Taylor DA8-A User manual

V-21A 1
TAYLOR STUDWELDING
SYSTEMS LIMITED
OPERATING GUIDE
FOR
TYPE DA8-A
DRAWN ARC STUDWELDING PISTOLS

V-21A 2
INDEX
PAGE CONTENT
3GENERAL INFORMATION
4SAFETY
5INTRODUCTION TO STUDWELDING
6MODEL VARIANTS
7SET UP & WELDING - CHUCKS
8SET UP & WELDING - STANDARD DA8-A
10 SET UP & WELDING - A1 & A2 MODELS
12 SET UP & WELDING - A3 & A4 MODELS
13 WELDING - ALL MODELS
15 COMPONENT EXPLOSION & PARTS LISTING
20 ACCESSORIES
26 EC DECLARATION

V-21A 3
GENERAL INFORMATION
MANUFACTURERS DETAILS
TAYLOR STUDWELDING SYSTEMS LIMITED
COMMERCIAL ROAD FIND US
DEWSBURY ON
WEST YORKSHIRE GOOGLE
WF13 2BD MAPS
ENGLAND
TELEPHONE :[phone]
FACSIMILE :[phone]
e-mail :[e-mail]
DIRECT SALES TEL :[phone]
INTERNET :www.taylor-studwelding.com
PURPOSE AND CONTENT OF THIS GUIDE
This guide has been wrien for :
The operator of the welding machine.
Installaon and maintenance personnel.
Purchasing personnel.
This guide contains informaon on :
Installaon and connecon
Operaon.
Technical data.
Spare parts and Accessories.
FURTHER INFORMATION
Should you require addional technical informaon, please contact us directly (details above) 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. 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 guide to the new owner. Please
immediately inform us of the name and address of the new owner, in case we need to contact them
regarding the safety of the device.
Please read this guide carefully before installaon of the machine.
Please especially observe the safety instrucons.
Taylor Studwelding Systems Limited reserves the right to amend the contents of this manual without nocaon.

V-21A 4
SAFETY
PROTECT YOURSELF AND OTHERS !
These welding pistols whilst unconnected are inert but once connected as part of a complete welding installaon may
present potenal risks and dangers. Please read and understand these safety noces.
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 plug from the socket.
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 in the appropriate operang/installaon guides for
the equipment being used and must be in line with naonal, regional and local safety codes.
2. FIRE
During welding 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 DANGER before
entering the area.
To minimise the risks of exposure to electromagnec radiaon, operators should not drape the welding cables over
their shoulders or wrap them around themselves in any way whilst using the equipment. It is also recommended that
operators route the welding earth return cables away from themselves and do not stand between the two earth return cables
during welding
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.
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 and any other applicable documentaon. This guide must be made available to all operators at all mes
and further hard copies of this guide may be purchased from the manufacturer or downloaded from our website. Measures
must be taken to prevent the use of this equipment by unauthorised personnel. Please note that Taylor Studwelding Systems
Ltd also oer, at an addional cost, personnel training packages, should a cercate of competency be required for operang/
maintenance 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 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. Non of the components used in the manufacture are toxic, carcinogenic or harmful to health.
Please note that, in line with the WEEE direcve, Taylor Studwelding Systems Ltd oers a return for disposal policy.

V-21A 5
INTRODUCTION TO STUDWELDING
When matched with an appropriate controller and earth cables, the Taylor Studwelding DA8-A
studwelding pistol is intended for precision stud welding up to 10 mm diameter 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. This method is more commonly employed with welds having
a duraon of less than 100ms and this type of weld is referred to as short cycle stud welding. Although no
ferrule is employed, it is recommended pracce in short cycle welding to employ a suitable shielding gas
to reduce the amount of porosity in the completed weld and improve weld quality.
The DA8-A range of pistols are what are commonly referred to as “xed li” pistols. This is because the
pistol does not include a clutch assembly in the li mechanism. In praccal terms this means that
although the li can be user adjusted within its operaonal limits, should certain parameters change from
weld to weld, for example the studs to be welded vary in length or the surface being welded to being very
uneven, this will have an eect on the amount of li during the weld and may impact adversely on the
quality of the nished weld. Because of this, we recommend that only properly manufactured weld studs
be used and that customers should always strive to weld to at, even surfaces.
It is important to decide, based on your specic applicaon, which model variant of the DA8-A will be best
for you. For example. If you are welding standard drawn arc studs with ferrules, the standard DA8-A
would be your choice whereas if your applicaon calls for short cycle or CD type studs welding using a
template with 35mm posioning guides , the A2 would be the best choice. You could also select the A4
for this applicaon providing that the studs to be welded are under 40mm in length as this is limit for stud
length in the A3 and A4 variants. See page 6 for an outline of the dierent model variants.

