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804 001-B Installing Wire Guide And Drive Rolls: 1 Drive Roll Nut 2 Drive Roll Carrier Turn nut one click until lobes of nut line up with lobes of drive roll carrier. 3 Drive Roll Slide drive roll onto drive roll carrier. Turn nut one click. Repeat procedure for top drive roll. 4 Inlet Wire Guide Screw 5 Inlet Wire Guide (One Piece Anti-wear) The factory installed inlet wire guide is good for up to 5/64 inch diameter wire. Loosen securing screw. Align inlet guide so inlet guide screw is centered in groove in guide, or so tip is as close to drive rolls as possible without touching. Tighten screw. Aligning Wire Guide And Drive Rolls: View is from top of drive rolls looking down with pressure assembly open. 6 Drive Roll Securing Nut 7 Drive Roll 8 Wire Guide 9 Welding Wire 10 Drive Gear Turn screw in or out until drive roll groove lines up with wire guide. Close pressure roll assembly. Only bottom drive roll alignment is adjustable. Turn adjustment screw in or out until groove in drive roll lines up with wire guide as shown. Cleaning Drive Rolls: Remove drive rolls, and clean grooves using a wire brush. Tools Needed: 3/16 in Aligning Wire Guide And Drive Rolls 2 3 4 5 Installing Wire Guide And Drive Rolls 1 Correct Incorrect 8 7 6 10 9 OM-1500-19 Page 17 4-5. Connecting Welding Gun And Voltage Sensing Clamp Ref. 804 002-C ! Turn Off wire feeder and welding power source. Stop engine on welding generator. 1 Gun Securing Knob 2 Gun Block 3 Gun Outlet Wire Guide Loosen knob, insert gun end into block. Position outlet wire guide as close as possible to drive rolls without touching. Tighten knob. 4 Gun Trigger Plug 5 Gun Trigger Receptacle 6 Voltage Sensing Clamp Connect voltage sensing clamp to workpiece. 1 2 3 4 5 Internal Side View 6 4-6. Connecting Shielding Gas Ref. 804 003-A 1 Gas Hose With 5/8-18 Right-hand Thread Fittings (Customer Supplied) 2 Shielding Gas Cylinder Shielding gas pressure not to exceed 100 psi (689 kPa). 3 Valve 4 Flowmeter Close valve on cylinder when finished welding. Tools Needed: 5/8 in 1 Rear View 2 3 4 4-7. Connecting Weld Cable Turn Off wire feeder and welding power source. Stop engine on welding generator. 1 User-Suppled Weld Cable Follow wire manufacturer’s recommendations for weld cable polarity. 2 User-Suppled Male Connector 3 User-Suppled Female Connector Push female connector over male connector, and turn 1/4 turn clockwise. 804 004-A 21 3 From Wire Feeder Rear View 4-8. Weld Cable Sizes Weld Output Terminals Turn off power before connecting to weld output terminals. Do not use worn, damaged, undersized, or poorly spliced cables. Welding Amperes Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding*** 100 ft (30 m) or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft (105 m) 400 ft (120 m) 10 . 60% Duty Cycle 60 . 100% Duty Cycle 10 . 100% Duty Cycle 100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60) 150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95) 200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120) 250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 2/0 (2x70) 300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95) 2 ea. 3/0 (2x95) 350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95) 2 ea. 3/0 (2x95) 2 ea. 4/0 (2x120) 400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95) 2 ea. 4/0 (2x120) 2 ea. 4/0 (2x120) 500 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95) 2 ea. 4/0 (2x120) 3 ea. 3/0 (3x95) 3 ea. 3/0 (3x95) * This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable. **Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. ( ) = mm2 for metric use S-0007-F. ***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505. OM-1500-19 Page 18 OM-1500-19 Page 19 4-9. Installing And Threading Welding Wire Ref. 804 005-B Installing Wire And Adjusting Hub Tension: 1 Retaining Nut 2 Hub Tension Adjustment Knob Remove retaining ring, and install spool so hub pin fits spool hole. Reinstall retaining nut. Adjust tension knob so only a slight force is needed to turn spool. Threading Welding Wire: 3 Pressure Assembly Adjustment Knob Lay gun cable out straight. Open pressure assembly, hold wire tightly, and cut off end. Push wire through guides into gun. Close and tighten pressure assembly. Press jog switch until wire comes out gun. Feed wire against wooden surface, and tighten knob so wire does not slip. Cut off wire, and close door. Pull and hold wire; cut off end. 6 in (150 mm) 1 2 3 WOOD Tighten Clockwise Hold wire tightly to keep it from unraveling. 4-10. Display Board (PC20) DIP Switch Settings DIP Switch Settings: Display Hold ON Displays will hold their last value for five seconds after the trigger is...