OM-CWF-50A-01-2015

2-5-V

February 2015

Read this manual carefully before installing,

Commissioning, or operating this product.

Jetline Engineering, 15 Goodyear Street, Irvine, CA 92618

Telephone: (949) 951-1515 Fax: (949) 951-9237 Web site: www.jetline.com E-mail: sales@jetline.com

OPERATION MANUAL CWF-50A

Cold Wire Feeder

IMPORTANT

Jetline Engineering, of Irvine, California, U.S.A., warrants all new equipment to be free from defects

in material and workmanship for the period of one (1) year, provided that the equipment is installed and

operated according to instructions.

Jetline Engineering's obligation under this warranty is expressly limited to replacing or repairing any

defective part or correcting any manufacturing defect without charge during the warranty period, if Jetline's

inspection confirms the existence of such defects. Jetline's option of repair or replacement will be F.O.B.

factory at Irvine, California, and therefore no compensation for transportation costs of any kind will be

allowed.

The warranty period begins on the date of sale to the original-purchase user of the equipment.

Jetline Engineering, will not be liable for any loss or consequential damage or expense accruing

directly or indirectly from the use of equipment covered by this warranty.

This warranty supersedes all previous Jetline warranties and is exclusive with no other guarantees or

warranties expressed or implied.

When contacting the factory, please have the serial number and job number of your machine

available in order to reference the original factory configuration.

LIMITED WARRANTY

The installation, operation and maintenance guidelines set out in this manual will enable you to

maintain the equipment in peak condition and achieve maximum efficiency with your welding operation.

Please read these instructions carefully to become aware of every advantage.

Only experienced personnel familiar with

the operation and safe practice of welding

equipment should install and/or use this

equipment.

NOTICE

CAUTION

Table of Contents

Section I ........................................................................................................................................... 1 Safety Precautions ......................................................................................................................... 1

A. Arc Welding ....................................................................................................................... 1

B. Electric Shock ................................................................................................................... 1

C. Arc Rays ............................................................................................................................ 1 D. Fumes and Gases ............................................................................................................ 2

E. Cylinders ............................................................................................................................ 2

F. Welding .............................................................................................................................. 2 G. Moving Parts ..................................................................................................................... 3

H. EMF Information ............................................................................................................... 3 I. Principal Safety Standards ................................................................................................. 3

J. California Proposition 65 Warning .................................................................................... 3

Section II Introduction .................................................................................................................... 4

Section III Installation ..................................................................................................................... 6

Section IV Wire Feed Accessory Kits .......................................................................................... 9

Section V Operating Instructions ................................................................................................ 10

A. Preparation for Welding ............................................................................................. 10

B. Operation ....................................................................................................................... 10

C. Wire Guide Positioner ................................................................................................ 11

Section VI Maintenance ............................................................................................................... 12

Section VII Optional Accessories ............................................................................................... 13

A. 607B Spool Cover ........................................................................................................ 13 B. WGP-2ES Motorized Wire Guide Positioner ......................................................... 13

C. WGP-3 Compact Wire Guide Positioner ................................................................ 13

D. CHWS-100 Wire Straightener .................................................................................... 13

Section VIII Parts Lists ................................................................................................................. 14

-1-

Section I

Safety Precautions

A. Arc Welding

Arc Welding can be hazardous. Protect

yourself and others from possible serious

injury or death. Keep children away.

Pacemaker wearers keep away until

consulting your doctor.

In welding, as in most jobs, exposure to certain hazards

occurs. Welding is safe when precautions are taken.

The safety information given below is only a summary

of the more complete safety information that will be

found in the Safety Standards listed at the end of this

section. Read and follow all Safety Standards.

Have all installation, operation, maintenance and repair

work performed only by qualified people.

B. Electric Shock

Touching live electrical parts can cause fatal shocks or

severe burns. The electrode and work circuit is

electrically live whenever the output is on. The input

power circuit and machine internal circuits are also live

when power is on. When using mechanized wire feed,

the wire, wire reel, drive roll housing and all metal parts

touching the welding wire are electrically live.

Incorrectly installed or improperly grounded equipment

is a hazard.

