INSTRUCTIONS AND PARTS MANUAL CW-7 CIRCLE WELDER

Transcription

1 INSTRUCTIONS AND PARTS MANUAL CW-7 CIRCLE WELDER Please record your equipment identification information below for future reference. This information can be found on your machine nameplate. Model Number Serial Number Date of Purchase Whenever you request replacement parts or information on this equipment, always supply the information you have recorded above. LIT-CW-7-IPM-07 Bug-O Systems is guided by honesty, integrity and ethics in service to our customers and in all we do. A DIVISION OF WELD TOOLING CORPORATION 80 TECHNOLOGY DRIVE CANONSBURG, PENNSYLVANIA 7-9 USA PHONE: FAX:

2 SAFETY PROTECT YOURSELF AND OTHERS FROM SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS. ELECTRIC SHOCK can kill. ) The equipment is not waterproof. Using the unit in a wet environment may result in serious injury. Do not touch equipment when wet or standing in a wet location. ) The unused connectors have power on them. Always keep the unused connectors covered with the supplied protective panels. Operation of the machine without the protective panels may result in injury. ) Never open the equipment without first unplugging the power cord or serious injury may result. ) Verify the customer-supplied power connections are made in accordance with all applicable local and national electrical safety codes. If none exist, use International Electric Code (IEC) 90. ) Never remove or bypass the equipment power cord ground. Verify the equipment is grounded in accordance with all applicable local and national electrical safety codes. If none exist, use International Electric Code (IEC) 90. EQUIPMENT DAMAGE POSSIBLE. ) Do not plug in the power cord with out first verifying the equipment is OFF and the cord input voltage is the same as required by the machine or serious damage may result. ) Always verify both the pinion and wheels are fully engaged before applying power or equipment damage may occur. ) Do not leave the equipment unattended. ) Remove from the worksite and store in a safe location when not in use. FALLING EQUIPMENT can cause serious personal injury and equipment damage. Faulty or careless user installation is possible. As a result, never stand or walk underneath equipment. MOVING PARTS can cause serious injury. READ INSTRUCTIONS. Read the instruction manual before installing and using the equipment. ) Never try to stop the pinion from moving except by removing power or by using the STOP control. ) Do not remove any protective panels, covers or guards and operate equipment.

3 HIGH FREQUENCY WARNINGS SPECIAL PRECAUTIONS ARE REQUIRED WHEN USING PLASMA, TIG OR ANY WELDING PROCESS THAT USES HIGH FREQUENCY TO STRIKE AN ARC. WARNING: HIGH FREQUENCY CAN EFFECT MACHINE OPERATION AND THEREFORE, WELD QUALITY. Read the precautions below before installing and using the equipment. PRECAUTIONS: ) Some plasma or welding cables are strong sources of high frequency interference. NEVER lay a plasma or welding cable across the controls of the machine. ) Always physically separate the plasma or welding cable leads from the machine cables. For example, the plasma or welding cable leads should NEVER be bundled with a pendant cable or the machine power cord. Maximize the separation between any machine cables and the plasma or welding cables. ) Strictly follow the grounding procedures specified for the plasma or welding unit. NOTE: Some plasma and welding units produce exceptionally large amounts of high frequency noise. They may require a grounding rod be driven into the earth within six feet ( meters) of the plasma or welding unit to become compatible with an automatic cutting or welding process. ) If the high frequency is produced using a spark gap, adjust the points so the gap is as small as possible. The larger the gap, the higher the voltage and the higher the interference. ) Some plasma or welding units will inject high frequency interference into the AC power line. Use separate power line branches whenever possible to power the plasma or welding source and the machine. Do not plug them into the same outlet box. ) High frequency noise may enter the machine through the plasma or welding supply remote contactor leads. Some plasma and welding sources can produce noise spikes of up to several thousand volts. These sources are not compatible with automated cutting and welding equipment. It is recommended that the remote contactor leads on these plasma or welding sources not be connected to the machine. An alternate solution is to purchase a separate remote contactor isolation box.

4 CW-7 CIRCLE WELDER INSTRUCTIONS AND PARTS MANUAL TABLE OF CONTENTS PAGE -... Introduction / Features / Setup and Operation 7... CWO- Wire Feeder Controls 8... CWO-0 Rotation Controls 9... Technical Data / Dimensions 0... CWO-700 CW-7 Circle Welder / Exploded View... CWO-700 CW-7 Circle Welder / Parts List... CW-7 Circle Welder / Wiring Diagram... CW-7 Circle Welder / Wiring Diagram / Electrical Component Chart... CWO-9 CW-7 Collector / Exploded View / Parts List... CWO-9 Universal Power Cable / Exploded View / Parts List... CWO-9-M Miller Power Cable/ Exploded View / Parts List... CWO- CW-7 Racking System / Exploded View / Parts List... CWO-90 Horizontal Racker / Exploded View / Parts List 7... CWO-00 Wire Feeder Guard / Exploded View / Parts List 8... CWO-07 Meter Kit Assembly / Exploded View / Parts List 8... CWO-07 Meter Kit Assembly / Wiring Diagram 9... CWO-9 Shaft Assembly / Exploded View / Parts List 9... CWO-7 Cam Shaft & Spacer Assembly / Exploded View / Parts List 0... CWO-0-7" Cam Assembly / Exploded View / Parts List 0... CWO-98 " Wire Reel Mount Assembly / Exploded View / Parts List... CWO-0- Large Brush Holder and Support / Exploded View / Parts List... CWO-9 Housing Assembly / Exploded View / Parts List... CWO- P.M. Motor Assembly / Exploded View / Parts List... CWO-9 Transmission : Assembly / Exploded View / Parts List... CWE-0 Small Brush Holder Assembly / Exploded View / Parts List... CWO- Small Retainer Block Assembly / Detail View... CWO- GMA Wire Feeder Control / Exploded View / Parts List... CWO- GMA Wire Feeder Control / Wiring Diagram / Electrical Component Chart... CWO-0 Rotation Control / Exploded View / Parts List 7... CWO-0 Rotation Control / Wiring Diagram / Electrical Component Chart 8... CW-7 Gun Assemblies (MIG-FLUX CORED) 9... CW-7 Gun Assemblies (SUB ARC) 0... CW-7 Drive Roll Kits 0... CWO-90-_ K Subarc Gun Assembly / Exploded View / Parts List... CWO-700-_ Subarc Gun Assembly / Exploded View / Parts List... CWO-90 CW-7 Flux Hopper Assembly / Exploded View / Parts List... # Gun & Cable Assembly / Exploded View / Parts List... -Jaw Expandable Chucks... Optional Motorized Racking Equipment / CWO--MV / Exploded View / Parts List... Optional Motorized Racking Equipment / CWO-90-MH / Exploded View / Parts List... Optional Motorized Racking Equipment / CWP-0 / Exploded View / Parts List 7... Optional Motorized Racking Equipment / CWP- / Exploded View / Parts List 8... Optional Motorized Racking Equipment / PRS-00 / Exploded View / Wiring Diagram 9... Optional Motorized Racking Equipment / PRS-00 / Parts List 0... Optional Motorized Racking Equipment / CWP- / Exploded View / Parts List 0... Optional Motorized Racking Equipment / PRS-07 / Exploded View / Parts List... Preventive Maintenance / CW-7 Circle Welder... Warranty

