Miller | KD410407 | Owner Manual | Miller MW100 User manual

Miller MW100 User manual
December 1995
Form:
OM-154 405A
Effective With Serial No. KD41 0407
MW100
TOOlSfi
OWNERS
IMPORTANT:
material
MANUAL
Read and understand the entire contents of this manual, with special emphasis on the safety
before installing, operating, or maintaining this equipment. This unit and these
throughout the manual,
instructions
are
for use
only by persons trained and experienced in the safe operation of welding equipment. Do
install, operate, or maintain this unit. Contact your distributor if you do not fully
not allow untrained persons to
understand these instructions.
coven
5/92
ST-155 502
PRINTED IN USA
The
following safety
alert
symbol and signal words
special instructions.
are
used
throughout
this manual to call attention to and
identify
different levels of hazard and
WARNING
a
WARNING statements
injury or loss of life.
identify procedures
or
practices
which must be followed to avoid serious
personal
or
practices
which must be followed to avoid minor
personal
CAUTION
a
CAUTION statements identify procedures
injury or damage to this equipment.
ARC WELDING SAFETY PRECAUTIONS
WARNING
a
ARC WELDING
can
be hazardous.
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,
QUALIFIED PEOPLE
OPERATION, MAINTENANCE,
ELECTRIC SHOCK
can
kill.
5.
electrical parts can cause fatal shocks
burns. 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 on. 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.
or
severe
1.
Do not touch live electrical
2.
Wear
3.
Insulate
,_p~
6.
Turn off all
7.
Do not
10.
Ii.
or
stop engine before installing
4.
good
body.
electrical
(earth) ground.
(ground)
can
Wear
and/or
use
exhaust at the
arc
harness to
prevent falling
if
working
above floor
all
panels
and
covers
securely
in
replace
place.
a
welding
helmet fitted with
a confined space only if it is well ventilated,
wearing an air-supplied respirator. Shielding gases
welding can displace air causing injury or death. Be
breathing air is safe.
Do not weld in locations
near
degreasing, cleaning,
operations. The heat and rays of the arc can
form highly toxic and irritating gases.
to
approved air-supplied respirator.
Read the Material Safety Data Sheets (MSDSs) and the
manufacturers instruction for metals, consumables, coatings,
use an
safety
or
Work in
head out of the fumes. Do not breath the fumes
area
a
Repair
at once.
5.
and gases. Breathing these
be hazardous to your health,
fumes and gases.
only well-maintained equipment.
5.
3.
Welding producesfumes
fumes and gases
and cleaners,
a
a proper shade of filter (see
Safety Standards) to protect your face and
eyes when welding or watching.
Wear approved safety glasses. Side shields recommended.
Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
Use approved ear plugs or ear muffs if noise level is high.
4.
FUMES AND GASES can be hazardous
to your health.
If ventilation is poor,
to
ANSI Z49.1 listed in
6.
3.
Use
2.
welding
poorly spliced
level.
or
hearing.
remove
workpiece
damaged parts
Arc rays from the welding process produce intense
heat and strong ultraviolet rays that can burn eyes
and skin. Noise from some processes can damage
If inside, ventilate the
or
Do not touch electrode while in contact with the work
Wear
2.
to its
use.
damaged, undersized,
Do not wrap cables around your
1.
Keep your
worn,
Ground the
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
1
use
when not in
9.
Keep
~Q
equipment
6.
13.
..
equipment according
cables.
12.
input power
servicing this equipment.
this
circuit.
dry, hole-free insulating gloves and body protection.
yourself from work and ground using dry insulating
Disconnect
ground
Manual and national, state, and local codes.
parts.
mats or covers.
4.
install and
Properly
Owners
Touching live
~
AND REPAIR WORK PERFORMED ONLY BY
7.
Do not weld
on
coated metals, such
as
or
or
while
used for
sure
the
spraying
react with vapors to
galvanized, lead,
or
plated steel, unless the coating is removed from the
weld area, the area is well 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.
cadmium
exptosion.
5.
Watch for fire, and
Sparks and spatter fly oft from the welding arc. The
flying sparks and hot metal, weld spatter, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode or welding wire
to metal objects can cause sparks, overheating, or
6.
Be
WELDING
fire
can cause
or
and others from
3.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
11.
FLYING SPARKS AND HOT METAL
cause
Chipping
and
can
cause
throw oft
can
flying
2.
metal. As welds
explode
if
3.
damaged.
