1U-9600 Welding Group (U.S. and Canada) 1U-9601 Welding Group (All other countries){0599, 0679} Caterpillar

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Introduction

Important Safety Information

Illustration 1	g02139237
Think Safety

European Union Compliant, ICE marked

Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understood the Tool Operating Manual.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "DANGER", "WARNING", or "CAUTION". The Safety Alert "WARNING" label is shown below.

A non-exhaustive list of operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.

The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.

When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength, and material.

Literature Information

This manual contains safety information, operation instructions and maintenance information and should be stored with the tool group

Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.

Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.

Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DUST) for the latest available information.

Safety Section

The Safety section lists basic safety precautions.

Read and understand the basic precautions listed in the Safety section before operating or performing maintenance and repair on this service tool.

General Information Section

The General Information section describes tooling functions and features. The section provides useful information on individual parts, additional tooling, and resources.

Operation Section

The Operation section is a reference for the new operator and a refresher for the experienced operator.

Photographs and illustrations guide the operator through correct procedures for using the tool group.

Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and the tools capabilities.

Maintenance Section

The Maintenance section is a guide to tool inspection, cleaning, storage, and tool disposal

Service Parts Section

The Service Parts section is a reference for parts identification and available part numbers.

Safety Icon Nomenclature

Personal Protection/Important Information

Illustration 2	g02166423
Personal Protection/Important Information

Prohibited Action

No smoking

Hazard Avoidance

Crushing hazard (foot)

Crushing hazard (hand)

Pinch point

Fire hazard

Electrical Shock - Hazard

Fire hazard

Safety Section

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At operating temperature, the hydraulic tank is hot and under pressure. Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. Remove the filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly in order to relieve pressure.

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Personal injury or death can result from escaping fluid under pressure. Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause serious injury and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury. Always use a board or cardboard when checking for a leak.

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

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NOTICE
To prevent dirt and contaminants from entering the hydraulic system, always plug or cap the lines, fittings, or hoses as they are disconnected. This action also lessens the chance of oil spills.

General Information

Introduction

Illustration 3	g02773839

Table 1

Equipment and Tooling
Item No.	Part No.	Qty.	Description
(1)	1U-9619	1	Speed Control Assembly
(2)	1U-9604	1	Column
(3)	-		Tool Group (Not Service)
	-	1	Wrench, Open End 17 to 19 mm
	-	1	Wrench, Open End 14 to 17 mm
	-	1	Wrench, Open End 8 to 10 mm
	-	1	Wrench, Hex 6 mm
	-	1	Pliers, Diagonal
(4)	4C-9308	1	Cord, Power - 1U-9600 only
	1U-9609	1	Cord, Power - 1U-9601 only
(5)	1U-9610	1	Cord, Coil
(6)	-		Base, Magnetic (Not Serviced)
-	1U-9633	1	Transformer
-	1U-9602	4	Electromagnet
-	1U-9620	2	Fuse, Controls (250 V, 3.15 A)
-	1U-9619	1	Fuse, Power (250 V, 2 A)
(7)	1U-9625	2	Bushing
(8)	1U-9629	2	Clamp, Barrel
(9)	1U-9628	1	Brush Holder (former 12 mm thread)
	9U-5134	1	Brush Holder (16 mm thread)
(10)	1U-9639	1	Torch-Barrel Extension (Short)
(11)	1U-9606	1	Cone, Centering
(12)	1U-9621	2	Nozzle, Gas (Long)
	1U-9622	2	Nozzle, Gas (Short)
	1U-9640	2	Nozzle, Gas (Short-1U-9622 Modified)
(13)	1U-9635	5	Contact Tip, (.035 in) (1U-9600 Only)
	1U-9638	5	Contact Tip Short, (.035 in) (1U-9600 Only)
	1U-9617	5	Contact Tip, (0.8 mm) (1U-9601 Only)
	1U-9637	5	Contact Tip, (.030 in - Short tip for 0.8 mm wire) (1U-9601 Only)
(14)	1U-9614	1	Extension, Nozzle (Long)
	1U-9615	1	Extension, Nozzle (Short)
(15)	1U-9623	2	Holder, Nozzle (Long)
	1U-9624	2	Holder, Nozzle (Short)
(16)	1U-9630	1	Torch Body
(17)	1U-9607	2	Extension, Barrel (Long)
(18)	1U-9626	1	Nut
(19)	1U-9627	1	Torch Holder Assembly
(20)	1U-9612	1	Adapter, Torch (former, 12 mm thread)
	9U-5135	1	Adapter, Torch (16 mm thread)
(21)	1U-9605	1	Fixture, Centering
(22)	1U-9613	1	Liner, Teflon (10 m Pkg)
(23)	1U-9608	1	Adapter (No. 3 Morse Taper)
(24)	1U-9611	1	Remote Control
(25)	1U-9603	1	Head and Clutch Assembly
(26)	1U-9634	1	Drive Motor (1:360 Gear Ratio)
	1U-9632	1	Gear and Clutch Assembly
	1U-9631	1	Drive Motor (Optional 1:500 Gear Ratio)

Daily, Cat dealers encounter the need to rework worn bores and surfaces. This rework requires the addition of material (build-up) to the worn surface by welding.

The 1U-9600 1U-9601 Welding Groups are unique. This welding group reduces labor, decreases the waste of weld consumables, and improves repair quality.

Rework small bores (not easily assessable) or large bores, which are time consuming and can have considerable waste of weld consumables, if necessary. The welding group is designed for automatic welding of bore diameters ranging from 30 to 216 mm (1.2 to 8.5 inch). Can be used with existing Metallic Inert Gas (M.I.G.) wire welders and equipment.

It is also possible to rework out-of-round bores. The maximum out-of-roundness is 3 mm (0.1 inch). If the bore is out-of-round more than 3 mm (0.1 inch), to make the bore concentric, perform either grinding or machining. For additional reference, refer to Section ""Weld Torch Settings" ".

Additional Contact Information

For additional product support questions concerning this tool, contact the Caterpillar Dealer Service Tools Hotline at:

USA: 1-800-542-8665, Option 1International:: 1-309-578-7372

Setup Procedure

Selecting Power Setting of Base Unit

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NOTICE
Do not connect the unit to a power source before checking power setting. Damage will result to the base unit, if connected to improper power source.

Before starting the procedure, check the power setting on the base unit. The transformer must be adjusted to the local power supply requirements.