5 INTRODUCTION The CW-7 Circle Welder is designed for welding of nozzles into vessels or domed heads utilizing SUB- ARC, MIG or FLUX CORED PROCESS, with gas shielding. The CW-7 mounts on a -Jaw Chuck welding diameter " to 0" O.D. Features Amperage & wire speed control Wire feeder with one set of drive rolls / HP P.M. motor and rotational speed control 00 AMP gun & cable assembly Gas shielding kit with 0 VAC solenoid valve /8" ( mm) gas cup Burn back control 0 ft. ( m) power cable 0 ft. ( m) gas shielding hose 0 ft. ( m) weld cable Quick disconnects for all cables Weld contact switch Cold wire inch switch Wire direction switch Pre and post flow controls Wire reel adaptor for 0 lb. (7 kg) spools Adjustable vertical and horizontal torch positioning system Rise and fall cam assembly with 7" (78 mm) of travel Brushes and collector rings for welding current, rated at 00 AMPS 00% duty cycle Brushes and collector rings for all controls, eliminates cable and hose wrap SETUP AND OPERATION POWER SOURCE Use only constant voltage type power sources with this circle welder machine. If using a multiple process power source, be sure that it is set for constant voltage output as per the instructions in the manual for the power source. Set the power source polarity switch or properly connect the electrodes and work leads for the correct electrode polarity. GUNS AND CABLES All circle welders come equipped with a gun and cable assembly. It is our recommendation that at least once a week the liner be taken out of the cable and soaked overnight in a solvent solution. To keep the wire moving it is also recommended that a felt clip be saturated with a product like Ferro Slick and fed through the incoming tube of the wire feeder at least once a day.

6 Horizontal Rack SETUP AND OPERATION CONT'D. ADDITIONAL CABLES The circle welders are supplied with the following cables:. CWO-9 0' ( m) power cable that connects the power source to the cable connector on the top gear of the machine.. CWO-00 0' ( m) weld cable that connects the lead coming out of the top of the machine using the quick connect connector to your power supply.. CWO-90 0' ( m) gas shielding hose that connects the gas fitting on the top of the shaft to your shielding gas supply. WIRE SPEED AND VOLTAGE ADJUSTMENT The wire speed control on the front of the CWO- Wire Feed Control box has a dial that is calibrated directly in inches per minute. Set the voltage using the control on the power source. Cam RISE AND FALL OF THE CAM All circle welders are equipped with a rise and fall cam assembly. The cam assembly must be aligned before any other settings can be made. To align the cam rotate the machine so the horizontal rack is parallel to the pipe, then adjust the gun holder so it is perpendicular to the horizontal rack. Position torch tip to top dead center of joint. Loosen the set screws in the brass block on the cam, and rotate the cam to the vertical position as shown. Refasten set screws. CAM SETTING The cam setting is equal to distance B subtracted from distance A. Torch Holder Pipe Example: Let A= and B= -= The cam setting is. B A B A WHEEL ADJUSTMENT The CW-7 Racking System CWO- and the Large Vertical Racker CWO- 90 are equipped with adjustable wheels. Always check these components for proper wheel adjustment before using the machine. The wheels need adjustment if you can cock or wiggle the components out of alignment. The wheels should be snug but not prohibit movement along the path of travel. The wheels with the hex stand offs are adjustable. To adjust the wheels, loosen the hex bolt (A) until the adjustable bushing (B) can be rotated. Correct the wheel alignment by rotating the adjustable bushing (B). Once adjusted, hold the adjustable bushing (B) while tightening the hex bolt (A). Recheck alignment. B A MACHINE CONTROLS Operational parameters can be set using the two control boxes. Please refer to the sections in this manual entitled CWO- Wire Feeder Control for descriptions of the various welding parameters that are available, as well as CWO-0 Rotation Control for descriptions of the various speed and directional capabilities. MAKING A WELD. Position the gun to start position using the CWO- Racking System.. Connect the ground cable to the workpiece. The ground cable must make good electrical contact with the work.. Position the electrode in the joint. The end of the electrode may be lightly touching the work.. With manual/auto switch in the OFF position, set rotation direction and speed.. Weld process and rotation are both started by throwing the manual/auto switch to auto.. Weld process and rotation are stopped by throwing the manual/auto switch to OFF. WARNING: When using an open arc process, it is necessary to use correct eye head and body protection.

7 CWO- WIRE FEEDER CONTROLS WIRE FEED SPEED WIRE DIRECTION MANUAL / AUTOMATIC PREFLOW POSTFLOW PURGE - UP COLD INCH - DOWN BURNBACK WIRE FEED SPEED CONTROL: This control sets the feed speed of the wire feeder. Turn the knob to the left for slower speeds and to the right for higher speeds. The control is calibrated. The nameplate shows the wire speed for the given setting of the control. WIRE DIRECTION: Controls the direction the wire is being fed thru the feeder. Up to return wire to the spool. Down to feed the wire to the gun. MANUAL / AUTOMATIC: The manual position allows the operator to rotate the machine without welding to check the wire placement as well as the cam setting. The auto side will start the entire weld operation based on the operators settings, including machine rotation. PREFLOW CONTROL: This control, provides flow of shielding gas to the work before the arc is established. The gas solenoid valve is energized immediately when the gun trigger is closed, but the time delay before the wire feeder is energized is adjustable from 0 to. seconds. Turn the knob to the left for shorter delays and to the right for longer delays. POSTFLOW CONTROL: This control provides flow of shielding gas to the work after welding has stopped. Delay for the gas solenoid valve shutoff is adjustable from. to. seconds. Turn the knob to the left for shorter delays and to the right for longer delays. PURGE - UP / COLD INCH - DOWN SWITCH: This control provides control of some wire feeder functions without energizing the welding power source. The momentary up position energizes the gas solenoid but not the wire feeder or welding power source. The momentary down position energizes the wire feeder but not the gas solenoid or the welding power source. BURNBACK CONTROL: This control provides a precise time delay that allows the wire to be burned off at the end of the weld. This is useful for those applications where higher speed, fine wire feeding is used and there is a tendency for the electrode to overrun at the end of the weld and cause sticking in the crater. The delay is adjustable for optimum burnback depending on wire size, process, procedure, etc. 7

