Taylor DA1-A User manual

V-2U
OPERATING GUIDE
FOR
TYPES DA1-A,
DA2-A & DA3-A
DRAWN ARC PISTOLS
TAYLOR STUDWELDING
SYSTEMS LIMITED
A TAYLORMADE DRAWN ARC STUD WELDING PISTOL

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INDEX
PAGE No. CONTENT
3USEFUL INFORMATION.
5IMPORTANT SAFETY INFORMATION.
7INTRODUCTION TO STUDWELDING.
8SETTING UP AND WELDING.
12 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.
2

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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.

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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 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 !
5
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 !
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.

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INTRODUCTION TO STUDWELDING
7
The Taylor Studwelding DA2-A studwelding pistol when matched with an appropriate
controller and earth cables is intended for precision stud welding up to 20 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
8
As standard, the DA2-A pistol comes ed with standard
legs and a standard foot adaptor. The pistol has a standard
UK and American taper adaptor ed to the M10 thread on
the weld sha. This enables the use of standard UK tapered
DA chucks, enabling studs up to 20mm in diameter to be
welded (see g.1).
Other arrangements are available as shown in gs. 2 & 3.
In g.2 the adapter is not ed to the weld sha to
enabling standard European screw-on chucks to be used,
enabling studs up to 20mm 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 DA2-A 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
9
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.
Having set up the chuck, you are now ready to t it into the pistol.

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SETTING UP AND WELDING
10
Fit the chuck into the tapered sha
adaptor (g.1) and secure in place by
gently tapping the chuck to lock the taper.
The chuck may be subsequently removed
using a twist dri (see page 22 for tools)
inserted through the cross-drilled holes in
the taper adaptor.
Fit the ferrule grip into the foot adaptor
(g.2) and secure in place using the 2 set
screws in the foot adaptor. Do not over-
ghten the set screws as this may result in
damage to either the ferrule grip or the
foot adaptor or both.
Place a stud and ferrule into the chuck
and grip (g.3). Ensure the stud is pressed
fully home and that the ferrule is properly
seated in the grip.
Centre the ferrule over the stud (g.4).
Use the 2 countersunk socket screws set
in the foot washers to loosen and adjust
the posion of the foot adaptor on the
pistol legs. It is very important that the
ferrule does not bind on the stud as this
will cause poor, inconsistent and failed
welds.
1
2
3
4

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SETTING UP AND WELDING
11
Set the correct protrusion (g.5) by
loosening the two socket cap screws ed
at an angle in the sides of the front end
cap.
Slide the foot/leg assembly in/out (g.6)
to achieve the desired stud protrusion,
which should be around 2 - 4mm
depending on the diameter of stud being
welded. Protrusion is the distance from
the front face of the ferrule to the front
edge of the stud, not including the coned
p.
IMPORTANT! Please note that it is
necessary to check/reset the protrusion
when changing the stud length/diameter.
Adjustment of the pistol li is achieved by
turning the rear end cap of the pistol
(g.7). The cap has a “click” detent where
one “click” is approx’ equal to a 0.25mm
change in li. Turning the cap clockwise
(CW) will reduce li, whilst turning the
cap an-clockwise (ACW) will increase li.
Upon rst use when the li posion is
unknown, it is good pracce to zero the
pistol by turning the adjuster fully CW,
then in stages turning the adjuster ACW,
pulling the trigger between adjusts to observe the li, adjust unl the pistol begins to li. Once the
pistol begins to li, one click CW is the zero posion and the desired li can be set from this point.
PLEASE NOTE! It is possible to use
European type screw-on chucks with this
pistol. This is achieved by removing and
discarding the tapered chuck adaptor.
The adaptor can be removed by using a
pair of bars through the cross-drilled
holes in the adaptor and the front sha
adaptor (check under the rubber
protecon bellows for the sha hole).
Likewise the chuck is then ed (g.8) by
bracing the sha using this hole and an
appropriate wrench. It is IMPORTANT that the sha is properly braced when ng or removing
screw-on chucks. Failure to do so may result in damage to the pistol.
IMPORTANT! 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.
5
6
7
8
2 - 4mm

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EXPLODED DIAGRAMS & PARTS LISTINGS
12
ITEM QTY. PART No. DESCRIPTION
15½ 71-300-009 CONTROL CABLE
2571-300-004 WELDING CABLE
3171-101-030 CONTROL PLUG
4181-101-051 WELDING PLUG
5971-101-032 CABLE TIE (NOT SHOWN)
13
24
SEE PAGES 13 TO 16 FOR COMPLETE STAGED
BREAKDOWN OF PISTOL.

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ITEM QTY PART No. DESCRIPTION
1SEE PAGE 18 FOOT ASSEMBLY
2SEE PAGE 18 CHUCK & GRIP
3181-101-005 CHUCK GRIP
42Z105-05-040 SCREW
5181-101-298 BEARING BUSH
6181-101-190 FRONT END CAP
7181-101-297 A R PLATE
EXPLODED DIAGRAMS & PARTS LISTINGS
13
2
1
789
56
34
14 15
12 13
10 11
82Z120-05-025 SCREW
9281-101-191 LEG GRIP
10 2Z100-05-025 SCREW
11 2Z615-05-000 WASHER
12 181-111-044 BELLOWS
13 181-101-293 DAMPER
14 2Z600-06-000 WASHER
15 2Z105-06-010 SCREW

