j3, j4 butt welders - Micro Products Company
Contents
1. Type Stock Size Heat Space Grooves Tension Range Welder Steel 020 6 5 Front 1 Low J3S 20507 4 7 Middle 1 Low 080 1 9 Rear 1 Low Copper 2032 4 3 Front 2 Low J3C 040 3 4 Middle 3 Low 050 2 5 Middle 3 LOW 0647 1 6 Rear 3 Low Steel 040 10 3 Front 3 High J4S 060 8 4 Middle 3 High 080 6 9 Middle 3 High OO 4 6 Rear T High 160 1 9 Rear 1 High Copper 128 1 9 Rear 1 High 102 2 7 Rear 1 High 080 2 6 1 High 064 4 5 Middle 3 High Welders used for E C aluminum may use approximately the sam settings as copper TYPICAL OPERATING SEQUENCE J3C amp 235 245 Remember Material to be joined must be free of rust corrosion or other insulating material where it contacts welding dies 1 Cut wire ends to best joint configuration See figure 1 2 Set open space for proper die opening 3 Select proper weld heat and range 4 Place wire into welding dies so the ends touch midway between the welding dies 5 Push foot treadle down far enough to hold material in place in dies 6 Close flashguard 7 Push foot treadle down to bottom of stroke to finish clamp process and start weld process 8 Heat is imparted to wire ends through faying surfaces 9 Movable platen under upset pressures moves toward a closed position due to loss of compression yield strength of wire 10 A weld limit switch terminates electrical power flow through wire 11 Actual2. over travel of movable platen Calibration 1 Turn space adjusting knob 1 setting 2 movable head is pushed by is approximately 1 64 at 3 Tighten locknut 1 setting 15 6 3 WELD LIMIT SWITCH 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 obtain the adjustment 2 Loosen the limit switch adjusting screw locknu 3 Set open space adjusting knob to approximate 4 4 Slowly turn space adjusting knob clockwise toward f1 until the hex head bolt activates the limit switch 5 There should be 1 16 between the closest die edges 6 If the gap is greater than this screw bolt in to switch sooner activate the switch later If the gap is less 1 16 then screw the bolt out to activate the Repeat steps 3 and 4 after making bolt adjustmen 7 Tighten locknut ts until step 5 is achieved 8 The limit switch remains the same for all wire Sizes but can be used for a vernier control of heat in extrem than cases to add or subtract slight amounts of heat to assure levelness of welded material Figures 4 5 6 7 8 9 9A 10 16 HEADPIECE HOUSING SPACE ADJUSTING SCREW INSULATOR S
3. Number Clamp arm standard Clamp arm standard ass state model right left Clamp arm retaining screw Clamp arm ret tionary and movable Match machined w adjustable centers mbly complete w all Operating parts amp serial taining screw washer Weld transformer strap insulator Space adj Space adj Space knob Return spring Return spring usting knob usting screw tension spring movable head Nut Center 2 required Headpiece closed Headpiece closed Insulated stop adjusting Center adjusting rear front Clamp spring retaining pin and key Clamp spring insulating washers Clamp spring standard 1 16 insulating bushing adjusting screw and adjusting screw outer 4 req d Clamp spring assembly with all Operating parts Clamp spring metal 2 required inner bushing Clamp spring fiber bushing 2 required outer Clamp spring cross bolt Vasher set Clamp spring attaching bolt transformer steel Velding Specify 120 or 240 volts Velding Aluminum Velding transformer 240volts 60 hertz Clamp plate attaching screw nuts and inner 60 hertz copper or Heavy duty step down transformer Specify line and welder voltages Step down transformer mount transformer secondary clamp plate ting plate 2 req d Item 32584 32585 3251
4. The chalk will turn a straw anneal temperature 700 degrees F 14 6 SPECIAL ADJUSTMENTS HEADPIECES Refer to Figures 4 through 7 SPACE ADJUSTING KNOB Determines th amount of open space between the welding Turn space adjusting knob to the stop or the number The die seats should be level and the weld dies should have 1 32 between the closest die edges A Back headpiece close stop screw off of nylon the space adjusting knob turn the space adjusting shaft until dies are level and proper clearance so that the arrow pointer dies Calibration Lu 1 setting 2 Lay a straight edge across the die seats 3 4 If die seats are not level stop pad B Loosen the setscrew on C With a pair of pliers between dies exists D Retighten spacing knob is across from 1 Su A compression spring and stop pin are located beneath the spacing knob to assure repeatable positions and overthrow protection Check to make sure spacing knob has pressure applied to it from this spring and pin is no t bent or missing hence preventing proper adjustment replace as required HEADPIECE CLOSED ADJUSTMENT Prevents welding dies from touching and prevents possible to the stop at the number Adjust closed stop adjusting screw so that when the hand to a closed position the weld dies will not touch and there
