MAC TOOLS MW15O User manual

June 1992
Form: OM-154
500
Effective
With
Serial
No.
KC256471
MW15O
''\~7
~r
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~oLsfi
coven
5/92*
-
ST-155
63
PRINTED
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
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.
6.
7.
8.
9.
to.
,~
/~,.
~
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
yourface
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
others
not
to
watch the
arc.
g.
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
produces
fumes
and
gases.
Breathing
these
welding
can
displace
air
causing injury
or
death. Be
sure
the
~
~
fumes
and
gases
can
be
hazardous
to
your
health,
breathing
air
is
safe.
a_a.
6.
Do
not
weld
in
locations
near
degreasing,
cleaning,
or
spraying
1.
Keep
your
head
out
of
the
fumes.
~
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
poor,
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
manufacturers
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
.
.ApriI22,
1993
FORM:
OM-154
500
--
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.
NOTE
~
This unit
is
now
equipped
with
running
gear
and
has
been
renamed the
MW1
50K.
CHANGES
TO
SECTION
2INSTALLATION
Add
Figure
2-2A.
Installing
Safety
Chain,
to Section
2-2.
Installing
Gas
Supply
1
Cylinder
Bracket
As
Shipped
2
2
S-Nook
Crimp
between small
hole
in
bracket
and
chain.
3
Chain
4
Snap
4 Crimp
onto
open
end
of
chain.
5
Cylinder
Bracket
For
Large
Gas
Cylinder
-~
6
Gas
Fitting
Tools
Needed:
ST-160
791
CHANGES
TO SECTION
6-
PARTS
LIST
Change
Parts
List
as
follows:
Part
--
No.
Replaced
With
Description
12-37 137 800 157
044 Circuit
Card,
(Eft
w/KD352528)
12-
154
005 Deleted Eff
w/KD407671
12-53
147
578
152
872
Base,
(Eff
w/KD407671)
12-
Added
156
339
Bottle
Retainer,
(Effw/KD407671)
12-
Added 602 389
S
Hook,
(Effw/KD407671)
12-
Added
156 340
Chain,
(Eff w/KD407671)
12-
Added 602 384
Snap,
Chain
(Eff w/KD407671)
12-
Added 147893
Axle,
(Effw/KD407671)
12-
Added 090 693
Wheel,
8
in
(Eff w/KD407671)
12-
Added
602250
Washer,
.750
(Effw/KD407671)
12-
Added
121
614
Retaining
Ring,
(Effw/KD407671)
12-
Added
109
318
Caster,
2.500
(Eff w/KD407671)
**First
digit
represents
page
no

digits
following
dash
represent
item
no.
BE
SURE TO
PROVIDE MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT PARTS.
Figure
2-2A.
Installing Safety
Chain

WELDING
can
cause
fire
or
explosion.
Sparks
and
spatter
fly
off
from
the
weldin9
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
fire.
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.
FLYING
SPARKS
AND
HOT
METAL
can
cause
injury.
Chipping
and
grinding
cause
flying
metal.
As welds
cool,
they
can
throw
off
slag.
CYLINDERS
can
explode
If
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.
1.
Protect
compressed
gas
cylinders
from
excessive
heat,
mechanical
shocks,
and
arcs.
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.
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.
Do
not
weld
on
closed containers
such
as
tanks
or
drums.
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.
Do
not
use
welder
to
thaw
frozen
pipes.
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.
1.
Wear
approved
face
shield
or
safety
goggles.
Side
shields
recommended.
2.
Wear
proper
body
protection
to
protect
skin.
3.
Keep
cylinders
away
from
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.
6.
Turn
face
away
from
valve outlet when
opening
cylinder
valve.
7.
Keep
protective
cap
in
place
over
valve
except
when
cylinder
is
in
use
or
connected
for
use.
8.
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.
Govemmerit
Printing
Office,
Washington,
D.C.
20402.
Recommended
Safe
Practices for
the
Preparation
for
Welding
and
Cutting
of
Containers
That
Have
Held
Hazardous
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,
Batterymarch
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,
Rexdale,
Ontario,
Canada
M9W
1
P3.
Safe
Practices
For
Occupation
And
Educat
lanai
EyeAnd
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