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ITEM QTY PART No. DESCRIPTION
1181-101-299 SHAFT SPRING
2181-101-014 RING RET. PLATE
3181-101-015 LIFTING RING
4181-101-018 RING SPRING
5181-101-286 LIFTING HOOK
64Z100-04-008 SCREW
7181-101-345 HOOK SPRING
81Z120-06-016 SCREW
EXPLODED DIAGRAMS & PARTS LISTINGS
14
345
12
SEE BELOW FOR SHAFT
BREAKDOWN
678
COMPLETE SHAFT ASSEMBLY IS AVAILABLE UNDER PART No. : 81-101-134
13 14 15
11 12
910
17
16
ITEM QTY PART No. DESCRIPTION
9181-101-192 SHAFT ADAPTOR
10 1Z105-05-040 SCREW
11 181-101-194 INSULATOR
12 181-101-195 SHAFT BLOCK
13 181-101-197 INSULATOR
14 181-101-073 LIFTING SLEEVE
15 181-101-269 GUIDE ROD
16 181-101-193 INSULATOR
17 181-101-196 INSULATOR

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ITEM QTY PART No. DESCRIPTION
12Z100-04-016 SCREW
2181-101-275 BODY (PART OF)
3181-101-284 BODY RING
43Z120-04-008 SCREW
5181-101-285 REAR END CAP
62Z120-05-012 SCREW
7181-101-267 RETAINING RING
8181-101-039 WASHER
92Z650-05-016 PIN
EXPLODED DIAGRAMS & PARTS LISTINGS
15
123456
12
10 11
89
7
18
16 17
14 15
13
ITEM QTY PART No. DESCRIPTION
10 3Z400-03-008 SET SCREW
11 181-101-281 BACKSTOP
12 181-101-283 DETENT CAP
13 181-101-170 COIL
14 281-111-039 DETENT
15 2Z400-04-012 SET SCREW
16 181-101-280 COIL HOUSING
17 181-101-282 BACKSTOP DRIVER
18 2Z120-05-010 SCREW

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1
2
34
56
7
8910
11
12
13
14
EXPLODED DIAGRAMS & PARTS LISTINGS
ITEM QTY PART No. DESCRIPTION
1181-101-275 BODY (PART OF)
2181-101-288 FLEXI-BRAID
3181-101-279 PUSHBUTTON
42Z600-06-000 WASHER
52Z615-06-000 WASHER
62Z115-06-010 SCREW
73Z120-05-020 SCREW
8181-101-278 TERMINAL PLATE
91Z800-04-026 PIN
10 1Z600-04-000 WASHER
11 1Z225-08-914 SCREW
12 181-101-275 BODY (PART OF)
13 1Z700-06-S38 TERMINAL
14 181-101-287 CABLE SLEEVE
16

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ACCESSORIES
17
SEE PAGES 20 - 22 FOR OUR STANDARD DRAWN ARC, EUROPEAN AND GAS CHUCKS,
FERRULE GRIPS AND ACCESSORIES RANGE
1 2
3 4
5 6 7 8 9
10 11 12
SEE NEXT PAGE FOR COMPLETE
FOOT ASSEMBLY PART NUMBERS
ITEM QTY. PART No. DESCRIPTION
12Z400-05-008 GRUB SCREW
2181-101-002 STANDARD FOOT ADAPTOR (M3 - M12)
3281-101-004 STANDARD LEG (230mm)
4289-101-081 EXTENDED LEG (330mm)
52Z125-05-035 SCREW
6281-101-003 FOOT WASHER
7281-101-001 FOOT WASHER
8181-101-063 STANDARD FOOT ADAPTOR (M16 - M20)
9181-101-131 TRIPOD FOOT ADAPTOR (M16 - M20)
10 2Z415-08-050 GRUB SCREW
11 2Z510-08-000 LOCKNUT
12 181-101-126 TRIPOD FOOT ADAPTOR (M3 - M12)

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ACCESSORIES
18
STANDARD FOOT ADAPTOR
ASSEMBLY (M3 - M12,
STANDARD LEGS)
COMPLETE ASSEMBLY :
81-101-158
STANDARD FOOT ADAPTOR
ASSEMBLY (M16 - M20,
STANDARD LEGS)
COMPLETE ASSEMBLY :
81-101-159
TRIPOD FOOT ADAPTOR
ASSEMBLY (M3 - M12,
STANDARD LEGS)
COMPLETE ASSEMBLY :
81-101-140
STANDARD FOOT ADAPTOR
ASSEMBLY (M16 - M20,
STANDARD LEGS)
COMPLETE ASSEMBLY :
81-101-141

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ACCESSORIES
19
COMPLETE ASSEMBLY (NO LEGS)
PART NUMBER : 89-101-414
1 2 3 4 5 6 7 8 9
ITEM QTY. PART No. DESCRIPTION
1 1 89-101-249 Ø35mm NOSE CONE
2 3 Z400-05-006 GRUB SCREW
3 1 89-101-246 GAS CONE
4 1 89-101-245 FOOT ADAPTOR
5 1 PFS-P06-U1M-INT GAS FITTING
6 1 89-101-244 BELLOWS
7 2 Z400-05-010 GRUB SCREW
8 5.5 71-200-043 GAS PIPE
9 1 71-200-067 GAS PLUG

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ACCESSORIES - CHUCKS
EUROPEAN SCREW-ON TYPE
20
ØDPART NUMBER
3589-101-003
4589-101-004
5689-101-005
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 1
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.