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.
4.
5.
6.
Protect
compressed gas cylinders
mechanical shocks, and
Install and
from
excessive
heat,
7.
upright position by chaining
equipment cylinder rack to
8.
arcs.
cylinders in
them to a stationary support
prevent falling or tipping.
2.
welder to thaw frozen
use
pipes.
Remove stick electrode from holder
tip
when not in
Wear oil-free
or
Wear
protective garments such
approved
cut off
welding
wire at
use.
as
face shield
leather gloves,
a
safety goggles. Side
or
heavy
cap.
shields
Wear proper
body protection
to
protect skin.
Keep cylinders
away from any
welding
other electrical
or
circuits.
I J~~~
~
1.
drums.
slag.
~
r~
or
recommended.
grinding
CYLINDERS
J
1.
tanks
as
close to the
as
shirt, cuffless trousers, high shoes, and
can
partition
welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
contact
injury,
cool, they
closed containers such
Do not
10.
on
or
the hidden side.
on
9.
and hot metal.
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.
extinguisher nearby.
ceiling, floor, bulkhead,
Connect work cable to the work
Do not weld where
strike flammable material.
fire
Do not weld
Protect
flying sparks
a
on a
7.
1.
can
fire
keep
welding
8.
2.
flying sparks
that
can cause
fire.
yourself
aware
secure
a welding electrode to touch any cylinder.
only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is
Never allow
Use
in
an
or
use or
connected for
use.
Read and follow instructions
associated
equipment,
on
and CGA
compressed gas cylinders,
publication
P-i listed in
Safety
Standards.
PRINCIPAL SAFETY STANDARDS
Safety
in
Welding
and
Cutting, ANSI Standard Z49.1,
from American
Welding Society,
550 N.W. LeJeune Ad, Miami FL 33126
Safetyand Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402.
RecommendedSafe Practices for the
Society
Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American Welding
Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
Standard AWS F4.1, from American
National Electrical Code, NFPA Standard 70, from National Fire Protection Association,
Safe
Handling
of Compressed Gases in
Cylinders, CGA Pamphlet P-I,
from
Batterymarch Park, Quincy,
Compressed Gas Association,
MA 02269.
1235 Jefferson Davis
Highway,
Suite
501, Arlington, VA 22202.
Code for
Safety in Welding and Cutting,
Rexdale, Ontario, Canada M9W
CSA Standard Wi 17.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard,
1 P3.
Safe Practices For Occupation And Educational
Broadway,
Cutting
Eye And Face Protection,
ANSI Standard Z87. 1, from American National Standards Institute, 1430
New York, NY 10018.
And
Welding Processes,
NFPA Standard 51 B, from National Fire Protection Association,
Batterymarch Park, Quincy,
MA 02269.
Ref. Sri 2/92
TABLE OF CONTENTS
SECTION 1
1-1.
SPECIFICATIONS
Volt-Ampere
Curve And
SECTION 4
Duty Cycle Chart
SECTION 2INSTALLATION
2-1.
2-2.
2-3.
2-4.
2-5.
2-6.
Installing Work Clamp
Installing Gas Supply
Connecting Input Power
Gun Polarity For Wire Type
Installing Welding Gun
Threading And Feeding Welding
SECTION 3
OPERATION
2
MAINTENANCE & TROUBLESHOOTING
4-1.
Overload Protection
6
4-2.
Drive
7
4-3.
Gun Maintenance
8
4-4.
Troubleshooting
8
Assembly
Maintenance
2
2
SECTION 5
ELECTRICAL DIAGRAMS
9
3
Wire
3
SECTION 6PARTS
4
Figure
Figure
5
6-1. Main
LIST
Assembly
6-2. MWG-160M Gun
11
12
SPECIFICATIONS
SECTION 1
Table 1-1.
Welding
Power Source
Description
Specification
Type Of Output
Direct Current/Constant
Rated Weld
70
Output
Type Of Input
Power
16 Volts
Amperes,
Single-Phase; 60Hz;
At Rated
Output
15 A At 115 V
KVA/KW Used At Rated
Output
2.2 kVA/2 kW
Input Amperes
Max.
