ESAB A6 TFD1 Simplified Service Manual
ESAB A6 TFD1 Simplified Service Manual

ESAB A6 TFD1 Simplified Service Manual

Automatic welding machine
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A6 TFD1/TFD2/
TGD1
Automatic welding machine
Simplified service manual
333 534- -003
9612

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Summary of Contents for ESAB A6 TFD1

  • Page 1 A6 TFD1/TFD2/ TGD1 Automatic welding machine Simplified service manual 333 534- -003 9612...
  • Page 2: Table Of Contents

    ........... . SPARE PARTS LIST A6 TFD1/TFD2/TGD1 .
  • Page 3 WARNING ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAUTIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE BASED ON MANUFACTURERS’ HAZARD DATA. ELECTRIC SHOCK - - Can kill Install and earth the welding unit in accordance with applicable standards. Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
  • Page 4: Safety

    SAFETY Users of ESAB automatic welding machines have ultimate responsibility for ensuring that anyone who works on or near the equipment observes all the relevant safety precautions. The following recommendations should be observed in addition to the standard regulations that apply to the work place.
  • Page 5: Technical Description

    TECHNICAL DESCRIPTION The A6 TFD1 automatik welding machine is mounted on a tractor unit and intended for DC or AC submerged- -arc welding of butt and fillet welds. The A6 TFD2 automatik welding machine with two welding heads is mounted on a tractor unit and intended for DC or AC submerged- -arc welding of butt and fillet welds.
  • Page 6 Final reduction ratio 64:15 Sprocket ratio 8. Wire feed motor, A6 VEC (see instructions 333 533- -003) Wire feed motor with reduction gear 42 V (A6 TFD1/A6 TFD2) Motor speed 4000 rpm Gear ratio 156,1 Wire feed motor with reduction gear...
  • Page 7 A6 TFD1 A6 TGD1 A6 TFD2 - - 7 - - cfa4d1ea...
  • Page 8 Extra accessories for the A6 TFD1 A6 TFD2 and A6 TGD1 Ordering no. Fine wire straightener (not for the A6 TFD2) 332 565- -880 when accurate wire straightening is required for single wire not exceeding 2.5 mm diameter Guide wheel bogey (not for the A6 TFD2)
  • Page 9 334 299- -880 consisting of a wire feed unit for an A6 SFD1 for conversion of an existing A6 TFD1 automatic welding machine to MIG/MAG- -welding (wire diameter 1.0 - - 3.2 mm) Extra accessories for the A6 TFD2 (submerged- -arc welding)
  • Page 10: Installation

    5. Connection instructions, see page 17. DC welding: Connect control cable (08) for A6 TFD1 resp. (15) for A6 TGD1 between the weld- ing power source and the PEG1 control box. Connect the welding current lead carrying a cable lug (07) resp. (08) between the...
  • Page 11: Operation

    (This applies only to submerged -arc weld- ing). Filling with flux (A6 TFD1 and A6 TFD2) 1. Close the valve on the flux hopper 2. Remove the separating cyclone of the flux recovery unit, if fitted. Fill the hopper with flux, which must be dry 3.
  • Page 12 Conversion of the A6 TFD1 (submerged- -arc welding) to MIG/MAG- -welding 1. Replace the wire feed gear motor unit. 2. Make the necessary changes to the PEG 1 control unit as described in the PEG1 instruc- tion manual. Operating instructions for the PEG1 control box 1.
  • Page 13: Maintenance

    MAINTENANCE PEG1 control box, see instruction manual 333 470- -001. A6 VEC wire feed motor, see instruction manual 333 533- -003. Daily Clean dust and welding residue away from the moving parts of the machine. Check that all hoses and electrical connections are undamaged and correctly connected. Check that all screws and bolted joints are tight.
  • Page 14: Troubleshooting

    TROUBLESHOOTING Equipment Manual for control box PEG1, order no. 333 470-001. Manual for motor with gear A6 VEC, order no. 333 533-003. Check that the welding power supply is connected for the correct mains supply voltage that all three phases are live (phase sequence is immaterial) that all welding cables and connections are undamaged that all controls are correctly set that the mains power supply is disconnected before repairs are done...
  • Page 15: Dimension Drawing

