Miller Electric AUTO ARC MW 4110 Specifications

AUTO ARCJ
September 1990 FORM: OM-112
875D
Effective With Serial No. KA870779
MODEL: MW 4110
MW 4230
OWNERS
MANUAL
IMPORTANT: Read and understand the entire contents of this manual, with
special emphasis on the safety material throughout the manual, before
Installing, operating, or maintaining this equipment. This unit and these
Instructions are for use only by persons trained and experienced in the Safe
operation of welding equipment. Do not allow untraIned persons to install,
operate, or maintain this unit. Contact your dIstributor If you do not fuliy
understand these Instructions.
18-112 943-A
MILLER ELECTRIC
AM~G~Ud..Corr~any
Appleton,
1079
WI 54912 USA
Tel. 414-734-9821
Mig.
Co.
ONEYEAR LIMITED WARRANTY
EFFECTIVE: FEBRUARY 11, 1989
This warranty supersedes alt previous AUTO ARC warranties and is exclusive with no otherguarantees orwarranties expressed or implied.
COVERAGE
MILLER Electric Mfg. Co. warrants to the
buyer who purchases this AUTO ARC Welder (~WeIder) for
personal, family or household purposes (Consumer) that this
Welderwill be free from defects in material and workmanship for
a peflod of one year from the date of purchase. This warranty
covers only the onginal purchaser of this Welder. MILLER Elec
tric does not authorize any party, including its authorized dis
-
to offer any other warranty on behalf of MILLER Elec
tric. Upon expiration of the warranty period. MILLER Electric
shall have no further liability related to the Welder, except on
warranty claims made during the warranty period. No warranty
is made by MILLER with respect to engines, trade accessories
orotheritems manufactured by others. Such engines, trade ac
cessories and other items are sold subject to the warranties of
their respective manufacturers, if any. All engines are war
ranted by their manufacturer for two years from date of original
purchase, except Deu~ engines which have a one year, 2000
hour warranty.
tributors,
MILLER shall be required to honor warranty claims on war
ranted Equipment in the event of failure resulting from a defect
within the following periods from the date of delivery of Equip
ment to the original user:
1.
2.
Arc welders, power sources, and components
Original main power rectifiers
...
1 yew
3 years
(labor
3.
4.
5.
1 year only)
welding guns, feeder/guns and torches
Replacement or repair parts, exclusive of labor
All
Batteries
provided that MILLER is notified in
of such failure.
90 days
60 days
6 months
rized service facility, therefore, no compensation for transporta
tion costs of any kind will be alowed. Upon receipt of notice of
apparentdefect orfailure, MILLER shall instruct the claimant on
the warranty claim procedures to be followed.
THIS WARRANTY IS OFFERED IN LIEU OF ANY OTHER
EXPRESS WARRANTY; AND, EXCEPT TO THE EXTENT
PROHIBITED BY APPLICABLE LAW. THE DURATION OF
ALL IMPUED WARRANTIES. INCLUDING BUT NOT
LIMITED TO THE IMPUED WARRANTIES OF MERCHAN
TABIUTY AND FITNESS FOR A PARTiCULAR PURPOSE. IS
UMITED TO THE DURATION OF THIS WARRANTY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR REPRE
SENTATION AS TO PERFORMANCE, AND ANY REMEDY
FOR BREACH OF CONTRACT WHICH. BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPUCATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING ANY IMPUED WARRANTY OF MERCHANT
ABIUTY OR OF FITNESS FOR PARTICULAR PURPOSE.
WITH RESPECT TO ANY AND ALL EQUIPMENT FUR
NISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY
MILLER.
.
writing within thirty (30) days
WHAT IS NOT COVERED This warranty does not extend to
any Welder subjected to misuse, neglect, accident, or inwarranty repair by anyone except MILLER Electric or its autho
rizedservicestations. Further, thiswarrantyonlyextendstothe
original purchaser of this Welder.
In the case of MILLERs breach of warranty or any other duty
with respect to the quality of any goods, the exclusive remedies
therefore shall be, at MILLERs option (1) repair or (2) replace-
mentor, where authorized in wflnng by MILLER in appropriate
(3) the reasonable cost of repair or replacement at an
authorized MILLER service station or (4) payment of or credit
cases,
for the purchase price (less reasonable depreciation based
upon actral use) upon return of the goods at Consumers risk
and expense. MILLERs option of repair or replacement will be
F.O.B., Factory at Appleton, WI or FOB, at a MILLER autho
Some states do not allow limitations on how long an implied
warranty lasts, so the above limitation may not apply to you.
This warranty gives you specific legal rights, and you may also
have other rights which vary from state to state.
REMEDIES FOR A DEFECTIVE
THE PURCHASERS
WELDER, TO THE EXTENT PERMITrED BY APPLICABLE
LAW, ARE UMITED TO THE REMEDY PROVIDED BY THIS
WARRANTY. TO THE EXTENT ENFORCEABLE UNDER
APPUCABLE LAW, MILLER ELECTRIC SHALL IN NO
EVENT BE LIABLE FOR CONSEQUENTiAL, INCIDENTAL
OR SPECIAL DAMAGES ARISING OUT OF THE USE OF. OR
INABILITY TO USE, THE WELDER, WHETHER BASED ON
BREACH OF THIS WARRANTr~ MILLER ELECTRICS NEG
LIGENCE OR OTHER TORT, OR ON ANY THEORY OF
STRICT LIABIUTY.
OM.1128750-e,gO
-
RECEIVING-HANDLING
Before unpacking equipment, check carton for any damage that may have occurred dunng shipment. File any
claims for loss or damage with the delivering carrier.
Assistance for filing or settling claims may be obtained
frorrt the distributor and/or the equipment manufactur-
Use the
following spaces to record the Model Designa
or Style Number of your unit. The infor
is located on the data card or the nameplate.
tion and Serial
mation
Model
__________________________________________
ers
Transportation Department.
Serial
When requesting information about this equipment, al
ways provide the Model Description and Serial or Style
or
Style
No.
______________________________
Date of Purchase
______________________________
Number.
TABLE OF CONTENTS
Page
Section No.
SECTION 1
SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
1-1.
Introduction
1-2.
General Precautions
1-3.
Arc
1-4.
Standards Booklet Index
1
1
Welding
4
5
SECTION 2-SAFETY PRECAUTIONS AND SIGNAL WORDS
2-1.
General Information And
2-2.
Safety
SECTION 3
Aert
Symbol
And
Safety
Signal Words
6
6
SPECIFICATIONS
Volt-Ampere Curves
Duty Cycle
Description
8
9
3-6.
Supplied Equipment
Additional Required Equipment
Optional Equipment
10
3-7.
Consumable Parts
10
3-1.
3-2.
3-3.
3-4.
3-5.
8
9
9
SECTION 4INSTALLATION
11
4-3.
Site Selection
Shielding Gas Installation
Work Clamp installation
4-4.
Gun
12
4-1.
4-2.
4-5.
4-6.
4-7.
4-8.
No.
Polarity Selection Procedure
Welding Gun Installation
Welding Wire Spool Installation
Electrical Input Connections
Welding Wire Installation
11
11
13
13
13
14
SECTION 5-OPERATOR CONTROLS
5-1.
Power Switch
5-2.
ThicknessNo Its Switch
16
5-3.
Fine Tuning/Wire
16
5-4.
Welding Gun
16
16
Speed Control
Receptacle
Page
Section No.
SECTION 6- SEQUENCE OF OPERATION
6-1.
Gas Metal Arc
6-2.
Shutting
17
Welding (GMAW)
18
Down
SECTION 7- MAINTENANCE & TROUBLESHOOTING
7-1
7-2.
7-3.
7-4.
7-5.
7-6.
7-7.
7-8.
7-9.
7-10.
7-11.
20
Routine Maintenance
Overload Protection
21
21
Drive Roll
Replacing
Replacing Pressure Bearing
Replacing Wire Inlet Guide
Realigning Drive Housing
Circuit Board Replacement
Welding Gun Inspection And Upkeep
Contact Tube Replacement
Gun Liner Replacement
Troubleshooting
22
22
22
22
23
24
24
25
SECTION 8- ELECTRICAL DIAGRAMS
Diagram
Diagram
Diagram
Diagram
Diagram
Diagram
SECTION 9
9-1.
9-2.
SECTION 10
10-1.
10-2.
10-3.
10-4.
10-5.
10-6.
SECTION 11
8-1. Circuit
27
8-3.
Diagram For MW 4110 Models
Diagram For MW 4230 Models
Circuit Diagram For MW 4110 Motor Control Board PCI
Circuit Diagram For MW 4230 Models
27
8-2. Circu~
28
Motor Control Board PCi
28
8-4.
8-5.
8-6.
Wiring Diagram
Wiring Diagram
29
For MW 4110 Models
For MW 4230 Ampere Models
30
WELDING TECHNIQUES & TROUBLESHOOTING
Gas Metal Arc Welding (GMAW) Continuous Seam
Troubleshooting The Gas Metal Arc Welding (GMAW)
31
-
Process
....
32
AUTO BODY REPAIR APPLICATION
Pointers For Welding Auto Body Sheet Metal
Procedure For Welding Mild Steels
36
Procedures For
36
How To Prevent Glass
37
Welding Door Panels
Breakage And Spatter On Windows
Procedures For Welding Fenders And Quarter Panels
Welding Frames And High Strength (HSS) Steels
36
37
37
PARTS LIST
Figure 11-1. Main Assembly (Auto Arc MW 4230 Illustrated)
Figure 11-2. Drive Assembly, Wire
Figure 11-3. Circuit Card, Motor Control PCi
Figure 11-4. Circuit Card, Motor Control PCi
Figure 11-5. Exploded View 01 GA-16C Gun
38
41
42
44
46
LIST OF CHARTS AND TABLES
Table 3-1.
Chart 3-1.
Chart 3-2.
Table 4-i.
Specifications
Volt-Ampere Curves
Duty Cycle
Line Disconnect Or Supply Circuit
Suggested Settings For Welding
Table 6-1.
Table 7-i. Maintenance Schedule
Table 7-2. Troubleshooting
7
8
8
Fuse Size
14
18
20
26
No.
SECTION 1
-
SAFETY RULES FOR
OPERATION
INTRODUCTION
1.1.
Safe practices developed from experience in the use of
welding and cutting are described in this manual. Re
search,
development, and field experience have
evolved reliable equipment and safe installation, opera
tion, and servicing practices. Accidents occur when
equipment is improperly used or maintained. The rea
son for the safe practices may not always be given.
Some are based on common sense, others may require
technical volumes to explain. It is wiser to follow the
rules.
Read and understand these safe
install, operate,
to
Comply with
these
or
procedures
practices before at
service the equipment.
as
applicable
to the par
ticular
equipment used and their instruction manuals, for
personal safety and for the safety of others.
Failure to observe these safe practices may cause seri
ous injury or death. When safety becomes a habit, the
equipment
can
be used with confidence.
These safe practices are divided into two Sections:
1-General Precautions, common to arc welding and cut
ting; and 2-Arc Welding (and Cutting) (only).
Reference standards: Published Standards on safety
also available for additional and more complete pro
cedures than those given in this manual. They are listed
in the Standards Index in this manual. ANSI Z49.1 is the
are
most
WELDING
POWER SOURCE
welding
We learn by experience. Learning safety through per
sonal experience, like a child touching a hot stove is
harmftil, wasteful, and unwise. Letthe experienceof Oth
ers teach you.
tempting
OF ARC
complete.
The National Electrical Code, Occupational Safety and
Health Administration, local industrial codes, and local
inspection requirements also provide a basis for equip
ment installation, use, and service.
or cutting, (and chipping) to protect the eyes
from radiant energy and flying metal. Replace cover
glass when broken, pitted, or spattered. See 1 -3A.2.
Avoid oily
or
greasy clothing. A spark may
Hot metal such as electrode stubs and
should never be handled without gloves.
ignite
them.
workpieces
Medical first aid and eye treatment. First aid facilities and
a qualified first aid person should be available for each
shift unless medical facilities are close by for immediate
treatment of flash burns of the eyes and skin burns.
Ear plugs should be
worn
when
working on
overhead
or
in a confined space. A hard hat should be worn when
others work overhead.
Flammable hair preparations should not be used
intending to weld or cut.
by per
sons
B.
Toxic Fume Prevention
Severe discomfort, illness or death can result from
fumes, vapors, heat, or oxygen enrichment or depletion
that welding (or cutting) may produce. Prevent them with
adequate ventilation as described in ANSI Standard
Z49.1 listed in Standards Index. NEVER ventilate with
oxygen.
Lead-, cadmium-, zinc-, mercury-, and beryllium-bear
and similar materials, when welded (or cut) may pro
ing
duce harmful concentrations of toxic fumes. Adequate
local exhaust ventilation must be used, or each person in
the area as well as the operator must wear an air-sup
plied respirator. For beryllium, both must be used.
Metals coated with or containing materials that emit toxic
fumes should not be heated unless coating is removed
from the work surface, the area is well ventilated and, if
necessary, while wearing an air-supplied respirator.
Work in
a
confined space
only while
and, if necessary, while wearing
an
it is being ventilated
air-supplied respira
tor.
1-2.
GENERAL PRECAUTIONS
Different arc welding processes, electrode alloys,
and fluxes can produce different fumes, gases, and
radiation levels. In addition to the information in this
sure to consult flux and electrode manu
facturers Material Safety Data Sheets (MSDSs) for
manual, be
specific technical data and precautionary measures
concerning their material.
A.
Burn Prevention
Wear protective
clothing-gauntlet gloves designed for
use in welding, hat, and high safety-toe shoes. Button
shirt collar and pocket flaps, and wear cuffless trousers
to avoid entry of sparks and slag.
Wear helmet with safety goggles and glasses with side
shields underneath, appropriate filter lenses or plates
(protected by clear cover glass). This is a MUST for
Gas leaks in
a confined space should be avoided.
Leaked gas in large quantities can change oxygen con
centration dangerously. Do not bring gas cylinders into a
confined space.
Leaving confined space, shut OFF gas supply at source
prevent possible accumulation of gases in the space if
downstream valves have been accidentally opened or
to
left open. Check to be
re-entering it.
sure
that the space is safe before
Vapors from chlorinated solvents can be decomposed
by the heat of the arc (or flame) to form PHOSGENE, a
highly toxic gas, and other lung and eye irritating prod
ucts. The ultraviolet (radiant) energy of the arc can also
decompose trichloroethylene and perchloroethylene va
pors to form phosgene. DO NOT WELD or cut where sol
vent vapors can be drawn into the welding or cutting at
mosphere or where the radiant energy can penetrate to
OM-112 875
Page
1
atmospheres ~,containing even minute
trichioroethylene or perchloroØthylene.
C.
Fire and
amounts
of
Explosion Prevention
Causes of fire and explosion are: combustibles reached
by the arc, flame, flying sparks, hot slag or heated mate
nal; misuse of compressed gases and cylinders; and
menfas~ recommended in A6.O. Waterfilling just below
working level may substitufe for inerting.
