j5-8 butt welders - Micro Products Company
Contents
1. n the clamp arms The upset pressures are completely adjustable for various Sizes and types of materials Adjustme weld forging process This is obtained length of the pull bar by one of two me the pullbar turnbuckle or b changing by adjusting thods a rol the position capscrew on the lower part of the pullbar tate nt of the clamp spring pull determines the amount of upset pressure for the the of the 3 4 FLASH SPEED MECHANISM For new speed mechanism see addendum On Models J5ADU and J6ADU Welders echanism performs a unique mul addition of the spring loaded m h adpiec wv h igh pressu Mounted to just below cog The p these cogs of the mova flashing ac by means of This knob c the tube be Initial low current wh of the transpires Spring tens and the ups nables thes this 1 bar is grad mounted to urpose of is to crea ble platen to provide a friction tion a is welders to give a control On model J5SF and J6SF Welders precise flashing speed regulation and final upset drop off is obtained from its unique hydraulic cylinder located on the right of the weld head Flashing speed is set with the use of the flashing Speed adjusting knob which regulates the2. A good anneal approximat rubbed on obtaining apart expelled alumi Be extremely careful num by poor safety techniques this tempera color at 1 temperatur ing aluminum rod and wire can be somew it passes very quickly through hat difficult the plastic range and not to ge tely 700 degrees F the surface to be annea ed will t burned from for aluminum rod and wire is Common blue carpenters chalk assist in The chalk will turn a straw anneal temperature 700 degrees F trical magnetic to the wire surface 13 6 0 6 2 6 3 SPECIAL ADJUSTMENTS HEADPIECES Refer to Figure 4 SPACE ADJUSTING KNOB A Determines the amount of open space between the welding dies Calibration 1 Turn space adjusting knob to the stop or the number 1 setting 2 Lay a straight edge across the die seats 3 The die seats should be level and the weld dies should have the distance from table 1 between the closest die edges 4 If die seats are not level A Back headpiece close stop screw off of nylon stop pad B Loosen the setscrew on the space adjusting knob C With a pair of pliers turn the space adjusting shaft until dies are level and proper clearance between dies exists D Retighten spacing knob so that the arrow pointer is across from 1 5 A compression spring and stop pin are located beneath the spacing knob to
3. 6 6 CLAMP SPRING CROSS BOLT Refer to Figure 5 Assures maximum die shoe opening and non shorting of weld head when annealing Calibration 1 Adjust cross bolt on clap arm on the stationary head to where the clamp arm just contacts the weld die seat and approximately 1 8 to 3 16 clearance is evident between the clamp spring clevis and weld die seat 2 Adjust cross bolt on clamp arm on the movable head to where the clamp arm just contacts the weld die seat Tighten lock nuts 6 6 ELECTRO CUT As received the electro cut unit will be properly adjusted for space and spring tension for the entire stock range The headpiece is actually locked into a stationary position This is achieved by depressing the foot pedal to the bottom position and hold then turn the closed head adjusting screw until 3 16 is measured between the weld dies The open space bolt is then adjusted until the headpiece is locked into a stationary position TABLE 1 Distance between closest die edges Model Gopen space 1 J5CA C amp S 188 4 76mm J6S 313 7 94mm JTA 8 313 7 94mm J8C amp S 250 6 35mm J9C 250 6 35mm TABLE 2 Distance between closed die edges 16 Model weld cut off J5CA C amp S 219 5 56mm J6S 344 8 73mm JTA amp 344 8 73mm J8C S amp J9C 313 7 94mm Important Do not turn or remove the front center pivot screw and nut To remove the movable half of the weld
4. J5S J6S J8S J45C J5C J7C J8C No 20 Space adjusting screw X X X X X X X X 32553 knob 21 Space adjusting screw X X X X X X X X 80037 tension spring 22 Space adjusting screw X X X X X X X X 33024 23 Space adjusting screw X X X X X X X X fiber insert 24 Space adjusting screw X X X X X X X X 33024 fiber bumper 32 Clamp spring outer leaf X X X X X X X X 80038 33 Clamp spring inner leaf X X X X 80039 34 Clamp coil spring X X X X 80040 34A Clamp coil spring X O O 80041 heavy duty 35 Clamp coil spring guide X X X X X 33030 36 Clamp coil outer lug X X X X X X X X 33233 37 Clamp spring inner lug X X X X X X X X 33365 38 Clamp spring insulating X X X X X X X X 92910 washer 1 16 38A Clamp spring insulating X X X X X X X X 92906 washer 1 8 39 Clamp spring inner and X X X X X X X X 90217 outer leaf attaching screw and nuts 40A Clamp spring cross X X X X 33288 bolt washer and nuts steel 40C Clamp spring cross X X X X 33305 bolt washer and nuts copper 41 Clamp spring assembly X X X X X X X X 53007 center clevis 42 Clamp spring pull bar X X X X X X X X 90260 to center clevis attaching bolt and nut 42A Clamp spring pull bar O O O O X X X X 43002 with adjustable turnbuckle 42B Clamp spring pull bar X X X X 43003 without turnbuckle used on steel type welders only 43 Clamp spring assembly X X X X X X X X 90262 to center clevis attaching bolt and nut 44 Clamp spring assembly X X X X X X X X 90265 to clamp
5. 050 2 OLA 009 2 Cross section Cross section Cross section Cross section Minimum Thickness 010 020 5015 s0207 Maximum Width 140 Lees 1 0 Laa Operating Voltages 230 460 60 hertz 230 460 60 hertz 230 460 60 hertz 230 460 60 hertz Line Demand 460 37amps 100 duty 37amps 100 duty 37amps 100 duty 37amps 100 duty Volts 117ampse10 duty 117amps 10 duty 117ampse10 duty 117amps 10 duty Line Demand 230 74amps 100 duty 74amps 100 duty 74amps 100 duty 74amps 100 duty Volts 234amps 10 duty 234amps 10 duty 234amps 10 duty 234amps 10 duty Transformer Rating Single Phase AC 24 KVA 24KVA 24 KVA 24 KVA Heat Selection Switch 12 point 12 point 12 point 12 point Dimensions and Weights Truck Type Overall Height 44 112cm 44 112cm 44 112cm 44 112cm Weld Die Height 41 105cm 41 105cm 41 105cm 41 5 105cm Floor Space 3l x 28 167 31 x 28 31 x 28 17 3l x 28 1 79cm x 72cm 79cm x 72cm 79cm x 72cm 79cm x 72cm 50 rated duty cycle First your the be o p we lani suf lder ELECTRICAL determine that housing icient size appreciable loss duri not in operate properly if t line voltages In Pas GENERAL HOOK UP INSTRUCTIONS the available el ectrical service in t corresponds to the Electric