8 CWO-0 ROTATION CONTROLS Digital Readout Speed Control Travel Direction On/Off Switch Pilot Light DIGITAL READOUT: Displays reference number only. SPEED CONTROL: Controls the speed in which the machine travels. The depicted lines 0 to 00 should not be construed as inches per minute of travel. They should be considered as reference points only. TRAVEL DIRECTION: Controls the direction in which the machine will travel. Select forward for clockwise rotation, brake for stop, and reverse for counterclockwise rotation. ON/OFF SWITCH: The on/off switch enables/disables power to the rotation control box. PILOT LIGHT: The pilot light indicates whether the machine is on/off as dictated by the on/off switch. 8

9 TECHNICAL DATA Amperage: Input Voltage: Voltage: Wire Sizes: Rotation Speed: Cam Range: Welding Diameter: Shielding Gas: Height: Net Weight: Shipping Weight: 0-00 amps VAC 0-0 VAC.0-/" (.8-. mm).-. rpm 0"-7" (0-7 mm) "-" (0-00 mm) Solenoid Control " (8 mm) 0 lbs. (. kg) 80 lbs. (7.0 kg) DIMENSIONS " (7 mm) 0" (70 mm) " (80 mm) WELDING DIAMETER "-" (0-00 mm) 9

10 CWO-700 CW-7 CIRCLE WELDER / EXPLODED VIEW

11 CWO-700 CW-7 CIRCLE WELDER / PARTS LIST CWO- CW-7 Racking System CWO-90 Large Horizontal Racker CWO-00 Wire Feed Guard CWO-07 Meter Kit Assembly CWO-0- Brush Holder & Support Assembly CWO-9 CW-7 Housing Assembly 7 CWO-0 Slide Bar Mounting Assembly 8 CWO-0-7" Cam Assembly 9 CWO-8 Cable Support Bar 0 CWO-7 Camshaft & Bar Assembly CWO-87 Base Plate CWO-88 Motor & Transmission Plate Assembly CWO- Lifting Lug Assembly CWO- GMA Wire Feed Assembly CWO-9 Transmission SW : Assembly CWO- P.M. Motor Assembly #7 7 CWE-0 Small Brush Retainer Assembly 8 CWO-8 LN-7 Wire Feeder Assembly 9 CWE-00-/0 Weld Cable /0 *0 CWO-90 Flux Hopper Assembly (Subarc models only) CWO-9 CW-7 Collector CWO-00-/0 Weld Cable Inlet /0 CWO-9 Shaft Assembly, CW-7 AB, ABG CWO-98 Wire Reel Assembly CWO-99 CW-7 Guard Assembly CWO-9 Terminal Block Assembly 7 CWO-088 Wire Feeder Mount Plate 8 CWO-0 -/" Flange Bearing 9 CWO-900 # Load Spring Assembly 0 CWO-07 -/" I.D. Trantorque CWE-08 0" Diameter Aluminum Gear CWO-0 Rotation Control Box CWO- Control Mount Plate CWO-807 Solenoid Adaptor Kit CWO-90 Flux Hopper Notes:. See CWO-700-WD for wiring and cable information.. CWO- is shown with CWO--K kit installed.. CWO-0 is shown with CWO-0-K kit installed. * CWO-90 Flux Hopper Assembly is installed on Subarc models only

12 CW-7 CIRCLE WELDER / WIRING DIAGRAM IN FROM WELDER SUPPLY UNIT TO POWER CABLE

13 CW-7 CIRCLE WELDER / WIRING DIAGRAM / ELECTRICAL COMPONENT CHART ELECTRICAL COMPONENT CHART ITEM DESCRIPTION PART NO. Meter Kit Assembly CWO-07 Brush Holder & Support Assembly CWO-0- Power Cable CWO-9* GMA Pigtail CWO- GMA Wire Feed Control CWO- P.M. Motor Assembly CWO- 7 Small Brush Retainer Assembly CWE-0 8 LN-7 Wire Feeder Assembly CWO-8 9 Weld Cable /0 CWO-78 0 CW-7 Collector CWO-9 Weld Cable Inlet /0 CWE-00-/0 CW- Terminal Block CWO-9 Shunt Bar 00-0 CWO-008 Rotation Control Box CWO-0 Solenoid Adaptor Kit CWO-807 *CWO-9 For Universal Welders CWO-9-M For Miller Welders.

14 CWO-9 CW-7 COLLECTOR / EXPLODED VIEW / PARTS LIST CWO-7 Brass Ring.0" Dia x.88 Thk CWO-7 Brass Ring.0" Dia x.000 Thk 7 CWO-7 Micarta Spacer CWO-77 Micarta Spacer w/notch CWO-78 Micarta Sleeve.00" Dia x.70" Lg CWO-80 Micarta Sleeve.00" Dia x.7" Lg 7 CWO-7 Micarta Sleeve.87" Dia x.0" Lg 8 CWO-7 Top Plate CW- Collector 9 CWO-7 Bottom Plate CW- Collector 0 CON WTE 08 Pos Box Mounting Connector Plug TERM-9 #8 Red Ring Connector FAS-0 - x /" Rnd Hd Scr FAS-0 /"-0 x /" Soc Hd Set Scr FAS-0 - Hex Nut FAS-09 Hex Hd Cap Scr /8- x " WAS-00 /8" SAE Washer 7 FAS-00 Rnd Hd Slot Scr -0 x /8 Zinc 8 FAS-0 Hex Nut -0 9 BUG-0 Panel Connector, -T, M

15 CWO-9 UNIVERSAL POWER CABLE / EXPLODED VIEW / PARTS LIST CWO-9-M MILLER POWER CABLE / EXPLODED VIEW / PARTS LIST

16 CWO- CW-7 RACKING SYSTEM / EXPLODED VIEW / PARTS LIST ABR-00 V-Guide Ways " CWO-7 Vertical Racker CWO-9 Attachment Block CWO-0- Torch Angle Adjuster " CWO-0 # Load Spring Assembly CWO-90 HORIZONTAL RACKER / EXPLODED VIEW / PARTS LIST F A 8 7 F A BUG-0 Knob, Black CWO-7 Racker Shield CWO-78 Racker Plate CWO-79 Pinion T CWO-80 W Fixed Leg & Wheel Assembly CWO-8 W Adj. Leg & Wheel Assembly 7 CWO-87 Mount Plate (Large Racker) 8 CWO- Fixed Leg & Wheel Assembly 9 CWO-7 Adj. Leg & Wheel Assembly 0 FAS-07 Soc Hd Cap Scr /-0 x /" FAS-07 Hex Jam Nut /- MUG- Bearing Collet MUG- Knob, Locking MUG- Shaft MUG- Stand-Off MUG-79 Retaining Ring 7 WAS-00 /" SAE Washer 8 FAS-09 Soc Hd Cap Scr /-0 x " 7 F = FIXED WHEEL PLACEMENT A = ADJUSTABLE WHEEL PLACEMENT 0 8F 8F 9A 9A

