Miller AUTO ARC 120 Owner's Manual

June 1996
AUTO ARCS
Form:
OM-151 015C
Effective With Serial No. KG171 523
OWNERS
MANUAL
Auto Arcfi 120
CV/DC
Welding Power Source/Wire
For GMAW And FCAW
90
Amperes,
Usable
Welding
18 Volts At 20%
Range
Of 30 To 130
Uses 115 Volts AC,
Duty Cycle
Amperes
Single-Phase Input
Overheating, Short Circuit, And
Includes Gun,
Feeder
Welding Wire,
Power
Motor Overload Protection
Gas Valve, And Instructional Video
Read and follow these instructions and all
safety
blocks
Have
only
trained and qualified persons
or service this unit.
install, operate,
Call your distributor if you do not understand
the directions.
auto_arv 7/93
ST-149 330
U
Give this manual to the operator.
carefully.
6i~
1I~fl
call
For
or:
distributor,
help,
your
MILLER Electric Mfg. Co., P.O. Box 1079,
414-734-9821
Appleton, WI 54912
PRINTED IN USA
I
tax
I
J
LIMITED WARRANTY
(Equipment
This limited
with
Effective February 7, 1996
serial number preface of lCD
a
werrenty supersedes elI previous menufecturers werrenties end is exclusive with
Subject
LIMITED WARRANTY
to the terms end conditions
below,
or
other
no
newer)
guerentees
werrenties
or
expressed
or
implied.
MIG Guns/tiG Torches
werrentx to its
reteil purcheser thet new equipment sold eher the effective dete of this lim
ited wenenty is free of defects in metedel end wortmenship et the time it is shipped
tectory. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WAR
originel
*
APT, ZIPCUT
& PLAZCUT Model Plesme
Cutting
Torches
Remote Controls
from
*
Accessory
RANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MER
*
CHANTABILITY AND FIThESS.
Kits
Reptecement Pens
periods listed below, menufecturerwill mpeiror replece eny wer
rented pens orcomponents thet feit due to such defects in meteriel orworkmenehip.
Menufecturer must be notified in writing within thirty (30) deye of such defect or feil
urn, et which time menufecturer will provide instructions on the werrenty cleim pro
cedures to be followed.
Umited
1.
Itemsfumished by menufectumr, but menufectured by others, such es engines
ortrsde ecceesories. These items em covered bythe menufecturerswerrenty,
Menufecturer shell honor werrenty cleime on werrsnted equipment listed below in
the event of such e feilure within the werrentytime periods. Alt werrenty time periods
2.
Consumeble components; such
Within the werrenty
stert on the dete thet the
end
*
3.
Lebor
mein power rectifiers
Odginel
Inverters
releys
or
(input
end
Plesme Arc
*
Intellitig
*
Robots
2 Veers
3.
1 Veer
*
Cutting
Power Sources
contectors
Equipment thet hex been modified by eny petty other then menufecturer, or
equipment thet hex been improperiy instelled, improperiy opereted or misused
besed upon industry st~nderde, or equipment which hee not hed mesoneble
end necessery meintenence, orequipment which hex been used for operetion
outside of the epecificetione for the equipment.
PRODUCTS ARE INTENDED FOR PURCHASE AND USE
In the event of
e
werrenty cleim covered by this werrenty, the exclusive remedies
shell be, et menufectumrs option: (1) mpei~ or(2) replecement; or, where euthorized
in writing by menufecturer in eppropriete cesee, (3) the reesoneble cost of repeir or
Supplies
replecement et en euthorized service stetion; or (4) peyment of or credit for the put
price (less ressoneble deprecietion besed upon ectuel use) upon retum of the
goods et customers risk end expense. Menufecturers option of repeir or replece
ment will be FOB., Fectory et Appleton. Wisconsin, or FOB. et en euthorized ser
vice fecility es determined by menufecturer. Therefore no compensetion or reim
bursement for trensponetion costs of eny kind will be ellowed.
chese
(1 yeer lebor)
Pens end Labor
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN
ARETHE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENTSHALL MANUFAC
TURER BE LIABLE FOR DIRECT, INDIRECT, SPECIAL INCIDENTAL OR CON
SEQUENtiAL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED
ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY.
Pens end Labor
Motor Driven Guns
*
tips, cutting nozzles,
RIENCED IN ThE USE AND MAINTENANCE OF WELDING EQUIPMENt
Engine Driven Welding Generstors
(NOTE: Engines ere werrsnted seperstely by the engine menufecturer.)
Air Compressors
*
4.
contect
BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPE
Semi-Autometic end Autometic Wire Feeders
Invener Power
ee
to normel weer.
output rectifiers ontly)
Pens end Labor
Trsnsfornier/Rectifier Power Sources
*
to:
pens thet feil due
MANUFACTURERS
3 Veers
2.
epply
wee
SYeers Perte3Veers
*
shell not
if eny.
delivered to the originel reteil purcheser, or
equipment
one yeer efter the equipment ie sent to e North Americen distributor or eighteen
months efter the equipment ix sent to en Intemetionel distributor.
1.
Werrsnty
Process Controllers
IHPS Power Sources
*
Weter Coolent
*
HF Unite
*
Grids
*
Spot
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WAR
RANTY, GUARANTY OR REPRESENTATION ASTO PERFORMANCE, AND ANY
REMEDY FOR BREACH OP CONTRACT TORT OR ANY OTHER LEGAL
Systems
THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
OPERAtiON OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, IN
CLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS
FOR PARTICULAR PURPOSE, WITh RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MANUFACTURER IS EXCLUDED AND DISCLAIMED BY MAN
Welders
*
Loed Benks
*
SDX Trsnsforniers
*
Running Geer/Treilers
Plesme Cutting Torches (except APT, ZIPCUT & PLAZCUT Models)
Tecumseh Engines
Deutz Engines (outside North Americe)
Pield Options
(NOTE: Field options em covered under the limited werrenty for the rs
meining werrsnty period of the product they ere inetelled in, orfor e mini
whichever is greeter.)
mum of one yeer
*
*
*
5.
6 Months
6.
90
a]
Deys
UFACTURER.
Some stetee in the U.S.A. do not ellow limitetions of how
long en implied werrsnty
incidentel, indirect, epeciel or coneequentiel demeges, so
the ebove limitetion or exclusion mey not epply to you. This werrsnty provides spe
cific legel rights, end other rights mey be eveileble, but mey very from stete to etete.
lests,
or
the exclusion of
In Cenede, Iegieletion in some provinces provides for cenein edditionel werrenties
or remedies other then es eteted herein, end to the extent thet they mey not be
weived, the limitetions end exclusions set out ebove mey not epply. This Limited
Werrenty provides specific legel rights, end other rights mey be eveileble, but mey
very from province to province.
BeBeries
Pens end Labor
r_.
I
RECEIVING-HANDLING
Before
unpacking equipment, check carton for any damage that may have occurred during shipment. Fi)e any Claims for loss or damage
delivering carrier. Assistance for filing or settling claims may be obtained from distributor and/or equipment manufacturers
Transportation Department.
with the
When
requesting
Use the
or
information about this
following spaces to record
equipment, always provide
Model
Designation and Serial
or
Model
Designation
and Serial
Style Number of your unit.
or
Style
Number.
The information is located
on
the
rating label
nameplate.
.
Model
_________
Serial
or
Style
No.
Date of Purchase
brend_wer 3/96
ARC WELDING SAFETY PRECAUTIONS
WARNING
£~
ARC WELDING
be hazardous.
can
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.
In welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The
safety information given below is only a summary of the more complete safety information that will be found in the
Safety Standards listed on the next page. Read and follow all Safety Standards.
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY
QUALIFIED PEOPLE.
ELECTRIC SHOCK
can
kill.
terminal in disconnect box
live electrical parts can cause fatal shocks
bums. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is or,. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
Touching
or
severe
1.
Do not touch live electrical
2.
Wear
3.
4.
5.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays that
can burn eyes and skin. Noise from some processes
can damage hearing. Chipping, gnnding, and welds
cooling throw off pieces of metal or slag.
NOISE
Use
approved
I
I I
-
I
2.
ear
plugs
or ear
muffs if noise level is
FUMES AND GASES
to your health.
can
be hazardous
use
exhaust at the
4.
If ventilation is poor,
Read the Material
manufacturers
use an
If earth
with
and the
1.
2.
3.
can
explode
if
damaged.
a
over
your
body.
grounding of the workpiece is required, ground it directly
separate cable do not use work clamp or work cable.
Use only well-maintained equipment. Repair or replace
damaged parts at once. Maintain unit according to manual.
15.
Wear
a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact
workpiece or worktable as near the weld as practical.
to
ARC RAYS
2.
3.
4.
Wear
a welding helmet fitted with a proper shade of filter to
protectyourfaceandeyeswhenweldingorwatching(seeANSl
Z49.1 and Z87.1 listed in Safety Standards).
Wear approved safety glasses with side shields.
Use
and
protective screens or barriers to protect
glare; warn others not to watch the arc.
others from flash
5.
Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
5.
Work in
6.
Do not weld in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to
form highly toxic and irritating gases.
a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained
watchperson nearby. Welding fumes and gases can displace
air and lower the oxygen level causing injury or death. Be sure
the breathing air is safe.
