 LOCKNUT
42Z120-05-030 CSK SCREW
EXPLODED DIAGRAMS & PARTS LISTINGS
12
23
1
7
6
5
4
SEE PAGES 19 - 21 FOR A SELECTION OF CHUCKS AND FERRULE GRIPS
ITEM QTY PART No. DESCRIPTION
13Z125-05-010 CSK SCREW
21Z440-08-005 SET SCREW - NYLON
BREAKDOWN OF FRONT END
ASSEMBLY ON PAGE 13
12
SEE NOTE BELOW
IMPORTANT NOTE!
ITEM 2 COVERS THE SET SCREW INDICATED. THIS SET SCREW MUST BE LOOSENED TO ALLOW DISCONNECTION OF THE WELD BRAID PRIOR TO ATTEMPTED
REMOVAL OF THE FRONT END ASSEMBLY.
ITEM QTY PART No. DESCRIPTION
5281-101-003 FOOT WASHER
6281-101-001 FOOT WASHER
7281-101-004 LEG

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ITEM QTY PART No. DESCRIPTION
11Z510-10-000 LOCKNUT 2181-111-044 RUBBER BELLOWS 3181-101-439 BEARING HOUSING 4181-101-450 BEARING 5181-101-438 SHAFT 6171-101-011 CIRCLIP 7181-101-448 FRONT END CAP 81Z440-08-010 SET SCREW 9181-101-443 PULLER PLATE
10 181-101-444 LIFTING BOSS
910 11 78 56 34 12 21 14 15 18 19 20 16 12 13 17
EXPLODED DIAGRAMS & PARTS LISTINGS
ITEM QTY PART No. DESCRIPTION
11 2Z125-04-016 SCREW 12 1Z600-12-000 WASHER 13 171-101-230 SPRING 14 181-101-440 LEG CLAMP 15 1Z600-06-000 WASHER 16 1Z615-06-000 SPRING WASHER 17 1Z305-06-020 SCREW 18 181-101-442 CLAMP PLATE 19 1Z505-05-000 HEX NUT 20 1Z400-06-012 SET SCREW 21 1Z120-05-025 SCREW

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1
2
67,8&9 10
3
45
11 12 13
14
EXPLODED DIAGRAMS & PARTS LISTINGS
ITEM QTY PART No. DESCRIPTION
1181-101-350 PISTOL BODY
2181-101-279 TRIGGER SWITCH
32Z400-05-008 SET SCREW
ITEM QTY PART No. DESCRIPTION
4181-101-366 CABLE CONN BLOCK
51Z120-05-012 CSK SCREW
6181-101-374 BRAID ASSEMBLY
71Z115-06-010 SKT CAP SCREW
81Z615-06-000 SPRING WASHER
91Z605-06-000 PLAIN WASHER
10 181-101-351 HANDLE COVER
11 1Z700-06-022 TERMINAL
12 1Z205-04-020 CSK SCREW
13 1Z205-04-010 CSK SCREW
14 171-101-034 STRAIN SLEEVE

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ITEM QTY PART No. DESCRIPTION
16Z208-03-004 CSK SCREW 2181-101-353 REAR END CAP 34Z120-05-020 CSK SCREW
3 2 1
EXPLODED DIAGRAMS & PARTS LISTINGS
LIFTER ASSEMBLY SEE PAGE 16 FOR DETAILED BREAKDOWN
COIL ASSEMBLY SEE PAGE 16 FOR DETAILED BREAKDOWN

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34
12
7
78
56
11 12
10
79
17
15 16
13 14
NOTE # PARTS 81-101-369 & 81-101-371 (COIL C/W HYSTERESIS WASHER & MODIFIED
POLE PIECE) MUST BE PURCHASED AS A SET AND MAY NOT BE PURCHASED SEPERATELY
EXPLODED DIAGRAMS & PARTS LISTINGS
ITEM QTY PART No. DESCRIPTION
1181-101-355 RINGPULL GUIDE
2181-101-319 LIFTING HOOK
3181-101-304 LIFTING RING
4181-101-384 PIN
5181-101-346 SPRING
6181-101-360 RINGPULL
7181-101-369 SEE NOTE #
7181-101-371 SEE NOTE #
84Z205-03-008 CSK SCREW
ITEM QTY PART No. DESCRIPTION
9181-101-357 COIL MOUNT
10 181-101-358 SPRING SEAT
11 181-101-347 SPRING
12 181-101-356 DETENT RING
13 1Z400-08-008 SET SCREW
14 481-101-082 DETENT BALL
15 481-101-376 SPRING
16 181-101-359 COIL HOUSING
17 2Z800-04-010 PIN