1. Do not touch live electrical parts.

2. Wear dry, hole-free insulating gloves and

appropriate body protection.

3. Disconnect input power before installing or

servicing this equipment. Lockout/tagout input

power according to OSHA 29 CFR 1910.147

(see Safety Standards).

4. Properly install and ground this equipment

according to the operation manual and

national, state and local codes.

5. Always verify the supply ground-check and be

sure that input power cord ground wire is

properly connected to ground terminal in

disconnect box or that cord plug is connected

to a properly grounded receptacle outlet.

6. When making input connections attach proper

grounding conductor first - double-check

connections

.

7. Frequently inspect input power cord for

damage or bare wiring. Replace cord

immediately if damaged - bare wiring can kill.

8. Turn off all equipment when not in use.

9. If earth grounding of the part is required,

ground it directly with a separate cable - do

not use work clamp or work cable.

10. Do not touch electrode if you are in contact

with the work, ground, or another electrode

from a different machine.

11. Use only well-maintained equipment. Repair

or replace damaged parts at once. Maintain

unit according to manual.

12. Wear a safety harness if working above floor

level.

13. Keep all panels and covers securely in place.

14. Clamp work cable with good metal-to-metal

contact to part or worktable as near the weld as

practical.

C. Arc Rays

Arc rays can burn eyes and skin; noise can damage

hearing; flying slag or sparks can injure eyes.

Arc rays from the welding process produce intense

visible and invisible (ultraviolet and infrared) rays that

can burn eyes and skin. Noise from some processes can

damage hearing. Chipping, grinding and weld cooling

throw off pieces of metal or slag.

1. Use approved ear plugs or ear muffs if noise

level is high.

2. Use a welding helmet fitted with a proper

shade of filter to protect your face and eyes

when welding or watching.

3. Wear approved safety glasses with side

shields.

4. Use protective screens or barriers to protect

others from flash and glare; warn others not to

watch the arc.

5. Wear protective clothing made from durable,

flame-resistant material (wool and leather) and

-2-

foot protection where necessary.

D. Fumes and Gases

Fumes and gases can be hazardous to your health.

Welding produces fumes and gases. Breathing these

fumes and gases can be hazardous to your health.

1. Keep your head out of the fumes. Do not

breathe the fumes.

2. If inside, ventilate the area and/or use exhaust

at the arc to remove welding fumes and gases.

3. If ventilation is poor, use an approved air-

supplied respirator.

4. Read the Material Safety Data Sheets (MSDS)

and the manufacturer's instruction for metals,

consumables, coatings, cleaners, and

degreasers.

5. Work in a confined space only if it is well

ventilated, or while wearing an air-supplied

respirator. Always have a trained watch person

nearby.

6. Do not weld in locations near degreasing,

cleaning, or spraying operations. The heat and

rays of the arc can react with vapors to form

highly toxic and irritating gases.

7. Do not weld on coated metals, such as

galvanized, lead or cadmium plated steel,

unless the coating is removed from the weld

area, the area is well ventilated, and if

necessary, while wearing an air-supplied

respirator. The coatings and any metals

containing these elements can give off toxic

fumes if welded.

E. Cylinders

Cylinders can explode if damaged.

Shielding gas cylinders contain gas under high pressure.

If damaged, a cylinder can explode. Since gas cylinders

are normally part of the welding process, be sure to

treat them carefully.

1. Protect compressed gas cylinders from

excessive heat, mechanical shocks, slag, open

flames, sparks, and arcs.

2. Install cylinders in an upright position by

securing to a stationary support or cylinder

rack to prevent falling or tipping.

3. Keep cylinders away from any welding or

other electrical circuits.

4. Never weld on a pressurized cylinder -

explosion will result.

5. Use only correct shielding gas cylinders,

regulators, hoses and fittings designed for the

specific application; maintain them and

associated parts in good condition.

6. Turn face away from valve outlet when

opening cylinder valve.

7. Keep protective cap in place over valve except

when cylinder is in use or connected for use.

8. Read and follow instructions on compressed

gas cylinders, associated equipment, and CGA

publication P-1 listed in Safety Standards.

F. Welding

Welding can cause fire or explosion.

