MAC TOOLS MW 145 User manual

February
1995 Form:
OM-173
123
Effective With
Serial
No.
KF800297
OWNERS
MANUAL
MW145
U


Read
and
follow these instructions and all
safety
blocks
carefully.
Have
only
trained and
qualified
persons
install,
operate,
or
service
this
unit.
Call
your
distributor
if
you
do
not
understand
the
directions.

U Give
this
manual
to
the
operator.
U
For
help,
call
your
distributor
Too~fi
cover
5/94

ST-
801
021
PRINTED IN
USA

ARC
WELDING SAFETY PRECAUTIONS
~a
WARNING
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.
Inwelding,
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.
Touching
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
dry,
hole-free
insulating gloves
and
body protection.
3.
Insulate
yourself
from work and
ground
using
dry
insulating
mats
or covers
big
enough
to
prevent
any
physical
contact
with
the work
or
ground.
4.
Disconnect
input
power
or
stop
engine
before
installing
or
servicing
this
equipment.
Lockoutltagout input poweraccording
to
OSHA
29
CFR
1910.147
(see Safety Standards).
5.
Properly
install and
ground
this
equipment
according
to
its
Owners
Manual
and
national,
state,
and local codes.
6.
Always
verify
the
supply
ground

check and be
sure
that
input
newer
cord around wire is orooerlv
connected
to
around
terminal in disconnect box
or
that cord
plug
is connected
to
a
properly
grounded receptacle
outlet.
7.
When
making input
connections,
attach
proper
grounding
conductor first

double-check
connections.
8.
Frequently inspect input powercord
for
damage
or
bare
wiring

replace
cord
immediately
if
damaged

bare
wiring
can
kill.
9.
Turn oft
all
equipment
when
not
in
use.
10.
Do
not
use
worn,
damaged,
undersized,
or
poorly spliced
cables.
11.
Do
not
drape
cables
over
your
body.
12. If earth
grounding
of the
workpiece
is
required, ground
it
directly
with
a
separate
cable

do
not
use
work
clamp
or
work cable.
13.
Do
not
touch electrode
if
you
are
in
contact
with
the
work,
ground,
or
another
electrode
from
a
different machine.
14.
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.
16.
Keep
all
panels
and
covers
securely
in
place.
17.
Clamp
work
cable
with
good
metal-to-metal
contact to
workoiece
or
worktable
as near
the
weld
as
oractical.
ARC RAYS
can
burn
eyes
and
skin;
NOISE
can
damage
hearing;
FLYING
SLAG OR SPARKS
can
injure
eyes.
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,
grinding,
and welds
cooling
throw
off
pieces
of metal
or
slag.
FUMES
AND
GASES
can
be hazardous
to
your
health.
Welding
produces
fumes and
gases.
Breathing
these
fumes
and
gases
can
be
hazardous
to
your
health.
1.
Keep
your
head
out
of the fumes. Do
not
breathe the fumes.
2.
If
inside,
ventilate the
area
and/or
use
exhaust
at
the
arc
to
remove
welding
fumes and
gases.
3.
If
ventilation
is
poor,
use an
approved air-supplied
respirator.
4.
Read the
Material
Safety
Data
Sheets
(MSDS5)
and the
manufacturers
instruction for
metals,
consumables,
coatings,
cleaners,
and
degreasers.
Wear
a
welding
helmet
fitted
with
a
proper
shade of filter
to
protect
your
face and
eyes
when
welding
or
watching
(see
ANSI
Z49.1 and Z87.1 listed
in
Safety Standards).
Wear
approved
safety
glasses
with
side shields.
Use
protective
screens or
barriers
to
protect
others from
flash
and
glare;
warn
others
not to
watch
the
arc.
5.
Wear
protective
clothing
made
from
durable,
flame-resistant
material
(wool
and
leather)
and foot
protection.
5.
Work in
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.
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.
7.
Do
not
weld
on
coated
metals,
such
as
galvanized,
lead,
or
cadmium
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.
NOISE
ARC RAYS
2.
1.
Use
acoroved
ear
plugs
or ear
muffs
if
noise level is
high.
3.
4.
CYLINDERS
can
explode
if
damaged.
4.
Never
drape
a
welding
torch
over
a
gas
cylinder.
Shielding
gas
cylinders
contain
gas
under
high
5.
Never allow
a
welding
electrode
to
touch
any
cylinder.
pressure.
If
damaged,
a
cylinder
can
explode.
Since
6.
Never
weld
on a
pressurized
cylinder

