Miller MW100 User Owner's Manual

Form:
June 1992
Effective With Seria
OM-154 405
No. KC256506
MW100
tbois
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
not allow untrained persons to
install, operate,
or
the safe
operation of welding equipment. Do
maintain this unit. Contact your distributor if you do not
fully
understand these instructions.
coven
5/92
ST.155 502
PRINTED IN USA
The
following safety
alert
symbol
and
signal
words are used
this manual to call attention to and
throughout
identify
different levels of hazard and special instructions.
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.
~ IMPORTANT: statements
identify special instructions necessary for the most efficient operation
of this equipment.
ARC WELDING SAFETY PRECAUTIONS
WARNING
A~
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.
5.
live electrical parts can cause fatal shocks
or severe 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.
1.
Do not touch live electrical parts.
2.
Wear
3.
Insulate
yourself
body protection.
ground using dry insulating
and
mats or covers.
4.
Disconnect
input power
servicing this equipment.
or
stop engine
before
6.
Turn oft all
7.
Do not use worn,
ground
this
equipment according
to its
equipment
when not in
use.
damaged, undersized,
or
poorly spliced
cables.
8.
Do not wrap cables around your
body.
9.
Ground the workpiece to
electrical
10.
good
a
(earth) ground.
Do not touch electrode while in contact with the work
installing
11.
Use only well-maintained equipment.
damaged parts at once.
12.
Wear
(ground)
a
safety
harness to prevent
falling
if
Repair
or
working
above floor
replace
level.
or
13.
Keep all panels and
Wear
covers
securely
helmet fitted with
in
place.
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
1.
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
2.
Safety Standards) to protect your face and
eyes when welding or watching.
Wear approved safety glasses. Side shields recommended.
3.
Use
hearing.
can
be hazardous
Keep your
If inside, ventilate the area and/or
remove welding fumes and gases.
3.
If ventilation is poor,
.
use
exhaust at the
arc
to
approved air-supplied respirator.
Read the Material Safety Data Sheets (MSDSs) and the
manufacturers instruction for metals, consumables, coatings,
and cleaners,
use an
protective
screens or
barriers to protect others from flash
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.
Do not weld in locations near degreasing, cleaning, or spraying
operations.Theheatandraysofthearccanreactwithvaporsto
form highly toxic and irritating gases.
head out of the fumes. Do not breath the fumes.
1.
(see
6.
be hazardous to your health.
2.
proper shade of filter
Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Shielding gases used for
welding can displace air causing injury or death. Be sure the
breathing air is safe.
Weldingproducesfumesandgases. Breathingthese
can
a
5.
to your health.
fumes and gases
welding
and
4.
FUMES AND GASES
a
ANSI Z49.1 listed in
5.
4.
install and
Manual and national, state, and local codes.
circuit.
dry, hole-free insulating gloves
from work and
Properly
Owners
Touching
7.
Do not weld
cadmium
on
coated metals, such
plated steel,
weld area, the
area
unless the
as
coating
galvanized, lead,
or
is removed from the
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.
ERRATA SHEET
September 7,
FORM: OM-154 405
1993
Use above FORM number when
After this manual
to data
was
occurred. This sheet lists
exceptions
SPECIFICATIONS
CHANGES TO SECTION 1
1-1.
equipment design
extra manuals.
in this manual.
appearing later
Replace Figure
refinements in
printed,
ordering
Volt-Ampere Curve
And
Duty Cycle Chart
30
The
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.
-J
~15
Duty cycle is how long the unit can
operate withina ten minute period
0
without
o 10
causing
overheating
or
damage.
This unit is rated at 20%
5
allowing welding
duty cycle
2 minutes out of
every 10 minutes.
0
0
40
20
60
DC
100
80
This gun is rated at 60% duty cycle
when using CO2 shielding gas and
120
30% when
AMPERES
using
mixed
shielding
gas.
150
I
25
00
75
a
x
~
50
-J
37.5
25
0
10
IS
20
30
25
DUTY
CYCL~
40
50
60
70
60
90
00
%
ssbl.1 10/91 ST155869/sbl.310/91
Figure
1-1.
SB-121
Volt-Ampere Curve And Duty Cycle Chart
CHANGES TO SECTION 2-INSTALLATION
Replace Section 2-6. Threading And Feeding Welding Wire (see Page 2
CHANGES TO SECTION 6
Change
Parts List
as
Sheet)
follows:
Replaced
12-
120964
113 494
12-
120077
Deleted
12-
Added
135 615
~First
this Errata
PARTS LIST
Part
No.