Welding on closed containers, such as tanks, drums, or

pipes, can cause them to blow up. Sparks can fly off

from the welding arc. The flying sparks, hot part, and

hot equipment can cause fires and burns. Accidental

contact of electrode to metal objects can cause sparks,

explosion, overheating, or fire. Check and be sure the

area is safe before doing any welding.

1. Protect yourself and others from flying sparks

and hot metal.

2. Do not weld where flying sparks can strike

flammable material.

3. Remove all flammables within 35 ft (10.7 m)

of the welding arc. If this is not possible,

tightly cover them with approved covers.

4. Be alert that welding sparks and hot materials

from welding can easily go through small

cracks and openings to adjacent areas.

5. Watch for fire, and keep a fire extinguisher

nearby.

6. Do not weld on closed containers such as

tanks, drums, or pipes, unless they are properly

prepared according to AWSF4.1 (see safety

Standards).

7. Connect work cable to the work as close to the

welding area as practical to prevent welding

current traveling long, possibly unknown paths

and causing electric shock and fire hazards.

8. Wear oil-free protective garments such as

leather gloves, heavy shirt, cuffless trousers,

high shoes, and a cap.

-3-

G. Moving Parts

Moving parts, such as fans, rotors, and belts can cut

fingers and hands and catch loose clothing.

1. Keep all doors, panels, covers, and guards

closed and securely in place.

2. Have only qualified people remove guards or

covers for maintenance and troubleshooting as

necessary.

H. EMF Information

Considerations About Welding and the

Effects of Low Frequency Electric and

Magnetic Fields

The following is a quotation from the General

Conclusions Section of the U.S. Congress, Office of

Technology Assessment, Biological Effects of Power

Frequency Electric & Magnetic Fields - Background

Paper, OTA-BP-E-53 (Washington, DC: U.S.

Government Printing Office, May 1989):

".... there is now a very large volume of scientific

findings based on experiments at the cellular level and

from studies with animals and people which clearly

establish that low frequency magnetic fields can

interact with, and produce changes in, biological

systems. While most of this work is of very high

quality, the results are complex. Current scientific

understanding does not yet allow us to interpret the

evidence in a single coherent framework. Even more

frustrating, it does not yet allow us to draw definite

conclusions about questions of possible risk or to offer

clear science-based advice on strategies to minimize or

avoid potential risks."

To reduce magnetic fields in the work place, use the

following procedures:

1. Keep cables close together by twisting or

taping them.

2. Arrange cables to one side and away from the

operator.

3. Do not coil or drape cables around the body.

4. Keep welding power source and cables as far

away as practical.

5. Connect work clamp to part as close to the

weld as possible.

About Pacemakers:

The above procedures are among those also normally

recommended for pacemaker wearers. Consult your

doctor for complete information.

I. Principal Safety Standards

Reference as applicable

Safety in Welding and Cutting, ANSI Standard Z49.1,

from American Welding Society, 550 N.W. LeJeune

Rd, Miami, FL 33126

Safety and Health Standards, OSHA 29 CFR 1910,

from Superintendent of Documents, U.S. Government

Printing Office, Washington, D.C. 20402

National Electric Code, NFPA Standard 70 from

National Fire Protection Association, Batterymarch

Park, Quincy, MA 02269

Recommended Safe Practices for the Preparation for

Welding and Cutting of Containers That Have Held

Hazardous Substances, American Welding Society

Standard AWS F4.1, from American Welding Society,

550 N.W. LeJeune Rd, Miami, FL 33126

Safe Handling of Compressed Gases in Cylinders, CGA

Pamphlet P-1, from Compressed Gas Association, 1235

Jefferson Davis Highway, Suite 501, Arlington, VA

22202

Code for Safety in Welding and Cutting, CSA Standard

W117.2, from Canadian Standards Association,

Standards Sales, 178 Rexdale Boulevard, Rexdale,

Ontario, Canada M9W 1R3

Sales Practices for Occupation and Educational Eye and

Face Protection, ANSI

Standard Z87.1, from American National Standards

Institute, 1430 Broadway, New York, NY 10018

Cutting and Welding Processes, NFPA Standard 51B,

from National Fire Protection Association,

Batterymarch Park, Quincy, MA 02269

J. California Proposition 65 Warning

This product contains chemicals, including lead, known

to the state of California to cause cancer and birth

defects or other reproductive harm. Wash hands after

use. §248224

-4-

Section II Introduction

The cold wire feeder is designed to supply filler metal to the weld puddle in a mechanized

tungsten arc welding or plasma arc welding application. The system will accurately feed

0.020”, 0.030”, 0.035”, 0.045”, 0.062” and 0.093” (0.5 to 2.4 mm) hard and soft wires for

mechanized TIG or plasma welding.

