Thermal Arc 190 Fabricator Service Manual
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Thermal Arc 190 Fabricator Service Manual

Mig welding machine
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190

Service Manual

FABRICATOR
MIG WELDING MACHINE
Art # A-07329
Revision.Version No: AE.01
Operating Features:
Issue Date: June 9, 2006
190
Manual No.: 0-4878B
230
V

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  • Page 1: Service Manual

    FABRICATOR MIG WELDING MACHINE Art # A-07329 Service Manual Revision.Version No: AE.01 Issue Date: June 9, 2006 Manual No.: 0-4878B Operating Features:...
  • Page 3 WARNINGS Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment. While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use. Fabricator 190 MIG Welding Machine Service Manual Number 0-4878B for: Package System Part Number W1001500 Power Source Part Number 707209...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS ............1-1 1.01 Arc Welding Hazards ..................1-1 1.02 Principal Safety Standards ................1-4 1.03 Precautions De Securite En Soudage A L’arc ..........1-5 1.04 Dangers relatifs au soudage à l’arc ..............1-5 1.05 Principales Normes De Securite ..............
  • Page 5 TABLE OF CONTENTS (continued) TABLE OF CONTENTS SECTION 4: OPERATION ................... 4-1 4.01 Inside Panel ....................4-1 4.02 Power Supply Front Panel ................4-2 4.03 TWECO Weldskill MIG Gun ................4-5 4.04 Gun Consumable Parts ................... 4-5 4.05 Installing A New Wire Conduit Liner ............... 4-6 4.06 MIG Gun Maintenance ..................
  • Page 6 TABLE OF CONTENTS SECTION 8: CIRCUIT OPERATION ................8-1 8.01 Circuit Operation Of The Control PCB 7977964 ..........8-1 SECTION 9: PARTS LIST ..................9-1 9.01 Equipment Identification ................. 9-1 9.02 How To Use This Parts List ................9-1 9.03 External Replacement Parts (1) ..............9-2 9.04 External Replacement Parts (2) ..............

  • Page 7: Safety Instructions And Warnings

    FABRICATOR 190 WELDING MACHINE SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
  • Page 8 FABRICATOR 190 WELDING MACHINE 3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc. WARNING 4. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection. WELDING can cause fire or explosion.
  • Page 9 FABRICATOR 190 WELDING MACHINE 2. If used in a closed area, vent engine exhaust outside and away from any building air intakes. WARNING WARNING FLYING SPARKS AND HOT METAL can cause injury. Chipping and grinding cause flying metal. As welds cool, they can throw off slag.

  • Page 10: Principal Safety Standards

    FABRICATOR 190 WELDING MACHINE 1.02 Principal Safety Standards Safety in Welding and Cutting, ANSI Standard Z49.1, from American WARNING Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126. Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent STEAM AND PRESSURIZED HOT COOLANT can burn of Documents, U.S.

  • Page 11: Precautions De Securite En Soudage A L'arc

    FABRICATOR 190 WELDING MACHINE 1.03 Precautions De Securite En Soudage A L’arc MISE EN GARDE LE SOUDAGE A L’ARC EST DANGEREUX PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES ENFANTS S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT CONSULTE UN MEDECIN). CONSERVEZ CES INSTRUCTIONS.
  • Page 12 FABRICATOR 190 WELDING MACHINE AVERTISSEMENT AVERTISSEMENT LES VAPEURS ET LES FUMEES SONT DANGEREUSES LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUX POUR LA SANTE. ET LA PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE. Le soudage dégage des vapeurs et des fumées L’arc de soudage produit une chaleur et des rayons dangereuses à...
  • Page 13 FABRICATOR 190 WELDING MACHINE 7. Ne soudez des tôles galvanisées ou plaquées au plomb ou au cadmium que si les zones à souder ont été grattées à fond, que si AVERTISSEMENT l’espace est bien ventilé; si nécessaire portez un respirateur à ad- duction d’air.

  • Page 14: Principales Normes De Securite

    FABRICATOR 190 WELDING MACHINE Les accumulateurs contiennent de l’électrolyte acide et 1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien ventilées. dégagent des vapeurs explosives. 2. Si vous utilisez ces équipements dans un endroit confiné, les 1. Portez toujours un écran facial en travaillant sur un accumu-lateur. fumées d’échappement doivent être envoyées à...