Do not weld
cadmium
on
coated
plated steel,
metals,
such as
unless the
weld area, the area is well
coating
galvanized, lead,
or
is removed from the
ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
4.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
5.
Protect
compressed gas cylinders from excessive heat,
slag, open flames, sparks, and arcs.
lnstallcylindersinanuprightpositionbysecuringtoastationary
support or cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding or other electrical
8.
mechanical shocks,
9.
circuits.
poorly spliced
14.
cleaners, and degreasers.
CYLINDERS
or
Do not touch electrode if you are in contact with the work,
ground, or another electrode from a different machine.
7.
coatings,
Data Sheets
use.
13.
approved air-supplied respirator.
(MSDS5)
Safety
when not in
damaged, undersized,
Do not drape cables
arc to
instruction for metals, consumables,
worn,
11.
out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or
welding fumes and gases.
equipment
use
12.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
Keep your head
Do not
cables.
high.
remove
3.
Turn oft all
17.
.
1.
9.
10.
Always verify the supply ground check and be sure that input
power cord ground wire is properly connected to ground
ARC RAYS can burn eyes and skin;
NOISE can damage hearing; FLYING
SLAG OR SPARKS can injure eyes.
double-check connections.
Frequently inspect input power cord for damage or bare wiring
replace cord immediately if damaged bare wiring can kill.
16.
-
1.
conductor first
8.
Manual and national, state, and local codes.
Owners
6.
parts.
dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating
mats or covers big enough to prevent any physical contact with
the work or ground.
Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according
to OSHA 29 CFR 191 0.147 (see Safety Standards).
Properly install and ground this equipment according to its
7.
or that cord plug is connected to a
properly grounded receptacle outlet.
When making input connections, attach proper grounding
6.
7.
Never
welding torch over a gas cylinder.
welding electrode to touch any cylinder.
Never weld on a pressurized cylinder
explosion will result.
Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
a
a
Tum face away from valve outlet when
opening cylinder valve.
Keepprotectivecapinplaceovervalveexceptwhencylinderis
in
10.
drape
Never allow
use
orconnected for
use.
Read and follow instructions
associated
equipment,
compressed gas cylinders,
publication P-i listed in Safety
on
and CGA
Standards.
srl.1.1 2.194
WELDING
fire
can cause
explosion.
or
closed containers, such as tanks, drums,
or pipes, can cause them to blow up. Sparks can fly
off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal
6.
Be
objects
can cause
fire. Check and be
any
sparks, explosion, overheating, or
sure the area is safe before doing
aware
that
can cause
Welding on
fire
welding
on a
ceiling, floor, bulkhead,
or
partition
the hidden side.
on
Do not weld on closed containers such as tanks, drums, or
pipes, unless they are properly prepared according to AWS
F4.1 (see Safety Standards).
Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long,
possibly unknown paths and causing electric shock and fire
7.
8.
welding.
hazards.
1.
Protect
2.
Do not weld where
3.
Remove all flammables within 35 ft (10.7 m) of the welding arc.
If this is not possible, tightly cover them with approved covers.
4.
Be alert that welding
5.
yourself
and others from
flying sparks
flying sparks
can
and hot metal.
strike flammable material.
Do not
sparks and
tip
contact
ENGINE EXHAUST GASES
kill.
Engines produce harmful exhaust gases.
ENGINE
FUEL
can
fire
cause
or
explosion.
fuel is
1.
Stop engine
2.
Do not add fuel while
highly
smoking
or
checking
if unit is
cutoff
or
12.
welding
wire at
use.
protective garments such
heavy shirt, cuttless trousers, high shoes,
as
leather
and
a
gloves,
cap.
Remove any combustibles, such as a butane lighter
matches, from your person before doing any welding.
be hazardous.
can
equipment outside
or
in open, well-ventilated
1.
Use
2.
If used in a closed area, vent engine exhaust outside and
away from any building al r intakes.
3.
Do not overfill tan k
4.
Do riot
spill
allow
fuel. If fuel is
room
fo r fuel t o
spilled,
areas.
expand.
clean up before
starting
engine.
flammable.
and let it cool off before
when not in
ENGINES
can
pipes.
Wear oil-free
11.
WARNING
4~
welder to thaw frozen
use
Remove stick electrode from holder
10.
hot materials from
welding can
easily go through small cracks and openings to adjacent areas.
Watch for fire, and keep a fire extinguisher nearby.
Engine
9.
or
near
adding fuel.
sparks or
any
open flames.
MOVING PARTS
can cause
3.
injury.
Have
only qualified people remove guards or
troubleshooting as necessary.
covers
for
maintenance and
Moving parts, such as fans, rotors, and belts can
fingers and hands and catch loose clothing.
4.
To prevent accidental starting
negative () battery cable from
5.
Keep hands, hair,
cut
1.
Keep all doors, panels,
securely in place.
2.
StoD enaine before
covers,
installing
and
guards
closed and
connecting unit.
Reinstall
generate explosive
lases.
STEAM AND PRESSURIZED HOT
COOLANT can burn face, eyes, and
skin.
It is best to check coolant level when
to avoid scalding.
panels
or
guards and close
starting engine.
doors when
servicing
is
finished and before
SPARKS can cause BATTERY GASES
TO EXPLODE; BAT1ERY ACID can
burn eyes and skin,
Batteries contain acid and
clothing, and tools away from moving
parts.
6.
or
loose
during servicing, disconnect
battery.
engine
is cold
1.
Always
2.
Stop engine before disconnecting
wear a
face shield when
working
or
on a
battery.
connecting battery
cables.
3.
Do not allow tools to
4.
Do not
5.
Observe correct
It the
1.
use
cause
welder to
engine
is
sparks when working on a battery.
charge
polarity (+
warm
and
batteries
and
)
on
checking
or
jump
start vehicles.
batteries.
is needed, follow steps 2
and 3.
2.
Wear
3.
Tum cap
safety glasses and gloves and put a rag over cap.
slightly and let pressure escape slowly before
completely removing cap.
PRINCIPAL SAFETY STANDARDS
Safety in Welding and Cutting, ANSI Standard Z49.i, from
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards,
American
OSHA 29 CFR 1910, from
dent of Documents, U.S. Government
D.C. 20402.
Recommended Safe Practices for the
Superinten
Printing Office, Washington,
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-i, from Compressed Gas Association, 1235 Jefferson Davis High
way, Suite 501, Arlington, VA 22202.
Code for
Safety in Welding and Cutting,
Preparation
for
Welding
and
Cutting of Containers That Have Held Hazardous Substances, Ameri
Welding Society Standard AWS F4. 1, from American Welding So
ciety, 550 N.W. LeJeune Rd, Miami, FL 33126
can
Code, NFPA Standard 70, from National Fire Pro
Association, Batterymarch Park, Quincy, MA 02269.
levard, Rexdale, Ontario, Canada M9W 1 R3.
Safe Practices ForOccupation And Educational Eye And Face Protec
tion, ANSI Standard Z87.i, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
And
Welding Processes, NFPA Standard 51 B, from National
Association, Batterymarch Park, Quincy, MA 02269.
National Electrical
Cutting
tection
Fire Protection
srl.1.1 2/94
CSA Standard Wi 17.2, from
Sales, 178 Rexdale Bou
Canadian Standards Association, Standards
SECURITE
CONSIGNES DE
POUR LE SOUDAGE
MISE EN GARDE
a
A
LE SOUDAGE
LARC peut Øtre
A
LARC
dangereux.
LECART.
LES
SE PROTEGER ET PROTEGER LES AUTRES CONTRE LES BLESSURES GRAVES VOIRE MORTELLES. TENIR LES ENFANTS A
PERSONNES OUI PQRTEN! UN STIMULATEUR CARDIAQUE NE DOIVENT PAS NON PLUS SAPPROCHER DU POSTE DE SOUDAGE, A MOINS
DAVOIR CONSULTE UN MEDECIN.
Le
soudage, comme Ia plupart des travaux, prOsente certains dangers. Par contre, le soudage peut
qui simposent. Les consignes de sØcuritØ donnØes ci-aprŁs no font que rOsumer linforrration
mesures
a Ia page suivante. Lire et respecter toutos ces normes de sØcuntØ.
LINSTALLATION, LUTILISATION, LENTRETIEN ET LES REPARATIONS NE DOIVENT
ELEcTRIQUE peut tuer.
UN CHOC
des piŁces Olectriques peut
provoquer une electrocution ou des blessures graves.
LØlectrode et le circuit do soudage sont sous tension des
que lappareil est sur ON. Le circuit dentrØe et los circuits
intomes de Iappareil sont egalement sous tension a ce
moment-l.
En
soudage somi-automatique ou
Un
=~.
simple
contact
le
automatiquo,
jamais toucher
1.
Ne
2.
Porter des
gants
los
piŁces electriques
sous
secs ne
comportant
3.
4.
6.
8.
Verifierfrequemment 0 cordon dalimentation pourvoir sil nest pas
ondommage ou dØnudØ romplacer 10 cordon immOdiatement sil
cable dØnudØ peut provoquer une
est endommage
un
electrocution.