5. When the exact anneal temperature is reached the rotating needle on the dial indicating device will momentarily stop n sequenc the needle will drop back slightly and then start to move forward again At the star needle rel t of the second forward movement of the ase the anneal switch Heating the improperly wire beyond this pint will cause an treated anneal zone Allow wire to cool down below 1000 degrees F before removing wire from the anneal clamps Loss of coloring to wire procedures Be extremely careful of hot metal during handling 13 27 DETERMINING CORRECT ANNEAL TEMPERATURES The critical maximum heating associated with temperature will carbon steel temperature of the butt we Vary slightly wire is also the temperature for the annealing process lding procedures Pd easily determined by point the wire s carbon content To expand this process furt heated to a point of jus very close to degrees F anneal switc ct the correct a ct her nneal temperature At this poi h is importa 2 anneal ing area with a magne not be drawn When flux looking for so do not over heat to the wire surface du the magnet does the correct ann
6. L2 CR1 2 Line voltage Bad contactor x L2 S1 1 Line voltage Open wire to heat switch X L2 CR2 2 Line voltage Bad contactor x Note to perform repairs consult section 13 for parts identification 26 10 0 ELECTRICAL SCHEMATIC Note To perform repairs consult section 13 for parts identification 10 0 ELECTRICAL SCHEMATIC Unless otherwise specified all 115V control wires to be no 16 QEERATING Awg red neo SWITCH FS2 2 Unless otherwise specified all neu tral wires to be no 16 Awg white S1 may be a 4 point heat switch on some models B3275B 11 0 SAFETY REMINDERS The following accident prevention information is presented to eliminate potential hazards while operating inspecting or repairing Micro Wel equipment Welders GENERAL 1 Prior to using equipment d electric resistance welding Important safety compliance information for Micro Weld on basic operation and malfunction methods by personnel 2 Safety eyeglasses must be worn by all personnel operating or servicing welders 3 Use safety eq on welders 1 Determine that both operating voltages and her cycles of power weld nameplate located on weld housing 5 Check nameplate ratings and keep within capaci 1 categories stated therein ent or repairs must be made by persons r with operating principles of welder 7 Welder must be disconnected from power supply p
7. steel face Rivets lelding nneal earing ylon c nneal nneal nneal nneal nneal ment serrated steel face each steel faced per 100 pieces die shoes upper bronze frame mounting screws set center adjustable front enter insulator frame stationary frame movable frame power shunt cable frame space adjusting screw set die carrier bracket left hand or rear op ann eal eal die carrier bracket right hand nnea eal die carrier bracket slide type ront a lide b hunt c nneal nneal nneal nneal Handle Eccentr 5 55 5 5 5 zZ uw nneal racket adjusting knob screw nut able lug block flat pair attaching screw 2 required die shoe each 2 required die shoe pivot mounting stud anneal clamping ic Carrier strap and nut Item 90605 57601 57613 57660 57843 57802 57801 48215 32524 57810 32523 57810 32523 59084 32586 90252 32530 32931 32532 90603 32534 32533 93051 32535 32614 62046 37713 62055 62065 62157 32610 62053 62054 62107 6210 8617 32525 90603 62062 62059 62063 62060 35 Model Part no J4 53 J4 53A J4 54 J4 61 04 62 04 200 04 201 J4 172S J4 172R J4 172W J4 173 J4 174A J4 175 J4 178 J4 180 J4 181 J4 182 J4 183 J4 187 J4 151 J4 152 J4 153
8. 3 Tighten lock nuts 21 7 7 7 PREVENTATIVE MAINTENANCE Keep in mind that many years They ar designed to be as a these welders are precision built to last but will require good maintenance procedures utomatic as possible with a minimum dependence on the ability of the operator Adjustment the operat ts must be made by ting principles of AS REQUIRED Ta Remove flas headpieces to hings and loos prevent acc and a soft metal scraper Check condi tion of wel din those thoroughly fami the welders liar with e particles from welding umulation g dies and welding di replace as required Check condi all we QUARTERLY tion of clamp spring assemb broken springs 1 Repeat above itens Check anneal dies Use a soft brush e shoes lies and replace springs that have taken a set as as worn fiber bushings and washers lace all worn parts 3 Check for worn bearings and elongated holes on foot treadl assembl 4 General ANNUALLY Repeat above n for worn heck oted items and pull lubrication of all rod parts moving parts agnetic co nits do no ovabl ntactor ave contact E m u Clean weld m surfaces in R heck for Emery is area to etighten completely die sh
