MAC TOOLS MW13O User manual

June
1992
Form:
OM-154
404
Effective
With
Serial No. KC254343
MW13O
OWNERS
MANUAL
~
IMPORTANT:
Read and understand the entire
contents
of
this
manual,
with
special
emphasis
on
the
safety
material
throughout
the
manual,
before
installing, operating,
or
maintaining
this
equipment.
This
unit
and
these
instructions
are
for
use
only by
persons
trained
and
experienced
in
the
safe
operation
of
welding
equipment.
Do
not
allow
untrained
persons
to
install,
operate,
or
maintain this
unit.
Contact
your
distributor
if
you
do
not
fully
understand
these instructions.
L
.
1~oisfi
coven
5/9~

ST-155
507
PPINTED
IN
USA

The
following
safety
alert
symbol
and
signal
words
are
used
throughout
this manual
to
call
attention
to
and
identify
different
levels
of
hazard and
special
instructions.
a
WARNING
WARNING
statements
identify
procedures
or
practices
which
must
be
followed to
avoid
serious
personal
injury
or
loss
of
life
-________________________
a
CAUTION
CAUTION
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid
minor
personal
injury
or
damage
to
this
equipment.
~
IMPORTANT:
statements
identify
special
instructions
necessary
for the
most efficient
operation
of
this
equipment.
ARC
WELDING
SAFETY
PRECAUTIONS
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.
4. Disconnect
input
power
or
stop
engine
before
installing
or
servicing
this
equipment.
5.
Properly
install
and
ground
this
equipment
according
to
its
Owners
Manual
and
national,
state,
and local codes.
Turn
off
all
equipment
when
not
in
use.
Do
not
use
worn,
damaged,
undersized,
or
poorly spliced
cables.
Do
not
wrap
cables
around
your
body.
Ground
the
workpiece
to
a
good
electrical
(earth)
ground.
Do
not
touch
electrode
while
in
contact
with the work
(ground)
circuit.
11.
Use
only
well-maintained
equipment.
Repair
or
replace
damaged
parts
at
once.
12.
Wear
a
safety
harness
to
prevent falling
if
working
above floor
level.
13.
Keep
all
panels
and
covers
securely
in
place.
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.
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
informatic
that
will
be
found
in
the
Safety
Standards
listed
on
the
next
page.
Read
and
follow
all
Safety
Standards.
HAVE
ALL
INSTALLATION,
OPERATION,
MAINTENANCE,
~D
REPAIR
WORK
PERFORMED
ONLY
BY
QUALIFIED
PEOPLE.
6.
7.
8.
9.
10.
.
ARC RAYS
can
burn
eyes
and
skin;
1.
Wear
a
welding
helmet
fitted
with
a
proper
shade
of
filter
(see
NOISE
can
damage
hearing.
ANSI Z49. 1
listed
in
Safety
Standards)
to
protect
your
face
and
eyes
when
welding
or
watching.
Arc
rays
from
the
welding
process
produce
intense
2.
Wear
approved
safety glasses.
Side
shields
recommended.
heat
and
strong
ultraviolet
rays
that
can
burn
eyes
3. Use
protective
screens or
barriers
to
protect
others from
flash
and skin.
Noise from
some
processes
can
damage
and
glare;
warn
ethers
not to
watch
the
arc.
hearing.
4.
Wear
protective
clothing
made
from
durable,
flame-resistant
material
(wool
and
leather)
and
foot
protection.
5.
Use
approved
ear
plugs
or
ear
muffs
if
noise level is
high.
FUMES
AND
GASES
can
be
hazardous
5.
Work
in
a
confined
space
only
if
it is
well
ventilated,
or
while
~
to
your
health.
wearing
an
air-supplied respirator.
Shielding
gases
used
for
Welding
producesfumesand
gases.
Breathingthese
welding
can
displace
air
causing
injury
or
death.
Be
sure
the
fumes
and
gases
can
be
hazardous to
your
health.
breathing
air
is
safe.
6.
Do
not
weld
in
locations
near
degreasing.
cleaning,
or
spraying
I
Keep
your
head
out
of
the
fumes.
Do
not
breath
the
fumes,
operations.
The
heat and
rays
of
the
arc
can
react
with
vapors
to
form
highly
toxic and
irritating
gases.
2.
If
inside,
ventilate
the
area
and/or
use
exhaust
at
the
arc
to
remove
welding
fumes
and
gases.
7.
Do
not
weld
on
coated
metals,
such
as
galvanized,
lead,
or
3.
If
ventilation
is
coor,
use
an
approved air-supplied
respirator.
cadmium
plated
steel,
unless
the
coating
is removed
from
the
4. Read the
Material
Safety
Data
Sheets
(MSDSs)
and the
weld
area,
the
area
is
well
ventilated,
and
if
necessary,
while
manufacturers
instruction for
metals,
consumables,
coatings,
wearing
an
air-supplied
respirator.
The
coatings
and
any
metals
and
cleaners,
containing
these elements
can
give
off
toxic fumes
if
welded.