9.
de Ia piŁce et de Ia terre au moyen do tapis ou dautres
moyons isolants sutfisamment grands pour empOcher to contact
physique Łvontuel avec Ia piŁce ou Ia terre.
Couper
lalimentation
ou
proceder a
do Iappareil.
13.
15.
conforrnØmont ace manuel.
16.
17.
terre du cordon dalimentation
Verifier et
est bien
aue le fil de terre du cordon dalimontation
Larc de soudage produit des rayons visiblos et invisibles
intensos (ultraviolets et infrarouges) qui peuvent brOler
los yeux et Ia peau. Le bruit produit par certains procØdes
peut endommagor louIe. Des projections do metal ou do
laitier sont produitos par 10 piquage, to moulage ou to
refroidissement des soudures.
Utiliser des bouche-oreilles ou dos serre-tOte antibruit
do bruit est ŁlevØ.
approuvØs
Si
2.
vapeurs et des fumØes
Porter dos lunettos do sØcufltØ
4.
Utilisor des paravonts ou des barnOres de protection pour protØgor
los personnes a proximitØ contra los coups darc et lØblouissement;
avertir los autres personnes de ne pas regardor Iarc.
5.
5.
2.
vontiler le
poste de travail
ou
utiliser
Un
quil
est
ne
pas les
dispositif place
soudago.
nivoau do Iarc pour Øvacuer les vapeurs et fumØes do
3.
Si Ia ventilation est mauvaise, utiliser
adduction dair pur approuve.
4.
Consulter les fiches
relatives
au
Un
apparoil rospiratoire
6.
7.
a
2.
exploser
si elles
endommagees.
4.
5.
Los bouteilles contonant des gaz do protection sont a
Une bouteille ondommagee pout
haute pression.
oxploser. Etant dome que los bouteilles de gaz font
normalement partie du materiel de soudage, les traitor
avec le plus grand soin.
6.
les bouteilles do gaz comprime contro Ia chaleur intense,
les chocs, le laitier, les flammes nuos, les Øtincollos et larc.
8.
Proteger
Placer los boutoilles ala vorticalo en los fixant a un support fixe
chariot pour Øviter quelles ne tomberit ou ne basculent.
ou
a
un
3.
Tenir los bouteilles a IØcart du
electriques.
poste de soudage
ou
ignifuge durable (lame et
un espaco confine quo siI est bien ventilØ, ou en
portantun appareilrespiratoireaadductiondairpur. Demandor un
observateur ayant recu Ia borne formation do toujours so tenir a
proximite. Los vapeurs et fumØes do soudago peuvent dØplacer lair
dautres circuits
et causordes blessuros graves voire
quo lair ost propre a Ia respiration.
doxygOno
No pas soudor a proximitØ doperations do degraissago, do
nettoyage ou do pulvensation. La chaleur et los rayons do larc
pouvent rØagir avec los vapours pour former des gaz hautement
toxiquos et irritants.
Ne pas souder
sur
dos mOtaux rovOtus comme lacier galvanisØ, au
nait ØtO ontiŁrement dØcapØe,
quo le poste do travail soit bien vontilO. Sil y a lieu, porter un appareil
respiratoire a adduction dair pur. Los rovOtements ot los mOtaux qui
contiennent do tots ØlØments peuvent degagordes vapeurs toxiques
lors du soudaae.
dŁcjraissants.
LES BOUTEILLES peuvent
Øcrans latOraux.
p10mb ou cadmiØ a moms que Ia piŁce
signaletiques et les consignes du fabricant
mØtaux, produits dapport, rovOtements, nottoyants et
sont
avec
No travailler dans
mortelles. Sassurer
respirer.
A lintØrieur,
approuvØes
Porterdes vŒtemonts do protection en tissu
ot des chaussures do sØcuntØ.
et abaisser le niveau
Garder Ia tŒte a IextØneur des vapeurs et des fumees et
1.
un
3.
s-s
au
masque a serre-tOte muni dun verro filtrant do nuance
pour proteger le visage et los yeux quand on soudo ou
observe Ia travail do soudage (voir los normes ANSI Z49.i et Z87.1
donnOes sous Ia rubnque Principales normes do securitØ).
Porter
appropnØe
dangereux
1.
en
cuir)
LES VAPEURS ET LES FUMEES peuvent Œtre
Ia sante.
soudage produit des
de respirer.
harnais do sØcuntØ
un
RAYONNEMENT DE LARC
dangereuses pour
Le
quand on travaille on hauteur.
place tous los panneaux et capots.
Fixer 10 cable do retourde taon obtenirun bon contact mØtal-mØtal
avec Ia piŁce a souderou latable dotravail, le plus prŁs possible de Ia
Porter
Maintenir solidement
soudure.
BRUIT
1.
quand on est en contact avec Ia piŁce, Ia
provenant dune autre machine.
materiel en bon Øtat.
Nutiliser quun
Reparer ou remplacer
Entretenir lappareil
sur-le-champ es piŁces endommagØes.
Ne pas toucher IŁloctrode
terre ou une electrode
arrOter le moteur avant do
LE RAVONNEMENT DE LARC peut brUler les
yeux et Ia peau. Le BRUIT peut endommager
IouIe; les PROJECTIONS DE LAITIER OU LES
ETINCELLES peuvent blesser les yeux.
quand on no Iutilise pas.
uses, endommagOs, de grosseur
Ne pas enrouler los cables autourdu corps.
Si Ia piŁce soudOe doit Otre mise a Ia terre, le faire directement avec
no pas utiliser le connecteur do piŁce ou le cable
un cable distinct
de retour.
Installer et mettre a Ia terre correctement cot appareil conformØment
a son manuel dutilisation et au codes nationaux, provinciaux et
sassurer
hors tension
11.
14.
a
Iappareil
Ne pas utiliser des cables
insuffisante ou mal ØpissØs.
a
a
reparation ou a Ientretien
DØverrouiller Ialimentation selon Ia norme OSHA 29 CFR 1910.147
(voir normes de sOcuntØ).
municipaux.
Toujours verifier
Mettre
10.
Sisoler
linstallation,
5.
En effectuant les raccordemontsdentrØefixerdabordleconductour
de mise a Ia terre appropriØ et contro-vØrifior los connexions.
12.
pas de trous.
QUALIFIEES
7.
tension.
protection
DES PERSONNES
raccordØ ala borne do terre du sectionneur ou quo Ia fiche du cordon
priso corroctemont mise a Ia terre.
fil, le dØvidoir, to logement des galets
et des vØtements do
ETRE CONFIES QUA
ost raccordØe a une
avec
dentraInementet los piŁces metalliquos en contact avec
to f ii do soudago sont sous tension. Des matØnels mal
installØs ou mal mis a Ia terre prOsentent un danger.
Otre effectuØ en toute sØcuritØ quand on prend les
contenue dans los norrnes do sOcuntO ØnumØrOes
7.
jarnais poser un chalumeau soudeur sur une boutoille do gaz.
jamais laissor une electrode do soudage toucher une bouteille.
No jamais souder sur une boutoille sous pression : ello explosorait.
Nutilisor quo dos boutoillos do gaz do protection, dos dOtendours,
des tuyaux souples et des raccords appropriØs conus
pour
lapplication particuliŁre; consorvor ces matØriels et lours piŁces en
No
Ne
bon Otat.
Eloigner
le
visage
do Ia sortie du robinot do Ia boutoillo quand
on
louvre.
9.
10.
Replacer le chapoau
sur
Ia bouteille
aprŁs
utilisation.
Lire ot suivre les consignes relatives aux bouteilles do gazcomprimO,
au materiel connexe ainsi quo Ia publication P-i do Ia CGA donnØe
sous Ia rubrique Pnncipales normes de sOcuritØ.
$rl.1.2 2194
LE SOUDAGE
incendie
ou une
5.
Ne pas souder sur des recipients fermØs comme des
reservoirs, des fOts ou dos tuyaux: us peuvent exploser.
Larc do soudage pout produire des Otincellos.
Des
Otincelles, une piŁce chaude et un materiel chaud
peuvent provoquer des incendies et des blessures. Le
de lØlectrode
des objets
contact accidentel
sur
metalliques pout produire des Øtincelles, lexplosion, Ia
surchauffo ou un incendie. Sassurer que le lieu no
prOsonte pas do danger avant deffoctuor 10 soudage.
6.
peut
causer un
explosion.
1.
So
7.
8.
protegeret protegorles personnes a proximitØ des Otincolles et du
mOtal chaud.
2.
3.
Ne pas soudor dans un endroit o
des matØrlaux inflammables.
les Øtirtcelles peuvent atteindro
Enlevertoutes les matiŁres inflammables dans un rayon do moms do
10 m do larc. Si cola nest pas possible, bien los recouvriron utilisant
des bchos approuvees.
Prendre garde que les etincelles et es projections ne penetrent dans
des zones adjacentes en sinfiltrant dans dos petites fissures et
4.
9.
produisent
dos gaz
dechappement
ou une
12.
1.
1.
ArrØter 10 motour et le laisser rofroidir avant de verifier le nivoau do
ou do refaire 0 plein.
LES PI¨CES EN MOUVEMENT
des blessures.
peuvent
causer
2.