9. 8 CLEARANCE 19 6 4 HYDRAULIC CYLINDER Refer to Figures 8 For new type cylinder see addendum CONTROLS THE FLASHING SPEED AND UPSET POSITION Calibration 1 Set closed stop adjusting screw to stop movable head when 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 1 Loosen lock nut on piston cap 2 Rotate cap clockwise to make unrestricted movement of piston to begin when welding dies are closer together 3 Tighten locknut on piston cap B If unrestricted movement starts at a lesser distance 1 Loosen lock nut on piston cap 2 Rotate cap counterclockwise to make unrestricted movement of piston begin when welding dies are further apart 3 Tighten lock nut on piston cap 3 Set limit switch to cut off weld current 1 32 after unrestricted movement has begun 6 5 CLAMP SPRING AND UPSET PRESSURES Refer to Figure 9 UPSET PRESSURE Determines the amount of clamping and upset pressure available for weld process by making pull bar longer or shorter Calibration 1 With nothing in welding dies depress foot treadle 2 With a straight edge determine that bolts A B C D are all in alignment Lengthen or shorten pull bar to attain this setting This alignment sets the weld
10. 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 12 4 FRONT ANNEAL OPERATING PROCEDURES Close safety flashguard if so equipped Place welded stock into anneal clamps with upset burr Es Hu midway between anneal jaws being careful to push movable clamp jaw against its inward stop Carefully Be careful tighten wire into both jaws Push anneal switch in a jogging fashion to evenly heat up weld area to 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 not to get burned on the hot metal DIAL INDICATING ANNEAL DEVICE OPERATING PROCEDURES Proceed as with the following in instructed on front type anneal and proceed formation When heat is applied to the wire the heated wire will expand The dial indicator will start to move as the wire begins to heat up
11. series Air regulator and filter assembly Pressure gauge 3 way foot valve Flow control valve Quick exhaust wheel 10 amp steel type welders o s Grinding Heat switch Heat switch Heat switch Limit swi tch valve 2 X37 10 amp 10 amp fiber push kn Anneal switch old Limit switch o s Foot pedal Compression return sprin type o s style complete 8 hole ob housing 10 o s 028 9 Foot pedal return sprin Conversion kit g plunger o s old style housing mounted Limit and operating switch to current Safety approved type Except for die sets for these parts indicate for J3 23 58 Model J3C J4C Model J3 and J4 parts are interchangeable J3 58M or J3 581 J4 58C J4 58M and LH Item 32563 32562 32561 32611 32612 32613 APPL 77700 77708 ELELS 42603 77800 71822 77860 77862 77857 78511 57800 48214 32608 52526 57827 56520 80025 37 ADDENDEM HYDRAULIC CYLINDER Refer to Figures 12 CONTROLS THE FLASHING SPEED AND UPSET POSITION Calibration 1 Set closed stop adjusting screw to stop movable head when 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 Loose
12. 7 32518 93081 92706 37710 32553 32502 80037 80021 32504 85055 85055 32609 42504 42582 42642 90605 34 Model Part No 24 07 24 184 024 185 24 186 J4 92A J4 138A J4 138B J4 139A J4 140A J4 105A J4 106A J4 105A J4 106A J4 105L J4 120 J4 121 J4 58C J4 58M J4 58E J4 59 24 605 J4 60SA J4 60SB J4 60B J4 20A J4 30A J4 30B J4 31 J4 32 24 33 24 35 24 361 J4 36R J4 37 J4 38 J4 39 J4 44 J4 45 J4 46 J4 47 J4 51 J4 52 Descrip Screw Station Control Contact Relay High of tion secondary strap attaching ary head circuits step down transformer or welding 25 ampere anneal circuits 15 amperes f low heavy duty switch Heat sw itch 10 point type 25 ampere Heat sw itch 4 point type 25 ampere Heat sw itch knob for 25 ampere switch Heat sw Switch Operati Operati Anneal Operati itch housing for 25 ampere specify 4 point or 10 point ng switch short stem ng switch housing switch short stem ng switch housing Limit s witch long stem Limit s witch cover w attaching screws Limit s Velding Velding Velding lelding lelding Affixed Replac witch adjusting screw amp locknut dies pair copper dies pair copper alloy class 2 dies pair copper alloy class 4 die attaching screw 2 required die shoes upper pair
13. J4 154 J4 155 J4 156 J4 84C J4 86 J4 87 J4 68A J4 68C J4 68 J4 69 J4 71 J4 131C 24 131 24 132 24 133 24 134 24 135 24 136 J4 09R 24 091 J4 14F Description Eccentric Pin eccent Spring ann Dial indica anneal clamping ric attaching eal clamping Dial indica Complete fr indica tor Complete fr Caster rig Wheel only Return spri Switch leve ont ann swivel id 5 ng anneal rS tor assembly tor contact button ont anneal device with al device less dial or operating Pedal operating lever Plunger operating switch lever Plunger anneal switch lever Pull bar with clevis Pull bar tension adjusting disc Pull bar attaching screw Pull bar adjusting knob Foot pedal return spring new style Extension type ETS wire shear stationary housing ETS wire shear movable housing ETS wire shear handle ETS wire shear cutter pair ETS wire shear pivot bolt and nut ETS wire shear complete Lamp complete Lamp 25 or 40 watt standard base Flashguard Flash guard Flash guard Flash guard Flash guard 4 1 vise vise vise vise vise vise vise Clamp arm Right Clamp arm Left F H H H H H H H 2 aaa O Clamp spring Lamp receptacle Qus complete o s flap o s mounting bracket o s attaching bolt and washer