ERRATA
SHEET
September
2,
1993
FORM:
OM-154
404
Use
above
FORM
number when
ordering
extra
manuals.
After
this
manual
was
printed,
refinements
in
equipment
design
occurred. This
sheet
lists
exceptions
to
data
appearing
later
in
this
manual.
CHANGES TO
SECTION
2INSTALLATION
Replace
Section
2-6.
Threading
And
Feeding
Welding
Wire
(see
Page
2
on
this
Errata
Sheet)
CHANGES
TO
SECTION
6
PARTS
LIST
Change
Parts List
as
follows:
Part
Replaced
No. With
Description
12- 113494
147545
Cord
Set
12-
Added
135 615
Bushing,
nylon
.390
ID
x
.750
OD
x
.750
Ig
~First
digit
represents
page
no

digits
following
dash
represent
item
no.
BE
SURE
TO
PROVIDE
MODEL AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.

2-6.
Threading
And
Feeding Welding
Wire
a
~WARNING
~
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
SURF ACES
can
burn skin.

Allow
gun
to
cool
before
touching.
swarn5.1
10/91
/
swam2.1 9/91
TO
USE
1
LB
SPOOL:
1
Wire
Spool
2
Hub
Tension
Nut
Remove
and
retain
Tools Needed:
~
~
~:;-~-
_iii~
9/l6ir,
Install
1
lb
spool
7
Grasp
spool
in
one
hand and
turn
while
using
a
wrench
to
adjust
nut.
When
a
slight
force
is
needed
to turn
spool.
tension
is
set.
Loosen
wire
from
spool,
cut
off
bent
wire,
and
pull
6 in.
(150 mm)
of wire
from
spool.
3
Pressure
Adjustment
Open
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
straight.
7
Nozzle
8
Contact Tube
Remove
nozzle
and
contact
tube.
9
Gun
Trigger
Turn
ON
unit,
press
gun
trigger,
and
feed2in.
(55
mm)
of
wire
outof
gun.
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.
/
ST-SOC
316; Pef
ST~.
55 5~5
/ Ref. ST
55
504 S~0627-~
2
3
OM-154
404
Page
2
Figure
2-5.
Feeding
Welding
Wire