The welding group may be connected to 110, 220, and 240 V single-phase power supplies. The setting can be changed by setting the control dial on the side of the base unit.

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NOTICE
Do not use the 120 V setting on the base unit. Doing so, may damage the transformer.

A 1U-9633 Step-down Transformer is part of the base assembly and will be damaged if the correct voltage setting is not used. This transformer supplies low voltage to the base magnets, drive motor, and control panel.

To change the setting:

1. Remove snap ring and protective glass plate from the side of the base.

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Illustration 4	g02773856
Adjusting voltage setting

2. Use a screwdriver and turn the adjustment dial to the correct voltage setting. Refer to Illustration 4.

3. Replace the protective glass plate and snap ring.

4. Connect the power cord to the power source. The lamp on the base should now be illuminated.

Position the Base Unit

1. Position the base unit.

   1. Place the base unit on a smooth, clean surface, free from oil and grease. If the mounting surface is not large enough or is not flat, tack weld a piece of mild steel plate to the part being reworked.

   2. Position the base unit parallel and concentric to the bore.

      Note: As an extra safety precaution, secure the base with a clamp. Use this precaution whenever the equipment is used in a horizontal or overhead position.

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Illustration 5	g02773879
Attach base unit and centering fixture to work piece

2. With the base in approximate position, install the 1U-9604 Column and tighten the base column clamp. The column keyway should be in line with the centerline of the bore.

3. Center the column to the bore.

   1. Attach the 1U-9605 Centering Fixture to column and lock into position.

   2. Thread 1U-9606 Centering Cone onto 1U-9607 Barrel Extension .

   3. Install the subassembly into the centering fixture.

   4. Position the welding group so the centering cone is aligned with the bore to be reworked.

4. Secure the base in place.

   1. Connect the power cord of base.

   2. Magnetize base to the work piece.

Note: The magnets are deactivated with a push button on the base unit control panel.

Weld Head Assembly

The weld head assembly fits onto the column and is locked into position by the column clamp. This assembly can be adjusted to any height. The base column clamp can be loosened and the head/column assembly pivoted to a new position.

Illustration 6	g02773883
Attach 1U-9610 Coil Cord from base to speed control

Attach 1U-9610 Coil Cord from the base to the speed control assembly.

The weld head assembly consists of the following:

Illustration 7	g02773888
1U-9616 Speed Control Assembly

• A 1U-9616 Speed Control Assembly . This unit controls the speed and direction of rotation. The assembly is held in place by a thumb screw. Thumb screw allows the assembly to be positioned from side-to-side or removed and held as a remote unit. The speed of rotation is controlled by setting the potentiometer. A direction control switch controls the movement of the weld head. When the center position is off, left position allows downward movement. Depressing the button allows full-speed torch rotation up or down, depending on the switch position. The equipment is ready to use when the green light is illuminated.

• A 1U-9634 Drive Motor with a 1:360 ratio. The motor is attached to the assembly with four set screws. The motor turns the torch, allowing for the rework of 30 to 215 mm (1.2 to 8.5 inch) diameter bores.

• A 1U-9632 Gear Clutch . The clutch is attached to the drive motor and is located inside the weld head assembly housing. The gear clutch connects with a gear inside the head and clutch assembly.

• A 1U-9603 Weld Head and Clutch Assembly . This assembly supports the weld torch, provides torch rotation, and contains the lead screw for upward and downward movement. The lead screw provides a constant 3 mm (0.1 inch) of feed per revolution with a total travel of 127 mm (5.0 inch). A spiral metal ring protects the lead screw from dirt and weld spatter.

Note: To make the weld torch rotate without feed, move the lever on the weld head assembly counterclockwise to the stop position. In this position, feed movement is disengaged. Moving the lever clockwise engages the lead screw.

Weld Torch Assembly

The weld torch assembly conducts current to the work, carries shielding gas to prevent weld pool contamination, and provides a passage for the weld wire.

The weld torch assembly consists of the parts in the chart below.

Table 2

Weld Torch Assembly
Item	Description
(1)	Torch Adapter
(1)	Brush Housing
(1)	Barrel Extension
(2)	Barrel Clamps
(2)	Insulated Bushings
(2)	Nut
(1)	Torch Holder
(1)	Torch Body
(1)	Teflon Liner
(1)	Nozzle Holder
(1)	Contact Tip
(1)	Gas Nozzle

Note: The weld torch assembly is a current (voltage) carrying part. Observe standard safety practices applicable for arc welding.

The torch assembly has 200 amp maximum capacity.

The depth of reach is 100 mm (3.9 inch) using the torch body, 200 mm (7.9 inch) using 1 barrel extension, and 300 mm (11.8 inch) with an additional barrel extension.

The welding group can rework 30 to 215 mm (1.2 to 8.5 inch) diameter bores. To weld bores with 30 to 50 mm ( 1.1 to 1.9 inch) diameters, use a 1U-9624 Short Nozzle Holder . To weld bores with a diameter of 50 to 215 mm (1.9 to 8.5 inch), use the 1U-9615 Short Radial Nozzle Extension , 1U-9614 Long Radial Nozzle Extension , or a combination of both. Final adjustment is made by moving the 1U-9627 Torch Holder .

Assemble the Torch

Illustration 8	g02773897
Assemble brush housing to barrel extension

1. Assemble the 1U-9607 Barrel Extension to 1U-9628 Brush Housing or 9U-5134 Brush Housing and tighten.

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Illustration 9	g02773901
Install barrel clamp and insulated bushing

2. Slide a 1U-9629 Barrel Clamp onto the torch and clamp near the brush housing. Install a 1U-9625 Insulated Bushing onto the barrel extension.

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Illustration 10	g02773917
Tighten set screw and knurled ring

3. Install the subassembly from Steps 1 and 2 into the head and clutch assembly. Install a second insulated bushing and barrel clamp. Tighten the set screw to hold the assembly in place and firmly tighten knurled ring of the barrel clamp.

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Illustration 11	g02773922
Assemble torch (1) Torch Holder (2) Adjusting screws (3) Nut (4) Angle (5) Torch Body

4. Assemble the 1U-9630 Torch Body to the 1U-9627 Torch Holder . A 1U-9626 Nut is positioned between the two pieces and must be tightened. The angle on the torch body, in relation to the torch holder, must be parallel and facing away from the torch holder adjustment screw.