A container with unknown contents should be cleaned
(see preceding paragraph). Do NOT depend on sense of
smell or
Hollow
sight
to determine if it is safe to weld or cut.
castings or containers must be vented before
or cutting. They can explode.
stiorf circuits.
welding
BE AWARE THAT
flying sparks or falling slag can pass
through cracks, along pipes, through windows or doors,
and through wall or floor openings, out of sight of the
goggled operator. Sparks and slag can fly 35 feet.
Explosive atmospheres. Never weld or cut where the air
may contain flammable dust, gas, or liquid vapors (such
as gasoline).
To prevent fires and
Standard precautions. Comply with precautions in this
manual, and those detailed in CGA Standard P-i SAFE
HANDLING OF COMPRESSED GASES IN CYLIN
DERS, listed 11 in Standards Index.
explosion:
Keep equipment clean and operable, free of oil, grease,
and (in electncal parts) of metallic particles that can
cause short
circuits.
If combustibles are in area, do NOT weld or cut. Move
the work if practicable, to an area free of combustibles.
Avoid paint spray rooms, dip tanks, storage areas, venti
lators. If the work cannot be moved, move combustibles
at least 35 feet away out of reach of sparks and heat; or
protect against ignition with suitable and snug-fitting,
fire-resistant covers
Walls
or
work should be
shields.
on
near
heat-resistant covers or
Fire watcher must be
standing by with suitable fire extin
guishing equipment during and for some time afterweld
ing or cutting if:
a.
b.
appreciable combustibles (including building
construction) are within 35 feet
appreciable combustibles are further
can be ignited by sparks
than 35
feet but
c.
Pressure
1.
Regulators
Regulator relief valve is designed to protect only the
regulator from overpressure; it is not intended to protect
any downstream equipment. Provide such protection
with
one or more
relief devices.
Remove faulty regulator from service immediately for re
pair (first close cylinder valve). The following symptoms
indicate a faulty regulator:
Leaks-if gas leaks externally.
Excessive Creep-if delivery pressure continues to rise
with downstream valve closed.
Faulty Gauge-if gauge pointerdoes not move off stop pin
pressurized, nor returns to stop pin after pressure
when
release.
Repair. Do NOT attempt to repair. Send faulty regulators
repair to manufacturers designated repair center,
where special techniques and tools are used by trained
personnel.
for
openings (concealed orvisible) in floors orwalls
within 35 feet may expose combustibles to
sparks
d.
,
opposite sides should
(or cut). Walls, ceilings, and floor
protected by
Compressed Gas Equipment
Never connect a regulator to a cylinder containing gas
other than that for which the regulator was designed.
shields.
combustibles
touching
not be welded on
D.
Cylinders
2.
combustibles adjacent to walls, ceilings, roofs,
or metal partitions can be ignited by radiant or
conducted heat.
Cylinders must be handled carefully to prevent leaks and
damage to their walls, valves, or safety devices:
Hot work
permit should be obtained before operation to
ensure supervisors approval that adequate precautions
Avoid electrical circuit contact with cylinders including
third rails, electrical wires, or welding circuits. They can
produce short circuit arcs that may lead to a serious acci
have been taken.
dent.
After work is done, check that
glowing embers, and flames.
area
is free of
sparks,
be welded on or cut, unless container has first
been cleaned as described in AWS Standard A6.O, listed
7 in Standards index.
never
a
thorough steam orcausticcleaning (or a
solvent or water washing, depending on the combusti
bles solubility) followed by purging and inerting with ni
trogen
or
OM-112 875
carbon dioxide, and
Page
2
or
DOT
assurance
An empty container that held combustibles, or that can
produce flammable or toxic vapors when heated, must
This includes:
ICC
(See 1-3C.)
using protective equip-
marking must be on each cylinder. It is an
safety when the cylinder is properly han
of
dled.
Identifying gas content. Use only cylinders with name of
gas marked on them; do not rely on color to identify gas
content. Notify supplier if unmarked. NEVER DEFACE
or alter name, number, orother markings on a cylinder. It
is illegal and hazardous.
Empties: Keep valves closed, replace caps securely;
keep them separate from FULLS and return
promptly.
mark MT;
Prohibited use.~Never use a cylinder or its contents ior
other than its intended use, NEVER as a support or
outlet away from peo.ple and
~with a clean lintless c~om.
of
sources
ignition. Wipe
roller.
regulator to cylinder. Before connecting, check
regulator label and cylinder marking area, and
thatthe regulator inlet ~nd cylinderoutlet match. NEVER
CONNECT a regulator designed for a particular gas or
gases to a cylinder containing any other gas.
Match
Locate or secure
cylinders
so
they
cannot be knocked
over.
Passageways
areas~where
and work areas.
clear of
Keep cylinders
they may be struck.
Transporting cylinders. With a crane, use a secure sup
port such as a platform or cradle. Do NOT lift cylinders off
the ground by their valves or caps, or by chains, slings,
or
magnets.
Do NOT expose cylinders to excessive heat, sparks,
slag, and flame, etc. that may cause rupture. Do not al
low contents to exceed 130F.
Cool with water spray
that the
lighten
connections. When
assembling
threaded
con
nections, clean and smooth seats where necessary.
Tighten. If connection leaks, disassemble, clean, and
retighten using properly fitting
wrench.
Adapters. Use a CGA adapter (available from your sup
plier) between cylinder and regulator, if one is required.
use two wrenches to tighten adapter marked RIGHT and
LEFT HAND threads.
where such exposure exists.
Protect cylinders particularly valves from bumps, falls,
falling objects, and weather. Replace caps securely
when
moving cylinders.
Stuck valve. Do NOT use a hammer orwrench to open a
cylinder valve that can not be opened by hand. Notify
your
supplier.
Never try to mix any gases in
Never refill any
a
cylinder.
cylinder.
Cylinder fittings should
never
be modified
or
exchanged.
gases.
Use ferrules or clamps designed for the hose (not ordi
nary wire or other substitute) as a binding to connect
hoses to fittings.
No copper
to
tubing splices.
splice hose.
Use
only standard brass fit
Avoid
long runs to prevent kinks and abuse. Suspend
hose off ground to keep it from being run over, stepped
on, or otherwise damaged.
Coil excess hose to prevent kinks and
Protect hose from
sparks, slag,
regulator of residual gas through suitable vent be
opening cylinder (or manifold valve) by turning ad
justing screw in (clockwise). Draining prevents exces
sive compression heat at high pressure seat by allowing
seat to open on pressurization. Leave adjusting screw
engaged slightly on single-stage regulators.
Drain
Stand to side of
Hose
Prohibited use. Never use hose otherthan that designed
for the specified gas. A general hose identification rule
is: red for fuel gas, green for oxygen, and black for inert
tings
damage by sharp edges,
Open cylinder valve slowly so that regulator pressure in
creases slowly. When gauge is pressurized (gauge
reaches regulator maximum) leave cylinder valve in fol
lowing position: For oxygen, and inert gases, open fully
to seal stem against possible leak. For fuel gas, open to
less than one turn to permit quick emergency shutoff.
Use pressure charts (available from your supplier) for
safe and efficient, recommended pressure settings on
regulators.
Check for leaks on first pressurization and regularly
there-after. Brush with soap solution (capfull of Ivory Liq
uid* or equivalent per gallon of water). Bubbles indicate
leak. Clean off soapy water after test; dried soap is
bustible.
E.
and
by
and open flame.
Repair leaky or worn hose by cutting
ing (1-2D3). Do NOT tape.
regulator while opening cylinder valve.
com
tangles.
Examine hose regularly for leaks, wear, and loose con
nections. Immerse pressured hose in water; bubbles in
dicate leaks.
area
out and
splic
Proper Connections
Clean cylinder valve outlet of impurities that may clog
orifices and damage seats before connecting regulator.
Except for hydrogen, crack valve momentarily, pointing
User
ResponsibilIties
Remove leaky or defective equipment from service im
mediately for repair. See User Responsibility statement
in equipment manual.
F.
Leaving Equipment
Close gas supply at
G.
4.
Pressurizing Steps:
5.
fore
Mixing gases.
3.
Regulator outlet (or hose) connections may be identified
by right hand threads for oxygen and left hand threads
(with grooved hex on nut or shank) for fuel gas.
Unattended
source and drain
gas.
Rope Staging-Support
Rope staging-support should not be used for welding
cutting operation; rope may burn.
or
Trademark of Proctor & Gamble.
OM.112 875
Page
3
ARC WELDING
1-3.
.Viewirig the
Comply with precautions in 1-1, 1-2, and this section.
Arc Welding, properly done, is a safe process, but a
careless operator invites trouble. The equipment carries
high currents at significant voltages. The arc is very
bright and hot. Sparks fly, fumes rise, ultraviolet and in
traredenergy radiates, weldments are hot, and com
pressed gases may be used. The wise operator avoids
unnecessary risks and protects himself and others from
accidents. Precautions are described here and in stan
dards referenced in index.
A.
Burn Protection
Comply
with
The welding
in 1-2.
visibly bright, Its radiation
can damage eyes, penetrate lightweight clothing, reflect
from light-colored surfaces, and burn the skin and eyes.
Skin burns resemble acute sunburn, those from gasshielded arcs are more severe and painful. DONT GET
BURNED; COM PLY WITH PRECAUTIONS.
Protective
1.
Clothing
Wear long-sleeve clothing (particularly for gas-shielded
arc) in addition to gloves, hat, and shoes (1-2A). As nec
essary, use additional protective clothing such as leather
jacket or sleeves, flame-proof apron, and fire-resistant
leggings. Avoid outer garments of untreated cotton.
Bare skin protection. Wear dark, substantial clothing.
Button collar to protect chest and neck and button pock
ets to prevent entry of sparks.
2.
Eye
and Head Protection
area.
See that all persons
wearing
are
goggles.
Before starting to weld, make
doors are closed.
sure
that screen
flaps
or
bay
B.
Toxic Fume PreventIon
Comply
with
precautions
in 1-2B.
Generator engine exhaust must be vented to the outside
air. Carbon monoxide can kill.
Fire and
Comply
is intense and
weld. PrOvide face shields for all persons
at the weld.
looking di rectly.
Others working in
flash
C.
precautions
arc
who will be
with
Equipments
equipment.
Explosion Prevention
precautions
in 1 -2C.
rated capacity. Do not overload arc welding
It may overheat cables and cause a fire.
Loose cable connections may overheat
or
flash and
cause a tire.
Never strike an arc on a cylinder or other pressure ves
sel. It creates a brittle area that can cause a violent rup
ture or lead to such a rupture under rough handling.
D.
Compressed Gas Equipment
Comply
E.
with
precautions
in 1 -2D.
Shock Prevention
Exposed hot conductors or other bare metal in the weld
ing circuit, or in ungrounded, electrically-HOT equip
ment can fatally shock a person whose body becomes a
conductor. DO NOT STAND, SIT, LIE, LEAN ON, OR
TOUCH a wet surface when welding, without suitable
protection.
Protect eyes from exposure to
electric arc without protection.
Welding
helmet
arc.
NEVER look at
an
To protect
shield
containing a filter plate shade
no. 12 or denser must be used when welding. Place over
face before striking arc.
or
Protect filter plate with
a
clear cover
or
IMMEDIATELY.
pitted,
or
loose filter plates must be replaced
clear cover plate when broken,
Replace
spattered.
Flash goggles with side shields MUST be worn underthe
heitnet to give some protection to the eyes should the
helmet not be lowered over the face before an arc is
struck. Looking at an arc momentarily with unprotected
eyes
(particularly a high intensity gas-shielded arc)
retinal bum that may leave
in the field of vision.
cause a
area
a
shock:
Wear dry insulating gloves and body protection. Keep
body and clothing dry. Neverwork in damp area without
adequate insulation against electrical shock. Stay on a
dry duckboard, or rubber mat when dampness or sweat
be avoided. Sweat, sea water, or moisture be
and an electrically HOT part or grounded
metal reduces the electrical resistance, and could en
able dangerous and possibly lethal currents to flow
can not
plate.
Cracked or broken helmet or shield should NOT be
worn; radiation can pass through to cause burns.
Cracked, broken,
against
can
permanent dark
tween
body
through the body.
voltage will exist between the electrode and any con
ducting object in the work circuit. Examples of Conduct
ing objects include, but are not limited to, buildings, elec
trical tools, work benches, welding power source cases,
workpieces, etc. Never touch the electrode and any
metal object unless the welding power source Is of f.
A
1.
Arc
Grounding
the
Equipment
welding equipment
the National Electrical
3.
Protection of
Enclosed welding
Nearby Personnel
For production welding, a sepa
best. In open areas, sur
with low-reflective, non-combusti
area.
rate room or enclosed
bay is
round the operation
ble screens or panels. Allow for free air circulation, par
ticularly at floor level.
OM-112 875
Page
4
grounded according
And
must be
grounded according
Code, and the work
to ANSI Z49.1
Safety
In
to
must be
Welding
Cutting.
When installing, connect the frames of each unit such as
welding power source, control, worktable, and water ci r
culatorto the building ground. Conductors must be ade
quate to carry ground currents safely. Equipment made
electrically HOTtiy stray current may shock, possibly fa
tally. Do NOT GROUND to electrical conduit, orto a pipe
carrying ANY gas or flammable liquid such as oil or fuel.
Three-phase connection. Check phase requirements of
equipment before installing. If only 3-phase power is
available, connect single-phase equipment to only two
wires of the 3-phase line. Do NOT connect the equip
ment ground lead to the third (live) wire, or the equip
ment will become electncally HOT-a dangerous condi
tion that can shock, possibly fatally.
Before welding, check ground for continuity. Be sure
conductors are touching bare metal of equipment
frames at connections.
If
line cord with a ground lead is provided with the
equipment for connection to a switchbox, connect the
ground lead to the grounded switchbox. If a three-prong
plug is added for connection to a grounded mating re
ceptacle, the ground lead must be connected to the
ground prong only. If the line cord comes with a threea
prong plug, connect to
a
grounded mating receptacle.
plug, or use a
Never remove the ground prong from a
plug with a broken off ground prong.
2.
-
Fully insulated electrode holders should be used. Do
use holders with protruding screws.
NOT
Connectors
Fully
lock-type
join welding cable lengths.
connectors should be used to
Cables
4.
Frequently inspect cables forwear, cracks and damage.
IMMEDIATELY REPLACE those with excessively worn
or damaged insulation to avoid possibly-lethal shock
from bared cable. Cables with damaged areas may be
taped to give resistance equivalent to original cable.
7.
Safety Devices
Safety
devices such as interlocks and circuit breakers
should not be disconnected or shunted out.
Before installation, inspection, or service, of equipment,
shut OFF all power and remove line fuses (or lock or redtag switches) to prevent accidental turning ON of power.
Disconnect all cables from welding power source, and
all 115 volts line-cord plugs.
pull
Do not open power circuit or change polarity while weld
ing. If, in an emergency, it must be disconnected, guard
against shock bums, or flash from switch arcing.
Leaving equipment
Terminals And Other
F.
14.
metal
power sources for
use
with the gas
welding (GMAW), gas tungsten arc
welding (GTAW) and similar processes nor
mally are equipped with devices that permit on
off control of the welding power output. When so
equipped the electrode wire becomes electri
cally HOT when the power source switch is ON
and the welding gun switch is closed. Never
touch the electrode wire or any conducting ob
ject in contact with the electrode circuit unless
the welding power source is off.
b.