--
on
digit represents page
With
no
Description
Cord Set
Bushing, nylon
.390 ID
x
digits following dash represent
.750 OD
item
x
.750
Ig
no.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
475
2-6.
Threading
Feeding Welding
And
Wire
WARNING
a
CYLINDERS
can
explode
from
Keep cylinders away
if
WELDING WIRE
wounds.
damaged.
welding
and
other
electrical circuits.
Never touch
cylinder
Do not press gun
with
Always secure cylinder
other stationary support.
ELECTRIC SHOCK
welding
to
can
electrode.
Do not
running gear, wall,
people,
or
kill.
point gun
or
trigger
cause
any metal when
so.
part of the body, other
threading welding
wire.
burn skin.
can
Allow gun to cool before
puncture
until instructed to do
toward any
HOT SURFACES
Do not touch live electrical parts.
can
touching.
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.
swarn5 1 10/91 / swarn2.1 9/91
TO USE I LB SPOOL:
Install 1 lb
Remove and retain
1
Wire
2
Hub Tension Nut
Spool
Grasp spool in one hand and
using a wrench to adjust
When a slight force is needed to
spool, tension is set.
while
spool
turn
nut.
turn
Loosen wire from spool, cut oft bent
wire, and pull 6 in. (150 mm) of wire
from
3
spool.
Pressure
Open
4
Adjustment
pressure
assembly.
Wire Inlet Guide
5
Drive Roll
6
Wire Outlet Guide
Thread
wire
along drive
let
through
guide. Close
Lay gun
inlet
guide,
roll groove, and into out
pressure
cable out
7
Nozzle
8
Contact Tube
assembly.
straight.
Remove nozzle and contact tube.
9
Gun
Trigger
Turn ON unit, press gun trigger, and
feed 2 in. (55 mm) of wire out of gun.
2
3
Turn OFF unit and reinstall contact
tube and nozzle.
10
Adjusting 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
adjustment
if
necessary.
Close door.
9
8
7
Tools Needed:
~ 9/16
in
ST.800 316 / Ret ST. 155 505 / Ret ST. 155 504 / S.0627.A
Figure
OM-154 405
Page
2
2-5.
Feeding Welding
Wire
explosion.
5.
Watch for fire, and keep
Sparks and spatter fly off 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 orwelding wire
to metal objects can cause sparks, overheating, or
6.
Be
WELDING
fire
can cause
or
can cause
and others from
1.
Protect
Do not weld where
3.
yourself
flying sparks
flying sparks
can
Remove alt flammables within 35 ft
(10.7 m) of the welding arc.
possible, tightly cover them with approved covers.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
FLYING SPARKS AND HOT METAL
cause
Do not
Ii.
1.
cool, they
and
cause
throw off
CYLINDERS
or
drums.
use
welder to thaw frozen
pipes.
Remove stick electrode from holder
tip
when not in
Wear oil-free
or
Wear
cut off
welding
wire at
use.
protective garments such as leather gloves, heavy
approved face shield
or
a
cap.
safety goggles. Side
shields
recommended.
grinding
can
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.
Chipping
closed containers such
9.
on
or
the hidden side.
Do not weld
this is not
4.
extinguisher nearby.
ceiling, floor, bulkhead,
fire
Connect work cable to the work
10.
If
on
a
on a
7.
and hot metal.
strike flammable material.
fire
welding
8.
fire.
2.
that
aware
can
2.
metal. As welds
flying
Wear proper
body protection
to
protect
skin.
slag.
explode
if
3.
damaged;
Keep cylinders away
from any
welding
or
other electrical
circuits.
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.
1.
Protect
mechanical shocks, and
2.
excessive
7.
upright position by chaining
equipment cylinder rack to
8.
arcs.
cylinders in
them to a stationary support
prevent falling or tipping.
Install and
from
heat,
compressed gas cylinders
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 on compressed gas cylinders.
associated equipment, and CGA 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 Rd, Miami FL 33126
Safetyand Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American
Society Standard AWS F4. 1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire Protection Association,
Safe Handling of Compressed Gases in
501, Arlington, VA 22202.
Cylinders, CGA Pamphlet P-I,
from
Batterymarch Park, Quincy,
Welding
MA 02269.