24 Volts DC
At Gun
Voltage
Gas Metal Arc
Welding Processes
At No Load
Speed Range
Wire Diameter
DC, 20% Duty Cycle
At 115 Volts AC
29 Volts DC
Open-Circuit Voltage
Control Circuit
Voltage (DC/CV)
22 To 286
(GMAW)
ipm (0.6
.023 And .030 in
Range
(0.6
16-1/2 in
Overall Dimensions
Length:
Weight
Net: 53 lb
And Flux Cored Arc
To 7.3
mm)
And 0.8
(419 mm);
(24 kg); Ship:
Welding (FCAW)
mpm)
Width: 9-1/2 in
62 lb
(241 mm); Height:
17 in
(432 mm)
(28 kg)
Welding Gun
Rated
Output (Air-Cooled)
160
Cable
Length
10 ft
1-1.
Volt-Ampere Curve
And
Amperes
(3 m)
Duty Cycle
USING GUN BEYOND DUTY CYCLE RATING
use
gun
beyond
Use gun at 30%
Gas
Chart
CAUTION
a
Do not
Duty Cycle Using CO2 Shielding
At 60%
duty cycle
when
using
mixed
can
damage gun.
using CO2 shielding gas.
rated amperage when
shielding
gas.
wtwarn8.1 10/91
The
30
volt-ampere
minimum
and
show the
curves
maximum
voltage
and amperage output capabilities
of the welding power source.
25
Curves of other
20
settings
fall be-
tween the curves shown.
I
o
> 15
Duty cycle is how long the unit can
operate within a ten minute period
o
without
10
causing overheating
or
damage.
This unit is rated at 20%
5
allowing welding
duty cycle
2 minutes out of
every 10 minutes.
0
20
0
40
60
r~r
120
100
80
AIA!~D~
~
I-~~~~
30% when
.
12S
-
-
-
-
.
~-----
75
using
mixed
shielding
gas.
ISO
00
This gun is rated at 60% duty cycle
when using CO2 shielding gas and
----
~
w
S..
0
50
37.5
-
25
IS
20
25
30
DUTY
Figure
Page
1
-
.
0
1-1.
CYCL8
40
-
.~
-
0
OM-154 405
-
-
.
50
60
70
80
90
00
~
Volt-Ampere Curve
ssbl.1 10/91
And
Duty Cycle
Chart
SB-155969/sbl.3
10/91 S9-121
475
SECTION 2INSTALLATION
2-1.
Installing
Work
Clamp
1
Work Cable
2
Work
3
1/4-20
3
Clamp
x
1/2 in
Self-Threading
Screw
Clamp
4
4
Insert
Jaw
through
screw
work cable. Thread
terminal
on
through
screw
jaw and clamp.
Nut
Flange
5
1
Secure
screw
with nut.
Tools Needed:
~ 3/8,7/1Gm
5T-154 816
Figure
2-2.
2-1.
Installing
Work
Clamp
Installing Gas Supply
a
WARNING
CYLINDERS
can
explode
if
BUILDUP OF SHIELDING GAS
health or kill.
damaged.
Keep cylinders away from welding
and
other
electrical circuits.
Never touch
Shut off
cylinder
with
Always secure cylinder
other stationary support.
welding
to
shielding
gas
supply
harm
can
when not in
use.
electrode.
running
gear, wall,
or
wam4.1 9/91
Obtain gas
cylinder and chain to
running gear, wall, or other station
ary support.
Q~
~JJ
\
\
1
1
Cap
2
Cylinder
Remove
Valve
cap,
stand
side
to
of
valve, and open valve slightly. Gas
flow blows dust and dirt from valve.
Close valve.
2
3
3
Cylinder (CO2 Shown)
4
CO2 0-Ring
5
Regulator
Install onto gas
face is vertical.
6
cylinder
(cubic feet
per
hour).
7
Gas Hose Connection
Install
Tools Needed:
that
Flowmeter
Flow rate is set to 20 cfh
7
so
gas
meter and
hose
welding
between
power
flow-
source.
~ 1-1/8,5/8in
ssb3.1
Figure
2-3.
Connecting Input
Connect unit to
fuses
or
a
2-2.
2/92
ST-154 583 / ST-154 623
Typical CO2 Regulator/Flowmeter Installation
Power
properly grounded receptacle of
circuit breakers. Select
an
al 5
or
20 ampere individual branch circuit protected by time-delay
(19 m) or 12 AWG for up to 75 ft (23 m).
extension cord of 14 AWG for up to 60 ft
OM-154 405
Page
2
2-4.