explosion
will result.
gas
cylinders
are
normally
part
of
the
welding
7. Use
only
correct
shielding
gas
cylinders, regulators,
hoses,
and
process,
be
sure
to treat
them
carefully.
fittings designed
for the
specific application;
maintain them
and
associated
parts
in
good
condition.
1.
Protect
compressed
gas
cylinders
from
excessive
heat,
8.
Turn
face
away
from
valve outlet
when
opening
cylinder
valve.
mechanical
shocks,
slag,
open
flames,
sparks.
and
arcs. 9.
Keep protective
cap
in
place
over
valve
except
when
cylinder
is
2.
Install
cylinders
in
an
upright
position
by
securing
to a
stationary
in
use or
connected for
use.
support
or
cylinder
rack
to
prevent
falling
or
tipping.
10.
Read and
follow instructions
on
compressed
gas
cylinders,
3.
Keep cylinders
away
from
any
welding
or
other
electrical
associatedequipment,andCGApublicationP-1
listed
in
Safety
circuits.
Standards.
srl.1.1 2/94

WELDING
can cause
fire
or
explosion.
Welding
on
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
objects
can cause
sparks, explosion, overheating,
or
fire.
Check
and be
sure
the
area
is safe before
doing
any
welding.
1.
Protect
yourself
and others
from
flying
sparks
and hot metal.
2.
Do
not
weld
where
flying
sparks
can
strike flammable material.
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 sparks
and hot materials
from
welding
can
easily
go
through
small cracks and
openings
to
adjacent
areas.
5.
Watch
for
fire,
and
keep
a
fire
extinguisher
nearby.
6.
Be
aware
that
welding
on
a
ceiling,
floor, bulkhead,
or
partition
can cause
fire
on
the hidden
side.
7.
Do
not
weld
on
closed
containers such
as
tanks, drums,
or
pipes,
unless
they
are
properly
prepared according
toAWS F4.
1
(see Safety
Standards).
8.
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 hazards.
9. Do
not
use
welder
to
thaw
frozen
pipes.
10.
Remove stick
electrode
from
holder
or
cut
off
welding
wire
at
contact
tip
when
not
in
use.
11.
Wear oil-free
protective
garments
such
as
leather
gloves, heavy
shirt,
cuffless
trousers,
high
shoes,
and
a
cap.
12.
Remove
any
combustibles,
such
as
a
butane
lighteror
matches,
from
your person
before
doing
any
welding.
ENGINES
can
be
hazardous.
ENGINE EXHAUST GASES
can
kill.
1.
Use
equipment
outside
in
open,
well-ventilated
areas.
Engines
produce
harmful exhaust
gases.
2.
If
used
in
a
closed
area,
away
from
any
building
ai
vent
engine
exhaust outside and
r
intakes.
MOVING PARTS
can
cause
injury.
3. Have
only
qualified people
remove
guards
or covers
for
maintenance and
troubleshooting
as
necessary.
4.
To
prevent
accidental
starting during servicing,
disconnect
negative
()
battery
cable from
battery.
5.
Keep
hands, hair,
loose
clothing,
and tools
away
from
moving
parts.
6.
Reinstall
panels
or
guards
and close doors when
servicing
is
finished
and
before
starting
engine.
SPARKS
can
cause
BATTERY
GASES
1.
Always
wear
a
face
shield
when
working
on a
battery.
TO
EXPLODE;
BATTERY
ACID
can
2.
Stop engine
before
disconnecting
or
connecting battery
burn
eyes
and skin,
cables.
3.
Do
not
allow
tools
to
cause
sparks
when
working
on a
battery.
Batteries contain acid and
generate
explosive
4.
Do
not
use
welder
to
charge
batteries
or
jump
start
vehicles.
gases.
5.
Observe
correct
polarity
(+
and
)
on
batteries.
STEAM AND
PRESSURIZED HOT
1.
If
the
engine
is
warm
and
checking
is
needed,
follow
steps
2
COOLANT
can
burn
face,
eyes,
and
and 3.
skin.
2. Wear
safety glasses
and
gloves
and
put
a
rag
over
cap.
ltisbesttocheckcoolantlevelwhenengineiscold
3.
Turn
cap
slightly
and
let
pressure escape
slowly
before
to
avoid
scalding.
completely
removing
cap.
PRINCIPAL SAFETY STANDARDS
Safely
in
We/ding
and
Cutting,
ANSI Standard
Z49.1,
from American
Welding Society,
550
N.W.
LeJeune
Rd,
Miami FL
33126
Safely
and
Health
Standards,
OSHA
29
CFR
1910,
from
Superinten
dent
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,
Ameri
can
Welding
Society
Standard AWS
F4.
1,
from American
Welding
So
ciety,
550
N.W. LeJeune
Ad, Miami,
FL 33126
National
Electrical
Code,
NFPA Standard
70,
from National
Fire Pro
tection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
sri
1.1
2/94
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
Safely
in
Welding
and
Cutting,
CSA Standard
W117.2,
from
Canadian Standards
Association,
Standards
Sales,
178
Rexdale Bou
levard,
Rexdale,
Ontario,
Canada
M9W
1
R3.
Safe
Practices
For
Occupation
And Educational
Eye
And
Face
Protec
tion,
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.
a
WARNING
ENGINE
FUEL
can cause
fire
or
explosion.
Engine
fuel
is
highly
flammable.
3.
4.
Donotoverf
Do
not
spill
engine.
illtan
fuel.
kallo
If
fuel
wroomforfuelt
is
spilled,
clean
oexpand.
up
before
starting
1.
Stop
engine
and let
it
cool
off before
checking
or
adding
fuel.
2. Do
not
add fuel while
smoking
or
if unit is
near
any
sparks
or
open
flames.
Moving
parts,
such
as
fans,
rotors,
and belts
can
cut
fingers
and
hands and catch loose
clothing.
1.
Keep
all
doors,
panels,
covers,
and
guards
closed
and
securely
in
place.
2.
Stoo
eng
ne
before
installing
or
connecting
unit.