V-21A 6
MODEL VARIANTS
The basic standard model of the DA8-A pistol is
shown here on the le. This model is supplied rigged
as standard to use European screw-on chucks and
for welding standard drawn arc studs with ceramic
ferrules .
Four other model variants are available, each rigged
dierently to handle dierent more specic
applicaons. These are shown below.
DA8-A
COMPLETE PISTOL PART NUMBER :
99-101-063
DA8-A1 DA8-A2
99-101-064 99-101-065
Uses standard European Uses standard European
Screw-on chucks and Screw-on chucks and
long/gas chucks. long/gas chucks.
Rigged for gas purging and Rigged for gas purging and
ed with a 30mm nose ed with a 35mm nose
piece piece
DA8-A3 DA8-A4
99-101-066 99-101-067
Uses CD type chucks Uses CD type chucks
Fied with one-piece Fied with one-piece
30mm front cap. 35mm front cap.
Can be rigged for gas Can be rigged for gas
purging oponally. purging oponally.

V-21A 7
SET UP AND WELDING - CHUCKS
Select the required weld stud on the basis of process, diameter, length and material. See
our separate catalogues entled “Drawn Arc Stock List” & "Capacitor Discharge Stock List"
which can be found by scanning the adjacent QR codes or
alternavely are available from your local Taylor stockist.
DRAWN ARC CD
Select the required chuck, appropriate to the pistol variant
and weld stud diameter. European screw-on chucks have a
female M10 mounng thread and mount directly onto the
male M10 thread on the sha of the standard A, A1 & A2
variants whilst CD type
chucks t directly into the
chuck nut on the front of
the sha of the A3 & A4 variants (a list of available chucks
of both types may be found in the accessories secon of
this guide on pages 20 - 25).
CD type chucks have an
adjustable backstop which
needs to be adjusted to
suit whatever length of
stud has been selected (up
to a maximum length of 40mm). This is because the pistol variants using the CD type
chucks have a xed length setup. The stud must be inserted fully into the chuck unl the
ange of the stud hits the face of the chuck and then adjusted out by turning the adjuster
screw unl there is an approximate gap of 3 - 4mm between the face of the chuck and the
back of the stud ange.
Euro chucks do not have any adjustment.
This is because the pistol variants using
these chucks adjust for the length of the
stud on the pistol and not in the chuck.
Instead they have a blind depth hole into
which the weld stud is loaded. If welding
with ferrules, select the appropriate size
of ferrule grip to suit the ferrules being used.

V-21A 8
SET UP AND WELDING - STANDARD DA8-A
Having selected and where necessary prepared
the chuck, it can now be ed to the pistol. To
begin, remove the foot assembly by loosening
the thumbscrews on the front end cap (chuck
ng may be accomplished without removing
the foot assembly. However, removal of the
assembly provides easier access).
Slide the chuck into bellows support and screw
the chuck into posion on the M10 mounng
thread on the front of the pistol sha.
Tighten the chuck into posion using an
appropriate wrench (usually 14mm A/F for Euro
chucks - see page 25).
IMPORTANT! Do not over-ghten chucks. This
requires only hand ghtening. Over-ghtening may result in un-warraned damage to your
pistol.
Re-fit the foot assembly by sliding into the front end cap and
tightening the thumbscrews then fit the brass ferrule grip into the
foot adaptor. Ensure the ferrule grip is an appropriate match to
the chuck fitted earlier. The ferrule grip is held in position by two
set screws positioned 180° apart in the foot adaptor. Gently
secure the ferrule grip using a 2.5mm hex key. Again, be aware
that over-tightening may damage the grip.