Equipment without output
on/oft control
(no
Sup
STANDARDS BOOKLET INDEX
or
1.
ANSI Standard Z49.1, SAFETY IN WELDING
AND CUTTING obtainable from the American
Welding Society, 550 N.W. LeJeune Rd, Miami,
FL 33126.
2.
NIOSH, SAFETY AND HEALTH IN ARC WELD
ING AND GAS WELDING AND CUTTING ob
tainable from the Superintendent of Documents,
U.S. Government Printing Office, Washington,
D.C. 20402.
3.
OSHA, SAFETY AND HEALTH STANDARDS,
29CFR 1910, obtainable from the Superinten
dent of Documents, U.S. Government Printing
Office, Washington, D.C. 20402.
4.
ANSI Standard Z87.1, SAFE PRACTICES FOR
OCCUPATION AND EDUCATIONAL EYE AND
FACE PROTECTION obtainable from the Ameri
can National Standards Institute, 1430 Broad
way, New York, NY 10018.
5.
ANSI Standard Z41 .1, STANDARD FOR MENS
SAFETY-TOE FOOTWEAR obtainable from the
American National Standards Institute, 1430
Broadway, New York, NY 10018.
arc
contactor)
ProtectIon For Wearers of Electronic Life
For more information, refertothefollowing standards
their latest revisions and comply as applicable:
Equipment with output on/ott control (contactor)
Welding
the
Magnetic fields from high currents can affect pacemaker
operation. Persons wearing electronic life support
equipment (pacemaker) should consult with their doctor
before going near arc welding, gouging, or spot welding
operations.
Electrode
a.
near
power source.
port Devices (Pacemakers)
Exposed Parts
Terminals and other exposed parts of electrical units
should have insulating covers secured before operation.
6.
Always shut OFF and
equipment.
unattended.
disconnect all power to
Keep cable dry, free of oil and grease, and protected
from hot metal and sparks.
5.
arc
off.
welding
insulated
power sources used with shielded
welding (SMAW) and similar proc
esses may not be eq~uipped with welding power
output on-off control devices. With such equip
ment the electrode is electrically HOT when the
power switch is turned ON. Never touch the
electrode unless the welding power source is
metal
Power disconnect switch must be available
Electrode Holders
3.
Welding
OM-112 875 Pa9e 5
6.
ANSI St~ndard Z49.2, FIRE PREVENTION IN
THE USE OF CUTTING AND WELDING PROC
ESSES obtainable from the American National
~rorn the Compressed Gas Association, 1235 Jef
ferson Davis Highway, Suite 501, Arlington, VA
22202.
Standards Institute, 1430 Broadway, New York,
NV 10018.
7.
AWS Standard A6.0, WELDING AND CUTTING
~CONTAlNERS WHICH HAVE HELD COMBUS
TIBLES obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126.
8.
NFPA Standard 51, OXYGEN-FUEL GAS SYS
TEMS FOR WELDING, CUTTING, AND ALLIED
PROCESSES obtainable from the National Fire
Protection Association, Batterymarch Park,
Quincy, MA 02269.
9.
12.
CSA Standard W117.2, CODE FOR SAFETY IN
WELDING AND CUTTING obtainable from the
Canadian Standards Association, Standards
Sales, 178 Rexdale Boulevard, Rexdale, Ontario,
Canada M9W 1 R3.
13.
NWSA booklet, WELDING SAFETY BIBLIOG
RAPHY obtainable from the National Welding
Supply Association, 1900 Arch Street, Philadel
phia,
14.
Welding Society Standard AWSF4.1,
RECOMMENDED SAFE PRACTICES FOR THE
PREPARATION FOR WELDING AND CUTTING
OF CONTAINERS AND PIPING THAT HAVE
HELD HAZARDOUS SUBSTANCES, obtainable
from the American Welding Society, 550 N.W.
LeJeune Ad, Miami, FL 33126.
15.
ANSI Standard Z88.2, PRACTICE FOR RESPI
RATORY PROTECTION, obtainable from the
American National Standards Institute, 1430
Broadway, New York, NY 10018.
NFPA Standard 70, NATIONAL ELECTRICAL
CODE obtainable from the National Fire Protec
tion Association, Batterymarch Park,
Quincy,
MA
02269.
10.
11.
NFPA Standard 51 B, CUTTING AND WELDING
PROCESSES obtainable from the National Fire
Protection Association, Batterymarch Park,
Quincy, MA 02269.
PA 19103.
American
CGA Pamphlet
HANDLING OF COM
PRESSED GASES IN CYLINDERS obtainable
,
SECTION 2- SAFETY PRECAUTIONS AND SIGNAL WORDS
2-1.
A.
GENERAL INFORMATION AND SAFETY
2-2.
General
Information presented in this manual and on various la
on the unit pertains to equipment
bels, tags, and plates
design, installation, operation, maintenance, and
troubleshooting which should be read, understood, and
followed for the safe and effective use of this equipment.
B.
Safety
The installation, operation, maintenance, and trouble
of arc welding equipment requires practices
and procedures which ensure personal safety and the
safety of others. Therefore, this equipment is to be in
stalled, operated, and maintained only by qualified per
Sons ifl accordance with this manual and all applicable
codes such as, but not limited to, those listed at the end
of Section 1
Safety Rules For Operation Of Arc Weld
Power
Source.
ing
ALERT
SYMBOL
AND
SIGNAL
The following safety alert symbol and signal words are
used throughout this manual to call attention to and iden
tify different levels of hazard and special instructions.
a
This safety alert symbol is used with the signal
words WARNING and CAUTION to call atten
tion to the safety statements.
a
WARNING statements identify procedures or
practices which must be followed to avoid seri
ous personal injury or loss of life.
a
CAUTION statements identify procedures or
practices which must be followed to avoid minor
personal injury or damage to this equipment.
The
nameplate of this unit uses international symbols for
labeling the front panel controls. The symbols also ap
pear at the appropriate section in the text.
SAFETY
WORDS
shooting
OM-112 875
Page
6
IMPORTANT statements identify special instructions
necessary for the most efficient operation of this equipmerit.
SECTION 3- SPECIFICATIONS
Table 3-1.
SpecificatIons
Welding Power Source
Max.
Model
Rated
Weld Output
Open.
Circuit
Voitage
MW 4110
90 Amperes
@ 18 Volts DC
20%DutyCycle
30
input At Rated Load
Single-Phase
Voltage
Amperes At
At Gun
11SV
230V
)(VA
20
10
3
@ 21 Volts DC
30% Duty Cycle
Electrode
Wire Feed
Wire
Diameter
Speed
Capability
Weight
Net
KW
2.2
Ship
70-400 ipm
(1.8-10.2mpm)
.023 in.
88 lbs.
95 lbs.
(0.6mm)
(40kg)
(43kg)
47-690 ipm
(1.2-17.5mpm)
.023 thru .035 in.
94 lbs.
101 lbs.
(0.6thruo.9mm)
(43kg)
(46kg)
24 Volts
DC
l20Amperos
MW 4230
Electrode
Control
Circuit
32
20
4.7
3.9
MWG-160 Gun
Ampere Rating
With CO
60% Duty
C~cie
l6oAmpores
Wire
DIameter
.023 in.
(0.6 mm)
Cabie
Length
lOft. (3.0 m)
Cooling
Metho
Air
15 In.
19 In.
(381 mm)
(483 mm)
TB- 1 12 943-A
Figure
3-1. Overall Dimensions
OM-112 875
Pago
7
VOLT-Aii~lPERE
3-1.
(3*
~Referio the Duty Cycle Charts (Chart 3-2) to determine
the output of the welding power source at various duty
cycles.
CURV~S (Chart 3-1)
RATED OUTPUT
The volt-ampere curves show the minimum and maxi
mum voltage and amperage output capabilities of the
unit ft~om the minimum and maximum
FINE TUNING/WIRE SPEED control.
settings
of the
IMPORTANT:
Decreasing welding amperes
increases
DUTY
CYCLE
welding
power
duty cycle.
CAUTION:
EXCEEDING
RATINGS will damage
a
source.
Do not exceed indicated
Chart 3-1. Volt-Ampere Curves
Chart 3-2. Duty
MW 4110 Models
A.
duty cycles.
Cycle
50
A. MW 4110 Models
40
I 5C
125
~,30
I-
100
-J
(I)
w
0
>
~20
75
0
Lii
0~
x
I0
50
a
d
0
~
S8.l10 683
2~
B. MW 4230 Models
0
40
10
15
20
i~
25 30
DUTY
40
50607080
100
CYCLE
428
SA109
30
B. MW 4230 Models
206
-
-
20
160
Ca
a
10
100
90
.~
~
90
%
0
0
60
100
D.C.
160
A~P~ES
200
70
250
%
60
SB-124 625
I .6
40
wry cye.E x
3-2.
A.
90
100
S8.124 624
DUTY CYCLE
Welding
Power Source
(Chart 3-2)
The MW 4110 is rated at 20 percent duty cycle; there
fore, the unit can be operated at rated load for two con
B.
Welding Gun
The MW 4230 is rated at 30 percent duty cycle; there
fore, the unit can be operated at rated load for three con
secutive minutes, but it must idle forthe remaining seven
The duty cycle of a welding gun is the percentage of a ten
minute period that a gun can be operated at a given load.
This gun is rated at 60% duty cycle using CO2 shielding
gas. This means that the gun can be operated six min
utes out of every ten with the CO2 shielding gas. The re
maining four minutes the gun should be idle to permit
minutes to allow proper
proper cooling.
secutive minutes out of ten, but it must idle for the
maining eight minutes to allow proper cooling.
OM-112 875
Page
8
cooling.
re
a
CAUTION: EXCEEDING THE RATED AM
PERAGE WITH CO~ OR FAILING TO RE
DUCE THE WELDING AMPERAGE OR DUTY
CYCLE WHEN USING A MIXED SHIELDING
GAS can result In damage to the gun.
The weldi~ig power source is factory equipped with
ft. (3 m) input power cord and built-in gas valve.
3-5.
ADDITIONAL REQUIRED EQUIPMENT
ure
Do not exceed rated amperage when
using
a
10
(Fig
3-3)
Co2.
Reduce
duty cycle
ing gases such
3-3.
as
when using mixed shield
carbon dioxide and argon.
DESCRIPTION
The MW 4110 is
single-phase, constant voltage, dc arc
and wire feed system designed
for Gas Metal Arc Welding (GMAW) using a MWG-1 60
gun and .023 in. (0.6 mm) welding wire. Rated weld out
put is 90 amperes, 18 volts dc, at 20% duty cycle.
welding power
a
source
The MW 4230 is a single-phase, constant voltage, dc arc
welding power source and wire feed system for Gas Met
al Arc
Welding (GMAW) using a MWG-1 60 gun and .023
in. (0.6 through 0.9 mm) welding wire.
through .035
Rated weld output is 120 amperes, 21 volts dc, at 30%
duty cycle.
All units
are protected against short circuit overload
(contact tube shorting to work) and overheating. If either
condition occurs, the unit automatically shuts down.
3-4.
SUPPLIED EQUIPMENT
(FIgure 3-2)
Figure
3-3. AdditIonal
Supplies Required
Contact yoursupplier or see the yellow pages of the local
telephone book for the location of the nearest welding
supply company to obtain the necessary equipment.
A.
Gas
Cylinder
Two types of gas
are generally used with Gas Metal Arc
Welding (GMAW) of thin gauge sheet steel. Carbon
dioxide (C02) is the gas recommended for use with this
welding power source/gun combination. A mixture of 75
percent argon and 25 percent carbon dioxide also gives
favorable results. Obtain a cylinderof selected shielding
gas. When welding power source is installed on running
gear, a 20 lb. cylinder is the largest that can be used.
B.
Figure
3-2.
Regulator/f lowmeters provide a constant shielding gas
pressure and flow rate dunng the welding process. Be
cause gases have different properties, each regulator!
flowmeter is designed to be used with a specific gas or
mixture of gases. Regulator/flowmeters cannot be
changed from one gas to another unless the proper
adapters are installed. Be sure to obtain the proper regu
Supplied Equipment
Equipment supplied with the welding power source and
requiring customer installation or assembly is listed be
low:
1.
2.
Welding
gun with 1/2 in. (13 mm)
and two contact tubes.
Work
clamp.
seam
Regulator/Flowmeter
nozzle
lator/fiowmeter for the type of gas used.
C.
Gas Hose
Measure distance from gas cylinder to welding power
Obtain good quality 5/8 in. (16 mm) O.D., S.A.E.
gas hose, and install 5/8-18 right-hand thread fittings on
both ends of hose.
source.
OM-112 875
Page
9
D.
Spool Of ~Jlre
Selection of the correct welding wire is important in Gas
Metal Arc Welding (GMAW). There are many types of
wire from which to choose, but certain wires are best
suited for welding thin gauge sheet steel. The American
Welding Society (AWS) classification for GMAW wires is
usually indicated on the label of the wire spool. Two AWS
wire classes recommended are E7OS-6 and E7OS-3.
The E7OS-6 provides a more fluid (wetter) weld puddle
and a flatter bead; however, E7OS-6 is acceptable for
use with this welding power source. Obtain a spool of se
lected wire.
E.
Personal
When
This unit
can
be equipped with two
styles
of
running
gear. If running gear was ordered with the unit, see runfling gear Owners Manual for installation procedures.
CONSUMABLE PARTS
3-7.
The following parts
are
subject
to wear under normal
usage:
1.
Contact tubes
2.
Contact tube adapters (170 Ampere Model Guns
Safety Equipment
Only)
using this welding power
source, wear a welding
helmet, fitted with the proper filter lens, to protect the
eyes from the welding arc. Also important is wearing pro
tective
OPTIONAL EQUIPMENT
3-6.
3.
Nozzle
4.
Drive Rolls
clothing, safety glasses, and gloves to prevent in
Spare parts should
jury.
SECTION 4
be available at all times.
INSTALLATION
Cap
Flowmeter
Gas Cylinder
Valve
CO2 Cylinder
CO2 Washer
CO2 Installation
Fiowmeter
Regulator
Cap
Argon or Argon
Cylinder
Argon Installation
Figure
OM-112 875
Page
10
4-1.
TypIcal Regulator/Flowmeter Installation
Mix
SB-109 492
SITE SELECTION
4-1.
(FIgure 3-1)
B.
Reguttor/Flowm.eter (Customer Supplied) (Fig.
-
Select
an
installation site which
ure4-1)
provides
the
following:
1.
1.
Correct input power supply (see unit nameplate)
2.
Shielding
gas supply
3...
Adequate
ventilation and fresh air
With the cylinder securely installed, remove the
cylinder cap, stand to one side of cylinder valve,
and open valve slightly. When gas flows from cyl
inder, close valve. This procedure blows Out dust
dirt that may have accumulated around the
or
supply
valve seat.
No flammables
4.
2.
5.
A clean and
6.
Proper temperature
dry
regulator/f Iowmeter
The
equipped with
area
for use
that avoids extremes of heat
cold
or
must
be
properly
stem, nut connectors, and gasket
with either CO2 cylinders or inert gas type
a
cylinders.