ArrOtor le moteur avant de mettre
en
place
utilise
on
soi comme
presenter
Utiliser lo materiel a lextØrieur,
ventulØs.
Si
sur
un
briquet a
danger.
un
dans dos lioux ouvorts ot bion
moteur dans un local ferme, evacuer los gaz
a loxtØrieur ot loin dos pnses dair du btimont.
un
No pas fumer en faisant 10 plein ou si
dØtincellos ou do flammos nues.
3.
Ne pas romplir le reservoir a
dilatation du combustible.
4.
Si on ronverso du carburant,
No pas ronversor du carburant.
nettoyer les lioux avant do faire dØmarrer le moteur.
3.
ras
lappamil
bord:
so
prevoir
trouve a
proximite
2.
4.
5.
los portes, los pannoaux, los capots et los
sont bien fermØs ot bion a leur place.
Sassurerquo
tuyaux.
de
lespace
pour Ia
Seulos des personnos qualifieos doivent dOmonter los protectours
los capots pour faire lentrotien ou los reparations nOcessaires.
ou
Los piŁces en mouvement comme les vontilateurs, los
rotors ot los courroios pouvont coupor los doigts et los
mains et happor los vOtements amples.
1.
Ne pas portordes matiŁres combustibles
gaz ou des allumettes quand on soudo.
dechappement
explosion.
Le carburant est hautomont inflammable.
des
Portordes vØtoments de protection non huileux comme des gants en
dos pantalons sans revers, dos
une chemise epaisso,
chaussuros montantos ot un casque.
nocifs.
incendie
un
degeler
cuir,
LES MOTEURS peuvent
DES MOTEURS
LE CARBURANT peut provoquer
r
chalumoau soudeur pour
11.
2.
Les motours
0
Enlever lØloctrode enrobØe du porte-electrode ou couper le fil de
soudage au ras du bec contact quand on no lutilise pas.
MISE EN GARDE
LES GAZ DECHAPPEMENT
peuvent Œtre mortels.
Ne pas utiliser
10.
ouvertures.
a
Prendre garde aux incendies ot toujours avoir un oxtinctour a
proximite.
So rappeler quo si Ion soude sur un plafond, un plancher, une cloison
ou autre, le feu pout prondre do lautre cte.
Ne pas souder sur des recipients fermØs comme des reservoirs, des
fOts ou dos tuyaux a moms quils no soient prepares do faon
appropneo conformØment ala norrne F4.1 de lAWS (voir Ia rubnquo
Principales norrnes do securitO).
Raccordor lo cable de retour a Ia piŁce, 10 plus prŁs possible de Ia
zone de soudago, pour empØchor quo le courant de soudage ne
suive uno trajoctoire longuo ot Øventuellemont inconnue et quil no
provoque des risques dØlectrocution et dincendie.
ou
protecteurs
demarrage accidentel dun systŁme pendant
reparations, dØbrancher le cable negatif () do Ia
un
Eloignor los
mains, les chevoux, los vŒtements amplos ot los outils
piŁces en mouvomont.
Replacer los capots ou los protecteurs et reformer les portes une fois
lentretien et los reparations torminØs et avant do faire dOmarror 10
des
6.
do raccordor
Pour ompOchor
lontretien ou les
batterie.
un
moteur.
LES ETINCELLES peuventfaire EXPLOSER LE
GAZ DES BATTERIES; LELECTROLYTE peut
brLiler Ia peau et les yeux.
Les batteries contiennent
dos vapeurs explosives.
1.
Touiours~
ortor un Øcran facial
un
quand
on
produit
acide et
travaillo
sur une
degagent
battorie.
LA
~f.
ET
DE
VAPEUR
LE
LIQUIDE
REFROIDISSEMENT
SOUS
BRULANT
PRESSION peuvent brOler ~a peau et les yeux.
II
vaut
mieux verifier 10
du
nivoau
liquide do
rofroidissomont quand 0 motour est froid afin dØviter los
2.
ArrOter le moteur avant do branchor
Ia batterlo.
3.
Ne pas faire dos Øtincellos
batlono.
4.
Ne pas utilisor Ia source do courant do soudage pour
batteries ou pour faire dØmarrer un vØhicule.
5.
No pas intorvertir Ia polaritØ des batteries.
1.
Si on
etares
2.
Welding
Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of
Documents, U.S. Government Printing Office, Washington, D.C. 20402.
Recommended Safe Practice for the Preparation for Welding and Cutting
of Containers That Have Held Hazardous Substances, norme AWS F4. 1,
do American Welding Society, 550 N.W. Lejeuno Rd, Miami FL 33126
National Electrical Code, NFPA Standard 70, do Ia National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269.
sri .1.2 2/94
los outils
quand
quand
on
travaille
sur une
charger
los
le moteur ost chaud, suivre los
Porter dos Iunettes do sØcuntØ ot des
3.
gants et placer un chiffon
Toumer lentemont le bouchon ot laissor Ia pression
lentomont avant denlevor complŁtoment 10 bouchon.
PRINCIPALES NORMES DE
delArnorican
dolt verifier le niveau
2 et 3.
do dØbrancher los cables de
sur
lo
bouchon.
brOlures.
Safety in Welding and Cutting, norme ANSI Z49.1,
Society, 550 N.W. Lojoune Rd, Miami FL 33126
avec
ou
sOchapper
SECURITE
Handling of Compressed Gases in Cylinders, CGA Pamphlet P-i, de
Compressed Gas Association, 1235 Jefferson Davis Highway, Suite
501, Arlington, VA 22202.
Safe
Ia
Regles de sØcuritØ en soudage, coupage et procadØs connexes, norme
CSA W1i7.2, do lAssociation canadienne do normalisation, vente do
norrnos, 178 Rexdalo Boulevard, Roxdale (Ontario) Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face Protection,
ANSI Z87.1, do lAmorican
National Standards Institute, 1430
Broadway, Now York, NY 10018.
norme
Cutting
Welding Processes, normo NFPA 51 B, do Ia National Fire
Association, Batlorymarch Park, Quincy, MA 02269.
and
Protection
EMF INFORMATION
Considerations About
NOTE ~
Welding
And The Effects Of Low
Frequency
Electric And
Magnetic Fields
The
To reduce
of the U.S.
following is a quotation from the General Conclusions Section
Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields
Background Paper~ OTA-BP-E-53 (Washington, DC: U.S.
Govemment Printing Office, May 1989): .
there is now a very
large volume of scientific findings based on experiments at the
cellularlevel and from studies with animals and people which clearly
establish that low frequency magnetic fields can interact with, and
produce changes in, biological systems. While most of this work is
of very high quality, the results are complex. Current scientific
understanding does not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet
allow us to draw definite conclusions about questions of possible
risk or to offer clear science-based advice on strategies to minimize
or avoid potential risks.
procedures:
magnetic fields
in
the
workplace,
1.
Keep cables close together by twisting
2.
Arrange cables
3.
Do not coil
4.
Keep welding power
practical.
source
Connect work
to
or
use
taping
to one side and away from the
the
following
them.
operator.
.
.
5.
or
drape cables around the body.
clamp
and cables
workpiece
as
as
far away
as
close to the weld
as
possible.
About Pacemakers:
The
above procedures are among those also normally
recommended for pacemaker wearers. Consult your doctor for
complete information.
modlO.1 4/93
TABLE OF CONTENTS
SECTION 1
-
SECTION 2
2-1.
2-2.
SAFETY INFORMATION
SPECIFICATIONS
Volt-Ampere
Duty Cycle
1
Curves
2
2
SECTION 3INSTALLATION
3-1.
3-2.
3-3.
3-4.
3-5.
3
Installing Work Clamp
Polarity For Wire Type
Selecting A Location And Connecting Input
Threading Welding Wire
Installing Gas Supply
3
Gun
3
Power
4
5
6
SECTION 4- OPERATION
7
SECTION 5- MAINTENANCE & TROUBLESHOOTING
10
5-1.
Routine Maintenance
10
5-2.
Overload Protection
10
5-3.
Repairing Drive Assembly
Wire Spool And Adjusting Hub
Troubleshooting
5-4.
5-5.
Cleaning
Installing
Or
11
Tension
SECTION 6
ELECTRICAL DIAGRAM
SECTION 7
WELDING METHODS & TROUBLESHOOTING
7-1.
7-2.
Flux Cored Arc Welding (FCAW)
Welding Troubleshooting
SECTION 8- PARTS LIST
Figure
Figure
8-1. Main
8-2. Drive
Assembly
Assembly,
12
13
14
And Gas Metal Arc
15
Welding (GMAW)
15
17
20
20
Wire
23
OM-151 015C6/96
SECTION 1
-
SAFETY INFORMATION
modl.1 2/93
Read all
safety
messages
all
safety
messages to avoid
Obey
Learn the
1
meaning
throughout
this manual.
injury.
of WARNING and CAUTION.
2
Safety
2
SignalWord
2
\
a WARNING
ELECTRIC SHOCK can
=9
installing
/
or
input power
servicing,
Keep away from moving parts.
means possible minor
injury or equipment damage can
happen.
Keep
3
Statement Of Hazard And
Result
4
Safety
MOVING PARTS
Do not touch live electrical parts.