14. MICRO PRODUCTS COMPANY MANUFACTURERS OF PRECISION WELDING MACHINES J3 J4 BUTT WELDERS SERVICE MANUAL TABLE OF CONTENTS 1 0 SPECIFICATIONS 2 0 GENERAL HOOK UP INSTRUCTIONS 3 20 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 TROUBLE SHOOTING 10 0 ELECTRICAL SCHEMATIC 11 0 SAFETY REMINDERS 12 0 BUYERS GUIDE 13 0 PARTS LIST 1 0 SPECIFICATIONS Model J3C Model J4C Model J3S Model J4S Model J4Sf Stock Size 0327 tO 064 to 5920 tO 040 to 004 sq to Range 064 128 080 60 2030 Sq Diameter 81mm 1 62mm 51mm 2mm 1mm 4mm 2 58mmsq to 1 588mm 3 25mm 19 35mmsq Cross sectional Material Copper amp EC Copper amp EC Steel Alloy Steel Alloy Steel Alloy Aluminum Aluminum Stainless Stainless Stainless Standard Operating 230 Volts 230 Volts 230 Volts 230 Volts 230 Volts Voltages 115 Volts 115 Volts 115 Volts 115 Volts 115 Volts Input Power Cycle 60 Hertz 60 Hertz 60 Hertz 60 Hertz 60 Hertz Line Demand 115 volts 24 amps 100 77 amps 10 24 amps 100 77 amps 10 9 a
15. S 2 90205 CS Lock Washer 2 92775 Flat Washer 2 92759 Synthane Washer 4 92914 Plate 62206 Cylinder 78648 FIGURE 12 39 CHEE 40 J3 amp J4 TRUCK PARTS 41 LA 1 STA SNA T ng Z dd Y Qr gt z 7 lt 5 lt 1 FIGURE 4 42 FIGURE 5 43 DIES 32530 COPPER 32531 MALLORY 4 015 BASIC STEEL FLASH HEAD 55 32532 ELECTROLOY J4 01A SF COMPLETE STEEL FLASH HEAD ASSY 44 62061 62059 62062 ES NY a Ej 92003 i 32526 lt B ow B 5782 N Y MODEL J3 amp J4 ANNEAL RIGHT KR 33 KI 318444 80022 Aaa i 45
16. TOP PIN SECTION C C FIGURE 6 CLOSED STOP MOVABLE ADJUSTING SCREW HEADPIECE HOUSING NYLON CLOSED STOP BUMPER SN ELLA NV AT S sS STATIONARY HEADPECE SECTION A A HOUSING CLOSED STOP ADJUSTING SCREW LIMIT SWITCH ADJUSTING SCREW FIGURE 7 17 SOCKET SET SCREW CLEVIS 14 20 UNC THD SPACE ADJUSTMENT REW KN JAM NUT E op 36 24 UNF THD 2 REQ D WASHER NEEDLE VALVE CYL PISTON CYL HOUSING WASHER SPRING RETAINING SPRING WASHER 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 NOTE C FLASHING SPEED ADJUSTMENT KNOB NO 1 ON KNOB IS SLOWEST FLASHING SPEED TURN KNOB COUNTER CLOCKWISE TO INCREASE FLASHING SPEED NOTE D BUTTERFLY VALVE CLOSES INDOWNWARD MOVEMENT OPENS FOR FREE RETURN OF PISTON NOTE E STEP OFF ALLOWS HYDRAULIC OIL TO BYPASS PISTON GIVING UNRESTRICTED MOVEMENT NOTE F OIL USED SHOULD BE SINCLAIR DURO 150 OR EQUIVA LENT FIGURE 8 CLAMP ARM MINIMUM TENSION MAXIMUM TENSION ll TE N CENTER LINE CLAMP SPRING MINIMUM TENSION CENTER LINE PULL BAR FIGURE 9 FIGURE 9A ARM CONTACTS WELD DIE HOLDER NO CONTACT BETWEEN ARM AND CLEVIS FIGURE 10 ARM CONTACTS WELD DIE 2 HOLDER 7 1 16 TO 1
17. ate the weld limit switch observe the reading goes to zero Release the weld limit and operating switches the reading should remain at zero 23 9 1 3MODEL J3 amp J4 115 VOLT TABLE Use Schematic B3275B PROBLEM PRESS WELD LIMIT PRESS TEST LEAD METER IF NO OPERATING SWITCH ANNEAL CONNECTION READING READING SWITCH ACTUATED SWITCH L2 FUl 5 VAC Bad fuse connection L2 FU1 2 5 VAC Open fuse Open wire to operating L2 51 5 VAC switch L2 FS1 2 5 VAC Bad operating switch X L2 FS2 5 VAC Open wire to anneal switch L2 FS2 2 5 VAC Open anneal switch X Open wire to weld limit L2 LS1 5 VAC switch X L2 LS1 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 81 1 Line voltage Open wire to heat switch x L2 CR2 2 Line voltage Bad contactor x 9 1 4 MODEL J3 J4 230 VOLT TABLE Use Schematic B5741A X1 X2 5 VAC Bad control transformer T2 X2 FU1 5 VAC Bad fuses connection X2 FU1 2 5 VAC Open fuse Open wire to operating X2 FS1 5 VAC switch X2 FS1 2 5 VAC Bad operating switch x 2 FS2 5 VAC Open wire to anneal switch 2 52 2 5 VAC Open anneal switch X Open wire to weld limit X X2 LS1 5 VAC switch X2 LS1 2 5 VAC Bad weld limit switch x L2 CR1 Line voltage Open wiring to contactor