17 CWO-00 WIRE FEEDER GUARD / EXPLODED VIEW / PARTS LIST BUG-09 Hinge /" x " Lg CWO-008 Plastic Guard FAS-0 Soc Hd Cap 0- x /" HDW-00 Steel Hair Pin Zinc Plated BUG-97 Binding Post, #8- x / Lg BUG-98 Binding Post Screw, #8- x / Lg 7

18 CWO-07 METER KIT ASSEMBLY / EXPLODED VIEW / PARTS LIST " Cond. 8 AWG. SJO Cord CSR WTE 087 Wire Strain Relief CWO-9 DC Volt Meter, 0-0 VDC CWO-97 DC AMP Meter, 0-00 ADC CWO-99 " x 7" Front Meter Plate CWO-7 Alum. Box, Powder Coated 7 FAS-0 Pan Hd Scr #0- x /" 8 FAS-0 Hex Nut #0-9 FAS-9 Sheet Metal Scr # x /8" 0 TERM WTE 09 #0 Ring, Red TERM-00 /" Red Ring TERM- /" Blue Ring WAS-0 #0 Internal Star Washer 9 CWO-07 METER KIT ASSEMBLY / WIRING DIAGRAM

19 CWO-9 SHAFT ASSEMBLY / EXPLODED VIEW / PARTS LIST BUG-909 Outlet Bushing, Oxygen CWO-09 O-Ring, Oxygen, Fuel CWO-778 Shaft CW-7AG / CW-7ABG CWO-7 CAM SHAFT & SPACER ASSEMBLY / EXPLODED VIEW / PARTS LIST CWO- Ball Joint Rod End /8- RH CWO-0 Ball Joint Rod End /8- LH CWO-908 Spacer CWO-9 Pipe / Cam Shaft FAS-099 Hex Hd Cap Scr /8- x " FAS-9 /8- Hex Jam Nut - RH 7 FAS-9 /8- Hex Jam Nut - LH 8 FAS-9 Hex Hd Cap Scr /8- x -/" 9 WAS-00 /8" SAE Washer

20 CWO-0-7" CAM ASSEMBLY / EXPLODED VIEW / PARTS LIST BUG-098 Delrin Washer /8" BUG-90 Locking Collar CWO-07 End Plate CWO-08 Center Plate CWO-0 Knob CWO-8 Base Plate 7 CWO- Screw 8 CWO- Rod 9 CWO-99 Scale 0 FAS-0 Set Scr #0- x /8" FAS-0 Set Scr #0- x /8" FAS-09 Set Scr /8"- x /" FAS-0 Soc Hd Cap Scr #0- x /8" CWO-98 " WIRE REEL MOUNT ASSEMBLY / EXPLODED VIEW / PARTS LIST BUG-9 Reel, 0 lbs. CWO-7 Wire Reel Support Assembly FAS-0 Hex Nut /- FAS-0 Hex Hd Cap Scr /- x -/" WAS-08 /" Lock Washer 0

21 CWO-0- LARGE BRUSH HOLDER AND SUPPORT / EXPLODED VIEW / PARTS LIST CWE- Large Brush Holder Support CWO-9 Attachment Bar CWO- Large Brush Holder CWO- Spring Clip CWO-7 Large Brush -/" x /" x " CWO-8 Micarta Spacer 7 CWO-9 Micarta Bushing 8 FAS-00 Hex Hd Cap Scr /- x." 9 FAS-00 Hex Hd Cap Scr /- x " 0 FAS-009 Hex Hd Cap Scr /- x " FAS-07 Hex Hd Cap Scr /-0 x / FAS-09 Hed Hd Cap Scr /-0 x " WAS-0 /" Split Lock Washer WAS-080 /" SAE Flat Washer WAS-08 /" Split Lock Washer CWO-9 HOUSING ASSEMBLY / EXPLODED VIEW / PARTS LIST 8 7 CWO- /-8 x /" NPSM Hex HD Plug, Brass CWO-8 Center Tube Housing CWO-8 Top Housing Plate CWO-87 Lower Housing Plate CWO-97 Plastic Bushing CWO-99 Angle For Guard 7 FAS-0 Soc Hd Cap Scr 0- x /" 8 8 FAS-08 Soc Hd Cap Scr 0- x /"

22 CWO- P.M. MOTOR ASSEMBLY / EXPLODED VIEW / PARTS LIST CWO-07 P.M. Motor 07 CWO-7 P.M. Motor Bracket #970 CWO-77 Gear, P.M. Motor FAS-0 Set Scr /-0 x /8" TER-WTE-08 #8 Fork Blue RB-8FL-T&B CWO-9 TRANSMISSION : ASSEMBLY / EXPLODED VIEW / PARTS LIST CWO-7 Transmission : FAS-09 Hex Hd Cap Scr /-0x" FAS- /-0 Hex Nut WAS-00 /" SAE Washer WAS-0 /" Lock Washer UNI-0 Slave Pinion

23 CWE-0 SMALL BRUSH HOLDER ASSEMBLY / EXPLODED VIEW / PARTS LIST CWE- Retainer Support Small CWE- Pos Small Ret. Block Assembly FAS- Soc Hd Cap Scr 0-x" FAS-09 Hex Hd Cap Scr /-0x /" WAS-00 /" SAE Flat WAS-0 /" Split Lock Washer CWO- SMALL RETAINER BLOCK ASSEMBLY / DETAIL VIEW / PARTS LIST WHITE 0" BLACK 0" RED 0" ORANGE 0",,, CWO- Small Brush Retainer Blk CWO-8 Brush /8" x /8" x 7/8" CWO-87 Brush Holder CWO-87 Cap CWO-87 Clip TERM WTE 00 # Fork Blue

