BA - 322210 - 0021 - PLII 609A For 712-En

6 Kripes Road - PO Box 260 - East Granby, CT 06026 USA
Fax: (860) 653-0486 E-Mail: info@magnatech-lp.com

Phone: (860) 653-2573 Web: www.magnatech-lp.com
Operating and Maintenance

Instruction Manual
For
Pipeliner II Model 609A

Orbital Weld Head
- Wire Feed on Floor (WFOF) version
- Wire Feed on Hand (WFOH version
- Wire Feed Push-pull (WFPP) version
For Use With

MPS 4000 Power Source & Model 712 Controller
(See Separate Manual)
Rev 01-14-2009
TABLE OF CONTENTS
SECTION TITLE PAGE
1.0 INTRODUCTION 1
1.1 Copyright Notice
2.0 PIPELINER IIC COMPONENT INVENTORY 2
2.1 Weld Head 609A

2.2 Guide Rings
2.3 Optional Installed Components/Kits
2.4 Optional Free-Standing (Unattached) Components
3.0 SAFETY INSTRUCTION AND WARNING FOR OPERATION AND ARC

WELDING EQUIPMENT 4
3.1 Important to Read

3.2 Introduction
3.3 Shock Prevention
3.4 Burn Prevention
3.5 Toxic Fume Prevention
3.6 Compressed Gas Cylinder Handling
3.7 Equipment Warning Labels
3.8 Additional Safety and Health Information
4.0 WARRANTY POLICY & SUPPORT 11
4.1 General
4.2 Support
5.0 SPECIFICATIONS 16
5.1 Pipeliner Weld Head
6.0 INSTALLATION 18
7.0 FUNCTIONAL DESCRIPTION - WELD HEAD 19
7.1 Oscillator
7.2 Arc Gap Control (Torch Proximity Control)
7.3 Tractor
7.4 Torch and Cable
7.5 Guide Ring/Flx-Track
8.0 SET-UP AND OPERATION 21
8.1 Mounting the Friction Drive Guide Ring

8.2 Install Weld Head on Guide Ring
8.3 Adjust Head for New Guide Ring Size
8.4 Check Electrical, Gas, and Water Connections
8.5 Training Outline
TABLE OF CONTENTS - CONTINUED
SECTION TITLE PAGE
9.0 USE OF WELD HEAD ON PREHEATED PIPE 28
10.0 ADAPTOR FEET KITS FOR PIPELINER GUIDE RING TO ALLOW 29

USE ON SMALLER PIPE SIZES
11.0 TORCH EXPENDABLE COMPONENTS LIST 32
11.1 For "Binzel" Torch P/N 103364-6
12.0 SUMMARY OF CAUTIONS 33
12.1 Shock Prevention

12.2 Safety and Health Precautions
12.3 Check Electrical Connections
12.4 Prevent Torch Cable Wrap-Up
12.5 Observe Torch Position Before Oscillating or "Centering" Torch
12.6 Always Stop Motors Before Reversing
12.7 Abrasive Grinding Dust Will Cause Premature Wear
12.8 Heat Damage
12.9 Exposure to Rain
12.10 Obstruction of Weld Head Rotation
13.0 WELD PROCESS DEVELOPMENT 35
14.0 ELECTRODE EXTENSION OFTEN NEGLECTED WHEN USING 43

SELF-SHIELDED CORED WIRES
15.0 PREVENTING THE EFFECTS OF MOISTURE CONTAMINATION OF 46

FLUX CORE WIRE
16.0 BILLS OF MATERIALS/DRAWINGS 48
17.0 ELECTRICAL SCHEMATICS 49

1.0 INTRODUCTION
The Pipeliner Welding System is designed for mechanized welding applications using
the high-deposition GMAW/FCAW processes for efficient joining. Circular Guide Rings
allow use for pipe-to-pipe and pipe-to-fitting butt welding. Flx-Track allows linear welding
on flat or curved workpieces (ID and OD). A simple adaptor (optional) allows use for
socket and fillet welding applications. An optional pendular torch oscillator is
recommended for fillet applications, and welding pipe with wall thicknesses over 50mm
(2”).
The weld Head is designed to be used with the Pipeliner model 712 Controller, MPS
4000 Power Source and Water Circulator.
This Weld Head is available in three versions:

• Floor mounted wire feeder
• Hand mounted wire feeder
• Push-pull system
This manual covers general operating instructions, as well as assistance in weld

procedure development.
The appropriate interconnect cables and accessories are provided.
When the equipment is first received we recommend that a quick inventory is taken of all
items using the packing list enclosed with the shipment.
ATTENTION:ALL FASTENERS ON THESE WELD HEAD MODELS ARE METRIC
1.1 COPYRIGHT NOTICE
This manual and the information contained herein is the property of Magnatech
Limited Partnership. It is proprietary and shall not be copied in whole or in part
without the prior express written permission of Magnatech Limited Partnership.
Information and instructions in this document are subject to change and

Magnatech Limited Partnership reserves the right to change specifications and
data without notice.
This documents is based on the latest design version at the time of publication.
Some deviations in actual operation, from this document, are possible depending
on the production generation of a particular machine.
Edition publication date – April 2007. Copyright 2007 by Magnatech Limited

Partnership. All rights reserved.
1
2.0 PIPELINER IIC COMPONENT INVENTORY
Each model comes equipped with the following components:
2.1 WELD HEAD 609A S/N _________________________
1Pipeliner II Weld Head Model 609A (WFOF)609AF0AWC0

Floor-mounted Feeder with Pneumatic
Mounting and Pendular Oscillation Option
1 - Weld Head - 103951-PD
1 - Torch Cable - 103090-15-PD
1 - Accessories Kit - 104017-1
1 - Dual Regulator - 38416
1 - Operation Manual - Manual
1Pipeliner II Weld Head Model 609A (WFOF)609AF0A0C0

Floor-mounted Feeder with Pneumatic
Mounting
1 - Weld Head - 103951-P
1 - Torch Cable - 103090-15-P
1Pipeliner II Weld Head Model 609, 609AGEB0CP

Pneumatic Mounting, w/Push Pull Wire
Feeder (WFPP)
1 - Weld Head - 103951-P
1 - Torch Cable - 103364-25-P
1 - Wire Drive Kit - 104022-1
1Pipeliner II Weld Head Model 609A, 609AGEB0C9

Pneumatic Mounting, 2-Roll Head-
Mounted Feeder (WFOH)
1 - Weld Head - 103951-P
1 - Torch Cable - 103364-25-P
2
1Pipeliner II Weld Head Model 609A, 609AGEBWC9
Mounted Feeder (WFOH), 25' (8m)
Torch Cable
1 - Torch Cable - 103364-25-P
1Pipeliner II Weld Head Model 609A, 609AGEC0C9

Mounted Feeder, 50' (15m)
Torch Cable, (WFOH)
1 - Weld Head - 103951-P
1 - Torch Cable - 103364-50-P
1Pipeliner II Weld Head Model 609A, 609AGECW9

Mounted Feeder, 50' (15m) Torch
Cable w/Pendular Oscillator (WFOH)
1 - Torch Cable - 103364-50-PD
2.2 GUIDE RINGS
1103040-XXXXX Guide Ring Assembly - Friction Drive

A/R103070-XXXX Adaptor Foot Set - Guide Ring Radial Extension
2.3 OPTIONAL INSTALLED COMPONENTS/KITS:
1103190-1Torch Axial Slide Assembly - MIG (For Socket Welding)
2.4 OPTIONAL FREE-STANDING (UNATTACHED) COMPONENTS:
1103408-50Extension Cable 15m (50’)
3
3.0 SAFETY INSTRUCTION AND WARNING FOR OPERATION AND ARC WELDING
EQUIPMENT
!WARNING!
Read Before Proceeding
3.1 IMPORTANT: The nature of the GMAW process creates some potential
hazards. In accordance and compliance with the international safety regulations,
the "exclamation symbol" indicates that this equipment is to be considered
"Hazardous" UNTIL an operator has been made aware of these potential
hazards by READING THIS MANUAL. The "lightening flash" symbol indicates
that there are potential electrical hazards. The display of these symbols make it
the OPERATOR'S RESPONSIBILITY TO INSURE THAT HE HAS READ
AND/OR BEEN MADE AWARE OF ALL OF THE SAFETY RELATED ITEMS
CONTAINED IN THIS MANUAL.
READ AND UNDERSTAND THESE INSTRUCTIONS BEFORE INSTALLING,

OPERATING OR SERVICING MAGNATECH EQUIPMENT OR AUXILIARY
EQUIPMENT SUPPLIED AS PART OF THE WELDING SYSTEM.
3.2 INTRODUCTION
Welding products and welding processes can cause serious injury or death, and
possible damage to other equipment if the operator does not strictly observe all
safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and
cutting. These practices must be learned through study and training before using
this equipment. Anyone not having extensive training in welding practices should
not attempt to weld.
Safe practices are outlined in the American National Standard Z49.1 entitled:
SAFETY IN WELDING AND CUTTING. This publication and other guides to
what you should learn before operating this equipment are listed later in this
section.
3.3 SHOCK PREVENTION
Bare conductors, or terminals in the output circuit, or ungrounded, electrically-live

equipment can fatally shock a person. To protect against shock, have a
competent electrician verify that the equipment is adequately grounded. Do not
make contact with terminals and parts that are electrically HOT.
The body's electrical resistance is decreased when wet, permitting dangerous
4
currents to flow through the body. Do not work in damp area without being
extremely careful. Stand on dry rubber mats or dry wood and use insulating
gloves when dampness or sweat cannot be avoided. Keep clothing dry.
3.3.1 Installation and Grounding of Electrically Powered Equipment
Electrical equipment must be installed and maintained in accordance with the

National Electrical Code, NFPA 70, and local codes. A power disconnect switch
must be located at the equipment. Check equipment nameplates for voltage and
phase requirements. If only 3-phase power is available, connect single-phase
equipment to only two wires of the 3-phase line. DO NOT CONNECT the
equipment grounding conductor (lead) to the third live wire of the 3-phase line as
this makes the equipment frame electrically HOT, which can cause fatal shock.
If a grounding lead (conductor) is part of the power supply cable, be sure to

connect it to a properly grounded switch box or building ground. If not part of the
supply cable, use a separate grounding lead (conductor). Do not remove a
ground prong from any plug. Use correct mating receptacles. Check ground for
electrical continuity before using equipment.
3.3.2 Torch and Work Cables
Inspect cables often for damage to the insulation. Replace or repair

cracked or worn cables immediately. Do not use a welding current in
excess of rated cable capacity, as the cable will overheat.
3.3.3 Power Source Output Terminals
The Fronius TPS-450 Power Source completely shields the output

terminals when the Torch and Ground Cables are connected.
3.3.4 Service and Maintenance
Shut OFF all power at the disconnect switch or line breaker before
inspecting or servicing the equipment. Unplug the input power cord. If the
equipment is wired directly to an electrical box. lock the switch OFF (or
remove line fuses) so that power cannot be turned ON accidentally.
Disconnect power to equipment if it is to be left unattended or out of
service.
3.3.5 Fuses and Circuit Breakers
Replace fuses and circuit breakers with equivalent sizes.
3.4 BURN PREVENTION
The welding arc emits high energy radiation in the infrared and ultraviolet range.
This energy penetrates lightweight clothing and is reflected from light-colored
surfaces. The arc rays can injure the eyes permanently and burn the skin, just
as in "sunburn". Never look at an electric arc without eye protection.
5
3.4.1 Protective Clothing
Wear gloves, suitable long sleeved shirts/jackets, safety shoes, welding

helmet, and other articles needed to shield the skin and to prevent injury
from arc burns. Wear ear plugs if welding overhead or in a confined
space. Wear a hard hat if others are working above you.
3.4.2 Eye and Head Protection
Protect your eyes and head by wearing a welding helmet fitted with a
double lens; use a clear lens outside and a colored, welding filter inside.
Use at least a number 10 filter. If welding over 100 amps, use a number
12 filter (or darker as appropriate).
Always lower the helmet before striking the arc. Wear safety glasses with
side shields under the helmet to protect the eyes from flying particles and
side arc flashes when the helmet is up.
Protect the eyes of other people in the area by use of opaque, non-
reflecting and nonflammable screens around your welding station. Allow
good air circulation, especially at floor level. Do not permit anyone to
view the arc unless he uses a correct hand shield, or helmet.
3.5 TOXIC FUME PREVENTION:
Breathing the fumes created during welding or cutting can cause illness or death
if adequate ventilation is not provided. Provide ventilation in accordance with
ANSI Standard Z49.1.
Some Fume Sources are:
3.5.1 Weldments
Metals containing lead, cadmium, zinc, mercury and beryllium can

produce harmful toxic fumes when welded or cut. Adequate local exhaust
ventilation must be used for the operator and persons in the area.
3.5.2 Coated Weldments
Remove coatings that emit toxic fumes when heated or use exhaust
ventilation and/or an air-supplied respirator.
3.5.3 Vessels That Have Contained Toxic Materials
Vapors from chlorinated solvents can be decomposed by the arc to form

the highly toxic gas called PHOSGENE or other damaging products. The
ultraviolet radiant energy of the arc can also decompose trichloroethylene
and perchloroethylene vapors to form PHOSGENE. Do not weld or cut
unless such containers have been thoroughly cleaned following AWS
Standard A6.0.
6
3.5.4 Welding Area
Do not weld in locations close to chlorinated vapors coming from

degreasing, cleaning or spraying operations. The heat and rays from the
arc react with the vapors to form highly toxic PHOSGENE. Work in a
confined space only if it is being adequately ventilated, and if ventilation is
not adequate, wear an air-supplied respirator (see ANSI 2.37).
3.6 COMPRESSED GAS CYLINDER HANDLING:
Follow precautions below and those outlined in CGA Standard P-1, Precautions
For Safe Handling Of Compressed Gases in Cylinders.
3.6.1 Cylinders
Handle carefully to prevent damage. Keep away from welding cables or

other electrical circuits. Use only cylinders with name of gas marked on
them; DO NOT rely on color identification. Close valves on empties and
return promptly. Secure cylinders so they cannot be knocked over. Keep
temperature below 130 degrees F.
3.6.2 Pressure Regulators
Use the correct regulator for the gas and cylinder at hand. Remove any
suspected faulty regulator and return to manufacturer's service center for
repair.
3.7 EQUIPMENT WARNING LABELS:
Inspect all precautionary labels on the equipment.
3.8 ADDITIONAL SAFETY AND HEALTH INFORMATION:
3.8.1 ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING. Order

from the American Welding Society, P. O. Box 351040, 550 N. W.
LaJeune Road, Miami, FL 33125.
3.8.2 ANSI Standard Z87.1, SAFE PRACTICE FOR OCCUPATION AND

EDUCATIONAL EYE AND FACE PROTECTION. Order from American
National Standards Institute, 1430 Broadway, New York, NY 10018.
3.8.3 ANSI Standard Z241.1, Standard for Men's Safety-Toe Footwear. Order
from same as item 2.
3.8.4 American Welding Society Standard F4.1-80, WELDING AND CUTTING

CONTAINERS WHICH HAVE HELD COMBUSTIBLES. Order same as
for Item 1.
3.8.5 OSHA Standard 29 CFR, Part 1910, Subpart Q, WELDING, CUTTING

AND BRAZING. Order from Superintendent of Documents, U.S.
7
Government Printing Office, Washington, DC 20402.
3.8.6 NFPA Standard 51B. CUTTING AND WELDING PROCESSES. Order

from the National Fire Protection Association, Batterymarch Park, Quincy,
MA 02269.
3.8.7 CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES IN

CYLINDERS. Order from the Compressed Gas Association 1235 Jeff
Davis Highway, Arlington, VA 22202.
3.8.8 CSA Standard W117.2, CODE FOR SAFETY IN WELDING AND

CUTTING. Order from Canadian Standards Association, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
8
9
10
4.0 WARRANTY POLICY & SUPPORT
4.1 General:
Magnatech warrants equipment that it manufactures to be free from defects from

material and workmanship under normal use and service for the periods defined
below. This Warranty shall apply to the Original Purchaser only, and is not
transferable. All warranty time periods start on the date that the equipment was
delivered to the original retail purchaser. Our sole obligation under this warranty
is limited to repairing or replacing the defective part or parts, which in our
judgment show evidence of such defects. All warranty repair work shall be
accomplished at the factory and Magnatech assumes no obligation to perform
warranty service at a customer's facility. If requested, Magnatech shall supply
warranty parts for customer installation, but reserves the right to request the
return of parts declared defective. This warranty is given in lieu of and to the
exclusion of any and all other warranties, express or implied. Specifically, and
without limiting the generality of the above disclaimer, Magnatech disclaims any
warranty of merchantability or fitness for any particular purpose as to any and all
goods sold to the Buyer (whether for the ultimate use of the Buyer, or any other
person) pursuant to the purchase order, contract or in connection therewith.
See Detailed Warranty Terms and Magnatech's General Terms and Conditions.
11
MAGNATECH LIMITED WARRANTY
Effective November 2008
GENERAL:
Magnatech warrants equipment that it manufactures to be free from defects from material and workmanship under normal use and service for
the periods defined below. This Warranty shall apply to the Original Purchaser only, and is not transferable. All warranty time periods start on
the date that the equipment was delivered to the original retail purchaser. Our sole obligation under this warranty is limited to repairing or
replacing the defective part or parts, which in our judgment show evidence of such defects. All warranty repair work shall be accomplished at
the factory and Magnatech assumes no obligation to perform warranty service at a customer's facility. This warranty is given in lieu of and to the
exclusion of any and all other warranties, express or implied. Specifically, and without limiting the generality of the above disclaimer, Magnatech
disclaims any warranty of merchantability or fitness for any particular purpose as to any and all goods sold to the Buyer (whether for the ultimate
use of the Buyer, or any other person) pursuant to the purchase order, contract or in connection therewith.
COVERED COMPONENTS:
A. 1 Year – Parts and Labor B. 6 months
All Magnatech Power Sources/ Controllers Switches
All Model Water Circulators (with exception of Pump)
All Weld Heads C. 3 months – Parts and Labor
Torch cable assemblies
Relays
Batteries
EXCLUDED COMPONENTS:
Magnatech Limited Warranty shall not apply to:
1. Equipment Supplied Not Manufactured By Magnatech

With respect to standard equipment supplied by Magnatech as part of a complete welding system, Magnatech extends the same warranty as
offered by the individual manufacturer of this standard equipment if any. In many instances such items are warranted directly by the
manufacturer, and Magnatech may, from time to time, inform the customers of such warranty coverage; however, Magnatech does not
guarantee the accuracy of completeness of its information regarding such warranties.
2. Expendable Items
This warranty does not cover certain items considered expendable and certain high wear items offered herein. Expendable items consist of
welding torch components, wire feed conduits, motor brushes, fuses, bulbs and filters.
3. Modification And Misuse

This warranty does not apply to products which have been modified in any way by any party other than Magnatech; nor to products which
have not been installed and operated in accordance with applicable industry standards; or to products which have been used other than
under usual conditions for which they are designed; nor to products that have not received proper care, protection and maintenance under
supervision of competent personnel.
UTILIZATION FOR INTENDED PURPOSE ONLY:

The Tubemaster, Pipemaster, and Pipeliner systems are intended to be used SOLELY for GTAW or GMAW/FCAW orbital welding applications.
Any other use is deemed to be “not for the intended purpose” and the manufacturer shall not be liable for any damage resulting there from.
Utilization for the intended purpose includes:

• observance of all instructions in the operating manual
• performance of all prescribed inspection and maintenance work
Magnatech products are intended for purchase and use by commercial/industrial users and persons trained and experienced in the use and
maintenance of welding equipment.
PERFORMANCE OF WARRANTY REPAIRS – LOCATION:

Magnatech’s obligation under this warranty shall be limited to the repair or replacement, at its option, of any goods or any components or parts
thereof sold by Magnatech to Buyer that prove to be defective upon Magnatech’s examination. Returned goods shall be delivered F.O.B.
Magnatech’s plant, East Granby, Connecticut, at Buyers risk and expense.
DISCLAIMER:
Magnatech shall not be otherwise liable for any damages including but not limited to incidental damage, consequential damage, or special
damages, whether such damages result from negligence, breach of warranty, or the result of repair and replacement activity, including, but not
limited to any losses due to downtime or loss of use. Magnatech shall not be held liable for any lost profit or other damage, delay or loss which
may result directly or indirectly from the adjustment, alteration, repair, maintenance, operation, or interruption thereof, of any said equipment.
There are no warranties of fitness for any particular purpose of said equipment or any other warranties (expressed, implied or statutory)
concerning the performance capabilities thereof. Magnatech shall not be liable for any consequential, indirect or incidental losses or damages
incurred as the result of any breach of warranty or as a result of any repair or replacement activity, including, but not limited to any losses due to
down time or loss of use. Magnatech shall not be liable for any losses, injuries or damages sounding in tort, whether for the negligence of
Magnatech or its agents, officers or employees or in a strict liability theory.
To the extent permitted by law, the remedies provided herein are the sole and exclusive remedies. In no event shall Magnatech be liable for
direct, indirect, special incidental or consequential damages (including loss of profit), whether based on contract, tort, or any legal theory.
Any express warranty not provided herein and any implied warranty guaranty or representation as to performance, and any remedy for breach of
contract tort or any other legal theory which, but for this provision might arise by implication, operation of the law, custom of trade or course of
dealing including any implied warranty of merchantability or fitness for particular purpose, with respect to any and all equipment furnished by
Magnatech is excluded and disclaimed by Magnatech.
PO Box 260, 6 Kripes Rd MAGNATECH Limited Partnership
East Granby, CT 06026 USA Orbital Welding Systems
T: (860)653-2573 for your Industrial Revolution
F: (860)653-0486
info@magnatech-lp.com
www.magnatech-lp.com
MAGNATECH PRODUCT WARRANTY REGISTRATION

Please provide the following information and mail/fax to Magnatech. This will allow us to insure correct
replacement parts are supplied, service bulletins reach the correct person, and provide a contact person for
service.
Product Name:
S/N:
Product Name:
S/N:
Product Name:
S/N:
Product Name:
S/N:
Company Name:
Company Address:
Dealer:
Date Purchased
Individual Purchasing:
Name:
Address:
Phone:
Fax:
E-Mail:
Individual to Be Contacted about Upgrades, Service Issues:

Name:
Address:
Phone:
Fax:
E-Mail:
13
Magnatech Ltd. Partnership Affix
P. O. Box 260 Postage
East Granby, CT 06026
Magnatech Limited Partnership

Attn: Sales Dept.
P. O. Box 260
East Granby, CT 06026
14
4.2 Support:
Now that you have purchased a Magnatech product, we want to confirm that we
intend to support you after the sale with the expedient service and technical
support which we strive to maintain at world-class standards.
A. Sales
U.S. Headquarters:
Tel: (860) 653-2573
Fax: (860) 653-0486
E-Mail: info@magnatech-lp.com
John Emmerson - President, Ext. 10
Ken LeDuc - Technical Specialist, Ext. 15
Bryan Kirkland - Sales Order Administration, Ext. 14
Glen Gautieri - Quoting, Ext. 37
Reta Holt - Exec. Asst., Ext. 10
Europe, Middle East, India:

Tel: +(31) 321-38-6677
Fax: +(31) 321-31-4165
E-Mail: info@magnatech-europe.com
W. Wijnholds - Cell +31 (653) 32 5818
Ralph Wijnholds - Cell +31 (653) 548891
B. Spare Parts
Bryan Kirkland - Spare Parts, Ext. 14
C. Service Support (U.S.)
Dave Richard, Vice Pres. - Chief Elect. Eng., Ext. 19

Ted Kingsley - Chief Mechanical Engineer, Ext. 24
Patrick Sweeney - Embedded Systems Eng., Ext. 36
Neil Young - Senior Weld Technician, Ext. 28
D. Welding Development Assistance/Problem Solving
Neil Young - Senior Weld Technician, Ext. 28

E. Accounting (U.S.)
Glen Gautieri - A/R, Ext. 37

John Rinaldi - A/P, Bookkeeping, Ext. 12
15
5.0 SPECIFICATIONS:
5.1 SPECIFICATIONS PIPELINER WELD HEAD
APPLICATIONS
Pipe Size: 6" pipe (168mm) and larger
Guide Rings: For 6" pipe (168mm) and larger
Wall Thickness: Wall Thickness: Unlimited
Pipe Material: All materials which can be welded with GMAW or

FCAW process.
Linear and Large Diameter Flx-Tracks available.