    DIMENSION DRAWING A6 TFD1 A Butt welding B Fillet welding dfa4m01a dfa4m01b - - 15 - - cfa4m11a...
  • Page 16 DIMENSION DRAWING A6 TFD2 dfa4m02a dfa4m02b - - 16 - - cfa4m11a...
  • Page 17: Diagram

    DIAGRAM A6 TFD1/TFD2 01. Welding power source (DC) 02. Control box 03. Motor with gear 04. Straightener 05. Connector 06. Contact tube 07. Welding cable 08. Control cable 09. Cable 10. Welding power source (AC) 11. Filler wire unit A6 TGD1 01.
  • Page 18 - - 18 - - cfa4e11a...
  • Page 19: Spare Parts List A6 Tfd1/Tfd2/Tgd1

    SPARE PARTS LIST A6 TFD1/TFD2/TGD1 Edition 9612 Spare parts are to be ordered through the nearest ESAB agency as per the list on the back of the cover. Kindly indicate type of unit, serial number, denominations and ordering numbers according to the spare parts list.
  • Page 20 Reservdelsförteckning - - Spare parts list - - Ersatzteilverzeichnis - - Liste de pècees détachèes Component designation Item Orderingno. Denomination Remarks in the circuit diagram 334 190- -880 Automatic welding A6 TFD1 machine 147 649--881 Flux hopper compl. 148 487--880 Holder 334 294--001 Attachment 334 707--880 Wire support 145 063--906...
  • Page 21 Reservdelsförteckning - - Spare parts list - - Ersatzteilverzeichnis - - Liste de pècees détachèes - - 21 - - s334190...
  • Page 22 Reservdelsförteckning - - Spare parts list - - Ersatzteilverzeichnis - - Liste de pècees détachèes Component designation Item Orderingno. Denomination Remarks in the circuit diagram 334 191- -880 Automatic welding A6 TFD2 machine 333 001--910 Control box 333 001--901 Control box Screw B8x9.5 153 872--880...
  • Page 23 Reservdelsförteckning - - Spare parts list - - Ersatzteilverzeichnis - - Liste de pècees détachèes - - 23 - - s334191...
  • Page 24 Reservdelsförteckning - - Spare parts list - - Ersatzteilverzeichnis - - Liste de pècees détachèes Component designation Item Orderingno. Denomination Remarks in the circuit diagram 0409 536--01 Clamp 0409 536--03 Clamp 334 191- -881 Automatic welding A6 TFD2 machine 333 001--910 Control box 333 001--905 Control box...
  • Page 25 Reservdelsförteckning - - Spare parts list - - Ersatzteilverzeichnis - - Liste de pècees détachèes - - 25 - - s334191...
  • Page 26 Reservdelsförteckning - - Spare parts list - - Ersatzteilverzeichnis - - Liste de pècees détachèes Component designation Item Orderingno. Denomination Remarks in the circuit diagram Screw M6x25 Washer D12/6.4x1.5 0409 536--01 Clamp 0409 536--03 Clamp - - 26 - - s334191...
  • Page 27 Reservdelsförteckning - - Spare parts list - - Ersatzteilverzeichnis - - Liste de pècees détachèes - - 27 - - s334191...
  • Page 28 Reservdelsförteckning - - Spare parts list - - Ersatzteilverzeichnis - - Liste de pècees détachèes Component designation Item Orderingno. Denomination Remarks in the circuit diagram 334 178- -880 Automatic welding ma- A6 TGD1 chine 334 707--880 Wire support 145 063--909 Motor with gear 42 V 147 428--880...
  • Page 29 Reservdelsförteckning - - Spare parts list - - Ersatzteilverzeichnis - - Liste de pècees détachèes - - 29 - - s334178...
  • Page 30 Component designation Item Orderingno. Denomination Remarks in the circuit diagram 147 649- -881 Flux hopper compl Optional equipment (OPC) Optional equipment (A6 TFD1/ TFD2) 154 007--001 Hopper for flux 146 837--001 Window 147 645--001 Fitting Washer D8/4.3x0.8 191 898--108 Rivet...