WELDING
can cause
fire
or
explosion.
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
te
metal
objects
can
cause
sparks,
overheating,
or
fire.
Protect
yourself
and
others
from
flying
sparks
and hot
metal.
Do
not
weld
where
flying
sparks
can
strike
flammable
material.
Remove
all
flammableswithin
35
ft
(10.7
m)
of the
welding
arc.
If
this
is
not
possible,
tightly
cover
them with
approved
covers.
Be
alert that
welding
sparks
and hot
materials
from
welding
can
easily
go
:hrough
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
or
drums.
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
shces.
and
a
caD.
PRINCIPAL
SAFETY
STANDARDS
Safety
in
Welding
and
Cutting,
ANSI Standard
Z49.1,
from
American
Welding Society.
550
N.W. Le.Jeune
Rd,
Miami FL
33126
Safety
and Health
Standards,
OSHA
29 CFR
1910,
from
Superintendent
of
Documents,
U.S. Government
Pnnting
Office,
Washington,
D.C.
20402.
Recommended Safe
Practices
for
the
Preparation
for Weldingand
Cuttingof
Contain
era
That
Have Held
Haza
rdous
Substances.
American
Welding
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,
Batteryrnarch
Park,
Quincy,
MA
02269.
Safe
Handling
of
Compressed
Gases
in
Cylinders,
CGA
Pamphlet
P-I,
from
Compressed
Gas
Association,
1235
Jefferson
Davis
Highway.
Suite
501,
Arlington,
VA
22202.
Code for
Safety
in
Welding
and
Cutting,
CSA Standard
Wi
17.2,
from Canadian
Standards
Association.
Standards
Sales,
178 Rexdale
Boulevard,
Rextiale, 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
510,
from
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
TABLE
OF CONTENTS
SECTION
1

SPECIFICATIONS
1-1.
Volt-Ampere
Curve
And
Duty Cycle
Chart
1
SECTION
2
INSTALLATION
2-i.
Installing
Work
Clamp
2
2-2.
Installing
Gas
Supply
2
2-3.
Connecting
Input
Power
2
2-4.
Gun
Polarity
For Wire
Type
3
2-5.
Installing Welding
Gun
3
2-6.
Threading
And
Feeding Welding
Wire
4
SECTION
4
MAINTENANCE
&
TROUBLESHOOTING
4-1.
Overload Protection
6
4-2.
Drive
Assembly
Maintenance
7
4-3.
Gun
Maintenance 8
4-4.
Troubleshooting
8
SECTION
5
ELECTRICAL
DIAGRAMS
9
SECTION
6
PARTS LIST
Figure
6-1.
Main
Assembly
Figure
6-2.
MWG-1
60M
Gun
11
12
1.
2.
3.
4.
I
FLYING SPARKS
AND
HOT
METAL
can
1.
Wear
approved
face
shield
or
safety
goggles.
Side
shields
cause
injury,
Chipping
and
grinding
cause
flying
metal.
As
welds
cool,
they
can
throw
off
slag.
2.
recommended.
Wear
proper
body
protection
to
protect
skin.
CYLINDERS
can
exptodelf
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,
-
3.
Keep-trtinders--away-lrom--any
welding-or
other electrical-
circuits.
4.
Never
allow
a
welding
electrode
to
touch
any
cylinder.
5. Use
only
correct
shielding
gas
cylinders,
regulators,
hoses,
and
fittings
designed
for
the
specific
application;
maintain them
and
associated
parts
in
good
condition.
1.
Protect
compressed
gas
cylinders
from
excessive
heat,
mechanical
shocks,
and
arcs.
S.
7.
Turn
face
away
from
valve outlet when
opening
cylinder
valve.
Keep
protective
cap
in
place
over
valve
except
when
cylinder
is
in
use or
connected
for
use.
2.
Install
and
secure
cylinders
in
an
upright
position
by
chaining
them
to
a
stationary
support
or
equipment
cylinder
rack
to
prevent
falling
or
tipping.
8. Read and follow
instructions
on
compressed
gas
cylinders.
associated
equipment,
and
CGA
publication
P.1
listed
in
Safety
Standards.
SECTION
3OPERATION