The wire feeder can be mounted as an assembly or the components can be removed from

the mounting plate and installed in a number of positions with respect to each other.

The system consists of a 9700W control, D.C. motor-driven four feed roll assembly, spool

adapter, and a wire guide positioner. The positioner incorporates X-Y-Z movements of the

wire tip. The positioner includes a universal torch mounting bracket.

The basic components of the wire feeder are:

(See Figure 1)

1. Wire drive unit: consists of motor, drive housing, and wire spool assembly to feed

wire. (Part number CWF-50-DA.)

2. 9700W Control: includes a keypad, display, encoder control knob, and start/ stop

switches. The SCR motor controller is built into the control box and provides a wire feed

speed of 4 to 200 IPM (10 to 508 CPM) with a speed holding accuracy of +1% of base

speed.

For operating details and function of controls, see 9700W Operation Manual.

3. WGP-1 Wire Guide Positioner: guides wire into puddle.

Note: The wire guide positioner can be used either as a left hand or right hand assembly.

To change configuration as supplied by factory, reverse thumb knob, set screw, and spring.

(See WGP-1 drawing. item numbers 13, 18, and 24.)

4. Spool adapter: holds 12” (305 mm) diameter wire spools.

5. Wire Feed Accessory Kit: conduit, feed rolls, inlet guides, outlet guides, and tips for

0.020”, 0.030”, 0.035”, 0.045”, 0.062” and 0.093” (0.5 to 2.4 mm) hard and soft wire. Order

kits separately for desired wire size.

-5-

Figure 1

CWF-50 Cold Wire Feeder Set up of Components

-6-

Section III Installation

As standard, the unit is provided with 6 ft. (1830 mm) of cable between the control and the

wire drive assembly. The control is typically mounted near the feeder due to the length of

the control cable.

1. To mount the wire drive assembly, transfer mounting holes from the wire feeder’s

aluminum mounting plate to the mounting surface. (See Figure 2 for mounting hole

dimensions.)

2. The 9700W control must be mounted in a suitable manner providing adequate

ventilation. The control should not be mounted in a high temperature environment.

3. Slip the wire guide positioner onto the torch barrel and tighten the wing nuts. You

may choose from one of three sets of mounting holes depending upon the brand of the

torch to be used.

The wire guide tip angle should be set roughly by positioning the guide and tightening the

screw. The tip should be approximately on the same level as the tungsten.

4. Select the wire feed accessory kit for the size wire your application requires. The kit

will include inlet and outlet guides, conduit, wire guide tip, and feed rolls. Be sure all

components match the wire size to be used. (Refer to Figure 3)

Proper installation of the wire feed kit is very critical to the successful operation of the cold

wire feed unit. Proper installation helps avoid “bird-nesting” at the feed rolls and smooth

wire feed delivery into the weld puddle.

a. The inlet guide should be inserted until the “set screw” properly aligns with the

notched section on the guide. The closer the tapered tip is to the feed rolls the better.

b. The intermediate guide needs to be inserted prior to the mounting of the feed

rollers. The intermediate guide also has a “notched” section which should align with the

screw holding it in position.

c. The feed rolls need to be mounted securely. If not tightened, they will loosen and

will eventually fall off.

d. The conduit assembly is then fitted into the outlet guide assembly. This step may

need to be repeated in order to fit it correctly. First, the end and inside of the conduit must

be deburred. The wire must slide freely into the conduit.

Next the conduit should be chamfered. The conduit needs to be as close as possible

to the feed rolls in order to avoid “bird-nesting”, especially on soft wires. Putting a chamfer

on the conduit allows you to get the conduit very close to the feed rolls.