  • Page 15: Introduction

    Include the Service Manual number and equipment identification numbers. Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format by going to the Thermal Arc web site listed below and clicking on the Literature link: http://www.thermalarc.com June 9, 2006...

  • Page 16: Symbol Chart

    FABRICATOR 190 WELDING MACHINE 2.03 Symbol Chart Note that only some of these symbols will appear on your model. Wire Feed Function Single Phase Wire Feed Towards Workpiece With Three Phase Output Voltage Off. Three Phase Static Frequency Converter- Welding Gun Dangerous Voltage Transformer-Rectifier Purging Of Gas...

  • Page 17: General Information

    FABRICATOR 190 WELDING MACHINE 2.04 General Information 2.06 Protective Filter Lenses The Fabricator 190 is a semiautomatic Gas Metal Arc Protective filter lenses are provided to reduce the intensity Welder (GMAW/FCAW-commonly MIG) with an integrated of radiation entering the eye thus filtering out harmful wire feed unit.

  • Page 18: User Responsibility

    This equipment or any of its parts should not be altered from standard specification without prior written approval of Thermal Arc. The purchaser of this equipment shall have the sole responsibility for any malfunction which results from improper use or unauthorized modification...

  • Page 19: Power Supply Specifications

    FABRICATOR 190 WELDING MACHINE 2.13 Power Supply Specifications Package System Part Number W1001500 Power Source Part Number 707209 Power Source Weight 128lb (58kg) Power Source Dimensions HxWxD 33 x 16.3 x 34.7” (including wheels and cylinder carrier) (838 x 414 x 866mm) Number of Phases 1∅...

  • Page 20: Wire Drive Specifications

    FABRICATOR 190 WELDING MACHINE 2.14 Wire Drive Specifications Wire Drive Specifications Control Circuit Supply 30VA @ 24VAC Wire Drive Motor Supply 40VA @ 2 to 24VDC (Intermittent Duty) Wire Speed Range 80 to 700 IPM (2 to 18 m/min) Wire Diameters .023”...

  • Page 21: Installation

    FABRICATOR 190 WELDING MACHINE SECTION 3: INSTALLATION 3.02 Location 3.01 Environment Be sure to locate the Power Supply according to the The Fabricator 190 is NOT designed for use in following guidelines: environments with increased hazard of electric shock. In areas, free from moisture and dust. Examples of environments with increased hazard of electric shock are: In areas, free from oil, steam and corrosive gases.

  • Page 22: Mains Supply Voltage Requirements

    Install a power outlet for each Power Supply and fit fuses as per the machine specifications. WARNING Thermal Arc advises that your Fabricator be electrically connected by a qualified electrical trades-person. The Fabricator 190 Power Supply is factory connected for the following input power supply voltage:...

  • Page 23: Quick Set Up

    FABRICATOR 190 WELDING MACHINE 3.05 Quick Set Up 4. Fix the cable stowage hook to the Power Supply cylinder bracket with the bolts provided. 5. Fit the gas Regulator/Flowmeter to the gas cylinder CAUTION and connect the gas hose from the rear of the Power Supply to the Flowmeter outlet.

  • Page 24: Installation Of Shielding Gas (Gmaw) Process

    FABRICATOR 190 WELDING MACHINE 3.06 Installation of Shielding Gas Adjusting Regulator (GMAW) Process Adjust control knob of regulator to the required flow rate, indicated on gauge dial. (Refer to Figure 3-1 and data charts Refer to Figure 3-2. Approx. 20 CFH. NOTE The gas flow rate should be adequate to cover the weld zone to stop weld porosity.
  • Page 25 FABRICATOR 190 WELDING MACHINE Shielding Regulator and “Cracking” Flow Meter Shielding Shielding Shielding Art # A-07401 Gas Hose Figure 3-2: Gas Cylinder Installation June 9, 2006...

  • Page 26: Attaching The Gun And Cable Assembly To The Power Source

    FABRICATOR 190 WELDING MACHINE 3.07 Attaching the Gun and Cable Assembly to the Power Source The Fabricator 190 is supplied with a Tweco Weldskill gun 190 10217 air-cooled torch. The Weldskill gun is designed with an ergonomic handle and fewer parts to cause performance problems.
  • Page 27 FABRICATOR 190 WELDING MACHINE Art # A-07339 Front Panel Access Hole Trigger Receptacle Figure 3-4: Route Gun Cable Through Access Hole and Connect Trigger Loosen Thumbscrew Art: A-07601 Tighten Thumbscrew Figure 3-5: Mount Gun Cable to Adapter Socket June 9, 2006...