SPECIFICATIONS
1.1.
Volt-Ampere
Curve
And
Duty Cycle
Chart
SECTION
2
-
INSTALLATION
2-1.
Installing
Work
Clamp
2
2-2.
Installing
Gas
Supply
2
2-3.
Gun
Polarity
For
Wire
Type
2
Installing
Welding
Gun
3
Connecting
Input
Power
3
Threading
And
Feeding Welding
Wire
4
SECTION
4-
MAINTENANCE
&
TROUBLESHOOTING
4-1.
Thermal Overload Protection
6
4-2.
Overload
Protection
6
4-3.
Drive
Assembly
Maintenance
7
4-4.
Gun Maintenance
4-5.
Troubleshooting
SECTION
5
ELECTRICAL DIAGRAMS
9
SECTION
6
PARTS LIST
Figure
6-i.
Main
Assembly
11
5
Figure
6-2.
GA-i
6C Gun
7.
8.
9.
10.
2-4.
2-5.
2-6.
8
8
SECTION 3OPERATION
12

SECTION
1

SPECIFICATIONS
Table
1-1.
Welding
Power Source
Specification
Description
Type
Of
Output
Direct
Current/Constant
Voltage
(DCICV)
Rated
Weld
Output
120
Amperes,
21
Volts
DC,
30%
Duty
Cycle
Type
Of
Input
Power
Single-Phase;
60
Hz;
At 230
Volts AC
Input Amperes
At
Rated
Output
20A
KVAIKW Used
At Rated
Output
4.7
kVN3.9
kW
Max.
Open-Circuit
Voltage
32 Volts
DC
Control Circuit
Voltage
At
Gun
24
Volts
DC
Welding
Processes
Gas
Metal
Arc
(GMAW)
And
Flux
Cored
Arc
Welding
(FCAW)
Speed
Range
47
To
690
pm
(1.2
To
17.5
mpm)
Wire
Diameter
Range
.023
To
.035
in.
(0.58
To 0.89
mm)
Overall Dimensions
Length:
27
in.
(686
mm);
Width:
12 in.
(305
mm);
Height:
22-1/2
in.
(571
mm)
Weight
Net:
117
lbs.
(53
kg);
Ship;
120
lbs.
(54
kg)
Welding
Gun
Rated
Output
(Air
Cooled)
160
Amperes
At
60%
Duty
Cycle
Using
CO2
Shielding
Gas
Cable
Length
10
ft.
(3
rn)
1-1.
Volt-Ampere
Curve
And
Duty
Cycle
Chart
U
SING 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.
~am8
I
10/91
~
The
volt-ampere
curves
show
the
:
30
20
I
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
period
without
causing
overheating
or
damage.
This
unit
is
rated
at
30%
duty
cycle
~..
~
~
~2L
s.....
allowing
welding
3
minutes
out of
every
10 minutes.
0
00
00
00
200
200
This
gun
is
rated
at
60%
duty cycle
D.C. AIERES
when
using
CO2
shielding
gas
and
-
 
 

 
.
30%
when
using
mixed
shielding
gas.
50
~
  
-
-
..
w
100
S
00
10
60
50












Sc

-
 
-
.,
- -

.
  


  
  



 -
-
-



 
-
-
.5
50
35
30
40
50 60 10
00 00 00
~JT~
C~V..5
S
sObl.1
10/91

58-124 625/
Sbl.3
10/91

SB-124
624
a
CAUTION
Figure
1-1.
Volt-Ampere
Curve
And
Duty
Cycle
Chart
OM-154
500
Page
1

SECTION
2INSTALLATION
1
--
1
Insulator
2
Bolt
3
Smaller
Hole
2
4
Work
Clamp
Tabs
2-1.
Installing
Work
Clamp
Tools
Needed:
Be
nd
tabs
around work cable.
~i
7/16
in.
3/8
In.,
5
6
Work
Cable
From
Unit
Nut
Ref
ST.025
I9O~C
Figure
2-1.
Installing
Work
Clamp
2-2.
Installing
Gas
Supply
a
WARNiNG
Obtain
gas
running
gea
cylinder
and chain
to
r,
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
4
Cylinder
(CO2
shown)
CO2
0-Ring
Tools
~_
1-1/8
in.,
5/8
in.
a
WARNING
C

YLINDERS
can
explode
if
damaged.

Keep
cylinders
away
from
welding
and
other
~
BUILDUP
OF
SHIELDING GAS
can
harm
health
or
kill.
electrical
circuits.