Disconnect
CAUTION
______________________________
kiII.i~
before
Symbol
WARNING means possible death
or serious injury can happen.
a CAUTION
3
______________________________
Alert
1
when
all panels
operating.
and
injure.
can
covers
closed
/
5
Instructions To Avoid
Hazard
5
6
READ SAFETY BLOCKS at start of
Section 3-1 before proceeding.
;1 ~I I ~e
~
Turn Off switch when
Safety
NOTE
Special
using high frequency.
ation
Figure
1-1.
Safety
Symbol (If Available)
Banner
Read safety blocks for each sym
bol shown.
7
NOTE
Hazard
instructions for best oper
not related to
safety.
Information
SECTION 2- SPECIFICATIONS
Table 2-1.
Welding
Power Source
Specifications
Type
Of
Usable
Constant
Output
Rated Weld
Description
Output
90
Voltage (CV), Direct Current (DC)
Amperes,
Single-Phase
Input Amperes At Rated Output
20
KVNKW Used At Rated
3 kVN2.7 kW
Output
Open-Circuit Voltage
Control Circuit
Voltage
DC, 20% Duty Cycle (See Section 2-2)
30 To 130 A
Amperage Range
Type Of Input
Max.
18 Volts
At Gun
115 Volts AC, 60 Hertz
Amperes
30 Volts DC
24 Volts DC
From The Factory Set For Gas Metal Arc Welding
Solid Or Aluminum Wire And External Shielding Gas)
Welding Processes
Shipped
Flux Cored Arc Welding
External Shielding Gas)
Calculated
Speed Range
Approximate
Wire Feed
Wire Diameter
Input
At No Load
Range
5 To 800
iprn (7.1 To
iprn (.13 To
.023 To .035 in
Range
Power Cord With
283 To 716
Plug
(FCAW) (Uses
17.9
20
(0.58 To
(GMAW) (Uses
Wire With Flux Inside And
Requires
No
mpm)
rnpm)
0.89
mm)
7ft(2.1 m)
Overall Dimensions
Length:
Weight (with gun)
Shipping
17 in
(432 mm); Width: 10
80 lb
(36 kg);
Net 73 lb
in
(254 mm); Height: 15-1/2
in
(394 mm)
(33 kg)
OM-151 015
Page
1
2-1.
Volt-Ampere Curves
The
volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities
of the welding power source.
Curves of other settings fall be
tween the curves shown.
30
25
20
Co
15
0
0
10
5
0
20
0
60
40
100
80
120
DC AMPERES
SB-124 646-A
Figure
2-2.
2-1.
Volt-Ampere Curves
Duty Cycle
CAUTION
a
E XCEEDING DUTY CYCLE RATINGS will
Do not exceed indicated
damage
unit.
duty cycles.
wam7.1 2/92
Duty cycle
150
without
125
is how
operate within
a
long
the unit
ten minute
can
period
causing overheating
or
damage.
-
This unit is rated at 20% duty cycle
allowing welding 2 minutes out of
100
every 10 minutes.
Co
75
.
w
a
~
<
50
~
-J
w
~
37.5
25
0
-
10
15
20
25
30
% DUTY
40
50
60 70 8090100
CYCLE
SB-124 655-A
Figure
OM-151
Ol5Page2
2-2.
Welding
Power Source
Duty Cycle
Chart
SECTION 3-INSTALLATION
Table 3-1. Items Included With
Welding
Power Source
Quantity
Item
Welding Gun Shipped Set To Feed .023 in (0.6 mm)
(See Gun Owners Manual Form 112 934)
1
Hard
Wire
Spool Of
VHS
lOft
Wire .023 in
1
Hard Wire
(0.6 mm)
1
Videotape (28 Minutes)
(3 m)
Work Cable And
1
Clamp
6ft(1.8m)AirHose
Contact Tubes
(2
3-1.
Installing
Customer must
Work
.023 in, And 3
.030 in, 3
Monocoil Liner For .023
NOTE ~
1
.035
8
in)
1
.030 in Wire
supply proper shielding gas
for desired
application.
Clamp
Insulator
1
2
Bolt
3
Smaller Hole
4
Work
Clamp
Tabs
Bend tabs around work cable.
2
3
5
Work Cable From Unit
6
Nut
Tools Needed:
3/8,7/l6in
Ref. ST-025 190-C
Figure
3-2.
Gun
Polarity
For Wire
3-1.
Installing
Work
Clamp
Type
WARNING
a
E LECTRIC SHOCK
can
Do not touch live electrical
Turn Off
welding
kill.
parts.
power source, and disconnect
input power
before
inspecting
or
installing.
swaml.1 2/93
~STRAIGHT
I POLARITY
I
REVERSE ~
POLARITY
For Solid
Stool Or
For Flux
Cored Wires
DCEP
J
2
Polanty ~Jumper
wire
Wires
DCEN
Polarity Changeover Label
Always
Aluminum
(FCAW
Process)
1
2
(GMAW)
Process)
mended
Links
read and follow
manufacturers
welding
recom
polarity.
Close door.
GUN POLARITY CHANGEOVER
Tools Needed:
3/8in
ST-151 358
Figure
3-2. Gun
Polarity Jumper
Link Position
OM-151 015
Page
3
3-3.
Selecting
A Location And
a
Connecting Input
WARNING
ELECTRIC SHOCK
can
only qualified persons
AIRFLOW
and possible
BLOCKED
kill.
overheating
Do not touch live electrical parts.
Have
Power
causes
damage
to
unit.
install unit.
Do not block
Installation must meet National Electrical Code and
Warranty
all other codes.
or
filter airflow.
is void if any
1
type of filter is used.
18 in (457 mm) Open Space
At Front And Sides For Good
Airflow
Label
2
Rating
3
Grounded
A
20
circuit
ampere
Receptacle
individual
branch
protected
by time-delay
fuses or circuit breaker is required.
4
Plug
From Unit
Select extension cord of 12 AWG
for up to 75 ft (23 m) or 10 AWG for
up to 140 ft (46 m).
3
2
4
ST-149 354-A
Figure
OM-151 015
Page
4
3-3. Location And
Input
Power Connections
3-4.
Threading Welding
£~
Wire
WARNING
CYLINDERS
can
explode
Keep cylinders away
from
if
WELDING WIRE
wounds.
damaged.
welding
and
other
electrical circuits.
Never touch
cylinder
Do not press gun
with
welding electrode.
Do not
Always secure cylinder to running gear, wall,
other stationary support.
people,
or
can
puncture
until instructed to do
trigger
so.
toward any part of the body, other
any metal when threading welding wire.
or
can
burn skin.
kill.
Allow gun to cool before
Do not touch live electncal
cause
point gun
HOT SURFACES
ELECTRIC SHOCK
can
touching.
parts.
The welding wire, drive rolls, drive assembly, and all
metal parts touching the welding wire are electrically
live when welding or feeding wire using gun trigger.
swam2.1 9191 Iswam5.1 10/91
Tools Needed:
Spool
1
Wire
2
Welding Wire
3
Inlet Wire Guide
4
Pressure
5
Drive Roll
6
Outlet Wire Guide
7
Gun Conduit Cable
Adjustment
Lay gun cable
Hold wire
tightly
to
keep
it from
out
Knob
straight.
unraveling.
-+
~-6in-~
(1
Open pressure assembly.
50
mm)
Pull and hold wire; cut off end.
Push wire thru guides into gun;
continue to hold wire.
P~ER
~
Remove gun nozzle
and contact tube.
Close and tighten pressure assembly,
and let go of wire.
Set switch.
~t~Il
-~
Press gun
trigger until wire
out of gun. Reinstall
contact tube and nozzle.
comes
-e
-4
Feed wire to check drive roll pressure.
knob enough to prevent slipping.
Tighten
c4~J~J
Cut oft wire.
Close and latch door.
Ref. ST-i 51 289/ Ref. ST-i 5i 357 / Ref. ST-i 56 256-A / S-0627-A
Figure
3-4.
Threading Welding
Wire
OM-151 015
Page
5
3-5.
Installing Gas Supply
WARNING
4A
CYLINDERS
can
explode
if
BUILDUP OF SHIELDING GAS
health or kill.
damaged.
Keep cylinders away from welding and
other
electrical circuits.
Never touch
cylinder
Shut off
with
Always secure cylinder
other stationary support.
welding
to
shielding gas supply
can
when not in
harm
use.
electrode.
running gear, wall,
or
wam4.1 9/91
Obtain gas cylinder and chain to
running gear, wall, or other station
ary support so cylinder cannot fall
and break off valve.
1
Cap
2
Cylinder Valve
Remove
cap,
stand
to
side
of
valve, and open valve slightly. Gas
flow blows dust and dirt from valve.
Close valve.
1~~~~
3
Cylinder
4
Regulator/Flowmeter
Install
5
so
face is vertical.
Gas Hose Connection
Fitting has 5/8-18 right-hand
threads. Install air hose.
6
Argon
Flow
Adjust
Typical flow rate is 20 cfh (cubic
feet per hour). Check wire man
ufacturers
flow
recommended
Gas
rate.
7
CO2 Adapter
8
0-Ring
Install
adapterwith 0-ring between
and
regulator/flowmeter
CO2
cylinder.