18. ating and keep within size range for each welder WATER It is important that if a welder is to be operated for an extended period of time and headpieces heat up water lines must be connected On most model J series Micro Weld welders water cooled headpieces are an option which can be added at our factor Connect hoses to inlet and outlet provided at the back of the welder A shut off should be installed in the should run to an during the weld cycle and the temperature of the water at the drain should feel hot to the hand This will prevent inlet line and the hose from the outlet open sight drain Water should only flow condensation on the welder headpieces which could drip on the welding transformer and cause it to ground out AIR Air operated model J series Micro Weld welders are an option Should you have this option air operation cylinders require a 90 P S I air source An air regulator will be provided to set the minimum amount of pressure needed for the material being welded 3 0 BASIC OPERATING PARTS 3 1 WELD HEAT SELECTION GENERAL OPERATING INSTRUCTIONS This setti ng determines th welding power factors in various plants material composition specified In general amount of heat available for Because of considerable variations 1 n voltage and larger si h
19. complete movable half stationary half handle Sliding block spring cap screw and nut special special for hand clamp type for hand clamp type special 3 32 thickness Also used for hand clamp Item 62061 92602 80022 77851 62012 62168 62067 80049 42563 42576 42576 42626 42503 90233 42578 64013 64006 64008 64043 90624 64007 52539 58151 58166 42506 90601 60009 60013 60012 60007 60008 80024 90300 32511 32510 80019 36 Model Part No J4 55 J4 56 J4 57 J4 58EA J4 58EB J4 58EC J4 225A J4 226C J4 226D J4 22 6E J4 228A J4 232 J4 233 J4 234 J4 235 24 236 J4 90A J4 102 J4 103 J4 104 J4 122 J4 123 J4 S80 J4 176 J4 177 J4 1400 NOTE 4 58 Welders Description Hand clamp Hand clamp Hand clamp locking handle mounting bracke mounting bracke Stationary head movable head Velding di Velding di 3 radius grooves set pieces 2 Or Type Velding di capaci set ty to 5 8 pieces flat stock Type Replacement Replacement capaci Air conversion set ty to 3 4 air diaphragm Replacement Foot pedal boot type lever assembly pieces flat stock kit complete state model cylinder type 12 comp type 12 12 J4
20. d 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 heats up but weld is not complete Low heat Secondary transformer connections Loose or dirty welding dies Starting space adjust Increase weld heat Clean and tighten transformer connections 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 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 connect
21. e hydraulic Flashing usting passing the slowest flashing the k requires a slower the piston is nt T t of the piston ng dies are closer together perfectly sound and have little upset burr usually indicate too low heat or 1 valve is bypassed his bypass point can be the piston cap clockwise causing the to begin when the Properly made welds are Poor welds WELDING DIES AND DIE SHOES thr 1 Welding dies serv voltages for welding to prevent slippage during the be placed into small grooves and Flat stock must be pl grooves rear of the dies purposes 2 large wire into to carry C to align material ends weld cycle ncorrect flashing speeds urrent and and 3 wire must the large Small laced against the stop in the The die shoe holds the material securely into the lower welding die during the weld process HAND SHEAR An accessory hand shear may be affixed to welder to assist in trimming waste materials prior to welding Several types are available from Micro Products Company 3 27 FILING VISE Accessory machinist available to assist burring operations vises or spec ANNEALING DEVICES ial Micro Weld vises are the operators to hold wire during de Three types of annealing devices are available to assist in processing weld zones the weld cycle They are a non ferrous
22. eal temperat the exact point the material so that when we lec to not attach of loss of magne beyond this the jogging off on of test the t during the off period it will trical magnetic to the wire surface ure has been achieved tic qualities The critical but in direct proportion to Since carbon steel ferromagnetic the exact annealing temperatu the loss of magnetic qualities at is re can be that a wire that is gradually beginning to show some color is about 1000 the We are point Annealing after welding to enable an operator to draw carbon steel certain assist i wire is very import techniques have b n drawing high carbon steel wire tant for the wire mill and n developed by others which may Possibly the methods described here will be beneficial to your operation ANNEALING ALUMINUM WIRE AND ROD Anneal since blows A good anneal apart expelled alumi ing aluminum rod and wire can be somew it passes very quickly through the pla hat difficult stic rang and approximately 700 degrees F the surface this temperature color at th rubbed on obtaining temperatur Be extremely careful num by poor safety techniques not to ge for aluminum rod a to be annealed will t burned from nd wire is Common blue carpenters chalk assist in