6. 5 3 1 2 1 025 750 8 4 2 2 1 Uzbx 185 8 7 Rear al 2 1 Steel 017x1 2000 9 7 2 2 2 J6ADU 032x1 000 9 8 2 2 d Copper 020x 1 1 5125 6 5 2 2 062 250 4 6 2 2 iL 4 3 SIZE STOCK MATERIAL HEAT SPACE GROOVE TENSION inches 1875 Strand Steel 7 3 16 Middle 1 110 Strand Steel 8 3 16 Front 1 123 Strand Steel 8 3 16 Front 1 A E E WIT A CORRECT BURR AND EVEN HEAT PENETRATION IK A POOR WELD WITH IMPROPER UPSET AND A MINIMUM AMOUNT OF HEAT PENETRATION BURR REMOVAL EXAMPLES GOOD POOR POOR Weld burr must be removed as close to parent metal as possible Incom plete burr removal or excessive grind ing will cause tension breaks on sub seguent wire drawing operations Bend test The weld burr should be the diameter of the rod above vise jaws and bent back forth until rod breaks A good weld will break across or on either side of the weld EXAMPLES OF GOOD WELDS EXAMPLES OF POOR WELDS GOOD WELD WILL BREAK ACROSS WELD ON A BEND TEST EE A POOR WELD WITH LITTLE FUSION AND NO UPSET BURR RECOMMENDED SHEAR CUTS EE BLADE es SHEAR BLADE PLACE IN DIE GROOVES AS ILLUSTRATED CROSSING CUT ENDS Note A A1 designation indicates position of fraying surfaces for op timum weld alignment weld heat and upset pressure utilization FIGURE 1 RECOMMENDED SHEAR CUT FOR FLAT STOCK a FIGURE 2 TYPICAL OPERATING SEOUENCE J5 Remember Materia
7. B3559B 11 2 2 VELOA ANNEAL FLASHGUAAD OPERATING SW SAFETY SW LIMIT sw T2 WELO TRANSFORMER MEAT CONTROL AUTO TRANSFORMER 13 Unless otherwise specified all 120V control wires to be no 16 Awgred Unless otherwise specified all neutral wires to be no 16 Awg white Where possible use orange wire on high voltage wirin For 460 Vac operation use solid jumper as shown for 2 use dashed jumpers as shown 24 above 200V Vac operation 11 0 SAFETY REMINDERS The following accident prevention information is presented to eliminate potential hazards while operating or repairing Micro Wel inspecting d electric resistance welding ameplate rated load time lag parameters functional of equipment Important safety compliance information for Micro Weld Welders GENERAL l Prior to using equipment an operator must be instructed on basic operation and malfunction methods by qualified personnel 2 Safety eyeglasses must be worn by all personnel Operating or servicing welders 3 Use safety equipment properly and keep safety equipment on welders 1 Determine that both operating voltages and hertz cycles of power supply correspond to ratings listed on weld nameplate located on weld housing 5 Check nameplate ratings and
8. Used on welders suitable for welding non ferrous and low carbon steel wire and rod A Close safety flashguard if equipped with interlocking switch B Place welded stock into anneal clamps with upset burr midway between anneal clamps clamp securely into position C Push annealing switch with a jogging action to heat material to desired temperatur D After the material has lost its color carefully remove the wire from the anneal jaws and remove the upset burr Be extremely careful not to get burned on the hot metal 11 5 6 FRONT OR DIAL INDICATING ANNEAL DEVICES A cam type clamp anneal located beneath the welding dies One clamp is stationary and the other is movable clamp which is attached to a unique mechanism which allows the hot expanding and annealing wire to remain straight without the normal bowing or bending This feature assists in preventing fractures in weld zone during anneal process Both type of devices front or dial type are suitable for low carbon steel mild steel stainless steel and high carbon steel 5 7 FRONT TYPE ANNEAL OPERATING PROCEDURES A Close safety flashguard if so equipped B Place welded stock into anneal clamps with upset burr midway between anneal jaws being careful to push movable clamp jaw against its inward stop Carefully tighten wire into both jaws C Push anneal switch in a jogging fa
9. X 33203 and movable castings matched machined w pivots and center 01A Complete headpiece X X 33287 assembly w all operating parts state model number 05 Headpiece return spring X X X X X X X X 33017 guide 06 Headpiece return spring X X X X X X X X 80036 07 Headpiece return spring X X X X X X X X 33018 insulated bushing 07A Return spring plug X X X X X X X X 85051 08L Clamp arm Std left X X X X 33004 O8R Clamp arm std Right X X X X 33005 08L Clamp arm Std left X X X 33008 08R Clamp arm std Right X X X X 33009 08L Clamp arm Std left X 33012 08R Clamp arm std Right 33013 0 Clamp arm retaining X X X X X X X X 33019 screw al Headpiece adjustable X X X X X X X X 33023 center front or rear 3 Open headpiece stop X X X X X X X X 93111 screw and nut nylon 4 Open head stop nut X X X X X X X X 33020 6 Closed headpiece stop X X X X X X X X 53030 button 6A Closed head stop X X X X 33027 assembly 6A Closed head stop X X X X 33029 assembly 7 Closed headpiece screw X X X X X X X X 92906 insulating washer 8 Closed headpiece screw X X X 33026 insulating tube 8 Closed headpiece screw X X X X X 33028 insulating tube 9 Closed headpiece stop X X X X X X X X 33352 Screw stationary 32 Applicable Welders Non Ferrous Ferrous Welders Welders Part Item No Description J45S
10. casting open stop 36 Applicable Welders Non Ferrous Ferrous Welders Welders Part Item No Description J45S J5S J6S J8S J45C J5C J7C J8C No 76 Front anneal movable X X X X 62069 casting shunt lug 76 Front anneal movable X X X X 62070 casting shunt lug TT Front anneal movable X X X X 62076 casting shunt cable TT Front anneal movable X X X X 62077 casting shunt cable 78 Front anneal assembly X X X X 11851 dial indicator 81 Front anneal assembly X X X X 62012 dial indicator 82 Standard anneal O O O X X X X 62072 bracket stationary head 83 Standard anneal X X X X 62073 bracket movable head 84 Standard anneal bracket X X X X 90231 mounting screws 6 rq d 18 Anneal pedal return X X X X X X X X 80043 Spring 19 Foot pedal return X X X X X X X X 43073 Spring 19A Foot pedal assembly X X X X X X X X 43100 bushings 20 Foot pedal return X X X X X X X X 80044 spring old style prior to Ser No 6152 21 Foot pedal return X X X X X X X X 80045 spring new style after Ser No 6152 32 Caster complete X X X X X X X X 48104 stationary type 32A Caster complete swivel X X X X X X X X 48105 type 32B Replacement caster X X X X X X X X 48119 wheel only 33 Caster brake knob and X X X X X X X X 43528 stud assembly 34 Filing vise m
11. edge determine that bolts A B C and D are all in alignment Lengthen or shorten the pull bar to attain this setting This alignment 3 Should you requir sets the wel sser pressur der for maximum upset pressure 1 for small er stock sizes the pull bar can be decrease ups A Pull t pressures as per maximum upset pressure lengthened to the following bar with five holes at lower end different upset pressures for five The top hole is 15 1 Remove the nut and bolt at the lower end of the pull bar Move pull bar Replace Za 3 Pull by number j B to the desired setting the bolt and nut bar with turnb ust above top of turnbuckle uckle Read upset pressure Number one is maximum upset pressure 1 Loosen locknu turn C W 2 Adj E 3 Tighten Lesser pressures ar 4 ust turnbuc c w lengthens locknut indicated when center bolts t at bottom of turnbuckle kle to desired setting B and C are abov e centerlin 5 Do not shorten th e pull N bar to such a position so that the center bol centerline El ts cross bolt adjustme amp spri Pressures should not be increased or decreased by nts wv B and C are below the ng breakage could occur