SECTION
1

SPECIFICATIONS
Table
1-1.
Welding
Power
Source
Specifications
Description
Type
Of
Output
Direct
Current/Constant
Voltage
(DC/CV)
Rated
Weld
Output
90
Amperes,
18 Volts
DC,
20%
Duty
Cycle
Type
Of
Input
Power
Single-Phase;
60
Hz;
At
115 Volts
AC
Input Amperes
At
Rated
Output
20A
KVAIKW
Used
At
Rated
Output
3
kVN2.2
kW
Max.
Open-Circuit Voltage
30
Volts
DC.
Control
Circuit
Voltage
At
Gun
24
Volts
DC
Welding
Processes
Gas
Metal Arc
(GMAW)
And
Flux
Cored
Arc
Welding
(FCAW)
Calculated
Speed
Range
At No
Load
28310716
ipm
(7.1
To 17.9
mpm)
Wire
Diameter
Range
.023
To
.035
in.
(0.58
To 0.89
mm)
Overall
Dimensions
Length:
16-1/2
in.
(419
mm);
Width: 9-1/2 in.
(241 mm);
Height:
17
in.
(4.32
mm)
Weight
Net:
73
lbs.
(33
kg);
Ship:
80 lbs.
(36
kg)
Welding
Gun
Rated
Output
(Air
Cooled)
160
Amperes
At
60%
Duty
Cycle
Using
CO2 Shielding
Gas
Cable
Length
lOft.
(3
m)
1-1.
Volt-Ampere
Curve
And
Duty
Cycle
Chart
A~
CAUTION
U,
~-
-I
0
>
~
o 20
40
60
80
100
DC
AMPERES
120
1O
126
100
~,
13
<
50
31.5
25
0
USING
GUN
BEYOND
DUTY
CYCLE RATING
can
damage
gun.

Do
not
use
gun
beyond
rated
amperage
when
using
CO2
shielding
gas.

Use
gun
at
30%
duty
cycle
when
using
mixed
shielding
gas.
wMam8.1
¶0/91
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.
Duty
cycle
is
how
long
the unit
can
operate
within
a
ten
minute
penod
without
causing
overheating
or
damage.
This
unit
is rated
at
20%
duty
cycle
allowing
welding
2
minutes
out
of
every
10
minutes.
This
gun
is
rated
at
60%
duty cycle
when
using
CO2
shielding
gas
and
30%
when
using
mixed
shielding
gas.
1.
16
20
26
30
40
50
60
103090100
Z
DUTY
CYC*.E
ssbl.1
10/91

SB-124
646-A/
sbl3 ¶0/91

SB.124
655.A
Figure
1-1.
Volt-Ampere
Curve
And
Duty
Cycle
Chart
OM-154 404
Page
1

2-1.
Installing
Work
Clamp
2-2.
Installing
Gas
Supply
BUILDUP
OF
SHIELDING
GAS
can
harm
health
or
kill.

Shut
off
shielding
gas
supply
when
not
in
use.
worn4
1
9/91
Obtain
gas
cylinder
and
chain
to
running
gear,
wall, or
other station.
ary
support.
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
(CO2
Shown)
4
CO2
0-Ring
5
Regulator
Install
onto
gas
cylinder
so
that
face
is
vertical.
6
Flowmeter
Flow
rate
is
set to
20
cfh
(cubic
feet
Tools
Needed;
per
hour).
Figure
2-2.
Typical
CO2
Regulator/Flowmeter
Installation
7
Gas
Hose
Connection
Install
gas hose
between
flow-
meter
and
welding
power
source.
ssb3.1
2/92

ST.154
583
/
S1.154
623
2-3.
Connecting
Input
Power
Connect
unit
to
a
properly
grounded
receptacle
of
a
20
ampere
individual branch
circuit
protected
by
time-delay
fuses
or
circuit
breakers.
Select
an
extension cord
of
12
AWG
for
up
to
75
ft.
(23
m)
or
10
AWG
for
up
to
140
ft.
(46 m).
SECTION 2INSTALLATION
2
Tools
Needed:
¶
~
3/8in.,
7/16
in.
1
Work
Cable
2 Work
Clamp
3
1/4-20
x
1/2
in.
Self-Thread.
ing
Screw
4
Clamp
Jaw
Insert
screw
through
terminal
on
work cable.
Thread
screw
through
law
and
clamp.
5
Flange
Nut
Secure
screw
with
nut.
ST-154
816
Figure
2-1.
InstallIng
Work
Clamp
a
WARNING
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.
6
5
3
~===~
1-1/8
in.,
5/8
in.
OM-154
404
Page
2