IMPORTANT: A gasket should be installed to prevent
leaks. Do not use lubricants or sea/mg agents.
7.
Proper
8.
Adequate space for opening side access doors
for installation, maintenance, and repair func
tions.
Base
mounting holes provide the capability to install and
the unit on a running gear or in a permanent loca
airflow around unit
secure
3.
Install gas regulator/flowmeter onto gas cylinder
valve; keep the face of the regulator/flowmeter
gauge in vertical position, and tighten stem nut
securely to gas cylinder valve.
4.
A
shielding gas output fitting is provided at the
of the welding power source for making gas
rear
tion.
connections. Attach
a
WARNING: FIRE OR EXPLOSION can result
from placing unit on or over combustible
surfaces; RESTRICTED AIRFLOW can cause
overheating and possible damage to Internal
parts.
one end of the gas hose to
this output fitting. Attach other end of the gas hose
to the regulator/f Iowmeter.
WORK CLAMP INSTALLATION
4-3.
(Figure 4-2)
(3 m) work cable with lug extends out of the front
panel. Install work clamp onto the work cable as follows:
A 10 ft.
Do not locate unit over combustible surfaces.
Maintain at least 18 inches (457 mm) of
unrestricted space on a/i sides of unit, and keep
underside free of obstructions.
a
WARNING: ELECTRIC SHOCK
can kill.
Do not touch live electrical parts.
Shutdown
welding powersource, anddiscon
input power employing lockout/tagging
procedures before installing work clamp.
Do not place any filtering device over the in
take air passages that provide airflow for coo/mg
this unit.
Warranty is
void if any type of
used at intake air passages.
filtering
nect
Lockout/tagging procedures consist of removing
input power plug from receptacle, padlocking
line disconnect switch in open position, remov
ing fuses from fuse box, or shutting off and red
tag9ing circuit breaker or other disconnecting
device is
device.
4-2.
SHIELDING GAS INSTALLATION
a
WARNING: PRESSURIZED CYLINDERS can
rupture causing serious personal Injury and
loss of life; FALLING CYLINDERS can cause
serious Injury and equipment damage.
Step
Keep cylinders away from welding
or
other
Step
6
2
electrical circuits.
Never allow a
welding
electrode to touch any
cylinder.
Step
4
Step
Always fasten cylinder securely to running
gearbracket, a wall, orotherstationary support.
A.
Gas
Cylinder (Customer Supplied) (Figure 4-1)
Chain the
cylinder to
a
wall
or
other stationary support to
prevent the cylinderfrom failing over and breaking oft the
valve. If optional running gear is used, secure gas cylin
der to
3
running
gear with
supplied chain.
Steps
1 and 5
S.0250
Figure
4.2. Work
Clamp
Installation
OM-112 875
Page
11
1.
Slide one piece of
su~pIied insulating sleeve onto
Place work cable inside the handle of the work
with the flattest inner surface.
Lockout/taggingprocedures consist of removing
input power plug from receptacle, padlocking
line disconnect switch in open position, remov
ing fuses from fuse box, or shutting off and red
tagging circuit breaker or other disconnecting
Align the smaller hole in the work clamp handle
with the hole in the work cable terminal lug. Se
cure the terminal lug to the work clamp with the
The welding power source has jumper links that allow
the userto select the polarity of the unit. The jumper links
can be positioned for Reverse Polarity (DCEP) or
supplied
Straight Polarity (OCEN) welding (see Figure 4-3).
work cable.
2.
clamp
3.
4.
5.
nut and bolt.
Bend the tabs on the end of the work
around the work cable.
Slide
device.
insulating
sleeve
on
was shipped with the links positioned for Re
Polarity (DCEP) welding using solid steel wire with
the Gas Metal Arc Welding (GMAW) process. If using
flux cored wire (without adding a shielding gas) and the
Flux Cored Arc Welding (FCAW) process, position links
for Straight Polarity (DCEN). Straight Polarity (DCEN)
can also be used for welding with solid wire on very thin
The unit
clamp
verse
work cable over work
clamp handle.
6.
Slide
remaining insulating sleeve over other work
clamp handle.
metal.
jumper links are located behind the access door.
polarity changeover label (Figure 4-3) is located
next to the polarity changeover board on the center
baffle of the unit. If it is necessary to change jumper link
positions, proceed as follows:
The
The
4-4.
GUN POLARITY SELECTION PROCEDURE
(FIgure 4-3)
a
WARNING: ELECTRIC SHOCK
1.
Open
2.
Loosen hardware securing jumper
ity changeover board.
3.
Reposition jumperlinks as necessary, andtighten
jumper link securing hardware.
4.
Close and
can kIll.
Do not touch live electrical parts.
Shut down welding powersource, and discon
nect
input power employing lockout/tagging
or changing
procedures before inspecting
left side
access
door.
links to polar
connections.
P STRAIGHT
POLARITY
I
Wires,~ (
For Flux
Cored
(FCAW
process)
L
secure access
door.
REVERSE
POLARITY
)
DCEN
DCEP
For Solid
Steel Or
Aluminum
Wires
J
(GMAW)
process)
Polarity Changeover
GUN POLARITY CHANGEOVER
Label
S-116 599
I
Polarity Changeover
Board
Hub
Gun/Feeder
Connector
Gun/Feeder Connector
Securing
FIgure
OM-112 875
Page
12
4-3. Gun
Polarity Selection
Knob
WELDING GUN INSTALLATION (Figures 4.3
4-5.
And
a
4-4)
WARNING: ELECTRIC SHOCK can kill.
GUN receptacle, insert
fully clckwise.
WELDING
4-6.
Do not touch live electrical parts.
Shutdown welding powersource, and discon
1.
input power employing lockout/tagging
procedures before inspecting or installing.
Open
2.
Remove
3.
Slide
Lockout/tagging procedures consist of removing
input power plug from receptacle, padlocking
line disconnect switch in open position, remov
ing fuses from fuse box, or shutting ott and redtagging circuit breaker or other disconnecting
(Figures 4-3
IMPORTANT: The outlet guide is provided as part of the
gun assembly.
1.
Open
2.
Loosen the
access
SPOOL
INSTALLATION
door.
gun/feeder connector securing
knob.
left side door.
retaining pin
from hub.
spool of wire onto hub so that wire feeds off
spool. Do not loosen wire from spool.
bottom of
spool until hole in spool aligns with pin in
spool onto hub until it seats against
back flange of hub.
Rotate
4.
hub. Slide
device.
Gun/Feeder Connector Installation
And 4-4)
WIRE
(Figure 4-4)
nect
A.
the connector, and rotate collar
5.
retaining pin onto hub in a position which
prevents wire spool from moving in or out.
6.
Close and
Reinstall
secure access door.
4-7.
ELECTRICAL INPUT CONNECTIONS
a
WARNING: ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
IMPORTANT:
Shutdown welding power source, and discon
the
nect input power employing lockout/tagging
procedures before inspecting or installing.
Wire guides should be installed so that
tip of the guide is as close to the drive rolls as possi
ble without
3.
touching.
eder connector is flush
against
drive
Tighten the gun/feeder connector securing knob.
5.
Close and
secure access
Gun Switch Connection
line disconnect switch in open position, remov
ing fuses from fuse box, or shutting ott and redtagging circuit breaker or other disconnecting
device.
assembly.
4.
B.
Lockout/tagging procedures consist of removing
input power plug from receptacle, padlocking
Insert gun/feeder connector through access hole
in front panel and into drive assembly until gun/fe
door.
A.
(Figure 5-1)
The WELDING GUN receptacle is provided for making
switch control connections. Align the keys on the gun
switch connector with the keyways in the WELDING
Electrical
Input Requirements
The National Electrical Code (NEC) (Article 630B., 1987
Edition) provides standards for amperage handling ca
pability of supply conductors based on the duty cycle of
the
welding power
source.
Front Panel
Pressure Roll
(Shown
in
Assembly
Open Position)
Hub Pin
Gun
Wire
Spool
I
Retaining
Pin
Wire inlet
Guide
SA-109 356-s
FIgure
4-4.
WeldIng
Gun And Wire
Spool
installation
OM-112 875
Page
13
The MW 4110 models have a 20% duty cycle (2 minutes
of every 10 minutes can be used for welding); therefore,
~a
the supplied cord and attached plug comply with NEC
standards for 20% duty cycle. Be sure that the building
supply and receptacle comply with NEC standards and
any additional state and local codes.
supply.
B.
input Conductor ConnectIons For MW 4110
Models
MW 4110 models are
equipped
can kill.
Do not touch live, electrical parts.
Do not connect an input conductor to the
ground terminal in the line disconnect device.
Do not connect the ground conductor to an
input line terminal.
Incorrect input connections can result in an
electrically energized welding power source
chassis. The ground terminal is connected to
The MW 4230 (230 Volts only) models have a 30% duty
cycle (3 minutes of every 10 minutes can be used for
welding); therefore, the supplied cord and ring terminals
comply with NEC standards for 30% duty cycle.
IMPORTANT: The supply wiring for the welding power
source must be capable of handling a 15 ampere load for
the MW4 110 models, anda 20 ampere load for the MW
4230 models. The welding power source must be the
only load connected to the supply circuit. Poor unit per
formance or frequently opening line fuses or circuit
breakers can result from an inadequate or improper
WARNING: ELECTRIC SHOCK
the
welding power source chassis
grounding purposes only.
and is for
Models requiring 230 volts input have prewired power
cables with three conductors and ring terminals. Check
the nameplate for input voltage requirement, and con
nect the conductors to a properly grounded and pro
tected line disconnect device capable of handling 230
VAC at 20 amperes (see Figure 4-5). The black and
white conductors must be connected to the line terrrii
nals, and the green conductor must be connected to a
proper ground. Use a grounding method that is accept
able to the local electrical inspection authority.
with a cord and threeGround Conductor
prong polarized plug. Check nameplate for input voltage
requirement, and connect the plug to .a properly
grounded and protected (fuses or circuit breakers) 115
VAC receptacle capable of handling 15 amperes.
C~
Input Conductor Connections For MW 4230
Figure 4-4)
Models (Table 4-1 And
a
WARNING: ELECTRIC SHOCK
can kill.
Do not touch live electrical parts.
Install
a
fusible line disconnect switch in the
to the welding power source.
input Circuit
Read and follow safety information at begin
of entire Section 4-7 before proceeding.
ning
The line disconnect switch provides a safe and
convenient means to completely remove all
electrical power from the welding power source
whenever it is necessary to inspect or service
the unit.
Input Power
Welding
From
(230
Source
Volt Models
Only)
S9.124 654.~
Table 4-1 provides
size line fuses.
guidelines
for
selecting the proper
Figure
Table 4-1. Line Disconnect Or
Fuse Size
Supply Circuit
4-8.
A.
Fuse Size
Model
In
Amperes*
MW411O
30
MW 4230
30
*Fuse size is based
cent of the rated
power
source
OM-112 875 Pago 14
4.5. Power Cable Connections
(230 Volt Models Only)
on not more than
WELDING WIRE INSTALLATION
Threading Welding
a
WIre
(Figure 4-4)
WARNING:
ELECTRIC SHOCK can kill;
MOVING PARTS can cause serious injury.
Do not touch live electrical parts.
Keep away from moving parts.
Do not energize welding powersource until in
200 per
input amperage of the welding
s-oogv~-ea
(Article 630 of NEC).
structed to do so.
The welding wire and all metal parts in contact
with it are energized while welding.
WELDING
WIRE
cause
can
wounds; HOT SURFACES
dnv~e rolipressurØ just tightly enough to prevent
the wire from slipping on or against drive roll dur
ing operation.
puncture
can cause severe
burns.
Do not press gun
trigger until instructed to do
SION
Do not point gun toward any part of the body,
any conductive surface, or other personnel
when threading welding wire.
Allow gun to cool before
2.
Open
install
and
secure
welding
Do not
touching.
spool according
to Section
~
drive roll pressure
adjust
Lay gun cable assembly out
possible.
as
straight and flat as
can
kill.
Do not touch live electrical parts.
Loosen pressure
adjustment knob, pivot pressure adjustment arm free of cover, and pivot pressure roll assembly away until it is in an open position (see Figure 4-4).
LOOSE WELDING WIRE
CAUTION:
cause
The
WELDING
firm hold
on
wire
Unreel and
straighten approximately
rapidly
6 in.
can
cause
puncture
Do not point gun toward any part of the body,
other personnel, or any conductive surface
when threading welding wire.
during installation,
Spooled wire has a tendency to unravel
when loosened from the spool.
WIRE
wounds.
can
removal, and threading operations.
welding wire is electrically energized whenthe gun trigger is depressed.
ever
Injury,
Keep
4.
overtighten
WARNING: ELECTRIC SHOCK
4.6.
3.
cause
ment knob.
left side access door.
wire
damage equipment and
can
poor wire feedIng.
10.
1.
EXCESSIVE DRIVE ROLL TEN.
CAUTION:
so
11.
Energize welding power
12.
Depress and hold the gun trigger until the wire
feeds approximately 1/4 in. (6 mm) out the gun
nozzle. if wire feeds more than 1/4 in. out nozzle,
cut wire off to 1/4 in.
13.
Deenergize welding
14.
Adjust
(152
source.
mm) of wire from wire spool.
5.
Cut oft any wire that is bent, and
or
remove
any burrs
sharp edges.
hub tension
power
source.
according
to Section 4-8B, if
necessary.
6.
Route welding wire into wire inlet guide, along
drive roll groove, and into wire outlet guide in gun
feeder/connector.
7.
Pivot pressure roll assembly downward onto
drive roll, making sure that wire is riding in drive
roll groove.
8.
Pivot pressure adjustment arm up until the washer on the adjustment arm is seated on top of the
cover.
9.
Rotate the pressure adjustment knob in a clockwise direction until the drive roll and pressure
bearing
are
tight against the welding wire. Adjust
15.
Close and
secure
left side
access
door.
IMPORTANT: Fora smoother weld start, be sure weldiflg wire extends 1/4 in. (6 mm) out end of contact tube
and has a sharp end.
B.
Hub Tension
Adjustment
Check hub tension by slowly pulling the wire toward the
drive roll. The wire should unwind freely, but hub tension
should be sufficient to keep the wire taut and prevent
backlash when wire feeding ceases. If adjustment is re
quired, loosen or tighten the hex nut on the end of the
spindle support shaft accordingly.
OM-112 875
Page
15
SECTION 5- OPERATOR CONTROLS
Fine
Tuning/
Wire Speed
Control
Power
Switch
Thicknessivoits
Switch
Gun Switch
Gun
T8-112 g43-A
Receptaci.
Figure
5-1.
POWER SWITCH
5-1.
Operator Controls
(Figure 5-1)
a
POWER
Do
not
can
damage
contact
change position of THICKNESS!
welding or under load.
VOLTS switch while
-e
Arcing causes the contacts to become pitted and
eventually inoperative.
Placing the POWER switch in the ON position energizes
the welding power source. Placing the POWER switch in
the OFF position shuts down the welding power source.
5-2.
ARCING
CAUTION:
surfaces.
5-3.