Compressed Gas Association, 1235 Jefferson Davis Highway, Suite
Code for Safety in Welding and Cutting, CSA Standard Wi 17.2, from Canadian Standards Association, Standards Sales, 178 Rexdaie Boulevard,
Rexdale, Ontario, Canada M9W 1 R3.
Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard Z87. 1, from American National Standards Institute, 1430
Broadway, New York, NY 10018.
Cutting And Welding Processes,
NFPA Standard 51
B, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
TABLE OF CONTENTS
SECTION 1
i-i.
Volt-Ampere Curve And Duty Cycle Chart
SECTION 2
2-i.
2-2.
2-3.
2-4.
2-5.
2-6.
SECTION 4
SPECIFICATIONS
INSTALLATION
Installing Work Clamp
Installing Gas Supply
Connecting Input Power
Gun Polarity For Wire Type
Installing Welding Gun
Threading And Feeding Welding Wire
SECTION 3OPERATION
2
MAINTENANCE & TROUBLESHOOTING
4-i.
Overload Protection
4-2.
Drive
4-3.
Gun Maintenance
8
4-4.
Troubleshooting
8
Assembly
Maintenance
6
7
2
SECTION 5
ELECTRICAL DIAGRAMS
3
SECTION 6
PARTS LIST
4
Figure
Figure
2
9
3
5
6-1. Main
Assembly
6-2. MWG-i 60M Gun
11
12
SPECIFICATIONS
SECTION 1
Table 1-1.
Power Source
Welding
Description
Specification
Type Of Output
Direct Current/Constant
Rated Weld
70
Output
Input Amperes
At Rated
Max.
Welding
29 Volts DC
At Gun
24 Volts DC
Gas Metal Arc
Processes
(GMAW)
Speed Range At No Load
22 To 286
Wire Diameter
.023 And .030 in.
Range
Length: 16-1/2
Weight
Net: 53 lbs.
Output (Air Cooled)
160
Cable
Length
10 ft.
Volt-Ampere Curve
gun beyond
Use gun at 30%
Width: 9-1/2 in.
(419 mm);
(24 kg); Ship:
And
Amperes At
62 lbs.
(241 mm); Height:
17 in.
(432 mm)
(28 kg)
60%
Duty Cycle Using CO2 Shielding Gas
(3 m)
Duty Cycle
USING GUN BEYOND DUTY CYCLE RATING
use
(0.6 And 0.8 mm)
in.
Chart
CAUTION
a
Do not
Welding (FCAW)
Gun
Rated
1-1.
And Flux Cored Arc
ipm (0.6 To 7.3 mpm)
Overall Dimensions
Welding
Duty Cycle
Hz; At 115 Volts AC
2.2 kVA/2 kW
Open-Circuit Voltage
Voltage
60
I 5A At 11 5V
Output
KVAJKW Used At Rated Output
Control Circuit
Amperes,
Single-Phase;
Power
Type Of Input
Voltage (DCICV)
16 Volts DC, 20%
duty cycle
when
using
mixed
can
damage
gun.
using CO2 shielding gas.
rated amperage when
shielding gas.
wfwam8.1 10/91
The
volt-ampere
minimum
and
curves
show the
maximum
voltage
and amperage output capabilities
of the welding power source.
Curves of other settings fall be
tween the curves shown.
~N
~,R
.~
~
~Z
i
d
M~
Duty cycle
63
~;
S~~ ~S
~
~ ~
without
S
a
long
the unit
ten minute
can
period
causing overheating
or
damage.
~
RM~E
is how
operate within
This unit is rated at 20% duty cycle
allowing welding 2 minutes out of
~__,
every 10 minutes.
S
This gun is rated at 60% duty cycle
when using CO2 shielding gas and
0
20
.0
60
D.C.
so
oo
so
30% when
.o
~
using
mixed
shielding
gas.
ISO
-
25
-
100
-.-
-
-
~,-.~-
75
-.
-..
-
-
-
---
-
-
--
-
~
~-.
~
s
SO
.
~
37.5
-
25
-
0
0
IS
20
25
30
.0
-
-
-
---
--
...
.
50
60
70
60
-
-
9000
o.rry c,o.E S
SSb1.1 10191
Figure
OM-154 405
Page
1
1-1.
Volt-Ampere Curve
And
Duty Cycle Chart
SB-121 090/ sDl .310/91
5B-121 475
SECTION 2INSTALLATION
Installing
2-1.