Gun
Polarity
For Wire
Type
a__WARNING
ELECTRIC SHOCK
can
Do not touch live electrical
Turn Off
welding
kill.
parts.
power source, and disconnect
input
power before
inspecting
or
installing.
swami .1
c STRAIGHT
POLARITY
I
REVERSE ~
POLARITY
I
For Solid
For Flux
Steel Or
Cored Wires
Aluminum
(FCAW
Process)
Polarity Changeover
2
Polarity Jumper
Wires
Label
Links
Always
read and follow
wire
manufacturers
mended
welding
recom
polarity.
Close door.
(GMAW)
Process)
OCEN
1
OCEP
GUN POLARITY CHANGEOVER
2
Tools Needed:
cI::II::::J===:tlJ
3/8 in
Ref. ST155
Figure
2-5.
Instatling Welding
2-3. Gun
508
Polarity Connections
Gun
1
Gun
Securing
2
Drive
3
Gun
Assembly
Trigger
Insert leads,
3
grommet
leads to
4
Nut
one
on
Leads
time, through
panel. Connect
at a
front
matching
leads in unit.
Gun End
Loosen
securing
through
front
bottoms
Tighten
nut.
Insert end
panel opening until it
against drive assembly.
nut.
Close door.
2
3
Tools Needed:
~ 5116)n
Ref. ST-I 55 506
Figure
OM-154 405
Page
3
2-4. Gun Connections
2-6.
And
Threading
Feeding Welding
WARNING
a
CYLINDERS
J~TjL
Wire
can
explode
from
Keep cylinders away
if
WELDING WIRE
wounds.
damaged.
welding
and
other
electrical circuits.
Never touch
Always
other
cylinder
secure
Do not press gun
with
cylinder
welding
electrode.
Do not
running gear, wall,
to
people,
or
can
trigger
cause
puncture
until instructed to do
so.
point gun toward any part of the body, other
or
any metal when
threading welding wire.
stationary support.
ELECTRIC SHOCK
can
Do not touch live electrical
kill.
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.
jijpiuI~
H OT SURFACES
burn skin.
can
Allow gun to cool before
touching.
swarn5.1
10/91 /swarn2 19191
Spool
1
Wire
2
Hub Tension Nut
TO USE 1 LB SPOOL:
Grasp spool
Remove and retain
Install 1 lb
in one hand and turn
while
using a wrench to adjust nut.
When a slight force is needed to turn
spool
spool,
tension is set.
Loosen wire from
spool,
cut off bent
wire, and pull 6 in (150 mm) of wire
from spool.
3
Pressure
Open
4
Adjustment
pressure
assembly.
Wire Inlet Guide
5
Drive Roll
6
Wire Outlet Guide
Thread
wire through inlet guide,
along drive roll groove, and into outlet guide. Close pressure assembly.
Lay
gun cable out
7
Nozzle
8
Contact
straight.
Tip
Remove nozzle and contact
9
Gun
tip.
Trigger
Turn On unit, press gun trigger, and
feed 2 in (55 mm) of wire out of gun.
Turn Off unit and reinstall contact
and nozzle.
2
3
10
Adjusting
tip
Pressure
Turn On unit and check drive roll
pressure by feeding wire against a
wood board or concrete surface;
wire should feed
steadily
without
slipping.
Tighten
pressure
necessary.
adjustment
if
Close door.
9
8
Tools Needed:
-~ 9/16
in
ST.800 316 I Ref. ST. 155 505 / Ref. ST-155 504 / S-0627-A
Figure
2-5.
Feeding Welding Wire
OM-154 405
Page
4
SECTION 3
a
OPERATION
READ SAFETY BLOCKS at
WARNING
MOVING PARTS
Keep away
from
can cause
pinch points
Keep all doors, panels,
and securely in place.
ARCING
injury.
such
covers, and
as
drive rolls.
guards
Do
not
can
beginning
damage switch.
change Voltage switch position
while
welding.
closed
inside switch
switch to fail.
Arcing
can
damage contacts, causing
1
Insulating Gloves
2
Safety Glasses
With Side
Shields
3
Helmet
Welding
Wear
dry insulating gloves, safety
glasses with side shields, and a
welding helmet with a correct
shade of filter (see ANSI Z49.1).
sb3.1 10/91
Figure
3-1.