12. keep within capacities and material categories stated therein 6 Adjustment or repairs must be made by persons thoroughly familiar with operating principles of welder 7 Welder must be disconnected from power supply prior to maintenance or repair procedures 8 Reduce air supply pressures or disconnect from air source for pneumatically equipped welders prior to maintenance or repair procedures 9 Welders equipped with water cooling accessories must have water supply turned off during idle periods and allow only enough water to flow to cool heated components during weld operation ELECTRICAL l Refer to National Electrical Code and local regulations for adequate electrical wiring to power welder Do not operate welder with inadequate electrical power supply cords or cable 2 All welders must be ground through power supply and welder ground connection terminal securely tightened 3 All welders must be able to be disconnected from power source either by a double breaking disconnect switch or unplugged by standard rated plugs 4 All welders must be fused to prevent injury should an electrical malfunction occur Welders must never be fused for an ampere load that exceeds the ratings stated on weld nameplate Normally welders are fused using the n S tandard fuses al llow this specification 25 5 Electric power cords to welder must be kept in good condition Report any damage or potential hazards to maintenance pe
13. speed of the oil passing the internal valve Number 1 indicates the slowest flashing speed Turn the knob counterclockwise to increase the flashing speed Generally larger stock requires a slower flashing speed Final upset is obtained when the piston is compressed to a point where the internal valve is bypassed allowing unrestricted movement This bypass point can be adjusted by rotating the piston cap clockwise causing the unrestricted movement of the piston to begin when the welding dies are closer together Properly made welds are perfectly sound and have little upset burr Poor welds usually indicate too low heat or incorrect flashing Speeds 3 5 DOUBLE UPSET MECHANISM the double upset ltifunction task lever bar across the welder The led owed by flash then an initially low upset pressure foll urfaces on nd rest type of controlled increased or decreased trot This the small hanges low the ups knob the amount lever arm at the e ile there is the bogs to overpower Opposing surface of the lower cog The wedging action ion t pressur still all additiv t pressur el set tension pressure up force but also the ups t speed nd of of compression on a spring in which previously gave a fric creat y accumulated to achieve the fi This not only increases th which is ex critical in the weldability of c
14. ADJUSTMENT 74 20 UNC THD SCREW KNOB WASHER me IR II LA HH Y WZ ZEE NEEDLE VALVE VA SS Y 7 9444 WE SAAG N RETAINING FLARE BOTTOM ASSEMBLY CLEVIS MUST BE INSULATED ELECTRICALLY FROM SCREW IN PISTON AND FROM ARM EXTENDING FROM MOVABLE HEADPIECE OF WELDER CAP KEYED TO PISTON LOOSEN LOCK NUT AND ROTATE CAP CLOCKWISE TO MAKE UNRESTRICTED MOVEMENT OF PISTON TO BEGIN WHEN WELDING DIES ARE CLOSER TO GETHER FLASHING SPEED ADJUSTMENT KNOB NO 1 ON KNOB IS SLOWEST FLASHING SPEED TURN KNOB COUNTER CLOCKWISE TO INCREASE FLASHING SPEED BUTTERFLY VALVE CLOSES IN DOWNWARD MOVEMENT OPENS FOR FREE RETURN OF PISTON STEP OFF ALLOWS HYDRAULIC OIL TO BYPASS PISTON GIVING UNRESTRICTED MOVEMENT OIL USED SHOULD BE SINCLAIR DURO 150 OR EQUIVA LENT 19 POSITION A POSITION C POSITION OF COGS WHEN WELD POSITION D LIMIT SWITCH UPPER ADJUSTABLE COG POSITION OF COGS WHEN DIES ARE OPEN FOR STARTING POSITION IS COMPLETED COG PRESSURE c Fa HELP ADJUSTMENT ae POSITION B SET COG PRESSURE WITH FOOT TREADLE UP THESE EDGES MUST LINE UP WHEN CLAMPED ON STOCK POSITION OF COGS WHEN WELDING DIES ARE 1 16 APART POINT OF CUT OUT FOR LIMIT SWITCH MAINTAIN FLAT AND SQUARE SURFACES WHEN WELDING FLAT STOCK FIGURE 8 LIMIT SWITCH ADJUSTMENT 7 0 PREVENTATIVE MAINTENANCE Keep in mind that these welders are preci
15. MICRO WELD J5 8 BUTT WELDERS MICRO PRODUCTS COMPANY SERVICE MANUAL J5 8 BUTT WELDERS SERVICE MANUAL TABLE OF CONTENTS 1 0 SPECIFICATIONS 2 0 GENERAL HOOK UP INSTRUCTIONS 3 0 GENERAL OPERATING INSTRUCTIONS 4 0 SUGGESTED SETTINGS 5 0 TYPICAL OPERATING SEQUENCE 6 0 ANNEALING INFORMATION 7 0 SPECIAL ADJUSTMENTS 8 0 PREVENTATIVE MAINTENANCE 9 0 DIAGNOSTIC CHART FOR TROUBLESHOOTING 10 0 ELECTRICAL SCHEMATIC 11 0 SAFETY REMINDERS 12 0 BUYERS GUIDE 13 0 PARTS LIST 1 0 SPECIFICATIONS MODELS FOR STEEL WIRE MODEL J5S MODEL J6S MODEL J8S Stock Size Range 060 7 250 Ol 375 2230 500 1 5mm 6 35mm 4 75mm 953mm 6 35mm 12 7mm Material Suitability Steel rod Steel rod Steel rod E C Aluminum Operating Voltages 230 460 60 hertz 230 460 60 hertz 230 460 60 hertz Line Demand 460 volt 22amps 100 duty 22amps 100 duty 37amps 100 duty cycle 70amps 10 duty 70amps 10 duty 117ampsQ10 duty cycle Line Demand 230 volt 44amps 100 duty 44amps 100 duty 74amps 100 duty cycle 39amps 10 duty 39amps 10 duty 234amps 10 duty cycle Transformer Rating Single Phase AC 4 0 KVA 4 0 KVA 24 0 KVA Heat Selection Switch 6 point 6 point 12 point Dimensions and Weights Truck Type Overall H
16. OOTING OF WELDER xercised wh present i safety p electrical n making n the welder recautions TROUBLE SHOOTING TABLE see section 9 1 3 This electri cal trouble suggested met individual st order give schematic table test n s poi hod of eps of S hoo trouble shooting the table should be performed in the ts ting table is furn the welde tion 10 nts Thi ec a differen corresponding con should be bu nected to FINAL ELECTRICAL CHECKS to make the S tes furnished for valid ished as a T3 The The electrical these tests shows the table may be used for welders with t closely related wiring by usin test points LI amp switch should be set to the During all tests L2 of the welder 1 position Set the heat switch to the number 1 position voltmeter across the welding dies The meter reading will the weld specifica switch VAC Consul Rotate the hea voltage is not defective reading goes switches th t switch Actuate the to zero e reading s wel tion sheet for through all settings read at any setti ng d limit switch Rel ase th houl ld remain at zero g line vol The hea age T connect the Press the operating typically be less than 10 this value If the the heat switc