Work
Clamp
1
Work Cable
2
Work
3
Clamp
1/4-20
1/2 in. Self-Thread
x
ing Screw
4
Jaw
Clamp
Insert
through
screw
work cable. Thread
terminal
on
through
screw
jaw and clamp.
5
Flange
Secure
Nut
screw
with nut.
Tools Needed:
______~
~
3/8 in.,
7/16 in.
Figure
2-1.
Installing
Work
Clamp
Installing Gas Supply
2-2.
a
WARNING
C YLINDERS
explode
can
Keep cylinders away
S
from
if
welding
and
other
electrical circuits.
Never touch
cylinder
with
Always secure cylinder
other stationary support.
welding electrode.
to
BUILDUP OF SHIELDING GAS
health or kill.
damaged.
running gear, wall,
or
Shut off
~
shielding gas supply
harm
can
when not in
use.
warn4.1 9/91
Obtain gas
running
cylinder
gear, wall,
or
and chain to
other station
ary support.
D~
UUU
6
1
Cap
2
Cylinder
1
Remove
Valve
cap,
stand
side
to
of
valve, and open valve slightly. Gas
flowblowsdustanddirtfromvalve.
Close valve.
2
3
3
Cylinder (CO2 Shown)
4
CO2 0-Ring
5
Regulator
Install onto gas
face is vertical.
6
cylinder
so
that
Flowmeter
Flow rate is set to 20 cfh
(cubic feet
per
hour).
7
Gas Hose Connection
7
Tools Needed:
Install
gas
meter and
1-1/Bin.,
5/8 in.
ssb3.1
Figure
2-3.
Connecting Input
Connect unit to
fuses
or
a
2-2.
hose
welding
2/92
between
power
flow-
source.
ST-154 583/ ST-154 623
Typical CO2 Regulator/Flowmeter Installation
Power
of al 5 or 20 ampere individual branch circuit protected by time-delay
extension cord of 14 AWG for up to 60 ft. (19 m) or 12 AWG for up to 75 ft. (23 m).
properly grounded receptacle
circuit breakers. Select
an
OM-154 405 Page 2
2-4.
Gun
Polarity
a
For Wire
Type
WARNING
ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
Turn OFF
welding
power source, and disconnect
input power
before
inspecting
or
installing.
swarnl.1 9/91
I
Polarity Changeover Label
2
Polarity Jumper
Links
Always
read and follow
wire
manufacturers
mended
welding
recom
polarity.
Close door.
2
Toots Needed:
c::::::::::J=u
3/8 in.
Ref ST.155 506
Figure
2-5.
Installing Welding
2-3. Gun
Polarity Connections
Gun
.3
I
Gun
2
Drive
3
Gun
Securing
Nut
Assembly
Trigger
Leads
Insert leads,
one at a time, through
grommet on front panel. Connect
leads to matching leads in unit.
4
Gun End
Loosen
through
bottoms
Tighten
securing nut. Insert end
panel opening until it
against drive assembly.
front
nut.
Close door.
1
2
3
Tools Needed:
~ 5/16 in.
Ref. ST.155 506
Figure
OM-154 405
Page
3
2-4. Gun Connections
2-6.
Threading And Feeding Welding Wire
a
WARNING
CYLINDERS
can
Keep cylinders
explode
from
away
if
damaged.
welding
and
other
electrical circuits.
Never touch
cylinder
WELDING WIRE
wounds.
Do not press gun
with
Always secure cylinder
other stationary support.
ELECTRIC SHOCK
welding electrode.
to
can
can
trigger
cause
puncture
until instructed to do
so.
point gun toward any part of the body, other
people, or any metal when threading welding wire.
Do not
running gear, wall,
or
kill.
HOT SURFACES
Do not touch live electrical parts.
burn skin.
can
Allow gun to cool before
touching.
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.
Swarn5.1
10/91 / Swarn2.1 9/91
1
Wire
2
Hub Tension Nut
Spool
Grasp spool in one hand and
while using a wrench to adjust
When a slight force is needed to
spool, tension is set.
Loosen wire from
3
6 in.
pull
from spool.
Pressure
Open
nut.
turn
spool and cut off
(150 mm) of
bent wire and
wire
turn
Adjustment
pressure
assembly
4
Wire Inlet Guide
5
Drive Roll
6
Wire Outlet Guide
Thread
wire through inlet guide,
along drive roll groove, and into Out
let guide. Close pressure assembly.