EMF
INFORMATION
N
OTE
LI~i~
Considerations
About
Welding
And
The
Effects
Of
Low
Frequency
Electric
And
_____________________
Magnetic
Fields
The
following
is
a
quotation
from the
General
Conclusions Section To
reduce
magnetic
fields
in
the
workplace,
use
the
following
of
the
U.S.
Congress,
Office
of
Technology
Assessment,
Biological
procedures:
Effects
of Power
Frequency
Electric
&
Magnetic
Fields
1.
Keep
cables
close
together
by
twisting
or
taping
them.
Background Paper,
OTA-BP-E-53
(Washington,
DC: U.S.
Government
Printing
Office,
May 1989):
.
.
.
there is
now a
very
2.
Arrange
cables
to
one
side
and
away
from
the
operator.
large
volume of scientific
findings
based
on
experiments
at
the
3.
Do
not
colt
or
drape
cables around the
body.
cellular
level and
from studies
with
animals
and
people
which
clearly
establish
that low
frequency
magnetic
fields
can
interact
with,
arid 4.
Keep
welding
power
source
and cables
as
far
away
as
produce
changes
in,
biological
systems.
While
most
of this work
is
of
very
high quality,
the
results
are
complex.
Current
scientific
5.
Connect
work
clamp
to
workpiece
as
close
to
the
weld
as
understanding
does
not
yet
allow
us
to
interpret
the evidence in
a
possible.
single
coherent
framework.
Even
more
frustrating,
it
does
not
yet
About
Pacemakers:
allow
us
to
draw definite
conclusions about
questions
of
possible
The above
procedures
are
among
those
also
normally
risk
or
to
ofter
clear
science-based
advice
on
strategies
to
minimize
recommended
for
pacemaker
wearers.
Consult
your
doctor
for
or
avoid
potential
risks.
complete
information.
modlO.1
4/93
TABLE
OF
CONTENTS
SECTION
1

SAFETY
INFORMATION
1
SECTION
2
SPECIFICATIONS
1
2-1.
Volt-Ampere
Curve
2
2-2.
Duty
Cycle
2
SECTION
3INSTALLATION
3
3-1.
In,stalling
The
Running
Gear
3
3-2.
Installing
Work
Clamp
4
3-3.
Installing
Gas
Supply
4
3-4.
Selecting
GMAW Or
GTAW
Welding
Process
5
3-5.
Selecting
Gun/Torch
Polarity
5
3-6.
Installing
Supplied
GMAW
Gun Or
Optional
MWTIG
Torch
6
3-7.
Selecting
A
Location
And
Connecting
Input
Power
7
3-8.
Installing
Wire
Spool,
Adjusting
Hub
Tension,
And
Threading Welding
Wire
7
SECTION
4OPERATION
10
SECTION
5
MAINTENANCE
&
TROUBLESHOOTING
11
5-1.
Overload
Protection
11
5-2.
Drive
Assembly
Maintenance
13
5-3.
Gun
Maintenance
14
5-4.
Troubleshooting
14
SECTION
6-
ELECTRICAL
DIAGRAMS
15
SECTION
7-
PARTS LIST
18
Figure
7-1.
Main
Assembly
18
Figure
7-2.
Running
Gear
19
Figure
7-3.
MWG-160M Gun
20
OM-173 1232/95