-7-

At this point, slide the conduit through the outlet guide. You should extend the

conduit beyond the tapered end of the outlet guide approximately 1/4” (6 mm). Tighten the

set screw securely, holding the conduit properly in position.

e. Insert the outlet guide/conduit assembly into the drive roll assembly. Position it

so the chamfered conduit is very close to the drive rolls. (Make sure the end of the outlet

guide is clear of the drive rolls.) Tighten the outlet guide securely by turning the hand knob.

f. Run the conduit to the torch as required. Remember sharp twists and turns

affect the flow of the wire. Test the path of the conduit with the torch in its fully retracted

and extended positions.

If the conduit is too long, cut the end, making sure it is completely deburred.

g. Strip 4” (100 mm) of the outer cover on the conduit. Slide the bare conduit into

the wire guide tip. Tighten the set screw holding the conduit securely into position.

Note: On a rare occasion, you may have to pull this end of the conduit from the tip

when initially feeding wire. Let the wire extend about 6” to 8” (150 to 200 mm)

beyond the conduit and then feed the wire into the tip until the conduit is back into

normal position.

The wire guide tip is held in position by a set screw. The tip can slide into the

clamping mechanism on the WGP-1 Wire Guide Positioner.

5. Electrical Connections:

As standard, the feeder is shipped with an electrical connector and 6 ft. (1380 mm)

cord suitable for 115 volts 50/60 Hz power supply. Operation for 220 volts is configurable.

If you need to start the wire feeder from a remote signal, you must supply a normally

open, maintained contact closure to Connector S2, Pins A and B.

-8-

Figure 2

Mounting Plate Dimensions

-9-

Section IV Wire Feed Accessory Kits

Wire Size *Complete

Accessory

Kit

Conduit - 6

ft (2 m)

Outlet

Guide

Inlet Guide Wire Guide

Tip

Feed Rolls

& Inlet

Guide

**Curved

Wire Guide

Tip

0.020”

(0.5 mm)

20B6020K 42-23

PT-40-

NAT

OG-020 056192 WGT-020 053693 N/A

0.030”

(0.8 mm)

20B6030K 44N3545 OG-035-45 056192 WFT-030 046780 CWGT-030

0.035”

(0.9/1 mm)

20B6035K 44N3545 OG-035-45 056192 WGT-035 046781 CWGT-035

0.045”

(1.2 mm)

20B6045K 44N3545 OG-035-45 056193 WGT-045 046782 CWGT-045

0.062”

(1.6 mm)

20B6062K 45N116 OG-062 056195 WGT-062 046784 N/A

0.093”

(2.4 mm)

20B6093K 18630F OG-17 056196 WGT-093 046789 N/A

*Includes inlet and outlet guides, feed rolls, wire guide tip, and 6 ft (2 m) conduit.

**Requires WGP-3 wire guide positioner for curved tips.

Wire Feed Roll Kits, parts and optional items are sold separately.

Figure 3 – Wire Drive Components

-10-

Section V Operating Instructions

A. Preparation for Welding

Mount the spool of welding wire on the spool adapter so the wire will be pulled from the low

side of the coil. Adjust the friction brake on the wire spool by adjusting the screw in the

center of the spool. If adjusted properly, the spool will feed smoothly and will not coast or

continue to spin when feeding stops.

Debur the end of the wire, then insert it into the inlet guide through the feed rolls and the

outlet guide. (Refer to Figure 3).

Press the power switch to the “On” position and feed the wire into the conduit by pressing

touch pad arrow key. Continue to feed the wire through the conduit and the wire guide tip

until a desired amount extends beyond the tip.

B. Operation

See your separate 9700W Operation Manual for details of the control and how to use it.

The operation of a CWF-50 is not difficult. The following sequence is suggested:

1. Turn on power to unit.

2. Using the touch pad arrow key, inch the wire forward a little. Trim the wire if there is

a ball on the end of the wire. This step is especially necessary if feeding wire and using an

arc length control. A ball on the end of the wire could touch the tungsten when feeding

initially. If the wire contacts the tungsten, you will get a “ball” on the end of the tungsten.