Applications:
FILLER WIRE MODULE
Wire Size 0.8/0.9/1.0/1.2mm (.030/.035/0.040/.045")

Other sizes available.
Speed Capability 0 - 22m/min. (0 - 722”/min.)
Spool Size 4.5 - 5 kg (10 lb) – Wire Feed on Head

or
12kg (25lb) Wire Feed on Floor and Push-Pull
OSCILLATION MODULE
Oscillation Stroke Amplitude: 51mm (2")
Oscillation Speed: 21.4cm/minute (0-100 IPM)
Oscillation Dwell: 0-1.0 second independently adjustable at either

oscillation stroke endpoint.
Cross Seam Adjustment: 51mm (2") Standard
TORCH ARC LENGTH – (VERTICAL MOTION)
Stroke: 66mm (2.6") (motorized)
Torch Advance/Retreat 152cm (60")

(Correction Speed) per minute maximum.
16
TORCH PROPULSION MODULE 0-76cm/minute (0-30 IPM)
Clutch allows rapid repositioning of weld Head.
WATER-COOLED TORCH 300 amps at 100% duty cycle.
TORCH CABLE LENGTH WFOF -4.6M (15’)

WFOH-1.5M (50’)
WFPP-8m (25’)
Extension cables available.
WELD HEAD DIMENSIONS/WEIGHT
Minimum
Axial Radial Overall
Length Clearance Width
Model A1 B2 C3 Weight
609 37.5cm 24.1cm 41.3cm 26.5 lbs

WFPP 14.75" 9.50” 16.25”
609 38.7cm 24.8cm 30.5cm 9.5 kg

WFOF 15.25” 9.75” 12” 21.5 lbs
609 66.7 cm 26.7cm 36.8cm 14.4 kg

WFOH 26.25” 10.5” 14.5” 31.75 lbs
1 Center of oscillation stroke
2 Center of vertical stroke
3 Weight without wire spool (WFOH). Includes 1.6 kg
(3.5) of Torch Cable Weight (Partial)
Guide Rings
Diameter Tolerance: For a 2 segment Guide Ring, the tolerance is +/- 6mm or (+/-
0.25”) on pipe nominal diameter. (This corresponds to 3 mm =/- 0.125” tolerance per
joint X 2.) Each joint adds 3mm (0.125”) to the OD tolerance.
Joints per Diameter:

Two joints: For Guide Rings up to 152 cm (60”)
Three Joints: For Guide Rings up to 231 cm (91”)
Four Joints: For Guide Rings up to 310 cm(122”)
Flx-Track
Minimum/maximum Radius: Workpiece ID/OD must be greater than
2.44 m (8’)
17
6.0 INSTALLATION
(Refer to Hook-Up Schematic in Section 17)
Installation of the welding system consists of locating and interconnecting the various
system components such as the welding power supply, water circulator, controller,
shield gas, work cable, weld Head and extension cables (if any).
6.1 Locate the welding power supply in the work area. Take into consideration the
torch cable length and extension cables (if any), as well as cable wrap around
the work piece.
6.2 Install and connect electrical service to the MPS-4000 Power Supply, and Model
712 according to the instructions in the separate manual provided.
6.3 For the head-mounted wire feed model, connect the torch cable to the power
source (and water/gas connections to the Controller and water cooler). For
WFOF and WFPP versions, the torch cable connects directly to the wire feeder
central connector.
6.4 Connect the Control Cable for the weld Head to the rear of the Model 712
Controller. (NOTE: This control cable is inside the Torch Cable umbilical.)
6.5 Connect the work cable (ground clamp) to the work piece.
18
7.0 FUNCTIONAL DESCRIPTION - WELD HEAD
ATTENTION: ALL FASTENERS USED ON THIS WELD HEAD ARE METRIC.

ALL MOTORS AND OTHER ELECTRICAL COMPONENTS ON THE
HEAD ARE OPERATED WITH 42V DC CURRENT OR LESS,
PREVENTING ANY SHOCK HAZARD.
The Pipeliner Weld Head consists of the following subsystems:
Oscillator
Torch Arc Gap Control Mechanism
Tractor
Torch Cable
Wire Feeder (WFOH and WFPP)
Spool Mount (WFOH only).
Guide Ring
7.1 OSCILLATOR
The Oscillation function is powered by a DC motor driven cross-slide.
The purpose of the oscillation mechanism is to provide both torch oscillation

(weave) and to provide a means of remotely adjusting the torch cross seam
position. Cross seam adjustment is 1" (25mm) with a maximum oscillation
amplitude of 2" (51mm).
Two limit switches in the oscillator prevent over-travel damage in either direction. A
rotary potentiometer mounted within the oscillator module provides positional
feedback information to servo controls located in the Controller.
7.2 ARC GAP CONTROL (TORCH PROXIMITY CONTROL)
The contact tip-to-work piece distance is manually adjustable via a "JOG" switch
on the Remote Control Pendant. The vertical correction motion is produced by a
D.C. motor driven cross-slide. Two limit switches on the cross-slides prevent
over-travel damage to the mechanism in either direction. The Arc Gap Control
stroke is 2.6" (66mm).
7.3 TRACTOR
The Tractor Assembly provides mounting for the previously described

assemblies. Propulsion is accomplished by powered rollers which drive against
two V-belts mounted on the Guide Ring (or Flx-Track Patented). The permanent
magnet gear motor is mounted on a pivoting bracket. A lever is used to pivot the
motor pinion gear out of engagement with the drive gear and acts as a clutch.
Four roller bearings directly underneath the four drive/idler rollers retain the Head
on the Guide Ring. These rollers provide a load against the underside of the
steel rim of the Guide Ring, allowing positive friction propulsion of the multi-vee
drive rollers against the mating V-grooves of the Guide Ring. To mount the Head
or to adjust the Head for a different size guide ring, see Section 8.
19
The TRAVEL DIRECTION SWITCH determines the direction of rotation of the
weld Head when welding is initiated. It should be noted that there is no
conventional "forward" direction for the Pipeliner. This switch allows bi-
directional welding - for example the use of double down or double up welding
techniques where travel direction is changed twice per pass.
7.4 TORCH AND CABLE
The water-cooled torch is rated at 300 amperes at 100% duty cycle. The torch
body is designed to accept standard Binzel torch components. All torch services
as well as the control cable for the welding Head functions are contained within
the umbilical.
7.5 GUIDE RING/FLX-TRACK
The Guide Ring serves to mount the weld Head on the pipe being welded and
forms an integral part of the propulsion system. Rotation of the weld Head
around the pipe is accomplished by a friction drive system, consisting of the
powered V-rollers driving against the two V-belts which are attached to the guide
ring surface (U.S. Patent No.)
Guide Rings consist of two identical half sections which quickly bolt together.
Guide Rings are available for all standard pipe sizes 6" (168mm) and larger.
It is possible to use a Guide Ring on pipe smaller than the size for which it is
designed. For example, using stand-off adaptors, a 12" (324mm) Guide Ring
can be practically used on pipe as small as 8" (219mm).
Flx-Track allows the Head to be mounted on either flat or curved surfaces using
various mounting systems.
ATTENTION! Flx-track is designed to be used within the following limits:
• When using magnets for mounting, ensure that magnets are clean of
metal debris before using and have maximum contact with the surface.
Be aware that magnets will permanently lose holding force if heated. A
safety cable is required to prevent unexpected release of the Flx-Track.
• When using vacuum cups for mounting, periodically clean the cups to
ensure a tight seal against the surfaces.
20
8.0 SET-UP AND OPERATION
8.1 MOUNTING THE FRICTION DRIVE GUIDE RING (P/N 103040-XXXXX)
8.1.1 Adjust the tensioning screw on the "hinge side" of the guide ring so there
is approximately ½" (13mm) space between the tab and the slot of each
rail.
8.1.2 Open the guide ring and place it over the top of the pipe with the
tensioning screw heads facing you. (Hinge at 12 o'clock position.)
8.1.3 Position the feet of the guide ring approximately 6.875" (175mm) from the
center of the weld joint.
8.1.4 On the "latch side" of the guide ring (latch at 6 o'clock position), install the
catch bar into the receiver block. (Loosen the latch side tensioning
screw, if required.)
8.1.5 Tighten the latch side tensioning screw. (Approximately 10 inch/pounds

or 1.13 N-M).
8.1.6 If the tab/slot gap is significantly different between the hinge side and
latch side of the guide ring, readjust the tensioning screws to balance the
gap.
8.1.7 If the two dovetails are not the same radius as the guide ring (see sketch
below), the tractor may hesitate or stall as the rollers cross the joint. This
can be corrected by careful use of a hammer or heavy pliers.
8.2 INSTALL WELD HEAD ON GUIDE RING
8.2.1 The Pipeliner II Head is mounted on the pipe by rotating four hardened
steel rollers under the steel edges of the circular guide ring or Flx-Track.
These are spring-loaded with an internal spring to provide the load to
firmly engage the V-rollers with the V-belt. (The rim is pinched by the
action of the steel roller and V-rollers or the Caliper Actuator.) The spring
loading of the four rollers must be released to remove the weld Head.
Two options are available to accomplish this:
A. Push-button pneumatic release (standard)

B. Manual thumb screw release
Both methods of actuation include a rotary cam function. As the spring

load is reduced to zero, the rollers are simultaneously pivoted outward
from under the steel rim, allowing the Head to be removed.
WARNING!! Never disassemble this spring-loaded actuators without obtaining

factory instructions. Serious injury to face, eyes and upper
body could result. If the spring is accidentally freed,
consult factory for directions. Wear Eye Protection!
21
8.2.2 Using the Pneumatic Push Button Release Option
The four thumb screws can be replaced with four miniature pneumatic
cylinders (factory installation only). A push-button valve mounted on the
Head pressurizes all four cylinders which cause all four rollers to
simultaneously move downward and outward, allowing the Head to be
installed or removed.
Attention! Keep your finger on the valve until the Head is in place on the
Ring/Track or fully removed.
Caution! Keep fingers away from the roller until pushbutton valve
released to avoid injury.
The pneumatic option requires 11 - 12 BAR (250 psi) pressure only

during actuation of the pneumatic cylinders to release or install the Head.
No pressure is required once mounted or removed.
Note: The pressure can be supplied from an external source. A separate

pressure hose is included in the torch cable umbilical. We recommend,
however, that a special gas regulator be purchased which provides this
pressure from the same gas bottle used for torch purge gas. This
provides a preset pressure at a fitting to which the pneumatic hose is
attached. A secondary pressure regulator/flow meter provide standard
control of torch shielding gas.
American Bottle Threading - Order P/N 34816

For European or other bottle threading, contact the local Harris regulator
distributors to obtain the adaptor which is threaded into the valve body.
8.2.3 Using the Manual Thumb Screws
To install the Head, rotate all four thumb screws (at the top of each
caliper actuator) clockwise (CW) until they stop turning. This will cause
all four rollers to move downward from the under space of the weld Head,
and outward away from the side of the Head.
To mount the Head, place it on the Guide Ring or Track, ensuring that all
four V-rollers are lined up in the V-belt grooves. Holding the Head in
place with one hand, turn the four screws CCW until no further force is felt
on the screw.
Recommendation! Engage one of the rollers on either side of the

Ring/Track first to prevent accidentally allowing the Head to fall.
Attention! When mounted, all four rollers should be fully underneath the
steel strip: if not, repeat the mounting procedure above. (Proper location
of limit pins in the pivoting caliper assembly is necessary. See Section
8.2.4.)
22
8.2.4 Using Limit Pins to Limit Pivoting/Swiveling Range of Caliper Assemblies
When placing the Head on the Guide Ring/Track, gravity may cause the
assemblies to pivot so as not to be 90° to the V-belt and will require that
the assembly be positioned manually using the limit pins to minimize this
and simplify installation. The pins are unscrewed by finger and installed
in the proper threaded hole location for a specific range or pipe OD sizes,
for flat seam welding applications, and for ID tank welding applications.
See following Chart and Sketch.
8.2.5 Remove Tractor Adaptors on ID Welding Applications
The weld Head is equipped with an adaptor to properly position all four
rollers on various pipe diameters. These are used, or are left in place for
all pipe OD’s and flat track applications, but must be removed for ID
welding.
8.3 ADJUST HEAD FOR NEW GUIDE RING SIZE
8.3.1 If necessary, change location of limit pins (see Section 8.2).
8.3.2 If necessary, install or remove adaptors (see Section 8.2).
8.4 CHECK ELECTRICAL, GAS, AND WATER CONNECTIONS
Check the electrical power, control, and ground connections to be sure they are
correct and tightly mated. Turn on the welding power supply, controller, and
water circulator. Check for water leaks. Open the valve on the shield gas bottle
and check for leaks.
8.5 TRAINING OUTLINE - PIPELINER IIC
8.5.1 HOOK UP
8.5.1.1 Unpack unit from shipping container or skid
8.5.1.2 Inspect for damage.
8.5.1.3 Inventory all parts and accessories from packing list.
8.5.1.4 Check primary input power at customer facility.
8.5.1.5 Be sure power supply is switched for proper voltage before

connecting.
8.5.1.6 Remove cooler and check or fill with Magnatech-approved

coolant. If extension cables supplied, explain possible need
for two-step filling operation.
23
24
8.5.1.7 Hook up weld Head to Controller. All connections are specific.
Emphasize do not force connection, and if difficult, probably
incorrect.
8.5.1.8 Gas In from gas supply, Gas Out to Weld Head.
8.5.1.9 Ensure water lines are correctly mated by color.
8.5.1.10 View fuses and connections.
8.5.1.11 Connect Pendant.
8.5.1.12 Following connection of Weld Head, Controller, and Power

Source, power up unit.
8.5.1.13 Check for water leaks and adjust for suitable gas flow.
8.5.1.14 For pneumatic push button option install special

regulator/flowmeter and connect pneumatic line in torch cable
to the regulator.
8.5.2 WELD HEAD SET-UP - PIPELINER IIC
8.5.2.1 Explain guide ring function.
8.5.2.2 Demonstrate guide ring installation.
8.5.2.3 Special attention to gap spacing at dovetail joint being equal, and
distance and squareness to joint to be welded.
8.5.2.4 Explain the use of adaptors for smaller pipe OD’s.
8.5.2.5 Initial weld Head set-up Pipeliner IIC
A. Install filler wire on Head. Discuss importance of

precision/level wound, clean wire.
B. Explain torch components and wire conducting, break

down to view components and change out procedures.
Demonstrate cleaning.
8.5.2.6 Weld Head Installation.
A. Install Pipeliner II on properly positioned guide ring
B. Emphasize guide ring placement and the minimized

steering required when in correct position
C. Demonstrate torch removal, maintenance and cleaning

while on pipe.
25
D. Demonstrate torch angles, i.e., lag, lead, in (towards weld
Head), out, etc. Explain usage advantages and possible
problems.
E. Demonstrate weld Head installation on the guide ring at

different positions. Demonstrate use of clutch for rapid
positioning of weld Head.
8.5.2.7 Pendant.
A. Show and explain Pendant Control layout.
B. Demonstrate each variable on the Pendant, i.e., oscillation

dwell time, travel speed, etc.
C. Stress the importance of electrode position when

oscillating to ensure sidewall fusion.
D. Explain excursion time and dwell time functions and how

these variables determine optimum travel speed.
E. Identify and demonstrate switch on weld Head controlling

rotation direction.
F. Demonstrate Use the center function on Pendant and to

correctly position torch tip for stringer beads and
oscillation.
G. Let operators operate functions on Pendant (no arc) to

become familiar with each parameter and adjustment.
8.5.3 WELDING
Note: It is recommended that the initial welding demonstration be carried

out by the instructor using developed parameters. Perform demonstration
with set-up to be used in construction, i.e. Manual Root and Hot Pass -
Fill and Cap with Orbital, use of Internal Clamp, etc. It should be
assumed that the trainees have never seen the system in operation;
therefore, they need to be shown that the equipment can and will produce
high-quality welds with minimal operator adjustments. Stress the fact that
the operators must monitor the welding and make corrections, if
necessary.
A. Make a good initial weld with pre-established parameters to

demonstrate a customer-acceptable weld.
B. On the next weld, demonstrate the effects during welding of

changing parameters such as: (I) electrode stick-out, (ii) oscillation
width, (iii) dwell and excursion time, (iv) travel speed, (v) wire
feed, (vi) arc trim, (vii) gas flow, etc.
C. Stress the importance of watching and pre-positioning of the torch
cable to avoid binding or snagging, etc.
26
D. Demonstrate proper grinding technique and transition of
start/stops.
E. Demonstrate different torch positions and possible usage.
F. Demonstrate the adjustment of pre-purge gas time and proper gas

flow range.
G. Stress importance of contact tip wear on welding performance.
H. Discuss contact tip location (flush/recessed) for different welding

modes.
I. Explain Control functions of the MPS-4000 Power Source,

including proper selection of wire diameter, wire alloy, and how
these choices select a preferred shielding gas.
J. Explain the synergic concept and that this operates in both

“Standard” and “Pulsed modes. Explain Arc Trim.
K. Explain Power Boost function (if applicable).
8.5.3.1 Operator Welding
Once the parameters for a proper weld have been established and
used successfully, the trainees should start to make welds under
Instructor supervision. Change individual parameters to an
unacceptable value and coach trainees on readjusting them until
reaching an acceptable range.
Trainees having made successful welds should graduate to using

the actual customer pipe, with the Instructor assisting in weld
development.
27
9.0 USE OF WELD HEAD ON PREHEATED PIPE.
If the Pipeliner Head and Guide Ring are to be used on preheated pipe, precautions may
be required to prevent damage for preheats of 95º C (200ºF) or lower, no special action
is required. For preheat higher (especially if preheat temp is to be over 150ºC (300ºF) it
is necessary to use an oversize Guide Ring and spacers (adaptors) to create additional
air spaces between the Guide Ring/weld Head and hot pipe surface. We recommend
using a Guide Ring which is oversized compared to the pipe OD by 10cm (4”) – using
5cm (2”) spacers (adaptors) attached to each of the square tubes of the Guide Ring.
This will increase the radial distance required for welding. We recommend that the
heating coils be wrapped with insulating material to minimize heating of the Head and
Guide Rings.
28
10.0 ADAPTOR FEET KITS FOR PIPELINER GUIDE RING TO ALLOW USE ON
SMALLER PIPE SIZES
The standard guide ring uses square aluminum tubes 25mm (1”) high which are the
component which contacts the pipe OD. There is a number of reasons and situations
why you might want to adapt this guide ring to a different size of pipe. You would do this
by attaching additional square or rectangular metal tubes on each of the square
standard tubes. We can provide an additional 25mm (1”) square tube or a 50mm (2”)
rectangular tube. In some case, however, the pipe sizes are not in even increments or
1” or 25mm or it might even be a special non-standard size. In this case, we have to use
a combination of the square or rectangular tube, and a flat metal spacer shim to
accommodate the specific pipe OD. It is not possible to use the spacers/adaptors on
only some of the square tubes. They have to be applied to each and every square tube.
(See Drawing 103040 Guide Ring Assy Friction Drive)
There is a number of reasons why someone might wish to adopt a guide ring to a
smaller size pipe. These are:
10.1 To save cost. A given guide ring can be used on pipe up to 125mm (5”) smaller
in size by using adaptors. This is a less expensive than buying additional guide
rings. This is not a good solution, however, for a customer that is changing pipe
sizes frequently as it takes some time to screw all the adaptors onto the existing
square tubes or subsequently remove them.
10.2 To allow use of a standard guide ring on a special non-standard size of pipe.
While Magnatech has the capability of engineering a guide ring for any size, we
would charge additional for that service. In most cases, the additional radial
clearance is not significant and the customer could use the next size larger
standard pipe guide ring with adaptors.
10.3 For applications where the weld Head must be used on preheated pipe. For
some pipe materials and applications, a relative high preheat temperature must
be used which may have to be maintained during the entire duration of the weld.
To avoid damage to the Head, it is beneficial to create more air space between
the weld Head and the pipe OD. This can be done with the adaptor/spacers. In
addition, sometimes this preheat is done using resistance coils which are
wrapped around the pipe. By raising the weld Head off the pipe surface, there is
enough room for these heating coils.
The reason that a universal adaptor set to cover any situation is that every size
guide ring has a varying number of the standard square tubes - the larger the
guide ring size, the greater number of tubes. There are also four distinct
situations:
! A situation where the pipe size is close enough to the standard that a
25mm adaptor for tube cannot be used and only a flat metal “shim” can
be used which must be machined to the correct height at Magnatech.
! The situation where the customer wants to weld a pipe exactly 2” smaller
(or two times 25mm) in size, in which case one additional square tube is
used.
29
! The case where the customer wants to weld a pipe that is exactly 4” (or
two times 50mm) smaller in size and will use the rectangular tube.
! The case with either the square or rectangular tube where the flat metal
shim is required because of an intermediate size.
To order adaptor kits separately, specify the following:

1. Guide Ring Size to be used.
2. Actual pipe O.D. (must be smaller)
30
31
11.0 TORCH EXPENDABLE COMPONENT LISTS
11.1 FOR "BINZEL" TORCH P/N 103364-L
(STANDARD COMPONENTS USED ON BINZEL MB-602-D TORCH)
MAGNATECH BINZEL
P/N P/N DESCRIPTION
8891 039.0008 GAS DIFFUSER

8894 145.013 NOZZLE, SMALL CONICAL - (0.61"/15/5MM DIA.)
8890 145.0088 NOZZLE, CONICAL (0.71"/18MM)
8893 145.0052 NOZZLE, CYLINDRICAL (0.87"/22MM)
CONTACT TIP COMPONENTS - STANDARD DUTY APPLICATIONS (M8)
8892 142.0023 CONTACT TIP HOLDER

8810 140.0214 CONTACT TIP .035" (0.9MM)
8812 140.0442 CONTACT TIP .045" (1.1MM/1.2MM)
M NUMBERS REFER TO THREADING (M-8 CONTACT TIPS MUST BE USED WITH

M-8 CONTACT TIP HOLDER, ETC.)
WIRE CONDUIT
MAGNATECH
P/N DESCRIPTION
101664-45-2-160 Tube, Wire guide-Outlet, 0.35”/.045” (.9mm/1.1mm) x 16” (41cm)

101664-45-1-030 Tube, Wire Guide-Inlet, .035”/.045” (.9mm/1.1mm) x 3” (8cm)
WIRE DRIVE ROLLERS

(Must Be Ordered For Specific Wire Diameters)
MAGNATECH FRONIUS
P/N P/N DESCRIPTION
80006 42.0001.1827 Wire Drive Roll 0.9mm (.035”)

80007 42.0001.1828 Wire Pressure Roll 0.9mm (.035”)
80004 42.0001.0382 Wire Drive Roll 1.2mm (.045”)
80005 42.0001.0385 Wire Pressure Roll 1.2mm (.045”)
Note 1: One Drive Roll and Three Pressure Rollers used per set.
Note 2: Drive Rolls above have U-shaped groove for hard wire and flux-core. Other
groove geometries available - consult factory.
32
12.0 SUMMARY OF CAUTIONS
12.1 SHOCK PREVENTION
Always disconnect the AC power plug before removing the panels of the
Controller to avoid electrical shock and the possibility of shorting or grounding the
electrical circuitry.
Always disconnect primary power to the power source before removing panels.
Do not remove panels from the power source until the maintenance manual has
been read and fully understood, as there may be lethal voltage present even
after the primary power is disconnected. Heed all installation instructions and
warnings given in the Power Source Manual.
WARNING NEVER operate the Pipeliner Head with the MPS Power Supply
Switch to Stick Electrode (SMAW) or GTAW modes. Open circuit
voltage will be present on the torch at all times. Touch the Torch
and a grounded workpiece will result in an electrical shock.
12.2 SAFETY AND HEALTH PRECAUTIONS
Breathing the fumes created during welding can cause illness or death. Provide
adequate ventilation in accordance with ANSI Standard Z49.1.
A MIG (GMAW/FCAW) arc emits intense infrared and ultraviolet radiation which
can cause permanent eye damage without adequate protection. We recommend
a #10 eye shield or darker. Arc radiation can penetrate light clothing and cause
sunburn. Use suitable work clothes and use a sunscreen compound on exposed
skin.
12.3 CHECK ELECTRICAL CONNECTIONS
Be sure that all external electrical connections are clean and tight. In particular,
the ground-to-work clamp must make a good electrical contact to assure
minimum voltage drop. Adhere to the power source manufacturer's grounding
recommendations. Check for gas and water leaks immediately following cable
hook-up before system is first operated.
12.4 PREVENT TORCH CABLE WRAP-UP
Do not allow the umbilical to "hawser" on the pipe while welding. Keep the
number of turns wrapped around the pipe to a minimum by pre-winding if
possible. Preventing the Head from rotating may result in damage to the tractor
motor or other mechanical assemblies. Prevent the cables from contacting a hot
or preheated pipe.
12.5. OBSERVE TORCH POSITION BEFORE OSCILLATING OR "CENTERING"

TORCH
Do not set oscillation to an amplitude which will cause the gas nozzle or torch
body to contact the work. The sudden impact of the torch against the pipe can
33
damage the oscillator mechanism. Raise the torch out of the groove before
actuating the centering control.
12.6 ALWAYS STOP MOTORS BEFORE REVERSING
Do not snap reverse motors. Switch motor to the "OFF" position before reversing
direction. Fast reversing can reduce motor power and shorten life.
12.7 ABRASIVE GRINDING DUST WILL CAUSE PREMATURE WEAR
Avoid grinding in the vicinity of the weld Head and Pendant. Grinding dust is
extremely abrasive and should not be allowed to contact weld Head and controls.
12.8 BE CAUTIOUS ABOUT HEAT DAMAGE TO HEAD
Remove the weld Head from preheated pipe when not actually welding.
12.9 DO NOT EXPOSE SYSTEM TO RAIN
Do not allow the weld Head or Pendant to be exposed to rain.
12.10 CHECK TO ENSURE THAT WELD HEAD ROTATION WILL NOT BE

OBSTRUCTED
Ensure that the rotation of the weld Head will be unobstructed by adjacent
structure, pipes, etc. If a doubt exists, jog the Head around prior to striking an
arc and carefully observe for interference.
34
13.0 WELD PROCESS DEVELOPMENT
It is not possible within the context of this operation manual to provide a comprehensive
guide to weld procedure development. Weld procedure development requires the
experience of a competent individual experienced in the GMAW or FCAW process.
It is also important to note at this point that the Pipeliner should more properly be termed
a Mechanized Pipe Welding System. The Pipeliner Pipe Welding System is not truly
automatic in that it is not adaptive. The Pipeliner System will manipulate the torch as
required to make the weld in a highly repetitive and accurate fashion. However, the
Pipeliner System cannot sense variations in such things as fit-up and bevel geometry
which would allow it to make in-process corrections. Any procedure developed must
take into account normal variations in fit-up, prep machining etc. which will always occur
"in the field". However, the more repeatable the end prep geometry and fit-up can be
made, the more repeatable will be the welding results. It is to be expected that several
trials will have to be made before a satisfactory weld procedure can be determined. A
good starting point in developing any weld procedure is to extrapolate a previously
developed program which was been done on similar material, or pipe size, and/or bevel
geometry. If a given trial weld is unsatisfactory but shows promise, repeat the weld
changing only one parameter at a time. Always develop a procedure with the goal of
making it as tolerant as possible to weldment variations.
13.1 GENERAL COMMENTS ON WELD PROCEDURE DEVELOPMENT
The ARC TRIM CONTROL may have to be adjusted when changing shielding
gas composition, cable lengths, and sometimes with change of brand of filler
material. Start out with the ARC TRIM knob in its center position, and gradually
adjust while welding until the desired arc length/stick-out is achieved. It may be
necessary to maintain a very short arc length for puddle control when welding in
the overhead position - even at the expense of a slight amount of spatter.
13.2 The Pipeliner II can be used in all modes of metal transfer - short circuit
(Standard or non-Pulsed), globular, spray, and pulsed spray. We recommend
operation in either Standard or Pulsed mode. The MPS-4000 Power Supply will
provide programmed synergic operation in both modes. Ensure that the proper
filler wire diameters and types have been selected on the power source, and that
the appropriate shielding gas is being used. Ensure that the filler wire is of the
correct alloy and designated “ALL POSITION”.
13.3 Wire speed may be increased during sidewall DWELL periods (when using
POWER BOOST function), usually in the range of 20% - 50%. Wire speed
reductions of greater than 10 per cent during DWELL may result in an unstable
arc.
13.4 WELD PROCESS TROUBLESHOOTING GUIDE
Irregular arc start. 1. Check gas valves, increase flow 20 liters/min (45-55
CFH).
2. Check ground-return circuit.
3. Check circuit to start switch.
35
Irregular wire feed, burnback. 1. Check drive roll pressure.
2. Check, adjust wire feed speed.
3. Clean or replace contact tip.
4. Check input line voltage for fluctuations.
5. Remove kinked electrode wire; replace wire spool.
6. Lubricate or replace conduit liner.
Overheating welding cables. 1. Use larger cables.