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Illustration 12	g02773937
Assemble torch assembly to barrel

5. Assemble the torch assembly to the barrel.

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Illustration 13	g02773946
Thread torch adapter to brush housing and install Teflon liner.

6. Thread the 1U-9612 Torch Adapter or 9U-5135 Torch Adapter into the brush housing. The torch adapter mates existing semi-automatic weld guns and cables to the welding group. The torch adapter has a threaded male end and a non-threaded female end. To adapt existing weld guns to the welding group:

   1. Remove the nozzle, contact tip, and tip adapter.

   2. Drill and tap the torch adapter to fit your weld equipment. The threads of weld guns may vary from product to product. Make sure that all threaded connections are gas tight.

      The welding group uses a 1U-9613 Teflon Liner for the wire to travel through. Metal spring liners and cable assemblies in existing weld guns can also be used, providing they enter the torch adapter to a minimum depth of 38 mm (1.5 inch). This will ensure alignment between the existing metal spring liner and the Teflon liner used in the welding group.

7. Install the Teflon liner, which can be spliced together to obtain an appropriate length. A splicing procedure is provided in the Section ""Splicing Teflon Liners" ".

   1. Select a suitable length of Teflon liner. The length of the Teflon liner is not an exact dimensional length.

   2. Position the torch holder parallel with the centerline of the barrel extension.

   3. With the radial extensions and nozzle holder removed, insert the Teflon liner through the top of the torch adapter.

   4. Push the weld wire completely through the Teflon liner. Attach the existing weld gun by threading the torch adapter to the weld gun.

   5. Run the weld wire through the Teflon liner until wire extends through the other end.
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   Illustration 14	g02773976
   Teflon liner should press lightly against nozzle holder

   6. The Teflon liner should press lightly against the torch and into the counterbore of the nozzle holder.

8. Attach the radial extensions, nozzle holder, and contact tip. Trim the weld wire to length.

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Illustration 15	g02773978
Install gas nozzle

9. Install gas nozzle. Use short gas nozzle with short nozzle holder. Rework the contact tip, if necessary, so it is flush with the length of the gas nozzle. This setup is good for 30 to 60 mm (1.2 to 2.6 inch) diameter bores. For all other applications, use long nozzle holder, long contact tip, and long gas nozzle.

Illustration 16	g02773985

Note: 1U-9611 Remote Control Cord can be attached to the existing semi-automatic weld gun. To rework, remove the existing on/off trigger and attach the remote control cord to the existing wires.

Splicing Teflon Liners

Teflon liners can be spliced together using heat shrinkable tubing with a 4.76 ID x 0.51 to 0.64 wall x 50 mm (.187 ID x .020 to .025 wall x 2.0 inch) length.

1. Place a 50 mm (2.0 inch) length of shrink tubing completely onto the Teflon tubing near the end being spliced.

2. Apply heat and shrink the tubing firmly onto the Teflon liner.

3. Slide the shrinkable tubing over the end of the Teflon tubing half way [approximately 25 mm (1.0 inch)].

4. Add the repaired section or the extended length of Teflon.

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NOTICE
Heat shrinkable tubing repair should not be at any bend made when the Teflon liner is installed in the welding group.

For additional information, refer to Alpha Wire Corporation FIT 295.

Welding Procedure

The function of the Welding Group is to deposit sufficient material to build up a worn surface. The build-up thickness can be increased or decreased by adjusting the potentiometer, controlling torch rotation, or speed.

Prepare Welding Surface

Before starting to weld, check the following items:

1. Make sure that the bore is free of weld, contaminants such as grease, oil, and dirt. These contaminants can cause porosity in welds.

   Bores with fabricated bosses or counterbores trap grease and oil. Use an oxygen-fueled gas torch with a rosebud tip to heat the bore and burn off any contaminants. After heating, allow the bore to cool slowly.

Position Weld Torch

1. Connect power to the welding group. Rotate the lead screw until torch assembly is inside the bore to be welded.

2. Rotate the torch slowly to center. If adjustments are required, move the weld head assembly or move the entire unit slightly.

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Illustration 17	g02773988
Adjust torch position and check final position

3. Once the alignment is correct, actuate magnets and tighten all clamps.

4. Position the torch at the lowest point in the bore with the weld wire flush to bottom of bore. Use a small metal scale to check the wire position.

5. Adjust the tip of the gas nozzle to within 1 mm (0.04 inch) of the bore wall. Adjusting provides proper gas shielding and wire extension.

6. Move the torch body and gas nozzle into final position by adjusting the two thumb screws.

7. Before welding begins, rotate the torch and check final positioning.

Final Preparation and Welding

1. Cover the bottom of the bore with copper plate. The copper will support the molten weld pool as weld material is deposited.
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   Illustration 18	g02773990
   Clamp copper plate under bore

   1. Cut a piece of 4C-8722 Copper Plate [6.0 x 300 x 300 mm (0.25 x 12.0 12.0 inch)] and cover the entire bottom of the bore area.

   2. Clamp into place.

   3. Spray the copper and torch nozzle with anti-spatter solution to prevent weld spatter build-up.

      Note: The gas nozzle must not touch the copper back-up plate.

2. Connect the ground cable to the work piece.

3. Set the switch on the speed control assembly to the left (torch movement upwards).

4. Set the clutch lever on the head and clutch assembly to the neutral position. This will allow the torch to remain stationary, permitting weld build-up around the bottom of the bore opening.

5. Turn the power supply ON, purge the system with shielding gas and adjust the regulator for the recommended gas flow. Start the arc.

   Note: Refer to Section ""Weld Parameters" " for the types of wire for build-up. To obtain pot setting, refer to Section ""Potentiometer Settings" ". Once the arc is started, adjust for wire feed speed, voltage, and the potentiometer settings on the speed control assembly.

6. Start torch rotation and begin welding by depressing the button on the remote control cord.

7. Take note where the welding begins. When the torch rotates to the starting point, engage the clutch. The torch will index, or raise, 3 mm (.1 inch) per revolution. Adjust the weld settings to the proper recommendations.

   Note: With proper welding preparation and weld settings, the weld should be smooth and uniform. Little weld spatter should be produced.

8. Continue welding to the top of the bore. When the torch reaches the top edge of the bore, disengage the clutch and allow one additional revolution to ensure that the bore edge is built up to size.