24 CWO- GMA WIRE FEEDER CONTROL / EXPLODED VIEW / PARTS LIST , BUG- Toggle Switch BUG-87 Power Receptacle CON-0S Panel Connector, T F CWO-79 Panel Connector, T M CWO- Wire Feed Control Case CWO- Wire Feed Control Cover 7 CWO-A Wire Feed Front Panel 8 CWO-B Wire Feed Rear Panel 9 CWO- Toggle Switch 0 FAS-00 Rnd Hd Scr -0 x /" FAS-0 Rnd Hd Scr #- x /" FAS-0 Hex Nut -0 FAS-0 Hex Nut #- PCB- Motor Control Board PCB-0 Timing Control Board 0 SCW WTE 0 # x / Pan Hd 7 SCW WTE 08 Pan Hd Scr #- x /" 8 STOF-009 Stand Off #- 9 WAS-00 # Internal Star Lock Washer 0 WAS-0 # Internal Star Lock Washer MUG-89 Hole Plug." MS-A8-S Panel Connector, T M ABP-09 Toggle Switch BUG-988 On-Off Switch Plate LDC- Plain Washer for LN-7 LDC- Hex Nut 0- for LN-7 7 LDC-0 Knob for LN-7 8 LDC-0 Potentiometer for LN-7 9 LDC-07 Transformer & Lead Assembly 0 LDC-09 Resistor for LN-7 LDC-08 Switch for LN-7 LN7 WTE Circuit Breaker 0V.A LDC-0 Reed Switch Assembly for LN-7

25 CWO- GMA WIRE FEEDER CONTROL / WIRING DIAGRAM 7 POWER SOURCE INPUT F A B C E D RED GRN RESET CIRCUIT BREAKER BLU BLU RED RED RED J J POT BLU BLU BLU BLU BLU BLU BLU BLU BLU GROUND LEAD PROTECTOR RESET E GRN D A C B WIRE BLK MOTOR BLK WHT WHT 9 WHT/RED MAN/AUTO WHT GRN WHT LIGHT GLP REED SWITCH GRN WHT OUTPUT RED BLK TX BLK BLK BLK YEL YEL RED RED WHT/BLU WHT WHT CBO-0 X 7 J C9 7 WHT BLK GOF-07 GOF-0 WHT/RED B A SOLENOID WHT/RED JB RED RED RED RED BLU BLU BLU BLU TIMER BOARD B S S B T P T C CAP WTE 0 = INDICATES CONTROL BOARD ITEMS ABP-09 ELECTRICAL COMPONENT CHART ITEM DESCRIPTION PART NO. Toggle Switch ON-Off-ON BUG- Power Receptacle BUG-87 Panel Connector T-F CON-08 Toggle Switch ON-NONE-ON CWO- Timer Board PCB-0 Panel Connector T, F MS-A8-S 7 Panel Connector, T, Male CWO-79 = INDICATES CONTROL BOARD ITEMS THAT ARE NOT USER REPLACEABLE.

26 CWO-0 ROTATION CONTROL / EXPLODED VIEW / PARTS LIST 0,, 8,7,,, , 9 ARM-79 Toggle Switch BUG-9 Power Cord CON-PS0M Plug, Straight -Pin Male BUG-987 Knob Fluted BUG-99 Knob CSR-WTE-97 Cord Strain Relief 7 CWO- Rotation Box Front Panel 8 CWO-7B Rotation Box Rear Panel 9 CWO-0 Indicator Light 0 CWO V Spd Ctrl w/isolator CWO-89 Rotation Control Case CWO-80 Rotation Box Cover FAS-0 #- x /" Pan Head Zinc FAS-0 Hex Nut - FHO-088 Fuse Holder MPD-0 Fuse Amp 7 FUS-07 Fuse Amp 8 MUG-8- Rotary Switch Assembly 9 0 SCW-WTE-0 #- x /" Sht Mt Scr 0 TERM-WTE-097 # Red Fork WAS-0 # Internal Star Washer " WRE-WTE-00 8/ SJO 00V Cord MUG-89 Hole Plug.00" BUG- Multi-turn Potentiometer FAS-00 #-0 x /8" Pan Hd SCF-00 #-0 Self Clinching Nut 7 BUG-7 Meter Display Board 8 MDS-0 Display Bezel 9 BUG- Hole Plug /"

27 CWO-0 ROTATION CONTROL / WIRING DIAGRAM / ELECTRICAL COMPONENT CHART = INDICATES ITEMS THAT ARE SUPPLIED TOGETHER. ELECTRICAL COMPONENT CHART ITEM DESCRIPTION PART NO. Toggle Switch ARM-79 Red Neon Lamp CWO-0 Speed Control Board w/resistor CWO- Fuse amp MPD-0 Fuse amp FUS-07 Rotary Switch MUG-8-7

28 CW-7 GUN ASSEMBLIES (MIG/FLUX-CORED) CWO-0-A #.0 GUN ASSEMBLY MIG/FLUX.0 WIRE SIZE CWO-807 H- CONTACT TIP 0 CWO-80 CT-7 NOZZLE CWO-80 CT NOZZLE INSULATOR CWO-80 SW GAS DIFFUSER CWO CABLE LINER CWO AMP CABLE CWO-0-B #.0 GUN ASSEMBLY MIG/FLUX.0 WIRE SIZE CWO-808 H- CONTACT TIP 0 CWO-80 CT-7 NOZZLE CWO-80 CT NOZZLE INSULATOR CWO-80 SW GAS DIFFUSER CWO CABLE LINER CWO AMP CABLE CWO-0-C # / GUN ASSEMBLY MIG/FLUX / WIRE SIZE CWO-809 H- CONTACT TIP 0 CWO-80 CT-7 NOZZLE CWO-80 CT NOZZLE INSULATOR CWO-807 GAS DIFFUSER CWO CABLE LINER CWO AMP CABLE CWO-0-D # / GUN ASSEMBLY MIG/FLUX / WIRE SIZE CWO-80 H- CONTACT TIP 0 CWO-80 CT-7 NOZZLE CWO-80 CT NOZZLE INSULATOR CWO-808 GAS DIFFUSER CWO CABLE LINER CWO AMP CABLE CWO-0-E # / GUN ASSEMBLY MIG/FLUX / WIRE SIZE CWO-80 H- CONTACT TIP 0 CWO-80 CT-7-NOZZLE CWO-80 CT NOZZLE INSULATOR CWO-80 H-- CABLE LINER CWO-808 H-GAS DIFFUSER CWO AMP CABLE CWO-0-G #.0 GUN ASSEMBLY MIG/FLUX.0 WIRE SIZE CWO-80 H- CONTACT TIP 0 CWO-80 CT-7 NOZZLE CWO-80 CT NOZZLE INSULATOR CWO-80 SW GAS DIFFUSER CWO CABLE LINER CWO AMP CABLE 8