Safety Equipment
1
Power Switch
Use switch to turn unit On and Oft.
2
Wire
Speed Control
Use control to select a wire feed
speed. The numbers around the
control are not a wire feed speed
(see
3
cover).
rear
Weld Selector Switches
Switches
are
voltage (see
work
Connect
paint-free
as
close
used to select
rear
clamp
location
as
on
possible
Use wire brush
an arc
cover).
or
clean metal at weld
to
clean,
workpiece,
to weld area.
sandpaper
joint area.
to
Tools Needed:
Rel. ST-155 503 / SC-I 53 020
Figure
OM-154 405 Page 5
3-2. Controls
SECTION 4
a
MAINTENANCE & TROUBLESHOOTING
WARNING
ELECTRIC SHOCK
can
Do not touch live electrical
Turn Off
M OVING PARTS
kill.
Keep
parts.
power source, and disconnect
before inspecting, maintaining, or
welding
input power
servicing.
HOT PARTS
can cause severe
Allow
cooling
servicing.
period
before
burns.
maintaining
or
~
away from
can cause
injury.
moving parts.
Keep away from pinch points such
as
drive rolls.
*~
Maintenance and
only by qualified
troubleshooting
to be
persons.
performed
swarnR 2
2/9~
Table 4-1. Maintenance Schedule
Maintenance
Time
Before each
After each
Tighten
use.
spool
all connections. Check gun and clean nozzle.
Blow out gun liner. Clean and check wire drive parts;
of wire.
Every
3 months.
Tape
Every
6 months.
Blow out
4-1.
or
replace
cracked cables; clean and
or vacuum
tighten
replace
as
connections.
necessary.
unreadable labels.
Replace
inside of unit.
Overload Protection
READ SAFETY BLOCKS at start of
Section 4 before proceeding.
A.
Overheating
Thermostat TP1
protects the unit from damage due
weld output stops. The fan
B.
keeps running
to
overheating.
If main transformer
gets
hot, TP1 opens and
too
to cool the transformer. Wait several minutes before
trying
to weld.
Motor Fuse Fl
Turn Off and
unplug
door,
handle, and
remove
unit. Unlatch
remove
door/wrapper.
1
Fuse Fl
(See
Parts List For
Rating)
If this fuse opens, the wire drive
motor does not run.
Check and replace fuse if neces
sary. Twist fuse holder clockwise to
secure.
Reinstall wrapper and
latch door.
handle, and
Tools Needed:
~
3/8 in
ST-155 723 / ST-i 52 031
Figure
4-1. Fuse Fl Location
OM-154 405
Page
6
4-2.
Drive
Assembly
Maintenance
L
____
7 ] 9~
_____
~
READ SAFETY BLOCKS at start of
Section 4 before proceeding.
Turn Oft and
unit.
unplug
Spool
1
Wire
2
Gun Contact
Tip
Cut welding wire off at contact tip.
Retract wire onto spool and secure.
3
Pressure Roll Arm
4
Cotter Pin
5
Pin
6
Screw
7
Bearing
Remove
new
bearing
bearing
Reinstall
and
arm
with cotter
onto
pin
with
and
screw.
secure
pin.
8
Setscrew
9
Smooth Groove For Hard Wire
10
Drive Roll
Remove drive roll
2
shown. Install
as
secure
shown.
as
wire brush to clean drive roll.
Push drive roll onto shaft with de
sired groove in. Turn drive roll so one
setscrew faces flat side of shaft, and
Use
a
tighten
both setscrews.
11
Knurled Groove For FluxCored Wire
12
Wire Inlet Guide
Remove
by pressing on
cutting off one end
near housing and pulling it out of
hole. Push new guide into hole from
rear until it snaps in place.
guide
barbed
area or
Thread
welding
wire
(see Section
2-6). Close door.
Tools Needed:
~
5/~1
ST.156 504/ST.154 199
Figure
OM-154 405
Page
7
4-2. Drive
Assembly Maintenance
Gun Maintenance
4-3.
READ SAFETY BLOCKS at start of
Section 4 before proceeding.
FLYING METAL CHIPS AND DIRT
Point gun
from
awa y
people
and in
a
can cause
safe direction when
and
injury
blowing
damage equipment.
out with
compressed
air.
swarnlO,1 10/91
Turn Off and
1
Wire
Cut
welding
unplug unit.