Shut
off
shielding
gas
supply
when
not
in
use.
Never touch
cylinder
with
welding
electrode.
Always
secure
cylinder
to
running
gear,
wall,
or
other
stationary
support. warn4.I
9/91
5
Regulator
Install
onto
gas
cylinder
so
that
face
is vertical.
6
Flowmeter
Flow
rate
is
set to
20
cfh
(cubic
feet
2per
hour).
7
Gas
Hose
Connection
Install
gas
hose
between
flowmeter
and
welding
power
source.
ssb3P 2/92

ST-154
583
/
ST.l
54
623
Figure
2 -2.
TypIcal
CO2
Regulator/Flowmeter
Installation
2-3.
Gun
Polarity
For Wire
Type
ELECTRiC
SHOCK
can
kill.

Do
not
touch
live
electrical
parts.

Turn
OFF
welding power
source,
and disconnect
inputpower
before
inspecting
or
installing.
swaml.1
9/SI
There
are
two
Jumper
links
(1
set)
across
each
set
of
terminals. Be
sure
to
move
each
set
of
links
when
changing
polarity.
Tools Needed:
3 Pilot
Light
(See
Section
4.1)
3/8
in.
Close
door.
Ref. sT.149631.c
I
Polarity
Changeover
Label
2
Polarity
Jumper
Links
Always
read
and follow
wire
man
ufacturers
recommended
polarity.
Figure
2-3.
Gun
Polarity
Connections
OM-154
500
Page
2

2-4.
lnstallin.g
Welding
Gun
2-5.
Connecting
Input
Power
a
WARNING
-
ELECTRIC SHOCK
can
kill.
I
S
Do
not
touch
live electrical
parts.

Turn
OFF
welding
power
source,
and
disconnect
input
power
before
inspecting
or
installing.

Have
Only
qualified
electrician
install
unit.

Installation
must
meet
National Electrical
Code and
all
other
codes.
swam3.1~
~0/~1
Have
Only
qualified
persons
make
this installation.
1
18
in.
(457 mm)
Open
Space
At Front
And
Rear
For
Good
Airflow
2
Rating
Label
Supply
correct
input
power.
3
230
Volts
AC
Wall
Receptacle
4
Input
Conductors
5
Grounding
Conductor
Select
size and
length
using
Table
2-1.
Conductor
insulation
must
comply
with
national, state,
and
local
codes.
Install
and
connect
input
conduc
tors
and
grounding
conductor
in
conduit
or
equivalent
between
wall
receptacle
and
deenergized
line
disconnect
switch. Be
sure
ground
ing
conductor
goes
to
an
earth
ground.
6 Line
Disconnect Switch
Of
Proper
Rating
Obtain
and install
switch
and
wall
receptacle.
7
Line
Fuses
Select
fuses
or
circuit breakers
using
Table
2-1.
Install
into
deenergized
line
disconnect
switch.
8
Input
Power
Plug
Turn
OFF
unit
POWER
switch,
and
connect
plug
to
wall
receptacle.
____________
ub~~_3/92A
-
ST.149
630
1
Gun
Securing
Knob
2
Drive
Assembly
3 Gun
End
Loosen
securing
knob.
Insert end
through
front
panel
opening
until
it
bottoms
against
drive
assembly.
Tighten
knob.
4
Gun
Trigger
Plug
Insert
into
receptacle
and
tighten
threaded
collar.
Close
door.
Ref. ST.t46 629~B
Figure
2-4.
Gun
Connections
5-
7
Figure
2-5. Location
And
Input
Power Connections
OM-154
500
PageS

Table
2-1.
Electrical
Service
Requirements*
Input
Amperes
At
Rated
Output
Circuit Breaker
Size
Range
In
Amperes
Fuse
Size
In
Amperes2
- 
Input
Conductor
Size
In
AWG/KcmiI3
Maximum
input
Conductor
Length
In
Feet
(Meters)4
Grounding
Conductor
Size.
In
AWG/KcmiI5
20
31
thru
41
30
14
These
values
are
calculated
from
the
1990 edition
01
the
National
Electrical
Code
(NEC).
Circuit breaker
range
is
t
50%
to
not
more
thuan
200%
ot
rated
input
amperage
of
the
welding
pow
er
source
(Article 630.t2(a)
of
NEC).
Standard fuse
size
is
that
closest
to
I
50%
of
rated
input
amperage
of
the
welding
power
source
(A
rticle
630-126
of
NEC).

Input
conductor size
us
for insulated
CoPoer
wire
with
75C
ratuflq
with
not
more
than
three
single
cu
rrent.carrying
conductors
in
a
cable or
raceway
(Article
630-16
of
NEC1.