  • Page 28: Feedrolls

    FABRICATOR 190 WELDING MACHINE 3.08 Feedrolls A feedroll consists of two different sized grooves. As delivered from the factory, the feedroll is installed for .023” (0.6mm). When the feedroll is installed, the visibly marked size refers to the groove which will be in use. The groove closest to the motor is the one to thread the wire through.

  • Page 29: Installing Wire Spool

    FABRICATOR 190 WELDING MACHINE 3.09 Installing Wire Spool Installation of 8” (203mm) spool 1. Remove the spool retaining pin (6) from spool hub (7). 2. Fit the spool (5) onto the spool hub (7). 3. Ensure that the drive pin engages the mating hole in the spool. 4.

  • Page 30: Inserting Wire Into The Feedhead And Welding Gun

    FABRICATOR 190 WELDING MACHINE CAUTION 3.10 Inserting Wire into the Feedhead and Welding Gun Use care in handling the spooled wire as it will tend to “unravel” when loosened from the spool. Grasp the end of the wire firmly, and WARNING don’t let go of it.
  • Page 31 FABRICATOR 190 WELDING MACHINE Art # A-07568 Feedroll kit consists of idler roll and drive roll Figure 3-9: Opening Pressure Arm and Inserting Wire Art # A-07570 Wire Threaded Through Feedroll Figure 3-10: Wire Installed June 9, 2006 3-11...

  • Page 32: Polarity Changeover

    FABRICATOR 190 WELDING MACHINE 3.11 Polarity Changeover WARNING ELECTRIC SHOCK CAN KILL! Make certain the machine is unplugged from the power receptacle. Do not plug machine in until told to do so in these instructions As delivered from the factory, the output polarity is connected for DCEP (reverse polarity). CABLE CONNECTIONS PROCESS POLARITY...
  • Page 33 FABRICATOR 190 WELDING MACHINE Art # A-07571 Terminal Knob Figure 3-11: Remove Terminal Knobs Art # A-07340 DCEN DCEP Polarity Polarity Terminal Terminal Terminal Polarity Cable Connect the work cable to the vacant terminal Figure 3-12: Terminal Polarity Setting June 9, 2006 3-13...
  • Page 34 FABRICATOR 190 WELDING MACHINE 3-14 June 9, 2006...

  • Page 35: Operation

    FABRICATOR 190 WELDING MACHINE SECTION 4: OPERATION WARNING The electrode wire will be at welding voltage potential while it is being fed through the system. 4.01 Inside Panel 1. Burnback Control Knob: Burnback time is the difference between the wirefeed motor stopping and switching off of the welding current.

  • Page 36: Power Supply Front Panel

    FABRICATOR 190 WELDING MACHINE 4.02 Power Supply Front Panel Weldskill Art # A-07476 Figure 4-2: Fabricator 190 Front Panel June 9, 2006...
  • Page 37 FABRICATOR 190 WELDING MACHINE 1. Handle Bar 7. Output Voltage Control Switch: The Output Voltage Control Switch sets the voltage level to the welding 2. Thermal Overload Indicator: The critical component terminals. The output voltage is increased when the for thermal protection are the rectifier stack and the switch is rotated in the clockwise direction.
  • Page 38 FABRICATOR 190 WELDING MACHINE 13.Torch Trigger Receptacle (continued) Socket Pin Function Gun Switch Gun Switch (contact closure provided between pins A and B to energize the contactor). Not Used Not Used Figure 4-3: Torch Trigger Receptacle Pin-out June 9, 2006...

  • Page 39: Tweco Weldskill Mig Gun

    Contact your Thermal Arc distributor to order TWECO replacement parts, options and accessories. For assistance in locating a Thermal Arc distributor, contact the Thermadyne office listed in the inside rear cover that is nearest to you. 4.04 Gun Consumable Parts Refer to the appendix section of this manual for the list of consumable items, including nozzels, contact tips, gas diffusers and conductor tubes.