23. eat settings Welding heat is selected by means of a heavy d a high low range switch and O the welder graduated from of voltage for high just below the of the heat switch wi n some models The heat switch is conveniently nameplate 1t ng operation O is located on The range swit Other numbers are eq high to low to allow just the weldi h low range switch the front and wide variety in exact heat setting cannot be es of stock use higher uty switch See tale 1 located on the left side of Number 1 indicates high heat indicates low welding heat 4 or 10 ually the right amount n models with the right tch sets the range number th the low range sel where the high range settings leave off The heat or range swi ttings picking up tch should never be changed to a new setting during a welding operation Table 1 Heat Switch H L Model Settings Range J3C 4 Yes 235 10 Yes 4 Yes 245 10 Yes J4SF 4 No SPACING MECHANISM The welder is capable of welding a variety of material sizes correspondi located on but each major cha ng change in t Spacing is obtained by ro nge in material size requires a The spacing the lower right knob determines th he open space of the jaws tating the space adjusting knob Side of the headpiece housing amount o
24. er for maximum pressures 3 Should you require lesser pressures for smaller wire sizes the pull bar can be lengthened to decrease pressure as per the following See figure 9A A Loosen hand wheel on the foot pedal assembly B Rotate disc so number on disc lines up with notch on back up plate C Tighten hand wheel 1 Lesser pressures are indicated when center bolts B and C are above the centerlin 20 5 Do not shorten the pull bar to such a position so that the center bolts B and c are below the centerline Clamp spring breakage could occur 6 Pressures should not be increased or decreased by cross bolt adjustments Important Do not turn or remove the front center pivot screw and nut To remove the movable half of the weld head as specified in the preventive maintenance techniques loosen and remove the rear center pivot only CLAMP SPRING CROSS BOLT Refer to Figure 10 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 16 to 1 8 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
25. f weld upset and expelled metal projecting from the weld zone UPSET Ups PRESSURE MECHANISM pressures ar required for all weld operations The model J series of Micro Wel form Th sizes and types of 1 determines th materials spring pul weld forgi length of the pull ng process amo This is d welders obtains i unique spring assemblies located on upset pressures are completely adjust Adjustment unt of upse obtained by adjusting the ts pressures the clamp arms able for various of the clamp t pressure for the bar by rotating the E foot pedal pressure assembl Y tension disc on the Number 1 denotes FLASH SPEED MECHANISM On model J4SF weld r precis speed is set with knob which regula internal valve N speed flashing speed flashing speed 211 adjus unres weldi Turn the knob counterclockwise Gen Fin compressed to a poin owing unrestricted moveme ted by rotating tricted movemen e use of the flash umber 1 indicates th erally larger sto al upset is obtain t where th rn int i e ed when al ng speed adj tes the speed of the oil to increase the greatest upset flashing speed regulation and final upset drop off is obtained from 11 cylinder located on the right of the weld head th ts uniqu
26. full appreciable loss duri operate properly if t ng nere E ampere load wi he weld cycl is more t to the welder must be of th no lder will not variation in Th han a 10 W the line voltages general the welder should be fused with a slow blow fuse of the 100 duty cycle rating The minimum power cable size rating Electric Code and local by using this same current Refer to the National regulations for adequate power sizes and fusing guidelines Remember line voltages to the welder can be obtained electrical disconnect methods to the welding machine are potentially dangerous should the power cords be damaged or severed The welding voltages at the welding dies will not harm an operator since they do not exceed 5 volts SAFETY PRECAUTIONS 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 Disconnect electrical service befor servicing welder high voltages are located within the base of the welder MECHANICAL Safety glasses must be worn by operator while using welder Keep all safety guards on wel Operators must be instructed prevent injury Check namepl material lders and use properly on basic operation of unit to late r
27. ie 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 4 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 and oxidize surface will insulate the welding dies and reduc ffective welding voltage 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 anda major cause of wire breaks Types of welding die shoes picture TYPES OF WELDING DIE SHOES NON FERROUS WIRE TYPE z le FERROUS WIRE TYPE SHOE SERRATED STEEL FACE CAST BRONZE SHOE CAST BRONZE SHOE WITH SERRATED l B EXAMPLE OF WELDING DIES STANDARD V GROOVE TYPE FOR ROUND OR SQUARE WIRE 4 STEEL PLATE WELDING DIE SHOE SIZE CHART WELDING DIE SIZE CHART z 1 4 ET S5 E L Ln Ic J3 23 9 0 DIAGNOSTIC CHART FOR TROUBLE SHOOTING WELDING ACTION CAUSE REMEDY Weld action normal but weld burr doesn t extend beyon