2-4.
Gun
Polarity
For
Wire
Type
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.
2-5.
Installing
Welding
Gun
Figure
2-3.
Gun
Polarity
Connections
swami
I
9/91
Tools
Needed:
~
5/16
in.
3
I
Gun
Securing
Nut
2
Drive
Assembly
3
Gun
Trigger
Leads
Insert
leads,
one
at
a time,
through
grommet
on
front
panel.
Connect
leads
to
matching
leads
in
unit.
4
Gun End
Loosen
securing
nut.
Insert
end
through
front
panel
opening
until it
bottoms
against
drive
assembly.
Tighten
nut.
Close
door.
Ret.
ST.155
506
Tools Needed:
~
3/8
in.
1
Polarity Changeover
Label
2
Polarity
Jumper
Links
Always
read and
follow
welding
wire
manufacturers
recom
mended
polarity.
3
Pilot
Light
(see
Section
4-lA)
Close
door.
2
Ref.
ST-155
506
2
Figure
2-4.
Gun
Connections
OM-154
404
Page
3

2-6.
Threading
And
Feeding
Welding
Wire
a
WARNING
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.
swarn5.1
¶0/91/
swarn2.1
9/91
Tools
Needed:
1
Wire
Spool
2 Hub
Tension
Nut
Grasp
spool
in
one
hand
and
turn
while
using
a
wrench
to
adjust
nut.
When
a
slight
force
is
needed
to turn
spool,
tension is
set.
Loosen
wire
from
spool
and
cut
off
bent wire
and
pull
6
in.
(150
mm)
of
wire
from
spool.
3 Pressure
Adjustment
Open
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
straight.
7
Nozzle
8
Contact
Tube
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
feeding
wire
against
a
wood board
or
concrete
surface:
wire
should feed
steadily
without
7
slipping.
Tighten
pressure
adjustment
if
nec
essary.
Close
door.
9/16
in.
Ret. ST- 155
505 /
Ret. ST.155
504
/
S-0627.A
Figure
2-5.
Feeding
Welding
Wire
23
0
OM-154
404
Page
4

SECTION
3 OPERATION
I
1!~3~
~
READSAFETYBLOCKSatbeg1nning
MOVING
PARTS
can
cause
injury.
ARCING
can
damage
switch.

Keep
away
from
pinch
points
such
as
drive
rolls.

Do
not
change
VOLTAGE
switch
position
while

Keep
all
doors,
panels,
covers,
and
guards
closed
welding.
and
securely
in
place.

Arcing
inside
switch
can
damage
contacts,
causing
switch
to
fail.
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
3-1.
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.
As
VOLTAGE
switch
set
ting
increases,
wire
speed
range
also increases. The
numbers
around
the
control
are
not
a
wire
feed
speed
(see
rear
cover).
3
Voltage
Switch
Use
switch
to
select
an
arc
voltage.
The
higher
the
selected
number,
the
thicker
the
material
that
can
be
welded
(see
rear
cover).
4
Work
Clamp
Use wire
brush
or
sandpaper
to
clean
metal
at
weld
joint
area.
Tools
Needed:
Connect
work
clamp
to
clean.
paint-free
location
on
workpiece,
as
close
as
possible
to
weld
area.
Figure
3-2.
Controls
Ref.
ST-155
508
/
SC-
53 021
OM-154 404
Page
5

SECTION
4-
MAINTENANCE
&
TROUBLESHOOTING
gA
WARNING
ELECTRIC
SHOCK
can
kill.

Do
not
touch
live
electrical
parts.

Turn
OFF
welding
power
source,
and disconnect
input
power
before
inspecting,
maintaining,
or
servicing.
HOT
PARTS
can
cause
severe
burns.