Weld Completion

1. When the welding is complete:

   1. Shut OFF the arc, welding group, and power supply.

   2. Trim the welding wire at the contact tip.

   3. Clean the gas nozzle of weld spatter.

2. After weld is complete, allow the build-up to cool.

3. If additional build-up is required in the same bore, the torch can be adjusted, rotated downward, and the process started over.

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Illustration 19	g02773997
Remove torch holder

4. If a new location is reworked, follow steps below. If welding is complete, refer to Step 5.

   1. Loosen the torch holder and remove from the barrel extension. Leave the torch body, radial extensions, nozzle holder, contact tip, and gas nozzle attached to the torch holder.
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   Illustration 20	g02774003
   Remove brush housing, barrel extension, and weld gun

   2. Remove the bottom barrel clamp and insulated bushing. The brush housing, barrel extensions, and attached semi-automatic weld gun can be removed from the head and clutch assembly.

   3. Deactivate the base unit magnets and move the bore welding group to the new location.

5. If no additional welding is required, remove the welding group.

6. Grind the top surface of the bore smooth. Remove the weld spatter using a grinder, or wire brush, from inside the bore. Spatter removal will help the machining operation by reducing cutting pressures and increasing tool life.

Disassembly

1. Trim the weld wire so wire can be pulled through the contact tip and Teflon liner.

2. Remove gas nozzle and nozzle holder.

3. Disconnect the brush housing from the torch adapter.

4. Remove the semi-automatic weld gun from the torch adapter.

5. Remove the Teflon liner.

6. Remove the torch holder (disassembly of torch holder is not necessary).

7. Remove the bottom barrel clamp and insulating bushing.

8. Remove the brush housing and barrel extensions.

9. Remove the head assembly. Place all parts into carrying case.

Other Features

Illustration 21	g02774016
Morse taper adapter

The welding group comes with a 1U-9608 Adapter (Number 3 Morse Taper). The adapter allows the column and head assembly to be held in the spindle of a radial drill or horizontal mill. When using the adapter, thread it into the top of the column.

Illustration 22	g02774019
Welding flat surfaces

The welding can also be used to build up flat surfaces. For boss or flange build-up, use the following procedure.

1. Adjust the torch body outward to edge of the surface by loosening or tightening the knobs on the torch holder until the weld wire in near the edge of the outside diameter.

2. Place the clutch lever (on head and clutch assembly) in neutral position.

3. Start the torch rotation and begin welding.

4. Make one complete revolution. Stop welding and readjust the torch holder to a smaller diameter. Each new weld pass must overlap a third of the preceding weld.

5. Continue to reduce the diameter until the face has a layer of weld material.

Maintenance and Repair

The welding group is assembled in modules. Nineteen set screws are used to assemble the unit, making repair simpler.

Check for Wear

1. Check the following items to determine if items need replacing.

   1. Contact tips require changing when the orifice becomes elongated. Replacement is required when the tip is 50 percent larger than the wire diameter.

   2. Change Teflon liner every 15 service hours.

   3. Gas nozzles require changing when weld spatter build-up obstructs the gas flow.

Fuses

Illustration 23	g02774023
Fuse location

Illustration 24	g02774036
Fuse location

The base contains the power transformer. There are three fuses to check if power is unavailable to part of the unit. There is an incoming line fuse protecting the transformer, a fuse for the magnets, and a fuse for the motor.

1U-9633 Transformer

If the 1U-9633 Transformer requires replacement:

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Illustration 25	g02774038
Remove cover

1. Remove the four setscrews and cover plate.

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Illustration 26	g02774041
Replace transformer unit

2. Unplug and remove transformer, and then install a new unit. The transformer is a sealed unit and cannot be repaired.

1U-9602 Magnets

Illustration 27	g02774043
Remove setscrew

1. Remove magnets by removing the set screw on the top side of the base housing.

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Illustration 28	g02774045
Unplug and install new magnet

2. Unplug the magnet and install a new 1U-9602 Magnet . New magnets must be resurfaced, level with bottom surface of base housing.

Top Casting

The top casting contains the speed control assembly, drive motor, gear clutch, and head and clutch assembly.

Speed Control Assembly

Illustration 29	g02774049
Speed control assembly

Illustration 30	g02774050
Remove control by unplugging from drive motor

Drive Motor

Illustration 31	g02774051
Remove cover plate

1. The drive motor is removed by removing three set screws from the cover plate on the bottom side of the casting.

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Illustration 32	g02774065
Remove center screw

2. Remove the flat head screw which holds the gear clutch to the motor spindle.

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Illustration 33	g02774066
Remove four screws

3. Remove the four set screws holding the drive motor in place.

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Illustration 34	g02774069
Remove motor

4. Remove the motor.

Head and Clutch Assembly

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Illustration 35	g02774072
Remove set screw

1. The head and clutch assembly is removed by loosening the set screw on the side of the housing and lifting the unit out.

   The gear clutch should be removed before removing the head and clutch assembly.

   When installing a new head and clutch assembly, a location pin provides proper alignment.

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Illustration 36	g02774077
Protective spring

2. A protective spring shield on the head and clutch assembly protects the lead screw from dirt and weld spatter during welding. Lead screw should be lubricated, lightly, every 50 hours.

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Illustration 37	g02774082
Lubricate lead screw, gear, and gear clutch

3. Lubricate the lead screw, gear, and gear clutch with 4C-9792 Grease (8 oz. tube). This grease is water and temperature resistant.

Disassembly and Assembly

This section provides disassembly, assembly, and adjustment procedures for the major components in the welding group.

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NOTICE
The 1U-9600 Welding Group is a precision instrument. Extreme care must be used when repairing any component.

1U-9603 Head and Clutch Unit

Disassembly

1. Compress and secure telescopic spring (19) with three pieces of soft wire.

2. Remove two set screws (21) from end of bushing (20). Remove bushing and telescopic spring.

3. Remove screws (6) (six or eight, depending on model) which retains bellows (5) .

4. Engage ball handle (26), (27) and turn main spindle (7) clockwise [looking from bushing (20) end] to separate from gear and clutch assembly.

5. Separate plastic cover (1) by removing retaining ring (4) .

6. Loosen Allen cap screw (18) .

7. Using a 9U-6737 Spanner Wrench , turn adjustment cover (17) counterclockwise.

   Note: If the adjustment cover will not loosen, heat may be applied to loosen the Loctite used during assembly. Carefully heat the area to 260° to 315°C (500.0° to 600.0°F). Use a heat indicator, such as a tempstick, to monitor the temperature.