28. ions to heads Clean rod where clamped in dies Replace dies and shoes Clean build up of flash materials Check contactor for poor contacts 24 1 1 2 ELECTRICAL TROUBLE SHOOTING WELDER Caution Extreme care should b xercised when making these tests Dangerous voltages are present in the welder Only persons familiar with electrical safety precautions should perform these tests TROUBLE SHOOTING TABLE see section 9 1 3 and 9 1 4 This electrical trouble shooting table is furnished as a suggested method of trouble shooting the welder individual steps of the table should be performed in the order given to make the test valid The electrical schematic section 10 furnished for these tests shows the table test points This table may be used for welders with a different but closely related wiring by using corresponding test points During all tests line voltage should be connected to Ll 6 L2 of the welder heat switch should be set to the 1 position FINAL ELECTRICAL CHECKS Set the heat switch to the number 1 position connect the voltmeter across the welding dies Press the operating switch The meter reading will typically be less than 10 VAC Consult the weld specification sheet for this value Rotate the heat switch through all settings If the voltage is not read at any setting the heat switch may be defective Actu
29. mps 100 29 amps 10 9 amps 100 29 amps 10 24 amps 100 77 amps 10 Line Demand 230 volts 12 amps 100 38 amps 10 12 amps 100 38 amps 10 5 amps 100 15 amps 10 5 amps 100 15 amps 10 12 amps 100 38 amps 10 Heat Selection Switch w high low Range Switch 4 Point 4 Point 10 Point 10 Point 4 Point 50 duty cycle rating 4 KVA 4 KVA 1 5 KVA 1 5 KVA 4 KVA DIMENSIONS AND WEIGHTS 4 Wheel Truck 2 Stationary 2 Stationary 2 Stationary 2 Stationary 2 Stationary Mounted Casters 2 Casters 2 Casters 2 Casters 2 Casters 2 Swivel Swivel Swivel Swivel Swivel Casters Casters Casters Casters Casters Floor Space 24 x 24 24 x 24 24 x 24 24 x 24 24 x 24 61cm x 61cm 61cm x 61cm 61cm x 61cm 61cm x 61cm 61cm x 61cm Welding Die Height 41 104cm 41 104cm 41 104cm 41 104cm 41 104cm Height 53 1 2 I 2 322 53 172 53 1727 Overall 136cm 136cm 136cm 136cm 136cm Welder Weight 180Lbs 82 Kg 180Lbs 82 Kg 180LBs 82 Kg 180Lbs 82 Kg 1801bs 82 Kg Other vol ltages available 22 2 GENERAL HOOK UP INSTRUCTIONS trical service in your rating located on the ELECTRICAL First Determine that available elec plant corresponds to the nameplate welder housing Electrical wiring sufficient size to deliver
30. n 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 1 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 after unrestricted movement has begun 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 38 J4SF N S HYDRAULIC CYLINDER ASSEMBLY 62205 Clevis 62207 3 8 16 Nut 92083 3 8 Lock Washer 92776 3 8 16 HHCS 90262 114 20 HHC
31. oes f required Remove mova centers surfaces p must be fre good alignment Check headp xC ssive wear it into clamp ors cloth works well to b or poorly aligned contacts within Some older Model J3 and J4 series transformer secondary strap connects to headpiec ring all a bright and shiny condition in clamp arm assemblies Replace as arm openings where ble welding headpiece by loosening rear pivot Check olish and thoroughly clean re install movable headpiece and adjust movable headpiece do not have any side the condi tion of the pivot cen ter Re lubricate and so tha play E e to pivot and die seat surfaces mu iec welders b used in a corrosive atmosphere castings if worn replace 5 oxides and repaint as required t the Headpiece st be in hould the clean off 22 8 0 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 d
32. on of fraying surfaces for op timum weld alignment weld heat and upset pressure utilization SQUARE CUT SHEAR EXAMPLE FOR SIZES 020 to 160 RECOMMENDED SHEAR CUT FOR FLAT STOCK WHEN WELDING ON J4SF FIGURE 2 EA EAS 5 2 ANNEALING INFORMATION An anneal operation will be required on hard drawn or carbon steel wire and rod Annealing will accomplish tow 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 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 FRONT OR DIAL INDICATING ANNEAL DEVICES