V-21A 9
SET UP AND WELDING - STANDARD DA8-A
With the correct stud and ferrule to be welded ed
into the chuck/ferrule grip, loosen the thumbscrews
and slide the foot assembly unl the stud is
protruding past the ferrule to the desired distance.
Once this is set, re-ghten the thumbscrews.
Remove the ferrule and check the centrality of
the stud in the ferrule grip by looking straight
down the centre of the pistol sha. If the stud
appears to be o-centre. Use a 3mm hex key to
loosen the foot screws on the foot adaptor and
re-posion the adaptor on the legs (the holes in
the adaptor are designed to allow adjustment).
Re-ghten the screws once the adjustment has
been made.
The next step is to set the required li for
welding. This must be done in three stages to
ensure that the li is set properly. Stage one is
to back the li o so that the pistol can be
properly posioned to set the li. To back the
li o, twist the rear end cap adjuster an-
clockwise unl the pistol indicator is in the MAX
posion.
Stage two is to “zero” the li. NOTE Ensure that the pistol is not connected to the
controller whilst performing this stage. To do this the pistol (with a
stud and ferrule loaded) needs to be pressed into the posion as if a
weld is about to take place with the sha moving back unl the
ferrule is hard against the surface. With the pistol held rmly in this
posion, turn the rear end cap adjuster clockwise and connue to
turn it unl it reaches the zero posion. This is the point where
further turning of the adjuster will start to force the stud forward,
liing the ferrule away from the surface. This is the zero posion.

V-21A 10
SET UP AND WELDING - STANDARD DA8-A
Stage three is to set the required li. The rear
end cap adjuster has a click detent which
allows the adjuster to stop every half-turn. This
means that each half-turn ≈ 0.5mm li.
Therefore, if 2mm of li is required, turn the
rear end cap adjuster an-clockwise 4 clicks
from the zero posion to set the li.
IMPORTANT! If any changes are made to the
seng of the pistol, the chuck, ferrule grip, stud length etc. The li may be aected and
this procedure may need to be re-executed to ensure that the required li is applied.
SET UP AND WELDING - A1 & A2 MODELS
Having selected and where necessary prepared
the chuck, it can now be ed to the pistol. To
begin, remove the foot assembly by loosening
the thumbscrews on the front end cap (chuck
ng may be accomplished without removing
the foot assembly. However, removal of the
assembly provides easier access).
Slide the chuck into bellows support and screw the chuck
into posion on the M10 mounng thread on the front of
the pistol sha.
Tighten the chuck into posion using an appropriate
wrench (usually 14mm A/F for Euro chucks - see page 25).
IMPORTANT! Do not over-ghten chucks. This
requires only hand ghtening. Over-ghtening may
result in un-warraned damage to your pistol.

V-21A 11
SET UP AND WELDING - A1 & A2 MODELS
With the correct stud to be welded ed
into the chuck, loosen the thumbscrews
and slide the foot assembly unl the stud
is protruding past the nose cone to the
desired distance. Once this is set, re-
ghten the thumbscrews.
Check the centrality of the stud in the nose cone
by looking straight down the centre of the pistol
sha. If the stud appears to be o-centre. Use a
3mm hex key to loosen the foot screws on the
foot adaptor and re-posion the adaptor on the
legs (the holes in the adaptor are designed to
allow adjustment). Re-ghten the screws once the
adjustment has been made.
The next step is to set the required li for
welding. This must be done in three stages to
ensure that the li is set properly. Stage one is
to back the li o so that the pistol can be
properly posioned to set the li. To back the
li o, twist the rear end cap adjuster an-
clockwise unl the pistol indicator is in the MAX
posion.
Stage two is to “zero” the li. NOTE Ensure that the pistol is not
connected to the controller whilst performing this stage. To do this
the pistol (with a stud loaded) needs to be pressed into the posion
as if a weld is about to take place with the sha moving back unl the
nose cone is hard against the surface. With the pistol held rmly in
this posion, turn the rear end cap adjuster clockwise and connue
to turn it unl it reaches the zero posion. This is the point where
further turning of the adjuster will start to force the stud forward,
liing the nose cone away from the surface. This is the zero posion.