FINE TUNING/WIRE SPEED CONTROL
ure
THICKNESSNOLTS SWITCH (Figure 5-1)
(Fig
5-1)
WIRE SPEED FINE TUNING
2
olo
The FINE TUNING/WIRE SPEED control provides se
lection of the speed at which welding wire feeds into the
weld. Rotating the FINE TUNING/WIRE SPEED control
clockwise increases wire feed speed.
The scale around the FINE TUNING/WIRE SPEED con
percent arid does not indicate the ac
trol is calibrated in
tual wire feed
DO NOT OPERATE
SWITCH UNDER LOAD
IMPORTANT:
The THICKNESSNOLTS switch
four welding voltages:
Very Thin
Thin
3Thicker
4 Thickest
1
2
OM-112 875
Page
provides
a
selection of
MW4I1O
Model
MW4230
Model
20
23
25
29
20
23
27
32
16
Volts
Volts
Volts
Volts
DC
DC
DC
DC
Volts
Volts
Volts
Volts
DC
DC
DC
DC
trol may be
5-4.
speed.
The FINE TUNING/WIRE SPEED
con
adjusted while welding.
WELDING GUN RECEPTACLE
(Figure 5-1)
Connect gun switch to this receptacle according to Sec
tiOn 4-5. When the gun switch Is closed, the contactor in
the welding power source energizes, shielding gas
flows, and wire feeds.
SECTION 6- SEQUENCE OF OPERATION
a
WARNING:
ELECTRIC SHOCK can kill;
MOVING PARTS can cause serious Injury;
IMPROPER AIRFLOW AND EXPOSURE TO
ENVIRONMENT can damage Internal parts.
Do not touch live electrical parts.
Keep away
Keep all
operating.
from
covers
3.
Wear
4.
Be sure polarity changeover
position (see Section 4-4).
Select
5.
4-8. Install
in
panels
welding
wire and
and
clothing.
links
are
while
place
to Section
shielding gas according to Section 4-2.
Connect work
6.
in desired
shielding gas (see Table
6-1). Thread welding wire according
moving parts.
and
dry insulating gloves
clamp to clean, bare
metal at work-
piece.
is void if the welding power source is
operated with any portion of the outer enclosure
Warranty
Set weld parameters using the THICKNESS1
7.
VOLTS switch and FINE TUNING/WIRE SPEED
control appropriate for the base metal thickness
and type of shielding gas (see Table 6-1).
removed.
ARC RAYS, SPARKS, AND HOT SURFACES
burn eyes and skin; NOISE can damage
can
hearing.
Wear correct eye, ear, and
FUMES AND GASES
your health.
Keep your head
can
If ventilation is
Close regulator/flowmeter flow adjustment knob,
and slowly open the gas cylinder valve.
9.
Purge shielding gas
body protection.
seriously
a
breathing device.
WELDING
wounds.
WIRE
can
puncture
cause
a.
Do not point gun toward any part of the body,
any conductive surface, or other personnel.
HOT
METAL, SPATTER, AND SLAG
cause
b.
a
use
Do not
fire
it.
Allow work and
Place POWER switch on the
in the ON position.
d.
and know
flammable material.
equipment
to cool before
MAGNETIC FIELDS FROM HIGH CURRENTS
welding power
affect pacemaker
Depress gun trigger for approximately 15 sec
onds to allow for adjustment of regulator/flowmeter and to purge gas hose of air.
IMPORTANT: Gas pressure of 6 pounds or flow rate of
15 Cfh are typical. Welding out of position at high wire
feed speeds, or welding in a drafty environment will re
quire
more
shielding gas.
operation.
e.
Wearers should consult their doctor before
See Section 1
Safety Rules For Operation Of
Arc Welding Power Source for basic welding
safety information.
-
GAS METAL ARC WELDING
(GMAW)
1.
Install and connect unit
2.
Prepare weld joint (see Sections
according
Place POWER switch on welding power source
position, and retighten drive roll pres
sure according to Section 4-8.
in OFF
going near arc welding, gouging, orspot welding
operations.
6-1.
Release drive roll pressure.
source
handling.
can
kill; ARC
Place Line Disconnect switch in the ON posi
c.
extinguisher nearby,
use near
can
can
fire and burns.
Keep
WARNING: ELECTRIC SHOCK
RAYS can burn eyes.
tion.
Watch for fire.
how to
follows:
Keep the welding wire isolated from the work
clamp or any conductive surface when not weld
ing.
The welding wire is electrically energized when
ever the gun trigger is depressed.
approved
use
as
Do not touch live electrical parts.
breathing fumes and
inadequate,
line
harm
out of the fumes.
Ventilate to keep from
gases.
8.
10.
Wear
welding helmet with proper
cording to ANSI Z49.1.
filter lens
11.
Place POWER switch on welding power
ON position, and begin welding.
12.
Adjust hub tension and drive roll pressure
essary (see Section 4-8).
13.
Adjust
ac
source
in
as nec
to Section 4.
9 and
10).
FINE TUNING/WIRE SPEED control as
necessary.
OM-112 875
Page
17
6-2.
SHUTTING DOWN
3.
Stop welding.
2.
Place POWER switch in OFF
Shut off gas
position.
Table 6-1.
Suggested SettIngs
MW 4110 Models
co2
20cfh+
*AdjuSt
+cth
=
Page
Welding
GMAW
~_______
12 ga.
14 ga.
16 ga.
18 ga.
20 ga.
22 ga.
24 ga.
Range
4
3
2
2~
1
1
1
70%
55%
48%
43%
25%
10%
6%
3
3
2
1
1
80%
60%
70%
60%
50%
Speed*
Range
Feed
18
when not in use.
Settings
Speed*
FINE TUNING/WIRE SPEED control as
cubic feet per hour
OM.112 875
-
For
supply
Material ThIckness
OPerator
Control
Feed
75% Argon
25% CO2
20 cfh+
cylinder valve.
HIGH CONCENTRA11ON OF
WARNING:
SHIELDING GAS can harm heafth or kill.
1.
Shielding Gas
And Flow Rate
Close gas
required.
MW 4230 Models
Wire Type,
Shielding Gas,
And Flow Rate
Wire
)Derator
Diameter Control
(Inch)
-
GMAW And FCAW
Material Thickness
1/4 In.
3/16 In.
1/8 In.
Settings (6.4 mm) (4.8 mm) (3.2 mm)
Range
14 ga. 16 ga.
18 ga.
22 ga. 24 ga.
3
2
2
1
1
100%
80%
70%
60%
55%
45%
4
3
2
2
1
1
60%
60%
50%
40%
30%
4
1
.023
Feed
,~.
Speed*
E7OS-6
Range
Co2
4
35%
.030
Feed
80%
Speed
20 Cl h+
75%
4
4
3
2
65%
60%
50%
40%
30%
20%
15%
4
3
2
2
1
1
1
100%
90%
80%
70%
60%
50%
40%
3
3
2
2
1
1
80%
70%
60%
4
3
3
3
2
2
Speed*
75%
70%
60%
50%
40%
33%
Range
3
3
2
1
1
1
Range
1
1
1
.035
Feed
Speed*
~_______
Range
.023
Feed
Speed*
E7OS-6
Range
75% Argon
25% CO2
4
.030
Feed
90%
Speed
20 Cl h+
Range
50%
45%
30%
1
.035
Feed
.030
25%
-
Feed
E7IT-GS
Flux Core
Speed
40%
65%
45%
40%
30%
20%
Range
3
3
2
1
1
1
60%
50%
40%
30%
4
4
3
3
Speed
100%
100%
90%
Range
4
4
3
75%
75%
65%
4
4
3
Speed
60%
60%
50%
Range
4
3
3
Speed
90%
85%
Range
4
4
85%
85%
.035
Feed
Speed
Range
20%
10%
3
2
75%
70%
3
2
2
60%
55%
1
.023
Feed
ER 308
Stainless
Steel
85%
60%
.030
Feed
Tn-Mix
Speed
50%
20 cf h+
Range
.035
Feed
2
1
1
.030
Aluminum
Feed
Argon
20 Cf h+
80%
3
90%
90%
85%
2
2
1
90%
90%
80%
.035
Feed
Speed*
Adjust
+cfh
=
FINE TUNING/WIRE SPEED control
as
85%
required.
cubic feet per hour
IMPORTANT: it in doubt, set THICKNESS/VOLTS switch for voltage desired and set FINE TUNING/WIRE
SPEED to 50. The weld can be started and fine tuned during operation. It input voltage is low, a higher
THICKNESSNOLTS setting may be required to obtain desired weld.
OM-112 875
SECTION 7- MAINTENANCE & TROUBLESHOOTING
ROUTINE MAINTENANCE
7-1
(Table 7-1)
IMPORTANT: Ever, six months inspect the labels on
this unit for legibility. All precautionary labels must be
maintained in a clearly readable state and replaced
when necessary. See Parts List for part number of
precautionary labels.
a
WARNING: ELECTRIC SHOCK
outer enclosure, and use a clean, dry airstream or vac
uum suction for the cleaning operation. If dusty or dirty
conditions
C.
are
present, clean the unit monthly.
Inspection
WARNING: Read and follow safety informa
tlon at beginnIng of entire SectIon 7-1 before
a
proceeding.
Do not touch live electrical parts.
Every six months, inspect the gun, hoses, and cables. If
dusty or dirty conditions are present, inspect the unit
monthly. Inspection should consist of the following:
Open
1.
2.
side access door.
Inspect gun
can cause serious
equipment.
Remove grease and grime from components,
moisture from electrical parts and cable.
4.
HOT SURFACES can cause severe burns.
Allow
cooling period before servicing.
Maintenance to be performed only by qualified
persons.
a
Frequency
CAUTION: FLYING DIRT AND METAL CHIPS
can
Injure personnel
and
damage equip
ment.
Point gun liner only in a safe direction away
from personnel and equipment when cleaning
with compressed air.
Table 7-1. Maintenance Schedule
Maintenance
Every
month.
Every
6 months.
Units in heavy service environ
ments: Check labels, weld ca
bles, clean internal parts.
Check all labels (see IMPOR
TANT block, Section 7-1). Clean
internal parts (see Section
7-1B).
Frequency
of service is based on units operated 40
hours per week. Increase frequency of maintenance if
usage exceeds 40 hours per week
Blow out the gun wire
5.
Close and
6.
D.
secure side access
door.
Cleaning Of Drive Rolls
a
WARNING: Read and follow safety Informa
beginning of entire Section 7-1 before
tion at
proceeding.
MOVING PARTS
can cause
away from
serious
injury.
moving parts.
HIGH ROTATIONAL SPEED can cause dam
age to drive rolls and Injure personnel.
This unit is equipped with an exhaust fan and relies on
forced draft for adequate cooling. The fan motor is
manufacturedwith lifetime sealed bearings and requires
Do not allow drive rolls to rotate at high speed
if compressed air is used for cleaning the drive
roll assembly.
maintenance.
WARNING: Read and follow safety lnfomia
tion at beginning of entire SectIon 7-1 before
liner with com
lated.
Keep
Cleaning
guide
pressed air when changing wire. This will remove
any metal chips and dirt that may have accumu
Fan Motor
4~
required.
Repairor replace, as required, all hose and cable;
give particular attention to frayed and cracked in
3.
injury.
Keep away from moving parts.
Internal
as
sulation and areas where hose and cables enter
MOVING PARTS
B.
for broken areas, cracks, and loose
parts; tighten, repair, and replace
device.
no
Upkeep
can kill.
Shutdown welding powersource, and discon
nectinputpoweremp!oying !ockouttagging pro
cedures before inspecting, maintaining, or se,v
icing.
Lockout/tagging procedures consist of removing
input power plug from receptacle, padlocking
line disconnect switch in open position, remov
ing fuses from fuse box, or shutting off and redtagging circuit breaker or other disconnecting
A.
And
It is necessary to remove the drive rolls for proper clean
ing of the wire grooves (see Section 7-3 for removal and
installation instructions). Use a wire brush to clean rolls.
proceeding.
Every six
months blow out or vacuum dust and dirt from
the inside of the welding power source. Remove the
OM-112 875
Page
20
IMPORTANT: Failure to properly maintain the drive rolls
result in a buildup of wire particles which decreases
the efficiency of the wire feeding operation.
can
OVERI~.OAD PROTECTION
7-2.
-
Lbckoutitaggingproceduresconsistof removing
plug from receptacle, padlocking
line disconnect switch in open position, remov
ing fuses from fuse box, or shutting off and red
tagging circuit breaker or other disconnecting
input powr
Short Circuit Shutdown
A.
The unit is protected from damage due to contact tube
short by optical coupler OC1 on motor control circuit
board PCi. If the contact tube is shorted to the work-
piece
while
welding,
device.
MOVING PARTS can
completely shuts down. To
re~ume operation, remove contact tube fromworkpiece,
and continue welding.
B.
Keep
away from
serious
Injury.
moving parts.
left side access door.
1.
Open
2.
Loosen pressure
Thermal Overload Protection
Rectifier SR2 is protected from overheating bya normal
ly-closed thermostat TP1 in the relay CR1 and contactor
CR2 control circuitry. Should overheating occur, TP1
would open
causing CR1 and thereby the contactor to
drop out (deenergize) thereby stopping all weld output.
The thermostat automatically closes when the unit cools
down. Allow
a
cooling period
before
7-3.
a
REPLACING DRIVE ROLL
result of
necessary to
Proceed
a
as
adjustment knob, pivot pres
adjustment arm free of cover, and pivot pres
sure roll assembly away until it is in an open posi
sure
tion.
3.
Remove the drive roll securing bolt in the end of
the motor shaft, and remove the drive roll from the
shaft.
4.
Slide new drive roll onto motor shaft until the drive
roll bottoms against shoulder of motor shaft.
5.
Reinstali
6.
Pivot pressure roll assembly downward onto
drive roll, making sure thatwelding wire is riding in
drive roll groove.
continuing opera
tion.
As
cause
the unit
(Figure 7-1)
wear or a change in wire size, it may be
replace the drive roll and wire inlet guide.
follows:
WARNING: ELECTRIC SHOCK can kill.
7.
securing bolt,
and
tighten.
Pivot pressure adjustment arm up until the wash
the adjustment arm is seated on top of the
er on
Do not touch live electrical parts.
Shutdown
welding powersource, and discorl
nect input power employing locko ut/tagging pro
cedures before inspecting, maintaining, or serv
icing.
cover.
8.
Adjust drive roll pressure according
to Section
4-8.
9.
Close and
secure
side access door.
Pressure
ill Cover
Pressure
Adjustment
Arm
SB.091 19O.~
Figure
7-1. DrIve Roll And Pressure
Bearing Replacement
OM-112 875
Page
21
REPLACING PRESSURE BEARING
7.4.
(Figure
Loosen wire
4.
inlet.~uide securing
screw.
7-1)
stall
WARNING: ELECTRIC SHOCK can kill.
A~
Do not touch live electrical parts.
Shutdown we/ding powersource, anddiscon
nect input power employing locko uttagging pro
cedures before inspecting, maintaining, or serv
icing.
Lockoutitagging procedures consist of removing
input power plug from receptacle, padlocking
line disconnect switch in open position, remov
ing fuses from fuse box, or shutting off and redtagging circuit breaker or other disconnecting
guide
guide.