2. Check, tighten cable connections.
3. Use shorter cables.
Unstable arc. 1. Check, tighten cable connections.

2. Clean weld joint areas.
3. Change contact tip.
4. Correct contact tip-to-workpiece distance.
5. Correct ARC TRIM CONTROL setting.
6. Replace low pressure Gas cylinder. Gas mixtures may
vary at low bottle pressures.
Incomplete fusion. 1. Check joint geometry preparation.

2. Shorten arc length.
3. Clean weld joint area.
4. Reduce electrode (wire) stick-out.
5. Increase oscillation width and dwell
6. Reduce travel speed.
Dirty welds. 1. Maintain gas nozzle closer to weld puddle.

2. Increase gas flow.
3. Decrease torch angle.
4. Check torch cables for gas leaks.
5. Shield arc from drafts.
6. Check gas diffuser for damage; replace.
7. Keep unused electrode wire in sealed shipping
containers.
8. Clean weld joint area.
Arc blow. 1. Rearrange or split ground connection.

2. Demagnetize workpiece.
Excessively wide bead. 1. Reduce power.

2. Increase welding speed.
Porosity in welds. 1. Keep unused electrode wire in sealed shipping

containers.
2. Clean weld joint areas.
3. Hold gas cup closer to work.
4. Increase gas flow.
5. Decrease torch angle.
6. Check torch and cables for air, water leaks.
7. Shield arc from drafts.
8. Check gas cup for damage; replace.
36
Undercutting. 1. Reduce power.
2. Reduce welding speed.
37
Cracked welds. 1. Check design of root opening, root face dimensions,
angle.
2. Check electrode wire compatibility with base metal.
3. Change welding speed or shielding gas to obtain a more
convex bead.
4. Change torch angle to improve deposition.
5. Revise joint design.
6. Determine if alloy requires preheat and/or post weld
heat treatment.
7. Check wire for moisture in flux. (Weld using new sealed
spool)
8. Check gas for contamination. Change gas bottle.
13.4.1 MAINTAIN PROPER CONTACT TIP RECESS
For FCAW welding, the contact tip should be recessed

approximately 13mm (0.5') from the nozzle end.
13.4.2 MAINTAIN PROPER ELECTRODE STICK-OUT
The recommended electrode stick-out is critical for all-position

FCAW electrodes. These electrodes have a fast freeze slag. If
less than the minimum parameters recommended are utilized, the
slag may freeze too rapidly trapping escaping gas moisture and
causing worm tracks on the weld surface. The electrode stick out
should be approximately 25mm (1”) or more from the contact tip.
Many welders are used to welding GMAW vertical-up with the

nozzle between 1/4” (6.4 – 9.6 and 3/8” (6.4 – 9.6mm) from the
weld surface. They typically use a contact tip that was designed
for GMAW spray transfer. The electrode stick-out they often
utilize is less than 1/2” (13mm). If you use less than the minimum
electrode stick-out, you will use less voltage, less weld energy,
and increase the potential for fast freeze weld to trap excess
porosity.
Damaged GMAW and FCAW contact tips can be machine down

so that the contact tip is at least 1/2” (13mm) recessed in the
nozzle for FCAW welds.
13.4.3 CAUSES OF POROSITY AND “WORM HOLES” OR “WORM

TRACKS” (FCAW)
Porosity and worm tracks are usually the result of a combination

of incorrect electrode extension, incorrect parameters, humidity,
electrode moisture, mill scale, rust, paint, oils, or poor weld
technique.
38
With a shorter than recommended electrode extension, the energy
to the weld puddle is reduced, resulting in gas moisture which
would normally escape before the puddle solidifies being trapped
in the freezing puddle. This may appear as scattered pores, or as
long connected pores or tracks immediately underneath the slag.
The longer electrode extension also provides resistance heat to
the electrode which provides additional energy to the weld and
reduces the opportunity for moisture or lubricants on or in the
electrode to enter into the weld.
In areas where humidity levels are high, porosity and worm track
potential increase. The FCAW transfer characteristics are less
sensitive to mill scale than in the GMAW spray transfer mode,
however the mill scale is often the cause of excess porosity. To
avoid effects of surface contaminants, clean the area with a
grinder before welding.
Another way to reduce porosity is to avoid weaving. If the correct

size flux cored electrode is utilized, weaving is not required for
most flux cored applications in any welding position. The
backhand technique used for flat and horizontal position weld will
also reduce porosity. The backhand technique is also beneficial
when a fillet weld size is large, over 5/8” (16mm), and fluid fillet
weld puddle is difficult to control. If porosity or worm tracks occur,
remember that the best solution is to utilize weld practices that
increase heat at the weld.
13.4.4 FILLER WIRE – IMPORTANT CONSIDERATIONS WHEN

ORDERING
When ordering wire for the Pipeliner LL, specify:
Level Wound, regardless of spool size
Wire to be supplied in Sealed Bags or hermetically sealed

tins with desiccant (This is an available option from most
suppliers.)
Failure to do this will result in wire feeding problems and “worm-

hole” type porosity if the flux picks up the moisture.
39
Remote Pendant
40
PIPELINER WELD LOG SHEET
INDIVIDUAL PASS DATA
PIPE SIZE:_____________________________
WALL:_________________________________
TRAVEL DELAY:_______________________
ACTUAL WIRE SPEED:
PRIMARY:_______________________
DWELL:_________________________
ARC TRIM DIAL SETTING:____________________________________________________________
ACTUAL VOLTS:_______________________
ON / OFF PULSE FREQUENCY:____________________
TRAVEL SPEED DIAL SETTING:_______________________________________________________
ACTUAL TRAVEL SPEED AT PIPE:____________________________________________________*
*(GUIDE RING DIA./PIPE DIA. X DIAL SETTING IN IPM)
ON / OFF
ON / OFF
ON / OFF
OSCILLATION SPEED DIAL SETTING:__________________________________________________
OSCILLATION WIDTH DIAL SETTING:_________________________________________________
OSCILLATION INNER DWELL: 0. SEC.
OSCILLATION OUTER DWELL: 0. SEC.
GAS NOZZLE ORIFICE:________________________________________________________________
CONTACT TIP SIZE: FLUSH/EXTENDED___________________________________________________
CONTACT TIP SIZE: STD./TAPERED______________________________________________________
STICK OUT:____________________________________________________________________________
LEAD OR LAG ANGLE:__________________
SHIELD GAS COMPOSITION:____________________________________________________________
TOTAL ARC TIME:______________________________________________________________________
NOTES:______________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________
__________________________________
C:\My Docs\Manuals\609A-708 Pipeliner II-C.wpd December 8, 1997
41
PIPELINER WELD LOG SHEET
DATE:____________________
Pipe Size:___________” O.D. (__________mm) x ________” (_______mm) Wall Thickness
Pipe Material:________________________________________________________________________
PQR No.:________________________________
Company Developed For:______________________________________________________________
Program Developed By:_______________________________________________________________
Weld Position:____________ Weld Progression (Double-Up or Double-Down):____________
Joint Geometry:______________________________________________________________________
Filler Material:_________________________________________ Wire Diameter:_______________
System Model/Power Source Used:____________________________________________________
Gas Nozzle Orifice:___________________________________________________________________
Contact Tip Size: Flush/Extended______________________________________________________
Contact Tip Size: Std./Tapered________________________________________________________
Stickout:_____________________________________________________________________________
Amperage Range Used:_______________________________________________________________
Voltage Range Used:_________________________________________________________________
(Lead or Lag Angle):______________
Shield Gas Composition:______________________________________________________________
Backing or Root Pass Method:_________________________________________________________
Preheat Required:____________________________________________________________________
Interpass Temp Limitations:___________________________________________________________
Heat Input Limitations:________________________________________________________________
Total Passes:________________________________________________________________________
Total Arc Time:____________
Notes:______________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
C:\My Docs\Manuals\609A-708 Pipeliner II-C.wpd June 16, 1997
42
14.0 ELECTRODE EXTENSION OFTEN NEGLECTED WHEN USING SELF-SHIELDED
CORED WIRES
43
44
45
15.0 PREVENTING THE EFFECTS OF MOISTURE CONTAMINATION OF FLUX CORE
WIRE
46
47
16.0 BILLS OF MATERIALS/DRAWINGS
48
TOP LEVEL PART NUMBER
PART NUM DESCRIPTION I I

o >- ,1.~03=-:9:..=5-,-1-...:..1 _ _~M=.EC_H_A-,-N:.:...IC:-A_l -l....:1+--+-+-1_1+-~+-~....:...1HIH_+...:..1+--l-H....:1+--+--l-f--1-/--+-+-~1-l-HI~
Lfiffir-
J:::::; 103951-0 MECHANICAL & DITHER 1 1 1 1 1 1 1
ow
uJ ~ 103951-P PNEUMATIC 1
3: « 103951-PO PNEUMATIC & DITHER I 1
103090-15 MPS4000, WOF, MECH.
103090-15-0 MPS4000, WOF, MECH, DITHER
103090-15-P MPS4000, WOF, PNEU.
103090-15-PO MPS4000, WOF, PNEU, DITHER
103364-25-4 MPS4000, 4 ROll WOH, MECH.
103364-25-40 MPS4000, 4 ROll WOH, MECH, DITHER
103364-25-4P MPS4000, 4 ROll WOH, PNEU.
103364-25-4PO MPS4000, 4 ROll WOH, PNEU, DITHER
103364-50-4 MPS4000,4 ROll WOH, MECH.
f3 103364-50-40 MPS4000, 4 ROll WOH, MECH, DITHER
o iii 103364-50-4P MPS4000, 4 ROll WOH, PNEU.
<
W ~ itl 103364-50-4PO MPS4000, 4 ROll WOH, PNEU, DITHER
J:
01-
..J
~ ~ 103364-25 MPS4000, 2 ROll WOH, MECH.
Ww ww w 103364-25-0 MPS4000, 2 ROll WOH, MECH, DITHER
~:I: !;( -l
<II) ~ ~ 103364-25-P MPS4000, 2 ROll WOH, PNEU.
(1)>-
Ow u. () 103364-25-PO MPS4000, 2 ROll WOH, PNEU, DITHER
~~ o 06
w ::l :::c 103364-50 MPS4000, 2 ROll WOH, MECH.
o iii ~ 103364-50-0
o MPS4000, 2 ROll WOH, MECH, DITHER
:E ~ 103364-50-P
103364-50-PO
MPS4000, 2 ROll WOH, PNEU.
MPS4000, 2 ROll WOH, PNEU, DITHER -
N
o
f--1_0_39.:-9=--:6_-1_5_ _+-M_P_S4_0_0_0,,--P_U_S_H_-P_U_l_l.:-,M -E-C-H-·----/-i-i-i-/-i-i-hI--I--I--HhHHHH'---I'---I-lH-l-t--t-1+-+--+_; ~

103996-15-0 MPS4000, PUSH-PUll, MECH, DITHER 1 ~
)--------I---'-------'-----'--------+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+--+--+--+--+--+--+---+---+---+---+---+---,I
103996-15-P MPS4000, PUSH-PUll, PNEU.
103996-15-PO MPS4000, PUSH-PUll, PNEU, DITHER
103996-25 MPS4000, PUSH-PUll, MECH.
103996-25-0 MPS4000, PUSH-PUll, MECH, DITHER
103996-25-P MPS4000, PUSH-PUll, PNEU.
103996-25-PO MPS4000, PUSH-PUll, PNEU, DITHER
w w 103761-2 WIRE DRIVE KIT - 4 ROll, WOH (5 PIN) 11111111
Q;; & 104022-1 WIRE DRIVE KIT - 2 ROll, WOH 11111111
3: 0 104023-1 WIRE DRIVE KIT - PUSH-PUll 11111111
104017-1 ACCESSORIES KIT - MIG 1 1 1 1 11111111
<i
() 104017-2 ACCESSORIES KIT - MIG, WOH 1111111111111111
«
38416 REGULATOR, DUAl- METERl250 PSI 11 11 11 11 11 1 1 1 1
0::>-
~ ~ MPS 4000 (W /712) XXXXXXXXXXXXXXXXXXXXXXXXXXXX
Q...cn
WIRE ON THE FLOOR (15 ') x X X X
WIRE ON THE HEAD (4 ROLL, 25') X X X X
(-------'--------'----------+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+--1-+-+-+--1--1--1--1--1--+--+- '-
PUSH-PULL ( 15') X X X X
PUSH-PULL ( 25') I I X X X X
MECHANICAL ACTUATORS X X X X X X! xl xl X X X X X X
~ PNEUMATIC ACTUATO_R_S +_iH_X-+-X-j_+-+-X--j--X-I--+_+[_X-j-X-j1-1 X X I X X IX X 1-.0!.

b DITHER IX IX X ,X X I iX IX I IX X X XI X IX I X
OPTION SPARES 104176-XX 01"'- ('11M 10 10
...- ...-/...- 1"'- 10
lit I I I I I
1'-;/;0:> 0>1~1"'-1('I ('IlMlv
CD 10 10 10 <0 I' CD CD
I I I I
('I ('I ('I ('I
I I
10
I I I •
N
I
('I ('I
CD I'-
I
0> 0MMMM
0:> ('I
I I
"'-1('1 MM'l'v
I I
<0 CD
I I I I
10 CD
CD
I
CD
I
MAGNATECH LIMITED PARTNERSHIP 07/16/08
EAST GRANBY, CONNECTICUT 06026
WELDHEAD MODEL 609A
609AXXXXXX OPTIONS
PART NUMBER DESCRIPTION QTY
103040-XXXXX GUIDE RING ASSEMBLY - POLY-TRACK®, 0.0. 1 per pipe size

(-XXXXX SPECIFIES PIPE NOMINAL 0.0. IN HUNDRETHS
OF AN INCH ie XXX.XX INCHES)
104440-XXXXX GUIDE RING ASSEMBLY - POLY-TRACK®, 1.0. 1 per pipe size

(-XXXXX SPECIFIES PIPE NOMINAL 1.0. IN HUNDRETHS OF
AN INCH IE XXX.XX INCHES). REQUIRES ONE PIN 104420-1
EXPANDER ASSEMBLY FOR EACH GUIDE RING
INSTALLATION)
104420-1 EXPANDER ASSEMBLY - 1.0. GUIDE RING 1

(USE W 11 04440-XXXXX)
103070-XXXX ADAPTOR FOOT SET - GUIDE RING RADIAL EXTENSION AIR

(-XXXX SPECIFIES RADIAL EXTENSION OF GUIDE RING
FEET IN THOUSANDTHS OF AN INCH ie X.XXX INCHES.
QUANTITY REQUIRED DEPENDS ON GUIDE RING SIZE)
103190-1 TORCH AXIAL SLIDE ASSEMBLY - MIG 1

(NOT AVAILABLE ON 609AXXXWXX PART NUMBERS)
104176-1 GENERIC SPARES - 609A, LONG LIST (W/ MOTORS) AIR

104176-2 GENERIC SPARES - 609A, SHORT LIST (W/OUT MOTORS) AIR
104176-XX OPTION SPARES, 609AXXXXXX AIR
(SEE SHEETS 1 FOR APPLICABLE "DASH NUMBER")
SK2460-090 FLX-TRACK, POLY-TRACK® - 90 INCHES 1

SK2474-1 MAGNET ASSY, MODIFIED - FLX-TRACK 8 per 90" track
104294-1 VACUUM CUP KIT - 90" FLX-TRACK (REQUIRES 80206-XXX 1 per 90" track
VACUUM PUMP KIT)
104295-1 SPARE PARTS - VACUUM CUP KIT AIR
80206-110 VACUUM PUMP KIT - 11 OV, 50/60HZ (USE W 1104294-1 KIT) 1
80206-220 VACUUM PUMP KIT - 220V, 50/60HZ (USE W/104294-1 KIT) 1
SPECIAL NARROW GROOVE TORCH EXPENDABLES FOR MPS-4000

104452-1 NOZZLE, MIG - NARROW GROOVE 1
104453-1 CONTACT TIP HOLDER - NARROW GROOVE 1
80180-14t-45 CONTACT TIP, TAPERED - .045/1.2MM 1
NOTE: MPS 4000 Extension Cables are Listed as Options on the MPS
4000 Power Supply Keysheet.
ADDED: 609AGEAOMP; 609AGEAWMP; 609AGEAOCP AND 609AGEAWCP WELD HEADS CONFIGURATIONS WITH 103996-15;
IE 07/16/08
-15-P; -15-0 AND -15-PD TIC ASSEMBLIES AND SPARES 104176-63; -64; -65 AND -66 IN MPS4000 MATRIX
DELETED OBSOLETE MODELS, ADDED 104017-2 TO WOH MODELS TCK 12104/07
CHANGE DESCRIPTION BY DATE
Page 2 of 2
TORCH HEIGHT ASSEMBLY Sh t I 0f 2
MAGNATECH LIMITED PARTNERSHIP STO STROKE 06-Jun-OO
EAST GRANBY, CT 06026 USA 102830-1 102830-I-PL
TORCH HEIGHT ASSEMBLY Sh t 2 0 f 2
MAGNATECH LIMITED PARTNERSHIP SrD STROKE 06-Jun-OO
EAST GRANBY, CT 06026 USA 102830-1 I02830-I-Pl
•2I PART t
01980-1
01980-4
DESCRIPTION
COVER WHEEL - AGC MOTOR SIDE
COVER WHEEL - AGC SWITCH SIDE
OTY
I
I
TYPE
PART
PART
3 02025 GEAR SPUR - 24P X 12T X20 DEG. I PART
. 02832-1 BLOCK SWITCH TRIP - 2 PART
PART
5 02833-1 SLIDE lORCH HEIGHT - STD STROKE I
6 02834-1 RACK TORCH HEIGHT - SrD STROKE I PART
1 02836-1 HOUSING TORCH HEIGHT - I PART
8 02880-1 CLAMP SPLIT - LEAD/LAG ADJ. I PART
9 02881-1 SHAFT LEAD/LAG - 1 PART
10 02894-1 SHIELD SLIDE - . 1 PART
II 03116-2 TORCH HT. MTR. ASSY. - W/ CONNECTOR I ASSEMBLY
12 03111-2 TORCH HT. SI. ASSY. - W/ CONNECTOR I ASSEMBLY
13 0600 PIN. SPIRAL - 3/32 X 1/2 I PART
14 20141 JOURNAL - ASS'Y CONCENTRIC 25MM 2 PART
IS- 20142 JOURNAL - ASS'Y ECCENTRIC 25MM 2 PART
16 35085 CLAMP CABLE - 1/8 I PART
18 5269 PIN. ROll - 1/8 X 1/4 2 PART
19 5295 PIN. DOWEL - 3/32 X3/8 2 PART
20 NI 01-02C-12-C SCREW SHC - M2.0 X .40 X 12MM 2 PART
21 NI 01-03C-06-C SCREW SHC - M3.0 X .50 X6NN 3 PART
22 NI 01-03C-08-C SCREW SHC - M3.0 X .50 X8NN 3 PART
23 NI OI-03C-10-C SCREW SHC - M3.0 X .50 X 10MN 4 PART
24 NI 01-03C-16-C SCREW SHC - M3.0 X .50 X 16NM I PART
25 NIOI-03C-20-C SCREW SHC - M3.0 X .50 X20MM 5 PART
26 NI 01-04C-16-C SCREW SHC - M4.0 X .70 X 16MM 2 PART
21 NI03-03C-IO-C SCREW FlHDSOC - M3 X .50 X 10NM 2 PART
28 MI03-04C-14-C SCREW FLHDSOC - M4 X .10 X 14MM 2 PART
29 M401-02C-C NUT HEX - N2 2 PART
30 M50I-03C -fA -3 WASHER FLAT - M3 DIN 125 8 PART
31 M701-04C-060-8 INSERT HELICAL - N4-.1 X6 2 PART
TORCH HEIGHT ASSEMBLY Sht 1 of 2
MAGNATECH LIMITED PARTNERSHIP SHORT STROKE 05-Jun-00
EAST GRANBY, CT 06026 USA 102830-2 I02830-2-PL
NAGNATECH liMITED PARTNERSHIP TORCH HEIGHT ASSEMBLY 'Sht 2 of 2
EAST GRANBY, CT 06026 USA SHORT STROKE 05-Jun-OO
102830-2 102830-2-Pl
I PART I DESCRIPTION OTY TYPE
I 01980-1 COVER WHEEL - AGC MOTOR SIDE I PART
2 01980-4 COVER WHEEL - AGC SWITCH SIDE I PART
3 02025 GEAR SPUR - 24P X 12T X20 DEG. I PART
4 02832-1 BLOCK SWITCH TRIP - 2 PART
5 02833-2 SLIDE TORCH HEIGHT - SHORT STROKE I PART
6 02834-2 RACK TORCH HEIGHT - SHORT STROKE I PART
7 02836-1 HOUSING TORCH HEIGHT - I PART
8 02880-1 CLAMP SPLIT - LEAD/LAG ADJ. I PART
9 02881-1 SHAfT LEAD/LAG - I PART
10 03116-2 TORCH HT. MTR. ASSY .... W/ CONNECTOR I ASSEMBLY
II
12
03117-2
03455-1
03895-1
TORCH HT. sr. ASSY. - W/ CONNECTOR
SHIELD SLIDE - l.P. TORCH HE~GHT , I ASSEMBLY
PART
ASSEMBLY
13 OFfSET BRACKET WI PINS - TORCH HEIGHT ASY I
14 10600 PIN SPIRAL - 3/32 X 1/2 I PART
15 2014' JOURNAL - ASS'Y CONCENTRIC 25MN 2 PART
16 20142 JOURNAL - ASS'Y ECCENTRIC 25MM 2 PART
18 ~208 CLAMP CABLE - 3/16 I PART
19 5269 PIN ROLL - 1/8 X 1/4 2 PART
20 5295 PIN. DOWEL - 3/32 X3/8 2 PART
21 MI 01-02C-12-C SCREW SHe - N2.0 X .40 X 12MN 2 PART
22 MI 01-03C-06-C SCREW SHe - M3.0 X .50 X6MN 3 PART
23 MI 01-03C-08-C SCREW SHC - M3.0 X .50 X8MN 2 PART
24 MI 0'-03C-1 O-C SCREW SHC - N3.0 X .50 X 10MM ~ PART
25 N' 01- 03C - 16-C SCREW SHC - N3.0 X .50 X 16MM I PART
26 MI 01-03C-20-C SCREW SHe - M3.0 X .50 X 20MN 5 PART
21 NI01-04C-16-C SCREW SHC - M4.0 X .10 X 16NM 2 PART
28 MI03-03C-10-C SCREW fLHDSOC - N3 X .50 X 10MM 2 PART
29 NI03-04C-14-C SCREW fLHDSOC - N4 X .10 X 14MM 4 PART
30 N401-02C-C NUT HEX - M2 2 PART
31 N50 J-03C-FA-3 WASHER FLAT - M3 DIN 125 8 PART
32 M701-04C-060-8 INSERT HELICAL - M4-.1 X6 2 PART
Pagelofl
7/29/08
MAGNATECH LIMITED PARTNERSHIP
BILL OF MATERIALS
102888-2
MISCELANEOUS SCREW PACKAGE - MIG
PART QUANTITY
NUMBER DESCRIPTION USED
M101-02C-04-C SCREW, SOCHD - M2 X 0.4 X 4 2
MI0I-03C-12-C SCREW, SOCHD - M3 X 0.5 X 12 2
M101-0SC-16-C SCREW, SOCHD - M5 X 0.8 X 16 2
M102-03C-06-C SCREW, BUTHD - M3 X 0.5 X 6 4
MI03-03C-16-C SCREW, FLHDSOC - M3 X 0.5 X 16 4
M103-06C-16-C SCREW, FLHDSOC - M6 X l.OX 16 2
M201-S-03C-04-C SCREW, SETCUP - M3 X 0.5 X 4 2
M401-05C-C NUT, HEX - M5 X 0.8 2
M401-0SC-3 NUT, HEX - M5 X 0.8 4
M501-04C-FA-3 WASHER, FLAT - M4 SS 2
11294 WASHER, EPDM RUBBER - 1/8 X 1/4 X 1/16 2
ADDED: M101-05C-40-C (4) AND M401-05C-3 (4) IE 07/29/08