  • Page 40: Installing A New Wire Conduit Liner

    FABRICATOR 190 WELDING MACHINE 4.05 Installing A New Wire Conduit Liner Allen screw in the connector plug must be securely tightened onto the conduit to prevent its backward Removal movement. 1. Be sure the MIG gun cable is arranged in a straight NOTE line, free from twists, when installing or removing a When the conduit is fully inserted into the cable...

  • Page 41: Mig Gun Maintenance

    FABRICATOR 190 WELDING MACHINE 4.06 MIG Gun Maintenance 4.07 Basic Welding Technique Remove dust and metallic particles from the gun conduit Setting of the Power Supply by forcing clean, dry compressed air into the conduit once The setting of the Fabricator requires some practice by a week.
  • Page 42 FABRICATOR 190 WELDING MACHINE Distance from the MIG Gun Nozzle to the Work Piece The electrode stick out from the MIG gun nozzle should be between 5/64”(2.0mm) to 13/64”(5.0mm). This distance may vary depending on the type of joint that is being welded. Solid Wire Flux Cored Wire Art # A-07186...

  • Page 43: Technical Tips

    FABRICATOR 190 WELDING MACHINE 4.08 Technical Tips Reduce Porosity in the Weld Metal • Weld in still air to ensure gas coverage • Clean the dirty, oil, paint, oxidization or grease from the metal to be welded • Eliminate any gas leaks in the hose •...

  • Page 44: Spot Welding Operation

    FABRICATOR 190 WELDING MACHINE 4.09 Spot Welding Operation Fit an optional spot welding nozzle to the MIG gun for consistent spot welding operations. Refer to Figure 4-8 and the Spot Welding Nozzles table below. The Fabricator will operate effectively using .030” (0.8mm) electrode wire when spot welding.

  • Page 45: Gas Selection For Gas Metal Arc Welding

    FABRICATOR 190 WELDING MACHINE 4.10 Gas Selection for Gas Metal Arc Welding Filler Base Plate Transfer Suggested Welding Metal Type Comments Metal Thickness Mode Shielding Gas Positions Carbon Greater than ER70S-X Short 100% CO All Position High welding speeds. Good Steel 22 gauge Circuit...

  • Page 46: Welding Setting Selection Guide

    FABRICATOR 190 WELDING MACHINE 4.11 Welding Setting Selection Guide Material T ype Wire T ype Shielding Gas Wire Size and Flow Rate (Diameter) Art # A-07448 .023” (0.6mm) 100% CO .030” (0.8mm) 25cfh .035” (0.9mm) .023” (0.6mm) Solid 75% Ar (or hard) Steel .030”...
  • Page 47 FABRICATOR 190 WELDING MACHINE Voltage THICKNESS Step Wire Speed 22 ga. (0.8mm) 20 ga. (0.9mm) 18 ga. (1.2mm) 16 ga. (1.6mm) 1/8” (3.2mm) 3/16” (5.0mm) 1/4” (6.4mm) 5/16” (8.0mm) 2.25 2.75 2.25 2.75 3.25 3.75 4.75 1.25 2.75 4.25 4.75 3.25 6.25 6.25...
  • Page 48 FABRICATOR 190 WELDING MACHINE NOTES 4-14 June 9, 2006...

  • Page 49: Maintenance

    FABRICATOR 190 WELDING MACHINE SECTION 5: MAINTENANCE To clean the Power Supply, disconnect it from the mains 5.01 Routine Maintenance & Inspection supply voltage then open the enclosure and use a vacuum cleaner to remove any accumulated dirt and dust. The The only routine maintenance required for the Fabricator Power Supply should also be wiped clean.
  • Page 50 FABRICATOR 190 WELDING MACHINE Maintain more often Warning! if used under severe Disconnect input power before maintaining. conditions Each Use Visual check of torch Visual check of Consumable parts regulator and pressure Weekly Visually inspect the torch Visually inspect the Wire Visually inspect the body and consumables feed mechanisms...

  • Page 51: Troubleshooting

    If major components are faulty, then the Power Supply a. Ensure that the gas holes are not blocked and should be returned to an Accredited Thermal Arc Service gas is exiting out of the torch nozzle. Refer to Agent for repair.
  • Page 52 FABRICATOR 190 WELDING MACHINE 4. Misalignment of inlet/outlet guides. a. Wire will rub against the misaligned guides and reduces wire feedability. 5. Liner blocked with slag. a. Slag is produced by the wire passing through the feed roll, if excessive pressure is applied to the pressure adjustment device.