17. TER injury t be instructed lines must be It is important tha extended period of time connected welders wat outlet should only flow during water at the drain should feel prevent condensation on th r cool be added at our factory provided at the back of be installed in the inlet d headpieces Connect the weld line and the are an hoses head run to an open sight drain the weld le ty guards on welders and use properly on basic operation of unit to Check nameplate rating and keep within size range for each welder t if a welder is to be operated for an and headpieces heat On most model up water J series Micro Weld optio to inlet and outlet A shut off should hose Wa n which can from the ter should and the temperature of the hot to the hand welder headpieces This will which could drip on the welding transformer and cause it to ground AIR Air operated model J series Micro Weld welders are an option Should you have this option inders require a 90 psi air source will be provided needed for the material being welded air operation An air regulator to set the minimum amount of pressure GENERAL OPERATING INSTRUCTIONS BASIC OPERATING PARTS WELD HEAT SELECTION This setting determines the amount of heat available welding Because of cons
18. X X X X 77822 234 3 way foot valve X X X x X X X X 77860 complete 235 Flow control valve X X X X X X X X 77862 236 Quick exhaust valve x X X X X X X 77857 237 Operating switch X X X X X X X X 32523 housing 238 Operating switch X X X X X X X X 57810 240 Hose clamp X X X X X X X X 78107 241 Hose per foot state X X X X X X X X 78102 length 243 Pull bar with adjusting X X X X X X X X 43001 turnbuckle 200 Flashguard complete X X X X X X X X 43102 with switch switch housing and cord 201 Flashguard and mounting X X X X X X X X 43005 bracket only 202 Flashguard switch X X X X X X X X 32523 housing only 203 Flashguard switch X X X X X X X X 57810 204 Lower flash shield used X X X X X X X X 43000 with standard headpiece mounted anneal only 205 ey lock rear access X X X X X X X X 48209 door locking handle 205A Replacement key only X X X X X X X X 48210 identical 09L Clamp arm LH hand X 33076 clamp type special OOR Clamp arm RH hand X 33075 clamp type special Di Hand clamp torsion X X X X 80042 spring 52 Hand clamp handle X X X X 33034 53L Hand clamp cam LH X X X X 33036 53L Hand clamp cam LH X X X X 33037 53R Hand clamp cam RH X X X X 33038 53R Hand clamp cam RH X X X X 33039 54 Hand clamp handle X X X X 33035 05 Hand clamp clevis bolt X X X X 33236 56 Hand clamp set screw X X X X 90015 38 Part No Description Applicable Welders Ferro
19. ain the adjustment 2 Loosen the limit switch adjusting screw locknut 3 Set open space adjusting knob to approximate 4 4 Slowly turn space adjusting knob clockwise towar 1 until the hex head bolt activates the limit switch 5 There should be the distance shown in table 42 between the closest die edges 6 If the gap is greater than the amount specified in table 42 then screw the bolt in to actuate the limit switch later If the gap is less screw the bolt out to actuate the switch sooner 7 Tighten the limit switch adjusting screw locknut 8 The limit switch setting remains the same for all Sizes of material within the welders rating but can be used for a verier control of heat in extreme cases to add or subtract slight amounts of heat to assure levelness of welded material CLAMP SPRINGS AND UPSET PRESSURES Upset Pressur Det for Calibration ds rmines th the weld process by making pull A J5 amp J6 With nothing in the welding dies the foot treadle Refer to Figure 6 amount of clamp and upset pressure available bar longer or shorter depress J7 J8 8 J9 Place separate diameter drill rod pieces into each welding die prior too depressing the foot treadle Do not allow the rod end to touch between the dies The rod pieces are simply used to shim the welding die shoes from the welding dies to obtain the proper upset adjustments 2 With a straight
20. al wiring ate rating CO to deliver full wi mi th a slow bl OW nimum power use of cable size ng t neral the 100 ge he weld cycle here is more t the welder should be f T d der uty cycle rating to the welder can be obtai using this san Code and local ne current rating electrical regulatio Refer to National E located on the welder must ampere load with no he wel hat a 5 will variation fused The ned by Electric cable sized and type guidelines Remember line voltages to the weldi potentially dangerous should the severed harm an operator The welding voltages of t since they do not disconnect met thods ns for adequate power and fusing ng machine are power cords be damaged or he welding dies will not exceed 10 volts 2 2 SAFETY PRECAUTIONS 2 2 1 ELECTRICAL Maintain electrical cable to welder in good repair Welder must be grounded and connections securely tightened Heat switch must not be changed to new position while a weld Cycle is in process servicing welder high volt base of the welder 2 2 2 MECHANICAL Disconnect electrical S rvice befor tages are located within the Safety glasses must be worn by operator while using welder Keep all safe Operators mus prevent material WA
21. area is equal nt metal size Set open space for proper die opening Set movable cog on lever arm to proper adjustment High curren Movable pla Set leverage arm tension to proper adjustment Select proper weld heat Place material into weld dies so as the ends touch mid way between against the Push the fo to clamp th Close flash Heat is im surfaces moves towar the faying short lengt A weld limi the welding dies also flat stock should be rear stops in the dies ot treadle down to the bottom of the stroke e material guard to start the welding process parted to the material ends through faying t flow causes flashing ten under controlled speed and pressure d a closed position due to flashing until surfaces are covered with molten metal and a h of each part reaches forging temperature t switch terminates electrical poser flow through the material Actual weld or coalescence starts to be formed after electric po is applied of the cogs Welded mate Remove stoc Anneal weld zone and sections on either side if applicable Remove upse to the pare wer flow stops and clamp arm upset pressure Further movable platen travel then allows wedging action creating the high pressure upset rial quickly cools under pressure k from dies by releasing foot trea
22. arm attach bolt and nut 45A Clamp spring assembly X X 53008 complete type A 45B Clamp spring assembly X 53009 complete type B 45C Clamp spring assembly X X 53010 complete type C 45D Clamp spring assembly X X 53011 complete type D 45E Clamp spring assembly X 53012 complete type E 25 Limit switch long stem x X X X 59084 type 33 Part No Description Applicable Welders Ferrous Welders Non Ferrous Welders J45S J5S J6S J8S J45C J5C J7C J8C Item No 25A Limit switch short stem type X 57810 26 Limit Switch washers pr insulating 92915 26A Limit switch style cover new 53003 27 Limit switch connection cord 53002 Switch connection grip Limit cord 86164 Switch connection cord bushing Limit 48407 28 Limit switch protection shield safety 53004 29 Limit switch adjusting Screw and nut 53005 30 Anneal and operating Switch 57810 Anneal and operating Switch cover 32523 Welding contactor 25 ampere type 57609 5A Replacement coil 25 amp type 57619 5B Replacement contacts kit 15 amp type 57624 Welding contactor 50 ampere type 57610 6A Replacement amp type coil 50 57620 6B Replacement contacts kit 50 amp type 57625 Weld