8. Remove (15) and bearing (16) assembly. If the bearings are damaged, remove gear (15) which has a light press fit.

9. Disengage ball handle (26), (27) and remove.

10. Remove adjustment nut (13) and threaded bushing (12) by turning nut counterclockwise. Use the two 3.0 mm (.12 inch) diameter holes to rotate the bushing.

11. Remove centering ring (10) .

12. Thoroughly clean, deburr, and inspect all parts.

Illustration 38	g02774084
1U-9603 Head and Clutch Unit

Table 3

1U-9603 Head and Clutch Assembly
Item	Description	OEM Part No.	Cat Part No.
(1)	Cover (plastic)	306-0001	-
(2)	Bearing	306-0002	-
(3)	Retaining ring	306-0003	-
(4)	Retaining ring	306-0004	-
(5)	Bellows	306-0005	-
(6)	Screw	306-0006	-
(7)	Spindle	306-0007	-
(8)	Sleeve bearing	306-0008	-
(9)	Housing	306-0009	-
(10)	Centering Ring	306-0012	-
(11)	Magnet	306-0013	-
(12)	Threaded bushing	306-0014	-
(13)	Adjustment nut	306-0015	-
(14)	Screw	306-0016	-
(15)	Gear	306-0017	-
(16)	Bearing	306-0018	-
(17)	Adjustment cover	306-0019	-
(18)	Screw	306-0020	-
(19)	Telescopic spring	306-0022	-
(20)	Bushing	306-0023	-
(21)	Set Screw	306-0024	-
(22)	Key	306-0025	-
(23)	Retaining ring	306-0026	-
(24)	Bearing shim	306-0027	-
(25)	Screw	306-0028	-
(26)	Ball handle and lever	306-0100	-

Assembly and Adjustment

1. Install centering ring (10) in housing (9), aligning the two tapered surfaces.

2. Loosen Allen cap screw (25) in adjustment nut (13) .

3. Rotate adjustment nut counterclockwise (approximately one revolution), until the top face extends 0.78 mm (0.031 inch) past the face of the threaded bushing (12) .

4. Tighten Allen cap screw.

5. Assemble adjustment nut and bushing assembly by turning assembly clockwise until firmly seated in housing.

   Note: Centering ring must be loose in cavity, with adjustment nut and bushing firmly in place.

6. Rotate adjustment nut and bushing assembly counterclockwise until the tapped hole for ball handle (26), (27) aligns with slotted window. Install ball handle.

7. Adjust position of ball handle.

   1. Loosen Allen cap screw (25) .

   2. Position ball handle 5 to 10 mm (0.2 to 0.4 inch) from the locking end of 53 mm (2.0 inch) long slotted window.

   3. Maintain the position of ball handle and rotate adjustment nut clockwise until all movement of centering ring has been eliminated.

   4. Tighten Allen cap screw.

8. Test the adjustment by rotating adjustment nut and bushing assembly several times using ball handle.

   1. Feed engaged = Clockwise movement of ball handle against the stop, 5 to 10 mm (0.2 to 0.4 inch) from the end of the window, will lock centering ring in position.

   2. Feed disengaged = Total counterclockwise movement of ball handle will loosen centering ring, allowing ring to be moved and rotated by hand.

9. The 1U-9603 Feed Assembly is now properly adjusted. Use Loctite and secure ball handle.

10. Install gear (15) and bearing (16) assembly into adjustment cover (17). Thread assembly into housing (9) with ball handle in the fully disengaged position until gear cannot be rotated by hand.

11. Rotate adjustment cover counterclockwise until the gear can be rotated freely by hand (approximately 1.5 inch at the outside diameter). Check for free gear rotation with ball handle in both feed-engaged and disengaged positions.

12. Tighten Allen cap screw (18) .

13. The assembly is now properly adjusted. Install the remaining parts in order.

    1. Bellows (5) .

    2. Main spindle (7) and cover (1) .

    3. Telescopic spring (19) .

    4. End bushing (20) .

1U-9634 Drive Motor

Note: Drive motors should not be repaired, due to critical assembly specifications.

1U-9632 Gear and Clutch Assembly

Illustration 39	g02774203
1U-9632 Gear and Clutch Assembly

Table 4

1U-9632 Gear and Clutch Assembly
Item	Description	OEM Part No.	Cat Part No.
(1)	Gear	308-0001	-
(2)	Support plate	308-0002	-
(3)	Sliding cover	308-0003	-
(4)	Spring	308-0004	-
(5)	Bail	308-0005	-
(6)	Set screw	-	6V-8932
(7)	Nut	-	6V-8225
(8)	Key	308-0100	-
(9)	Shim	308-0200	-
(10)	Bolt	308-0300	-
(11)	Retaining ring	308-0500	-
(12)	Spring Pin	-	6V-8096

Disassembly

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NOTICE
The 1U-9600 Welding Group is a precision instrument. Extreme care must be used when repairing any component.

Note: Scribe a line on mating faces of items (2) and (3) to realign the hole for spring pin (12) .

1. Remove spring pin (12) using 1U-7277 Pin Driver .

2. Remove lock nuts (7), set screws (6), springs (4), and balls (5). Repeat process to all three sets. Remove key (8) and retaining ring (11) with 1P-1853 Snap Ring Pliers . Gear (1) should now rotate freely.

3. Separate support plate (2) from sliding cover, (3) using a hand bench press. This is a light press fit.

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NOTICE
Do not separate support plate (2) from sliding cover (3) with a hammer and punch. This will cause peening of the material in plate (2), making assembly difficult.

4. Clean, deburr, and inspect all parts.

5. Assemble parts in reverse order, applying 4C-9792 Lubricant (8 oz. tube Alpha 2000 grease) to all rotating surfaces.

   Note: Gear (1) must rotate freely prior to Step 2 of the assembly instructions.

Check for Proper Operation

1. Remove key (8) and retaining ring (11) using 1P-1853 Snap Ring Pliers , if necessary.

Show/hide table



Illustration 40	g02774238
Clamp part together using bolt, washers, and nut.

2. Assemble a 0S-1748 Bolt (A) (3/8-24 x 2 in long), two hardened 5M-2894 Flat Washers (B), and 1B-4203 Nut (C) through the center hole. Tighten nut to 11 to 14 N·m (100.0 ± 130.0 lb in) of torque.