29 CW-7 GUN ASSEMBLIES (SUB ARC) CWO-700-A #.0 GUN ASSEMBLY SUB ARC.0 WIRE SIZE CWO-807 H- CONTACT TIP 0 CWO-80 SW GAS DIFFUSER CWO CABLE LINER CWO-80 -SA NOZZLE FLUX CONE CWO AMP CABLE CWO-700-B #.0 GUN ASSEMBLY SUB ARC.0 WIRE SIZE CWO-808 H- CONTACT TIP 0 CWO-80 SW GAS DIFFUSER CWO CABLE LINER CWO-80 -SA NOZZLE FLUX CONE CWO AMP CABLE CWO-700-C # / GUN ASSEMBLY SUB ARC / WIRE SIZE CWO-809 H- CONTACT TIP 0 CWO-807 GAS DIFFUSER CWO CABLE LINER CWO-80 -SA NOZZLE FLUX CONE CWO AMP CABLE CWO-700-D # / GUN ASSEMBLY SUB ARC / WIRE SIZE CWO-80 H- CONTACT TIP 0 CWO-808 GAS DIFFUSER CWO CABLE LINER CWO-80 -SA NOZZLE FLUX CONE CWO AMP CABLE CWO-700-E # / GUN ASSEMBLY SUB ARC / WIRE SIZE CWO-80 H- CONTACT TIP 0 CWO-808 H-GASS DIFFUSER CWO LINER CWO-80 -SA NOZZLE FLUX CONE CWO AMP CABLE CWO-700-G #.0 GUN ASSEMBLY SUB ARC.0 WIRE SIZE CWO-80 H- CONTACT TIP 0 CWO-80 SW GAS DIFFUSER CWO CABLE LINER CWO-80 -SA NOZZLE FLUX CONE CWO AMP CABLE 9

30 CW-7 DRIVE ROLL KITS PART NO. CWO CWO-70-.0C CWO CWO-70-.0C CWO-70-/ CWO-70-/ DESCRIPTION DRIVE ROLL KIT.0 (0.9mm) SOLID WIRE DRIVE ROLL KIT.0 (0.9mm) CORED WIRE DRIVE ROLL KIT.0-.0 (.0-.mm) SOLID WIRE DRIVE ROLL KIT.0-.0 (.0-.mm) CORED WIRE DRIVE ROLL KIT / (.mm) SOLID/CORED WIRE DRIVE ROLL KIT.08-/ (.7-.mm) SOLID/CORED WIRE CWO-90-_ K SUBARC GUN ASSEMBLY / EXPLODED VIEW / PARTS LIST a PXS-0-/ Nozzle Insert PXT-070 Socket Head Screw PXS-09- Nozzle Insulator PXS- Hex Hd Scr /" & Nut /"- PXT Nozzle Body Roll Pin CWO-80 Nozzle Body *7 PXS-0-_ Contact Tip (Specify Wire Size*) 8 PXS-08 Flux Cone Plug (Insulator) 9 PXT Thumb Screw 0 PXT Flux Cone Roll Pin PXT-8 /" x 7" Flux Hose W/Fbr Ins A PXT-8-IN Fiber Insulator BUG--P Cone Body Assembly BUG- Locking Ferrule BUG- Flux Cone (Kp08-) BUG- Retaining Nut 7 *WIRE SIZES AVAILABLE: PART NO. CWO-90-/ CWO-90-/ CWO-90-/ WIRE SIZE /" (. mm) /" (.0 mm) /" (. mm) *REPLACEMENT CONTACT TIPS AVAILABLE: PART NO. WIRE SIZE AFW-9 /" (. mm) CWO-808 /" (.0 mm) CWO-809 /" (. mm) 0

31 CWO-700-_ SUBARC GUN ASSEMBLY / EXPLODED VIEW / PARTS LIST CWO-98 Adaptor-LN7 CWO-87 Bulk Head Connector QCB CWO-97 QCC 7" (89 mm) Liner CWO-9-/ Adaptor K /" CWO-70-7 Weld Cable /0 Assembly 7" (89 mm) Lg CWO-90-/ Sub-Arc Nozzle /" CWO-90-/ Sub-Arc Nozzle /" CWO-90-/ Sub-Arc Nozzle /" 7 FAS-0 Set Scr /-0 x / 7 CWO-90 CW-7 FLUX HOPPER ASSEMBLY / EXPLODED VIEW / PARTS LIST CWO-77 Hopper Support Rod CWO-70 Clamp Block /" CWO-78 /" Hose Barb CWO-79 Flux Hopper Steel " GOF-09 Handle w/bolts N/S 8" /" ID x " OD Clear Hose

32 # GUN AND CABLE ASSEMBLY / EXPLODED VIEW / PARTS LIST PARTS LIST WIRE SIZE ITEM QTY PART # DESCRIPTION / / / CWO-80 H- Contact tip X CWO-807 H- Contact Tip X CWO-808 H- Contact Tip X CWO-809 H- Contact Tip X CWO-80 H- Contact Tip X CWO-80 H- Contact Tip X CWO-80 CT-7 Nozzle Insulator X X X X X X CWO-80 CT Nozzle Insulator X X X X X X CWO-80 SW Gas Diffuser X X X CWO-807 Gas Diffuser X CWO-808 H Gas Diffuser X X CWO-80-0 Conductor Tube X X X X X X CWO Case w/binder Screws X X X X X X 7 CWO Cable Connector Block X X X X X X 8 CWO-80 Cable Hose Support X X X X X X 9 CWO-80 7 Connector Plug w/o-rings X X X X X X 0 CWO-80 -SA Nozzle Flux Cone X X X X X X CWO AMP Cable X X X X X X * CWO Cable Liner X X * CWO Cable Liner X X * CWO Cable Liner X * CWO Cable Liner X * ITEMS NOT SHOWN

33 -JAW EXPANDABLE CHUCKS -Jaw Expandable Chucks Mounts and automatically centers the Circle Welder on nozzles with or without flanges. As shown below. CWO-0 PART NO. FOR NOZZLE I.D. S WEIGHT CWO-0 "-0" (mm-mm) 9. lbs. (. kg) CWO- 8"-" (0-0 mm) lbs. ( kg) CWO- 0"-" (-0 mm) lbs. ( kg) CWO-.7"-7." (00-00 mm) lbs. (9 kg) CWO- CWO- CWO-

34 OPTIONAL MOTORIZED RACKING EQUIPMENT / CWO--MV / EXPLODED VIEW / PARTS LIST ABR-00-MH Motorized Horizontal V-Guide Ways " ABR-00-MV Motorized Vertical V-Guide Ways " CWO-7-MV Motorized Vertical Racker CWO-9 Attachment Block CWO-0- Torch Angle Adjuster " CWO-0 # Load Spring Assembly

