AGM JS-1 Instruction Manual Download Page 1

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AGM Pin Welder

Instruction Manual

Model JS-1

AGM

Industries, Inc.

16 Jonathan Drive, Brockton, MA 02301

TELEPHONE: 1 (800) 225-9990 FAX: 1 (800) 342-5246

www.agmind.com

Read equipment manufacturer’s manual before using this product. Failure
to do so can result in serious injury or death.

Summary of Contents for JS-1

Page 1: ...l JS 1 AGM Industries Inc 16 Jonathan Drive Brockton MA 02301 TELEPHONE 1 800 225 9990 FAX 1 800 342 5246 www agmind com Read equipment manufacturer s manual before using this product Failure to do so...

Page 2: ...ld in the rain 5 DO NOT look directly at the weld as it is taking place as this may cause eye injury 6 DO NOT touch the weld pin immediately after the weld has been made as the pin can become very hot...

Page 3: ...estions 18 Maintenance 19 Model 250 C Weld Gun Set up Sheets Welding Steel Pins 20 Welding Aluminum CD Pins 21 Welding Pins Over 7 Long 22 Welding Flanged Steel Stainless Studs up to 20 Dia 23 Welding...

Page 4: ...RRANTY No Warranty including warranty of merchantability express or implied is made in connection with the sale of this machine except that AGM Industries will repair or replace defective parts which...

Page 5: ...necessary controls for the welding process It also has a circuit to automatically discharge the weld capacitors through a resistor when the AC line switch is placed in the OFF position The weld gun h...

Page 6: ...d Manual Capacitance 38 000 fd Accuracy 005 on Center ACCESSORIES Input 95 130 VAC 60Hz 15 Amp Gun Lead Extension 24 Ft Weld Voltage 100 220 VDC Ground Cable 26 Ft Mode of Welding Contact Weld Polarit...

Page 7: ...eet for proper ground polarity 1 Insert the ground lead plug into the proper weld receptacle Rotate until tight Attach the ground clamp to clean portion of the work piece Remove paint rust etc as nece...

Page 8: ...th and proper system operation If Amber Weld Ready Light fails to glow within three seconds turn machine off and disconnect from power source to avoid serious damage to your welder INSPECTION OF WELDS...

Page 9: ...rtant that the collet protector be used whenever recommended Protectors are not required when using stops except when welding Power Base pins STOP This is required when welding non flanged studs or wh...

Page 10: ...sary when welding very long CD pins and studs It is used in conjunction with a stop and spark shield to stabilize the pin or stud SPARK SHIELD This protects the collet collet adapter assembly etc from...

Page 11: ...ked frequently for tightness D Slide the collet protector over the collet adaptor assembly making sure that it seats properly Tighten the set screws securely COLLET REMOVAL A Remove the collet protect...

Page 12: ...and tighten the collet holding set screws as previously described D Do Not use a collet protector INSTALLING TYPE 250C G STOP A Remove end cap and stop nut from rear of weld gun B Insert stop inside g...

Page 13: ...3 1 2 3500 3 750 3 7 8 3875 3 375 4 4000 3 250 4 1 2 4500 2 750 4 7 8 4875 2 375 5 5000 2 250 5 1 2 5500 1 750 5 7 8 5875 1 375 6 6000 1 250 6 1 2 6500 0 750 7 7000 0 250 437G TYPE STOP STUD LENGTH C...

Page 14: ...ary B Insert the collet adaptor assembly into the shaft assembly turning the adaptor as it is pushed down This will ensure that it is seated securely REMOVAL OF COLLET ADAPTOR ASSEMBLY A Slide the rub...

Page 15: ...ft C Unscrew the spring retainer and remove the washer from the housing D Remove the spring from the shaft E Slide the desired spring over the shaft F Replace the washer onto the end of the gun housin...

Page 16: ...item 1 from the gun housing H Unscrew the stop nut item 15 from the end of the shaft I Unscrew the knurled spring retainer item 17 from the gun housing J Remove the washer item 3 K Remove the spring i...

Page 17: ...17 ILLUSTRATION NO 1 Not Shown 2615 M ADAPTER ASSEMBLY INCLUDES ITEMS 25 13 14 24...