23. assure repeatable positions and overthrow protection Check to make sure spacing knob has pressure applied to it from this spring and pin is not bent or missing hence preventing proper adjustment replace as required HEADPIECE CLOSED ADJUSTMENT B Prevents welding dies from touching and prevents possible over travel of movable platen Calibration l Turn space adjusting knob to the stop at the number 1 setting 2 Adjust closed stop adjusting screw so that when the movable head is pushed by hand to a closed position the weld dies will not touch and there is approximately 062 at 1 setting 3 Tighten locknut HEADPIECE OPEN ADJUSTMENT C Adjus Adjus Ro WN RE CO ts maximum open position of headpiece tments Loosen locknut tate open space adjusting knob to the 49 setting Adjust the headpiece open stop screw to where it just ntacts the casting of the stationary headpiece 4 Tighten locknut 14 6 6 4 5 WELD LIMIT SWITCH D Determines the timing point of the weld cycle Adjustments 1 The limit switch is adjusted for actuation by a hex head bolt which contacts the limit switch plunger The weld dies will be used as a reference point to obt
24. clamp arm openings Replace as required 5 Remove movable welding headpiece by loosening rear pivot centers Check the condition of the pivot center surfaces polish and thoroughly clean Re lubricate and re install movable headpiece and adjust so that the movable headpiece do not have any side play Headpiece must be free to pivot and die seat surfaces must be in good alignment 6 Check headpiece castings if worn replace Should the welders be used in a corrosive atmosphere clean off oxides and repaint as required WELDING DIES AND DIE SHOES INFORMATION Description Welding dies Lower conducting electrode and clamp jaw Weld die shoes Upper clamping member Welding dies and die shoes in poor condition are the main causes of bad welds Care of die sets 1 Use a brass or fiber blade to remove particles of flashings that build up on die sets Excessive flash build up causes die burns on material and shorting of die sets 2 Do not attempt to clamp material that is not suited for welder into die sets Undersized materials will slip and burn die grooves Oversized materials will overstress clamping parts 3 Do not use welding die sets for a vise These parts will not withstand the mechanical abuse 1 Whenever welding dies are replaced clean bottoms of dies and corresponding die seats to a bright and clean condition before bolting them tightly into place an
25. d oxidize surface will insulate the welding dies and reduc ffective welding voltage 21 5 Welding die shoes must swivel freely within the clamp arm pivots to prevent cracking of die shoes File down die shoe boss if necessary 6 Welding die set will wear with use and must be changed occasionally for good welding results Keep an adequate supply of replacement parts available Wire and rod slippage is a problem caused by poor die sets and a major cause of wire breaks TYPES OF WELDING DIE SHOES EXAMPLE OF WELDING DIES STANDARD V GROOVE TYPE FOR ROUND OR SQUARE WIRE NON FERROUS WIRE TYPE FERROUS WIRE TYPE SHOE SERRATED zu x EER Ef CAST BRONZE SHOE 1 CAST BRONZE SHOE MEAE ist o WELDING DIE SHOE SIZE CHART WELDING DIE SIZE CHART _ Modei T r Y z Mode A B J5 1 1 4 7 8 5 16 J5 7 8 1 146 Me J6 J7 JB JS 1516 1134 112 6 7 1 1 4 1 3 16 5 8 4849 1 1 4 1 3 8 5 8 9 0 DIAGNOSTIC CHART FOR TROUBLE SHOOTING WELDING ACTION CAUSE REMEDY Weld action normal but weld burr doesn t extend beyond wire Lack of open space Increase open space until desired burr is obtained Molten metal is blown out and ends not joined Weld heat too high Weld limit switch Stock is too small Weak clamp spring Lower heat settings Set limit switch properly Check size rating of welder Replace clamp springs Weld area heat
26. dle t burr so as the enlarged weld area is equal nt metal size 10 5 4 ELECTRO CUT 1 The headpiece space should be set at 3 16 Place stock into the correct die groove 3 Press with your foot the operating treadle until it reaches the bottom position 4 Lower flashguard This will make the current flow to the transformer and burn the cable into N 5 Raise flashguard lift foot treadle to release cable Note If burn off has excess molten metal around the end this can be reduced by closing the space between the dies Refer to 7 7 Some cables have filler cord with an asphalt impregnation The asphalt will melt and run into the jaw grooves Jaw grooves must be kept clean also the connection between the die and die seat so that good electrical connection is maintained ANNEALING INFORMATION An anneal operation will be required on hard drawn or carbon steel wire and rod Annealing will accomplish two things 1 normalize the grain structure in the weld zone 2 will soften sections on either side of the immediate weld area To anneal follow directions of one of the following methods which is applicable to your welder STANDARD TYPE ANNEAL DEVICE With standard type anneal device cam anneal clamps attached directly to movable and stationary welding platens with L shaped brackets or similar devices
27. e with 12 point heat Selection switch Replacement secondary ribbon for 106 06C Auto transformer mounting ring stud for 106 06D Auto transformer mounting ring stud for 106 2 required 07 Secondary to headpiece retaining strap 46 Step down transformer 05KVA for use with 50 pere switch control rcuits P 3 57600 147 tep down transformer VA for use with 50 mpere switch control ircuits 57601 148 tep down transformer 5KVA for use with 100 ampere switch control eirocuits pg Rua 57602 Welding dies lower copper pair 33046 58C Welding dies copper pair lower 33049 58C Welding dies copper pair lower 33052 58M Welding dies lower alloy class No 2 pair 33047 Welding dies lower alloy class No 2 pair 33050 Welding dies lower alloy class No 2 pair 33053 Welding dies lower alloy class No 4 pair 33048 35 Applicable Welders Non Ferrous Ferrous Welders Welders Part Item No Description J45S J5S J6S J8S J45C J5C J7C J8C No 58bE Welding dies lower X X 33051 alloy class No 4 pair 58 Welding dies lower x X 33054 alloy class No 4 pair 58EA Welding d