OR
4
2
L
3
7
CO2 Gas
Tools Needed:
~ 1-1/8,5/8
in
ssb3.1* 12/92ST-158
Figure
OM-151 015
Page
6
8
3-5.
Typical Regulator/Flowmeter
Installation
697-A
SECTION 4- OPERATION
WARNING
AA
ELECTRIC SHOCK
Always
wear
Insulate
kill.
can
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
dry insulating gloves.
from work and
yourself
Wear
ground.
Keep
all
and
panels
covers
FUMES AND GASES
to your health.
Keep your head
Ventilate area,
securely
in
MOVING PARTS
all doors,
Keep
securely
and
breathing
can cause
near
Watch for fire;
Do not weld
fire
or
on
Allow work and
over
I
explosion.
panels,
place.
in
covers, and
as
drive rolls.
guards closed
MAGNETIC FIELDS FROM HIGH CUR
RENTS can affect pacemaker operation.
Pacemaker
~
=~
flammable material.
~
wearers
keep
away.
Wearers should consult their doctor before
~
keep extinguisher nearby.
Do not locate unit
injury.
device.
Safety Data Sheets (MSDS5) and
manufacturers instructions for material used.
Do not weld
can cause
Keep away from pinch points such
Read Material
WELDING
body protection.
~,
out of the fumes.
or use
helmet with correct shade of filter.
place
be hazardous
can
welding
Wear correct eye, ear, and
Do not touch live electrical parts.
near arc
welding, gouging,
or
going
spot welding opera
tions.
combustible surfaces.
closed containers.
equipment to
cool before
See Safety Precautions at beginning of manual for ba
sic welding safety information.
handling.
swam6.2
1
Insulating
2
Safety
3
Welding
10)91
Gloves
Glasses With Side
Shields
2
/
Helmet
dry insulating gloves, safety
glasses with side shields, and a
Wear
helmet with a correct
shade of filter (see ANSI Z49.1).
welding
sb3.1 10/91
Figure
4-1.
Safety Equipment
1
Work Cable
2
Work
Clamp
Connect work clamp to a clean,
paint-free location on workpiece,
as close to weld area as possible.
Use wire brush or sandpaper to
clean metal at weld joint area. Use
chipping hammer
after welding.
to remove
slag
Tools Needed:
sb4.1 2/93 / Ret. 5T-156 256-A
Figure
4-2. Work
Clamp
OM-151 015
Page
7
CAUTION
a
ARCING
Do not
Arcing
can
damage switch.
change ThicknessNoltage
inside switch
can
switch
position
damage contacts, causing
while
welding.
switch to fail.
wam5.1
1
Fine Tuning/Wire
Control
9/91
Speed
Use this control to select a wire
feed speed. As ThicknessNoltage
switch setting
increases, wire
speed range also increases. The
numbers around the control are not
a wire feed speed and are for
reference
2
only.
ThicknessNoltage Switch
Use this switch to select an arc
The higher the selected
number, the thicker the matenal
voltage.
that
can
3
Power Switch
be welded.
Use switch to turn unit On and Off.
ST-150 092
Figure
a
WARNING
BUILDUP OF SHIELDING GAS
Shut oft
4-3. Controls
shielding gas supply
can
when not in
harm health
or
kill.
use.
waml.1 9/91
1
Shielding Gas Cylinder
2
Valve
3
Gun
Trigger
cylinder just
Open valve
welding.
on
Gun
turns weld
trigger
gas flow
on
output and
and off.
Close valve on
ished welding.
cylinder
when fin
sb5.1 6/92
Figure
OM-151 015
Page
8
4-4.
Shielding
Gas
before
S-0780
Install &
Connect
)
Equipment~J}
Put On
Personal Safety
Equipment
Turn
O\
) )Equiprnent & Gas )
j) (lfApplicable) )
Set
controisj)
)~\
Do
Sample
Weld
)
J
Readjust Co~~i?~
And Prepare
ForWelding
J
_______________
Figure
~\
Install&Connec~\\
Using ) )
)Equipment
J
Knu~ed
Groo~Jj
)
Do
Sample
Hub
Tension To
Minimum
Adjust
Weld
I
4-5.
Sequence
Of
Operation
~\ Adjust Dnve Roli~~
i ) Pressure To
I 1
})
Minimum
For GMAW And FCAW
))Safety Equipme~)
T urn On
Put On Personal
And Adjust Gas
To 30 cfh
I
}
Straig
~\ Readjust Control~~
And Prepare For I
)
Figure
Welding~J
4-6.
Sequence
Of
Operation
For Aluminum
Welding
OM-151
Ol5Page9
SECTION 5- MAINTENANCE & TROUBLESHOOTING
WARNING
£~
ELECTRIC SHOCK
can
Do not touch live electrical
MOVING PARTS
kill.
Turn Off
welding power source, and disconnect
input power before inspecting, maintaining, or
servicing.
?
HOT PARTS
can cause severe
Allow
cooling
servicing.
__________
period
before
can cause
injury.
Keep away from moving parts.
parts.
Keep away from pinch points
such
as
drive rolls.
burns.
maintaining
or
iance
to
be
performed only by qualified
swam8.2 2/93
5-1.
Routine Maintenance
Turn Off all power before
maintaining.
~
3 Months
Replace
Cracked
Parts
Trigger Cord
Gun Cable
Gas Hose
Figure
5-2.
5-1. Maintenance Schedule
Overload Protection
READ SAFETY BLOCKS at start of
Section 5 before proceeding.
A.
Motor Fuse Fl
CAUTION
4~
STATIC ELECTRICITY
Put
on
grounded
wrist
can
strap
damage parts
BEFORE
handling
on
boards
circuit boards.
or
parts.
fwam5.1
9/91
Turn Off and unplug unit. Unlatch
door and remove door/wrapper.
1
Circuit Board PCi
Located behind fan.
2
Fuse Fl
(See
Parts List For
Rating)
Pull fuse from fuse holder on PCi.
To reinstall, push fuse into fuse
holder.
Reinstall wrapper, and latch door.
Tools Needed:
~ 3/8 in
ST-150 114/ST-149 327
Figure
OM-151 015
Page
10
5-2. Fuse Fl Location
B.
Overheating
Thermostat TP1 protects the unit from damage due to overheating. If main transformer Ti gets too hot, TP1 opens and
weld output stops. The fan keeps running to cool the transformer. Wait several minutes before trying to weld.
C.
Short Circuit Shutdown
If contact tube is shorted and sticks to
trigger,
turn Off
unit to continue
5-3.
unit, and
remove
workpiece,
the unit shuts down, but fan runs. To resume operation, release gun
workpiece. Check contact tube and replace if damaged. Turn On
contact tube from
operation.
Cleaning
Or
Repairing
Drive
Assembly
READ SAFETY BLOCKS at start of
Section 5 before proceeding.
.7
Turn Off and
unplug
unit.
Spool
1
Wire
2
Gun Contact Tube
Cut
welding
off at contact
wire
tube. Retract wire onto
spool
and
secure.
3
Pressure Roll Arm
4
Cotter Pin
5
Pin
6
Screw
7
Bearing
Remove
beanng
bearing
new
screw.
secure
as
shown. Install
and
secure
Reinstall am, onto
with cotter pin.
pin
8
Setscrew
9
Smooth Groove For Hard
Wire
10
Drive Roll
Remove drive roll
Use
a
as
with
and
shown.
wire brush to clean drive roll.
Push drive roll onto shaft with
desired groove in. Tum drive roll so
one setscrew faces flat side of
shaft, and tighten both setscrews.
11
Knurled Groove For FluxCored Wire
12
Wire Inlet Guide
Remove guide by pressing on
barbed area or cutting off one end
near housing and pulling it out of
hole. Push new guide into hole
from rear until it snaps in place.
Thread welding wire
3-4). Close door.
(see Section
Tools Needed:
5/64 in
Pet. ST-i 51 357 / ST-i 49 266-B
Figure
5-3.
Cleaning
Or
Repairing
Drive
Assembly
CM-i 51 015
Page
ii
5-4.
a
Installing
Wire
Spool
And
Adjusting
Hub Tension
READ SAFETY BLOCKS at start of
Section 5 before proceeding.
WARNING
N OTE ~
if hub tension is too
too
_____________________
tight,
motor fuse Fican open (see Section
loose, wire unravels and
can
become
tangled
5-2). If hub tension is
inside unit.
Turn Off and
unplug
unit.
Spool
1
Wire
2
Gun Contact Tube
If necessary, cut welding wire oft at
tube, and retract wire onto
contact
spool
3
and
secure.
Retaining
Remove
pin
4
Flub
5
Hub Pin
Pin
and
pull off spool.
Slide spool onto hub so wire feeds
off bottom. Turn spool until hub pin
fits hole in back of spooi. Push
retaining pin through hub.
6
Hub Tension Nut
Grasp spool in one hand and turn
while using a wrench to adjust hub
tension nut. When a slight force is
needed to turn
spool,
tension is
set.
Close and
secure
pressure
roll
assembly. Thread welding wire
(see Section 3-4). Close door.
6
Tools Needed:
9/16 in
Ref. ST-i 51 357/S-0499
Figure
OM-151 015
Page
12
5-4.
Installing Wire
And
Adjusting
Tension
5-5.
