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PRO 

WEL D 

3 0 0 -0 8 0 5 

1.0  INTRODUCTION  

Your new stud welding equipment is constructed 
of the finest components and material available.  
Used properly, this equipment will give you years 
of profitable, efficient service.  

The system incorporates the latest in engineering 
advances, for complete reliable welding of mild 
steel, stainless steel, and aluminum.  

2.0 WARRANTY   

          The electrical and mechanical components of the 

stud welder are thoroughly performance inspected prior 
to assembly in the welder. The assembled welder is 
completely performance checked. The welder is deliv-
ered to you in functional electro-mechanical condition.   

          All parts used in the assembly of the welder and 

its accessories are fully warranted for a period of 1 
YEAR from the date of delivery. In addition, the weld-
ing capacitors are warranted for a period of 1 YEAR 
from the date of delivery. The printed circuit boards 
used in all proweld equipment are warranted for a pe-
riod of 3 years.   

          Under the warranty, the manufacturer reserves 

the right to repair or replace, at their option, defective 
parts which fail during the guarantee period. Notice of 
any claim for warranty repair or replacement must be 
furnished to the manufacturer by the purchaser within 
ten (10) days after the defect is first discovered. The 
manufacturer does not assume any liability for paying 
shipping cost or any labor or materials furnished where 
such cost are not expressly authorized in writing.   

          The manufacturer does not warrant any parts or 

accessories against failures resulting from misuse, 
abuse, improper installation, maladjustment, or use not 
in accordance with the operating instructions furnished 
by the manufacturer. The warranty is valid only when 
studs are purchased from sources approved by the 
manufacturer or are of identical specifications to the 
manufacturer’s 

3.0  SUGGESTED SAFETY PRECAUTIONS  

In any welding operation, it is the responsibility of the 
welder to observe all safety rules to insure his or her per-
sonal safety and to protect those working in the area.  

Reference is directed, without endorsement or recommen-
dation, to ANSI Z49.1, Safety in Welding and Cutting, and 
to AWG Publication A6-66, Recommended Safe Practices 
for Gas-Shielded Arc Welding.  

1.  Always treat electricity with respect.  Under open cir-
cuit conditions, the welding machines output voltage may 
be dangerous.  

2.  Don’t work on live circuits or conductors.  Disconnect 
the main power before checking the machine or perform-
ing any maintenance.  

3.  Be sure the welding machine cabinet is properly 
grounded to a good electrical ground.  Consult local elec-
trical codes.  

4.  Never operate a welder in the rain, or operate a welder 
while standing in water.  Avoid wearing wet or sweaty 
clothes when welding.  

5.  Don’t operate with worn or poorly connected cables, 
and don’t operate the weld gun with loose cable connec-
tions.  Inspect all cables frequently for insulation failures, 
exposed wires, loose connections and repair as needed.  

6.  Don’t overload welding cables or continue to operate 
with over heated cables.  

7.  Don’t weld near flammable materials or liquids in or 
near the area, or on ducts or pipes carrying explosive 
gases. 

PAGE 1 

Содержание AG-805

Страница 1: ...OPERATION MAINTENANCE MANUAL ...

Страница 2: ......

Страница 3: ...SET UP 3 7 0 WELD TEST AND INSPECTION 5 7 1 WELD TEST 5 7 2 WELD INSPECTION 5 7 3 CAUSES OF POOR OR ERRATIC WELDS 5 7 4 TROUBLE SHOOTING POOR WELDS 7 8 0 MAINTENANCE 7 8 1 DISASSEMBLY 7 8 2 RE ASSEMBLY 7 8 3 WELD CABLE REPLACEMENT 8 8 4 CONTROL CABLE REPLACEMENT 8 8 5 GUN MAINTENANCE 8 PARTS LIST GUN ASSEMBLY ARC STD LD 9 10 9 0 TROUBLE SHOOTING GUIDE 11 ...

Страница 4: ...PRO WELD 300 0805 ...

Страница 5: ...300 0805 PRO WELD ...

Страница 6: ...PRO WELD 300 0805 ...

Страница 7: ...300 0805 PRO WELD ...

Страница 8: ...y parts or accessories against failures resulting from misuse abuse improper installation maladjustment or use not in accordance with the operating instructions furnished by the manufacturer The warranty is valid only when studs are purchased from sources approved by the manufacturer or are of identical specifications to the manufacturer s 3 0 SUGGESTED SAFETY PRECAUTIONS In any welding operation ...