SECTION
1
-
SAFETY
INFORMATION
modl.1
2/93
a
WARNING
a CAUTION

Read
all
safety
messages
throughout
this
manual.

Obey
all
safety
messages
to
avoid
injury.

Learn
the
meaning
of WARNING
and
CAUTION.
1
Safety
Alert
Symbol
1 2
2
\
~
3
ELECTRIC SHOCK
can
kiII.~
MOVING
PARTS
can
injure,

Do
not touch
live electrical
parts.

Keep
away
from
moving
parts.
I

Disconnect
input
power
betoreJj.
4

Keep
all
panels
and
covers
closed
I
when
operating.
I
installing
or
servicing.
5
2
Signal
Word
WARNING
means
possible
death
or
serious
injury
can
happen.
CAUTION
means
possible
minor
injury
or
equipment
damage
can
happen.
3
Statement
Of
Hazard And
Result
4
Safety
Instructions To
Avoid
Hazard
5 Hazard
Symbol
(If Available)
6
Safety
Banner
Read
safety
blocks for each
sym
bo shown.
7
NOTE
Special
instructions for
best
oper
ation

not
related
to
safety.
6~,T~~.1kl~t
~
READ
SAFETY
BLOCKS
at start
of
Section
3-1 before
proceeding.
NOTE
~
Turn Off switch
when
using high frequency.
Figure
1-1.
Safety
Information
SECTION
2- SPECIFICATIONS
Table 2-1.
Welding
Power Source
Specifications
Description
Type
Of
Input
Power
Single-Phase;
60
Hz;
At
115
Volts
AC
Type
Of
Output
Direct Current/Constant
Voltage (DC/CV)
Max.
Open-Circuit
Voltage
30
Volts DC
Control Circuit
Voltage
At
Gun
24
Volts DC
Welding
Processes
Gas Metal Arc
(GMAW).
Flux
Cored
Arc
(FCAW),
And
Gas
Tungsten
Arc
(GTAW)
Welding
Calculated
Speed Range
At
No Load 176 To 817
pm
(4.5
To 20.8
mpm)
Wire Diameter
Range
.023
To
.035
in
(0.58
To
0.89
mm)
Overall
Dimensions
Length:
18-1/8
in
(460 mm);
Width:
14-1/4
in
(362
mm);
Height:
18-1/4
in
(464 mm)
Weight
Rated Weld
Output
Net:
85
lb
(39
kg);
Ship:
92
lb
(42
kg)
Using
15
Ampere Plug
Using
30
Ampere
Plug
90
Amperes,
18
Volts
DC,
40%
Duty Cycle
140
Amperes,
18
Volts
DC,
40%
Duty Cycle
Input Amperes
At
Rated
Output
20
A At
115
V
36
A At 115
V
Input
Amperes
Used
While
Idling
0.54
A
0.54
A
KVA/KW Used At
Rated
Output
3
kVA/2.2 kW
4.5
kVA/4
kW
KVNKW Used While
Idling
0.06
KVNO.04
kW 0.06
KVA/0.04
kW
Welding
Gun
Rated
Output
(Air-Cooled)
160
Amperes
At
60%
Duty
Cycle
Using
CO2
Shielding
Gas
Wire Diameter
.023 And .035
(0.6
And 0.89
mm)
Hard And Flux
Cored
Wires
Cable
Length
10
ft
(3m)
OM-173
123
Page
1

2-1.
Volt-Ampere
Curve
Figure
2-1.
Volt-Ampere
Curve
2-2.
Duty
Cycle
a
~CAUTION
:~~!I~
The
volt-ampere
curves
show the
minimum
and
maximum
voltage
40
and
amperage
output
capabilities
of the
welding
power
source.
Curves of
other
settings
fall
be
tween
the
curves
shown.
30
U)
0
>
20
0
0
10
0
0
DC
AMPERES
ssbli
10/91