Troubleshooting
WARNING
A~
ELECTRIC SHOCK
can
Do not touch live electrical
kill.
MOVING PARTS
Turn Off
welding power source, and disconnect
input power before inspecting, maintaining, or
servicing.
HOT PARTS
Allow
can cause
injury.
Keep away from moving parts.
parts.
can cause severe
Keep away from pinch points
such
as
drive rolls.
burns.
cooling period before servicing gun
or
unit.
hooting
to be
performed only by qualified
swarn9.2 2/93
Table 5-1.
Trouble
Welding
Trouble
No weld
output; wire does
does not
Section
Remedy
not
feed; fan
run.
~
I
-~
Secure power cord
Replace building
plug
in
line fuse
Secure gun trigger plug
trigger switch.
receptacle.
circuit breaker if open.
or reset
in
receptacle
or
repair leads,
or
replace
Have nearest Factory Authorized Service Station/Service Distrib
utor check and replace Power switch.
No weld
output; wire does
not
feed; fan
~-.~
Thermostat TP1 open (overheating). Allow fan to run; the thermo
stat will close when the unit has cooled.
motor continues to run.
Check and
3-3
-5.
3.3
*
5.
--5.
--
5-2B
-~
motor fuse Fl.
replace
Have nearest
--S
5-2A
Factory Authorized Service Station/Service Distrib
replace switch control relay if necessary.
utor check and
No weld
output;
Connect work
wire feeds.
Replace
clamp
to
get good metal
F
output.
See Gun Owners
Figure
4-2
*
contact tube.
-5.
Check for proper connections at
Low weld
to metal contact.
polarity changeover
-I Connect unit to proper input voltage
or
board.
check for low line
3-2
I
~
voltage.
Manual
Table 5-2. Wire Drive/Gun Trouble
Trouble
Electrode
wire
feeding stops during
welding.
Section
Remedy
FI
~
Straighten gun
cable and/or
replace damaged parts.
-~
_____________________________________________________
Adjust
___________
drive roll pressure.
Change
-~
to propergroove.
Readjust
hub tension.
-~
Replace
contact tube if blocked.
replace
or
Replace
wire inlet
drive roll
or
guide
pressure
liner if
bearing
plug
Check and
motor fuse Fl.
replace
receptacle
if
Factory Authorized
dirty
or
worn or
or
Check and clear any restrictions at drive
Have nearest
5-4
-~
or
Secure gun trigger
trigger switch.
in
3-4
5-3
-5
Clean
5-3
plugged
-~
slipping.
repair leads,
assembly
or
-~
replace
and liner.
Service Station/Service Distrib-
5-3,
*
5-3
*
-~
~
5-2A
~
5-3,
*
s
utor check drive motor.
See Gun Owners
Manual
OM-151 015
Page
13
SECTION 6- ELECTRICAL DIAGRAM
PIG I
W~K
SB-i 62 261
Figure
OM-151 015
Page
14
6-1. Circuit
Diagram
For
Welding
Power Source
SECTION 7- WELDING METHODS & TROUBLESHOOTING
mod4.1 9/92
WARNING
a
ELECTRIC SHOCK
Always
wear
Insulate
kill.
can
7
dry insulating gloves.
yourself from
work and
Do not touch live electrical
Keep all panels
and
~
ground.
~
parts.
covers
securely
in
place.
,-,
~
0
FUMES AND GASES
can
be hazardous
to your health.
Keep your head
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
Wear
welding
helmet with correct shade of filter.
Wear correct eye, ear, and
MOVING PARTS
body protection.
can cause
Keep away from pinch points
Keep all doors, panels,
and securely in place.
injury.
such
covers, and
as
drive rolls.
guards closed
MAGNETIC FIELDS FROM HIGH CUR
RENTS can aftect pacemaker operation.
out of the fumes.
Ventilate area,
or use
Read Material
Safety Data Sheets (MSDSs)
manufacturers
instructions for material used.
breathing device.
Pacemaker
and
wearers
keep away.
Wearers should consult their doctor before
near arc
welding, gouging,
going
spot welding opera
or
tions.
W ELDING
can cause
Do not weld
near
Watch for fire;
fire
or
explosion.
flammable material.
WELDING CURRENT can
tronic parts in vehicles.
Disconnect both
keep extinguisher nearby.
damage
elec
battery cables before welding
on a
vehicle.
Do not locate unit
Do not weld
on
Allow work and
Flux Cored Arc
7-1.
N OTE
over
combustible surfaces.
Place work
equipment to
cool before
handling,
as
close to the weld
as
possible.
Welding
swam6.2 10/91
Welding (GMAW)
energized until gun trigger is pressed; therefore, welding wire
than 1/2 in (13 mm) beyond edge of nozzle a nd tip of wire
before lowering helmet and pressing trigger.
wire is not
should extend not
placed
See Safety Precautions at beginning of manual for ba
sic welding safety information.
And Gas Metal Arc
Welding (FCAW)
~
clamp
closed containers.
on seam
more
1
Hold Gun And Control Gun
Trigger
2
Workpiece
3
Work
4
Electrode Extension
(Stickout) 1/4 To 1/2 in
Clamp
2
(6 To
13mm)
5
Cradle Gun And Rest Hand
On Workpiece
5
4
<,
End View Of Work
Angle
Side View Of Gun
End View Of Work
Angle
GROOVE WELDS
Figure
Angle
Sid e View Of Gun
Angle
FILLET WELDS
7-1.
Holding
And
Positioning Welding
S-0421-A
Gun
OM-151 015
Page
15
N
Weld bead
~
T
_____________________
on gun angle, direction of travel, electrode extension
thickness of base metal, wire feed speed (weld current),
shape depends
(stickout), travel speed,
and voltage.
100
100
p
C)
_______________
4
Push
Drag
Perpendicular
GUN ANGLES AND WELD BEAD PROFILES
U
Short
Normal
Long
ELECTRODE EXTENSIONS (STICKOUT)
~t~c
S
Short
Normal
Long
FILLET WELD ELECTRODE EXTENSIONS
a
(STICKOUT)
p
p
C)
C)
C)
Normal
Slow
Fast
GUN TRAVEL SPEED
Figure
~
N OTE
7-2. Conditions That Affect Weld Bead
S-o634
Shape
single stringer bead is satisfactory for most narrow groove weld joints;
or bridging across gaps, a weave bead or
multiple stringer beads works better.
Normally,
a
however, for wide groove weld joints
Bead
Steady
Movement Along Seam
1
Stringer
2
Weave Bead
Side To Side
Movement Along Seam
3
Weave Pattems
Use
wide
weave
patterns
to
cover
a
in one pass of the elec
trode. Do not let weave width ex
3
/
area
ceed 2-1/2
electrode.
I
times
diameter
of
~
5-0054-A
Figure
OM-151 015
Page
16
7-3. Gun Movement
During Welding
POOR WELD BEAD
1
Large Spatter Deposits
2
Rough,
3
uneven
Crater
Slight
Welding
bead
During
4
Bad
5
Poor Penetration
Overlap
5
S-0053-A
GOOD WELD BEAD
1
Fine
2
Uniform Bead
Spatter
Moderate Crater
3
During
Welding
4
5
Weld
1/8 in
a new
bead
or layer for each
thickness in metals
(3.2 mm)
being welded.
4
No
5
Good Penetration Into Base
Metal
Overlap
S-0052-B
Figure
7-2.
7-4. Weld Bead Characteristics
Welding Troubleshooting
Table 7-1.
Porosity
small cavities or holes
Porosity
resulting from gas pockets in weld
metal.
S-0835
Possible Causes
Inadequate shielding gas coverage.
Corrective Actions
Check for proper gas flow rate.
Remove spatter from gun nozzle.
Check gas hoses for leaks.
Eliminate drafts
near
welding
Place nozzle 1/4 to 1/2 in
Hold gun
Use
Wrong gas.
Dirty welding
wire.
Welding
wire extends too far out of
(6-13 mm) from workpiece.
bead at end of weld until molten metal solidifies.
welding grade shielding gas; change
Use clean,
Eliminate
Workpiece dirty.
near
arc.
dry welding
pick
up of oil
to difterent gas.
wire.
or
lubricant
on
welding
wire from feeder
Remove all grease, oil, moisture, rust,
paint, coatings,
Use
wire
Be
a more
sure
highly deoxidizing welding
welding
wire extends not
more
or
liner.
and dirt from work surface before
welding.
(contact supplier).
than 1/2 in
(13 mm) beyond
nozzle.
nozzle.
OM-151 015
Page
17
Table 7-2. Excessive
I
.
:
Excessive Spatter
scattering of
molten metal particles that cool to
solid form near weld bead.
-
.~
Spatter
~---
I
I
.
S
..
S
S-0636
Corrective Actions
Possible Causes
Wire feed
Voltage
speed
too
too
Select lower wire feed
high.
Select lower
high.
Electrode extension
(stickout)
too
long.
voltage range.
Use shorter electrode extension
(stickout).
Remove all grease, oil, moisture, rust,
Workpiece dirty.
Insufficient shielding gas at welding
Dirty welding
speed.
arc.