V-21A 12
SET UP AND WELDING - A1 & A2 MODELS
Stage three is to set the required li. The rear
end cap adjuster has a click detent which
allows the adjuster to stop every half-turn. This
means that each half-turn ≈ 0.5mm li.
Therefore, if 2mm of li is required, turn the
rear end cap adjuster an-clockwise 4 clicks
from the zero posion to set the li.
IMPORTANT! If any changes are made to the
seng of the pistol, the chuck, stud length etc. The li may be aected and this procedure
may need to be re-executed to ensure that the required li is applied.
SET UP AND WELDING - A3 & A4 MODELS
Having selected and where necessary prepared
the chuck, it can now be ed to the pistol.
Insert the chuck into the opening in the chuck
nut and rmly push the chuck unl it comes to
rest at the boom of the opening. Once this is
done, ghten the chuck using the 17mm A/F
box spanner provided (see page 25).
IMPORTANT! Do not over-ghten chucks. This
requires only hand ghtening. Over-ghtening
may result in un-warraned damage to your
pistol.
The next step is to set the required li for
welding. This
must be done
in three stages to ensure that the li is set properly.
Stage one is to back the li o so that the pistol can be
properly posioned to set the li. To back the li o,
twist the rear end cap adjuster an-clockwise unl the
pistol indicator is in the MAX posion.

V-21A 13
SET UP AND WELDING - A3 & A4 MODELS
Stage two is to “zero” the li. NOTE Ensure that the pistol is not
connected to the controller whilst performing this stage. To do this
the pistol (with a stud loaded) needs to be pressed into the
posion as if a weld is about to take place with the sha moving
back unl the nose cone is hard against the surface. With the
pistol held rmly in this posion, turn the rear end cap adjuster
clockwise and connue to turn it unl it reaches the zero posion.
This is the point where further turning of the adjuster will start to
force the stud forward, liing the nose cone away from the
surface. This is the zero posion.
Stage three is to set the required li. The rear end cap adjuster has a click detent which
allows the adjuster to stop every half-turn. This means that each half-turn ≈ 0.5mm li.
Therefore, if 2mm of li is required, turn
the rear end cap adjuster an-clockwise 4
clicks from the zero posion to set the li.
IMPORTANT! If any changes are made to
the seng of the pistol, the chuck, stud
length etc. The li may be aected and this
procedure may need to be re-executed to
ensure that the required li is applied.
WELDING - ALL MODELS
Once the pistol has been set up, welding can
take place. The pistol will need to be connected
to an appropriate drawn arc stud welding
controller which has been connected in line
with its operang instrucons. The Taylor
Studwelding Systems pistols outlined in this
operang guide are designed to operate across
a range of drawn arc controllers including, but
not exclusive to, those manufactured by Taylor
Studwelding Systems Ltd.

V-21A 14
WELDING - ALL MODELS
Ensuring that a stud has been loaded, posion
the stud at the locaon on the work piece where
it is to be welded. Press down rmly on the
pistol unl the ferrule (or the face of the nose
cone if using instead) is rmly in contact with the
work piece. Do not drape or wrap the pistol
cables over or around yourself whilst operang
the equipment. Allow the cables to trail naturally
to the oor.
Press the trigger.
Once welding has taken place. Draw the pistol o the
welded stud. Always li the welding pistol vercally
from the welded stud. Failure to do this may cause
damage to the chuck, which will result in the chuck
and stud arcing together during subsequent welds
and thereby reducing the working life of the chuck.

V-21A 15
COMPONENT EXPLOSION AND PARTS LISTING
ITEM QTY PART No. DESCRIPTION
1171-101-030 CONTROL PLUG
25.5 71-300-009 CONTROL CABLE (per metre)
3181-101-051 WELD PLUG
4571-300-002 WELD CABLE (per metre)
5871-101-032 CABLE CLIP (NOT SHOWN)
2
1
4
3
PISTOL TYPE
DA8-A
ALL MODELS