ST-173 778
50 100
150
200 250
WELDING
LO

Do
not
weld
at
r
NGER THAN
RATED
DUTY
CYCLE
can
damage
unit
or
gun
and
void
warranty.
ated load
longer
than
shown below.
wlwarn8.2
8/93
Figure
2-2.
Duty
Cycle
OM-173
123
Page
2

SECTION
3-INSTALLATION
-1.
Installing
The
Running
Gear
Tools Needed:
LIIIIII~J1J
3/8,9/l6in
Figure
3-1.
Installing
The
Running
Gear
Install
running
gear
as
shown.
See
Parts
List for
parts
descriptions.
both
ends of
chain
are
in
slots in
and
chain is
tight
around
cylinder.
a
Remove
paint
from axle
grooves
before
installing
retaining rings.
a
51-801
025
OM-173
123
Page
3

3-2.
Installing
Work
Clamp
3-3.
Installing
Gas
Supply
CYLINDERS
can
explode
if
damaged.

Keep cylinders
away
from
welding
and
other
electrical circuits.

Never touch
cylinder
with
welding
electrode.

Always
secure
cylinder
to
running
gear,
wall,
or
other
stationary support.
BUILDUP
OF
SHIELDING
GAS
can
harm
health
or
kill.

Shut
off
shielding
gas
Supply
when
not
in
use.
Figure
3-3.
Typical
Regulator/Flowmeter
Installation
2
1
Insulator
2
Bolt
3
Smaller
Hole
4
Work
Clamp
Tabs
Bend
tabs
around
work cable.
5
Work
Cable
From
Unit
6 Nut
Tools Needed:
~
3/8,7/16
in
Figure
3-2.
Installing
Work
Clamp
Ret.
ST-025
190-0
warn4.1
9/91
Tools
Needed:
~
5/8,1-1/8
in
Argon
Gas Or
Mixed
Gases
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.
3
Cylinder
4
Regulator/Flowmeter
Install
so
face
is
vertical.
5
Gas
Hose
Connection
Fitting
has
5/8-18
right-hand
threads. Obtain
and
install
gas
hose
between
regulator/flowmeter
and
welding
power
source.
6
Flow
Adjust
Typical
flow
rate
is
20 cfh
(cubic
feet
per
hour).
Check
wire
manufactur
ers
recommended flow
rate.
7
CO2
Adapter
8
0-Ring
Install
adapter
with
0-ring
between
regulator/flowmeter
and
CO2
cylinder.
ssb3.
1 1
2.92

ST-i
58
697-A /
Ref. ST-
149 827-B
2
3
CO2
Gas
OM-173
123
Page
4

3-4.
Selecting
GMAW
Or GTAW
Welding
Process
a
WARNING
ELECTRIC
SHOCK
can
kill.
S
Do
not
touch
live
electrical
parts.

Turn
Oft
welding
power
source,
and disconnect
input
power
before
inspecting
or
installing.
swaml.1
2/93
3-5.
Selecting
Gun/Torch
Polarity
a
~.
WARNING.
ELECTRIC
SHOCK
can
kill.

Do
not
touch
live electrical
parts.

Turn
Off
welding
power
source,
and disconnect
input
power
before
inspecting
or
installing.
swaml.1
2/93
0
0]
Tools Needed:
1
Process
Changeover
Label
2
Process
Jumper
Link
Place
link in
correct
position
for de
sired
welding
process.
Close
door.
Ref. ST-801
029
~IIIII~t1
1/2
in
Figure
3-4.
Selecting
Welding
Process
c
STRAIGHT
I
REVERSE
~
For Solid
For Flux
Sleet Or
Cored
Wires
Aluminum
I
POLARITY POLARITY
I
DCEN DCEP
Process>
Process>
(GMAW>
(FCAW
Wires
GUN POLARITY
CHANGEOVER
2
Tools
Needed:
Ref. ST-801
029
ciii~~i==ij
3/8
in
1
Polarity
Changeover
Label
2
Polarity Jumper
Links
Always
read and follow
welding
wire
manufacturers
recom
mended
polarity.
For GTAW
welding
with
optional
MWTIG
torch,
use
Straight
Polarity
(DCEN).
Close
door.
Figure
3-5.
Gun/Torch
Polarity
Connections
OM-173 123
Page
5