3. Put gear (1) in a vice with soft copper jaws. Record the torque required to start rotating the assembly [Items (2) and (3) ]. For correct operation of the clutch assembly 5 to 8 N·m (50.0 to 60 .0 lb in) of break-away torque must be obtained.

Note: This setting will drive (rotate) the correctly adjusted 1U-9603 Head and Clutch Assembly and protect the gear train of the 1U-9634 Drive Motor .

Final Adjustment

1. Loosen three lock nuts (7) and three set screws (6), until nuts no longer touch springs (4) .

2. Using a 3 mm Allen wrench, turn set screws clockwise until the screws touch the springs.

3. Continue adjusting the set screws until 5 to 8 N·m (50.0 to 60.0 lb in) break-away torque is obtained. Approximately 1 to 1 1/4 turns.

4. Tighten the lock nuts, while holding set screws.

5. Recheck the break-away torque. Readjust if the correct torque value is not obtained.

Note: Prior to installing the 1U-9632 Gear and Clutch Assembly , rotate the mating gear in the 1U-9603 Head and Clutch Assembly . The gear should freely rotate by hand. If not, the 1U-9603 Head and Clutch Assembly must be cleaned and adjusted.

1U-9628 Brush Housing

Illustration 41	g02774259
1U-9628 Torch Brush Housing

Table 5

1U-9628 Brush Housing
Item	Description	Cat Part No.
(1)	Threads M16 x 1.0	-
(2)	Brush holder	-
(3)	Locknut	1U-9626
(4)	Plastic ring	-
(5)	Set screw (M5 x 0.8 x 8 mm long)	-
(6)	Spring	-
(7)	Carbon brush assembly	-
(8)	Set screw (M6 x 1.0 x 8 mm long)	095-1272
(9)	Spanner wrench hole	-
(10)	Slip ring holder	-
(11)	O-ring seal	-
(12)	Brush housing	-
(13)	Slip ring body	-
(14)	Insulating sleeve	-
(15)	Set screw (M6 x 1.0 x 16 mm long)	095-1274
(A)	Sleeve (5/8 OD x 1/2 ID x 1 inch long)	-
(B)	Nut M12	6V-8149
(C)	Set screw (M12 x 1.75 x 80 mm long)	9X-8483

Disassembly

Note: The 1U-9628 Brush Housing has been replaced by 9U-5134 Brush Housing in later production units.

1. Remove M6 x 1.0 x 16 mm long set screw (15) using a 3 mm Allen wrench.

2. Separate brush housing (12) (right-hand threads) from insulating sleeve (14) using an M12 x 1.75 x 80 mm long set screw (C), nut (B), and sleeve (A). Plastic ring (4) will slide out while the insulating sleeve and brush holder assembly are being separated.

   Note: Sleeve (A) can be made from hydraulic line or rigid copper tubing with 15.8 mm (0.62 inch) outside diameter x 12.7 mm (0.50 inch) inside diameter x 25 mm ( 1.0 inch) long.

3. Remove set screw (8) .

4. Separate brush holder (2) from brush housing (12) (right-hand threads) using two 1P-2851 Spanner Wrenches .

5. Remove three set screws (5) which retain carbon brush assembly (7) and spring (6) .

6. Thoroughly clean, deburr, and inspect all parts.

Brush Assembly and Spring Adjustment

Lubricate all rotating parts during assembly with 4C-9792 Grease (8 oz. tube Alpha 2000).

1. Install spring (6), carbon brush assembly (7), and three set screws (5), but do not completely tighten, allowing the brush assembly to move.

2. Insert slip ring holder (10). Holder must rotate freely. Assemble brush holder (2) and brush housing (12).

3. Tighten brush holder (2) and brush housing (12) until both faces meet. Then loosen 3/4 to one complete revolution.

4. Tighten three set screws (5). Now, retighten brush holder (2) and brush housing (12) to ensure proper electrical connection of the 1U-9628 Brush Housing .

5. Install set screw (8) which should be in alignment with the drill point in the brush holder (2).

6. Complete the assembly of remaining parts in reverse order of disassembly.

9U-5134 Brush Housing

Disassembly

Illustration 42	g02774265
9U-5134 Brush Housing

Table 6

9U-5134 Brush Housing
Item	Description	Cat Part No.
(1)	Brush holder	-
(2)	Insulating sleeve	-
(3)	Set screw (M5 x 0.8 x 10 mm long)	8T-9102
(4)	Brush assembly	-
(5)	Brush housing	-
(6)	Slip ring holder	-
(7)	Locking cap	-
(8)	Set screw (M6 x 1.0 x 16 mm long)	095-1274
(9)	Cap screw (M4 x 0.70 x 10 mm long)	095-0641
(10)	Set screw (M6 x 1.0 x 8 mm long)	095-1272
(11)	Spring	-

Note: The mating torch adapter is 9U-5135 Torch Adapter .

1. Remove M8 x 1.0 x 16 mm long set screw (8) .

2. Separate brush holder assembly (1) from insulating sleeve (2) using an 8 mm Allen wrench (right-hand threads).

3. Remove set screw (10) .

4. Remove three set screws (3), retaining brush assembly (4), and spring (11) .

5. Thoroughly clean, deburr, and inspect all parts.

Brush Assembly and Spring Adjustment

Lubricate all rotating parts with 4C-9792 Grease (8 oz. tube Alpha 200 grease) during assembly.

1. Install spring (11), brush assembly (4), and three set screws (3), but do not completely tighten, allowing the brush assembly to move.

2. Insert slip ring holder (6). Holder must rotate freely. Assemble brush holder (1) and brush housing (5).

3. Tighten brush holder (1) and brush housing (5) until both faces meet. Then loosen 3/4 to one complete revolution.

4. Tighten three set screws (3), and retighten brush holder (1) and brush housing (5) to ensure proper electrical connection of the 9U-5134 Brush Holder .

5. Install set screw (10) which should be in alignment with the drill point in brush holder (1).

6. Install the assembly in insulating sleeve (2) using an 8 mm hex wrench to align the threaded hole and install set screw (8) .

7. Test the assembly by holding insulating sleeve (2) and rotating the brush holder assembly (1) by hand.

1U-9616 Speed Control Assembly

CSTG will repair the electronics portion of the 1U-9616 Speed Control for $150.00 U.S., plus parts. Policies and procedures are in the Service Technology Tool Guide (Section 8) and Tool Announcement NEHG3401.