The operator should stop the weld and resharpen the tungsten. This action could also

cause adverse effects with the arc length control.

When the wire is inched forward, this is a good time to verify the wire’s position.

Adjust if necessary.

3. Retract wire to desired starting position using the Reverse key.

4. Check wire and wire spool briefly. Verify there is enough wire for the next weld and

that the wire is not wrapped around the spool holder.

5. Check wire feed speed setting, the start delay setting, and the stop retract setting.

These settings are critical to achieve the desired weld.

6. At this point, the unit is ready to feed wire. If the starting and stopping of the wire is

controlled remotely, the control will go through the start delay. Once this delay has timed

out, the unit will proceed to feed wire at the rate set on the dial.

-11-

When the remote start signal quits, the unit will go through the stop delay, then stop.

The unit then proceeds to enter the wire retract time, pulling the wire out of the weld zone.

This action prevents the wire from sticking in the weld puddle at the end of the weld.

Note: If the retract time is set too long, the wire could retract up into the wire tip. If this

happens, the wire could, on occasion, get stuck on the tip on the next weld.

7. If the unit is used manually, the operator will press the Start button when ready to

feed wire. The start delay will NOT be activated when using this method. Wire will feed

immediately once in the Run position.

When wire is no longer required the operator presses the Stop button. The unit will

stop feeding wire immediately and go into the wire retract procedure.

C. Wire Guide Positioner

Several adjustments are provided on the wire guide positioner in order to permit the exact

position of the wire as it enters the puddle.

1. Lateral adjustment of 1/4” (1/8” adjustment of tip on each side of weld seam). (6.4

mm total adjustment, 3.2 mm on each side.)

2. Vertical adjustment of 1/4” (6.4 mm) tip to work.

3. Coarse adjustment of guide tip angle, by loosening screw and setting in approximate

position.

The wire position should be checked at the beginning of the weld.

Jog the wire forward through the control and make required adjustments on the positioner.

Wire typically enters the weld puddle at the leading edge of the puddle. The wire should

contact the work piece about .04” (1 mm) in front of the weld puddle and slide under the

center of the welding arc.

Check tension of drive roll spring. Too much pressure will deform the wire and too

little pressure will cause wire slippage.

-12-

Section VI Maintenance

Periodically clean the drive rolls of dirt and chips. Occasionally check the wear of liners,

tips, and guides.

Periodically check, and replace if necessary, the carbon brushes on the motor. Failure to

replace worn brushes could cause severe damage to motor control.

Maintenance and electrical work must be performed by experienced and trained

personnel.

Whenever repairs are required, always turn all power controls off and disconnect all

electrical cables from power supply.

-13-

Section VII Optional Accessories

When you purchased your cold wire feeder, you may not have been aware of optional

enhancements for your unit. Jetline is pleased to offer these enhancements which can be

added to your system in the field.

If you are interested in these features, please do not hesitate to contact Jetline directly or

the nearest distributor for more information.

A. 607B Spool Cover

The 607B is a clear plastic cover designed and manufactured for Jetline’s wire feeders. The

cover mounts around the spool holder and encases the standard “30 lb/12 inch” wire spool

which fits onto the spool mounting adaptor. The main purpose of the cover is to protect the

wire from dust and weld particle build-up. The clear plastic allows the operator to see the

spool effectively. Installing the spool cover is a simple, perhaps 5 minute, job.

B. WGP-2ES Motorized Wire Guide Positioner

The standard wire feed unit is provided with a manually adjusted WGP-1 wire guide

positioner. In some applications, the operator cannot easily get to the positioner to make

the desired alterations to the wire’s location as it enters the weld puddle. Due to the cast

and helix in some wires, the need to adjust the wire’s position can be required.

Jetline offers the WGP-2ES motorized positioner so the operator can adjust the position of

the wire from a remote location. The positioner includes the motorized wire positioner, the

motor control, and a joystick pendant which the operator uses to move the wire guide tip to

the desired position. Speed of motion is adjustable to provide accurate positioning as

desired by the operator.

C. WGP-3 Compact Wire Guide Positioner

In some applications, the space envelope required by the standard WGP-1 is too large.