3-6.
Installing Supplied
GMAW
Gun
Or
Optional
MWTIG Torch
Tools Needed:
1
Gun/Torch
Securing
Nut
2 Drive
Assembly
3
Gun/Torch
Trigger
Leads
Insert
leads,
one
at
a time,
through
grommet
on
front
panel.
Connect
leads
to
matching
leads
in
unit.
4
Gun/Torch End
Loosen
securing
nut.
Insert end
through
front
panel opening
until it
bottoms
against
drive
assembly.
Tighten
nut.
Close door.
~=~:z~
1/2
in
Figure
3-6.
Gun/Torch
Connections
Ref. ST801
022
3
3
OM-173
123
Page
6

3-7.
Selecting
A
Location
And
Connecting
Input
Power
CYLINDERS
can
explode
if
damaged.

Keep
cylinders
away
from
welding
and other
electrical
circuits.

Never touch
cylinder
with
welding
electrode.

Always
secure
cylinder
to
running
gear,
wall,
or
other
stationary
support.
ELECTRIC
SHOCK
can
kill.

Do
not
touch
live
electrical
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.
WELDING
WIRE
can cause
puncture
wounds.

Do
not
press gun
trigger
until
instructed
to
do
so.

Do
not
point
gun
toward
any
part
of the
body,
other
people,
or
any
metal
when
threading welding
wire.
HOT SURFACES
can
burn skin.

Allow
gun
to
cool
before
touching.
1
When
reassembling plug,
be
sure
tabs line
up
with
notches.
5
1
18
in
(457
mm) Open
Space
At Front
And Rear For
Good
Airflow.
2
Rating
Label
3
Grounded
Receptacle
4
115
Volts,
15
Amperes
Plug
From
Unit
For9O
amperes
output,
connect at
tached
plug
to
a
properly
grounded
receptacle
of
a
20
ampere
individu
al branch
circuit
protected
by
time-
delay
fuses
or
circuit
breaker is
re
quired.
Select
extension
cord of
12
AWG
for
up
to
75
ft
(23
m)
or
10
AWG for
upto
140ft(46m).
5 115
Volts,
30
Amperes
Plug
(Supplied
With
Unit)
For
140
amperes
output,
remove
the
115
volts,
15
amperes
attached
plug,
and
replace
with
supplied
115
volts,
30
amperes
plug
as
shown.
6
Green
Lead
Connect
to
Ground
(Green)
Termi
nal.
7
Black
Lead
Connect
to
brass terminal.
8 White
Lead
Connect
to
silver
terminal.
Connect
the 30
amperes
plug
to
a
properly
grounded
receptacle
of
a
30
ampere
individual
branch
circuit
protected by
time-delay
fuses
or
circuit
breakers.
Select
extension cord of
12
AWG
for
up
to
75
ft
(23 m)
or
10
AWG
for
upto
140ft(46m).
5T-801
021
/
ST-801
030
Figure
3-7.
Selecting
A
Location
And
Connecting
Input
Power
3-8.
Installing
Wire
Spool,
Adjusting
Hub
Tension,
And
Threading Welding
Wire
~~r~YAI~1
: ~ II ~
______
_____________________________
swarn5.1
10/91 /swarn2.1
9/91
OM-173
123
Page
7

A.
Installing
Wire
Spool
And
Adjusting
Hub
Tension
FOR
STANDARD
WIRE
SPOOL:
4~
5
Turn
Off
and
unplug
unit.
1
Wire
Spool
2
Gun Contact
Tip
It
necessary,
cut
welding
wire off
at
contact
tip,
and
retract
wire
onto
spool
and
secure.
3
Retaining
Pin
Remove
pin
and
pull
off
spool.
4
Hub
5
Hub Pin
6
Bushings
Install
bushings
when
using
a
1
lb
spool.
Slide
spool
onto
hub
so
wire
feeds
off
top.
Turn
spool
until hub
pin
fits
hole
in back
of
spool.
Push retain
ing
pin
through
hub.
Remove and retain
7
Tools
Needed:
Figure
3-8.
Installing
Wire And
Adjusting
Tension
7
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
Figure 3-9).
Close door.
Rel
ST-iSO 093/S-0499/ST-801
029
N
OTE
~
If
hub
tension
is
too
tight,
motor
fuse
Fl
can
open
(see
Section
5-1).
If hub tension
_____________________
is
too
loose,
wire
unravels
and
can
become
tangled
inside
unit.
L~
FOR
1
LB WIRE
SPOOL:
6
t7%&17
7
/
.........u............)p~
Install
1 lb
spool
OM-173
123
Page
8