Remove inlet
5.
new
from drive
housing,
and in
IMPORTANT: Wire inlet guide should be installed as
close to the drive rolls as possible without touching them.
6.
lighten
wire inlet
7.
Thread
welding wire through wire drive assembly
according to Section 4-8.
guide securing
screw.
and gun
8.
Close and secure side access door.
device.
MOVING PARTS
can cause
serIous
Injury.
7-6.
REALIGNING DRIVE HOUSING (FIgure 7-2)
a
WARNING: ELECTRIC SHOCK
Keep away from moving parts.
left side access door.
1.
Open
2.
Loosen pressure
can
kill.
Do not touch live electrical parts.
welding powersource, and discon
lockout/tagging pro
cedures before inspecting, maintaining, orserv
icing.
Lockout/tagging procedures consist of removing
input power plug from receptacle, padlocking
line disconnect switch in open position, remov
ing fuses from fuse box, or shutting off and red
tag9ing circuit breaker or other disconnecting
Shutdown
adjustment knob, pivot pres
sure
adjustment arm free of cover, and pivot pres
sure
roll
nect input power employing
assembly away until it is in an open posi
tion.
pin from pressure lever hinge pin.
3.
Remove cotter
4.
Remove pressure lever assembly from
5.
Remove securing screw from pressure bearing,
and remove pressure bearing from pressure lever
hinge pin.
device.
MOVING PARTS
assembly.
6.
Install new pressure
ing
bearing,
serious
Injury.
moving parts.
and reinstall secur
screw.
7.
Reinstall pressure lever assembly onto
8.
Reinstall cotter pin onto end of
9.
Pivot pressure roll assembly downward onto
drive roll, making sure that welding wire is riding in
drive roll groove.
10.
can cause
Keep away from
hinge pin.
hinge.
The wire drive housing is made with mounting holes of
sufficient clearance to provide adjustment of the wire
guides up or down in relation to the drive rolls. This ad
justment has been factory set, but if readjustment be
comes necessary proceed as follows:
1.
2.
Remove wrapper from unit.
Loosen
mounting screws and the weld terminal
securing wire drive housing to cen
stud hardware
ter baffle.
Pivot pressure adjustment arm up until the wash
er on the adjustment arm is seated on top of the
cover.
3.
11.
Adjust
drive roll pressure
according
to Section
4-8.
12.
Close and secure side
access
drive roll groove.
door.
4.
7-5.
1.
2.
REPLACING WIRE INLET GUIDE
Open
Slide drive housing up or down until the wire can
be fed straight through the wire inlet guide and
into the wire outlet guide while wire is seated in
screws
and weld terminal stud
hardware.
(FIgure 7-1)
left side access door.
lighten mounting
5.
Reinstall wrapper.
Loosen pressure
adjustment knob, pivot pres
adjustment arm free of cover, and pivot pres
sure roll assembly away until it is in an open posi
sure
7.7.
CIRCUIT BOARD REPLACEMENT (Figure
7.2)
tion.
3.
Cut off welding wire at point where it enters wire
inlet guide, and pull wire out nozzle-end of weld
ing gun.
OM-112 875
Page
22
If circuit board PCi is at fault for a problem with the unit,
replace the board using the following procedure. Do not
attempt board repair. Contact the nearest Factory Au
thorized Service Station for correct replacement part.
-
.~Hub
Support
Standoff
Wire Drive
Mounting
Motor Control
Board PCI
Wire Drive Motor
Ref. SO-log 354-E
Figure
a
7-2. Motor Control Board PCi
WARNING: ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
1.
Remove wrapper.
2.
Remove terminal
RC1 on PCi.
3.
Note board mounting position, release PCi from
support standoff s, and remove PCi from center
Shut down
welding powersource, and discon
nect input power employing lockout/tagging
procedures before inspecting, maintaining, or
servicing.
MOVING PARTS can cause serious
Keep away
(ESD)
can
Install new PCi onto center baffle, and reconnect
terminal housing onto terminal header RC1 on
new PCI. Be sure that all pins on RC1 mate with
socket in terminal housing.
5.
Reinstall wrapper onto unit.
from
injury.
moving parts.
ELECTROSTATIC DISCHARGE
damage circuit boards.
Put on
BEFORE
properly grounded wrist
hand/mg circuit boards.
st rap
7-8.
WELDING GUN INSPECTION AND UPKEEP
Usage
and
Perform work
only at a static-safe
that plugs
are
work area.
icing.
Lockout/tagging procedures consist of removing
input power plug from receptacle, padlocking
line disconnect switch in open position, remov
ing fuses from fuse box, or shutting off and red
tagging circuit breaker or other disconnecting
properly installed and
can
Do not touch live electrical parts.
Shutdown welding po wersource, and discon
nect input poweremploying locko ut/tagging pro
cedures before inspecting, maintaining, orseri
aligned.
EXCESSIVE PRESSURE
WARNING: ELECTRIC SHOCK can kill.
a
INCORRECT INSTALLATION or misaligned
plugs can damage circuit board.
sure
shop conditions will determine frequency
required.
and type of maintenance
Transport circuit boards in proper staticshielding carriers or packages.
Be
from terminal header
4.
device.
a
housing
baffle in unit.
Lockout/tagging procedures consist of removing
input power plug from receptacle, padlocking
line disconnect switch in open position, remov
ing fuses from fuse box, or shutting off and redtagging circuit breaker or other disconnecting
CAUTION:
Replacement
device.
break circuit
board.
MOVING PARTS can
cause
serious
Injury.
Use
only minima/pressure and gentle move
ment when disconnecting or connecting
board plugs and removing or installing board.
IMPORTANT: A/I directions, such as left or right, are
with respect to the operator facing the unit front panel.
Retain all hardware removed during this procedure for
reinstallation unless specifically told otherwise.
Keep
1.
away from
Inspect gun every
moving parts.
three months or as use war
rants for broken areas, cracks and loose
tighten, repair and replace
2.
as
parts:
required.
remove any weld spatter or dirt which
has accumulated around the nozzle opening.
Carefully
OM-112 875
Pago
23
3
4
Remove any accumu~ation around the switch.
Repair
replace
or
as
required all hose and cab
1.
Remove nozzle...
2.
Cutoff any portion of the electrode wire which
tends beyond end of tube.
I~ng. give particular attention to frayed and
insulation and
cracked
area
where it enters
Remove contact tube and
3.
equipment.
5
Remove grease and
grime from components and
new con
Replace nozzle, and
4.
resume
operation.
parts and cables.
CAUTION: FLYING DIRT AND METAL CHIPS
can
with
tact tube.
moisture from electrical
a
replace
ex
Injure personnel
and
damage equip
ment.
7-10.
GUN LINER REPLACEMENT
a
WARNING: ELECTRIC SHOCK can kill.
(Figure 7-3)
Do not touch live electrical parts.
Point gun liner only in a safe direction away
from personnel and equipment when cleaning
with compressed air.
S
6
Blow out gun
casing
whenever the wire
7-9.
CONTACT
or
or
TUBE
liner with
compressed
Shutdown welding powersource, and discon
nect input power employing lockout/tagging
procedures before inspecting, maintaining, or
servicing.
air
Lockout/tagging procedures Consist of removing
input power plug from receptacle, padlocking
line disconnect switch in open position, remov
ing fuses from fuse box, or shutting off and redtagging circuit breaker or other disconnecting
liner is removed.
REPLACEMENT
(Figure
7-3)
a
device.
WARNING: ELECTRIC SHOCK can kill.
MOVING PARTS
Do not touch live electrical parts.
Shutdown welding po wersource, and discon
nect input power employing 10cko ut/tagging pro
cedures before inspecting, maintaining, orserv
icing.
Keep
Keep
can cause
away from
serious
Cut off any portion of the electrode wire which
beyond end of contact tube.
a
injury.
moving parts.
Nozzle
moving parts.
ex
tends
device.
MOVING PARTS
Injury.
Remove nozzle.
1.
2.
Lockout/tagging procedures consist of removing
input power plug from receptacle, padlocking
line disconnect switch in open position, remov
ing fuses from fuse box, or shutting off and red
tagging circuit breaker or other disconnecting
can cause serIous
away from
CAUTION:
LOOSE WELDING WIRE
3.
Remove contact tube.
4.
Retract wire onto wire spool.
5.
can
Injury.
Keep firm hold on wire during installation,
removal, and threading operations.
Spooled wire has a tendency to unravel rapidly
when loosened from the spool.
cause
Disconnect gun
assembly from wire drive
asse m
bly.
Contact Tube
Head
6.
Remove liner colIet.
7.
Lay cable assembly out flat and
in the cable/conduit).
8.
Pull out the liner from
straight (no
coils
Tube
Trigger
end of
gun assembly.
Gun/Feeder
Adapter
gun/feeder adapter
a
CAUTION: FLYING DIRT AND METAL CHIPS
Injure personnel and damage equip
can
ment.
Point gun liner only in a safe direction away
from personnel andequipment when cleaning
with compressed air.
9.
Blow out gun casing or liner with compressed air
whenever the wire or liner is removed.
10.
Insert new liner into gun/feeder adapter end of
gun. The liner should be flush with end of head
tube.
11.
Install collet and be sure liner is still flush with end
of head tube.
12.
Cut oft liner 1/16 in. (1.6 mm) from collet.
Uner
Coliet
SB.11O 831-A
Figure
7-3. MWG-160 Gun Parts
Replacement
OM.112 875
Page 24
13.
install corftact tube.
14.
Reinstall nozzle.
15.
Reinstall gun to wire drive
16.
Thread welding wire according to Section 4-8,
and resume operation.
assembly.
7-11~
1ROUBLESHOOTING (Table 7.2)
a
WARNING: ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
Shut down wire feeder and welding power
source, and disconnect
input power employing
before inspecting,
lockout/tagging procedures
maintaining, or servicing.
Lockout/tagging procedures consist of removing
input power plug from receptacle, padlocking
line disconnect switch in open position, remov
fuses from fuse box, or shutting off and red
tagging circuit breaker or other disconnecting
device.
ing
MOVING PARTS
can cause serious
Itis assumed that the upitwas properly installed accord
ihg to Section 4 of this manual, the operator is familiar
with the function of controls; the welding power source
was working properly, and that the trouble is not related
to the welding process. The following table is designed
to diagnose and provide remedies for some of the troub
les that may develop in this welding power source.
Use this table in conjunction with the circuit diagram
while performing troubleshooting procedures. If the
trouble is not remedied after performing these proce
dures, the nearest Factory Authorized Service Station
should be contacted. In all cases of equipment malfunc
tion, the manufacturers recommendations should be
strictly followed.
a
CAUTION: IMPROPER INPUT FUSES OR
CIRCUIT BREAKERS can damage unit and!
or
injury.
Use circuit breaker with amperage capacity
that matches Table 4-1 for the model used.
Keep away from moving parts.
HOT SURFACES
Allow
can cause severe
cooling period
Troubleshooting
to be
before
Input supply.
Be sure replacement input fuse amperage ca
pacity matches that listed in Table 4-1 for the
model used. Use fuse of same size and type.
burns.
servicing.
Correct overload problem before replacing fuse
resetting circuit breaker.
or
performed only by quati
lied persons.
OM-112 875
Page
25
Table 7-2.
TROUBLE
TroubleshootIng
REMEDY
PROBABLE CAUSE
No weld output; wire does not
feed.
Power cord plug not
wall
secure in
Secure plug in receptacle.
receptacle.
.
Line
fuse
circuit
or
breaker
Replace
line fuse or reset circuit breaker.
open.
Thermal overload.
Allow
Gun switch connection not
Se-
a
cooling period (see Section 7-2).
Secure gun switch connector in receptacle RC3.
cure.
open.
Replace gun switch
switch leads.
Power switch S2.
Replace S2.
Switch control
Replace CR1.
Gun switch,
No weld output; wire feeds.
Low weld output.
Electrode wire stops
while welding.
or
gun switch leads
relay CR1.
(if applicable)
metal contact.
Contact tube.
Replace
Low
Connect unit to proper input voltage
low line voltage.
feeding Sharp or excessive
cable
or
bend in gun
liner.
repair
Remakeworkconnectionensuringgoodmetalto
Work clamp connection loose
or incomplete due to rust, paint,
etc., on surface of workpiece.
input line power.
or
contact tube
Straighten
(see Section 7-9).
or
check for
gun cable and/or replace liner (see
Section 7-10).
Incorrect drive roll pressure.
Adjust
Incorrect hub tension.
Readjust hub tension (see Section 4-8).
Contact
tube
opening restricted; burnback of wire into
Replace
drive roll pressure (see Section 4-8).
contact tube
(see Section 7-9).
tube.
Friction in gun.
Check wire passage; clean, replace parts
quired (see Sections 7-9
Gun casing
plugged.
~
Broken or
liner.
Drive roll
or
liner
dirty
damaged casing
or
pressure roll
or
replace liner (see Section 7-10).
Clean
or
Replace damaged parts (see Section 7-10).
worn
wire leads
Excessive loading of drive
.
as re
7-10).
or
slipping.
Gun trigger switch
broken.
and
mo-
or
Replace drive roll or pressure bearing
quired (see Sections 7-3 and 7-4).
Replace switch;
as re
check connections.
Clear restriction in drive assembly.
tor.
OM-112 875
Page
26
Drive motor.
Contact nearest
tion.
Motor Drive Board PCi.
Replace
PCI
Factory Authorized Service Sta
according
to Section 7-7.
SECTION 8
ELECTRICAL DIAGRAMS
Circuit Diagram No. SB-119 059
Diagram
8-1. Circuit
Diagram
For MW 4110 Models
230
Circuit Diagram No. SB-119 063-C
Diagram
8-2. CircuIt
Diagram
For MW 4230 Models
OM-112 875
Page
27
Circuit
Diagram
8-3. Circuit
Diagram
Diagram
For MW 4110 Motor Control Board PCI
Circuit
Diagram
OM-112 875
Page
28
8-4. Circuit
Diagram
No. SC-i 37 798
Diagram
No. SC-i 37 801
For MW 4230 Models Motor Control Board PCI
132-B
P2
SC-1 9
No.
Diagram
CORD
Wiring
Models
41 0
MW
For
Diagram
Wiring
8-5.
Diagram
PC3
S2
0
N) cn
(I,
74 -C
23
SC-i
No.
Diagram
Wiring
Models
MW-4230
For
Diagram
Wiring
8-6.
Diagram
0
N)
-J UI -ł (0
~SECTION 9
a
.-
WELDING TECHNIQUES &
CAUTION: WELDING CURRENT can dam
age vehicle components and other elec
tronic
~
seam
TROUBLESHOOTING
before
lowering
the helmet and
pressing
the gun
trigger.
components.
Disconnect both
ing on a vehicle.
battery
cables before weld
Place work clamp as close to the weld
to avoid long electrical paths.
as
possible
Be sure gun to power source as well as cable
connections to work clamp are clean and
tight.
To minimize risk, disconnect the
from the vehicle.