Page 18: ...straight line motion from welded pin or stud Make sure all control and weld cable connections are kept tight and clean Make sure voltage setting and ground polarity is correct for the application When...

Page 19: ...freedom of the up and down motion The cables and plugs should also be checked for any obvious damage and repaired as required 2 Avoid dragging the welder by the cables as this will almost certainly da...

Page 20: ...Welding cables should be connected for Straight Polarity Ground to Positive For welding pins over 7 in length see page 22 WELDER SET UP STEEL STAINLESS WELD PIN Collet Protector Base Material Ground P...

Page 21: ...f the gun when welding to curved or narrow surfaces NOTE For welding pins over 7 in length see page 22 For pins 1 and shorter omit adapter and use standard protector 437 P The gun is now ready for wel...

Page 22: ...foot piece by loosening the two set screws 10 and sliding the assembly as required The pin should extend beyond the spark shield approximately as shown Tighten the setscrews securely G Check for free...

Page 23: ...ate Welding Voltage 4 40 M2 8 437 110 437 P 110 Un plated Steel POS 105 6 32 M3 437 136 437 P 136 Un plated Steel POS 120 8 32 M4 437 159 437 P 159 Un plated Steel POS 160 10 24 32 M5 437 185 437 P 18...

Page 24: ...stall the 1628 M leg support ring 2 over the three 1151 M legs 1 The metal inserts should face down toward the legs This ring ensures proper alignment of the stud or pin to the work C If a leg support...

Page 25: ...these holes To ensure that the welded stud is perpendicular to the work surface a third leg shortened by an amount equal to the template thickness may be used in the weld gun This leg is held in cont...

Page 26: ...set screws are tightened securely C Install two 1151 M legs 3 180 degrees apart in the faceplate of the weld gun D Install the third leg which has been shortened by the thickness of the template mater...

Page 27: ...art on page 13 WELDER SET UP STUD SIZE Stud Material Collet Ground Polarity Welding Voltage Flanged Non Flg 6 32 Aluminum 437 136 POS 180 140 8 32 Aluminum 437 159 POS 190 160 10 24 10 32 Aluminum 437...

Page 28: ...tighten the set screws 4 E Insert the stud through the spark shield protector and into the collet until stud rests against the stop F Check for freedom of movement between the spark shield and the st...

Page 29: ...nd un plated Steel 22 ga 033 And heavier POS 130 12 Ga 2 63mm 437 PM 437 MC M POS 160 10 Ga 3 42mm 437 PM 437 MC M POS 210 Note 1 Cables 1279 E and 1142 E standard 6 weld cables Consult factory for us...

Page 30: ...is interferes with the weld hence the pre drilling After the pins are welded in place cement is normally grouted around the head of the pin Foiled Faced Insulation Vapor Barrier When applying foil fac...

Page 31: ...e magnet 4 Place the new parts of the Repair Kit into the magnet 5 Screw the 437 PM 3 Collet Stem onto the cap screw A new collet stem should be used only if needed Note that this part is not included...

Page 32: ...32 WIRING DIAGRAM JS 1...

Page 33: ...CB2 3081 E 15 Circuit Breaker 15 Amp C2 2267 E Capacitor DR 3074 E Relay Discharge GB 2117 E Switch Gun Trigger L1 2295 E Light Weld Ready PC1 2487 E J1 Printed Circuit Board R16 3073 E Potentiometer...

Page 34: ...34 Illustration No 2...

Page 35: ...35 Illustration No 3...

Page 36: ...36 Illustration No 4...

Page 37: ...Set Up Chart 2475 E 1 AC Line Switch CB1 2487 E J1 1 Printed Circuit Board PC1 2703 E 1 Light AC Line L1 2988 E 1 Fan 2989 M 1 Fan Guard 3085 E 1 Heat Sink SCR 3070 M2 1 Chassis Painted 3071 M2 1 Cov...

Page 38: ...38 NOTES Welder Serial Number ________________ Gun Serial Number ________________ AGM Industries Inc 16 Jonathan Drive Brockton MA 02301 Telephone 1 800 225 9990 FAX 1 800 342 5246...

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