Lay gun
cable out
7
Nozzle
8
Contact Tube
straight.
Remove nozzle and contact tube.
9
Gun
Trigger
Turn ON unit, press gun trigger, and
feed 2 in. (55 mm) of wire out of gun.
Turn OFF unit and reinstall contact
tube and nozzle.
10
Adjusting
Pressure
Turn ON unit and check drive roll
pressure by
wood board
feeding
or
wire should feed
7
wire
against
concrete
steadily
a
surface;
without
slipping.
Tighten
pressure
adjustment
if
nec
essary.
Close door.
Tools Needed:
~ 9/16 in.
Ret. ST. 155 505 / Ref ST.155 ~fl4 / S.0R27.A
Figure
2-5.
Feeding Welding
Wire
OM-154 405 Page 4
SECTION 3
OPERATION
~t
READ SAFETY BLOCKS at beginning
of manual before proceeding.
~
M OVING PARTS
can cause
Keep away from pinch points
Keep all doors, panels,
and securely in place.
ARCING
injury.
such
covers, and
as
drive rolls.
Do not
can
while
welding.
guards closed
.
inside switch
switch to fail.
Arcing
1
switch.
damage
change VOLTAGE switch position
2
3
/
~s8
can
damage contacts, causing
Gloves
1
Insulating
2
Safety Glasses With Side
Shields
3
Welding
Helmet
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
Figure
3 -1.
10/91
Safety Equipment
1
Power Switch
Use switch to turn unit ON and
OFF.
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
4
Work
used to select
rear
Clamp
Use wire brush or
clean metal at weld
Connect
work
paint-free
as
close
an arc
cover).
clamp
location
as
sandpaper
(oint area.
on
possible
to
to
clean,
workpiece,
to weld area.
Tools Needed:
4
Ref. ST-155 503/ SC-153 020
Figure
OM-154 405
Page
5
3-2. Controls
MAINTENANCE & TROUBLESHOOTING
SECTION 4
WARNING
a
ELECTRIC SHOCK
can
Do riot touch live electrical
~
kill.
M OVING PARTS
can cause
injury.
Keep away from moving parts.
parts.
welding power source, and disconnect
input power before inspecting, maintaining, or
servicing.
Turn OFF
Keep away from pinch points
4
such as drive rolls.
.
HOT PARTS
can cause severe
cooling
servicing.
Allow
period
before
m
burns.
maintaining
or
Maintenance and troubleshooting
only by qualified persons.
to be
performed
swari,8 2~ ia/sr
Table 4-1. Maintenance Schedule
Time
Before each
After each
Maintenance
Tighten
use.
spool
all connections. Check gun and clean nozzle.
Blow out gun liner. Clean and check wire drive
of wire.
replace
Every
3 months.
Tape
Every
6 months.
Blow out
4-1.
or
cracked cables: clean and
or vacuum
parts; replace
as
necessary.
tighten connections. Replace
unreadable labels.
inside of unit.
Overload Protection
READ SAFETY BLOCKS at start of
Section 4 before proceeding.
A.
Overheating
Thermostat TP1 protects the unitfrom 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.
B.
Motor Fuse Fl
Turn OFF and unplug unit. Unlatch
door, remove handle, and 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 handle, and
latch door.
Tools Needed:
~:~===z~
~:
~r 3/8
in.
ST-155 723 / ST-r52 031
Figure
4-1.
Fuse Fl Location
OM-154 405
Page
6
4-2.
Drive
Assembly
Maintenance
~-jjjjlIrm~
~}i~~J ~
7
1_1r
READ SAFETY BLOCKS at start of
Section 4 before proceeding.
Turn OFF and
unplug
unit.
Spool
1
Wire
2
Gun Contact Tube
Cut welding wire off at contact tube.
Retract wire onto spool and secure.
3
Pressure Roll Arm
4
Cotter Pin
5
Pin
6
Screw
7
Bearing
Remove
bearing as shown.
bearing and secure with
new
Reinstall
2
arm
with cotter
onto
pin
and
Install
screw.
secure
pin.
8
Setscrew
9
Smooth Groove For Hard Wire
10
Drive Roll
Remove drive roll
Use
a
as
shown.
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
tighten both setscrews.
11
Knurled Groove For FluxCored Wire
12
WirelnletGuide
Remove
near
hole.
rear
guide
by pressing on
cutting off one end
housing and pulling it out of
Push new guide into hole from
barbed
area or
until it snaps in
Thread
welding
place.
wire
(see
Section
2-6). Close door.