  • Page 53: Welding Problems

    FABRICATOR 190 WELDING MACHINE 6.03 Welding Problems FAULT CAUSE REMEDY A. Undercut 1. Welding arc voltage a. Reduce voltage by reducing the output too high. voltage control switch position or increase the wire speed. 2. Incorrect torch angle a. Adjust angle (Refer to Section 4.07) 3.
  • Page 54 6. Weld speed too fast a. Reduce weld speed. G. Cold weld puddle. 1. Faulty rectifier unit a. Have an Accredited THERMAL ARC Service Agent to test then replace the faulty component. 2. Loose welding cable a. Check all welding cable connections.

  • Page 55: Power Supply Problems

    Gun when the gun trigger switch is (burn-back jam) Replace faulty component(s). depressed. 2. Faulty control PCB or Tweco Have an Accredited Thermal Arc Service Agent investigate the fault. F. Wire feeds when the gun trigger switch 1. Poor or no work lead...

  • Page 56: Wire Feeder Problems

    Turn on. Replace cylinder. 8 Gas flow continues after Gas valve has jammed open Have an Accredited Thermal Arc the torch trigger switch due to impurities in the gas Service Agent repair or replace has been released.

  • Page 57: Advanced Troubleshooting

    FABRICATOR 190 WELDING MACHINE SECTION 7: ADVANCED TROUBLESHOOTING If the problem cannot be solved by the basic (external) The secondary winding of T1 is connected to the Rectifier trouble shooting guide, the Power Source covers and/or Assembly (BR1). The BR1 rectifier converts the AC voltage the Wire Feeder covers will have to be removed.

  • Page 58: Pre-Power Up Checks

    FABRICATOR 190 WELDING MACHINE 7.04 Pre-Power Up Checks 7.05 Initial Setup Conditions 1. Set the power supply controls and connect cables as Visually Inspect follows: Visually inspect the inside the Power Source. The levels of current present in these units can cause burning or ON/OFF Switch to OFF Position arcing of PCB, transformers, switches, rectifier or MODE SELECTOR SWITCH to CONTINUOUS...

  • Page 59: Logic And Control Tests

    FABRICATOR 190 WELDING MACHINE 7.07 Logic And Control Tests 10. Depress Gun Switch Gas flows 1. Depress Gun Switch and observe the following Contactor energizes Gas flows Drive roll turns Contactor energizes After 4.5 seconds Drive Roll Turns Gas flow stops 2.

  • Page 60: Output Voltage Test

    FABRICATOR 190 WELDING MACHINE 7.08 Output Voltage Test 7.09 Wire Feed Test 1. Set MODE SELECTOR SWITCH to CONTINUOUS 1. Close the PRESSURE ADJUST DEVICE. Connect the position. GUN POLARITY LEAD to the POSITIVE WELDING TERMINAL (+). 2. Connect voltmeter probes to + and - Output Terminals 2.

  • Page 61: Primary Power Problems

    FABRICATOR 190 WELDING MACHINE 7.10 Primary Power Problems 7.11 Logic and Control Problems A. Green Indicator in ON/OFF Switch is not A. Nothing happens when gun switch is depressed; illuminated and fan does not turn when ON/OFF No gas flow, contactor does not energize, feed roll switch is in the ON position.

  • Page 62: Output Voltage Problem

    FABRICATOR 190 WELDING MACHINE 6. Open wires between Control PCB and Contactor 4. Defective Rectifier assembly coil a. Check per the rectifier assembly test procedure a. Measure between orange wire (#21A) to white on page 7-8. wire (#22A) at the Contactor for approximately 5.

  • Page 63: Test Procedures

    FABRICATOR 190 WELDING MACHINE 7.14 Test Procedures OUTPUT VOLTAGE CONTROL SWITCH The switch will apply 230VAC line voltage to different input taps to the Main Transformer. With gun switch closed, check for 230 VAC between terminal T2 on the contactor to each of the following terminal points on the switch: OUTPUT VOLTAGE CONTROL SWITCH position # To Switch terminal #...
  • Page 64 FABRICATOR 190 WELDING MACHINE RECTIFIER ASSEMBLY TEST Disconnect one of the Main Transformer connections from the rectifier assembly. Disconnect JB connector from Control PCB. Using a meter check for a forward biased diode between the following points: Art # A-07567 1 2 3 4 Figure 7.1: Rectifier Test Points Positive meter probe on NEGATIVE WELDING TERMINAL (-) to Plates #2 and 3...