Note: A loaner speed control unit may be available during repair. For further details, contact Caterpillar Service Technology Tool Repair Section.

Metric Tap and Die Sets

Metric tap and die sets are available for repair components.

Table 7

Metric Tap and Die Sets
Threads	Tap	Die
M6 x 1.0	8T-3081	8T-3064
M12 x 1.75	8T-3091	8T-3074
M14 x 1.0	4C-5894	4C-6925
M16 x 1.0	4C-4182	4C-4181

For additional metric taps and dies, refer to Special Instruction, NECG0604, "Caterpillar Tools and Supplies Catalog".

Parts Listing

Base Assembly

Illustration 43	g02774278
Base assembly

Table 8

Base Assembly
Item	Description	OEM Part No.	Cat Part No.
(1)	Housing	303-0100	-
(2)	Electromagnet	-	1U-9602
(3)	Electromagnet plug	303-0300	-
(4)	Electromagnet socket	303-0400	-
(5)	Cover	303-0500	-
(6)	Sight glass	303-0600	-
(7)	Clamping lever	303-0700	-
(8)	Shaft	303-0800 303-0900	-
(9)	Screw	303-1000	-
(10)	Retaining ring	303-1100	-
(11)	Cap screw	303-1400	-
(12)	Cap screw	303-1300	-
(13)	Warning plate	-	5P-9466
(14)	Rivet	303-1501	-
(15)	Pin	303-1502	-

1U-9633 Transformer Assembly

Illustration 44	g02774283
1U-9633 Transformer Assembly

Table 9

1U-9633 Transformer Assembly
Item	Description	OEM Part No.	Cat Part No.
(1)	Transformer housing	304-0001	-
(2)	Transformer	304-0002	-
(3)	Electrolytic capacitor	304-0003	-
(4)	Converter	304-0004	-
(5)	Voltage selector	304-0005	-
(6)	Inlet receptacle	304-0006	-
(7)	Outlet receptacle	304-0007	-
(8)	Shield 1 (aluminum)	304-0009	-
(9)	Shield 2 (aluminum)	304-0010	-
(10)	Inlet fuse holder	304-0011	-
(11)	Outlet fuse holder	304-0013	-
(12)	Outlet fuse (250V-2A)	-	1U-9619
(13)	Outlet fuse (205V-3.15A)	-	1U-9620
(14)	Push-button socket	304-1401	-
(15)	Push-button cover	304-1402	-
(16)	Lamp socket	304-1501	-
(17)	Lamp	304-1502	-
(18)	Lamp cover	304-1503	-

Illustration 45	g02774289
Incoming power setting

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NOTICE
Do not use the 120 V setting on the transformer. Doing so, may damage the transformer.

1U-9610 Coil Cord

Illustration 46	g02774296
1U-9610 Coil Cord

Table 10

1U-9610 Coil Cord
Item	Description	OEM Part No.
(1)	Cord	311-0100
(2)	Plug	311-0200
(3)	Receptacle	311-0300
(4)	Bolt (plastic head)	311-0400
(5)	Bolt retention (plastic washer)	311-0401

Transmission Housing Assembly

The top casting contains the speed control assembly, drive motor, gear clutch, and head and clutch assembly.

Illustration 47	g02774300
Transmission Housing Assembly

Table 11

Transmission Housing Assembly
Item	Description	OEM Part No.	Cat Part No.
(1)	Guide pin	301-0002	-
(2)	Transmission housing	301-0100	-
(3)	Clamping lever assembly	301-0200	-
(4)	Set screw (M6 x 1.0 x 10 mm long)	-	096-3779
(5)	Cover	301-0400	-
(6)	Cap screw (M4 x 0.7 x 13 mm long)	-	8T-3998
(7)	Knurled-head screw	301-0600	-
(8)	Cap screw	301-0700	-
(9)	Washer	301-0800	-
(10)	Thread Insert	301-0900	-
(11)	Nut	301-1000	-

1U-9616 Speed Control Assembly

Illustration 48	g02774302
1U-9616 Speed Control Assembly

Table 12

1U-9616 Speed Control Assembly
Item	Description	OEM Part No.	Cat Part No.
(1)	Housing	302-0001	-
(2)	Back plate	302-0002	-
(3)	Screw (M5 x 0.8 x 10 mm long)	302-0003	-
(4)	Selector switch	302-0005	-
(5)	Push-button switch	302-0006	-
(6)	Adapter plug	302-0007	-
(7)	Indicator dial	302-0008	-
(8)	Receptacle	302-0009	-
(9)	Potentiometer	302-0010	-
(10)	Electronic board	302-0011	-
(11)	Screw (M3 x 0.5 x 10 mm long)	302-0012	-
(12)	Plug for motor	302-0100	-
(13)	Rotary knob	302-0200	-
(14)	Film	-	NEEG2003
(15)	Cord	302-0400	-
(16)	Traction relief	302-0401	-
(17)	Spacer	302-0413	-
(18)	Lamp assembly	302-0500	-
(19)	Lamp	302-0501	-
(20)	Lamp socket	302-0502	-
(21)	Lamp cover	302-0503	-
(22)	Sleeve	302-0600	-

Illustration 49	g02774318
1U-9627 Torch Holder Assembly

Table 13

1U-9627 Torch Holder Assembly
Item	Description	OEM Part No.
(1)	Base	309-0601
(2)	Torch arm	309-0602
(3)	Teflon tube	309-0605
(4)	Axle	309-0603
(5)	Stud	309-0604
(6)	Knurled-head screw, short	309-0800
(7)	Knurled-head screw, long	309-0700

Illustration 50	g02774339
1U-9629 Barrel Clamp

Table 14

1U-9629 Barrel Clamp
Item	Description	OEM Part No.
(1)	Clamping sleeve	309-0301
(2)	Adapter bushing	309-0300
(3)	Set screw	309-0302

Torch Assembly

Illustration 51	g02774343
Torch Assembly

Table 15

Torch Assembly
Item	Gas Nozzle	Extension	Tip Holder	Diameter		Tips
				Min	Max
(1), (6), (12)	1U-9640	-	1U-9624	1.20	2.56	1U-9638
(2), (6), (12)	1U-9622	-	1U-9624	1.40	2.80	1U-9638
(3), (7), (13)	1U-9621	-	1U-9623	2.80	4.56	1U-9635
(3), (4), (7), (13)	1U-9621	1U-9615	1U-9623	4.40	6.00	1U-9635
(3), (5), (7), (13)	1U-9621	1U-9614	1U-9623	5.40	7.25	1U-9635
(3), (4), (5), (7), (13)	1U-9621	1U-9614, 1U-9615	1U-9623	6.75	8.75	1U-9635
Item (10) = 1U-9639 Barrel Extension (short) is placed between items (8) and (11) to extend the welding depth from 140 mm (5.5 inch) to 254 mm (10.0 inch). Barrel Extension also adds 28.5 mm (1.1 inch) to all the maximum bore diameters, per above chart. Note: The use of an anti-spatter solution will increase the life of these weld consumables.