28. eight 44 112cm 44 112cm 44 112cm Weld Die Height 41 5 105cm 41 5 105cm 41 5 105cm Floor Space LPR dd 317 28 15 31 x28 28 79cm x 72cm 79cm x 72cm 79cm x 72cm MODELS FOR COPPER AND E C ALUMINUM WIRE MODEL J5C MODEL J7C MODEL J8C Stock Size Range 080 250 1874 9 5 1987 500 2mm 6 35mm 4 75mm 953mm 4 75mm 12 7mm Material Suitability Copper and Copper and Copper and E C Aluminum E C Aluminum E C Aluminum Operating Voltages 230 460 60 hertz 230 460 60 hertz 230 460 60 hertz Line Demand 460 volt 37amps 100 duty 117ampse10 duty 5 6amps 100 duty 320amps 10 duty 5 6amps 100 duty cycle 320amps 10 duty cycle Line Demand 230 volt 74amps 100 duty 234amps 10 duty 111 100 duty 640amps 10 duty 111ampsQ100 duty cycle 640amps 10 duty cycle Transformer Rating Single Phase AC 24 0 KVA 36 0 KVA 36 0 KVA Heat Selection Switch 12 point 12 point 12 point Dimensions and Weights Truck Type Overall Height 44 112cm 44 112cm 44 112cm Weld Die Height 41 5 105cm 41 5 105cm 41 5 105cm Floor Space 3S1 x 28 t 317 n 28 157 SI x DE 7 79cm x 72cm 79cm x 72cm 79cm x 72cm 50 rated duty cycle FLASH WELDER NON FERROUS FLAT STOCK WELDER MODEL J5SF MODEL J6SF MODEL J5ADU MODEL J6ADU Stock Size Range 0 OO s050 2 012 2 128 2 005
29. ertain alumin the beret uated leverage cog and the movable headpiece is a matching he opposing s the points of the movement lever arm begins upon termination of weld a wedgi coupled wit tional some of the opposing surface Then the upper cog slides off ng action the lever arm ted in the clamp arm spring al high force are tremel upset um alloys 4 0 BASIC OPERATING PARTS GENERAL OPERATING INSTRUCTIONS 4 0 SUGGESTED SETTINGS OPEN PULLBAR MATERIAL SIZE HEAT SPACE GROOVE TENSION MODEL inches Steel 062 5 3 Front J5S 162 4 5 Rear 250 3 7 Rear Steel 187 4 4 Front J6S 250 4 6 Front 315 3 9 Rear Steel 250 10 6 Front J8S AAS 6 9 Rear 500 4 9 Rear Copper 062 11 4 Front J5C 128 6 5 Front 250 3 9 Rear Copper S25 10 3 Front 4 J7C 250 7 6 Front 4 3 9 Rear Copper 250 7 6 Front J8C 3d 3 9 Front 500 2 9 Rear 4 1 HYD OPEN PULLBAR MATERIAL SIZE CYL SPACE HEAT TENSION MODEL inches Steel 500 4 7 7 2 J5SF UST T50 5 7 5 2 062 x1 000 5 9 2 Steel 025 x 500 5 4 7 J6SF 083 1 000 5 4 5 U20 x1 125 6 9 5 4 2 OPEN PULLBAR ANVIL MATERIAL SIZE HEAT SPACE GROOVE TENSION ANVILE TENSION MODEL inches Aluminum J5ADU 033x 984
30. h may be observe the weld limit and operating 23 9 1 3 PROBLEM PRESS WELD LIMIT PRESS TEST LEAD METER IF NO OPERATING SWITCH ANNEAL CONNECTION READING READING SWITCH ACTUATED SWITCH X1 X2 5 VAC Bad control transformer Tl X2 FU1 5 VAC Bad fuse connection X2 FU1 2 5 VAC Open fuse Open wire to operating X2 PB1 5 VAC switch X2 PB1 2 5 VAC Bad operating switch X X2 LS1 5 VAC Open wire to flashguard X switch X2 LS1 2 5 VAC Open flashguard switch X Open wire to weld limit X X2 LS2 5 VAC switch X2 LS2 2 5 VAC Bad weld limit switch X L2 CR1 Line voltage Open wiring to contactor L2 CR1 2 Line voltage Bad contactor X L2 Si Line voltage Open wire to heat switch X For welders using autotransformer This terminal is L1 Note To perform repairs consult section 13 for parts identification 10 0 B3560B Note A Note B Note C Note D ge MATT oe wal ANNEAL SW ELECTRICAL SCHEMATIC x2 ust L 2 FLASHGUARD LIMIT SWITCH CONTACTOR Unless otherwise specified all 110V control wires to be no 16 Awg red Unless otherwise specified all neutral wires to be no 16 Awg white Where possible use orange wire on high voltage wiring above 200V For 460 Vac operation use solid jumper as shown for 230 Vac operation use dashed jumpers as shown Note A Note B Note C Note D
31. head as specified in the preventiv rear ceni 6 7 Controls the flashi Calibration amp Adjus ter pivo loosen and remove the maintenance techniques only ADU COGS amp SPRING BAR ng speed and upset pressure tments 1 Set head close stop screw to stop movable head when dies are 1 32 between closest t open space s between closest die PA 34 des 4 fi Ds off Se Sel ired star Se Light B gure 8 To set spring bar letely desired welds are obtained compl movable cog so its the lower cogs poin t the weld limit swi dies are 1 16 between closes have a s di dges figure 8C top so dies cannot open more than 1 8 edges left of the point is somewhat to the when the welding dies are set for figure BA tch to actuate when th ding t die edges Cogs should still t amount of opposing surface to overcome ting Space wel spring bar tension should be backed than increased in small increments until figure 8D 17 FIGURE 4 FIGURE 5 A SPACE ADJUSTING KNOB B HEADPIECE CLOSED ADJUSTMENT C HEADPIECE OPEN ADJUSTMENT D WELD LIMIT SWITCH 18 CLAMP ARM MINIMUM MAXIMUM TENSION PA f CENTER LINE oT eee CLAMP SPRING MINIMUM TENSION MAXIMUM TENSION LJ CLEVIS CENTER LINE FIGURE 6 CYL PISTON CYL HOUSING WASHER SPRING FIGURE 7 PULL BAR SOCKET SET SCREW SPACE
32. heating temperature for the annealing process associated with the butt welding procedures The critical temperature will vary slightly but in direct proportion to the wire s carbon content Since carbon steel is ferromagnetic the exact annealing temperature can be easily determined by the loss of magnetic qualities at that point To expand this process further heated to a point of just very close to the correct anneal t degrees F At this point the jo anneal switch is important so tha annealing area with a magnet durin not be drawn to the wire surface d flux looking for so do not over heat Annealing after welding to enab carbon steel certain assist i When the exact the magnet the correct anneal temperature has been achieved point of los the material b emperature gging off on of test the g the off period it will t when we lec u LO does not at wire is very importan technigues hav n drawing high tach s of magne eyond this t tor a wire that is gradually beginning to show some color is about 1000 the We are tic qualities point le an operator to draw the wire mill and been developed by others which may carbon stee l wire Possibly the methods described here will be beneficial to your Operation ANNEALING ALUMINUM WIRE AND ROD Anneal since blows
33. iderable variations in voltage and power factors in various plants and wide variety in material composition exact heat setting cannot be stock use higher specified In general larger sizes of heat setting Welding heat is selected by means of a heavy du either 6 or 12 steps of voltage The welder will be for ty switch equipped with one type or the other depending upon the model The switch is located conveniently on the right side of the welder Number 1 indicates or 12 indicates low welding heat Other numbers are equally graduated from high to low to allow just the amount of voltage for the weld operation The heat switch should never be changed to a new during a welding operation SPACING MECHANISM high heat number 6 right setting The welder is capable of welding a variety of material l size requires a sizes but each major change in materia corresponding change to be made in the open space of the jaws Spacing is obtained by rotating the space adjusting knob located on the right side of the headpiece housing The spacing knob determines the amount of weld upset and expelled metal projecting from the weld UPSET PRESSURE MECHANISM Upset pressures are required for all weld operations zone The model J series of Micro Weld welders obtains its pressures from unique spring assemblies located o