ADDED: 11294 (2) IE 07/22/08
REMOVED: M301-06-25-3 (2) IE 07/30/07
INITIAL RELEASE

MAGNATECH LIMITED PARTNERSHIP Page 1 of 1
EAST GRANBY, CONNECTICUT 06026 01/24/96
12/02/96
BILL OF MATERIALS 10/06/99
TOOL KIT • MIG
102889-2
PART QUANTITY
25014 BALLDRIVER HEX TOOL SET - INCH 1

·25026 BALLDRIVER HEX TOOL SET - METRIC 1
25056 RATCHET, MINIATURE 1
25057 ADAPTER, HEX - 5MM 1
25087 PLIERS, MIG - WELPER YS-50 1
25088 TOOL BOX - 16" PLASTIC 1
.. "
Sh t I () f 2
MAGNATECH LIMITED PARTNERSHIP BRACKETRY ASSEMBLY 05-Jun-OO
EAST GRANBY, CT 06026 USA TORCH MOUNTI NG I02938-I-PL
1()29~8-1
BRACKETRY ASSEMBLY Sh t 2 0f 2
MAGNATECH LIMITED PARTNERSHIP TORCH MOUNTING 05-Jun-OO
I PART t DESCRIPTION OTr TYPE
I 102895-1 BRACKET TORCH MOUNT - LONG I PART
2 102939-1 PLATE SLIDE - TORCH ADJUSTMENT I PART
3 102944-1 CLAMP SPLIT - WITH SLOT I PART
.. 25053 PI·N DOWEL - 1/2 X I
PIN DOWEL - 3/16 X 1/2
I PART
PART
5 5208 2
6 MI0I-04C -16-C SCREW SHC - M4.0 X .70 X 16NM I PART
7 NI01-06C-16-C SCREW SHC - M6.0 X 1.0 X 16MN I PART
8 N501-06C-fA-3 lASHER fLAT - N6 DIN 125 I PART
...
."
MAGNATECH liMITED PARTNERSHIP Page 1 of 2
EAST GRANBY, CONNECTICUT 06026 EC850 06/05/98
EC851 08/01/98
BILL OF MATERIALS EC 854 12/29/98
EC 862 11/05/99
PENDANT ASSEMBLY - PIPEllNER II 05/03/01
10/17/01
103059 ECN 889 10/19/02
PART QUANTITY
NUMBER· DESCRIPTION USED
3728 POT, 5-KOHMS, 3-TURN 1

4219 TERMINAL LUG 3
4264 KNOB (NUMBERED) 2
4927 RECEPTACLE 1
4959-1 POT, 100-KOHMS, 10-TURN 1
5369 SCREW 6-32 X % BHMS 4
5380 SCREW 6-32 X 1/4 BHMS 8
5930 RTV SEALANT AIR
8246 POT, 100-KOHMS, l-TURN 2
8257 POT, 5-KOHMS, 10-TURN 5
8316 CaNTACT (SOCKET) 3
8535 FOOT 4
10136 SCREW 8-32 X 3/8 BHMS 8
10146 WASHER #6, LOCK TYPE 8
10398 SCREW 10-24 X 1-1/4 RHO 8
11203 NUTIWASHER 6 - 32 4
·'50039 COUNTING DIAL 7
50311 SWITCH MOM. TOGGLE 4
50406 HANDLE 4
50447 RESISTOR, 2K, 3W 1
50682 CONNECTOR, MS31 02A28-21 P 1
51377 HOLE PLUG - 7/8" 1
51448 HOLE PLUG - 3/8" 1
51476 SWITCH ELEMENT, N.O. 4
51477 SWITCH ELEMENT, N.C. 1
·51478 LAMP HOLDER 4
51479 FRONT ADAPTOR FOR SWITCH 5
51480 SILICONE SWITCH COVER 5
MAGNATECH liMITED PARTNERSHIP Page 2 of 2
BilL OF MATERIALS
PENDANT ASSEMBLY - PIPELINER II
103059
PART QUANTITY
51481 LAMP 4
51605 ALT. ACTUATION - YELLOW LENS 3
51606 MOM. ACTUATOR - RED LENS 1
51607 MOM. ACTUATOR - GREEN LENS 1
51666 SWITCH SEAL 4
100557 COVER PANEL 1
101684 PENDANT BASE 1
·103009 PENDANT PANEL 1
103551-05 DIFFUSER - START WELD 1
103551-06 DIFFUSER - STOP WELD 1
103551-09 DIFFUSER - OSC ON 1
103551-10 DIFFUSER - TRAVEL STEP 1
103551-12 DIFFUSER - POWER BOOST 1
Models 708, 712

09/22/99
01/26/01
TORCH AND CABLE ASSEMBLY - 4000/WOF 11/13/01
11/05/02
103090-151-XX) 04/18/05a
02/15/07
07/09/07
PART QUANTITY
3777 CLAMP, CABLE - 5/16" NYLON 1
5245 SAFETY WIRE, 1/32" AIR
5942 HYDRAULIC SEALANT AIR
8080 TAPE, ELECTRICAL - BLACK AIR
8094 CLAMP, HOSE - 11.3mm. 2
8785-B FYRE JACKET - 3/4" ID BLACK AIR
10427 O-RING - .208" ID X .070" W 1

·10469 O-RING - .156" ID X .046" W 1
11085 SCREW HEX WASHER HEAD SLOTTED 6 X 1/2 2
35180 CABLE TIE, 6" X .280", SS, NYLON 2
38329 CLAMP, HOSE 7.0 mm. 2

38362 TUBING HEAVY DUTY WATER AIR
38363 HOSE, GAS - 7/16" OD X 1/16" WALL AIR
38364 NIPPLE HOSE 5/16"x 3/8 - 24 1

38541 TUBING, POLYETHYLENE - 3/8" OD X .062" WALL AIR
51064 WRAP, TIE, NYLON, W. EYE HOLE, 6-1/4L 2

80089-3545-15 CONDUIT, WIRE - .035"1.045" WIRE X 15' 1
80098-12 NOZZLE, WIRE INLET - 1.2mm. WIRE 1
80099 CAP NUT - M40 X 1.5mm. 1
80177-55-12-09 CABLE COVER, LEATHER, HOOKILOOP 1
10f4
BILL OF MATERIALS
TORCH AND CABLE ASSEMBLY - 4000lWOF
103090-151-XXI
PART QUANTITY
103024-2 GUIDE, WIRE INLET - FRONIUS 1
103091-3545-375 CONDUIT, WIRE - .035"1.045" WIRE, 3.75 LONG 1
103092-1 COVER, POWER ADAPTOR 1
103106-1 CLAMP, MOUNTING - MIG TIC 1
103984-180 POWER/WATER CABLE ASSY. - FEMALE "A' X 15' (180") 2
103985-238 HEAD CONTROL CABLE ASSY. - 19' 10" (238") 1
104268-1 ROD RADIUS CONTROL TORCH CABLE 2
104270-1 BLOCK MOUNTING TIC SMALL WIROD 1
104273-1 POWER ADAPTOR BRAZED WHO P-P WIROD 1
105220-3 TORCH AND MOUNT ASSEMBLY - MIG 1
M101-03C-05-C SCREW, SOCHD - M3 X 5mm. 4
M 103-04C-1 O-C SCREW, FLHDSOC - M4 X 10mm. 1
M201-S-03C-04-C SCREW, SET - M3 X 4 CUP 1
M501-04C-FA-3 WASHER, FLAT, 4mm. FORM A 1
20f4
BILL OF MATERIALS
TORCH AND CABLE ASSEMBLY - 4000/WOF
103090-151-XXI
PART QUANTITY
Add the Following Parts to Complete the Bill of Materials for the Given Dash Number Ass'y
103090-15 TORCH & CABLE ASSY - 4000, WFOF, MECHANICAL 1

Ml0l-03C-25-C SCREW, SHCS - M3 X 25mm. 1
103104-1 PLATE, CONNECTOR - TIC 1
103090-1 5-P TORCH & CABLE ASSY - 4000, WFOF, PNEUMATIC 1

103104-1 PLATE, CONNECTOR - TIC 1
103992-238 PNEUMATIC SUPPLY HOSE ASSY - 19' 10" (238") 1
103090-15-PD TORCH & CABLE ASSY - 4000, WFOF, PNEUM., DITHER 1

M501-04C-FA-3 WASHER, FLAT - M4mm. 1
8077 CLAMP, CABLE - 1/4", NYLON 1
103986-238 DITHER CONTROL CABLE ASSY - 19' 10" (238") 1
103834-1 PLATE, DUAL CONNECTOR - WIDITHER 1
30f4
BILL OF MATERIALS
TORCH AND CABLE ASSEMBLY - 4000lWOF
103090-151-XXI
PART QUANTITY
NUMBER DESJ:;RIPTIQN USED
Add the Following Parts to Complete the Bill of Materials for the Given Dash Number Ass'y
103090-1 5-0 TORCH & CABLE ASSY - 4000, WFOF, DITHER 1

M 101-03C-30-C SCREW, SHCS - M3 X 30mm. 1
M501-04C-FA-3 WASHER FLAT - M4mm. 1
8077 CLAMP, CABLE - 1/4", NYLON 1
103834-1 PLATE, DUAL CONNECTOR - W/D1THER 1
M101-03C-06-C SCREW, SHCS - M3 X 6mm. 4
Models 607,609
103024-2 WAS 103024-1 AND 103091-3545-375 WAS 103091-3545-357 IE 07/09/07

8094 (2) WAS (4)
REMOVED: 102191, 5208,102943-1, M103-Q4C-16-C (2), 5930, 5813 (2),103094-1,103095-1, IE 02/15/07
11247(4),38364, 10442 AND 102136-3.
ADDED: 105220-3
INITIAL RELEASE TK 09/19/96
40f4
tA~'" .... 'cR.euJ.~1.~. ... H£ II " ~l""'P
"C' C1't&~E. "0 /.. TEo 5~I'.Ew'·"F· I'lose·· P" /\E-F',
LJr:1'.
IV 1030'10- IS'" M,IOI~O"!('-25'-C " N(,)NE. NONE. NONE. lO~IO"'-1 NON .. No'N E w/o PNe,VMllnc 0/\ DI"HeR OPTlON5
~
G 103090- J5-P 101-03C-25'-C NoN!. NONE NONE. 10310'/-1 NONE. IO~'" l - 2'38 wi PNfUMltrlt:, ....../ 0 l"THE ~
G I030'1O-/~PD M IOI-O:lC' 30-C "'!iOI-O~'-FA- 3. 8077 IO';S6-2bS 'o~a'S'i-1 "''';1-03C-0' -C(~) 103"1'12 -Z'b wI PI/EUl>lIlTlC 2 PI"THE R
G- I03MO-I5-D MIOJ-03C-30-C r150/-0'fC -1'/.-3 8077 (03'66-238 103e3,/-\ MIa' -03C-O" -C (~) NON£. wlo "Nfl/Mime, lIJ/l>ITIifi.R,
C IOl.'t..,~-J W+!lo 'OI(;'~I· til'"'''' ~
11»'8'1 - 180(z) o 1/(8' UJ"~/II.VJ. ,,«t11 H Ol-:)·O"'·Q+·C ffj
Cl16Lf " p" ,s-z'tS, B080 ®

(sEE TReLe.)
8US'(
5C/leWS"F"
(S"" rAllLE)
F (J1(
I03'HH--?-~
NlIOI-OJC·O.5'~,(q)
..,
I}IJ/O, <'l(
.rJ(
tT7<
""'1'5 .Jt:.1..
~
10'1270-1
l0310£'- , r052~O-3 ® r2Jur It
ClAMI' "c"
($ee-rADLE)
L W Il$}IEfl. "1>"
(seE T/lBl e)
I....saEw··/l..
(Sf" T.48/..f)
PUNCH HOLE
80177-55-12 -,0'1
6-5LU.vE. Tile. R.AD lU.sCtonRL. ROO (104269-1) wI

800'18-12 (.ovr) T1I81WG (J8SQI), CENTERED AS SHOWN, AND WR FoP
W/TAPf.(8lltO). SeE- \1lE.'W A,
1030"- 35'j!i'-375 S - FLUSH IVII'''£~ lI>JE S w/7:S% ?E10Nlrl':C> W.Hf: 8/

103'185-23& 25% E:1i1't'~F'U:GJ.'fCOLIlFTE,; TE.!>rhfL~,
REF
4· rEsT Fot< ADE:QVAT/:: GAS fLOW.
3- No WATER lE/lI~fl6£€ GO PSI.
2 - VULTAGE. DRoP NOT TO /3xc.E/£D .'0 vl>C 100IiMf'5. e
1- WAiEfi FLOW TO BE . '15'& PM NlI~/ @. SOPS/D.
A - Z PlC-S.
NoTES:
'38'''' (Aif.) MU>I-S-O~C -0,· c.
~/n"z.. "AGNATI:CH. U"'TI:O I"AIUNEItSHIP
10'985-l311 lAt'.)
80\10 I U.T~.CO'tfCc::nc:UT
I TO
.,J
~- ~
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c=====E3-- PNEUMATIC SUPPLy(opnONAL)
I"c;;;R~'~~~~;;;iiia~~~~~.;,
TIt.
Am.
H
v ~
3·
~E ~.
0
f ,,~,,":,-: .... ~::,~ ~~

..:a=- ~ ...,. :,,__..,. L ----"
L:'•.:•.=.,;:,.::.'~•.;'..::.:.:.~.~'O::.'~o~..:::..:.:.:.;.~,:-~!IO~3~O~'}~O~~IV~,
I-I
Shflof2
MAGNA TECH LIMITED PARTNERSHIP SHIELD ASSEMBLY OB'NoY-OJ
EAST GRANBY, CT 06026 USA OSCILLATOR RACKS 103160-I-PL
103160·1
MAGNATECH LIMITED PARTNERSHIP SHIELD ASSEMBLY Sht 2 of 2
EAST GRANBY. CT 06026 USA OSCILLATOR RACKS 08-Nov-07
103160-1 103160-I-PL
# PART # DESCRIPTION OTY TYPE
I ID3089-1-( I SHIELD. RACK - FABRIC PART
2 103137-1 HOUSING. RACK SHIELD - PART
3 103138-1 PLATE. TOROUE REACTION - RACK SHIELD PART
4 103139-1 RUB STRIP - NYLON PART
5 ID3157 - I BUSHING. FIXED END - SPRING TUBE PART
6 103158-1 BUSHING. FREE END - SPRING TUBE PART
7 103159-1 TUBE. SPRING - SHIELD PART
8 103161-I-CI SPRING. SHIELD - TORSION PART
9 104210- I SUB-PLATE - RACK SHIELD PART
ID 104284-1 PLATE. ATTACHMENT - RACK SHIELD PART
II 5964-I-C5 TAPE. ACRYLIC - I INCH X 5 MIL PART
12 MIO 1-02C-06-C SCREW. SHC - M2.0 X .40 X 6MM PART
13 MI01-02C-08-C SCREW. SHC - M2.0 X .40 X 8MM 2 PART
14 MIDI-03C-08-C SCREW. SHC - M3.0 X .50 X 8MM 2 PART
15 MI01-03C-10-C SCREW. SHC M3.0 X .50 X 10MM 2 PART
16 MI01-04C-16-C SCREW. SHC - M4.0 X .70 X 16MM I PART
I7 MIO 1-04C-20-C SCREW. SHC - M4.0 X .70 X 20MM 2 PART
18 MI04-02C-04-C SCREW. FLHDSL - M2 X .4 X 4MM 2 PART
19 M20014 INSERT. THREADED RIVET - M4 X 2.0. STEEL 1.2661 2 PART
20 M501-03C-FA-3 WASHER. FLAT - M3. DIN 125A 2 PART
M200J4121 WAS M2000912J TCK f J 18/07
I CHANGE DESCRIPTION I BY I DATE