Jetline manufactures a wire guide positioner which requires less space, yet still gives the

operator the ability to adjust the wire position. The WGP-3 is designed to attach directly to

the torch, but includes a curved wire guide tip. Wire is fed vertically until the moment where

it is angled into the weld puddle.

D. CHWS-100 Wire Straightener

In some applications, minor deviations in wire position are a result of the cast in the wire.

The wire straightener can help limit the twist by using a 3 roll action. Tension on the center

roll is adjustable. The unit mounts on the inlet side of the drive roll assembly. The

straightener is designed to work on 0.035” and 0.045” (0.9/1.0 and 1.2 mm) wire.

-14-

Section VIII Parts Lists

The following pages provide a detailed parts list of all the elements of the cold wire feed

unit. Item numbers shown in the parts list refer to those numbers contained in the balloons

in the drawing. On each parts list, the quantities shown are the number of items used in

that particular assembly.

Two columns are included in the list to show the spare parts which are recommended to be

stocked by the user. The two levels can be defined as follows:

Level 1

These are the spares recommended for US domestic users whose use of the product does

not exceed 2000 hours per year.

Level 2

These are the spares recommended for international use of the product or for US domestic

users who will use the products in excess of 2000 hours per year.

The following parts lists are included in this manual.

Cold Wire Feeder Assembly

WGP-1 Wire Guide Positioner

WGP-2ES Wire Guide Positioner

WGP-3 Wire Guide Positioner

-15-

-16-

CWF-50-DA

Cold Wire Feeder Assembly

Recommended

Item Part Level Level

No. No. Description Qty I II

2 CWF-20B-100 Mounting Plate .........................................................1

3 CWF-20B-110 Mounting Bracket ....................................................1

4 CWF-20B-120 Cover Assembly .......................................................1

5 Drive Housing, includes: .........................................1

046779 Housing ....................................................................1

053842 Gear ..........................................................................4 2

10-32x7/8 Flat Head Screw .....................................................12

1/2-20x1 1/4 Hex Head Screw ......................................................4

6 0467__ Gear Driven Roll Kit ................................................1

(See chart in Section V for complete part number)

7 OG-030/045 Outlet Guide (See chart in Section V) .....................1

8 44N3545 Conduit and Liner (See chart in Section V) .............1

9 WGT-0__ Wire Guide Tip ........................................................1

(See chart in Section V for complete part number)

10 CWF-10-WG-60 Gear Reducer ...........................................................1

11 95611AO31 Insulating Washer ....................................................1

12 8527K134 Insulating Tube, 36” (914 mm) length .....................1

13 Natural Hard Fiber Insulation ..................................2

14 Natural Hard Fiber Insulation ..................................2

15 053841 Drive Gear ................................................................1 1

16 374831-A Spool Adapter ..........................................................1

17 MT3353-42CZ Motor, DC Servo, with flange..................................1

18 6010 Shielded Cable, 8 ft (2.5 m) .....................................1

19 3106A-145-6P Cable Connection .....................................................1

20 CWF-10-4R-9 Set Screw Collar ......................................................1

21 CWF-20B-140 Retainer ....................................................................1

22 8-32X5/8 Socket Head Screw ..................................................1

23 8-32X5/16 Button Head Screw ..................................................4

24 1/4-20X1/2 Socket Head Screw ..................................................4

25 1/4-20X5/8 Flat Head Screw .......................................................4

26 3/8-16X1 1/4 Hex Head Screw ......................................................2

27 3/8 Flat Washer ..............................................................2

-17-

-18-

WGP-1 (Rev L)

Wire Guide Positioner

Recommended

Item Part Level Level

No. No. Description Qty I II

2 WGP-1-230 Base ..........................................................................1

3 WGP-1-100 (REV E) Cam Plate .................................................................1

4 WGP-1-200 Housing ....................................................................1

5 WGP-1-210 (REV E) Bar ............................................................................1

6 WGP-1-220 Clamp .......................................................................1

7 WGP-XXX Shown for Reference (part of Wire Feed Kit)

8 WGP-1-240 Stud ..........................................................................2

9 WGP-1-250 V-Block ....................................................................2 1

10 Guide, Dowell ..........................................................1

11 Fulcrum Pin, Dowell ................................................1

12 Hinge Pin, Dowell ....................................................1

13 CL-1-KHS Knurled Head Screw ................................................1 1 1

14 CL-1-KN Knurled Nut .............................................................1 1 1

15 CL-1-SB Swing Bolt ...............................................................1

16 WGP-1-16 Lift Pin .....................................................................1

17 6655K13 Thrust Bearing .........................................................1