Miscellaneous Parts

Table 16

Miscellaneous Parts
Item	Description	OEM Part No.	Cat Part No.
-	Insert (box)	320-0000	-
-	Operational manual	-	NEHS0513
-	Box	320-0000	-
-	Side cutting pliers	-	1U-7228
-	Open-end wrench (17 mm)	-	6V-9097
-	Open-end wrench (19 mm)	-	6V-9099
-	Open-end wrench (14 mm)	-	6V-9094
-	Open-end wrench (8 mm)	-	1U-5548
-	Open-end wrench (10 mm)	-	6V-9090
-	Allen wrench (2 mm)	-	1U-7560
-	Allen wrench (5 mm)	-	1U-7564
-	Allen wrench (6 mm)	-	1U-7565
-	Lubricant	319-0000	-
-	Copper plate (12 x 12 x 0.25 in)	-	4C-8722

Table 17

Parts Required When Using Hydraulic Boring Bar
Qty.	Description	Cat Part No.
3	insulated bushings	4C-6420
1	Bore welder mounting shaft	4C-6429
1	Cable assembly (transformer to control)	4C-6434
1	Flange nut to secure mounting shaft	4C-6447
1	Cable assembly (control to motor)	4C-6492
4	Barrel extensions - 394 mm (15.5 inch) long	1U-9607

Warranty

The Welding Group has a 1 year warranty against defects in materials and workmanship. This warranty period begins with the date of delivery.

Troubleshooting

Table 18

Troubleshooting Information
Problem	Cause	Remedy
Power cord is connected, but test lamp at transformer does not light.	No line voltage is present. Fuses are defective.	Check power supply. Replace fuses. Replace power cord. Replace lamps. Replace transformer, according to instruction.
Electromagnets are not activated.	Fuse for magnets is defective (test lamp does not light). Magnet is defective.	Replace fuse. Replace magnet, according to instruction.
No voltage in control panel. Green test lamp does not light.	Outlet fuses at transformer are defective. Coil cord (transformer to speed control assembly) is defective. Lamp is defective. Speed control assembly is defective.	Replace fuses. Replace coil cord. Replace lamp. Replace speed control assembly.
Drive motor does not rotate.	Motor is defective. Speed control assembly is defective.	Replace motor, according to instruction. Replace speed control assembly, according to instruction.
Weld head and clutch assembly does not rotate.	Gear clutch is defective. Weld head assembly is defective.	Replace gear clutch, according to instruction. Replace weld head assembly, according to instruction.
Weld head assembly rotates, but still no feed action.	Lead screw is not in right-hand position. Weld head assembly is defective.	Place lead screw in right-hand position. Replace weld head assembly, according to instruction.
Weld torch is not rotating.	Set screw is not tight. Thumb screw of barrel clamp is not tight. Weld torch parts are not securely connected with each other.	Tighten set screw. Tighten thumb screw. Tighten weld torch parts to each other.
Unit does not turn on.	Remote control cord or switch is defective. Remote control is not correctly attached.	Replace remote control, according to instruction. Check attachment cord.
No wire feed.	Wire feed unit is defective. hose package has too many bends. Weld wire is burned into contact tip. Teflon liner is defective. Wrong contact tip is attached. Weld wire is bent.	Repair wire feed unit. keep hose package free of bends. Change contact tip. Replace Teflon liner. Install correct contact tip. Remove bent weld wire.
No inert gas flow.	Gas cylinder is not open, or is empty. Hose package is defective. Inert gas is leaking. Teflon liner in torch holder is defective. Bores in nozzle are plugged. Gas nozzle is plugged.	Replace or open gas cylinder. Replace hose package. Tighten all weld torch parts with enclosed tools. Replace torch holder. Clean nozzle holder. Clean or replace gas nozzle.
No welding circuit.	Hose package is defective. Weld torch parts are not securely tightened. Brush housing defective. Contact tip is defective. Ground cable is defective. Ground cable has no contact. Power source is defective.	Replace hose package. Tighten all weld torch parts with enclosed tools. Replace brush housing. Replace contact tip. Replace ground cable. Attach ground cable correctly. Repair power source.
Pore formation in weld deposit.	No inert gas. Surface is not clean. Windy conditions at welding location.	Restore gas supply. Burn off residues of oil, grease and paint from surface, or clean with metallic cutting disc. Protect with respective devices.
Excess drop formation at weld deposit.	Welding puddle is too diluted.	Reduce welding current.

Weld Parameters

Table 19

Welding Wire
Wire Type	Wire Part No.	Wire Dia.	WFS1 In/Min	Current	Volts
Alloy Rods Spool Arc 88	1U-6722	.035	220-280	110-140	17.5 ± .52
Use shielding gas 75%Ar/25%CO2 at a rate of 30 to 50 cu.ft./hr. 1 Wire Feed Speed 2 Voltage must be measured at the 1U-9630 Torch Body .

Potentiometer Settings

Instructions for Use of Charts

1. Determine the bore diameter and locate that measurement on right side of chart.

2. Refer to "Torch Travel Speeds" Chart in Attachment A for weld thickness.

3. Locate the known torch travel speed as shown on left side of "Weld Speed/Pot Setting" chart. Refer to Illustrations 52 and 53.

4. Once the Bore Diameter and the Torch Travel Speed are determined, set the Pot Setting at the point of intersection.

Table 20

For example:

Wire Dia. = (.035 in)

Weld Thickness = (3/16 in)

Torch Travel Speed = 14 in/min

Bore Dia. = (4 in)

Pot Setting = 2.80 on the Speed Control Assembly

Illustration 52	g02774350
Potentiometer setting chart for bore welder controller

Illustration 53	g02774356
Potentiometer setting chart for bore welder controller

Weld Torch Settings

Illustration 54	g02774376
Weld torch assembly