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ITEM QTY PART No. DESCRIPTION
12Z400-05-006 SET SCREW
2181-101-370 FOOT ADAPTOR
3181-101-005 UK TAPER CHUCK ADAPTER (OPTIONAL)
42Z120-05-020 CSK SCREW
5281-101-003 FOOT WASHER
6281-101-001 FOOT WASHER
7281-101-004 LEG
or 289-101-081 LEG (330 LONG. )
COMPLETE ASSEMBLY OF FOOT ADAPTER WITH STANDARD DA7-A LEGS IS AVAILABLE
UNDER PART NUMBER :89-101-158
PLEASE NOTE! ASSEMBLY DOES NOT INCLUDE UK TAPER CHUCK ADAPTER OR LONGER
THAN STANDARD LEGS.
ACCESSORIES - STANDARD FOOT ASSEMBLIES
3
12
4567

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ITEM QTY PART No. DESCRIPTION
1189-101-399 30mm NON-GAS NOSE PIECE
22Z400-05-005 SET SCREW
32Z120-05-020 SCREW
4281-101-003 FOOT WASHER
5181-101-370 FOOT ADAPTOR
6281-101-001 FOOT WASHER
7281-101-004 LEG
or 289-101-081 LEG (330 LONG)
PLEASE NOTE! ASSEMBLY DOES NOT INCLUDE LONGER THAN STANDARD LEGS.
ACCESSORIES - STANDARD FOOT ASSEMBLIES
12
34567

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ITEM QTY PART No. DESCRIPTION
1181-101-380 35mm GAS SHROUD
2181-101-411 CARRIER
3281-101-003 FOOT WASHER (FRONT)
4181-101-410 FOOT ADAPTOR
5181-101-409 CIRCLIP
6189-101-244 GAS BELLOWS
7171-200-226 GAS FITTING
81Z400-06-005 SET SCREW
92Z120-05-020 CSK SCREW
10 4½ 71-200-043 GAS PIPE
11 171-200-067 GAS PLUG
12 281-101-001 FOOT WASHER (REAR)
13 281-101-004 LEG (230mm)
or 289-101-081 EXTENDED LEG (330mm)
COMPLETE ASSEMBLY OF FOOT ADAPTER WITH
STANDARD DA7-A LEGS IS AVAILABLE UNDER
PART NUMBER :89-101-350
PLEASE NOTE! ASSEMBLY DOES NOT INCLUDE
LONGER THAN STANDARD LEGS.
ACCESSORIES - GAS FOOT ASSEMBLY
3456
12
12 13
11
910
78

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ACCESSORIES - CHUCKS
EUROPEAN SCREW-ON TYPE
ØDPART NUMBER
3589-101-003
4589-101-004
5689-101-005
511 89-101-007
6789-101-006
8989-101-008
10 11 89-101-010
12 13 89-101-012
ØDPART NUMBER
425 89-101-021
615 89-101-022
625 89-101-023
8689-101-024
825 89-101-025
10 489-101-026
10 689-101-027
12 689-101-028
TABLE 1 TABLE 2
LISTS OUR STANDARD STOCK RANGE OF CHUCKS.
TABLE 2 TABLE 2
LISTS OUR NON STOCK RANGE OF CHUCKS.
NOTE! NON STOCK CHUCKS WILL REQUIRE ADDITIONAL
DELIVERY LEAD TIMES AND MAY BE SUBJECT TO
MINIMUM ORDER QUANTITY.
PLEASE NOTE.
IF THE CHUCK THAT YOU REQUIRE IS NOT SHOWN HERE,
PLEASE CHECK WITH US.