35 OPTIONAL MOTORIZED RACKING EQUIPMENT / CWO-90-MH / EXPLODED VIEW / PARTS LIST BUG-0 Gear Motor (0:) CWO-80 W Fixed Leg & Wheel CWO-8 W Adj. Leg & Wheel CWO-87 Mount Plt Large Racker CWO-9 Racker Motor MT Plt CWO-9 Stand-Off 7 CWO- Fixed Leg & Wheel 8 CWO-7 Adj. Leg & Wheel 9 FAS-07 Soc Hd Cap 8- x /" 0 FAS-07 Soc Hd Cap /-0 x /" FAS-09 Soc Hd Cap /-0 x " GOF-0 Drive Pinion w/ Key WAS-00 /" SAE Washer CWO-9 Motor Enclosure BUG-98 Panel Connector -T, M GOF-0 QD Female 7 FAS-00 Soc Hd Cap -0 x /8" 8 FAS-0 Soc Hd Cap 8- x /" 9 FAS-0 Hex Nut -0

36 OPTIONAL RACKING MOTORIZED RACKING / CWP-0 / EXPLODED VIEW / PARTS LIST CWP- Motorized Vertical Heavy Duty Rack Assembly CWP- Motorized Vertical Heavy Duty Rack Assembly CWP-0 Vertical Racker for Heavy Duty WAS-0 / Split Lock Washer FAS- Hex Hd Cap Scr /-0 x -/ CWP- Horizontal Racker for Heavy Duty *7 CWO-97 Power Racker Cable *Not shown in drawing

37 OPTIONAL RACKING MOTORIZED RACKING / CWP- / EXPLODED VIEW / PARTS LIST , 8 9 CWP- Hvy Duty Rack 0: No Mounting Bracket CWO-9 Jaw Coupling /8" & /8" Bores With Spider CWO- /8" Pillow Block CWP- Screw for Mtrzd Hrz Hvy Duty Rack CWP- Mtrzd Hrz Slide Hvy Duty Rack CWP- Stud /- All Thread 7 CWO-8 "- Acme Nut and Bar Assembly 8 CWO-908 Hold Down Clip 9 CWO-90 T- Track " Lg 0 CWP- Horiz P.M. Motor Bracket #970 Mod FAS-0 Hex Nut /- WAS-08 / Split Lock Washer Zinc Plated WAS-080 / SAE Flat FAS-9-SS Soc Hd Cap Scr /8- x -/ Stainless Steel FAS--SS Phil Pan Hd Scr 0/ x /8" Stainless Steel 0 FAS-09-SS Hex Hd Cap Scr /-0 x " Stainless Steel 7 FAS-099 Hex Hd Cap Scr /8- x " 8 WAS-0 /8" Split Lock Washer Zinc Plated 9 WAS-00 /8 Washer Zinc Plated 0 FAS-0 Soc Hd Cap Scr /-0 x / WAS-0 /" Split Lock Washer Zinc Plated 7

38 OPTIONAL MOTORIZED RACKING EQUIPMENT / PRS-00/ EXPLODED VIEW / WIRING DIAGRAM 8

39 OPTIONAL MOTORIZED RACKING EQUIPMENT / PRS-00 / PARTS LIST ITEM COMPONENT ITEM DESCRIPTION 0VAC 0VAC VAC PRS- Input End Panel BUG-9.7 Amp Circuit Breaker BUG-9. Amp Circuit Breaker BUG-9 Amp Circuit Breaker BUG-9 Reset Seal, Transparent BUG-00 Transformer VAC BUG-00 Transformer 0VAC BUG-00 Transformer VAC PRS-0 Enclosure PRS- Output End Panel 7 MUG- Panel Connector, -T, F 8 BUG-0 Relay Bracket 9 BUG- Hold Down Spring 0 BUG-8 Relay Socket & Spring BUG-8 Relay, Pdt, A 0V, Plug In BUG- Relay A, 0VAC BUG-9 Relay 8VAC BUG-990 Panel Connector, -T, F CAS-770 Speed Control (Iron Rotor) BUG-9 Cord Grip BUG-9 Power Cord (0VAC Shown) GOF- Line Cord 0VAC BUG-98 Cap & Chain Assembly 7 FAS-0 8/ x /8 Pan Hd, Di-Chrome 0 8 FAS-0 Hex Nut 8-9 WAS-0 #8 Internal Star Lockwasher 0 SCW WTE 0 #8- x /8" Pan Head, Zinc FAS-00 Rnd Hd Slt Scr -0 x /8 Zinc 8 FAS-0 Hex Nut -0 8 WAS-00 # Internal Star Lockwasher 8 FAS-0 Pan Hd Slt - x / Black N/S SFX-9 Bumper, Cylindrical. x.0" 9

40 OPTIONAL MOTORIZED RACKING EQUIPMENT / CWP- / EXPLODED VIEW / PARTS LIST CWO-87 Plate CWO- Wheel & Leg Assembly, Fixed CWO-7 Wheel & Leg Assembly, Adjustable OPTIONAL MOTORIZED RACKING EQUIPMENT / PRS-07 / EXPLODED VIEW / PARTS LIST 0

41 PREVENTIVE MAINTENANCE / CW-7 CIRCLE WELDER IMPORTANT: Make sure the input power at the power source is turned off and the 0' weld cable is disconnected from the circle welder prior to working inside the circle welder. AFTER DAILY USE: Refer to CW-7 Exploded View Parts List. (Pg. 0, ) Racking System Item #: Inspect gear rack, hardened ways and wheels (remove all dirt, grease, weld spatter and rust). Check hardened ways for nicks and replace if necessary. Lubricate with a dry teflon or graphite spray lubricant. Adjust wheels for snug fit and smooth operation. Lubricate racker pinion with a dry teflon or graphite spray lubricant. Large Horizontal Racker Item #: Inspect wheels (remove all dirt, grease, weld spatter and rust). Adjust wheels for snug fit and smooth operation. Lubricate racker pinion and wheels with a dry teflon or graphite spray lubricant. Slide Bar Mounting Assembly Item #: Inspect hardened ways (remove all dirt, grease and weld spatter). Check hardened ways for nicks and replace if necessary. Lubricate with a dry teflon or graphite spray lubricant. Refer to CW-7 Electrical Component Chart. (Pg. ) Power Cable Item #: Inspect cable connector to make sure threads are not stripped and that the connector is not cracked. Check the cable for cuts, missing insulation and burn spots, replace if necessary. CW-7 Collector Ring Item #: Inspect cable connector to make sure threads are not stripped and that the connector is not cracked. Ensure that the connector is fastened properly to the large aluminum gear item #7 on the CW- Exploded View Parts List. EVERY SIX MONTHS: Refer to CW-7 Exploded View Parts List. (Pg. 0, ) Aluminum Gear Item #9 Do not grease this gear. Inspect gear teeth (remove all dirt, grease and weld spatter). Lubricate with a dry teflon or graphite spray lubricant. Replace gear if excessively worn. P.M. Motor Assembly Item #7: Do not grease this pinion. Inspect the drive pinion (remove all dirt, grease and weld spatter). Lubricate with a dry teflon or graphite spray lubricant. Replace pinion if excessively worn. Check set screw and tighten if necessary. Adjust motor assembly using the four adjustable mounting fasteners so that proper gear mesh is achieved between the aluminum gear item #9 and the motor drive pinion. " Cam Assembly Item #7: Inspect the slide rails and the cam pinion (remove all dirt, grease and weld spatter. Do not grease slide rails or cam pinion. Lubricate with a dry teflon or graphite spray lubricant. Replace cam pinion if excessively worn. Tighten all fasteners as needed. Wire Reel Assembly Item #: Periodically coat the wire wheel shaft with a thin layer of grease as needed. Inspect the shoe assembly and replace if excessively worn.