Hold
wire
tightly
to
keep
it
from
unraveling.
(150
mm)
Pull and hold
wire;
cutoff end.
7
1
Wire
Spool
2
Welding
Wire
3
Inlet Wire
Guide
4
Pressure
Adjustment
Knob
5
Drive Roll
6
Outlet
Wire
Guide
7
Gun
Conduit
Cable
Lay
gun
cable
out
straight.
Tools Needed:
~=Z~
9/16
in
Close and
tighten
pressure
assembly,
and let
go
of
wire.
Remove
gun
nozzle
and
contact
tip.
POWER
Set switch.
Press
gun
trigger
until
wire
comes
out
of
gun.
Reinstall
contact
tip
and
nozzle.
~lll~
Feed wire
to
check
drive
roll
pressure.
Tighten
knob
enough
to
prevent
slipping.
Cut
oft
wire.
Close
and latch door.
Ref.
ST-801
029
I Ref.
ST-i
72
500
/
S-0627-A
Figure
3-9.
Threading Welding
Wire
B.
Threading Welding
Wire
1
23
5 6
Open
pressure
assembly.
Push wire thru
guides
into
gun;
continue
to
hold wire.
OM-173
123
Page
9

SECTION
4-
OPERATION
READ
SAF
of
manual
ETY
BLOCKS at
beginning
before
proceeding.
MOVING
PARTS
can cause
injury.

Keep
away
from
pinch points
such
as
drive
rolls.

Do
not
change

Keep
all
doors,
panels,
covers,
and
guards
closed
I
welding.
Arcing
inside
switch
and
securely
in
place.
switch
to
fail.
Voltage
can
dam
switch
position
while
age
contacts,
causing
ARCING
can
damage
switch.
1 23
~S8
1
Insulating
Gloves
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
10/91
Figure
4-1.
Safety
Equipment
1
Wire
Speed
Control
Ref.
ST-801
023/ST-172 500
Tools
Needed:
Use control
to
select
a
wire
feed
speed.
As
Voltage
switch
setting
increases,
wire
speed
range
also
increases.
The
numbers around
the control
are
not
a
wire
feed
speed
(see
rear
cover).
Use
switch
to
select
an
arc
voltage.
The
higher
the
selected
number,
the
thicker the material that
can
be
welded
(see
end
of Parts
List).
Use
switch
to turn
unit
On
and
Off.
Connect
work
clamp
to
clean,
paint-free
location
on
workpiece,
as
close
as
possible
to
weld
area.
Use wire brush
or
sandpaper
to
clean
metal
at
weld
joint
area.
3
Power Switch
Figure
4-2.
Controls
OM-173
123
Page
10

SECTION
5-
MAINTENANCE
&
TROUBLESHOOTING
~a
WARNING
ELECTRIC SHOCK
can
kill.

Do
not
touch
live electrical
parts.

Turn
Oft
welding
power
source,
and disconnect
input
power
before
inspecting, maintaining,
or
;ervicing.
HOT
PARTS
can
cause severe
burns.

Allow
cooling
period
before
maintaining
or
servicing.
MOVING PARTS
can cause
injury.

Keep
away
from
moving
parts.

Keep
away
from
pinch points
such
as
drive rolls.
Maintenance and
troubleshooting
to
be
performed
qualified
persons.
swarn8 2
2/93
Table 5-1. Maintenance
Schedule
Time
Maintenance
Before
each
use.
Tighten
all connections.
Check
gun
and clean nozzle.
After each
spool
of wire. Blow
out
gun
liner.
Clean
and
check wire drive
parts;
replace
as
necessary.
Every
3
months.
Tape
or
replace
cracked
cables;
clean and
tighten
connections.
Replace
unreadable labels.
Every
6
months.
Blow
out
or vacuum
inside of
unit.
5-1.
Overload Protection
WARNING
READ
Sectio
SAFETY
n
5
befor
BLOCKS
at start
of
e
proceeding.
Figure
5-1.
Overheating
A.
Overheating
~I
~
-*
T~
+
~5
minutes
When
overheated,
thermostat
opens,
output
stops,
and
cooling
fan
keeps
running.
Let fan
run
for
15
minutes.
Start
welding.
ssblO.1
1/94
-.
Ref.
ST-8O1
021
.
OM-173
123
Page
11