Страница 9: ...lding tool Welds any length stud with a diameter range of 12 gauge through 5 8 inches Refer to figure 4 1 for weight and size specifications 5 0 UNPACKING There is very little to do when unpacking your ARC Stud Welding gun Your Stud Welder comes com plete with all the accessories and tool required for set up adjustment and maintenance Aside from the correct chuck ferrule grip and any special acces...

Страница 10: ...orward plunge of the stud Tighten the locking screws after centering the stud 3 The Plunge Length is the amount of stud exposed beyond the ferrule during initial set up Set the plunge by loosening the leg adjusting screws and moving the foot until the stud extends 1 8 to 3 16 past the end of the ferrule Tighten the leg adjusting screws after set ting the plunge and re check centering to be sure th...

Страница 11: ... and ferrule squarely against the ground work surface The main spring in the gun will take up the plunge length and the ferrule will seat against the base plate 8 Pull the trigger holding the gun completely still as above The gun will lift the stud from the base plate and draw an arc The end of the stud and the adjacent metal of the base plate will be melted by the weld arc The gun will then plung...

Страница 12: ...esults In an acceptable weld failure will occur in the stud material or tear out of a thin base plate Failure in the weld requires adjustment of procedure weld time and current setting 7 2 Weld Inspection Weld quality can be visually inspected Refer to Fig ure 7 1 as a reference to the quality of the weld 7 3 Causes Of Poor Or Erratic Welds 1 Loose chuck Does not grip stud tightly replace Not enou...

Страница 13: ...7 1 WELD INSPECTION GOOD STUD WELD A good full fillet STUD HANG UP Adjust foot to insure the stud is centered in the ferrule COLD WELD Increase weld current and or weld time HOT WELD Reduce weld current and or weld time PAGE 6 ...

Страница 14: ... this manual for location for numbers noted in this text 8 1 Disassembly of Gun 1 Loosen leg set screws 28 remove foot and leg assem bly Unscrew chuck adaptor and remove bellows 2 2 Unscrew end cap nuts 3 and remove front cover 4 3 Disconnect weld cable 31 from lifting rod assm 6 by removing screw 8 Remove lifting rod assembly 6 and main spring 7 4 Slide out lift stop housing 10 lifting ring 11 mo...

Страница 15: ...Lubricate lifting rod surface with a thin coat of high temperature bearing grease Lubricate M 24 M or equivalent PAGE 8 4 Install front cap 4 end cap nuts 3 bellow 2 and chuck adaptor 1 Make sure chuck adaptor is securely tightened 5 Guns with plunge damper replacement damper 33 has to be screwed all the way into the damper cover 32 Screw damper assembly into front cap 4 6 Install foot and leg ass...

Страница 16: ... 19 COIL YOKE BEARING 301 0009 ITEM DESCRIPTION PART NO 21 WAVE WASHER 102 0117 22 REAR COIL YOKE 301 0016 23 SCREW 8 32 X 1 4 SET 115 0010 24 LIFT ADJ SCREW 301 0008 25 REAR CAP 033 493 26 SCREW 8 32 X 3 4 PAN HD 037 521 27 HANDLE COVER 302 0009HD 28 SCREW 10 32 X 1 2 OVAL HD 115 0009 29 SCREW 5 16 18 X 3 8 SET 037 557 30 SPRING TRIGGER 302 0016 31 SNAP RING 302 0023 32 TRIGGER BUTTON 302 0013 33...

Страница 17: ...isassembly and clean Misalignment of accessories Re align fastener in center of i e legs foot piece grip by loosening the screws holding the foot and the legs Lift incorrectly set Adjust lift to recommend settings See section Set up of Weld Gun for suggested settings Weld quality appears Faulty or loose ground Clean area for grounding inconsistent from one connection Repair or tighten clamp weld t...

Страница 18: ...ouble shooting should be done by qualified personnel trained to work on this type of equip ment PROBLEM POSSIBLE CAUSE REMEDY Weld quality continued Poor quality fasteners Loose chuck Replace chuck Gun lifts but fastener Loose chuck Replace chuck Does not pull away from The work plate Accessory misalignment See previous problem for re alignment suggestions PAGE 11 ...

Страница 19: ...300 0805 PRO WELD ...

Страница 20: ...WELD PRO MANUFACTURED BY MADE IN THE U S A ...

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