  • Page 65: Circuit Operation

    FABRICATOR 190 WELDING MACHINE SECTION 8: CIRCUIT OPERATION 8.01 Circuit Operation Of The Control PCB 7977964 Power Supply 24VAC is taken from the auxiliary wiring of the fan. This voltage is then connected to the PCB 7977964 where it is half wave rectified and filtered.
  • Page 66 FABRICATOR 190 WELDING MACHINE CONNECTOR JB CONNECTOR JB Terminal JB-1 Torch circuit jumper installed wiper of wire speed control potentiometer, varies between <2V to approximately 4.7VDC (pot wiper) reference JA-5 or JB-5 Terminal JB-2 wire speed control potentiometer minimum (pot low) approximately 2VDC reference JA-5 Terminal...

  • Page 67: Parts List

    FABRICATOR 190 WELDING MACHINE SECTION 9: PARTS LIST 9.01 Equipment Identification All identification numbers as described in the Introduction chapter must be furnished when ordering parts or making inquiries. This information is usually found on the nameplate attached to the equipment. Be sure to include any dash numbers following the Part or Assembly numbers.

  • Page 68: External Replacement Parts (1)

    FABRICATOR 190 WELDING MACHINE 9.03 External Replacement Parts (1) ITEM ITEM ITEM ITEM ITEM P P P P P AR ART NUMBER T NUMBER T NUMBER T NUMBER T NUMBER DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION REF. DES . DES . DES .
  • Page 69 FABRICATOR 190 WELDING MACHINE 18 (inside cover) Art # A-07522 June 9, 2006...

  • Page 70: External Replacement Parts (2)

    FABRICATOR 190 WELDING MACHINE 9.04 External Replacement Parts (2) ITEM ITEM ITEM ITEM ITEM P P P P P AR ART NUMBER T NUMBER T NUMBER T NUMBER T NUMBER DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION 401840-004 Cable, Power Cable, Fab190/210 707206PKD Gas Hose,5/8"BSP,Fabricators See Note 1...
  • Page 71 FABRICATOR 190 WELDING MACHINE 9.05 Internal Replacement Parts-Wire Spool Assembly ITEM ITEM ITEM ITEM ITEM P P P P P AR ART NUMBER T NUMBER T NUMBER T NUMBER T NUMBER DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION REF. DES . DES .
  • Page 72 FABRICATOR 190 WELDING MACHINE 9.06 Internal Replacement Parts-Wire Feeder ITEM ITEM ITEM ITEM ITEM P P P P P AR ART NUMBER T NUMBER T NUMBER T NUMBER T NUMBER DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION REF. DES . DES . DES .

  • Page 73: Electrical Components (1)

    FABRICATOR 190 WELDING MACHINE 9.07 Electrical Components (1) ITEM ITEM ITEM ITEM ITEM P P P P P AR ART NUMBER T NUMBER T NUMBER T NUMBER T NUMBER DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION REF. DES . DES . DES .

  • Page 74: Electrical Components (2)

    FABRICATOR 190 WELDING MACHINE 9.08 Electrical Components (2) ITEM ITEM ITEM ITEM ITEM P P P P P AR ART NUMBER T NUMBER T NUMBER T NUMBER T NUMBER DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION REF. DES . DES . DES .

  • Page 75: Wheel Axle And Body Panels

    FABRICATOR 190 WELDING MACHINE 9.09 Wheel Axle and Body Panels ITEM ITEM ITEM ITEM ITEM P P P P P AR ART NUMBER T NUMBER T NUMBER T NUMBER T NUMBER DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION 707239PKD Panel, Cover RH, Fab190 707217WBLKPKD Bracket,Cylinder,Fab190 707207WBLKPKD Panel,Internal,Fab190 707187CLAPKD...
  • Page 76 FABRICATOR 190 WELDING MACHINE June 9, 2006 9-10...