Spool
wire off at contact
Retract wire onto
spool and
tip.
se
cure.
Gun
2
/~
Nut
Securing
Disconnect
nut and
leads. Loosen
gun and trigger
trigger
remove
leads.
3
Nozzle
4
Contact
5
Head Tube
6
Liner Collet
Tip
Di sassemble gun
shown.
Pull liner from this end. Blow gun
out with compres sed air.
6
7
\\~
as
Liner
7
casing
Insert
until
liner into gun
new
even
casing
with end of head tube.
Install collet onto liner.
Install contact
tip
and nozzle.
Insert gun into feeder and mark
where liner touches drive roll. Re
move
gun and cut liner oft. Rein
stall gun
\
so
possible
touching.
Tools Needed:
that liner is
to
drive
close
as
rolls
as
without
318,5116in
Thread
~
welding
wire
(see
Section
2-6). Close door.
Ref. ST.1 55 506 / Ref. 5T-1 55 509
Figure
4-4.
4-3. Gun Maintenance
Troubleshooting
READ SAFETY BLOCKS at start of
Sectio n 4 before proceeding.
Welding Trouble
No weld output; wire does not feed.
-m~_Secure_power cord plug in receptacle.
Motor fuse Fl open,
Replace building
Secure gun
No weld output; wire does not
motor continues to run,
No weld
output;
wire feeds.
feed; fan
-~
-ui
replace
2-3
-~
Fl.
-~
line fuse or reset circuit breaker if open.
trigger
leads
or
repair leads,
or
replace trigger
Connect work clamp to get
contact
]_ - Connect unit
to
good
1
metal to metal contact.
-~
2-5
-~
4-1 A
-~
I-,..
tip.
proper input voltage
or
check for low line
4-lB
-~
switch.
Thermostat TP1 open (overheating). Allow fan to run; the thermostat will close when the unit has cooled.
Replace
Low weld output.
Section
Remedy
voltage.
~
Figure
3-2
4-3
-~
2-3
OM-154 405
Page
8
Wire Drive/Gun Trouble
Electrode
wire
feeding stops during
Section
Remedy
Straighten
-~
gun cable and/or replace
damaged parts.
-~
4-3
welding.
Adjust
drive roll pressure.
Readjust
Replace
Clean
or
Replace
2-6
hub tension.
2-6
if blocked.
contact
tip
replace
wire inlet
drive roll
Secure gun
trigger
or
guide
pressure
leads
or
-s.
or
liner if
bearing
if
repair leads,
dirty
or
worn or
or
plugged.
slipping.
replace trigger
switch
Check and replace Fl.
Check and clear any restrictions at drive
Have nearest
Factory
assembly
and liner.
Authorized Service Station/Service Distrib
4-3
-~
4-2, 4-3
-~
4-2
-~
2-5
-~
4-lB
-~
4-2, 4-3
-~
utor check drive motor.
SECTION 5
ELECTRICAL DIAGRAMS
CR I
//
2
Dl
z
L
PLC I
6RN.
SA-153 694-A
Figure
OM-154 405
Page
9
5-1. Circuit
Diagram
For
Welding
Power Source
Th
P2
134-A
SC-154
CORD
POWER
GNU
Source
SPLIcE
Power
Welding
For
Diagram
Wiring
5-2.
Figure
TRIGER
2
SI
3
2
S2
2~
ropai LEADS
S3
0
01
0 CR -o 0) (a CD
0
LIST
SECTION 6PARTS
U,
U,
(I,
CJ
C)
0
C.,
CD
CJ
C.,
U,
CJ
c~S
c.J
>~
.0
E
C)
U,
U,
4
C
1~
-7
U,
/
C)
I
C.,
CJ
a,
\
0
/
C)
N.
-i
CD
C%J
CD
U-
OM-154 405
Page
11
Parts For Main
NOTE: All items indented
Item
No.
Part
No.
126 838
1
090 416
2
124817
3
151 828
4
112031
5
090 443
111 622
by
a
dot(s)
are
included with the item listed
directly
above.
I
Item
No.
Part
No.
Description
Item
No.
Drive
25
120675
Bracket
38
153722
Side Panel
26
111 931
Fan Motor
39
120 638
Thermostat, NC
27
005 656
Fan Blade
40
154 015
Transformer
28
153729
Handle
154 596
Cap,
Assembly
Hinge
.