  • Page 31 Reservdelsförteckning - - Spare parts list - - Ersatzteilverzeichnis - - Liste de pècees détachèes - - 31 - - s147649...
  • Page 32 Reservdelsförteckning - - Spare parts list - - Ersatzteilverzeichnis - - Liste de pècees détachèes Component designation Item Orderingno. Denomination Remarks in the circuit diagram 334 183- -880 Carriage 334 295--880 Guide handle 332 979--880 Guide arm 2121 107--42 Screw B12x16 334 165--880 Side plate...
  • Page 33 Reservdelsförteckning - - Spare parts list - - Ersatzteilverzeichnis - - Liste de pècees détachèes - - 33 - - s334183...
  • Page 34 Reservdelsförteckning - - Spare parts list - - Ersatzteilverzeichnis - - Liste de pècees détachèes Component designation Item Orderingno. Denomination Remarks in the circuit diagram Washer D16/8.4x1.5 2213 070--01 Steel ball Belleville washer D8/3.2x0.3 Washer D6.4/12x3 Washer D5/10x1 Screw M8x12 - - 34 - - s334183...
  • Page 35 Reservdelsförteckning - - Spare parts list - - Ersatzteilverzeichnis - - Liste de pècees détachèes - - 35 - - s334183...
  • Page 36 Reservdelsförteckning - - Spare parts list - - Ersatzteilverzeichnis - - Liste de pècees détachèes Component designation Item Orderingno. Denomination Remarks in the circuit diagram 154 465- -880 Slide, manually operated 154 464--001 Slide frame 154 463--880 Carrlage with slide rails 190 509--485 Stop screw M10x10...
  • Page 37 Reservdelsförteckning - - Spare parts list - - Ersatzteilverzeichnis - - Liste de pècees détachèes - - 37 - - s154465...
  • Page 38 Reservdelsförteckning - - Spare parts list - - Ersatzteilverzeichnis - - Liste de pècees détachèes Component designation Item Orderingno. Denomination Remarks in the circuit diagram 147 639- -880 Straightener 156 449--001 Clamp Screw M10x100 Washer D22/10.5x2 2155 036--01 Insulating sleeve 156 530--001 Clamp half 2129 000--01...
  • Page 39 Reservdelsförteckning - - Spare parts list - - Ersatzteilverzeichnis - - Liste de pècees détachèes - - 39 - - s147639...
  • Page 40 Reservdelsförteckning - - Spare parts list - - Ersatzteilverzeichnis - - Liste de pècees détachèes Component designation Item Orderingno. Denomination Remarks in the circuit diagram 0304 653- -85 Connector A6 TGD1 145 226--001 Insulating sleeve 190 680--313 O--ring OR 15.3x2.4 190 680--303 O--ring OR 5.3x2.4...
  • Page 41 Reservdelsförteckning - - Spare parts list - - Ersatzteilverzeichnis - - Liste de pècees détachèes - - 41 - - s0304653...
  • Page 42 Reservdelsförteckning - - Spare parts list - - Ersatzteilverzeichnis - - Liste de pècees détachèes Component designation Item Orderingno. Denomination Remarks in the circuit diagram 332 565- -880 Fine wire straightener for Optional equipment (A6TFD1/ TGD1) single wire 332 604--001 Housing (casing) 332 619--001 Roller...
  • Page 43 Reservdelsförteckning - - Spare parts list - - Ersatzteilverzeichnis - - Liste de pècees détachèes - - 43 - - s332565...
  • Page 44 Component designation Item Orderingno. Denomination Remarks in the circuit diagram 145 787- -880 Fine wire straightener for Optional equipment (A6 TFD1) twin wire Optional equipment (A6 SFD1) 145 788--001 Case 145 789--001 Roller 145 790--001 Roller 145 791--001 Searing bushing...
  • Page 45 Reservdelsförteckning - - Spare parts list - - Ersatzteilverzeichnis - - Liste de pècees détachèes - - 45 - - s145787...