Allow
cooling
period
before
maintaining
or
servicing.

4~
M
S

OVING PARTS
can cause
injury.
Keep
away
from
moving
parts.
Keep
awa)
from
pinch
points
such
as
drive
rolls.
Maintenance and
troubleshooting
to
be
performed
only
by
qualified
persons.
swarn8 2 10~9l
Table
4-1.
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.
4-1
.
Overload
Protection
READ
SAFETY BLOCKS
at start
of
Section
4
before
proceeding.
A.
Overheating
Thermostat
TP
1
protects
the unit
from
damage
due
to
overheating.
If
main
transformer
Ti
gets
too
hot,
TP
1
opens
and
weld
output
stops.
The
pilot
light
turns
off
and the
fan
keeps
running
to
cool the
transformer.
Wait
several minutes be
fore
trying
to
weld.
A~
CAUTION
STATIC
ELECTRICITY
can
damage
parts
on
circuit boards.

Put
on
grounded
wrist
strap
BEFORE
handling
boards
or
parts.
fwarn5.l~ 9/9~
Turn OFF
and
unplug
unit.
Unlatch
door,
remove handle,
and
remove
door/wrapper.
1
Circuit
Board
PCi
Located behind fan.
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.
Ref.
ST.155
640 /
ST.149
327
B.
Motor Fuse
Fl
Tools Needed:
3/8
in.
Figure
4-1.
Fuse
Fl
Location
OM-154
404
Page
6

C.
Short
Circuit
Shutdown
If
contact
tube
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
tube from
workpiece.
Check contact
tube and
replace
if
damaged.
Turn
ON
unit
to
continue
operation.
4-2.
Drive
Assembly
Mainten~
~e
READ
Sectio
SAFETY
BLOCKS
at start
~f
n
4
before
proceeding.
Turn
OFF
and
unplug
unit.
1
Wire
Spool
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. Install
new
bearing
and
secure
with
screw.
Reinstall
arm
onto
pin
and
secure
2
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
2~6).
Close
door.
Tools
Needed:
~=
5~.
ST-1555041ST154
199
Figure
4-2.
Drive
Assembly
Maintenance
OM-154
404
Page
7

4-3.
Gun
Maintenance
4-4.
Troubleshooting
READ
SAFETY BLOCKS at
start
of
Section
4
before
proceeding.
Trouble
Remedy

-~
Secure
power
cord
plug
in
receptacle.
 

Motor
fuse
Fl
open,
replace
fuse.
 
-~
Replace
building
line fuse
or
reset
circuit
breaker
if
open.
 
-~
Secure
gun
trigger
leads
or
repair
leads, or
replace
trigger
switch.
 


-~
Thermostat
TPI
open
(overheating).
Allow fan
to
run:
the
thermo-

-~
stat
will
close
when
the
unit
has cooled.

-~
Connect
work
clamp
to
get
good
metal
to
metal
contact.
 
-~
Replace
contact
tube.


-

-~
Connect
unit
to
proper
input
voltage
or
check
for low line
voltage.
J

.J
Section
2-3
4-lB
 
2-5
4-lA
Figure
3-2
4-3
2-3
does
not
feed.
does
not
feed:
fan

and
pilot
light
feeds.

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
READ
SAFETY
BLOCKS
at
start
of
Section
4
before
proceeding.
Tools
Needed:
3/8
in.
5/16
in.
swarr~lC
109
Turn
OFF
and
unplug
unit.
1
Wire
Spool
Cut
welding
wire off
at contact
tube.
Retract
wire
onto
spool
and
se
cure.
3
4
5
2
Gun
Securing
Nut
Disconnect
trigger
leads. Loosen
nut
and
remove
gun
and
trigger
leads.
6
3 Nozzle
4
Contact
Tube
5
Head
Tube
6Liner
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
tube
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
2-6).
Close
door.
Figure
4-3.
Gun
Maintenance
Ret. 5T-
155
506
/
Ret. ST.
155
509
OM-154
404
Page
8