Tools Needed:
~
5/6~1
ST-155504/ST-154 199
Figure
OM-154 405
Page
7
4-2. Drive
Assembly
Maintenance
4-3.
Gun Maintenance
READ SAFETY BLOCKS at start of
____
Section 4 before
I
FLYING METAL CHIPS AND DIRT
Point gun away from
people
and in
a
can cause
injury
safe direction when
blowing
and
proceeding.
damage equipment.
out with
compressed
air.
swarniOl 10/91
Turn OFF and
I
Tools Needed:
unplug unit.
Spool
Wire
Cut welding wire off at contact tube.
Retract wire onto
spool
and Se-
cure.
3/8 in.
5/16 in.
2
Gun
Securing
Nut
Disconnect trigger leads. Loosen
nut and remove gun and trigger
leads.
2
1
3
4
3
Nozzle
4
Contact Tube
5
Head Tube
6
Liner Collet
Disassemble gun
as
shown.
5
7
Liner
Pull liner from this end. Blow gun
casing out with compressed air.
Insert
until
6
~
liner into gun casing
with end of head tube.
new
even
Install collet onto liner.
~
Install contact tube and nozzle.
Insert gun into feeder and mark
where liner touches drive roIl. Re
gun and cut liner off. Rein
so that liner is as close as
possible to drive rolls without
move
~
stall gun
touching.
Thread welding wire
2-6). Close door.
R~t
Figure
4-4.
ST-155 506 / R~f ST.lcS ~
4-3. Gun Maintenance
Troubleshooting
READ SAFETY BLOCKS at start of
Section 4 before proceeding.
____
Welding Trouble
No weld output; wire does not feed.
Section
Remedy
]
Secure power cord
-~
in
plug
receptacle.
Motor fuse Fl open, replace Fl.
Replace building
Secure gun
No weld output; wire does not feed; fan
motor continues to run,
line fuse
trigger
leads
Thermostat TP1 open
-~
or
or
reset circuit breaker if open.
repair leads,
(overheating).
replace trigger
2-3
-~
4-1 B
-~
switch.
-~
2-5
Allow fan to run;thethermo-
-~
4-lA
or
--~
Connect work clamp to
get good
metal to metal contact.
Figure
~Replace contact tube.
Low weld output.
-~
stat will close when the unit has cooled.
No weld output; wire feeds.
I
(see Section
1
-.~I
Connect unit to proper
j
input voltage
or
check for low line
voltage.
3-2
4-3
-..~
2-3
OM-154 405
Page
8
Wire Drive/Gun Trouble
________________________________________________
Electrode wire
feeding stops during
Straighten
-~
gun cable and/or replace
damaged parts.
-~
4-3
welding.
________________________________________________________
____________
Adjust drive
Readjust
roll pressure.
2-6
hub tension.
2-6
Replace
contact tube if blocked.
Clean
replace wire inlet guide
or
Replace
drive roll
Secure gun
or
trigger
pressure
leads
or
or
liner if
bearing
if
repair leads,
dirty
or
worn or
or
plugged.
slipping.
replace trigger
switch.
Check and replace Fl.
-~
4-3
-a
4-2,4-3
-a
4-2
-~
2-5
-~
Check and clear any restrictions at drive
assembly
and liner
4-lB
4-2, 4-3
______________________________________________
Have nearest
Factory
Authorized Service Station check drive
---
--
motor.
SECTION 5
ELECTRICAL DIAGRAMS
CR1
//
2
Dl
I
L.
PLG I
CR/V.
TORCH
SA-1 53694-A
Figure
OM-154 405
Page
9
5-1. Circuit
Diagram
For
Welding
Power Source
P2
134-A
SC-154
CORD
POWER
GND
Source
SPLICE
Power
Welding
For
Diagr m
Wiring
5-2.
Figure
TPIGDSP
rDSo.1 LEADS
SI
S2
S3
0
En
0 En -o C) Co CD
0
SECTION 6
PARTS LIST
U,
U,
U,
p
0)
0
C~)
c,J
(0
c,J
(0
c~J
E
U,
C
CD
U,
/
C,,
/
C,
(4
/
r
/
/
0)
(4
0)
U,.
U-
OM-154 405
Page
11
Parts For Main
NOTE: All items indented
by
a
dot(s)
are
included with the item listed
Assembly
directly
above.
-_________________
Item
No.