34. ie set 4 pcs X X X X 33250 suitable for welding flat stock material 58EA Welding die set 4 pcs X X 33358 Suitable for welding flat stock material 58EA Welding die set 4 pcs x x 33362 suitable for welding flat stock material 58EB Welding dies set 4 X X X X 33261 pcs suitable for welding strand material State 2 exact material sizes 2 radius grooves 58EB Welding dies set 4 X X 33355 pcs suitable for welding strand material State 2 exact material sizes 2 radius grooves 58EB Welding dies set 4 X X 33363 pcs suitable for welding strand material State 2 exact material sizes 2 radius grooves 59 Welding die attaching X X X X X X X X 90624 screw 60S Welding die shoes X X X X 33056 upper steel faced pr 605 Welding die shoes X X 33062 upper steel faced pr 60SA Replacement steel faces X X 33055 for 60S each X X X X 33061 60SB Rivets for steel face X X X X 93051 insets each 60BC Welding die shoes X X X X X 33054 upper hardened bronze pair 60BC Welding die shoes X X X X 33063 upper hardened bronze pair 68A Complete front anneal X X X X 62136 assembly 68 Front anneal frame X X X X 62134 stationary casting 69 Front anneal frame X X X X 62135 movable casting 71A Front anneal movable X X X X 37713 casting bearing nylon insert 73 Front anneal movable X X X X 62137 casting adjustable pivot center 74 Front anneal movable X X X X 33017 casting closed stop 75 Front anneal movable X X X X 62138
35. ing contactor 100 ampere type 24044 7A Replacement 100 ampere type coil 57622 7B Replacement contacts kit 100 amp type 57626 03 Welding transformer complete ferrous welding type 6 primary leads Replacement primary coil only for No 103 Replacement secondary ribbon for No 103 Transformer mounting ring for No 103 Transformer mtg ring stud for No 103 2 req d Welding transformer complete ferrous welding type 2 primary leads used in conjunction with No 106 and 12 point heat Selection switch 104A Replacement primary coil for No 104 104B Replacement secondary ribbon for No 104 34 Part No Description Applicable Welders Ferrous Welders Non Ferrous Welders J45S J5S J6S J8S J45C J5C J7C J8C Item No 104D Transformer mtg ring stud for No 104 2 req d 105 Welding transformer complete non ferrous welding 2 primary leads used in conjunction with No 106 and 12 point heat Selection switch 05A Replacement primary coil for 105 std 05X Replacement primary coil for 105 extra capacity heavy duty type optional 05B Replacement secondary ribbon for 105 Transformer mounting ring for 105 Transformer mounting ring stud for 105 2 req d 06 Auto Transformer for us
36. l to be joined must be free of rust J6 J7 J8 J9 C SEA corrosion or other insulating material where it contacts welding dies DON Cut wire ends to best joint configuration See figure 1 Set open space for proper die opening Select proper weld heat and range Place wire into welding dies so the ends touch midway between the welding dies Push foot treadle down far enough to hold material in place in dies Close flashguard Push foot treadle down to bottom of stroke to finish clamp process and start weld process Heat is imparted to wire ends through faying surfaces Movable platen under upset pressures moves toward a closed position due to loss of compression yield strength of wire A weld limit switch terminates electrical power flow through wire Actual weld is formed after electric power flow stops and material is hot forged together with remaining upset pressure Welded material quickly cools under pressure Remove stock from dies by releasing foot treadle Anneal weld zone and sections on either side if applicable Remove upset burr so the enlarged weld area is equal in diameter to the parent metal size 5 1 J5SF AND J6SF ps Ow N Cut material ends to best joint configuration See Figure 2 Set open space for proper die opening Set flashing speed Select proper weld heat Place material i
37. n dies are 1 32 between closest die edges 2 To set unrestricted movement of hydraulic cylinder to begin when dies are 3 32 apart A If unrestricted movement starts at a greater distance l Loosen lock nut on cylinder 2 Rotate cylinder counterclockwise to make unrestricted movement of piston to begin when welding dies are closer together 3 Tighten locknut B If unrestricted movement starts at a lesser distance l Loosen lock nut on cylinder 2 Rotate cylinder clockwise to make unrestricted movement of piston begin when welding dies are further apart 3 Tighten lock nut 3 Set limit switch to cut off weld current 1 32 a after unrestricted movement has begun 31 PARTS LIST J45 J5 8 J45 J5 J6 J7 AND J8 Applicable Welders Non Ferrous Ferrous Welders Welders Part Item No Description J45S J5S J6S J8S J45C J5C J7C J8C No 0 Headpiece stationary X X X X 33096 and movable castings matched machined w pivots and center 01A Complete headpiece X X X X 33095 assembly w all operating parts state model number 0 Headpiece stationary X X 33100 and movable castings matched machined w pivots and center 01A Complete headpiece X X 33098 assembly w all operating parts state model number 0 Headpiece stationary X
38. nto weld dies so the ends touch midway between the welding dies also flat stock should be against the rear stops in the dies Push foot treadle down far enough to hold material in place in dies Close flashguard P e H ush foot treadle down to bottom of stroke to finish the lamping process and start weld process eat is imparted to the material end through faying surfaces High current flow causes flashing 11 Movable platen under controlled speed and pressure moves toward a closed position due to flashing until the faying short lengt When the mo speed is te limit switc material is surfaces are covered with molten metal and a h of each part reaches forging temperature vable platen reaches a preset point flashing rminated and upset pressure is applied Further movable platen travel then activates the weld h and electrical power flow through the terminated Actual weld is formed after electric power flow stops and material is hot forged together with remaining upset pressure Welded mate Remove stoc Anneal weld zone and sections on either side if applicable Remove upse to the pare J5ADU amp J6ADU Cut material ends to best joint configuration See T4 WN figure 1 rial quickly cools under pressure k from dies by releasing foot treadle t burr so as the enlarged weld