Increase flow of
Use
wire.
shielding gas
at
paint, undercoating,
regulator/f lowmeter
and dirt from work surface before
and/or prevent drafts
near
welding
welding.
arc.
clean, dry welding wire.
Eliminate
of oil
pickup
or
Table 7-3.
lubricant
on
welding
Incomplete
wire from feeder
or
liner.
Fusion
r
Incomplete Fusion failure of weld
metal to fuse completely with base
metal or a preceeding weld b::d.
~)
Possible Causes
Corrective Actions
Remove all grease, oil, moisture, rust,
Workpiece dirty.
paint, undercoating,
and dirt from work surface before
welding.
Insufficient heat
input.
Improper welding technique.
Select
Place
higher voltage range
stringer
Adjust
work
bead in proper
angle
hold
Keep
leading edge of
Use correct gun
adjust
location(s)
widen groove to
or
Momentarily
arc on
and/or
arc on
angle of
wire feed
at
joint during welding.
access
bottom
groove side walls when
weld
0 to 15
speed.
during welding.
using weaving technique.
puddle.
degrees.
Table 7-4. Lack Of Penetration
shallow f u
Lack Of Penetration
sion between weld metal and base
metal.
Lack of Penetration
S-0638
Possible Causes
Improper joint preparation.
Corrective Actions
Material too thick. Joint preparation and design must provide
wire extension and arc characteristics.
access
to bottom of groove while maintain
ing proper welding
Improper weld technique.
Maintain normal gun
Keep
Be
Insufficient heat
input.
arc on
sure
Select
Page
18
of 0 to 15
leading edge of
welding
higher
Reduce travel
OM-151 015
angle
weld
wire extends not
wire feed
speed.
degrees
to achieve maximum
penetration.
puddle.
more
speed and/or
than 1/2 in
select
(13 mm) beyond
higher voltage range.
nozzle.
Table 7-5. Excessive Penetration
Excessive Penetration
weld metal
base metal and hang
ing uridemeath weld.
melting through
Excessive Penetration
Good Penetration
Possible Causes
Excessive heat
input.
S0639
Corrective Actions
Select lower
and reduce wire feed
voltage range
Increase travel
speed.
speed.
Table 7-6.
Burn-Through
Bum-Throughweld
completely through
resulting
metal
melting
base
metal
metal
in holes where
no
remains.
S-0640
Possible Causes
Excessive heat
input.
Corrective Actions
Select lower
voltage range
Increase and/or maintain
and reduce wire feed
speed.
steady travel speed.
Table 7-7. Waviness Of Bead
Waviness Of Bead
weld metal
that is not parallel and does not
cover joint formed by base metal.
S-0641
Possible Causes
Welding
wire extends too far out of
Corrective Actions
Be
sure
wire extends not more than 1/2 in
welding
(13 mm) beyond
nozzle.
nozzle.
Unsteady
Support
hand.
hand
on
solid surface
or use
two hands.
Table 7-8. Distortion
contraction of weld
Distortion
metal during welding that forces
base metal to move.
Base metal moves
in the direction of
the weld bead.
So~2
Possible Causes
Excessive heat
input.
Corrective Actions
Use restraint
(clamp)
Make tack welds
Select lower
to hold base metal in
along joint
voltage range
Increase travel
Weld in small
before
position.
starting welding operation.
and/or reduce wire feed
speed.
speed.
segments
and allow
cooling
between welds.
OM-151 015
Page
19
Cl) m C)
-I Cl)
0z
!
Cl) -I
325-C
31
ST-149
30
33
28
36
27
38
22
13
40
8
12
1
17
9
29
41
8
7
6
5
4
50
3
2
FigB-2
I
1
19
Item
11 (0 C
0
01
0 01 -u CD (0 CD I) 0
-I
U)
U) U)CD 3 a.
1<
*Incudes
Parts For Main
NOTE: All items indented
Item
No.
1
..
by
a
dot(s)
are
included with the item listed
I
Part
No.
Description
Drive
Fig8-2
J
Assembly
Item
No.
Part
No.
Assembly
above.
directly
Description
Item
No.
23. 125552
Thermostat, NC
46
.
..
Part
No.
149 358
2
.010909
Nut, .375-16
24 +147 563
Wrapper
3
.010910
Washer, .375
25
089 899
Latch
47
4
.073355
Spring
26
.
134327
Label, waming
48
5
111 998
Pin,
27
.
126415
Clamp
49.
.
111929
Hub
28. 126416
Handle
.
50. 010047
134201
Stand-Off
29
6
7
8
9
.
.
.
10
Baffle,
119539
Circuit Card,
shutdown/burnback
center
Connector,
skt
006393
Relay,
24VAC DPDT
Motor, fan
005656
Blade, fan
.
129696
Contactor
15.
119264
Rectifier
13
14
16
.
.
.
Rheostat
18.
Switch
19
21
22
.
.
111 897
Knob, pointer .023 bore
Connector
w/Sockets
..
.
147 676
..
111 443
Bushing, strain relief
240/510 ID x .875mtg hole
33
.
.
.
147545
Cord Set
605 227
Nut
147462
Panel,
Fig
8-2
MWG-160 Gun
Knob
116619
Terminal
Assembly
Tubing, stl .625 OD
1 2ga wall x 1.000
113280
Hose, air
112811
Label, Auto Arc emblem
149 438
..
123770
Resistor
.
090 288
Varistor
37
.
162264
Capacitor,
elctlt 9l000uf
..
..
.
149 398
010 368
..
..
43
44
.
026 843
..
.
111 644
..
Panel, side lower
Transformer, pwr
45.
111 997
main 115
side of
Tube, contact .023
110786
Tube, contact .030
110787
Tube, contact .035
605409
Clamp,
hose
wrapper)
3.750d1p
dia
slfttng
Clamp, capacitor
173374
..
Stabilizer
Regulator/Flowmeter,
dual scale 035
SCFH
..Base
42.600325
.
(left
110785
Assembly
.
Label, Auto Arc MIG
welder
rear
36
39
x
(rear panel)
35
38. 022 160
Nameplate, (order by
model and serial number)
097 922
Valve, ll5VAC2way
34.116996
41
127023
147 560
30.
40. 147566
048 282
.
Bezel
.
35VDC
Panel, front
147461
17. 000 101
20
plug
24-l8ga
Connector,
111 931
12
146753
32
loskt
079 747
end
.
31
Fuse, gi slo-blo 5A
*073 426
.
Support
147562
118 936
11
cotter
.
Description
..
..
Clamp, grd 200A
Cable, portNo. 102/c
(order by ft)
Insulator, vinyl blk
Bushing, strain relief
.370/.430 ID x .875mtg
Recommended
Spare
Parts.
+When
ordering a component originally dis
playing a precautionary label, the label should
hole
also be ordered.
Switch, rocker SPST 1OA
Be
250 VAC
when
to provide Model and Serial
ordering replacement parts.
sure
Number
9
No.
Part
No.
1
110793
Handle
110795
Tube, head
Nut,MlOxl
Item
.
2
.
3
.
4
.
6
.
7
8
lNg
110780
110779
.
5
.
9
.
118571
112743
112751
112747
9
113018
9
113022
9
113020
10
Stop, nozzle
Adapter
Spring
Tip, contact .024 (.6 mm)
Tip, contact .030 (.8 mm)
Nozzle, slip type 1/2 orf
Nozzle, slip type 3/8 orf
128878
.
Nozzle, spot flat
Nozzle, spot
110794
.
Trigger Switch
Assembly
14
11
16
17
080565
Assembly
Jacket, head tube
110781
.
8
Description
Terminal
11
.
12
.
13
.
110797
Cable, lOft
Sleeve, rubber
14.
167440
Liner
15
110784
Collet
079974
0-Ring,
110796
Connector, gun/feeder
079878
Connector & Pins
048834
Connector
.
16
.
17
.
18
.
19
110792
.
.
1/2 ID
x
.103
3
OPTIONAL
Be
provide Model and Serial
ordering replacement parts.
sure to
when
Number
18
19
Figure
Ref. ST-hO 832-0
8-2. MWG-160 Gun
OM-151 015
Page
21
Parts For Drive
NOTE: All items indented
2
3
4
5
6
a
dot(s)
Part
No.
Description
.
124 506
..
12VDC
.
129 893
..
Item
No.
1
by
.
.
.
.
126 838
090416
124 817
090443
..
Motor,
are
included with the item listed
Item
No.
7
Insulator, housing drive
Assembly, wire
(consisting of)
Pin, hinge
Housing, wire drive
Bearing
Drive
8
9
.
.
.
Part
No.
Assembly, Wire
directly above.
Description
Item
No.
Part
No.
Description
112031
Lever
13
090415
..
604741
Cotter Pin
14.092237
..
010224
Pin
15.
119028
..
16
602 169
10. 058549
Spring
Wire Guide
.
.
.
.
..
Spring
Knob
V Drive Roll
Set Screw, 8-32
.187
x
.
..
.
..
.
..
11
.
085242
12. 085244
Fastener
Be
Cupped Washer
when
to provide Model and Serial Number
ordering replacement parts.
sure
2
3
5
Includes Items1
8Thru 14
7
14
8
11
10
Figure
OM-151 015
Page
22
8-3. Drive
9
Assembly, Wire
16
15
SC-121 448-C