9-1.
computer(s)
GAS METAL ARC WELDING
CONTINUOUS SEAM
FIgure
(GMAW)
TA-057 469-119
-
9-1. ContInuous Seam
The ability to produce a good bead while using the Con-S
tinuous Seam Gas Metal Arc process is dependent on
several factors. One of the most important, after wire
Figure
9-2. Gun Position
The gun can be moved along the seam in a steady move
ment known as the drag technique (see Figure 8-3), or it
can be oscillated a few degrees beyond each side of the
seam. The travel speed will be regulated by the type of
weld bead required, the thickness of the material, weld
ing current selected and the technique used. However,
the average speed is 15 to 20 inches per minute (0.4-0.5
mpm).
and
shielding gas selection, is the way the gun is held.
Cradle the gun in one hand and rest the side of the hand
on the workpiece (avoid doing this on hot material); use
other hand to hold gun and control the gun trigger. Posi
tion the gun either towatti or away from the body at a 45
to 60 degree lead angle (see Figure 8-2). This will give a
view of the arc and make it easier to follow the
seam while wearing a helmet. Maintain a 1/4 to 5/16 inch
good
(6-8 mm) distance from the bottom of the gun nozzle to
the workpiece during the arc starting and welding period.
Do not pull the gun back from the seam when the arc
starts, as this will create a long wire extension and result
in a poor weld.
The
welding wire is not energized until the trigger is
pressed. Therefore the welding wire can be extended
1/4 inch (6mm) beyond the gun nozzle and placed on the
a
aa
sw
TA-057 469-16
FIgure 9-3. WeldIng Techniques
Other welding techniques that affect the weld character
istics in the GMAW welding process include the back
hand and forehand technique, and the vertical up and
vertical down positions. In the backhand technique the
gun is positioned so that the electrode wire is feeding in
the opposite direction of arc travel. The filler metal is be
ing fed into the weld metal previously deposited. In the
forehand technique the gun is angled so that the elec
trode wire is fed in the same direction as the arc travel.
The backhand technique generally yields a more stable
arc and
less spatter
on
the
workpiece.
OM-112 875
Page
31
Direction of Arc Travel
Direction of Arc Tray
Backhand Technique
Forehand
Figure
9-4.
LongitudInal Gun
The vertical up and/or vertical down techniques describe
the direction of arc travel when the welding must be done
in the vertical
position. In both of these techniques gun
positioning extremely important because the arc must
be kept on the leading edge of the puddle to ensure cornis
Figure
9-2.
A.
Positions
plete weld penetration. The drag technique is generally
employed when welding in the vertical position, but
when bridging a gap, the arc can be oscillated from one
side of the work to the other.
Vertical Up
9-5.
Vertical Down
Welding
In The Vertical
Up
And Vertical Down Position
TROUBLESHOOTING THE GAS METAL ARC WELDING (GMAW) PROCESS
Porosity
.4
FIgure
OM-112 875
Page
32
Technique
9-6.
PorosIty
Correct~ve Actions
~..Posslble Causes
1.
Remove spatter from the gun
Inadequate shieldin g gas coverage.
nozzle:
Check gas hoses for leaks.
Eliminate drafts (from fans, open doors, etc.) blowing into the
welding
,..
arc.
Place nozzle 114 tO 5/16 in. (6-8 mm) from
Increase gas flow to
displace all
worlcpiece.
air from the weld zone.
Decrease excessive gas flow to avoid turbulence and the
trapment of air in the weld
en
zone.
Hold gun at end of weld until molten metal solidifies.
Check for frozen
2.
Wrong gas.
3.
Dirty welding
Use
wire.
.
CO2 regulator/f lowmeter.
welding grade shielding gas.
Use clean and
dry welding
Eliminate pick up of oil
conduit.
or
wire.
lubricant
on
welding
wire from feeder
or
4.
Remove all grease, oil, moisture, rust,
dirt from work surface before welding.
Workpiece dirty.
Use
5.
B.
Welding
wire extend s too far out of nozzle.
ExcessIve
a more
Welding
highly deoxidizing welding
wire should extend 114 in.
wire.
(6 mm)
out of nozzle.
Excessive spatter when
using CO2
CorrectIve Actions
shield-
ing gas.
C.
and
Spatter
Possible Causes
1.
paint, undercoating,
Select lower voltage range
WIRE SPEED control.
or
adjust
FINE TUNING/
incomplete Fusion
Figure
9-7.
Incomplete
Fusion
OM-112875P~.
Corrective
Causes
Actions
Clean weld surfaces of impurities (grease, oil, moisture, rust,
paint, dirt, etc.) prior
Select
to
welding.
higher voltage range
or
adjust FINE TUNING/
WIRE SPEED control.
When
technique.
using
a
weaving technique dwell momentarily
on
the
side walls of the groove.
Provide improved
Keep
access at
root of
electrode directed at the
joints.
leading edge
of the
puddle.
Provide proper gun angle (see Section 7.1).
FIgure
9-8. Lack of Penetration
CorrectIve Actions
Possible Causes
1.
Improper joint preparation.
Material too thick. Joint
quate to provide
preparation
and
design
must be ade
groove while
wire extension and arc characteris
access to the bottom of the
maintaining proper welding
tics.
2.
improper weld technique.
Maintain normal gun
(see Section 7-1).
.
Keep
3.
Insufficient heat
arc on
angle
to achieve maximum
penetration
leading edge of the puddle.
Select higher voltage range and wire speed.
input.
Reduce the travel speed.
Be
E.
Excessive Penetration
sure
welding
wire extends 1/4 in.
(6 mm)
out of nozzle.
(Burn-Through)
~
Figure
Possible Causes
1.
Excessive heat
input.
9-9. ExcessIve Penetration
Corrective Actions
Select lower voltage range and reduce wire speed.
Increase travel speed.
OM-112 875 Page 34
F.
Cracks in Weld Metal
Possible Causes
1.
Corrective Actions
Material too thick. Joint
improper joint preparation.
maintaining
preparation and design
must be ade
the b~):\om of the groove while
proper welding wire extension and arc characteris
quate to provide
access to
tics.
~.
2.
Heat input
shrinkage and
too
Select lower voltage range and reduce wire speed.
high causing excessive
distortion.
Increase travel speed.
G.
Wavinessof Bead
~.
~
Figure
9-10. Waviness of Bead
Possible Causes
wire extends too far out of nozzle.
1.
Welding
2.
Unsteady
H.
Corrective Actions
hand.
Welding
wire should extend 1/4 in. (6 mm) out of nozzle.
Support
hand
solid surface.
Humping
Figure
Possible Causes
1.
on
Excessive heat
input.
9-11.
Humping
Corrective Actions
Select lower voltage range
or
increase travel speed.
Weld in small segments and allow to cool between welds.
OM-112 875 Page 35
SECTION 10- AUTO BODY REPAIR APPLICATION
a
CAUTION: WELDING CURRENT can dam
age vehicle computers and other electronic
Clamp the new metal in place,
20.
and prepare to spot
weld.
components.
Disconnect both battery cables before weld
ing on a vehicle.
Place work
possible
to
clamp as close to the weld
avoid long electrical paths.
-Be sure gun to power source
connections to work clamp
as
Place the VOLTAGE ADJUSTMENT switch in the
21.
3
Install the spot nozzle
23.
shielding gas and power source turned
place the spot nozzle and press firmly against
the new material about 1/2 to 3/4 in. (12-18mm),
from the edge. Fit up must betightto assure good,
repeatable spot welds.
POINTERS FOR
SHEET METAL
Before
using
this
WELDING
equipment
AUTO
24.
piece
position to learn. Be sure that the material to
be welded is clean and free of paint and rust. The work
cable clamp must be attached to the parts being welded.
Clean surface to ensure proper grounding and to com
plete the current path.
from the center out
occur
if
on
each
welding begins
at the
Space spot welds 1 to 1/2 in. (25-38 mm) apart
around repair. Spot welds should be about 3/16
in. (5 mm) in diameter.
25.
to weld on a finished
Begin spot welding
side. Distortion may
corners.
BODY
of work, make a few practice welds on a sample piece of
material the same as that of the finished workpiece.
Whenever possible, weld in the fiat position since this is
the gun.
on,
tight.
10-1.
on
With the
well as cable
are clean and
as
To minimize risk, disconnect the computer(s)
from the vehicle.
position.
22.
IMPORTANT: Do not make continuous welds around
the repair as this will promote distortion and warpage.
the easiest
Use
a
.023 in.
dioxide
(0.6 mm) E7OS-6 wire and argon/carbon
shielding gas.
26.
After welding, remove the clamp and grind spot
flush to surface.
27.
Smooth the joints with body filler and finish.
10-3.
PROCEDURES FOR WELDING DOOR PAN
ELS
Use direct current straight polarity (electrode negative)
for reduced burn through. Check position of gun polarity
IMPORTANT: Every experienced autobody repairman
will have his own method of performing the folio wing pro
changeover jumper links according to information found
in a separate section previously covered in this manual.
If necessary, reposition jumper links.
cedures. However, this information is presented to show
how, in most cases, this welding po wer source can make
IMPORTANT: For maximum penetration on thicker ma
If the door is severely damaged, but the damage is pri
marily in the outer panel, or skin, the door can be easily
repaired without necessarily installing a whole new door.
terials such
18 gauge
(1.22 mm) and thicker, recon
nect for direct current reverse polarity (work lead to
negative, electrode wire to positive).
10-2.
as
the job easier and less time
1.
PROCEDURE FOR WELDING MILD STEELS
The
following are some basic guidelines that can be
using this welding power source to weld mild
high strength steels:
2.
Remove exterior
molding and hardware. It is not
necessary to remove window regulator, remote
control mechanisms, lock or runs.
Remove door assembly, and place on flat surface
edge of door extending over edges of surface
used when
with
or
to
17.
Use
a
power wire brush
or
consuming.
provide
room
to work.
sanderto remove paint
repaired. Two to
to bare metal in the area to be
Door Skin
three inches
(51-76mm) on either side of the weld
area should be cleaned for applying body filler af
ter welding is completed.
I
Damage
Inner Door
Remove
18.
metal using hand cutters,
shears, or a power hand grinder equipped with a
cutting wheel.
19.
Fit
damaged
In nor Door
a new
which
piece
was
of sheet steel
removed. The
new
over
the section
overlap the cut away section by one inch (25 mm).
OM-112 875
Page
36
Flange
S-04 t8
material should
FIgure
10-1.
Cutaway
Of Door Panel
Damage
If door t~s
the we(~
3.
an outer
panel reinforcement,
Grind off the hem flange and
4.
remove
break
the old
panel.
5.
Repair any damage
6.
Position the
to the inner
panel.
.welded ir~ place. Car-and body manufacturers have the
panels welded in different places. so it will be necessary
inspect the body to detet~nine where the welds are lo
cated in each case. After the old panel is removed, the
inner panels must be carefully checked, straightened or
to
replaced.
Continuous Seam
the end
7.
new
flange
Spot weld
outer
over
outer
panel
over
the inner
door and bend
flange.
panel reinforcement
to new door
panel.
weld new hem
to inner
8.
Spot
9.
Metal finish exterior surface,
interior trim and hardware.
flange
panel.
paint and assembly
Pulsed Seam
Weld.
Spot
Welds
S .0420
Figure 10-3. AutomotIve Body Sections
Assembled With ContInuous Seam, Pulsed,
And Spot Welds
panel can then be placed and held in posi
tion by vice-grips or c-clamp. When welding, start at the
center and proceed first in one direction and then the
The
S-0419
Figure
10-2. Hem
Flange
Removal
HOWTOPREVENTGLASS BREAKAGE AND
10-4.
SPATTER ON WINDOWS
them covered and as far away from the heat zone as
possible. When welding must be performed near win
dows, the windows should be covered and protected
from excessive heat by using wet rags. A putty like sub
stance which reduces heat transfer is available
welding supplier.
If burn
through
and spatter be
come problems, ensure that the correct voltage tap is
being used forthe size material being welded. Use an ar
gon and CO2 gas mixture and check travel speed.
10-5.
through
PROCEDURES FOR WELDING
AND QUARTER PANELS
other. In order to ensure reduced distortion due to heat,
weld only a section of 2 or3 in. (51-76mm) at a time. It is
important to constantly check the over all temperature of
the sheet steel around the welding area, because it is in
this concentrated heat area that warpage and distortion
will begin. Leave a gap and then weld another short sec
tion. When the weld is completed it can be hammered
down, filled with body putty and sanded.
10-6.
Spatter and excessive heat can become problems when
welding near windows. Protect the windows by keeping
your
new outer
FENDERS
WELDING FRAMES AND HIGH STRENGTH
(HSS) STEELS
The new HSS steels are used on many of the new econ
omy compact cars. HSS steels can be found in the steel
gussets, brackets, floor pans, and support members of
these new models. HSS steelsare thinner for weight re
duction and are heat sensitive. As heat is applied, the
strength decreases and cracking can occur, therefore
the heat affected zone must be kept as small as possi
ble. For this reason the GMAW welding process has be
come the preferred method for welding HSS steels, and
the oxacetylene welding or
wider heat affective area,
mended.
brazing processes,
are normally not
with its
recom
When a
complete panel must be replaced it will be nec
essary to remove the bolts securing the panel to the rest
of the structure, or to cut through the spot welds if the
panel is welded in place. In most cases afrontfenderwill
be bolted in place, while the other panels will be either
spot welded or continuous seam welded. The alignment
of front fenders is usually simple because the bolt holes
are
often
elongated
so
that the
position of the new front
aligned. Generally all
place.
fender can be shifted and correctly
other
panels
are
welded into
If the whole panel is to be replaced, the old panel must be
removed by cutting along the weld if welded by continu
ous seam, or by drilling out the spot welds if it is spot
Figure 10-4. ApplIcation Of Body Putty
OM-112 875
Page
37
(I) m C, -l 0 z
28
29
30
-I
-I Cl) r Cl) -I
11-3 1 -4
897~B
SD-1 2
Fig&
27
26
25
24
23
22
21
ilustraed)
20
19
4230
18
MW
Arc
(Auto
Asembly
Main
1 -1.
Figure
11-5
Fig
0
61
60
52
59
Quantity
Model
Item
No.
Dia.
Mkgs.
Part
No.