Pin
DriveHousing
.
Cotter Hair Pin
PressureLever
Bearing
.
.
Spacer
Description
Handle
087 156
Varistor
43
109039
Capacitor
Warning
31
089899
Latch
44
108105
Clamp
32
053297
Fuse Holder
45
118457
Stabilizer
33
*012 663
Fuse, slo-blo 3A
46
019663
Foot
34
119264
Rectifier
47
600 325
Cable
35
010047
Tubing
48
153 969
Clamp
36
116619
Terminal
49
154 845
MWG-160M Gun,
153 714
Regulator/Flowmeter
154829
Hose Kit
Label
9
085 242
10
010 224
Spring
11
058 549
Wire Guide
12
149 332
Hose
13
147635
Hose
14
154827
Drive Roll
116 996
Gas Valve
15
602169
Set Screw
605 227
Nyl Nut,
Pin
42
Wrapper
085 244
Fastener
Resistor
134464
8
.
117 116
+153 724
090415
Washer
Clamp
174504
Assembly
Link
Case
37
w/Cmpts
gas valve
113129
16
129 893
Insulator
113 494
Cord Set
119 021
Drive Motor
111 644
Bushing,
18
153727
Baffle
119 653
Rheostat
19
111 929
Hub
097 922
Knob
135 615
Bushing,
153 698
Rocker Switch, SPST
+When
20
010910
Washer
153 699
Rocker Switch SPDT
playing
21
073 355
Spring
155 530
Case
also be ordered.
22
010909
Nut
155 569
Nameplate
*Recommended
23
111 998
Cotter Hair Pin
111 443
Bushing, .875mtg
Be
24
120706
Relay
025 338
Bushing, .625mtg
when
x
.750 OD
089 120
cord set
028 509
1
15
14
16
17
18
.
Clamp,
Hose
.375450
Regulator, adapter
ordering a component originally dis
precautionary label, the label should
a
Spare
Parts.
to provide Model and Serial Number
ordering replacement parts.
Part
No.
Description
1
155817
Handle
2
110795
Head Tube
3
110780
Nut
4
110779
Jacket
Assembly,
5
110781
Stop
6
128878
7
154819
Adapter
Spring
8
154826
Contact
8
154825
Contact
9
154822
Nozzle, 1/2 ort
9
154821
9
154820
Tip,
Tip,
red
.023
.030
Nozzle, 3/8 ort
Nozzle, flat spot
10
110794
Trigger Switch Assembly
11
080565
Terminal
12
110792
Cable/Conduit
13
110797
Sleeve
14
154823
Liner, .030-035
15
120715
16
079974
0-Ring,
17
110796
Connector
18
047994
Terminal
Collet, .035
.500
OPTIONAL
Ret. ST-lb
Figure
PVCTubing
sure
Item
No.
2
(Fig 6-2)
Adapter Fitting
112 863
17
.390 ID
Coil
41
30
7
.
Description
29
092 237
Spring
Cupped
j
153695
6
.
Knob
Part
No.
Assembly
6-2. MWG-1 60M Gun
(Fig
832-D
6-1 Item
49)
OM-154 405
Page
12
Suggested Welding Settings
Gas
Shielding
Wire
Diameter
Operator
(inch)
Settings
Control
Material Thickness
12 ga. and
Thicker
Voltage
Thinner
14-l3ga.
17-l5ga.
20-l8ga.
High!
High!
Low!
Mm
or
Max
Mm
Max
Than2Oga.
Low!
Mm
Solid Steel
.023025
co2
Feed
Speed*
Voltage
Solid Steel
CO2
Feed
Speed*
High!
Voltage
E-71T-GS
+cfh
=
70
55
High!
Hiqh/
Low!
Max
Low!
or
Max
Mm
Mm
Max
100
100
90
65
HiQh!
Low!
Max
Low!
Lowf
50
60
Mm
Mm
Mm
.030
Feed
*Adjust
95
.023025
75% Ar
25%
Mm
100
WIRE SPEED control
as
Speed*
90
50
30
required.
cubic feet per hour
IMPORTANT: If in doubt, set WELD SELECTOR SWITCHES for thickness desired and set WIRE SPEED to 50. The weld can be started and fine
tuned during operation. If input voltage is low, a higher WELD SELECTOR SWITCHES setting may be required to obtain desired weld.
I
OM-154 405
Page
13
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