39. ounting X X X X X X X X 60022 bracket 35 Filing vise standard X X X X X X X X 78112 model 36 Fiber terminal block X X X X X X X X 53000 power input 44 Bench shear No 1 type X X X X X X 78202 capacity to 3 8 rod 44A Replacement blade X X X X X X 78205 bench shear No 1 type 45 Hand shear No 4 type X X 64009 capacity to 5 rod 45A Replacement blades No 4 X X 78204 shear pair 225 Air conversion kit X X X X X X X X Appl complete state model 226 Replacement air X X X X X 77702 cylinder 226A Replacement cylinder X X X X X 77709 diaphragm type No 16 37 Applicable Welders Non Ferrous Ferrous Welders Welders Part Item No Description J45S J5S J6S J8S J45C J5C J7C J8C No 227 Replacement cylinder X X X 77704 diaphragm type No 30 227A Replacement cylinder X X X SEA diaphragm type No 30 2218 Replacement cylinder X X X 77717 shaft protection boot type No 30 228 Upset plate and lever X X X X X mechanism type No 16 229 Upset plate and lever X X X 43515 mechanism type No 30 230 Lever mechanism return X X X X 80046 spring 230 Lever mechanism return X X X X 80048 spring 231 Lever mechanism X X X X X X X X 43091 bushings 2 req d 232 Air regulator and X X X X X X X X 77800 filter assembly 233 Pressure gauge X X X X
40. rsonnel 6 The weld heat selection switch potentiometer or range selection devices must not be changed to a new position while a weld operating is in process 12 0 BUYERS GUIDE HOW TO ORDER PARTS You must provide 1 Machine Model 2 Machine Serial Number 3 Voltage Then identify part s on part list last page in book and provide MICRO with the circled number CALL MICRO at 800 872 1068 Provide MICRO with your company name address and purchase order number 26 27 28 29 ADDENDEM Updated Cylinder Replacement Directions Remove the current cylinder along with the arm insulator bushing Remove both right side head bolts that fasten the head to the truck Place the cylinder plate direct on top of the head lining up the boltholes Using the bolts provided bolt down the plate to the head making sure that the bolt insulators are still intact on the plate While compressing the cylinder down attach the arm pivot to the head arm The speed of the cylinder retraction has been preset at the factory However adjustments may be needed to establish the correct upset cutoff Loosening the cylinder nut and then turning the cylinder itself up or down will alter the location of the weld upset See welder manual for correct machine setup ITEM NO 62210 30 THIS CYCLINDER CONTROLS THE SPEED AND UPSET POSITION Calibration 1 Set closed stop adjusting screw to stop movable head whe
41. s up but weld Low heat Increase weld heat is not complete Secondary transformer Clean and tighten connections transformer connections Loose or dirty welding dies Starting space adjust Clean welding dies and surfaces Decrease starting space Weld has complete burr but is dry and breaks off below surface of wire Upset pressure too great Limit switch settings High carbon steel wire Lower upset pressure Reset limit switch to Specifications Carbon steel wire often appears like this process wire by annealing weld before removing burr Welds good but poorly aligned Welding dies amp die shoes Starting space Loose pivot centers Replace worn dies and shoes Decrease starting space Return heads to factory Ends of wire buckle and may not weld Upset pressure too great Low weld heat Decrease upset pressure Increase weld heat Varying weld results Varying weld results Stock slipping Varying weld voltages Rod condition variations Dies and die shoes Flashings Rod cuts Weld contactor Worn dies and shoes Check electric lines Clean and tighten transformer connections Clean rod where clamped in dies Replace dies and shoes Clean build up of flash materials Check contactor for poor contacts 22 1 1 2 ELECTRICAL Caution these tests Extreme care should b Dangerous voltages ar Only persons familiar with should perform these tes TROUBLE SH
42. shion to evenly heat up weld area to the desired anneal temperature Let annealed are cool After the wire has lost its color carefully remove the wire from the anneal jaws and remove the upset burr F Be careful not to get burned on the hot metal Avo 5 8 DIAL INDICATING ANNEAL DEVICE OPERATING PROCEDURES A Proceed as instructed on front type anneal and proceed with the following information B When heat is applied to the wire the heated wire will expand C The dial indicator will start to move as the wire begins to heat up D When the exact anneal temperature is reached the rotating needle on the dial indicating device will momentarily stop E In sequence the needle will drop back slightly and then start to move forward again F At the start of the second forward movement of the needle release the anneal switch G Heating the wire beyond this pint will cause an improperly treated anneal zone H Allow wire to cool down below 1000 degrees F before removing wire from the anneal clamps Loss of coloring to wire Be extremely careful of hot metal during handling procedures 12 5 9 5 10 DETERMINING CORRECT ANNEAL TEMPERATURES The critical maximum Pd temperature of carbon steel wire is also the
43. sion built to last many years but will require good maintenance procedures They are designed to be as automatic as possible with a minimum dependence on the ability of the operator Adjustments must be made by those thoroughly familiar with the operating principles of the welders 7 1 AS REQUIRED 1 Remove flashings and loose particles from welding headpieces to prevent accumulation Use a soft brush and a soft metal scraper 2 Check condition of welding dies and welding die shoes replace as required 3 Check condition of clamp spring assemblies and replace all broken springs springs that have taken a set as well as worn fiber bushings and washers 7 2 QUARTERLY 1 Repeat above items Check anneal dies and replace all worn parts 3 Check for worn bearings and elongated holes on foot treadle assemble and pull rod parts 4 General lubrication of all moving parts N 20 7 8 3 ANNUALLY 1 Repeat above noted items Check for worn or poorly aligned contacts within magnetic contactor Some older Model J3 and J4 series units do not have contactors 3 Clean weld transformer secondary strap connects to m S R ovable headpiece Emery cloth works well to bring all urfaces in this area to a bright and shiny condition etighten completely 4 heck for excessive wear in clamp arm assemblies where die shoes fit into
44. us Welders Non Ferrous Welders J45S J5S J6S J8S J45C J5C J7C J8C Item No 90 Anneal mounting plate flat stock type X X X 62123 97 Anneal knob flat stock type X 62124 98 Anneal stud flat stock type 62125 99 Anneal clamp body flat stock type 62126 99A Anneal clamp body with shunt cable and lug flat stock type 62140 100 Anneal shoe clip flat stock type 62128 101 Anneal shoe flat stock type 158x Welding dies and die shoes flat stock type 4 piece set state model and serial number Note for flash welders only 159X Welding dies and die shoes flat stock type 4 piece set state model and serial number Note for dual upset welders only 160X Welding dies and die shoes round stock type 4 piece set radius grooves state sizes Note for dual upset welders only 109L Clamp arm special for J5ADU LH Note for dual upset welders only 109R Clamp arm special for J5ADU RH Note for dual upset welders only O Optional 39
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