33. rior to a a materia 6 Adjustm familia mainten 8 Reduce source supply correspond to ratings an operator must be instructed qualified uipment properly and keep safety equipment tz listed on ties and thoroughly nce or repair procedures ir supply pressures or disconnect from air 9 Wel all con lders have water supply low only enough nponents during for pneumatically equipped welders prior to maintenance or repair procedures quipped with wa water to flow to cool heated weld operation ter cooling accessories must turned off during idle periods and 28 ELECTRICAL 1 Refer to National Electrical for adequate elect operate welder wi cords or cable 1 ders must A wel welder All wel source nplugged by ll wel lectrical mal ri cal ders must unction occur ground connec ders must be n weld namepl Electric power condition te ameplate rated load tandard fuses allow cords be ground through power terminal to be disconnected from power either by a double breaking disconnect tion able wiring to power wel h inadequate el Code and local regulations ectrical securely Normal y welders are fu standard rated plugs t be fused to prevent i Welders must the r time
34. set pressure is applied Further movable platen travel then activates the weld limit switch and electrical power flow through the material is terminated 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 as the enlarged weld area is equal to the parent metal size 10 Examples of good welds A CORRECT BURR AND EVEN HEAT PENETRATION EXAMPLES OF POOR WELDS 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 sequent 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 FIGURE 1 picture A GOOD WELD WILL BREAK ACROSS WELD ON A BEND TEST LAZY A POOR WELD WITH LITTLE FUSION AND NO UPSET BURR RECOMMENDED SHEAR CUTS SHEAR BLADE 2 SHEAR BLADE PLACE IN DIE GROOVES AS ILLUSTRATED CROSSING CUT ENDS Note A A1 designation indicates positi
35. types of material b Front anneal used on low c dial indicating anneal FOOT TREADLE MECHANSIM The model J series Micro Weld wir which may have become bri Standard anneal or on low carbon st mild steel appl used on high carbon steel wire F lications ttle during used on teel wire and e and rod welders are activated by using a foot treadl the welding sequence replaced with an air activated me operator just has to move his foo weld process Some welding advan quality by using the air upset m activating strokes are exactly th All operations on the Micro Weld model J series rod welders are performed by a treadle mechanism when the tread device chanism so which performs The manual foot treadle may be that the t slightly tage is gai to activate the ned in weld chanism since all e same wire and single down stroke of the is released the operating parts are automatically next weld operating re spaced ready for the Blind guides can be designed for handicapped people 4 0 SUGGESTED SETTINGS Oil Size Stock Cylinder Space Heat Tension J4SF Welder flat stock DAI x Steel 7 7 4 1 042 x 514 Steel 4 9 2 T APPROXIMATE SETTINGS TO AID IN OBTAINING HIGH QUALTY WELDS
36. u A e fused for an ampere load that exceeds n s lag parameters f this specification to wel maintenance personnel The weld heat selection switch potentiomet selection devices must not be changed Ider must Report any damage or potential der Do not power supply supply and tightened switch or njury should an never be atings stated sed using the unctional to be kept LO a while a weld operating is in process in good hazards to er or range new position 29 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 13 0 PARTS LIST 30 31 32 LISTED DIES 32530 COPPER 92907 32531 MALLORY 4 015 BASIC STEEL FLASH HEAD ASSY 32532 ELECTROLOY J4 01A SF COMPLETE STEEL FLASH HEAD ASSY 33 13 0 PARTS LIST Model Part No J4 01 J4 01A J4 08R J4 08L J4 10 J4 18A 74 21 74 22 24 23 74 24 24 25 24 26 74 27 74 28 24 30 74 12 24 13 24 14 24 15 24 16 24 17 24 19 24 035 J4 03C J4 0 J4 04A J4 05 J4 06 Butt Welders J3 J4 Headpiece stat Description Headpiec
37. weld is formed after electric power flow stops and material is hot forged together with remaining upset pressure 12 Welded material quickly cools under pressure 13 Remove stock from dies by releasing foot treadle 14 Anneal weld zone and sections on either side if applicable 15 Remove upset burr so the enlarged weld area is equal in diameter to the parent metal size J4SF 1 Ow WN 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 into 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 place in dies Close flashguard Push foot treadle down to bottom of stroke to finish the s lamping process and start weld process eat is imparted to the material end through faying urfaces High current flow causes flashing Movable platen under controlled speed and pressure moves toward a closed position due to flashing until the faying surfaces are covered with molten metal and a short length of each part reaches forging temperature When the movable platen reaches a preset point flashing speed is terminated and up
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