Description
Figure
~2
3
3
110 720
089899
112814
127 738
4
134 464
5
+111 833
6
1
11-1. Main
MW 4110
MW 4230
Assembly
GA-16C GUN, (Fig 11-5)
LATCH
1
1
2
2
LABEL,AutoArcMW4llO(Ieftside)
1
LABEL, Auto Arc MW 4230 (left side)
LABEL, warning general precautionary
1
1
WRAPPER
1
1
112813
127991
119 263
601 066
124 062
117 275
087 156
LABEL,AutoArcMW4llO(rightside)
1
LABEL, Auto Arc MW 4230 (right side)
RECTIFIER, si diode (consisting of)
1
THERMOSTAT, NC open 167F close 140F
RECTIFIER, Si diode (consisting of)
THERMOSTAT, NC open 186F close 166F
VARISTOR, 10 joule 68VDC
I
9
9
10
010124
010 529
TUBING,stl.5000DxllgawaIlxl.250
1
11
604 657
602 213
010910
111 912
6
7
SR2
TP1
7
SR2
TPI
8
VR1
113 447
12
13
14
15
Figll-2
16
089 120
17
604 550
010 909
010910
073 355
111998
111929
126839
072817
108 342
111 931
117014
005 656
110 375
113 149
079 747
137797
137800
129696
108 358
116 619
601 835
038 887
116 620
038 618
090 087
112 583
117 116
123 770
117 116
109 039
123 768
108 105
128007
605 227
18
19
20
21
22
23
24
25
26
26
27
CR1
FM
FM
28
29
30
30
31
31
32
33
PCi
PCi
CR2
CR2
34
35
36
37
38
39
39
M
R2
R2-5
40
40
41
42
43
Cl
Cl ,2
1
1
1
1
1
TUBING, stl .625 OD x .156 wall x .875
FOOT, mtg stab
SCREW, cap sti hex hd .375-16 x 1.250
WASHER, lock stl spIlt .375
WASHER,fIatstISAE.375
INSULATOR, housing drive
DRIVEASSEMBLY,wire
CLAMP, hose .375-.450 clp dia slfttng
HOSE, nprn brd No. 1 (order by ft)
NUT, sti sit 1kg hex .375-16
WASHER,flatstlSAE.375
SPRING, cprsn .625 OD x .093 wire x 1.000
PIN,cotterhair.120x2.375
1
1
1
1
1
1
1
1
1
1
I
I
1
1
2
2
3ft
3ft
1
1
2
2
1
1
1
1
HUB,spool
1
1
BAFFLE,center
RELAY,encI24VACDPDT
BRACKET, mtg tan
MOTOR, fan 120V 50/60 Hz 2600RPM
1
1
1
1
1
1
MOTOR,fan23OV5O/6OHz2600RPM
BLADE, lan 6 in 4 wg 30 deg .175 bore CW
STAND-OFF SUPPORT, PC card
HOUSING, term hdr 14 pin
TERMINAL, contact hdr 24-18 wire
CIRCUIT CARD, motor control (Fig 11-3)
CIRCUIT CARD, motor control (Fig 11-4)
CONTACTOR,defprp25AlP24VACcoil
CONTACTOR, def pip 25A 2P 24VAC coil
TERMINAL ASSEMBLY, chgov (consisting of)
NUT, brs hex 10-32
STUD, pn bd brsl0-32 x 1.375
TERMINAL BOARD, chgov
LINK, jumper term bd pn
MOTOR, gear 24VDC
INSULATOR, motor to housing drive
RESISTOR, WW fxd 20W 50 ohm
RESISTOR ASSEMBLY, (consisting of)
RESISTOR, WWfxd 20W 50 ohm
CAPACITOR, elctlt 46000uf 35VDC
CAPACITOR, elctit 70000uf 35VDC
CLAMP, capacitor 2.500 dia
PANEL,rear
NUT, nyl hex jam .750 NPST
1
1
.
1
1
4
4
1
1
14
14
1
I
1
1
1
1
8
8
4
4
1
1
2
1
2
1
1
1
1
2
2
1
2
1
2
1
1
1
1
OM-112 875
Page
39
Quantity
Item
No.
Model
Dia.
Mkgs.
Part
No.
Description
Figure
~~44
44
PLG1
PLG1
45
46
47
47
48
48
GS1
GS1
Z
Z
49
50
Ti
50
Ti
113494
127933
111 443
112 811
116 996
128 751
112 635
123 609
111827
113 515
112 049
123 962
123749
51
52
53
54
54
55
56
57
58
59
59
60
11-1. Main
MW 4110
I
MW 4230
Assembly (Continued)
CORDSET,pwr300Vl4ga3/c7ft
CORDSET,pwr300Vl2ga3/c6ft
1
BUSHING, strain relief .240/.510 ID x .875 mtg hole
LABEL, Auto Arc emblem
VALVE, 115VAC 2 way custom port 1/8 orf
VALVE, 23OVAC 2 way custom port 1/8 orf
I
1
1
1
STABILIZER
STABILIZER
BASE
1
TRANSFORMER, pwr main 115V (consisting of)
COIL, pwr main
TRANSFORMER, pwr main 230V (consisting of)
1
1
1
1
1
1
1
1
COIL,pri/sec
1
SI
iii 897
SWITCH, rotary (consisting of)
1
1
~KNOB,pointer
1
1
Ri
127023
072 623
POTENTIOMETER, C sitd sit l/T 2W 1000 ohm
PANEL,front
PANEL,front
RECEPTACLE w/SOCKETS, (consisting of)
TERMINAL, female lskt 14-18 wire
BUSHING, strain relief .370/.430 ID x .875 mtg hole
1
1
111 831
RC3
116835
048 282
079 534
111 644
026843
010368
111 997
116830
097 922
137217
137 218
113 280
089 120
113 129
112 863
S2
S2
61
61
+When
i
1
1
1
4
4
1
1
INSULATOR
2
2
CLAMP,grdlOOA
1
1
SWITCH, SPST bA 25OVAC
SWITCH, DPST 1OA25OVAC
KNOB, pointer
NAMEPLATE,AutoArcMW4liO
NAMEPLATE, Auto Arc MW 4230
HOSE, gas (consisting of)
CLAMP, hose .375- .450 clp dia slitting
TUBING, PVC .250 ID x .062 waIl (order by ft)
FITTING, adapter hose kit
1
1
1
Page
40
1
1
1
1
1
2
2
4ft
4ft
1
1
ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-112 875
1
Part
Item
No.
Description
No.
Figure
1
2
3~
4
5
6
7
8
9
10
11
12
13
14
15
16
17
19
20
21
22
23
24
25
26
Assembly,
Wire
11-1 Item
(Fig
15)
126 838
090416
124 817
114 415
111 523
112 031
604 741
010224
058 549
085 242
085 244
090 415
092 237
WIRE DRIVE,
126652
604538
126 653
602 238
KNOB,plstcT2.000lgx.312-18
1
WASHER,flatstlSAE.312
WASHER, flat nyl .312 ID x .625 OD
WASHER, fiat-SAE 3/16
WASHER, lock-split No. 10
5
602 203
090105
090 106
602 207
602 240
112 749
126 651
602 211
128 129
18
11-2. DrIve
Quantity
(consisting of)
1
PIN,hinge
1
HOUSING, wire drive
SCREW, mach sti phflh 10-24
BEARING, ball
LEVER, pressure roll
.
PIN, cotter-hair .042
x
1
x
.625
1
1
1
.937
1
~PlN,springCS.187x1.000
.
1
GUIDE, wire inlet 1/16
FASTENER, pinned
WASHER, cupped stl .328 ID x .812 00
SPRING, compression .720 OD x 1.250
KNOB, ad justment tension
x
1
1
x
.125
I
lip
1
1
.Og4thk
1
1
3
3
SCREW,cap-hexhd5mmx22mm
SCREW, cap-hex hd 6mm x 16mm
WASHER, lock-split 1/4
WASHER, flat-std 1/4
1
1
1
ROLL, drive Auto Arc U groove .023-.030 wire
1
WASHER, shldr nyl .437 OD
WASHER, lock sti Split .312
1
x
SCREW, cap sti hexhd .312-18
262515
.328 ID
x
x
.7O3shldr
1
1.750
1
1
Includes
Items
4thrul3
13-~
12-j
11
(.
~19
8
23
22
9
)
21
Figure
11-2. Drive
~2O
Assembly,
SB.091 190.E
Wire
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-112 875
Page
41
SA-137 796
Figure
OM-112 875
Page
42
11-3. CircuIt Card, Motor Control PCi
Dia.
Mkgs;
Part
No.
Quantity
Description
PCi
137 797
Figure
Cl ,2
C3
035 833
097 488
059 122
CAPACITOR, polye film .033uf 100VDC
CAPACITOR, cer mono .l5uf 50V
CAPACITOR,cerdisc.Oluf500V
2
031 677
000 348
CAPACITOR, tantlm 5.6uf 35VDC
CAPACITOR, tantim .47uf 35V
CAPACITOR, elctlt 68uf 35VDC
CAPACITOR, cerdisc.Oluf 100 VDC
CAPACITOR, elctlt luf 5OVDC
CAPACITOR, cer disc .O5uf 500VDC
RELAY, end 24VDC SPDT
1
DIODE, rect 1A 400V
DIODE, zener 18V 1W
DIODE,zener4.7V1W
DIODE, sig .020A 75V
FUSE, mintrgl sb blo 12A
4
CLIP, fuse 15A .250 dia
IC,interfacellCi
TRANSISTOR, WT 15MA 40V
TRANSISTOR, PNP 200MA 80V
TRANSISTOR, NPN 500MA 80V
RESISTOR, MF .25W 2K ohm
POTENTIOMETER, cermet trmr 201T .5W 5K ohm
POTENTIOMETER,cermettrmr25lr.5W 10K ohm
RESISTOR,CF.25WlKohm
RESISTOR, WW fxd 3W 150 ohm
RESISTOR, MF .25W 1K ohm
RESISTOR, MF .25W 6.81K ohm
RESISTOR, CF .25W 3.3K ohm
RESISTOR,CF .25W 270 ohm
RESISTOR, C .5W 100 ohm
RESISTOR, CF .25W 100 ohm
RESISTOR,CF.25W4.7Kohm
RESISTOR, CF .25W 10K ohm
RESISTOR,CF.25W1.5Kohm
RESISTOR, CF .25W 27K ohm
RESISTOR,ClW6800hm
RESISTOR, CF .25W 47K ohm
TERMINAL, hdr 14 pin
THYRISTOR, SCA 15A200V
RECTIFIER, integ 30A 400V
2
TRANSFORMER,pulse
1
IC,Iinear337T
I
C4,6
C5
C7
C8
C9
ClO
Cli
CR1
Dl ,3,6,8
D2
D4,7
D5
Fl
OC1
01
02
03
Ri
R2
R3
R4
R5,i0
R6
R7
R8
R11,12
R13
R14
R15
A 16,21
R17
R18
R19
R20
RC1
SCR1,2
SRi
TI
VR1
111 944
044 176
028 290
031 670
099 018
026 202
037 243
037084
028 351
*125 847
089 835
114712
039 355
114 714
114 713
092 525
009 173
082 178
035825
004 592
072 560
035 830
035 887
035824
030 025
035 823
039331
035 827
039328
039 334
030843
039 335
113 148
125486
093 747
111 910
093331
11-3. CircuIt
Card, Motor Control (Fig
11-1 Item
30)
I
2
1
1
1
1
I
1
1
2
1
1
1
I
1
1
1
1
1
1
2
1
1
1
2
1
1
1
2
1
1
1
1
1
2
2
Recommended Spare Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-112 875
P
SA-137 799
Figure
OM-112 875
Page
44
11-4. Circuit Card, Motor Control PCi
Dia.
Part
Mkgs.
No.
Pci
137 800
Figure
Cl ,2
C3
035
097
059
031
000
CAPACITOR, poiye film .033uf IOOVDC
CAPACITOR, cer mono .15u1 50V
CAPACITOR, cer disc .01 uf 500V
CAPACITOR, elcttt 5.6uf 35V0C
CAPACITOR, tantlm .47uf 35V
CAPACITOR, elctlt 68uf 35V0C
CAPACITOR, cer disc .Oiuf 1000VDC
CAPACITOR, elcttt luf 5OVDC
CAPACITOR, cer disc .O5uf 500VDC
RELAY, end 24VDC SPOT
DIODE, rect 1A 400V
DIODE, zener 4.7V 1W
DIODE, sig .020A 75V
FUSE, mintr gI $10 blo 1 2A
CLIP, fuse 15A .250 dia
IC,interfacellCl
TRANSISTOR, UJT 15MA 40V
TRANSISTOR, PNP200MA8OV
TRANSISTOR, NPN 500MA 80V
RESISTOR, CF .25W 2K ohm
POTENTIOMETER, cermet trmr 25/T .5W 10K ohm
RESISTOR, WW fxd 3.25W 150 ohm
RESISTOR, MF .25W 1K ohm
RESISTOR, MF .25W 6.81K ohm
RESISTOR, CF .25W 3.3K ohm
RESISTOR,CF.25W270ohm
RESISTOR, C .5W 100 ohm
RESISTOR, CF .25W 100 ohm
RESISTOR, CF .25W 4.7K ohm
RESISTOR, CF .25W 10K ohm
RESISTOR, CF .25W 1.5K ohm
RESISTOR, CF .25W 27K ohm
RESISTOR,ClW68Oohm
RESISTOR, CF .25W 47K ohm
RESISTOR, CF .25W 470 ohm
POTENTIOMETER, cermet trmr 20/T .5W 5K ohm
2
TERMINAL,hdrl4pin
1
THYRISTOR, SCR 15A200V
RECTIFIER, integ 30A 400V
TRANSFORMER, pulse
IC, linear 337T
2
C4,6
C5
C7
C8
C9
ClO
Cli
CR1
Di ,3,6,8
D5
Fl
OC1
Qi
02
Q3
Ri
R2
R5,10
R6
R7
R8
Ril,12
R13
R14
R15
R16,21
Ri 7
R18
R19
R20
R22
P23
RC1
SCR1,2
SRi
TI
VR1
833
488
122
677
348
111 944
044 176
028 290
031
099
026
037
D4,7
*
Quantity
Description
*
670
018
202
084
028 351
125 847
089 835
114712
039 355
114714
114 713
092 525
082 178
004 592
072 560
035 830
035 887
035824
030 025
035 823
039 331
035 827
039 328
039 334
030843
039 335
039 106
009 173
113148
125846
093 747
111 910
093 331
Recommended Spare Parts.
11-4. CIrcuit
Card, Motor Control (Fig
11-1 item
30)
1
2
1
1
1
I
1
1
1
4
2
I
1
2
1
1
1
1
1
1
2
1
1
1
2
1
1
I
2
1
1
1
1
1
1
2
1
1
.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING
REPLACEMENT PARTS.
OM-112 875
Page
45
9
2
~-1o
1
1
11
16
17
12
18
19
SC-uo B32-C
Figure
OM-112 875 Page 46
11-5.
Exploded
View Of GA-16C Gun
4
2
3
I
1
tern
No.
Part
No.
110 720
1
2
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
110793
110 795
110780
110 779
110781
128 878
110782
112 743
112 747
Figure
11-5.
Exploded
View Of GA-16C Gun
1)
1
2
1
JACKET, head tube
~STOP,nozzle
ADAPTER, head tube/nozzle
SPRING,nozzle
TUBE, contact Auto Arc .024 (.06 mm)
NOZZLE, Auto Arc 1/2 ort
110797
112 745
110 784
SLEEVE, rbr
LINER, Auto Arc lOft (consisting of)
COLLET, liner .023-.030 wire
0-RING, .500 ID x .103 CS rbr
878
535
834
11-1 Item
HANDLE ASSEMBLY
TRIGGERSWITCHASSEMBLY
974
796
(Fig
TUBE, head (consisting of)
NUT,MlOxl
110794
080 565
110 792
079
110
079
079
048
Quantity
Description
TERMINAL, frict fern .110
x
.016 22-18 wire
CABLEJCONDUIT, lOft
CONNECTOR, gun/feeder
HOUSING PLUG & PINS, (consisting of)
TERMINAL, male 1 pin sz 16 18-14 wire
CLAMP, cable strain relief
1
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-112 875 Pa;e