Part
No.
126 838
I
Description
Drive
Assembly
Pin
1
090 416
Hinge
2
124817
DriveHousing
3
151 828
~CotterHairPin
4
112031
~Pressure Lever
5
090 443
111 622
Spacer
092 237
Knob
7
090415
Spring
8
085244
CuppedWasher
9
085 242
11
010 224
058 549
1
Part
No.
Description
J
HoseClamp
13
134834
Hose
Drive Roll
15
602169
Set Screw
16
129 893
Insulator
17
119021
DriveMotor
Thermostat, NC
154 015
Transformer
005 656
Fan Blade
28
153729
Handle
154596
Cap,
41
117 116
Resistor
42
087 156
Varistor
43
109039
Capacitor
Fuse Holder
44
108105
Clamp
Fuse, slo-blo 3A
45
118 457
Stabilizer
Rectifier
46
019663
Foot
010047
Tubing
47
600 325
Cable
116 619
Terminal Assembly
48
153 969
Clamp
038618
Link
49
154 845
MWG-160M Gun,
120 077
Blank,
153 714
Regulator/Flowmeter
Wrapper
30
134 464
Warning
31
089899
Latch
32
053 297
33
*012 663
34
119 264
35
36
Label
Case w/Cmpts
GasValve
605 227
Nyl Nut, gas
154 829
valve
Cord Set
120964
111 644
Bushing,
119 653
Rheostat
Baffle
19
111 929
Hub
097922
Washer
153 698
Rocker Switch, SPST
+When
Rocker Switch SPOT
playing
21
073 355
Spring
153 699
22
010909
Nut
155530
Adapter Fitting
Hose
Clamp, .375450
~Knob
ordering a component originally dis
precautionary label, the label should
a
also be ordered.
~Case
23
111 998
Cotter Hair Pin
155 569
Nameplate
*Recommended
24
120706
Relay
111 443
Bushing, .875mtg
Be
25
120675
Bracket
025 338
Bushing, .625nitg
Spare
Parts.
provide Model and Serial
when ordering replacement parts.
sure
Item
No.
1
2,
(Fig 6-2)
.250sq
~PVCTubing
089 120
153727
010910
.
113129
cord set
1
Hose Kit
112863
18
20
Coil
153695
Handle
+153 724
116996
154 827
120638
40
27
37
14
39
38
Wire Guide
149332
Side Panel
Fan Motor
Pin
12
Description
153722
111 931
Fastener
Spring
Part
No.
Item
No.
26
29
Bearing
6
10
J
Item
No.
to
Part
No.
Description
155 817
Handle
110795
Head Tube
2
110780
~Nut
3
110779
~Jacket
4
110781
5
128878
6
154819
~Stop
Adapter
~Spring
7
154826
ContactTube, .023
7
154825
ContactTube, .030
8
154822
NozzlØ,1/2orf
.9
Number
Assembly,
8
154
821
Nozzle, 3/8
8
154
820
Nozzle, flat spot
red
on
14
17
Ret. ST.l1O 832-0
Figure
6-2. MWG-160M Gun
(Fig
6-1 Item
9
110 794
Trigger
10
080565
Terminal
11
110 792
Cable/Conduit
12
110797
Sleeve
13
154 823
LIner, .030-.035
14
120 715
.
15
079974
0-Ring,
16
110 796
Connector
17
047994
Terminal
Switch
Assembly
Collet, .035
.500
OPTIONAL
49)
OM-154 405
Page
12
Suggested Welding Settings
Shielding
Gas
Wire
Diameter
Operator
(inch)
Settings
Control
Material Thickness
12 ga. and
Thicker
Voltage
Thinner
14-13 ga.
17-15 ga.
20-18 ga.
High!
Hi9h/
Low/
Mm
or
Max
Mm
Max
Than 20 ga.
Low!
Mm
Solid Steel
.023025
Co2
.
Feed
Speed*
Voltage
-
Mm
100
95
70
55
High!
Hi~h/
Low!
Low!
or
Max
Mm
Max
Mm
Solid Steel
.023. 025
75% Ar
25%
CO2
Feed Speed*
Highl
Voltage
E-71T-GS
.030
WIRE SPEED control
as
100
90
65
High!
Low!
Max
Low!
LowI
50
60
Mm
Mm
Mm
.
Feed
*Adjust
Max
100
Speed*
90
50
30
required.
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.
OM-154 405
Page
13