42 PREVENTIVE MAINTENANCE / CW-7 CIRCLE WELDER Refer to CW-7 Electrical Component Chart. (Pg. ) GMA Wire Feed Control Item #: Open control box, use an air hose to blow out dust and dirt. Check all wires for breaks and replace if necessary. Check all electrical connectors and plugs. If an electrical component fails refer to CWO- Wire Feeder Control electrical component chart for replacement parts or return for service. M- Rotation Control Item #: Open control box use an air hose to blow out dust and dirt. Check all wires for breaks and replace if necessary. Check all electrical connectors and plugs. If an electrical component fails refer to CWO-0 Rotation Control electrical component chart for replacement parts or return or service. LN-7 Wire Feeder Assembly Item #9: Check brushes for wear. Brushes should be replaced when their length is less than / inch. Replace strain relief on wire if pulled out of motor housing. Brush Holder & Support Item #: Inspect brush holder. Make sure constant tension is being applied on the brushes. Brushes should move freely within the brush holder. Check brushes for arc build-up. If brushes are pitted they will need replaced. Remove the brushes and sand them to ensure a smooth contact surface. Make sure all fasteners are tight. Small Brush Retainer Assembly Item #8: Inspect black brush holders for cracks and replace if needed. Check and make sure all wires are soldered properly to the holders. Replace the brushes when their length is less than / inch long. Remove the brushes and sand them to ensure a smooth contact surface. Make sure all fasteners are tight. Terminal Block Item #: Inspect the plastic terminal strip and make sure it is not cracked, replace if necessary. Make sure all terminal connections are tight. Make sure all ground wires are connected to the mounting screws of the terminal strip. EVERY TWELVE MONTHS: Refer to CW-7 Exploded View Parts List. (Pg. 0, ) -/" Bearing With Fasteners Item #: Do not grease the bearing, it is greased for life by the manufacturer. If the grease fitting has not been removed and plugged we suggest that you do so now. Earlier models may not have been plugged at time of assembly. P.M. Motor Assembly Item #: Bodine gear motor lubrication. Fill gear motor to oil level indicator with worm gear oil conforming to AGMA#EP compounded (SAE#90) oil or Bodine lubricant (#L-). Do not overfill. LN-7 Wire Feeder Assembly Item #7: Apply graphite grease to the gear teeth. Inspect the drive roll portion of the assembly, clean as necessary. Do not use solvents on the idle roll because it may wash the lubricant out of the bearings. Do not apply grease to the drive rolls. Transmission : Assembly Item #: Inspect for excessive wear and tear. Keep the transmission assembly clean and lubricate with Lubriplate #0-AA.

43 PREVENTIVE MAINTENANCE / CW-7 CIRCLE WELDER Refer to CW-7 Electrical Component Chart. (Pg. ) CW-7 Collector Item #: The collector ring should be sanded once a year. If the collector ring is pitted too badly it should be replaced. Inspect all wires coming out of the collector ring for cut or missing insulation. All wires should be fastened to the center shaft with a nylon cable tie. Tighten four set screws if needed. Weld Cable Inlet /0 Item #: Ensure that the cable is fastened tightly to the collector ring. Inspect the cable for cut or missing insulation. Make sure the micarta insulation tube on the cable is in good condition. Replace the cable if necessary. Solenoid Adaptor Kit Item #: Inspect for damage. Replace if necessary. GMA Pigtail Item #: Inspect the cable for cuts or missing insulation. Ensure that the elbow connector is not damaged. Ensure that all terminal ends are snug. Replace cable if necessary.

44 WARRANTY Limited -Year Warranty* Model Serial No. Date Purchased: Where Purchased: For a period ending one () year from the date of invoice, Manufacturer warrants that any new machine or part is free from defects in materials and workmanship and Manufacturer agrees to repair or replace at its option, any defective part or machine. HOWEVER, if the invoiced customer registers the Product Warranty by returning the Warranty Registration Card supplied with the product within 90 days of the invoice date, or by registering on-line at Manufacturer will extend the warranty period an additional two () years which will provide three () total years from the date of original invoice to customer. This warranty does not apply to machines which, after Manufacture s inspection are determined by Manufacturer to have been damaged due to neglect, abuse, overloading, accident or improper usage. All shipping and handling charges will be paid by the customer. The foregoing express warranty is exclusive and Manufacturer makes no representation or warranty (either express or implied) other than as set forth expressly in the preceding sentence. Specifically, Manufacturer makes no express or implied warranty of merchantability or fitness for any particular purpose with respect to any goods. Manufacturer shall not be subject to any other obligations or liabilities whatsoever with respect to machines or parts furnished by Manufacturer. Manufacturer shall not in any event be liable to Distributor or any customer for any loss of profits, incidental or consequential damages or special damages of any kind. Distributor s or customer s sole and exclusive remedy against Manufacturer for any breach of warranty, negligence, strict liability or any other claim relating to goods delivered pursuant hereto shall be for repair or replacement (at Manufacturer s option) of the machines or parts affected by such breach. Distributor s Warranty: In no event shall Manufacturer be liable to Distributor or to any customer thereof for any warranties, representations or promises, express or implied, extended by Distributor without the advance written consent of Manufacturer, including but not limited to any and all warranties of merchantability or fitness for a particular purpose and all warranties, representations or promises which exceed or are different from the express limited warranty set forth above. Distributor agrees to indemnify and hold Manufacturer harmless from any claim by a customer based upon any express or implied warranty by Distributor which exceeds or differs from Manufacturer s express limited warranty set forth above. HOW TO OBTAIN SERVICE: If you think this machine is not operating properly, re-read the instruction manual carefully, then call your Authorized BUG-O dealer/distributor. If they cannot give you the necessary service, write or phone us to tell us exactly what difficulty you have experienced. BE SURE to mention the MODEL and SERIAL numbers. *Bug-O System s warranty applies to Bug-O components only. Where other brands of power sources, wire feeders or sub components are a part of Bug-O Equipment, please refer to that specific Manufacturer s manual for warranty specifications on their components.