DRIVE WHEEL ASSEMBLY Sht I of 2
MAGNATECH LIMITED PARTNERSHIP CALIPER DRIVE 29-Sep-00
MAGNATECH LIMITED PARTNERSHIP DRIVE WHEEL ASSEMBLY Sht 2 of 2
EAST GRANBY, CT 06026 USA CALIPER DRIVE 29-Sep-00
103304-1 103304-I-PL
# PART # DESCRIPTION QTY TYPE
I 103323-1 SHAFT, SYNCRO - DRIVE CALIPER I PART
2 103326-1 BLOCK, BEARING - DRIVE 2 PART
3 103327-1 GEAR, DRIVE - 24P X 72T X 20 DEG I PART
4 103328-1 COVER, GEAR - DRIVE I PART
5 103329-1 PLATE, COVER - WIO SEALS I PART
6 103336-1 PLATE, LIMIT PINS - DRIVE CALIPER I PART
7 103337-1 PIN, SHOULDER - THREADED 4 PART
8 103555-1 DRIVE CALIPER ASSEMBLY - FRONT I ASSEMBLY
9 103555-2 DRIVE CALIPER ASSEMBLY - REAR I ASSEMBLY
10 104031-1 ROLLER, DRIVE - CALIPER DRIVE 2 PART
II 104045-1 TUBE, AXLE - DRIVE WHEELS I PART
12 20185 BEARING, BALL - 17MM X40MM X 11/16 2 PART
13 25071 PIN, HD SPIRAL - 3132 X 5/8 2 PART
14 35186 PLUNGER, SPRING - #10-32 X 314 4 PART
15 MI01-03C-25-C SCREW, SHC - M3.0 X .50 X 25MM 4 PART
16 M10 I-04C - 12 -C SCREW, SHC - M4.0 X .70 X 12MM 2 PART
17 M202-S-05C-16-C SETSCREW, SOCKET - FLAT X M5-.8 X 16MM 4 PART
18 M206-S-04C-04-C SETSCREW, SOCKET - NYLON TIP X M4-. 7 X 4MM 4 PART
Sh t I 0 f 2
MAGNATECH LIMITED PARTNERSHIP IDLER WHEEL ASSEMBLY 29-Sep-00
/
/
/
"../1
Sht 2 of 2
MAGNATECH LIMITED PARTNERSHJP IDLER WHEEL ASSEMBLY 29-Se~-OO
EAST GRANBY, CT 06026 USA 103305-' I03305-I-PL
#
1
PART t
103323-2
DESCRIPTION
SHAFT SYNCRO - IDLER CALIPER ,
OTr TYPE
PART
2 103326-2 BLOCK BEARING - IDLER 2 PART
3 . J 03335-1 BLOCK LIMIT PINS - IDLER CALIPER RIGHT I PART
4 103335-3 BLOCK LIMIT PINS - IDLER CALIPER LEFT 1 PART
5 103337-1 PIN SHOULDER - THREADED 4 PART
6 103556-7 IDLER CALIPER ASSEMBLY - REAR XXHO I ASSEMBLY
1 103556-8 IDLER CALIPER ASSEMBLY - FRONT XXHD I ASSEMBLY
8 104032-' ROLLER IDLER - FRICTION DRIVE 2 PART
9 104045-2 TUBE AXLE - IDLER WHEELS I PART
10 104047-1 BLOCK ALIGNMENT - IDLER 2 PART
II 20184 BEARING BALL - fOMM X30MM X 9/16 2 PART
12 25010 PIN HD SPIRAL - 3/32 X3/8 2 PART
~~~l.~=~ llJ~l- . . -.~,_.~~ . ,._-~ pL]lLG_E-B..I.~fRLN.G~_:~~ II Q:-l.~~LI. 5.1.~l.-~-~-. =---~._._---.~ .- .. _..... ~ __~_,~._".=,--,_. ______.__.__._._ ----=.~~ ---,--.. . -PART
-~ pA';rr""-~"------
14 MI0I-03C -16-C SCREWSHC - M3.0 X .50 X 16MM 4
15 MIO '-03C-20-C SCREW SHC - M3.0 X .50 X20MM 6 PART
16 M202-S-05C-IO-C SETSCREW SOCKET - fLAT XM5-.8 X IONN 4 PART
11 M206-S-04C-04-C SETSCREW SOCKET - NYLON TIP X M4-.1 X 4 4 PART
Sh t I 0 f 2
MAGNATECH LIMITED PARTNERSHIP VALVE AND FITTING ASSEMBLY 09-04-01
EAST GRANBY, CT 06026 USA PNEU WI MALE QD 103310-2-PL
103310-2
,~UT (I) pes.

/ 9 in LG.
eUT (I) pes.

4 3/4 in LG
eUT (2) pes 6 1/2 In. LONG

Sh t 2 0 f 2
MAGNATECH LIMITED PARTNERSHIP VALVE AND fiTTING ASSEMBLY 09-04-01
EAST GRANBY, CT 06026 USA PNEU WI MALE QD 103310-2-PL
103310-2
I PART t DESCRIPTION OTY TYPE
I 103334-1 ENCLOSURE VALVE - PNEUMATIC I PART
2 103340-' MANIFOLD ASSEMBLY - PNEUMATIC ACTUATOR I ASSEMBLY
3 103341-1 GUARD ACTUATION - PNEUMATIC VALVE I PART
4 103342-1648 STANDOFF M3 FIF - 1/4 HEX X 1.648 2 PART
5 104034-1 BUTTON ACTUATOR - VALVE 1 PART
6 104035-I-CI FILTER fOAM - VALVE EXHAUST I PART
7 3779 CLAMP CABLE - 1/2 3 PART
8 38389 VALVE 3 WAY - MINIATURE N.C. I PART
9 38391 fiTTING ELBOW - 110-32 SWIVEL I PART
10 38392 NIPPLE 110-32 - 1/4 HEX BRASS I PART
II 38393 NIPPLE SWIVEL - 110-32 BRASS I PART
12 38395 TEE UNION - 3/16 PUSH 2 PART
13 38396-CI TUBING NYLON - FLEXIBLE 3/16 X .046 BLACK 4 PART
14 38488 QUICK DISCONNECT, EXTERNAL - PM W/ FILTER I PART
15 MI01-03C-06-C SCREW SHC - M3.0 X .50 X6MN 2 PART
16 MI0I-03C - 10-C SCREW SHe - N3.0 X .50 X IONN 2 PART
11 MI0I-03C - I2-C SCREW SHC - N3.0 X .50 X 12MM 2 PART
18 NI0I-04C - I0-C SCREW SHC - M4.0 X .70 X IONN I PART
19 M201-S-03C-04-C SETSCREW. SOCKET - CUP XM3-.5 X 4MM I PART
20 M501-03C-fA-3 WASHER FLAT - M3 DIN 125 2 PART
21 M501-04C-fA-3 WASHER fLAT - N4 DIN 125 1 PART
22 MS03-04C-FJ-S WASHER LOCKING - INT N4 DIN 6791-J4 3 PART
--
09/19/00
11/13/01
04/28/05
02/13/07
TORCH & CABLE ASSEMBLY - 4000/WOH, 25'
103364-25-XXX
PART QUANTITY
3777 Clamp, Cable - 5/16 Nylon 1
5245 Safety Wire - 1/32 A/R
5943 LUBRICANT AIR
8080 Black Tape A/R
8094 Clamp, Hose - 11.3mm. 6
8283 Cable - 1/0 A/R
·8365 Nipple, "B" Size - 1/4 Barb 2
8785-8 Fyre Jacket - 3/4 10, Black A/R
88·26 Plug, Current 1
10610 Screw, SLHEX - #6 Self-tapping 4
35'180 Cable Tie, 6" x .280", SS, Nylon 4

------'-------------------- ~
38275 Quick Connect, Male - #25 X 1/4 Barb 2
38306 Quick Connect, Male - #21 X 1/4 Barb 1
38445 Hose, Reinforced Urethane, % Id, .035 Wall A/R
50048 Nut, Coupling - Left Hand 2
51312 Ferrule, Size 1/0 1
80177-55-01-09 Cover, Cable - Leather, Hook/Loop 1
10f5
BILL OF MATERIALS
TORCH & CABLE ASSEMBLY - 40001 WOH. 25'
103364-25-XXX
PART QUANTITY
80177-55-17-10 Cover, Cable - Leather, Hook/Loop
100955-3 End Cap, Split - Power Insulator
100955-4 End Cap, Split - Power Insulator 1
100967 Adaptor Assy., Power - Double 1
101410-1 Sleeve
103106-1 Clamp, Mounting - MIG TIC 1
103390-T Lable, Shrink - "Torch" 1
103985-285 Head control Cable Assy - 23' 9" (285") 1
103995-240 PowerlWater Cable Assy - Female "A"/Male liB" x 20' (240") 2
104270-1 Mounting Block Assy. - T/C, Small w/ Rod 1
105220-1 Torch and Mount Assembly - MIG 1
M 101-03C-05-C Screw, SOCHD - M3 X 5mm. 8
M101-03C-08-C Screw, SOCHD - M3 X 8mm. 2
M501-04-C-FA-3 Washer, Flat - M4, Form'A' 2
2of5
MAGNATECH LIMITED PARTNERSHIP-
BILL OF MATERIALS
TORCH & CABLE ASSEMBLY - 40001 WaH. 25'
103364-25-XXX
PART QUANTITY
ADD THE FOLLOWING PARTS TO COMPLETE THE BILL OF MATERIALS FOR THE
GIVEN DASH NUMBER ASSEMBLY
103364-25 Torch & Cable Assembly - 4000, 2-Roll WOH, Mech'I., 25' 1
103987-285 Wire Drive Control Cable Ass'y - 23' 9" (285") 1
103359-1 Plate, Dual Connector - MIG TIC 1
3777 Clamp, Cable - 5/16" Nylon 1
103364-25-P Torch & Cable Assembly - 4000, 2-Roll WOH, Pneum., 25' 1
103992-292 Pneumatic Supply Hose Ass'y - 24' 4" (292") 1
103364-25-PD Torch & Cable Assembly - 4000, 2-Roll WOH, Pneum.,

Dither, 25' 1
103805-1 Plate, Triple Connector - w/Dither 1

M 101-03C-06-C Screw, SOCHD - M3 x 6mm. 4
103986-285 Dither Control Cable Ass'y - 23' 9" (285") 1
3779 Clamp Cable - 1/2" Nylon 1
30f5
BILL OF MATERIALS
TORCH & CABLE ASSEMBLY - 40001 WOH. 25'
103364-25-XXX
PART QUANTITY
103364-25-0 Torch & Cable Assembly - 4000, 2-Roll WOH, Mech'l.,

Dither, 25'

103805-1 Plate, Triple Connector - w/Oither 1
M101-03C-06-C Screw, SOCHD - M3 x 6mm. 4

--3779 Clamp Cable - 1/2" Nylon 1
103364-25-4 Torch & Cable Assembly - 4000, 4-Roll WOH, Mech'l., 25' 1
·103364-25-4-P Torch & Cable Assembly - 4000, 4-Roll WOH, Pneum., 25' 1
4of5
EAST GRANBY« CONNECTICUT 06026
BILL OF MATERIALS
TORCH & CABLE ASSEMBLY - 40001 WQH. 25'
103364-25-XXX
PART QUANTITY
103364-25-4-PD Torch & Cable Assembly - 4000, 4-Roll WOH, Pneum.,

Dither, 25' 1
.103805-1 Plate, Triple Connector - w/Dither 1
Ml01-03C-06-C Screw, SOCHD - M3 x 6mm. 4

·103364-25-4-D Torch & Cable Assembly - 4000, 4-Roll WOH, Mech'l.,

Dither, 25' 1
103988--285 Wire Drive Control Cable Ass'y - 23' 9" (285") 1
·103805-1 Plate, Triple Connector - w/Dither 1
REMOVED: 102191,5208,102943-1, M103-04C-16-C (2), 5930,5813 (2),103094-1,103095-1,

11247(4),5399,11134,11067,11554-2 AND 102136-1. IE 02113/07
ADDED: 105220-1
50f5
09/19/00
11/13/01
02/15/07
TORCH & CABLE ASSEMBLY - 4000LWOH, 50'
103364-50-XXX
PART QUANTITY
3777 Clamp, Cable - 5/16" Nylon
5245 Safety Wire - 1/32" A/R
5943 LUBRICANT A/R
8080 Black Electrical Tape A/R
8094 Clamp, Hose - 11.3mm. 6
8283 Cable - 1/0 AIR
8365 Nipple, liB" Size - 1/4" Barb 2
8785-B Fire Jacket - 3/4" iO, Black A/R
8826 Plug, Current 1
10610 Screw, SLHEX - # 6 Self-tapping 4
35180 Cable Tie, 6" x .280", SS, Nylon 4
38275 Quick Connect, Male - #25 X 1/4" Barb 2
38306 Quick Connect, Male - #21 X 1/4" Barb 1
38445 Hose, Reinforced Urethane, 1/4" 10, .035" Wall A/R
50048 Nut, Coupling - Left Hand 2
51312 Ferrule, Size 1/0 1
10f5
BILL OF MATERIALS
103364-50-XXX
PART QUANTITY
100967 Adaptor Ass'y., Power - Double 1
101410-1 Sleeve 1
103106-1 Clamp, Mounting - MIG TIC 1
103390-T Label, Shrink - IITorch" 1
103985-585 Head control Cable Ass'y - 48' 9" (585") 1
103995-240 PowerlWater Cable Ass'y - Female uA"/Male uB" x 20' (240") 2
104270-1 Mounting Block Ass'y. - T/C,'Small wI Rod 1
105220-1 Torch and Mount Assembly - MIG 1
M501-04-C-FA-3 Washer, Flat - M4, Form'A' 2
2.ofS
BILL OF MATERIALS
103364-50-XXX
PART QUANTITY
103364-50 Torch & Cable Assembly - 4000, 2-Roll WaH, Mech'l., 50' 1
103364-50-P Torch & Cable Assembly - 4000, 2-Roll WaH, Pneum., 50' 1
103364-50-PD Torch & Cable Assembly - 4000, 2-Roll WOH, Pneum.,

Dither, 50' 1
30f5
MAGNATECH· LIMITED PARTNERSHIP
BILL OF MATERIALS
TORCH & CABLE ASSEMBLY - 4000/wOH, 50'
103364-50-XXX
PART QUANTITY
103364-50-0 Torch & Cable Assembly - 4000, 2-Roll WOH, Mech'l.,

Dither, 50' 1
·103987-585 Wire Drive Control Cable Ass'y - 48' 9" (585") 1
M101-03C-06-C Screw, SOCHO - M3 x 6mm. 4
103364-50-4 Torch & Cable Assembly - 4000, 4-RoIiWOH, Mech'l., 50' 1

1 03364~50-4-P Torch & Cable Assembly - 4000, 4-Roll WOH, Pneum., 50'
40f5
BILL OF MATERIALS
103364-50-XXX
PART QUANTITY
103364-50-4-PD Torch & Cable Assembly - 4000, 4-Roll WOH, Pneum.,

Dither, 50' 1

103805-1 Plate, ·Triple Connector - w/Dither 1

1 03364-50-4-0 Torch & Cable Assembly - 4000, 4-Roll WOH, Mech'I.,

Dither, 50' 1

103805-1 ~Iate, Triple Connector - w/Dither 1
, REMOVED: 102191, 5208,102943-1, M103-04C-16-e (2),5930,5813 (2),103094-1,103095-1,

11247(4),5399,11134,11067, 11554-2 AND 102136-1. IE 02115/07
ADDED: 105220-1
50f5
·
DATI: IIY
10522.0-'<8
~;o~(:):J_;.;~-"r~~);'~:p-:(~)8l':;-:r:)Z}0/13/01 cJ1(
K ~;~~.?~~~~=/:~':t~~O(;:1
~
~ OEL.f,T;: D: d"e'17) IJ 13'3, III 6"l)
MZO{-.s-~~C-"4"~
j _ '_~.:(~~1~)
hOPED !'Jon ~ 1- 6"
35180
®
IO'lZTO-/
103/01;-/
t>"Ol-03C-30-C
'M~'-OllC.-FII-.'3 ) ~-------
ClAIVIP "G"(StE TABLE
MIOI-03~-30-C
M50/-0~C-FA-3
3777
/03%'t
.'~
im7;IM
····X
IDLER CALIPER ASSEMBLY Shl I of 2
MAGNATECH LIMITED PARTNERSHIP REAR, XXHD 05-Sep-00
EAST GRANBY, CT 06026 USA 103556-7 103556-7-PL
/
MAGNATECH LIMITED PARTNERSHIP IDLER CALIPER ASSEMBLY Sht 2 of 2
EAST GRANBY, CT 06026 USA REAR, XXHD 05-Sep-00
103556-7 103556-7-PL
I 10022 WASHER, THRUST - 1/2 X 15/16 X 1132 2 PART
2 10023 BEARING, THRUST - 1/2 X 15/16 X .0781 PART
3 10084 RING, RETAINING - EXTERNAL, 1/2 PART
4 103316-3 BUSHING, LOWER - CALIPER, .219 HOLE PART
5 103317-1 BUSHING, UPPER - CALIPER SHAFT PART
6 103319-2 COUPLING, CAM FOLLOWER - IDLER CALIPER PART
7 103320-5 HOUSING, IDLER CALIPER - 3/16, XXHD PART
8 103552-1 BEARING BUNG - IDLER CALIPER PART
9 103554-5 SHAFT, CAL IPER - IDL, REAR, XHD PART
10 20007 BALL, CHROME STEEL - 5/16 DIA PART
II 20160 CAM FOLLOWER - 5/8 X 1/4-28,CROWNED,HEX PART
12 30301 O-RING - .984 ID X .039 WX 70SL PART
13 35176-C1222 SPRING, COMPRESSION - .950 X .105 X 2.20 PART
14 5046 SCREW, SHC - 1/4-28 X 1/2 PART
15 5208 PIN, DOWE L - 3/ I6 X I12 PART
16 5780 LABEL, WARNING - SPRING LOADED ASSY PART
17 MI I0-03C -06 -C SCREW, LOSOCHD - M3.0 X .50 X 6MM PART
IDLER CALIPER ASSEMBLY Sht I of 2
MAGNATECH LIMITED PARTNERSHIP FRONT, XXHD 05-Sep-OO
EAST GRANBY, CT 06026 USA 103556-8 103556-8-PL
/
MAGNATECH LIMITED PARTNERSHIP IDLER CALIPER ASSEMBLY Sht 2 of 2
EAST GRANBY, CT 06026 USA FRONT, XXHD 05-Sep-00
103556-8 103556-8-PL
I 10022 WASHER, THRUST - 1/2 X 15/16 X 1/32 2 PART
2 10023 BEARING, THRUST - 1/2 X 15/16 X .0781 PART
3 10084 RING, RETAINING - EXTERNAL, 1/2 PART
5 103317 - I BUSHING, UPPER - CALIPER SHAFT PART
6 103319-2 COUPLING, CAM FOLLOWER - IDLER CALIPER PART
7 103320-5 HOUSING, IDLER CALIPER - 3/16, XXHD PART
8 103552-1 BEARING BUNG - IDLER CALIPER PART
9 103554-6 SHAFT, CALIPER - IDL, FRONT, XHD PART
10 20007 BALL, CHROME STEEL - 5/16 DIA PART
20160 CAM FOLLOWER - 518 X 1/4-28,CROWNED,HEX PART
"
12
13
30301
35176-C1222
O-RING - .984 ID X .039 WX 70SL
SPRING, COMPRESSION - .950 X .105 X 2.20
PART
PART
14 5046 SCREW, SHC - 1/4-28 X 1/2 PART
15 5208 PIN, DOWE L - 3/ I6 X 1/2 PART
16 5780 LABEL, WARNING - SPRING LOADED ASSY PART
17 MII0-03C -06 -C SCREW, LOSOCHD - M3.0 X .50 X 6MM PART
MAGNATECH LIMITED PARTNERSIDP Page 1 of 1
08/20/01
BILL OF MATERIALS
MIXER KIT. WELDING GAS - FRONIUS. C02IAR. CGA CYL
l03731-FAAAA
PART QUANTITY
38411 FITTING, liT" - CGA 580

38433 MIXER, 2 GAS - Ar/C02, 180 SCFH
38434 REGULATOR, CYLINDER - PRESET, C02, CGA320
38435 REGULATOR, CYLINDER - PRESET, Ar, CGA580
103404-BBCBB-3 HOSE ASSEMBLY - MIXER SUPPLY, liB" R4 MALE 2
103404-CBCBB-3 HOSE ASSEMBLY - MIXER OUTLET
Model 708 - 2/3

WIRE DRIVE OPTION Sht I of 2
MAGNATECH LIMITED PARTNERSHIP 4 ROL L, SP IN 28-Jun-OI
EAST GRANBY, CT 06026 USA 103761-2 I03761-2-PL
MAGNATECH LIMITED PARTNERSHIP WIRE DRIVE OPTION Sht 2 of 2
EAST GRANBY, CT 06026 USA 4 ROLL, SPIN 28-Jun-01
103761-2 103761-2-PL
I 103758-1 BRACKET, EXTENSION - BASE PLATE ·1 PART
2 103760-1 BRACKET, ENCLOSURE - WIRE DRIVE 2 PART
3 103766-2 WIRE DRIVE ASSEMBLY - 4 ROLL,S PIN I ASSEMBLY
4 103767-1 SPOOL MOUNT ASSEMBL Y - 10#, 609 I ASSEMBLY
5 103769-1 BRACKET, SWIVELING - TORCH CABLE I PART
6 103772-1 BRACKET, TORCH CABLE - FRONIUS ON HEAD I PART
7 103773-1 BRACKET ASY - TORCH CABLE I ASSEMBLY
8 MI0I-03C -08 -C SCREW, SHC - M3.0 X .50 X 8MM 4 PART
9 MI0I-03C - I2-C SCREW, SHC - M3.0 X .50 X 12MM 7 PART
II MI0I-0SC - I2-C SCREW, SHC - M5.0 X .80 X 12MM 2 PART
12 MI03-06C-12-C SCREW, FLHDSOC - M6 X 1.0 X 12MM 6 PART
13 M50I-0SC -FA-3 WASHER, FLAT - MS, DIN 125A I PART
Sht I of 2
MAGNATECH LIMITED PARTNERSHIP WIRE DRIVE ASSEMBLY 20-Mar-07
EAST GRANBY, CT 06026 USA 4 ROL L, 5 PIN 103766-2-PL
103766-2
REF. WOODRUFF KEY

PIN 80002
18/5
00 E,
MAGNATECH LIMITED PARTNERSHIP WI RE DRIVE ASSEMBLY Sht 2 of 2
EAST GRANBY, CT 06026 USA 4 ROLL, 5 PIN 20-Mor-07
103766-2 103766-2-PL
I 01664-45-1-070 TUBE, WIRE GUIDE - 07.0 X .035/.045 I ASSEMBLY
2 01664-45-2-160 TUBE, WIRE GUIDE - 16.0 X .035/.045 I ASSEMBLY
3 02061 AXLE PLATE - MODIFIED I PART
4 02144 SHIM, LAMINATED - .404 X .615 X .002 2 PART
5 03349-1 SHIELD, DRIVE ROLLS - WIRE DRIVE I PART
6 03352-1 PLATE, MOUNTING - WIRE DRIVE I PART
7 03353- I PLATE, MOUNTING - WIRE GUIDE 2 PART
8 03354 - I BLOCK, PIVOT - WIRE DRIVE I PART
9 03363-4 MOTOR AND PIGTAIL ASSEMBLY - 609,W/ 5PIN I ASSEMBLY
10 03763-1 LEVER, LOADING - WIRE DRIVE I PART
II 03764-1 ENCLOSURE ASSEMBLY - WIRE DRIVE-FRONIUS I ASSEMBLY
12 0988 WASHER, FLAT - #6, FENDER 6 PART
13 5766 LABLE, WHITE ON CLEAR - 'PIPELINER' I PART
14 80000 ROCKER PLATE - WITH AXELS I PART
15 80003 TOOTHE D WHE EL - IDLERR 0 LLER I PART
16 80004 DRIVE ROLL, WIRE - 1.2H, (.045) I PART
17 80005 PRESSURE ROLL, WIRE - 1.2H, (.045) 3 PART
21 MI02-03C-06-C SCREW, BUTHD - M3 X .50 X 6MM 4 PART
22 MI03 -05C - I6-C SCREW, FLHDSOC - M5 X .80 X 16MM 3 PART
24 M205-S-05C-06-C SETSCREW, SOCKET - DOG X M5-.8 X 6MM I PART
25 M301-10-20-C SCREW, SHOULDER - 10MM X 20MM X M8 X CS I PART
26 M602-03-14-S PIN, ROLL - 3MM X 14MM I PART
MI02-03C-06-C (4) RESUMED IN THE MODEL AND THE DRAWING or THE ASSEMBLY IE 20-Mar -07
INITIAL RELEASE

09/22/99
TORCH AND CABLE ASSEMBLY· MILLERIBINZEl
103817·15
PART QUANTITY
3777 CLAMP, CABLE - 5/16 NYLON 1
·5208 PIN, DOWEL - 3/16 X 1/2 1
5245 SAFETY WIRE, 1/32 A/R
5297 PIN, DOWEL - 1/8 X 1/2 1
8080 TAPE, ELECTRICAL - BLACK A/R
8094 CLAMP, HOSE - 11.3 2
8140 STRAIN RELIEF - W/BUSHING

8284 ADAPTOR, HOSE 3
8308 HOSE, OVERBRAIDED EPDM - 1/4 10 X 1/16 WALL 30 FT.
8309 TUBING, SHRINK - 3/8 BIN.
8365 NIPPLE, "8" SIZE 2
8377 WIRE, TINNED COPPER - #10 30 FT.
8684 CONNECTOR 1
8773 HOSE, PLASTIC, BRAIDED, %" 12 FT.
8785-8 FYRE JACKET - 3/4 10 BLACK 26 IN.
10442 "0' RING -.364 10 X .070

10469 O-RING
10610 SCREW, HEXHDSL - #6 - 20 X 1/2 SELF TAPPING 8
10841 SCREW, RNHD, #6 - 32 X 3/8, NYLON 4
11133 NUT, THUMB - #10 - 24 X 1" DIA. 1
11189 SCREW, SET - #10 - 24 X 1-1/2, CUP 1

35159 CLAMP, HOSE - 13.3 6
35180 CABLE TIE, NYLON, 6" X .280", SS, NYLON 2
38306 FITTING, BARB - 1/4 TO #21 MALE aD 1
38363 HOSE, GAS - 7/16 00 X 1/16 WALL 15 FT.
38364 NIPPLE, HOSE - 5/16 X 3/8 -24 2

50048 NUT, "8" SIZE - LH 2
50475 CABLE, SHIELDED - 20C/22GA 18 FT.
51076* .~ CONNECTOR, PANEL - #14 SHELL, 19 soc. 1
Bill OF MATERIALS
TORCH AND CABLE ASSEMBLY - MlllERIBINZEl
103817·15
PART ·QUANTITY
80089-3545-15 CONDUIT, WIRE - .035/.045 WIRE X 15'

.. 80177-55-13-02 CABLE COVER, LEATHER, BLACK, 13' 2"
102136-3 TORCH ASSEMBLY - MIG 1
102191 THUMB SCREW 1
102898-1 COVER, POWER BLOCK 1
102899-1 CAP, COVER - POWER ADAPTOR 1
102943-1 CLAMP, SPLIT - WITH PIN 1
102946-1 ADAPTOR ASSEMBLY - BRAZED
103094-1 INSULATOR ASSY, TORCH
103091-3545-309 WIRE CONDUIT - STEEL WOUND, BAR
103095-1 SHIM, INSULATOR, TORCH
103104~l-·_··_··_··· PLATE, CONNECTOR - MIG TIC
103106-1 CLAMP, MOUNTING - MIG TIC

103107-1 BLOCK, MOUNTING - MIG TIC 1
103816-1 CAP, COVER - POWER ADAPTOR 1
104014-1 ADAPTOR PLUG, TIC - MILLER
106137 POWER - WATER CONNECTOR, MODIFIED 4
M101-03C-05-C SCREW, SOCHD - M3 X 5 4
M102-04C-10-C SCREW, BUTHD - M4 X 10 2
M103-04C-16-C SCREW, FLHDSOC - M4 X 16 2
M201-S-03C-04-C SCREW, SET, M3 X 4, CUP 2
M501-04C-FA-3 WASHER, FLAT, STEEL, M4 FORM A