V-21A 16
COMPONENT EXPLOSION AND PARTS LISTING
ITEM QTY PART No. DESCRIPTION
1171-101-222 BELLOWS SUPPORT
2171-101-003 BELLOWS
3171-101-004 BELLOWS RETAINING RING
4171-101-233 BODY RING
5171-101-203 REAR END CAP
64Z120-04-020 SCREW
7171-101-002 CHUCK NUT
3
2
1
6
5
4
SEE PAGE 20 - 25 FOR
CHUCKS AND ACCESSORIES.
NOTE! UNIQUE PARTS ONLY IDENTIFIED. OTHER PARTS ARE SAME AS ABOVE DIAGRAM
7
SEE PAGE 20 - 25 FOR CHUCKS
AND ACCESSORIES.
PISTOL TYPE
DA8-A, A1 & A2
PISTOL TYPE
DA8-A3 & A4

V-21A 17
COMPONENT EXPLOSION AND PARTS LISTING
ITEM QTY PART No. DESCRIPTION
1171-101-200 PISTOL BODY MOULDING PAIR
2171-101-223 DECAL STICKER
32Z250-10-019 SCREW
1
2
3
PISTOL SCHEMATIC
RED or BLUE 1
COIL
BLUE or RED 24 PIN
CONTROL
YELLOW or GREEN 3PLUG
TRIGGER SWITCH
GREEN or YELLOW 4
PISTOL TYPE
DA8-A
ALL MODELS

V-21A 18
COMPONENT EXPLOSION AND PARTS LISTING
ITEM QTY PART No. DESCRIPTION
1171-101-220 FLEXI-BRAID ASSEMBLY
23Z600-05-000 WASHER
31Z115-05-012 SCREW
41Z200-04-006 SCREW
51Z700-05-022 TERMINAL
62Z115-05-008 SCREW
7171-101-201 TERMINAL PLATE
8181-101-279 PUSHBUTTON SWITCH
92Z225-08-914 SCREW
10 2Z605-05-999 WASHER
11 171-101-214 CABLE CLIP
12 171-101-033 CABLE SLEEVE
13 171-101-252 HEADER
14 3Z615-05-000 WASHER
15 171-101-034 CABLE SLEEVE
PISTOL TYPE
DA8-A
ALL MODELS
1
2
3
4
56
7
8
9
SEE NEXT PAGE FOR 10
SHAFT BREAKDOWN
11 13
12 14 15

V-21A 19
COMPONENT EXPLOSION AND PARTS LISTING
ITEM QTY PART No. DESCRIPTION
1171-101-231 SPRING
2171-102-071 BEARING
3171-101-208 BEARING HOUSING
4171-101-221 SHAFT
5172-103-035 POLE PIECE
6172-103-042 COIL
7171-101-210 COIL MOUNT
8271-101-213 DETENT
9171-101-211 COIL MOVER
10 171-101-011 CIRCLIP
11 2Z800-04-026 PIN
12 171-101-219 INDICATOR LABEL
13 1Z400-04-012 SCREW
14 171-101-209 SHAFT
789
456
123
12 13
10 11
]
PISTOL TYPE
DA8-A, A1 & A2
PISTOL TYPE
DA8-A3 & A4
NOTE! UNIQUE PARTS ONLY IDENTIFIED.
OTHER PARTS ARE SAME AS ABOVE DIAGRAM
14
]
NOTE! THESE COMPONENTS
ARE NOT AVAILABLE SEPERATELY.

V-21A 20
ACCESSORIES
STANDARD FRONT END ASSEMBLY - DA8-A
COMPLETE ASSEMBLY AVAILABLE UNDER
PART NUMBER :89-101-322
DOES NOT INCLUDE ITEM 10.
NOTE! ITEM 10 IS FOR LOW VOLUME WORK ONLY
8
67
45
23
1
9
10
ITEM QTY PART No. DESCRIPTION
12Z125-05-035 SCREW
2281-101-003 FOOT WASHER (FRONT)
34Z400-05-008 SET SCREW
4181-101-336 FOOT ADAPTOR
5281-101-001 FOOT WASHER (REAR)
6272-103-092 LEG (110 LONG. STANDARD WITH DA8-A)
or 281-101-004 LEG (230 LONG. OPTIONAL EXTRA)
or 289-101-081 LEG (330 LONG. OPTIONAL EXTRA)
7181-101-328 FRONT END CAP
82Z400-05-004 SET SCREW
9281-101-339 THUMBSCREW
10 189-101-399 NON FERRULE WELD ADAPTOR (OPTIONAL EXTRA)