Maximum
length
is
to
prevent
more
than
a
3%
voltage
drop
between
service
entrance
and
input
Icr
murals
of
the
welding
power
source
(Articles
210.19(a)
and
215-2(b)
01
NEC).
The
grounding
conductor
shall be
colored
or
identified
as
specified
in
the
NEC.
Grounding
con.
ductor
size for
copper
wire is
not
required
to
be
larger
than
input
conductor
(Article
250-95 of
NEC)
S -0092-C
Input
Voltage
230
65
(20)
14
2.6.
Threading
And
Feeding
Welding
Wire
4~
WARNING
C
YLINDERS
can
explode
if
damaged.

Keep
cylinders
away
from
welding
and
other
electrical
cirCuitS.
S
Never
touch
cylinder
with
welding
electrode.
S
Always
secure
cylinder
to
running
gear,
wall,
other
stationary
support.
or
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.
5
3
S
9
LI
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.
swern5.t
10/91
/
awarn2.1 9/91
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.
(150mm)
of
wire
from
spool.
3Pressure
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
outlet
guide.
Close
pressure
as~
sembly.
6
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
Tools
Needed:
~
9/16
in.
Turn
ON
unit and
check drive roll
pressure
by
feeding
wire
against
a
wood
board
or
concrete
surface;
wire
should
feed
steadily
without
Tighten
pressure
adjustment
if
nec~
essary.
Close
door.
Ref.
ST.
149
632.C
/
S-0627-A
Figure
2-6.
FeedIng
Welding
Wire
OM154
500
Page
4

SECTION
3
OPERATION
MOVING
PARTS
can
cause
injury.
=~~
READ
SAF
of manual
ETY
BLOCKS
at
beginning
before
proceeding.
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
2
/
~
3
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.t
0/SI
FIgure
3
-1.
Safety
Equipment
1
Wire
Speed
Adjustment
Con
trol
Use
control
to
select
a
wire feed
speed.
As
VOLTAGE ADJUST
MENT
switch
setting
increases,
wire
speed
range
also
increases.
The
numbers
around
the
control
are
not
a
wire
feed
speed
(see
rear
cover).
2
Voltage Adjustment
Switch
Use
switch
to
select
an
arc
voltage.
The
higher
the
selected
number,
the thicker
the material that
can
be
welded
(see
rear
cover).
3
Power
Switch
Use switch
to turn
unit
ON
and
OFF.
4
Work
Clamp
Use wire
brush
or
sandpaper
to
clean
metal
at
weld
joint
area.
Connect
work
clamp
to
clean,
paint-free
location
on
workpiece,
as
close
as
possible
to
weld
area.
Ref. ST.150
192A
fRet ST.153
448
Figure
3-2.
Controls
Tools
Needed:
OM.154 500
Page
5

SECTION
4-
MAINTENANCE
&
TROUBLESHOOTING
a
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.
MOVING
PARTS
can
cause
Injury.

Keep
away
from
moving
parts.

Keep
away
from
pinch
pOints
such
as
drive rolls.
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.
Thermal Overload
Protection
If
rectifier
SR2
overheats,
thermostat
TP1
opens
stopping
all
weld
output.
If
this
condition
occurs,
the
pilot
light
next
to
the
gun
polarity
jumper
link
terminals
goes
out
and
the
fan
motor
runs.
Allow unit
to
cool
about
15
minutes
before
trying
to
weld.
4-2.
Overload Protection
A.
Short Circuit Shutdown
READ
SAFETY
BLOCKS at
start
of
SectIon
4
before
proceeding.
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.
Maintenance
and
troubleshooting
to
be
performed
only
by
qualified
persons.
swarnA 2 1O/9~
B.
Motor
Fuse
Fl
Figure
4-1.
Fuse
Fl
Location
OM..154
500
Page
6

4.3.
DrIve
Assembly
Maintenance
i~~J
.r#~E~-jlft
READ
SAFETY
BLOCKS
at
start
of
LtT~
~

Section
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
with
cotter
pin.
2
8
Screw
9 Drive
Roll
Remove
drive roll
as
shown.
Use
a
wire
brush
to
clean drive roll.
Push
drive
roll
onto
shaft
and
rein
stall
screw
and
washers.
10 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.
Ref. ST.tSO
193-C
I
ST-155
579
Figure
4-2.
Drive
Assembly
Maintenance
Tools Needed:
_____
_____
-
OM-154
500
Page
7