  • Page 77: Appendix 1: Options And Accessories

    FABRICATOR 190 WELDING MACHINE APPENDIX 1: OPTIONS AND ACCESSORIES • Contact your Thermal Arc distributor to order options and accessories. For assistance in locating a Thermal Arc distributor, contact the Thermadyne office listed in the inside rear cover that is nearest to you.

  • Page 78: Appendix 2: Options And Accessories (Con't)

    FABRICATOR 190 WELDING MACHINE APPENDIX 2: OPTIONS AND ACCESSORIES (CON'T) SPOT WELDING NOZZLES TYPE NO. 3 NO.5 500 AMP MINI & NO. 1 NO. 2 250 NO.4 400 150 AMP Flat Arc Spot 21-62-FAS 22-62-FAS 23-75-FAS 24A-62-FAS 25CT-125-FAS 1210-1520 1220-1520 1230-1530 1240-1520 1250-1560...
  • Page 79 FABRICATOR 190 WELDING MACHINE PAGE LEFT INTENTIONALLY BLANK June 9, 2006...

  • Page 80: Appendix 3: Power Supply Circuit Diagram

    FABRICATOR 190 WELDING MACHINE APPENDIX 3: POWER SUPPLY CIRCUIT DIAGRAM 18A(BRN) 18A(BRN) 24(VIO) 24(VIO) Terminal block Terminal block 2A 2A K1\1 K1\1 L1 L1 T1 T1 23(DK BRN) 23(DK BRN) 18(BRN) 18(BRN) (12) (12) (1) (1) (2) (2) (11) (11) White L2 L2 K1\2...
  • Page 81 FABRICATOR 190 WELDING MACHINE S2 S2 POSITIVE OUTPUT (ORN) (ORN) TERMINAL T2 T2 T3 T3 T4 T4 NEGATIVE F2 F2 OUTPUT (GRY) (GRY) TERMINAL S1 S1 T1 T1 OVERLOAD OVERLOAD 27(WHT) 27(WHT) F1 F1 (WHT) (WHT) Spot Spot Torch Trigger Torch Trigger Wirespeed 1k Wirespeed 1k...

  • Page 82: Appendix 4: Main Printed Circuit Board Schematic

    FABRICATOR 190 WELDING MACHINE APPENDIX 4: MAIN PRINTED CIRCUIT BOARD SCHEMATIC 30 VAC Art # A-07520 June 9, 2006...
  • Page 83 FABRICATOR 190 WELDING MACHINE 82 BENNING SREET WEST LEBANON, NH 03784, USA DESCRIPTION: FABRICATOR MAIN PCB 7977964 Art # A-07520 June 9, 2006...

  • Page 84: Appendix 5: Volt-Amp Curves

    FABRICATOR 190 WELDING MACHINE APPENDIX 5: VOLT-AMP CURVES Switch VA Curves Art # A-07519 SW 8 SW 7 SW 6 SW 5 SW 4 SW 1 SW 2 SW 3 AMPS June 9, 2006...

  • Page 86: Limited Warranty

    No employee, agent, or representative of thermal arc is authorized to change this warranty in any way or grant any other warranty, and thermal arc shall not be bound by any such attempt.

  • Page 87: Warranty Schedule

    WARRANTY SCHEDULE This information applies to Thermal Arc products that were purchased in the USA and Canada. April 2006 ENGINE DRIVEN WELDERS ARRANTY ERIOD ABOR Scout, Raider, Explorer Original Main Power Stators and Inductors .................. 3 years 3 years Original Main Power Rectifiers, Control P.C. Boards ..............3 years...

  • Page 89: Global Customer Service Contact Information

    GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Thermadyne USA Thermadyne Asia Sdn Bhd 2800 Airport Road Lot 151, Jalan Industri 3/5A Denton, Tx 76207 USA Rawang Integrated Industrial Park - Jln Batu Arang 48000 Rawang Selangor Darul Ehsan Telephone: (940) 566-2000 West Malaysia 800-426-1888 Fax: 800-535-0557 Telephone: 603+ 6092 2988...
  • Page 90 World Headquarters Thermadyne Holdings Corporation Suite 300, 16052 Swingley Ridge Road St. Louis, MO 63017 Telephone: (636) 728-3000 Fascimile: (636) 728-3010 Email: sales@thermalarc.com www.thermalarc.com...

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