18 VV-38 Compression Spring .................................................1 1

19 1/4-20x7/8 Socket Head Screw ..................................................2

20 1/4-20x5/8 Socket Head Screw ..................................................2 2 2

21 1/4 Flat Washer ..............................................................1

22 11256 Compression Spring .................................................1 1

23 3025 Knob .........................................................................2 1 1

24 3/8-16-5/16 Nylock Set Screw .....................................................1

25 WGP-1-260 V-Mount (Optional Item, Large Clamp Kit)............1

26 WGP-1-261 V-Clamp (Optional Item, Large Clamp Kit)............1

27 WGP-1-262 Stud (Optional Item, Large Clamp Kit) ...................2

28 1/4-20-5/8 Socket Head Screw ..................................................2

29 WGP-1-263 Base Extension (Optional Item, extended base) ......1

30 1/4-20x3/4 Socket Head Screw (Optional Item, extended base) ....2

31 6435K12 Collar, 1/4 diameter .................................................1

32 6391K143 Bronze Bearing, 1/4 x 1/2 x 1 ..................................1

-19-

-20-

WGP-2ES (Rev E)

Motorized Wire Guide Positioner

Recommended

Item Part Level Level

No. No. Description Qty I II

2 WGP-1 Basic Wire Guide Assembly ....................................1

5 WGP-2-5 (REV C) Motor Bracket, detail ...............................................1

6 WGP-2-6 Screw........................................................................1

7 WGP-2-7 Motor Bracket, detail ...............................................1

8 WGP-2-10 Driven Pulley, detail ................................................1

9 1375K34 Driven Pulley, detail ................................................2

10 WGP-2-10 Driven Pulley ...........................................................1

11 1679K86 Belt ...........................................................................2 1 1

12 WGP-2-9 Motors and Cable Assembly, set .............................1

13 4-40x1/4 Socket Head Screw ..................................................6

14 DWM-202 Cover ........................................................................2

15 #2-216 O-ring seal ................................................................4

16 9045 Control Assembly, for reference

17 Lift Pin, detail ..........................................................1

-21-

-22-

WGP-3

Compact Wire Guide Positioner

Recommended

Item Part Level Level

No. No. Description Qty I II

2 WGP-3-2 Base Detail ...............................................................1

3 WGP-3-3 Yoke Detail ..............................................................1

4 WGP-3-4 Slide Detail...............................................................1

5 WGP-3-5 Rotor Detail ..............................................................1

6 WGP-1-250 V-Block Detail .........................................................2 1

7 WGP-1-240 Stud ..........................................................................2

8 WGP-3-8 Pin Detail .................................................................1

9 WGP-3-9 Clamp Detail ............................................................1

10 WGP-3-10 Tube Detail...............................................................1

11 WGP-3-11 Spacer Detail ............................................................1

12 Fender Washer .........................................................1

13 XX-68 Compression Pin ......................................................1 1

14 L-35 Compression Pin ......................................................1 1

15 2813 Compression Pin ......................................................1

16 CL-1-KHS Knurled Head Screw ................................................1 1 1

17 CL-6-KHS Knurled Head Screw ................................................1 1 1

18 CL-2-SLB Button, radius loc .....................................................1

19 1/4-20x3/4 Socket Head Screw ..................................................3 2 2

20 1/4 Flat Washer ..............................................................1

21 1/420 Hex Nut ....................................................................1

22 1/4-20x2 1/4 Hex Head Screw ......................................................1

23 1/8x3/4 Roll Pin ....................................................................1

24 CWGT Curved Wire Guide Tip Detail .................................1

25 3025 Knob .........................................................................2 1 1