No
weld
output;
wire
does
not
feed;
fan
~

-.
motor
continues
to
run
and
pilot
light
is
oft.
Section

2-5
4-2
-
-
2~4
4
4-4. Gun
Maintenance

READ
SAFETY
BLOCKS
at
start
of
Section
4
before
proceeding.
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.
cwan,toI
09
Turn
OFF
and
unplug
unit.
Tools Needed:
1
Wire
Spool
~
Cutwelding
wire off
atcontacttube.
3/8
in.
Retract
wire
onto
spool
and
se
cure.
2
Gun
Securing
Knob
Loosen
knob
and
remove
gun
and
trigger
plug.
3 Nozzle
3
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
new
liner
into
gun
casing
until
even
with
end of
head tube.
6
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 oft. 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.
Ref.
ST-149
529-C
/
Ref.
ST-155
509
Figure
4-3.
Gun
Maintenance
4-5.
Troubleshooting
j
READ
SAFETY
BLOCKS at start
of
-.
SectIon
4
before
proceeding.
Welding
loubie
No
weld
output;
wire
does
not
feed.
1---~
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
plug
In receptacle
or
repair
leads,
or
replace
trigger
switch.
TherrnostatTPl
open (overheating).
Allow
fan
to
run;
the
thermo
stat closes when the unit
has cooled.
No weld
output;
wire
feeds.
Low
weld
output
-
Connect
work
clamp
to
get
good
metal
to
metal contact
Replace
contact
tube.
---1__4-1
Figure
3-2
~
4-4

-s(
Connect
unit
to
proper
input
voltage
or
check
for
low line
voltage.
~

-.~
2-5
OM-154
500
Page
8

230
VQ.TS
SECTION
5
ELECTRICAL DIAGRAMS
Figure
5-1. CIrcuit
Diagram
For
Welding
Power
Source
SB.153
629
Straighten
gun
cable
and/or
replace
damaged
parts.
Adjust
drive
roll
pressure.
Readjust
hub
tension.
Wire
Drive/Gun
Trouble
Remedy
Section
Electrode
wire
feeding
stops
during
i.

-~

44
welding.
I
_____________________________________________________ ___________
2-6
2-6
-~
4.4
-.~
4-3.4-4
.~
4-3
-~
2-4
-~
4-2
-~
4-3,4-4
--a
--
Replace
contact
tube
if
blocked.
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
plug
in
receptacle
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.
IONTICAL C~ECT~D ~.Th~(S
200 4~TS
220 V~.TS
T~O4
OM-154
500
Page
9

I
IIA(P102-e)
~I
~
jJ
2

fl
6C
S8(PLG2-52)
6
BI
-\
SA(RC3
I)
r
jT
~I
lU4~)-6I
eAI~
2)
54A(OPI~
~
,flM.02-6)
~
aBIPLG2-)4)
Ilb(PLG2-2)
cJ~
l5A(~I-2)

DRIVE
MOTOR
ZI
194(PLG2-3)
~
15R2-
13A(PLG2-4)
(B
B
TI
______
________
1~T~
SR2
~
I
12i
0

1-2]
TI-~C

~
~
3IB(CS-~G5
23(S~)
jolAc
~
(e@~J
3IC(TEI-I~G)
24(S)
______________
25(SI)
26(SI
____________________
______________________________
6A(IRI_-B)
26A(~2
UPIT
_____________________
___________________________
J1(FN
24V)
~IZIE(~2
BOTIIWS)
es_AcK(~2
8OTT)~4)
ICR
(cR1-SI
-~
 134(I)-BEG)
12A)Rl-CWI
-~
l1#(CR)-3)

-~
158)cR)-2)
I
IC
(
1~
66(CRI-6)
To
74)C52
RIIRIT)
306(TEI-Pos
2
SR)CR2
COIL
Tj
3IC(T~I-~
~
~(CRi-A
P162
2
1
(
COIL
28A(TI)
L
~(S2
WIPER)
I6)I1t(PfI~R
~O)
278(GSI
COIL)
27A(SI
C1141114j
:~
R
D
CR2
3A(S2
WIPER)
&ACE(POWER
cCRO
2
5 6
B
~
P
C.