*51076 CONNECTOR FUNCTIONALLY EQUIVALENT TO 51080 CONNECTOR W/51 082 BACKSHELL.
Model 607A/609A
MAGNATECH LIMITED PARTNERSHIP PAGE 1 OF 3
12/01/99
TORCH AND CABLE ASSEMBLY - LINCOLN. WFOF. MECH.
103818-15
PART QUANTITY
3777 CLAMP, CABLE - 5/16" NYLON

5208 PIN, DOWEL - 3/16" X 1/2"
5245 SAFETY WIRE, 1/32" A/R
5297 PIN, DOWEL - 1/8" X 1/2" 1
5813 SCREW, FLHDSOC #8 - 32 X 5/8", ST 2
5930 RTV, BLACK A/R
8080 TAPE, ELECTRICAL - BLACK A/R
8094 CLAMP, HOSE - 11.3mm. 2
8140 STRAIN RELIEF - W/BUSHING
8284 ADAPTOR, HOSE 3
8308 HOSE, OVERBRAIDED EPDM - 1/4" ID X 1/16" WALL A/R
8309 TUBING, SHRINK - 3/8" 81N.
8684 CONNECTOR
8773 HOSE, PVC - 1/4" ID, INNER BRAID 15'
8785-B FYRE JACKET - 3/4" ID BLACK 26 IN.
10442 O-RING -.364" ID X .070"
10469 O-RING -.156" ID X .046"
10610 SCREW, HEXHDSL - #6 - 20 X 3/8" SELF TAPPING 8
10841 SCREW, RNDHD, #6 - 32 X 3/8", NYLON 4
11189 SCREW, SET - #10- 24 X 1-1/2", CUP
11133 NUT, THUMB - #10- 24 X 1" DIA.
35159 CLAMP, HOSE - 10.5mm. 5
38182 MINIATURE HOSE CLAMP
38306 QD, MALE - #21 3
38363 HOSE, GAS - 7/16" OD X 1/16" WALL 15 FT.
38364 NIPPLE, HOSE - 5/16" X 3/8 -24 2
50534-6 RETAINING BUSHING
BILL OF MATERIALS
TORCH AND CABLE ASSEMBLY - LINCOLN, WFOF, MECH.
103818-15
PART QUANTITY

51076* CONNECTOR, PANEL - #14 SHELL, 19 SOC.
51297 CABLE TIE, NYLON, 5-1/2" X .14" 2
80089-3545-1 5 CONDUIT, WIRE - .035"1.045" WIRE X 15'
80093-45 GUIDE, OUTLET - .035"1.045" WIRE
80094 ADAPTOR, GUIDE
80177-55-13-02 CABLE COVER, 13' 2" - LEATHER, BLACK
102136-3 TORCH ASSEMBLY - MIG
102191 THUMB SCREW
102898-1 COVER, POWER BLOCK
102943-1 CLAMP, SPLIT - WITH PIN
102958-1 WASHER, INSULATOR - NOZZLE
103094-1 INSULATOR, TORCH
103104-1 PLATE, CONNECTOR - MIG TIC
103107-1 BLOCK, MOUNTING - MIG TIC
103432-1 SLEEVE, ADAPTOR - TIC TO LINCOLN WIF
103816-1 CAP, COVER - POWER ADAPTOR
BILL OF MATERIALS
TORCH AND CABLE ASSEMBLY - LINCOLN, WFOF, MECH.
103818-15
PART QUANTITY

M101-03C-25-C SCREW, SOCHD - M3 X 25
M102-04C-10-C SCREW, BUTHD - M4 X 10 2
M103-04C-16-C SCREW, FLHDSOC - M4 X 16 2
M201-S-03C-04-C SCREW, SOCSET - M3 X 4, CUP 3
M501-04C-FA-3 WASHER, PLAIN, FLAT, M4, FORM A
*51076 CONNECTOR FUNCTIONALLY EQUIVALENT TO 51080 CONNECTOR W/51082 BACKSHELL.
Model 607A/609A
09/22/99
BILL OF MATERIALS
TORCH AND CABLE ASSEMBLY - PANASONICLBINZEL
103819-15
PART QUANTITY
3777 CLAMP, CABLE - 5/16" NYLON

3903 WIRE, 18 AWG. - BLACK 17 FT.
4284 TERMINAL, RING
5208 PIN, DOWEL - 3/16" X 1/2"
5245 SAFETY WIRE, 1/32" AIR
5297 PIN, DOWEL - 118" X 1/2"
5775 COVER, PLASTIC - MS 31 06/14S/C
8094 CLAMP, HOSE - 11.3mm. 2
8102 STRAIN RELIEF - WIBUSHING
8140 STRAIN RELIEF - WIBUSHING
8284 ADAPTOR,HOSE 3
8307 HOSE, OVERBRAIDED EPOM - 1/8" ID X 1/16" WALL 2 FT.
8308 HOSE, OVERBRAIDED EPDM - 1/4" ID X 1/16" WALL 30 FT.
8309 TUBING, SHRINK - 3/8" 81N.
8363 NUT, "B" SIZE
8365 NIPPLE, "B" SIZE 3
8684 CONNECTOR
8690 CONNECTOR, INLINE
8773 HOSE, PVC - 1/4" ID, INNER BRAID 9 ~ FT.
8785-B FYRE JACKET - 3/4" ID BLACK 26 IN.
10175 WASHER, LOCK - #4, INT.
10442 "0' RING -.364" ID X .070" 1
10610 SCREW, HEXHDSL - #6 - 20 X 3/8" SELF TAPPING 8
10841 SCREW, RNDHD, #6 - 32 X 3/8", NYLON 4
11189 SCREW, SET - #10 - 24 X 1-1/2", CUP
11133 NUT, THUMB - #10- 24 X 1" DIA.
BILL OF MATERIALS
TORCH AND CABLE ASSEMBLY - PANASONIC/BINZEL
103819-15
PART QUANTITY

38182 MINIATURE HOSE CLAMP
38363 HOSE, GAS - 7/16" OD X 1/16" WALL 15 FT.
38364 NIPPLE, HOSE - 5/16" X 3/8 -24 2
50048 NUT, "B" SIZE - LH 2
50534-6 REDUCING BUSHING
51076 (OR 51080 & 51082) CONNECTOR, PANEL - #14 SHELL, 19 SOC.
80089-3545-1 5 CONDUIT, WIRE - .035"/.045" WIRE X 15'
80093-45 GUIDE, OUTLET - .035"/.045" WIRE
80094 ADAPTOR, GUIDE
80177-55-13-02 CABLE COVER, 50 FT. - LEATHER
85159 CLAMP, HOSE - 13.3mm. 5
102136-3 TORCH ASSEMBLY - MIG
102191 THUMB SCREW
102898-1 COVER, POWER BLOCK
102943-1 CLAMP, SPLIT - WITH PIN
100175 FITTING, WATER-MODIFIED 2
102896-1 POWER BLOCK - W /D ADAPTOR
102897-1 NIPPLE, POWER BLOCK - WID ADAPTOR
103094-1 INSULATOR ASSY, TORCH
5813 SCREW, FLHDSOC, #8-32 x 5/8" 2
5930 RTV, BLACK A/R
BILL OF MATERIALS
TORCH AND CABLE ASSEMBLY - PANASONIC/BINZEL
103819-15
PART QUANTITY

103104-1 PLATE, CONNECTOR - MIG TIC
103107-1 BLOCK, MOUNTING - MIG TIC
103277-1 SLEEVE, ADAPTOR - OTC TIC TO PANASONIC W/F
M 101-03C-05-C SCREW,SOCHD - M3 X 5 4
M 101-03C-06-C SCREW, SOCHD - M3 X 6
M 101-03C-08-C SCREW, SOCHD - M3 X 8 2
M 101 -03C-30-C SCREW, SOCHD - M3 X 30
M 102-04C-1 O-C SCREW, BUTHD - M4 X 10 2
M 103-04C-1 6-C SCREW, FLHDSOC - M4 X 16 2
M201-S-03C-04-C SCREW, SOCSET - M3 X 4, CUP 3
M501-04C-FA-3 WASHER, FLAT, M4 FURM'A', ST
MODEL 607/609
HINGE ASSEMBLY Sht I of 2
MAGNATECH LIMITED PARTNERSHIP POLY-TRACK GUIDE RING 06-Noy-02
EAST GRANBY, CT 06026 USA 103879-H 103879-H-PL
MAGNATECH LIMITED PARTNERSHIP HINGE ASSEMBLY Sht 2 of 2
EAST GRANBY, CT 06026 USA POLY-TRACK GUIDE RING 06-Noy-02
I03879-H I03879-H-PL
I 103041-3 BAR, CONNECTING - HINGE 2 PART
2 103043-3 SHAFT, CONNECTING - HINGE I' PART
3 103043-4 SHAFT, CONNECTING - LATCH I PART
4 103757-1 SCREW, CAPTIVE - MODIFIED M6 X 80 I PART
5 11196 WASHER, FLAT - #4, HARD, THICK I PART
6 35140-C2 SPRING, COMPRESSION - .360 X .035 X 2.500 I PART
7 5239 PIN, ROLL - 3/32 X 3/4 4 PART
8 MI0I-03C -06 -C SCREW, SHC - M3.0 X .50 X6MM I PART
10 M20017 WASHER, FLAT - M6, HARD, THICK I PART
II M501-06C-FA-3 WASHER, FLAT - M6, DIN 125A 2 PART
LATCH ASSEMBLY Sht I of 2
MAGNATECH LIMITED PARTNERSHIP POLY-TRACK GUIDE RING 06-Nov-02
EAST GRANBY, CT 06026 USA 103879-L 103879-L-PL
MAGNATECH LIMITED PARTNERSHIP LATCH ASSEMBLY Sht 2 of 2
EAST GRANBY, CT 06026 USA POLY-TRACK GUIDE RING 06-Nov-02
I03879-L I03879-L-PL
I 103041-3 BAR, CONNECTING - HINGE I PART
2 103041-4 BAR, CONNECTING - LATCH I PART
3 103043-3 SHAFT, CONNECTING - HINGE I PART
4 103043-4 SHAFT, CONNECTING - LATCH I PART
5 103757-1 SCREW, CAPTIVE - MODIFIED M6 X80 I PART
6 I1196 WASHER, FLAT ~ #4, HARD, THICK I PART
7 35140-C2 SPRING, COMPRESSION - .360 X .035 X 2.500 I PART
8 5239 PIN, ROLL - 3/32 X 3/4 2 PART
9 MI01-03C-06-C SCREW, SHC - M3.0 X .50 X6MM I PART
10 M10I-03C - I0-C SCREW, SHC - M3.0 X .50 X 10MM 8 PART
II M20017 WASHER, FLAT - MG, HARD, THICK I PART
12 M501-0GC-FA-3 WASHER, FLAT - MG, DIN 125A 2 PART
Sht I of I
MAGNATECH LIMITED PARTNERSHIP OSC. & POT. DRIVE ASSEMBLY 23-Apr-08
103205-1 COVER, POTENTIOMETER - PART
2 103929-1 WASHER, TEFLON - 1/4 X 5/8 X 1/16 PART
3 103931-1 GEAR, SPUR - 24P X 12T X 20 DEG. PART
4 103932-1 PULLEY, TIMING - 1/4 BORE. .08P X .815PD PART
5 103933-1 HOUSING & INSERTS ASSEMBLY - INCH ASSEMBLY
6 103935-' OSC. MOTOR ASSY. - WI POT DRIVE ASSEMBLY
7 103953-1 PULLEY, TIMING - .08P X .459PD, MODIFIED ASSEMBLY
8 103980-1 OSC. POT. ASSEMBLY - POT. DRIVE ASSEMBLY
9 11210 SPACER, SHAFT - .250 X .375 X .016 PART
10 25070 PIN, HD SPIRAL - 3132 X 3/8 PART
30291 BELT, TIMING - .oap X 4.40PL X 1/8W PART
"1312 MI01-03C-04-C
MI01-03C-08-C
SCREW, SHC - M3.0 X .50 X 4MM
PART
PART
15 M20018 SETSCREW, SOCKET - BRASS TIP X M3-.5 X 3MM 4 PART
DELETED 103202-' 23-Apr-08

CHANGE DESCRIPTION DATE
Sht I of 2
MAGNATECH LIMITED PARTNERSHIP OSC. & POT. DRIVE ASSEMBLY 02-May-00
NUT &LOCKWASHER
SUPPLIED WI POT
MAGNATECH LIMITED PARTNERSHIP osee & POT. DRIVE ASSEMBLY Sh t 2 0 f 2
EAST GRANBY, CT 06026 USA 103930-1
02-Moy-00
103930-I-Pl
I PART t DESCRIPTION QTY TYPE
I 103202-1 PLATE MOUNTING - POT. PART
2 103205-1 COVER POTENTIOMETER - PART
3 103929-1 WASHER TEFLON - 1/4 X5/8 X 1/16 PART
4 103931-1 GEAR SPUR - 24P X 12T X20 DEG. PART
5 103932-1 PULLEY TIMING - .08P X .815PO PART
6 103933-1 HOUSING & INSERTS ASSEMBLY - OSC. POT. DRIVE ASSEMBLY
7 103935-1 OSC. MOTOR ASSY. - W/ POT DRIVE ASSEMBLY
8 103953-1 PULLEY TIMING - .08P X .459PO MODifiED ASSEMBLY
9 103980-1 OSC. POT. ASSEMBLY - POT. DRIVE ASSEMBLY
10 11210 SPACER SHAfT - .250 X .375 X .016 PART
II 25010 PIN HD SPIRAL - 3/32 X 3/8 PART
12 30291 BELT TIMING - .oap X 4.40PL X 1/8W PART
13 MI 01-03C-04-C SCREW SHC - N3.0 X .50 X4MM PART
14 NI01-03C-08-C SCREW SHC - N3.0 X .50 X8NN PART
15· NI02-03C·-06-C SCREW. BUTHD - M3X .50 X6NM 4 PART
16 MZOOl8 SETSCREW. SOCKET - BRASS TIP XM3-.5 X3 4 PART
OSCILLATOR ASSEMBLY Shf I of 2
MAGNATECH LIMITED PARTNERSHIP CALIPER DRIVE. 4" 02-May-01
EAST GRANBY. CT 06026 USA 103949- I 103949-I-PL
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MAGNATECH LIMITED PARTNERSHIP OSCILLATOR ASSEMBLY Sht 2 of 2
EAST GRANBY, CT 06026 USA CALIPER DRIVE, 4 11
02-May-01
103949-1 103949-I-PL
D PART # DESCRIPTION aTY TYPE
I 02810-3 SLIDEWAY, FLAT - 4 IN, POT BELT I PART
2 02828- I BLOCK, SWITCH TRIP - 2 PART
3 02829-1 RACK, OSCILATOR - DRIVE, 24P I PART
4 03088- I SIDE SHIELD ASSEMBLY - LONG I ASSEMBLY
5 03088-2 SIDE SHIELD ASSEMBLY - SHORT I ASSEMBLY
6 03136-1 BRACKET, MOUNTING - TORCH HEIGHT ASSEMBLY I PART
7 03160-1 SHIELD ASSEMBLY - OSCILLATOR RACKS I ASSEMBLY
8 03173-2 OSC. LIM. SW. ASSY. - WI CONNECTOR I ASSEMBLY
9 03342-0562 STANDOFF, M3 FIF - 1/4 HEX X 9/16 3 PART
10 03342 - I188 STANDOFF, M3 FIF - 1/4 HEX X 1-3/16 2 PART
II 03930-1 OSC. &POT. DRIVE ASSEMBLY - I ASSEMBLY
12 03942-1 STRAP, STIFFENING - OSCILLATOR I PART
13 03945- I-C I SHIM, LAMINATED - .156 ID X 7/16 OD I PART
14 03948- I BASE PLATE - OSCILLATOR I PART
15 20142 JOURNAL - ASS'Y, ECCENTRIC 25MM 2 PART
16 20144 CAP SEAL - 25mm 4 PART
17 20169 JOURNAL - BLIND HOLE 25MM 2 PART
18 8199 ACTUATOR, SWITCH - 2 PART
25 MI03 -03C - I0-C SCREW, FLHDSOC - M3 X .50 X 10MM 2 PART
26 MI03-04C-08-C SCREW, FLHDSOC - M4 X .70 X 8MM 2 PART
27 MI03-04C-14-C SCREW, FLHDSOC - M4 X .70 X 14MM 4 PART
28 M104 -02C - 10 -C SCREW, FLHDSL - M2 X .4 X IOMM 4 PART
29 M20025 STUD, FLUSH HEAD - .04 X M4 X 12MM I PART
30 M401-02C-C NUT, HEX - M2 2 PART
31 M501-03C-FA-3 WASHER, FLAT - M3, DIN 125A 14 PART
32 M507-04C-TV-S WASHER, C'SUNK LOCK - M4 2 PART
ADDEDM20025 05/02/01
INITIAL RELEASE

Sh t 1 0 f 2
NAGNATECH LIMITED PARTNERSHIP TRACTOR AND OSC. ASSEMBLY I7-Mor -00
EAST GRANBY, CT 06026 USA CALIPER DRIVE. 609A 103950-I-PL
103950-1
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I II
I I I I
I
,
I
-----
0
MAGNATECH LIMITED PARTNERSHIP TRACTOR AND OSC. ASSEMBLY Sht 2 of 2
EAST GRANBY, CT 06026 USA CALIPER DRIVE, 609A 17-Mor-OO
103950-1 I03950-'-Pl
1 PART t DESCRIPTION OTY TYPE
I 103114-2 TRAVEL NTR. ASSY. - TACH 180: I CONNECTOR I ASSEMBLY
2 103304-1 DRIVE WHEEL ASSEMBLY - CALIPER DRIVE I ASSEMBLY
3 103305-1 IDLER WHEEL ASSEMBLY - I ASSEMBLY
4 103332-1 GEAR DRIVE - 21 TOOTH PINION I PART
5 103344-1 HOUSING SWITCH - TRAVEL REVERSE I PART
6 103345-1 BLOCK BEARING STANDOFF - 2 PART
7 103346-1 BLOCK BEARING STANDOFf - SNALL PIPE 2 PART
8 103347-' BLOCK STOP - LIMIT PIN I PART
9 103426-2 SWITCH ASSEMBLY TRAVEL REVERSE - LOCKING I ASSEMBLY
10 103493-1 CLUTCH ASSEMBLY - TRAVEL MOTOR I ASSEMBLY
II 103495-1 ARM RETAINER - TRAVEL CLUTCH I PART
12 103949-1 OSCILLATOR ASSEMBLY - CALIPER DRIVE 4- I ASSEMBLY
13 35082 BAll PLUNGER - I PART
I. 5818 NUT HEX - 110-32 1 PART
15 MI 01-03C-08-C SCREW SHC - M3.0 X .50 X8NM 2 PART
16 NI 0I-03C-16-C SCREW SHC - M3.0 X ~50 X 16NM 4 PART
17 NI01-03C-20-C SCREW. SHC - M3.0 X .50 X20NN 2 PART
18 NI 0I-03C-30-C SCREW SHC - M3.0 X .50 X30MM 2 PART
19 NI 0I-04C-12-C SCREW SHe - M4.0 X .10 X 12MM I PART
20 NI OI-04C-16-C SCREW SHC - M4.0 X .10 X 16MM 10 PART
21 NI 01-04C-25-( SCREW. SHC - M4.0 X .10 X25MM 4 PART
22 M201-S-03C-04-C SETSCREW SOCKET - CUP XM3-.5 X4MM 2 PART
23 M501-03C-FA-3 WASHER fLAT - N3 DIN 125 2 PART
24 M501-04C-FA-3 WASHER. FLAT - M4 DIN 125 12 PART
25 M503-04C-FJ-S WASHER LOCKING - INT N4 DIN 6791-J4 I PART
WELDHEAD ASSEMBLY Sht I of 2
MAGNATECH LIMITED PARTNERSHIP MODEL 609A, MECH. 02-MAY-OI
MAGNATECH LIMITED PARTNERSHIP WELDHEAD ASSEMBLY Sh t 2 0 f 2
EAST GRANBY, CT 06026 USA MODEL 609A, MECH. 02-MAY-01
103951-1 103951-I-PL
I 102830-1 TORCH HEIGHT ASSEMBLY - STD STROKE I ASSEMBLY
2 102938- I BRACKETRY ASSEMBLY - TORCH MOUNTING I ASSEMBLY
3 103308-1 ACTUATOR ASSEMBLY, MECHANICAL - DRIVE CALIPER 2 ASSEMBLY
4 103308-2 ACTUATOR ASSEMBLY, MECHANICAL - IDLER CALIPER 2 ASSEMBLY
5 103333-1 ENCLOSURE, ELECTRICAL - TRACTOR I PART
6 103342-0562 STANDOFF, M3 FIF - 1/4 HEX X 9/16 3 PART
7 103348-1 PLATE, COVER - ENCLOSURE CUTOUT I PART
8 103418-11 UNIV. FRICT. DRV HD PCB - STD WIO CCS I ASSEMBLY
9 103425-1 CABLE, HEAD TO TIC - WI CONNECTOR I ASSEMBLY
10 103950-1 TRACTOR AND OSC. ASSEMBLY - CALIPER DRIVE, 609A I ASSEMBLY
25038 PLUG, CHASSIS - 1/4 X 1/16 2 PART
"
12
13
25063
3777
PLUG, CHASSIS - 3/8 X 1/16
CLAMP, CABLE - 5/16
I
I
PART
PART
14 4208 CLAMP, CABLE - 3/16 2 PART
15 5766 LABLE, WHITE ON CLEAR - 'PIPELINER' I PART
16 5770 LABLE, WHITE ON CLEAR - MAGNATECH/PATENT#, 3/4 X 3 2 PART
17 80117 HANDLE,OFFSET - 3/8D X 3H X 4-1/4L 2 PART
19 MI01- 03C - 10-C SCREW, SHC - M3.0 X .50 X 10MM 2 PART
22 MI 02-03C-1 O-C SCREW, BUTHD - M3 X .50 X 10MM I PART
24 M401-04C-C NUT, HE X - M4 I PART
25 M501-03C-FA-3 WASHER, FLAT - M3, DIN 125A 3 PART
26 M501-04C-FA-3 WASHER, FLAT - M4, DIN 125A I PART
27 M503-04C-FJ-S WASHER, LOCKING - INT M4, DIN 6797-J4 6 PART
28 M503-05C-FJ-S WASHER, LOCKING - INT M5, DIN 6797-J5 4 PART
ADDED M401-04C-C 05/02/01

INITIAL RELEASE

Sh t lor 2
MAGNATECH LIMITED 'PARTNERSHIP WELDHEAD ASSEMBLY 02-MAY-01
EAST GRANBY, CT 06026 USA MODEL 609A, PNEU. 103951-P-PL
I03951-P
/
\ /
\ /
\ /
\ /
\ /0 0
\
\
~
\, ~
'r:(
MAGNATECH LIMITED 'PARTNERSHIP WELDHEAD ASSEMBLY Sh!2of2
EAST GRANBY, CT 06026 USA MODEL 609A, PNEU. 02-MAY-01
103951-P 1039'SI-P-PL
# PART • DESCRIPTION OTY TYPE
I 102B30-1 TORCH HEIGHT ASSEMBLY - STD STROKE I ASSEMBLY
2 102938-1 BRACKrTRY ASSEMBLY - TORCH MOUNTING I ASSEMBLY
3 103309-1 ACTUATOR ASSEMBLY, PNEUMATIC - IDLER CALIPER 2 ASSEMBLY
4 103309-2 ACTUATOR ASSEMBLY, PNEUMATIC - DRIVE CALIPER 2 ASSEMBLY
5 103310-2 VALVE AND FITTING ASSEMBLY - PNEU WI MALE OD I ASSEMBLY
6 103333-1 ENCLOSURE ELECTRICAL - TRACTOR I PART
7 103342-0562 STANDOFF. M3 FIF - 1/4 HEX X 9/16 3 PART
8 103418- I I UNIV. FRICT. DRV HD PCB - STD WIO CCS I ASSEMBLY
9 103425-1 CABLE. HEAD TO TIC - WI CONNECTOR I ASSEMBLY
10 103950-1 TRACTOR AND OSC. ASSEMBLY - CALIPER DRIVE. 609A I ASSEMBLY
II 2S038 PLUG CHASSIS - 1/4 X 1/16 I PART
12 2 S063 PLUG. CHASSIS - 3/8 X 1/16 I PART
13 3777 CLAMP. CABLE - S/16 I PART
14 4208 CLAMP. CABLE - 3/16 2 PART
IS S766 LABLE. WHITE ON CLEAR - 'PIPELINER' I PART
16 S170 LABLE. WHITE ON CLEAR - MAGNATECH/PATENTI, 3/4 X 3 2 PART
11 80 I 17 HANDLE,OFFSET - 3/8D X 3H X 4-1/4L 2 PART
19 101
I0 I-0 3C - I0 -C SCREW, SHC - 1013.0X .SO X 10MM 2 PART
20 MI01-05C-16-C SCREW, SHC - 1015.0X .80 X 16MM 4 PART
21 MI02-03C-06-C SCREW, BUTHD - 1013X .SO X 6MM 4 PART
22 101
I02 -0 3C - I0 -C SCREW, BUTHD - 1013X .50 X 10MM I PART
23 MI03-06C-16-C SCREW. FLHDSOC - M6 X 1.0 X 16MM 2 PART
24 M401-04C-C NUT, HE X - 1014 I PART
2S MSOI-03C-FA-3 WASHER, FLAT - 1013,DIN 12SA 3 PART
26 MSOI-04C-FA-3 WASHER, FLAT - 1014,DIN 12SA I PART
27 MS03-04C-FJ-S WASHER, LOCKING - INT 1014.DIN 6797-J4 6 PART
28 MS03-0SC-FJ-S WASHER, LOCKING - INT loiS,DIN 6797-JS 4 PART
ADDED M~OI -O~C-C 0510210 I

INITIAL RELEASE

MAGNATECH LIMITED PARTNERSHIP WELDHEAD ASSEMBLY Sht 2 of 2
EAST GRANBY, CT 06026 USA MODEL 609A, PNEU., DITHER
I03951-PD
02- Au 1- 00
10395 -PD-Pl
t PART t DESCRIPTION ary TYPE
I 02830-1 TORCH HEIGHT ASSEMBLY - STD STROKE I ASSEMBLY
2 02944-1 CLAMP SPLIT - WITH SLOT I PART
3 03190-1 TORCH AXIAL SLIDE ASSEMBLY - MIG I ASSEMBLY
4 03309-1 ACTUATOR ASSEMBLY PNEUMATIC - IDLER CALIPER 2 ASSEMBLY
5 03309-2 ACTUATOR ASSEMBLY PNEUMATIC - DRIVE CALIPER 2 ASSEMBLY
6 03310-2 VALVE AND FITTING ASSEMBLY - PNEU WI MALE 00 I ASSEMBLY
1 03333-1 ENCLOSURE ELECTRICAL - TRACTOR I PART
8 03342-0562 STANDOFF M3 Flf - 1/4 HEX X 9/16 3 PART
9 03418-11 UNIV. FRICT. DRY HD PCB - STD "0 CCS 1 ASSEMBLY
10 03425-1 CABLE, HEAD TO TIC - WI CONNECTOR I ASSEMBLY
II 03840-1 DITHER OSCILLATOR ASSEMBLY - PIPELINER II I ASSEMBLY
12 03950-1 TRACTOR AND 05C. ASSEMBLY - CALIPER DRIVE 609A 1
., ASSEMBLY
13 25038 PLUG CHASSIS - 1/4 X 1/16 PART
14 25063 PLUG CHASSIS - 3/8 X 1/16 I PART
15 . 3111 CLAMP CABLE - 5/16 I PART
11 5766 LABLE WHITE ON CLEAR - 'PIPELINER' I PART
18 5170 LABLE WHITE ON CLEAR - MAGNATECH/PAT.PEND 3/4 X3 2 PART
19 80111 HANDLE OffSET - 3/80 X3H X4-1/4L 2 PART
21 NI01-03C-06-C SCREW SHC - N3.0 X .50 X6MM I PART
22 NI01-03C-12-C SCREW SHC - M3.0 X .50 X 12MM 2 PART
23 NI01-04C-16-C SCREW SHC - N4.0 X .70 X 16MM I PART
24 M10 1-05C-16-C SCREW SHC - M5.0 X .80 X 16MM 4 PART
25 MI01-06C-20-C SCREW SHC - M6.0 X 1.0 X20WN I PART
26 MI02-03C-06-C SCREW BUTHD - N3 X .50 X6NM .- PART
21 MI02-03C- I0-C SCREW 8UTHD - N3 X .50 X 10NN I PART
28 M501-03C-FA-3 WASHER, fLAT - M3 DIN 125 4 PART
29 M501-06C-fA-3 WASHER FLAT - N6 DIN 125 I PART
30 M503-04C-FJ-S WASHER LOCKING - INT N4 DIN 6197-J4 6 PART
31 M503-05C-FJ-S WASHER LOCKING - INT N5 DIN 6191-J5 .- PART
..,.
WIRE DRIVE ASSEMBLY Sh t I 0f 2
MAGNATECH LIMITED PARTNERSHIP PUSH-PULL 07-Feb-08
MAGNATECH LIMITED PARTNERSHIP WIRE DRIVE ASSEMBLY Sh t 2 0 r 2
EAST GRANBY. CT 06026 USA PUSH-PULL 07-Feb-08
103955-1 103955-I-PL
1I PART I DESCRIPTION OTY TYPE
I 103957-1 CLAMP CABLE - pop INLET FLANGE I PART
2 103959-1 TUBE TRANSFER - WIRE CONDUIT I PART