  • Page 46 Item Orderingno. Denomination Remarks in the circuit diagram 334 289- -880 Contact equipment single Optional equipment (A6 SFD2) wire Optional equipment (A6 TFD1) 156 907--001 Cartridge 154 381--001 Contact tube 332 948--001 Flux tube 333 094--880 Clamp 334 278--880 Guide insert...
  • Page 47 Reservdelsförteckning - - Spare parts list - - Ersatzteilverzeichnis - - Liste de pècees détachèes - - 47 - - s334289...
  • Page 48 Component designation Item Orderingno. Denomination Remarks in the circuit diagram 334 290- -880 Contact equipment single Optional equipment (A6 TFD1) wire 417 959--880 Contact equipment L=220 153 299--880 Flux nozzle 334 290- -881 Contact equipment single Optional equipment (A6 TFD1)
  • Page 49 Reservdelsförteckning - - Spare parts list - - Ersatzteilverzeichnis - - Liste de pècees détachèes - - 49 - - s334290...
  • Page 50 Component designation Item Orderingno. Denomination Remarks in the circuit diagram 334 291- -880 Contact equipment Twin-arc, Optional equipment (A6 TFD1) with nozzle holder 333 852--880 Contact device 2185 245--80 Thrust roller 145 787--880 Fine wire straightener 153 299--880 Flux nozzle...
  • Page 51 Reservdelsförteckning - - Spare parts list - - Ersatzteilverzeichnis - - Liste de pècees détachèes - - 51 - - s334291a...
  • Page 52 334 291- -882 Contact equipment Twin- -arc, Optional equipment (A6 SFD1) with contact jaw Optional equipment (A6 SFD2) Optional equipment (A6 TFD1) 417 959--880 Contact equipment L = 220 2185 245--80 Thrust roller 145 787--880 Fine wire straightener...
  • Page 53 Reservdelsförteckning - - Spare parts list - - Ersatzteilverzeichnis - - Liste de pècees détachèes - - 53 - - s334291b...
  • Page 54 Orderingno. Denomination Remarks in the circuit diagram 153 143- -880 Guide lamp compl. Optional equipment (A6 SFD1) Optional equipment (A6 SFD2) Optional equipment (A6 TFD1/ TFD2) 153 142--880 Guide lamp 153 141--001 Holder 153 141--002 Holder 2111 029--34 Roll pin...
  • Page 55 Reservdelsförteckning - - Spare parts list - - Ersatzteilverzeichnis - - Liste de pècees détachèes - - 55 - - s153143...
  • Page 56 Remarks in the circuit diagram 153 142- - 880 Guide lamp Optional equipment (A6 SFD1) Optional equipment (A6 SFD2) Optional equipment (A6 TFD1/ TFD2) Optional equipment (A2SFD1/SGD1) Optional equipment (A2 Multitrac) 153 142- -002 Lens tube 153 142- -003 Bulb...
  • Page 57 Reservdelsförteckning - - Spare parts list - - Ersatzteilverzeichnis - - Liste de pècees détachèes - - 57 - - s153142...
  • Page 58 Component designation Item Orderingno. Denomination Remarks in the circuit diagram 153 592- -880 Add, equipment for air- -arc Optional equipment (A6 TFD1) 153 450--001 Clamp 153 449--001 Cover 147 551--002 Idling roller 154 187--001 Stub shaft 154 188--001 Screw stud...
  • Page 59 Reservdelsförteckning - - Spare parts list - - Ersatzteilverzeichnis - - Liste de pècees détachèes - - 59 - - s153592...
  • Page 60 ESAB subsidiaries and representative offices Europe NORWAY Asia/Pacific ROMANIA AS ESAB ESAB Representative Office AUSTRIA AUSTRALIA Larvik Bucharest ESAB Ges.m.b.H ESAB Australia Pty Ltd Tel: +47 33 12 10 00 Tel/Fax: +40 1 322 36 74 Vienna- -Liesing Ermington Fax: +47 33 11 52 03...

This manual is also suitable for:

A6 tfd2A6 tgd1

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