B.
Motor Fuse
Fl
a
CAUTION
STATIC ELECTRICITY
can
damage
parts
on
circuit
boards.

Put
on
grounded
wrist
strap
BEFORE
handling
boards
or
parts.
C.
Short Circuit
Shutdown
If
contact
tip
is
shorted
and sticks
to
workpiece,
the unit
shuts
down,
but
fan
runs.
To
resume
operation,
release
gun
trigger,
turn
Off
unit,
and
remove
contact
tip
from
workpiece.
Check
contact
tip
and
replace
if
damaged.
Turn On unit
to
continue
operation.
twarn5.1
9/91
Turn
Oft
and
unplug
unit. Unlatch
door,
remove
handle,
and
remove
door/wrapper.
1
Circuit Board PCi
2
Fuse
Fl
(See
Parts List
For
Rating)
If
this
fuse
opens,
the
wire drive
motor
does
not
run.
Pull fuse from
fuse holder
on
PCi.
To
reinstall,
push
fuse
into fuse
holder.
Reinstall
wrapper
and
handle,
and
latch
door.
Tools Needed:
~
3/8 in
ST-801
024
Figure
5-2.
Fuse Fl Location
OM-173
123
Page
12

5-2.
Drive
Assembly
Maintenance
~frs~)~
READ
SAFETY BLOCKS
at
start
of
7
1
~f~
~
Section
5
before
proceeding.
Turn
Oft
and
unplug
unit.
1
Wire
Spool
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
bearing
as
shown.
Install
new
bearing
and
secure
with
screw.
Reinstall
arm
onto
pin
and
secure
with
cotter
pin.
8
Setscrew
9
Smooth
Groove For
Hard
Wire
10
Drive
Roll
Remove drive roll
as
shown.
Use
a
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
Flux
Cored
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
(see
Section
3-8).
Close
door.
Tools
Needed:
~
5/~1
51-155 504 / 5T-154
199
Figure
5-3.
Drive
Assembly
Maintenance
1
OM-173
123
Page
13

5-3.
Gun
Maintenance
5-4.
Troubleshooting
Section 5
before
proceeding.
READ SAFETY BLOCKS at
start
of
Welding
Trouble
Remedy
INo
weld
output;
wire
does
not
feed.

-~
Secure
power
cord
plug
in
receptacle.


~
Check
and
replace
motor
fuse
Flit
open.
 
-
Replace
building
line
fuse
or
reset
circuit
breaker
if
open.


-~
Secure
gun
trigger
leads
or
repair
leads,
or
replace
trigger
switch.


-~
No
weld
output:
wire
does
not
feed;
fan
(

-~
Thermostat
TP1
open
(overheating).
Allow
fan
to
run;
the thermo-
i

-~
motor
continues
to
run.
stat
will
close
when the unit has cooled.
I
No
weld
output;
wire
feeds.
J

-~
Connect
work
clamp
to
get
good
metal-to-metal
contact.


-~
Replace
contact
tip.

-~
Low
weld
output.

-..~
Connect
unit
to
proper
input
voltage
or
check
for
low
line
voltage.

-..~
Section
3-7
5-1
 
3-6
5-1
Figure
4-2
5-3
3-7
::
WARNING
FLYING
METAL
CHIPS AND DIRT
can cause
injury
and
damage
equipment.

Point
gun away
from
people
and in
a
safe direction
when
blowing
out
with
compressed
air.
swarnlo.1
10/91
READ SAFETY BLOCKS
at
start
of
Section
5
before
proceeding.
3
4
5
1 2
Tools
Needed:
~
3/85/l6in
Turn
Off
and
unplug
unit.
1
Wire
Spool
Cut
welding
wire off
at contact
tip.
Retract wire
onto
spool
and
se
cure.
2
Gun
Securing
Nut
Disconnect
trigger
leads. Loosen
nut
and
remove
gun
and
trigger
leads.
3 Nozzle
4
Contact
Tip
5 Head Tube
6 Liner
Collet
Disassemble
gun
as
shown.
7
Liner
Pull liner from this end. Blow gun
casing
out
with
compressed
air.
Insert
new
liner
into
gun
casing
until
even
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 off.
Rein
stall
gun
so
that
liner
is
as
close
as
possible
to
drive rolls without
touching.
Thread
welding
wire
(see
Section
3-8).
Close door.
Ref.
ST-801
022 /
Ref. ST-155
509
7
Figure
5-4.
Gun Maintenance
OM-173
123
Page
14