3 103960-2 INLET FLANGE W/ PIN - (SEE TABLE) I ASSEMBLY
4 103961-1 GUIDE OUTLET - pop WIRE DRIVE I PART
5 103962-1 OUTLET FLANGE W/ PIN - PIP WID I ASSEMBLY
6 103963-1 MOUNT CLAMP - Pop WIRE DRIVE I PART
7 103966-1 ARM PIVOT - Pop WID MOUNT I PART
8 I03976-I-C I INSULATOR. MYLAR - pop WID I PART
9 104046-1 HOUSING. WIRE DRIVE - PUSH/PULL I PART
10 104456-1 MOTOR &PIGTAIL ASSEMBLY - pop WIRE DRIVE I ASSEMBLY
II 105308- I NOZZLE INLET. MODIFIED - PUSH/PULL I PART
12 5973-C4 TAPE KAPTON - 3/4 X 2MIL 2 PART
13 80184 NUT. CAP - M72 X 1.5 2 PART
14 80185 NOZZLE. WIRE GUIDE - 0.8 - 1.2mm 2 PART
15 80186 COVER. WIRE DRIVE - PUSH/PULL I PART
16 80188 AXLE 9.5mm - DRIVEN ROLL ARM I PART
17 80191 LOADING BLOCK - PUSH/PULL I PART
18 80193 AXLE DRIVEN WHEEL - PUSH/PULL I PART
19 80194 TENSION BLOCK - PUSH/PULL I PART
20 80207 ARM. TENSIONER - WIRE DRIVE I PART
21 80208 TENSIONER ASSEMBLY - WIRE DRIVE I PART
22 80229-012 WIRE DRIVE ROLL - 1.2mm W/ KEYWAY I PART
23 80229-P12 WIRE PRESSURE ROLL - 1.2mm W/ BEARING I PART
24 8094 CLAMP HOSE - on IKER 11.3MM 2 PART
25 MI01-03C-16-C SCREW SHC - M3.0 X .50 X 16MM I PART
28 MI01-05C-16-C SCREW. SHC - M5.0 X .80 X 16MM I PART
29 MI01"06C-25-C SCREW SHC - M6.0 X 1.0 X 25MM I PART
30 MI 01-06C-40-C SCREW SHC - M6.0 X 1.0 X 40MM I PART
31 MI12-03C-08-C SCREW PHILLIPS CHSHD - DIN7985 M3 X8 2 PART
32 M20020 RING RETAINING - EXTERNAL. 6MM I PART
33 M20021 RING. RETAINING - EXTERNAL 8MM I PART
34 M20022 WASHER. LOCK - DBL SERATED M6 I PART
35 M204-S-04C-08-C SETSCREW. SOCKET - CONE X M4-.7 X8MM 3 PART
36 M406-06C-C NUT HEX FLANGE - M6 X 1.0 DIN6923 I PART
37 M501-03C-FA-3 WASHER FLAT - M3. DIN 125A I PART
38 M501-05C-FA-3 WASHER. FLAT - M5. DIN 125A I PART
39 M501-06C-FA-3 WASHER HAT - M6 DIN 125A I PART
... ... ........ ... ..... .....
105308-1 WAS 80196 IE 01-Feb-08

DElETED 80190-12(21. 80189. 80192; ADDED 80229-PI2. 80229-D12 1CK 10-Jul-01
Sht , of 2
MAGNATECH LIMITED PARTNERSHIP ADJ KNOB ASSY 05-Dec-OI
EAST GRANBY, CT 06026 USA WI SPRING & BUTTON /03970-/-PL
103970-1
SPRINGS IN
SERIES AS
SHOWN
MAGNATECH LIMITED PARTNERSHIP ADJ KNOB ASSY Sht 2 of 2
EAST GRANBY, CT 06026 USA WI SPRING &BUTTON 05-Dee-OI
103970-1 f 03910-'-Pl
t PART t DESCRIPTION OTY TYPE

I 103965-2 KNOB ADJUSTMENT - ASSY WI NUT I PART
2 35185-CI SPRING WASHER BELLEVILLE - 3/16 X3/8 X .015 X .027 15 PART
3 80204 LOADING 8UTTON - P-P THREADED I PART
4 M405-03C-C NUT LOCKING HEX - M3X.4 NYLON I PART
5 M501-03C-FA-3 WASHER FLAT - M3 DIN 125 I PART
£ 1R~T .... CLI'9,N/P "e" eIfBLE. "0 PLATE.' E" 5ci\EW' "F" liDS e. "P" flE.F'.
F' I0:3~96' -2;;- 3777 NONE. 10335'1/-/ NON!:. NONE. wlo PNlWMilnc lOR DITHER'OPT/ONS
F- !03<j<jG-25:-P 3777 NONE 103351-1 NONE lo3"1n-;358 wlpNEUMIlTIC" w/O DITI-l,Ef(.
-------
F 10 3',';} 96- Z5-P D 377'] 103"186-358 103805-1 MIOI-C>3C-0' -c(~) 103'1"12.-358. wI PJiEUMI\'T1C.&,DJI1-l E R
F /039'36- ?s:-D 377'1 103"166-358 103805"-\ Mlal cO~C-06 -c (~) NONE. tvlo PNEVMI1TIC, W/bITHER,
-------
,03"1 Blf-300(a)
S?'fs, 8080 ®
8094
I05ZZQ-I® '
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fl.EF
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8080
","
80177-55-22 -M
b~SLEE.VETHERADIUS C.NTRL.ROD (lii4:268-I)WI

80098-/2 (.OllS) TUB IM<'r(:>H41),C. e.IIlTER EDAS;'HOWN) A lIID WRAP
W/TAIOE,(8080}: SE~ VIE.W A.
5 -Fi ~'s fJ,Wf/-TER.L!NE s wi 7S~6 f)F..lo"'~e'D
WATt, ,;/
, 2'5%' ETHUENEGI-YCOL AFTER ,-rF:ST!tJ{i,.
103:185-358
REF. "1- 'rEsT FoR. ;J1)E c:iIJ.97:fG"/:; r,:c,.C'
lO'lZ,73-'2,II$s·r 3 -WJ9T1:f( I-.[AKT·EST~ j'J1) j.~fflj\/JGf'~ fD PSI
103987-358 - - - - - " . .
REF. /0'16')
2- vOl~-r.AGE reO? NoT TD cXttf"D /.SO v DC. e t'OO,.,mps
8oo~'
- 2 PU:.S.
3&4-73 fREF".;
MAGNATECH .l.IMITED PAfIITNERSHl1'
- , 103985--:358 (RE.f»
80eo I
-'
USTMANS\'. CONN'RC1ICUT
o c::=====E:3-- PNEVMATIC 5UPPlY(OPTIONAL)

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II lIllT.¥ ·CL~MP"C··Ci'l"e.LE.' L E. ScltEw,"f" 110SE."P" RE.F:
J1"U-If-'-\::'O"-";"'l"'9:"6'-'_-I_-5~+-'-----------+' ';;0=-r"77-'--+"-N::'O!<N=;E.:=-"--t'-''''()3=C>-=5'-9-=--I-t-=N'''-''D';;NC=~'-'.'---'---PN~O::'N"'e.'-· ..L'---f~w-"l"''O:..·'-PN-. -W-M~Il-n":'c-b~'-D-/T-H-E-R-o-P-T-IO-N":" "--5+
\O;)996-15-P 3777 NONE. IO:,~59-1 NONE. 103'1'12.-238 W/PNEU/V1/1iIC"e.u!ODITH,EI\.
I03396-15-PJ) 3779 I03'1a6-23B 10:0805-1 Miol-O~C.-O' -C(~) !039'fZ-23S+W-/;":P=-)j-'--,E-V'"CM-'--fl'"C'Te::·-,--,C:-'''''£:-,-D;-':.//1-1=·'"C=
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10:>996 -15-11 377.9 I03~86- 238 10-:0805-\ MIOI ~O~C-06 -c (~) NON E. (;;10 PNEVMIl:PC';ciJ;"'-b'-,T"'/i""'E .,--·-R-------J
I03~ 9'/-180 (2)

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PUNCH t40l,..e
c;#!!iLe i#.:.i'l>ciVT;;T:6~16HT
fiN}? ,CONDUIT I,S ?VS;Hl!:I>:,IH.--
8080 - 8008:t-~S4$- 15, lteF.'
80177-55- /2-,M
b- ~l..i;,&.-lVET·HE fl,Al)~U$C.t.lT~l..ll.OO,' {.~e-t>,wl

8005'8-12, (d'lS) 1:l.l!}l~6-(3i541},CItIltT"HP ASf.JoI'O;il.iN;Aiw W4Af'
W/T)\.Ill=-(3080).· SE.E ·YII:WA. ' , '
5-iiUSi-I,WIHFRLINES w/7S% D£IO""~eD I.VAT€,R)
, 1::5%: ETflr'./..ENc. GI.-'f<!oL RFTER'TEsiJNf5,.
'1- t£"7 FOR. rJDE QU/iTL6f1 snow,
3-Wf/TU i--.~!JKT£$T; No.LB1KliGE€ GO PSI,
z- 'v'on"flGE l),zo1" NOT TO £xCffiD .90VDC.€/OO,,';'1'$
/-lA..!/rrEiR FI,OlU TE::>T; .,/S6P M MIN.e..S-01"s/
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Page 1 of3

BILL OF MATERIALS
TORCH AND CABLE ASSEMBLY - P-P, 15'
103996-15(-XX)
PART QUANTITY

5245 SAFETY WIRE, 1/32 AIR
8094 CLAMP, HOSE - 11.3 MM. 2
8785-B FYRE JACKET - 3/4 ID BLACK AIR
10427 O-RING - .208 ID X .070 W 1
10469 O-RING - .156 ID X .046 W 1
11085 SCREW, HEX WASHER HEAD - #6 X 1/2, SLOTTED 2
35137 CLAMP, HOSE - 10.0 MM. 2
35180 CABLE TIE, 6" X .280, SS, NYLON 2
38329 CLAMP, HOSE - 7.0 MM. 2
38445 HOSE, REINFORCED URETHANE - 1/2 ID X .035 W AIR
38473 TUBING, NYLON - FLEXIBLE, 3/8 x .05, BLK AIR
38541 TUBING, POLYETHYLENE - 3/8 OD X .062 WALL AIR
80089-3545-15 CONDUIT, WIRE - .035/.045 WIRE X 15' 1
80098-12 NOZZLE, WIRE INLET - 1.2MM WIRE 1
80099 CAP NUT - M40 X 1.5 1
80177-55-12-09 CABLE COVER, LEATHER - 5.5W x 12'9"L 1
103091-3545-375 CONDUIT, WIRE - .035/.045 WIRE, 3.75 LONG 1
103956-1 KNOB, THUMB - WIRE CONDUIT 1
103958-1 FITTING, FLANGED - WIRE CONDUIT 1
103981-1 CLAMP, MOUNTING - MIG TIC, P-P 1
103984-180 POWER/H20 CABLE ASSY-FEMALE "A' x 15' (180") 2
103987-238 WIRE DRIVE CONTROL CABLE ASSY - 19' 10" (238") 1
Page 2 of3

BILL OF MATERIALS
103996-15(-XX)
PART QUANTITY
103989-1 FITTING, BARB-WIRE CONDUIT HOSE 1

104271-1 BLOCK MOUNTING TIC LARGE W/ROD 1
104273-2 POWER ADAPTOR BRAZED WHO P-P WIROD 1
M 103-04C-1 O-C SCREW, FLHDSOC - M4 X 10 1
M501-04C-FA-3 WASHER, FLAT, 4MM FORM A 2
Page 3 of3

BILL OF MATERIALS
103996-1 5f-XX)
PART QUANTITY
Add The Following Parts to Complete The Bill of Materials For The Given Dash Number Assy
103996-15 (T & C ASSY - 4000, P-P, MECH.)

103359-1 PLATE, DUAL CONNECTOR - TIC 1
103996-15-P (T & C ASSY - 4000, P-P, PNEU.) 1

103359-1 PLATE, DUAL CONNECTOR - TIC
103992-238 PNEUMATIC SUPPLY HOSE ASSY - 19' 10" (238")
3777 CLAMP, CABLE - 5/16 NYLON
103996-15-PD (T & C ASSY - 4000, P-P, PNEU., DITHER)

3779 CLAMP, CABLE - 1/2, NYLON 1
103986-238 DITHER CONTROL CABLE ASSY - 19' 10" (238 ") 1
103805-1 PLATE, TRIPLE CONNECTOR - WIDITHER 1
M 101-03C-06-C SCREW, SHCS - M3 X 6 4
103996-15-D (T & C ASSY - 4000, P-P, MECH., DITHER)

M 101-03C-06-C SCREW, SHCS - M3 X 6 4
Model 609 A
INITIAL RELEASE 07/16/08
CHANGE DESCRIPTION DATE

EAST GRANBY, CONNECTICUT 06026 01126/01
11/12/01
04/18/05
TORCH AND CABLE ASSEMBLY - 4000/P-P 02/13/07
07/09/07
1 03996-25(~
PART QUANTITY

5245 SAFETY WIRE, 1/32 AIR
8094 CLAMP, HOSE - 11.3 MM. 2
8785-B FYRE JACKET - 3/4 ID BLACK AIR
10427 O-RING - .208 ID X .070 W 1
10469 O-RING - .156 ID X .046 W 1
11085 SCREW, HEX WASHER HEAD - #6 X 1/2, SLOTTED 2
35137 CLAMP, HOSE - 10.0 MM. 2
35180 CABLE TIE, 6" X .280, SS, NYLON 2
38329 CLAMP, HOSE"': 7.0 MM. 2
38445 HOSE, REINFORCED URETHANE - 1/2 ID X .035 W AIR
38473 TUBING, NYLON - FLEXIBLE, 3/8 x .05, BLK AIR
38541 TUBING, POLYETHYLENE - 3/8 OD X .062 WALL AIR
80089-3545-25 CONDUIT, WIRE - .035/.045 WIRE X 25' 1
80098-12 NOZZLE, WIRE INLET - 1.2MM WIRE 1
80099 CAP NUT- M40X 1.5 1
80177-55-22-09 CABLE COVER, LEATHER - 5.5WX22'9"L 1
103091-3545-375 CONDUIT, WIRE - .035/.045 WIRE, 3.75 LONG 1
103956-1 KNOB, THUMB - WIRE CONDUIT 1
103958-1 FITTING, FLANGED - WIRE CONDUIT 1
103981-1 CLAMP, MOUNTING - MIG TIC, P-P 1
103984-300 POWER/H20 CABLE ASSY-FEMALE "A'X25' (300") 2
103987-358 WIRE DRIVE CONTROL CABLE ASSY - 29' 10" (358") 1
Page 1 of 3
BILL OF MATERIALS
TORCH AND CABLE ASSEMBI,.Y - 400011'.-1'
103996-25/-XXJ
PART QUANTITY
103989-1 FITTING, BARB-WIRE CONDUIT HOSE 1

104271-1 BLOCK MOUNTING TIC LARGE W/ROD 1
104273-2 POWER ADAPTOR BRAZED WHO pop WIROD 1
M 10 1-03C-05-C SCREW, SOCHD - M3 X 5 8
M 103-04C-1 O-C SCREW, FLHDSOC - M4 X 10 1
M501-04C-FA-3 WASHER, FLAT, 4MM FORM A 2
Page 2 of3
BILL OF MATERIALS
TORCH AND CABLE ASSEMBLY - 4000/P-P
103996-251-XXI
PART QUANTITY
NUMBEB DESCBIPTION USED
Add The Following Parts to Complete The Bill of Materials For The Given Dash Number Assy
103996-25 (T & C ASSY - 4000, poP, MECH)

103359-1 PLATE,DUAL CONNECTOR - TIC 1
103996-25-P (T & C ASSY - 4000, poP, NEW)
103359-1 PLATE, DUAL CONNECTOR - TIC 1
103996-25-PD (T & C ASSY - 4000, pop, PNEU., DITHER) 1
M 101-03C-06-C SCREW, SHCS - M3 X 6 4
103996-25-0 (T & C ASSY - 4000, pop, MECH., DITHER)
M 101-03C-06-C SCREW, SHCS - M3 X 6 4
Models 607, 609
103024-2 WAS 103024-1 AND 103091-3545-375 WAS 103091-3545-357 IE 07/09/07

REMOVED: 102191. 5208,102943-1, M103-Q4C-16-C (2). 5930, 5813 (2),103094-1.103095-1,
11247(4),5399,11134,11067, 11554-2 AND 102136-1. IE 02113/07
ADDED: 105220-1
Page 3 of 3
BRACKETRY ASSEMBLY Sht I of 2
MAGNATECH LIMITED PARTNERSHIp· lOW PROFILE MIG 06-Jun-OO
EAST GRANBY, CT 06026 USA 104000-1 104000-I-Pl
MAGNATECH LIMITED PARTNERSHIP BRACKETRY ASSEMBLY Sht 2 of 2
LOW PROfiLE MIG 06-Jun-OO
I PART t DESCRIPTION OTY TYPE
I 102944-2 CLAMP SPLIT - WITH 2 SLOTS I PART
2 103999-1 BLOCK NOUNTING - LOW PROFllEBRACKETRY I PART
3 104001-1 BRACKET PLATE WI PINS - lOW PROFILE BRACKETRY I ASSEMBLY
. 104002-1 PLATE SLIDE - TORCH ADJUSTMENT I
I
PART
PART
5 MI01-04C-16-C. SCREW SHC - M4.0 X .70 X 16MM
6 MI0I-06C - 16-C SCREW SHC - M6.0 X 1.0 X 16MM I PART
7 MI03-06C-16-C SCREW FlHDSOC - M6 X 1.0 X 16MM 2 PART
8 M501-06C-FA-3 WASHER FLAT - M6 DIN 125 1 PART
9 M501-06C-TV-S WASHER C'SUNK LOCK - M6 2 PART
CONDUIT ASSEMBLY Sht I of 2
MAGNATECH LIMITED PARTNERSHIP W/F TO TORCH, 2 ROLL 28-Jun-OO
INSTALL WITH 5930 (RTV)

DO NOT CONTAMINATE CONDUIT ID
MAGNATECH LIMITED PARTNERSHIP CONDUIT ASSEMBLY Sht 2 of 2
'If TO TORCH 2 ROll 28-Jun-OO
1
104016-I-Pl
I PART t DESCRIPTION Ory TYPE
I 103527-150-040 o WI RE CONDUI T .0351 .045 WI RE .- 15.0 LG X 0.4/0.0 STRIP I PART
2 103941 . . 1 COLLAR THREADED - IIO-2~ X 1/4 00 X 3/8 l 1 PART
..
. -... -_.:...- -.---' _

....-. -_._...... - _._ ... _ _ _ _ _ ...... _ _ _ ...... - •• wOo _,_ • _ •• - ••
--- -_._._---_...... .-.........
" __ .. -..... ,,- _...... - _._-_ -_ _
.. .• ........
EAST GRANBY, CONNECTICUT 06026 04-Dec-07
BILL OF MATERIALS
ACCESSORIES KIT - MIG
104017-X
PART NUMBER DESCRIPTION QTY

104017-1 ACCESSORIES KIT - MIG 1
102888-2 MISCELLANEOUS SCREW PACKAGE 1
102889-2 TOOL KIT 1
104018-1 TORCH ACCESSORIES KIT - BINZEL TORCH 1
38396 TUBING, NYLON - 3/16 X .046, BLACK 3'
I
104017-2 ACCESSORIES KIT - MIG, WOH 1
102888-2 MISCELLANEOUS SCREW PACKAGE 1
102889-2 TOOL KIT 1
104018-1 TORCH ACCESSORIES KIT - BINZEL TORCH 1
38396 TUBING, NYLON - 3/16 X .046, BLACK 3'
105359-1 NUT, HUB - 15# SPOOL, LONG WAY 1
ADDED-2 TCK 12/04/07

09/12/00
BILL OF MATERIALS
TORCH ACCESSORIES KIT - BINZEL TORCH
104018-1
PART QUANTITY
8891 GAS DIFFUSER 2

~8892 CONTACT TIP HOLDER 1
8812 CONTACT TIP - .045 5
8894 NOZZLE - 15mm' 1
8890 NOZZLE - 18mm 1
Sh t I 0 f 2
CONDUIT ASSEMBLY 8-AUG.-01
MAGNATECH LIMITED PARTNERSHIP W/F TO SPOOL, 2 ROLL I04021-I-PL
4- 7I I 6± I / I 6
MAGNATECH LIMITED PARTNERSHIP CONDUIT ASSEMBLY Sht 2 of 2
EAST GRANBY, CT 06026 USA W/f TO SPOOL# 2 ROLL 8-AUG. -0 I
104021-1 104021-I-PL
I PART I DESCRIPTION OTr TYPE
I 103527-156-000 oWI RE CONDUIT .035/.045 WIRE - 15.6 LG X 0.0/0.0 STRIP I PART
2 103956-1 KNOB THUMB - WIRE CONDUIT I PART
3 104013-1 RETAINER CONDUIT - 2 ROll WOH I PART
4 M204-S-04C-04-CSETSCREW SOCKET - CONE XM4-.1 X4MM I PART
-"
-
WIRE DRIVE KIT Sht I of 2
MAGNATECH LIMITED PARTNERSHIP 2 ROLL, WOH 6-AUG-01
____._ _-'
EAST GRANBY, CT 06026 USA
-=--__.
104022-1 104022-I-PL
--l _
':'-';i'
MAGNATECH LIMITED PARTNERSHIP WIRE DRIVE KIT Sht 2 of 2
EAST GRANBY, CT 06026 USA 2 ROLL, WOH 6-AUG-OI
104022-1 I04022-I-Pl
-.
.... --
j PART t DESCRIPTION OTY TYPE
I 103955-1 WIRE DRIVE ASSEMBLY - PUSH-PUll I ASSEMBLY
2 104016-1 CONDUIT ASSEMBLY - WfF TO TORCH 2 ROll I ASSEMBLY
3 104021-1 CONDUIT ASSEMBLY - I/F TO SPOOL 2 ROLL 1 ASSEMBLY
4 I04208-1 SPOOL MOUNT ASSEMBLY - 10f LO PROF I ASSEMBLY
--
--
--
--
----
----- -----_..• ---------
--
--
--
--
WI RE OR IVE KIT Sbt I of 2
MAGNATECH LIMITED PARTNERSHIP PUSH-PUll 28-Jun-OO
EAST GRANBY, CT 06026 USA 104023-1 I04023-I-PL
MAGNATECH LIMITED PARTNERSHIP WI RE DRIVE KIT Sht 2 of 2
EAST GRANBY. CT 06026 USA PUSH-PULL 28-Jun-OO
104023-1 104023-I-Pl
•2
I
PART •
103955-1
104016-1
DESCRIPTION
WIRE DRIVE ASSEMBLY - PUSH-PULL
CONDU IT ASS.£MBlY - W/F TO TORCH 2 ROll
QTY
I
I
TYPE
ASSEMBLY
ASSEMBLY
-------- - - - - - - - - ---------_._--_._------
------- -_._-_ .... ----- --- ...._.- ._. __._.- .. __ - - - - - - _ _--_ _-_.__
... ... .. ._.. _ ...... _--_.. _-------.- --_._- 1--------------
-,
Page 1 of 13

BILL OF MATERIALS
SPARE PARTS 609A
104176-XX
PART QUANTITY
GENERIC SPARES
104176-1 Spares, Generic, 609A, Long List 1

103174-2 MotorlTach. Tractor Assy. 1
103930-1 Osc. & Pot. Drive Assy. 1
103176-2 Torch Height Motor Assy. 1
102888-2 Misc. Screw Package 1
103418-11 Limit Switch Circuit Board Assy. 1
103173-2 Osc. Limit Switch Assy. 1
103177-2 Torch Height Limit Switch Assy. 1
20160 Cam Follower 2
103494-1 Wear Plate - Clutch 1
103332-1 Gear, Drive 21-Tooth Pinion 1
20141 Concentric Journal Assy. 2
20142 Eccentric Journal Assy. 2
103426-2 Switch Assy. Travel Reverse 1
103425-1 Head Connector Cable 1
20007 Ball, Caliper, 0 5/16 4
30178 a-Ring, Torch 1
103469-1 Plug, Insulating, Torch 4
10254 - Screw, SCHS, #6 - 32 x 7/8 4
11161 Washer, Insulating, Torch 4
11162 Insulator, Screw, Torch 4
Page 2 of 13

BILL OF MATERIALS
SPARE pARTS. 609A
104176·XX
PART QUANTITY
104176-2 Spares, Generic, 609A, Short List 1

102888-2 Misc. Screw Package 1
103418-11 Limit Switch Circuit Board Assy. 1
103177-2 Torch Height Limit Switch Assy. 1
20160 Cam Follower 2
103494-1 Wear Plate - CI utch 1
103332-1 Gear, Drive 21-Tooth Pinion 1
20141 Concentric Journal Assy. 2
20142 Eccentric Journal Assy. 2
103426-2 Switch Assy. Travel Reverse 1
103425-1 Head Connector Cable 1
20007 Ball, Caliper, 0 5/16 4
103469-1 Plug, Insulating, Torch 4
10254 Screw, SCHS, #fj - 32 x 7/8 4
11161 Washer, Insulating, Torch 4
11162 Insulator, Screw, Torch 4
Page 3 of 13
BILL OF MATERIALS
SPARE PARTS 609A
104176-XX
PART QUANTITY
SPARE PARTS FOR OPTIONS

104176-10 Spares, Option, 609AFOAOMO 1
103090-15 Torch & Cable Assy, 4000, WOF, Mech. 1
104176-11 Spares, Option, 609AFOAWMO 1
103090-15-D Torch & Cable Assy, 4000, WOF, Mech., Dither 1
103841-1 Motor & Pins Assy., Dither Module 1
103842-1 Pot & Pins Assy., Dither Module 1
103851-1 Pigtail Assy., Dither Module 1
104176-12 Spares, Option, 609AFOAOCO 1

103090-15-P Torch & Cable Assy, 4000, WOF, Pneu. 1
103309-1 Idler Caliper Actuator 1
103309-2 Drive Caliper Actuator 1
103310-2 Valve & Fitting Assy. 1
38396 Hose, 03/16 3'
38399 Fitting, Hose 0114 Push, #10 - 32 x 90E 1
38428 Splicer, Tube, 0 1/4 1
38475 OlD #10 - 32, Brass 1
104176-13 Spares, Option, 609AFOAWCO 1

103090-15-PD Torch & Cable Assy, 4000, WOF, Pneu., Dither 1
103842-1 Pot & Pins Assy., Dither Module 1
38396 Hose, 03/16 3'
38399 Fitting, Hose 0 1/4 Push, #10 - 32 x 90E 1
38428 Splicer, Tube, 0 1/4 1
38475 OlD #10 - 32, Brass 1
Page 4 of 13
BILL OF MATERIALS
SPARE pARTS. 609A
104176-XX
PART QUANTITY
104176-22 Spares, Option, 609AGEBOM9 1

103364-25 Torch & Cable Assy., 4000, WOH, Mech. 1
104456-1 Motor & Pigtail Assy - P-P Wire Drive 1
80185 Nozzle, Wire Guide - 0.8 - 1.2mm 2
105359-1 NUT, HUB -15# SPOOL, LONG WAY 1
8873 HUB NUT - 10# SPOOL 1
104176-23 Spares, Option, 609AGEBWM9 1

103364-25-D Torch & Cable Assy., 4000, WOH, Mech., Dither 1
80185 Nozzle, Wire Guide - 0.8 -1.2mm 2
103842-1 Pot. & Pins Assy., Dither Module 1
8873 HUB NUT -10# SPOOL 1
104176-24 Spares, Option, 609AGEBOC9 1

103364-25-P Torch & Cable Assy., 4000, WOH, Pneu. 1
38396 Hose, 0 3/16 3'
38399 Fitting, Hose, 0 1/4 Push, #10 - 32 x 90E 1
38428 Splicer, Tube, 0 1/4 1
38475 Q/D #10 - 32 Brass 1
Page 5 of 13
BILL OF MATERIALS
SPARE pARTS. 609A
104176-XX
PART QUANTITY
104176-25 Spares, Option, 609AGEBWC9 1

103364-25-PD Torch & Cable Assy., 4000, WOH, Pneu., Dither 1
38396 Hose, 0 3/16 3'
38428 Splicer, Tube, 0 1/4 1
38475 Q/D #10 - 32 Brass 1