PLC
I
OM-154
404
Page
9
SECTION
5
ELECTRICAL
DIAGRAMS
Figure
5-1.
Circuit
Diagram
For
Welding
Power
Source
J-y
TCPCI-4
S5-153
693
Straighten
gun
cable
and/or
replace
damaged
parts.
Adjust
drive roll
pressure.
Readjust
hub tension.
Replace
contact
tube
if
blocked.
Wire
Drive/Gun
Trouble
________________________________________________
__________
Electrode
wire
feeding
stops during

-~


~
4.3
welding.
_____________________________________________________
___________
2-6
2-6

4.3
-~
4-2.4-3
-~
4-2
-~
2-5
-~
4-18
-~
4-2.4-3
--
--
Clean
or
replace
wire inlet
guide
or
liner if
dirty
or
plugged.
Replace
drive
roll
or
pressure
bearing
if
worn or
slipping.
Check
and
replace
Fl.
Secure
gun
trigger
leads
or
repair
leads,
or
replace
trigger
switch
Check
and
clear
any
restrictions
at
drive
assembly
and liner.
Have
nearest
Factory
Authorized Service
Station
check
drive
motor.
WOPK

SECTION
6PARTS LIST
>.
E
a)
U)
U)
4
C
I
U,
C.,
C.)
0
I
N
cJ
(0
C.,
/
/
C.,
/
0
C,
OM-154
404
Page
11

2A)FAN
143105
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SP~
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C,
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326
UM
05
lYE
P05
T050I
CASTDG
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13A(IORCH
TRIGGER
LEAD
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30A)TEI
-
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0)
84(IC4ACH
TRIGGER
LEAD)
31A(IEI
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POWER
CORD
C52)LIl
SIDE
\
Figure
5-2.
Wiring
Diagram
For
Welding
Power
Source
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2
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LD
SIDE
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CI)(~1
1I._~.____~._:II1
R2
SC.154
I33A

Parts
For
Main
Assembly
NOTE:
All
items
indented
by
a
dot(s)
are
included
with the
item
listed
directly
above.
Item Part
No.
No.
Description
126
838
Drive
Assembly
1
090416
-HingePin
2
124817
Drive
Housing
3
151
828
Cotter
Hair
Pin
4
112031
Pressure Lever
5
090
443
Bearing
111
622
-
Spacer
6 092237
Knob
7
090415
Spring
8
085244
CuppedWasher
9
085
242
Fastener
10
010224~
~SpflngPtn
11
058
549
Wire
Guide
12
149332
Nose
Clamp
13
134834
Hose
14
154827
Drive Roll
15
602169
SetScrew
16
129 893
Insulator
17
124
506
Drive
Motor
18
153727
Baffle
19
111
929
Hub
20
010910
Washer
21
073 355
Spring
22 010909
Nut
23
111
998
Cotter
Hair
Pin
24
048 573
Light
25 134
201
Stand-Off
Support
26
119 539
Circuit Card
I
Item
Part
J
No.
No.
Description
27
*073
426
Fuse,
slo-blo
5A
118 936
Housing,
10
pin
079747
Terminal
28 006
393
Relay
29
111
931 Fan
Motor
30 005
656
Fan Blade
31
153729 Handle
154596
Cap,
Handle
32 +153
724
Wrapper
33 134 464
Warning
Label
34 089899 Latch
35~
120 675~ Bracket
36
129
696
Contactor
37
119
264
Rectifier
38 010047
Tubing
39 116619
Terminal
Assembly
038618 Link
40
Case
w/Cmpts
116996
GasValve
605
227
Nyl
Nut,
gas
valve
113494
Cord Set
111
443
Bushing,
cord
set
000 101 Rheostat
097 922 Knob
153
698
Rocker
Switch,
SPST
111
897
Rotary
Switch
127023
Knob
155530
Case
Item
Part
J
No.
No.
Description
155 570
Nameplate
111
644
Bushing,
.875mtg
025 338
Bushing,
.625mtg
41
153722
Side Panel
42
125 552
Thermostat,
NC
43
147676
Transformer
147534
-Coil
44
117116
Resistor
45
087 156 Varistor
46
109039
Capacitor
47
108
105
Clamp
48 118457
StabiIizer~
49
019663 Foot
50
600325
Cable
51
153969
Clamp
52
154 845
MWG.160M
Gun.
(Fig
6.2)
153
714
Regulator/Flowmeter
154 829 Hose
Kit
112 863
Adapter
Fitting
113129
PVClubing
089
120 Hose
Clamp,
.375450
*Recommended
Spare
Parts.
+When
ordering
a
component
originally
dis
playing
a
precautionary
label,
the label should
also be ordered.
Be
sure
to
provide
Model
and
Serial
Number
when
ordering
replacement
pans.
1
155817
110 795
2
110780
3
110779
4
110781
5 128878
6
154819
7
154826
7
154825
7
154824
8
154822
8
+154821
8
+154820
9 110794
10
080565
11
110792
12 110797
13 154823
14
120715
15
079974
16 1107~6
17
047994
OPTIONAL
Handle
Assembly,
red
Head Tube
-
Nut
-
Jacket