8873 HUB NUT -10# SPOOL 1
104176-26 Spares, Option, 609AGECOM9 1
103364-50 Torch & Cable Assy., 4000, WOH, Mech. 1
104176-27 Spares, Option, 609AGECWM9 1
103364-50-D Torch & Cable Assy., 4000, WOH, Mech., Dither 1
105359-1 NUT, HUB -15#SPOOL, LONG WAY 1
Page 6 of 13
BILL OF MATERIALS
SPARE PARTS 609A
104176-XX
PART QUANTITY
104176-28 Spares, Option, 609AGECOC9 1

103364-50-P Torch & Cable Assy., 4000, WaH, Pneu. 1
38396 Hose, (2) 3/16 3'
38399 Fitting, Hose, (2) 1/4 Push, #10 - 32 x 90E 1
38428 Splicer, Tube, (2) 1/4 1
38475 QID #1 0 - 32 Brass 1
8873 HUB NUT -10#SPOOL 1
104176-29 Spares, Option, 609AGECWC9 1

103364-50-PD Torch & Cable Assy., 4000, WaH, Pneu., Dither 1
38396 Hose, (2) 3/16 3'
38399 Fitting, Hose, (2) 1/4 Push, #10 - 32 x 90E 1
38428 Splicer, Tube, (2) 1/4 1
38475 QID #1 0 - 32 Brass 1
Page 7 of 13
BILL OF MATERIALS
SPARE PARTS, 609A
1Q4176-XX
PART QUANTITY
104176-30 Spares, Option, 609AGEBOMP 1

103996-25 Torch & Cable Assy., 4000, PIP, Mech. 1
104456-1 Motor & Pigtaii Assy - P-P Wire Drive 1
80207 Pivot Lever - P-P Wire Drive 1
104176-31 Spares, Option 609AGEBWMP 1

103996-25-0 Torch & Cable Assy, 4000, PIP, Mech., Dither 1
103842-1 Pot. & Pins Assy" Dither Module 1
103851-1 Pigtaii Assy" Dither Module 1
104176-32 Spares, Option, 609AGEBOCP 1

103996-25-P Torch & Cable Assy, 4000, PIP, Pneu. 1
80185 Nozzle, Wire Guide - 0,8 - 1.2mm 2
38396 Hose, 0 3/16 3'
38399 Filling, Hose, 0 1/4 Push, #10 - 32 x 90E 1
38428 Splicer, Tube, 0 1/4 1
38475 Q/D #10 - 32 Brass 1
Page 8 of 13
BILL OF MATERIALS
SPARE PARTS 609A
104176-XX
PART QUANTITY
104176-33 Spares, Option, 609AGEBWCP 1

103996-25-PD Torch & Cable Assy, 4000, PIP, Pneu., Dither 1
103310-2 Valve & Filling Assy. 1
104456-1 Motor & Pigtail Assy - pop Wire Drive 1
80207 Pivot Lever - pop Wire Drive 1
38396 Hose, 0 3/16 3'
38428 Splicer, Tube, 0 1/4 1
38475 QID #10 - 32 Brass 1
104176-55 Spares, Option, 609AGEBOM8 1

103364-25-4 Torch & Cable Assy, 4000, WOH, MECH. 1
103363-4 Motor & Pigtail Assy. (5 PIN) 1
103349-1 Shield, Drive Rolls 1
105359-1 NUT, HUB -15#SPOOL, LONG WAY 1
104176-56 Spares, Option, 609AGEBWM8 1
103364-25-4D Torch & Cable Assy, 4000, WOH, Mech., Dither 1
103349-1 Shield Drive Rolls 1
103841-1 Motor & Pins Assy, Dither Module 1
103842-1 Pot. & Pins Assy, Dither Module 1
Page 9 of 13

BILL OF MATERIALS
SPARE PARTS 609A
104176-XX
PART QUANTITY
104176-57 Spares, Option, 609AGEBOC8 1

103364-25-4P Torch & Cable Assy., 4000, WOH, Pneu. 1
38396 Hose, 03/16 3'
38399 Fitting, Hose 0 1/4 Push, #10 - 32 x 90E 1
38428 Splicer, Tube, 0 1/4 1
38475 QID #10 - 32, Brass 1
104176-58 Spares, Options, 609AGEBWC8 1
103364-25-4PD Torch & Cable Assy., 4000, WOH, Pneu., Dither 1
103309-1 Idler Caliper actuator 1
38396 Hose, 0 3/16 3'
38428 Splicer, Tube, 0 1/4 1
38475 QID #10 - 32 Brass 1
Page 10 of 13

BILL OF MATERIALS
SPARE PARTS 6Q9A
104176-XX
PART QUANTITY
104176-59 Spares, Option, 609 AGECOM8 1

103364-50-4 Torch & Cable Assy., 4000, WOH, Mech. 1
1033363-4 Motor & Pigtail Assy (5 PIN) 1
103349-1 Shield Drive Rolls 1
104176-60 Spares, Option, 609 AGECWM8 1
103364-50-4D Torch & Cable Assy., 4000, WOH, Mech., Dither 1
103363-4 Motor & Pigtail Assy. 1
104716-61 Spares, Option, 609AGECOC8 1
103364-50-4P Torch & Cable Assy, 4000, WOH, Pneu. 1
103363-4 Motor & Pigtail Assy. (5PIN) 1
38396 Hose, 0 3/16 3
38399 Filling, Hose 0 1/4 Push, #10 - 32 x 90E 1
38428 Splicer, Tube, 0 1/4 1
38475 Q/D #10 - 32, Brass 1
Page 11 of 13
BILL OF MATERIALS
SPARE PARTS 609A
104176-XX
PART QUANTITY
104176-62 Spares, Option, 609AGECWC8 1

103364-50-4PD Torch & Cable Assy., 4000, WaH, Pneu., Dither 1
103363-4 Motor & Pigtail Assy., 5 PIN 1
38396 Hose, 03/16 3'
38428 Splicer, Tube, 0 1/4 1
38475 QID #10 - 32 Brass 1
104176-63 Spares, Option, 609AGEAOMP 1

103996-15 Torch & Cable Assy., 4000, PIP, Mech. 1
104176-64 Spares, Option 609AGEAWMP 1

103996-15-0 Torch & Cable Assy, 4000, PIP, Mech., Dither 1
Page 12 of 13
BILL OF MATERIALS
SPARE PARTS 609A
104176-XX
PART QUANTITY
104176-65 Spares, Option, 609AGEAOCP 1

103996-15-P Torch & Cable Assy, 4000, PIP, Pneu. 1
38396 Hose, 0 3/16 3'
38428 Splicer, Tube, 0 1/4 1
38475 QID #10 - 32 Brass 1
Page 13 of 13
BILL OF MATERIALS
SPARE PARTS 609A
104176-XX
PART QUANTITY
NUMBER DESCRIPTiON USED
104176-66 Spares, Option, 609AGEAWCP 1

103996-15-PD Torch & Cable Assy, 4000, PIP, Pneu. Dither 1
104456-1 Motor & Pigtail Assy - pop Wire Drive 1
80207 Pivot Lever - pop Wire Drive 1
38396 Hose, 0 3/16 3'
38428 Splicer, Tube, 0 1/4 1
38475 QID #1 0 - 32 Brass 1
ADDED: 104176-63, -64, -65 AND -66 IE 07116108

ADDED 105359-1, 8873 TO -22,-23,-24,-25,-26,-27,-28,-29,-55,-56,-57.-58,-59,-60,-61,-62
DELETED -14 THRU -21, -34 THRU -54 TCK 12104107
103310-2 WAS 103310-1 ON -12,-13,-24,-25.-28,-29,-32,-33,-57,-58,-61,-62
ADDED: 80207 TO 104176-30, -31, -32 AND -33 IE 08108107
CHANGE DESCRIPTiON BY DATE
SPOOL MOUNT ASSEMBLY Sht I of 2
MAGNATECH LIMITED PARTNERSHIP 101 lO PROF 06-Aug-01
EAST GRANBY, CT 06026 USA
_ _---L-
104208-1
-=-~~ _'__
104208-I-PL
___l
NOTES:
I) ASSEMBLY SHOWN IS LEFT HANDED, (PARTS ARE THE SAME)
2) FOR RIGHT HANDED ASSEMBLY, ROTATE
SCALE 2: 5 PIN, 100746-5
SPOOL MOUNT ASSEMBLY Sht 2 of 2
EAST GRANBY, CT 06026 USA lOt lO PROF
104208-1
06- Au 3- 01
10420 -I-PL
i PART t DESCRIPTION OTY TYPE
I 100746-5 COVER - WIRE SPOOL I PART
2 10129 WASHER LOCKING - INT. TOOTH X.8 I PART
3 101698 SPOOL MOUNT - TOP I PART
4 103180-1 SPINDLE SPOOL MOUNT - BOTTOM I PART
5 103185-1 BRACKET SPOOL MOUNT - 10. SPOOL MODEl 610 I PART
6 25084 PIN ROLL - 1/8 X 3/16 2 PART
7 35048-CI SPRING WASHER BELLEVILLE - 1/4 X 1/2 X .018 X .034 20 PART
8 8810 HUB SPOOL - 101 I PART
9 8813 NUT HUB - SPOOL MOUNT I PART
10 MI01-04C-40-C SCREW SHC - M4.0 X .70 X 40NN I PART
II MI02-04C-06-C SCREW BUTHO - M4 X .70 X 6NM I PART
12 MI03- 06C - I6-C SCREW FLHOSOC ~ N6 X 1.0 X 16MM 2 PART
13 M50 I-04C-fA- 3 WASHER FLAT - M4 OIN 125 1 PART
--.
.~
MAGNATECH LIMITED PARTNERSHIP TORCH AND MOUNT ASSEMBLY Sh 1 lor 2
EAST GRANBY, CT 06026 USA MIG 27-0(1-08
105220-1 105220-I-PL
FILL THE SPACE

I----:---:-~ BETWEEN THE ELBOWS
WHEN THE ASSEMBLY IS COMPLETED AND THE

SILICONE IS CURED, PRESSURE TEST THE WATER PASSAGE
FOR LEAKS AT 100 PSI.
MAGNATECH LIMITED PARTNERSHIP TORCH AND MOUNT ASSEMBLY Sh t 2 0 r 2
EAST GRANBY, CT 06026 USA MIG 27-0c t -08
105220-1 105220-I-PL
1 PART 1 DESCR IPTION QTY TYPE
I 10132 INSERT HELICAL LOCKING - 18-32 X .2.46 2 PART
2 10155.4-2 ADAPTOR - SEE TABLE I PART
3 102017 TORCH BLOCK - BOTTOM I PART
.4 102021 SQUARE SPACER - TORCH I PART
5 102166 TUBE GUIDE - TORCH I PART
6 102191 THUMB SCREW - 18-32 X 1-7/8 I PART
7 1025.4 SCREW SHC - 16-32 X 7/8 .4 PART
8 1029.43-1 CLAMP SPLIT - W/ PIN HOlE I PART
9 10309.4-1 INSULATOR TORCH - W/ INSERTS I ASSEMBLY
10 103095-1 SHIM INSULATOR - 607/BINZEL TORCH I PART
II 103273- I SLEEVE STEPPED - INSULATOR I PART
12 103.469-1 PLUG TAPERED SILICONE - MIG TORCH PL -II .4 PART
13 103801-1 TORCH AND COATING ASSEMBLY - MPS .4000 MIG I ASSEMBLY
1.4 10990 INSERT HELICAL - 16-32 X .276 .4 PART
15 11067 WASHER HAT - RUBBER 110 I PART
16 1113.4 KNOB PLASTIC - 1 8 SHC I PART
17 11161 WASHER GIO - .281 X .151 X.0625 .4 PART
18 11162 SCREW INSULATOR - KYNAR PVDF.290 X .0.47 X .500 X/1.40 .4 PART
19 1129.4 WASHER EPDM RUBBER - 1/8 X 1/.4 X 1/16 I PART
20 30177 O-RING - 9/16 ID X 3/32 WX NITRILE I PART
21 30178 O-RING - 1-1/8 ID X 3/32 WX NITRILE I PART
22 5005-S SCREW SHC - 18-32 X 5/8 I PART
23 5208 PIN DOWEL - 3/16 X 1/2 I PART
2.4 5813 SCREW FLHDSOC - 18-32 X 5/8 2 PART
25 5930 ADHESIVE/SEALANT - BLACK SILICONE 2 PART
26 MI03-0.4C-16-C SCREW FLHDSOC - M.4 X .70 X 16MM 2 PART
10132 121 -os 161, REMOvED 112A1 (AI IE 10121108

ADDED: 1129A IE 01122108
ADDED: SECOND VIE. ILOIER LEFT CORNERI AND INSTRUCTIONS FOR THE TEST OF THE ASSEMllLY IE 03101108
INITIAL RELEASE IE 02101101
MAGNATECH LIMITED PARTNERSHIP TORCH AND MOUNT ASSEMBLY Sh I I 0 ( 2
EAST GRANBY, CT 06026 USA MIG 27·0c 1-08
105220-3 105220·3-PL
FILL THE SPACE

i----:=-:''.:::-1 BETWEEN THE ELBOWS
WHEN THE ASSEMBLY IS COMPLETED AND THE

SILICONE IS CURED, PRESSURE TEST THE WATER PASSAGE
FOR LEAKS AT 100 PSI.
MAGNATECH LIMITED PARTNERSHIP TORCH AND MOUNT ASSEMBLY Sh t 2 0 r 2
EAST GRANBY, CT 06026 USA MIG 27-0c t -08
105220-3 105220-3-PL
•I PART 1
10132
DESCR IPYlON
INSERT HELICAL LOCKING - 18-32 X .2.46
QTY
2
TYPE
PART
2 102017 TORCH BLOCK - BOTTOM I PART
3 102021 SQUARE SPACER - TORCH I PART
.4 102191 THUMB SCREW - 18-32 X 1-7/8 I PART
5 1025.4 SCREW SHC - 16-32 X 7/8 .4 PART
6 1029.43-1 CLAMP SPLIT - W/ PIN HOLE I PART
7 10309.4-1 INSULATOR TORCH - W/ INSERTS I ASSEMBLY
8 103095- I SHIM INSULATOR - 607/BINZEL TORCH I PART
9 103273-1 SLEEVE STEPPED - INSULATOR I PART
10 103.469-1 PLUG TAPERED SILICONE - MIG TORCH PL-II .4 PART
II 103801-3 TORCH AND COATING ASSEMBLY - MPS .4000 MIG I ASSEMBLY
12 10.4.42 O-RING - .36.4 10 X .070W X NITRILE I PART
13 10990 INSERT HELICAL - 16-32 X .276 .4 PART
1.4 11161 WASHER GIO - .281 X .151 x.0625 .4 PART
15 11162 SCREW INSULATOR - KYNAR PVDF.290 X .0.47 X .500 XII.40 .4 PART
16 30177 O-RING - 9/16 10 X 3/32 WX NITRILE I PART
17 30178 O-RING - 1-1/8 10 X 3/32 WX NITRILE I PART
18 3836.4 FITTING MNPT TO BARB - I PART
19 5208 PIN DOWEL - 3/16 X 1/2 I PART
20 5813 SCREW FLHDSOC - 18-32 X 5/8 2 PART
21 5930 ADHESIVE/SEALANT - BLACK SILICONE 2 PART
22 MI03-0.4C-16-C SCREW FLHDSOC - M.4 X .70 X 16MM 2 PART
10132 121 WAS 161, REIlOVED 112.47 w IE 10/27/08

ADDED: SECOND vIEW ILOWER LEFT CORIIERI AIID IIISTRUCTIONS FOR THE TEST or THE ASSEMBLY IE 03/07108
1111 T1AL RELEASE IE 02/08/07
REV PART NUM FEATURE "A" DEPTH "B" REF LET CHANGE RECORD ATE BY
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.300 DIA C'BORE,. 765 DP
4 PLACES
.188 DIA,. 750 DEEP,
.2965±.0005 DIA C'BORE, .160 DEEP
. 560±. 00 I, TYP.
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1/4-MIN. FULL THREAD, r- 2 PLACES
2 PLCS
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.385
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. 250 DIA, DEPTH "B" (SEE TABLE>

.4375±.0005 DIA C'BORE. .420 DEEP
.270, 2 PLACES
MAGNA TECH limited
. Eost Gronb
Portnership
C1 06026
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BINZEL COMPo
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3 /03041-3 BAR, CONNEC11 KG - HINGE 3 PART
4 103041-4 BAR CONNECTING - LATCH I PART
5 103042- XXXXX RAIL AND BELT ASSEMBLY - GUIDE RING 4 ASSEMBLY
6 103043-3 SHAFT, CONNECTING - HINGE 2 PART
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II 25059 RIVET, STEEL - 1/8 X .313-.375 20 PART
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13 5239 PIN ROLL - 3/32 X 3/4 6 PART
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6 103498-1 POST, ADJUSTMENT - TRAVEL CLUTCH I PART
7 25043 PIN, DOWEL 416HT - 3/16 X 1-1/4 I PART
8 35156-C0578 SPRING COMPRESSION - .390 X .047 X 1.25 I PART
10 MI01-02C-08-C SCREW SHC - M2.0 X .40 X8MM I PART
MAGNATECH limited Partnership

East Granb CT 06026
o[SCRIf'T1011
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A ADDED 103183- I. MARK I NG 1/9/99 TCK
103555-X B ADD PIN 5208 8116/99 MJ
# PART # DESCRIPTION OTY TYPE L(} c ADDED NOTE USING IRTVl 4/5/02 JJP
- L(}
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6 /03317-1 BUSHING, UPPER - CALIPER SHAFT PART
7 103319-1 COUPLING, CAM FOLLOWER - DRIVE CALIPER PART fI7\
4
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East Granbv, CT 06026
DRIVE CALIPER ASSEMBLY

(SEE TABLE)
DIMENSION LIMITS UNLESS OTHERWISE SPECIFIED DRAWN BY TCK
ANGLES ± 0.5
FILLETS .031 MAX.
EDGE BREAK. 031 MAX.
.XX ± 0.01
.XXX ± 0.005
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SCALE I: 2
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DATE
REV PART NUM 103554-3 DESC2 SHEET 1 OF 1

SIZE DRAWl NG • REV
B 103555-1 103554-1 FRONT
R 103555-2 103554-3 REAR I B 103555 C
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6 103351-1 PLATE MOUNTING - WIRE SPOOL I PART
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8 103159-1 BRACKET SPOOL MOUNT - 101 SPOOL I PART
9 25084 PIN ROLL - 1/8 X 3/16 2 PART
10 35048-CI SPRING WASHER, BELLEVILLE - 1/4 X 1/2 X .018 X .034 20 PART
II 35093~C 1 . SPRING COMPRESSION - .360 X .035 X r.75 I PART
12 5087 WASHER FLAT - 1/4 AN960C416 I PART
13 80" 7 HANDLE OFFSET - 3/80 X 3H X 4-1/4L I PART
14 88.10-- HUB SPOOL - 101 1 PART
15 8813 NUT HUB - SPOOL MOUNT I PART
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17 MI01-04C-40-C SCREW SHC - M4.0 X .70 X 40MM I PART
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19M 103- 05C - I6-C SCREW FLHDSOC - M5 X .80 X 16MM 2 PART
20 MI03-06C-16-C SCREW FLHOSOC - M6 X 1.0 X 16MM 2 PART
21 M501-04C-FA-3 WASHER, FLAT - M4 DIN 125 I PART
NAGNATECH Limited Partnership

East Granb CT 06026
DESCRIPTION
SPOOL MOUNT ASSEMBLY

10i, 609
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8 03847- SLEEVE, SPLIT - 10MM X 1/2 I PART
9 03848- SPACER, SPLIT - 10MM X 3/4 I PART
10 03849- WASHER RETAINER - MODIFIED #8 SAE I PART
II 03850- -C I GASKET, ADHESIVE - DITHER MODULE I PART
12 03851- PIGTAIL ASSEMBLY - DITHER MODULE I ASSEMBLY
13 20201 BUSHING, DELRIN AF - 5MM X 10MM X GMM I PART
14 30284 GEAR, SPUR - AlB 64P X 64T X 20 DEG I PART
15 30286 GEAR, SPUR - 64P X 24T X20 DEG, 5MM BORE I PART
16 80178 GEARBOX, PLANETARY - #17 X8: I I PART
17 MI01-03C-10-C SCREW, SHC - M3.0 X .50 X IOMM 4 PART
19 MI01-04C-10-C SCREW. SHC - M4.0 X .70 X IOMM 4 PART
22 MI03-03C-08-C SCREW, FLHDSOC - M3 X .50 X8MM I PART
23 M501-03C-FA-3 WASHER, FLAT - M3 DIN 125 4 PART
MAG NATECH l imi ted Partner sh ip

East Granb CT 06026
DESCRIPTION
DITHER OSCILLATOR ASSEMBLY

PIPELINER II
DIMENSION LIMITS UNLESS OTHERWISE SPECIFIEO DRAWN BY TCK
ANGLES ± 0.5
FILLETS .031 MAX.
.XX ± 0.01
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SCALE I: 2
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FRACTI ONAl ± 1/64 DATE 29 -i,~e p- 99
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17.0 ELECTRICAL SCHEMATICS
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BA - 322210 - 0021 - PLII 609A For 712-En

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6 Kripes Road - PO Box 260 - East Granby, CT 06026 USA

Fax: (860) 653-0486 E-Mail: info@magnatech-lp.com

Operating and Maintenance

Pipeliner II Model 609A

For Use With

SECTION TITLE PAGE

1.1 Copyright Notice

2.0 PIPELINER IIC COMPONENT INVENTORY 2

2.1 Weld Head 609A

3.0 SAFETY INSTRUCTION AND WARNING FOR OPERATION AND ARC

3.1 Important to Read

4.0 WARRANTY POLICY & SUPPORT 11

5.1 Pipeliner Weld Head

7.0 FUNCTIONAL DESCRIPTION - WELD HEAD 19

8.0 SET-UP AND OPERATION 21

8.1 Mounting the Friction Drive Guide Ring

SECTION TITLE PAGE

9.0 USE OF WELD HEAD ON PREHEATED PIPE 28

10.0 ADAPTOR FEET KITS FOR PIPELINER GUIDE RING TO ALLOW 29

11.0 TORCH EXPENDABLE COMPONENTS LIST 32

11.1 For "Binzel" Torch P/N 103364-6

12.0 SUMMARY OF CAUTIONS 33

12.1 Shock Prevention

13.0 WELD PROCESS DEVELOPMENT 35

14.0 ELECTRODE EXTENSION OFTEN NEGLECTED WHEN USING 43

15.0 PREVENTING THE EFFECTS OF MOISTURE CONTAMINATION OF 46

16.0 BILLS OF MATERIALS/DRAWINGS 48

17.0 ELECTRICAL SCHEMATICS 49

This Weld Head is available in three versions:

This manual covers general operating instructions, as well as assistance in weld

The appropriate interconnect cables and accessories are provided.

ATTENTION:ALL FASTENERS ON THESE WELD HEAD MODELS ARE METRIC

1.1 COPYRIGHT NOTICE

Information and instructions in this document are subject to change and

Edition publication date – April 2007. Copyright 2007 by Magnatech Limited

Each model comes equipped with the following components:

2.1 WELD HEAD 609A S/N _________________________

1Pipeliner II Weld Head Model 609A (WFOF)609AF0AWC0

1Pipeliner II Weld Head Model 609A (WFOF)609AF0A0C0

1Pipeliner II Weld Head Model 609, 609AGEB0CP

1Pipeliner II Weld Head Model 609A, 609AGEB0C9

1Pipeliner II Weld Head Model 609A, 609AGEC0C9

1Pipeliner II Weld Head Model 609A, 609AGECW9

2.2 GUIDE RINGS

1103040-XXXXX Guide Ring Assembly - Friction Drive

2.3 OPTIONAL INSTALLED COMPONENTS/KITS:

1103190-1Torch Axial Slide Assembly - MIG (For Socket Welding)

2.4 OPTIONAL FREE-STANDING (UNATTACHED) COMPONENTS:

1103408-50Extension Cable 15m (50’)

READ AND UNDERSTAND THESE INSTRUCTIONS BEFORE INSTALLING,

3.3 SHOCK PREVENTION

Bare conductors, or terminals in the output circuit, or ungrounded, electrically-live

The body's electrical resistance is decreased when wet, permitting dangerous

3.3.1 Installation and Grounding of Electrically Powered Equipment

Electrical equipment must be installed and maintained in accordance with the

If a grounding lead (conductor) is part of the power supply cable, be sure to

3.3.2 Torch and Work Cables

Inspect cables often for damage to the insulation. Replace or repair

3.3.3 Power Source Output Terminals

The Fronius TPS-450 Power Source completely shields the output

3.3.4 Service and Maintenance

3.3.5 Fuses and Circuit Breakers

Replace fuses and circuit breakers with equivalent sizes.