Stop
-
Adapter
-
Spring
Contact
Tube,
.023
Contact
Tube,
.030
Contact
Tube,
.035
Nozzle,
1/2
art
Nozzle,
3/8
art
Nozzle,
flat
spot
Trigger
Switch
Assembly
Terminal
Cable/Conduit
Sleeve
Liner.
.030-035
-
Collet,
.035
0-Ring,
.500
Connector
Terminal
6
Item Part
No. No.
Description
.9
15
16
Ref.
ST-lie
832-0
Figure
6-2.
MWG-160M
Gun
(Fig
6-1 Item
52)
OM-154
404
Page
12

Suggested
Welding
Settings
Wire
Type,
Shielding
Gae,
And Flow
Rate
Wire
Diameter
(inch)
Operator
Control
settings*
Metal
Thickness
1/8
in.
(3.2
mm)
12
ga.
14
ga.
16
ga.
18
ga.
20
ga.
22
ga.
And
Thinner
E-71T-GS
Flux
Core
0.030
Voltage
Wire
Speed
4
30
3
30
3
20
1
25
1
20
1
20


0.035
Voltage
Wire
Speed
4
30
3
25
2
25
1
25
1
25
1
20


ER7OS-6,
Mild
Steel.
CO2
20
cTh+
0.023
Voltage
Wire
Speed
4
50
4
50
3
50
2
45
2
40
1
30
1
30
0.030
Voltage
Wire
Speed
4
40
4
40
3
40
3
40
2
40
1
40
1
35
ER70S-6,
Mild
Steel,
75%
Argon
25%
CO2.
20
cfh+
0.023
Voltage.
Wire
Speed
4~
60
4-
55
3~
50
2
45
2
40
1
35
1
35
0.030
Voltage
Wire
Speed
4
50
4
50
3
50
3
50
2
~5
1
45
1
40
ER
308,
Stainless
Steel,
Tri.Mix.
20cTh+
0023
~
Voltage
Wire
Speed
40
35
4
35
3
30
3
30
2
20


0.030
Voltage
Wire
Speed
4
30
4
30
4
30
3
25
3
20
2
15

0.035
Voltage
Wire
Speed
15
4
15
4
15
3
15
2
15




Aluminum,
Argon.
30
cTh+
0.030
Voltage
Wire
Speed


4
85
3
80
2
75
1
70




0.035
Voltage
WIre
Speed

4
~
4
60
2
60
2
55
 
*00
not
change
VOLTAGE
switch
position
while
welding.
WIRE SPEED value
in
table
is
a
starting
value
only,
and
WIRE
SPEED
control
setting
can
be
fine
tuned
during
welding.
+cth
=
cubic
feet
per
hour
OM-154
404
Page
13