~
27A(CR2
T~
22
I
~
S2
______
____is
LI
~1
~I
RC3
0
(It 0
32(~I
WORK)
I
~,
0
-u
0
(0
0
TE
i
32
____________
304
(FE)
-PUS)
SC(CR2
COIL)
F24V.
I)
278)CR2
IcR)
RIQIT
CR2
lIP
LEFT
~I~IIJ
29B(C2-POS)
+
R3
P4
Ci
(POE)
]1~1~~~
(POE
~c2-~6)
CI
(S~G
I
CI
lEG)
___________
GND
POWER
CORD
(PLGI)
SC-153
644
Figure
42.
Wiring
Diagram
For
Welding
Power
Source

0
UI
0 0
-U
I0
0
ST-155
497
(1)
m
C) 0
z
0)
-I
U)
r
Cl)
-I
2
3
I
4
11
Fig
6-2
~46
60
59
53
Figure
6-1.
Main
Assembly

Parts
For
Main
Assembly
NOTE:
All
items
indented
by
a
dot(s)
are
included
with the item
listed
directly
above.
1
089
899
Latch
2
134
464
Warning
Label
3
+151 565
Wrapper
126
838
Drive
Assembly
4 090
416
Hinge
Pin
5
124817
DriveHousing
6 151
828
Cotter
Hair
Pin
7
112031
PressureLever
8
090
443
Bearing
111
622
Spacer
9
090415
Spring
10
092237
Knob
11 085244
CuppedWasher
12
085242
Fastener
13
010
224
Spring
Pin
14
058 549
Wire
Guide
15
126652
Knob
16 149332
Hose
Clamp
17
134834 Hose
18
154828
Drive
Roll
19
126653
NyiWasher
20
111
912 Insulator
21
147573
Bracket
22
126
651
Nyl
Shldr
Washer
23
048 573
Light
24
058428
Hub
25
057
745
Spring
26
058628
Brake Washer
27
010191
FiberWasher
28
057
971
Keyed
Washer
29
057 543
Spring
30
605941 Washer
31
058
427
Retaining Ring
32
085980
Nut
33
134
201
Stand-Oft
Support
Bushing
Baffle
Contactor
Circuit Card
Fuse,
slo-blo
12A
Housing,
14
pin
Terminal
Relay
Varistor
Rectifier
Thermostat,
NC
Insulation
Terminal
Assembly
Link
Drive Motor
Insulator
Resistor
Assembly
Resistor
Capacitor
Clamp
Fan Blade
Fan Motor
Bracket
Stabilizer
Rear Panel
w/Cmpts

Gas
Valve
Nyl
Nut,
gas
valve
Cord
Set

Bushing,
cord
set
Rear
Panel
Bezel
Speed
Nut

Handle
Cap,
Handle
Base
I
Item Part
J
No.
No.
DescriptIon
54
087341
Foot
55
147
313 Transformer
146943
Coil
56
147
576
Lower
Panel
57
Front Panel
w/Cmpts
072 623
Potentiometer
097
922
Knob
048 482
Receptacle
wlSockets
079
534
Terminal
111
897
Rotary
Switch,
4posn
127023
. .
Knob
116 830 Rocker
Switch,
DPST
147
442
Front
Panel
146619 Bezel
147548
SpeedNut
154005
Handle
154
596
Cap.
Handle
153 448
Nameplate
004 214
Bushing,
2.000mtg
lii
644
Bushing,
.875mtg
58
600 325
Cable
59
026 843 Insulator
60
010368
Clamp
61
110 720
GA-16C
Gun,
(Fig
6-2)
153
714
Regulator/Flowmeter
154829
Hose
Kit
112
863
Adapter
Fitting
113129
PVCTubing
089
120
Hose
Clamp,
.375450
+When
ordering
a
component
originally
dis
playing
a
precautionary
label,
the
label
should
also
be ordered.
*Recommended
Spare
Parts.
Be
sure
to
provide
Model
and
Serial Number
when
ordering
replacement
parts.
Item Part
No.
No.
DescrIPtIon
1
110793 Handle
Assembly
110795 Head
Tube
2
110780
Nut
3
110779 Jacket
4
110781
Stop
5 128878
Adapter
6 154819
Spring
7
154826 Contact
Tube,
.023
7
154
825
Contact
Tube,
.030
7
154824
Contact
Tube,
.035
8 154822
Nozzle,
1/2
on
8
154821
Nozzle,3/8orf
8 154820
9
110794
10 080565
11
110792
12
110797
13
154823
14
120715
15
079974
16
110796
17
079878
079535
18
048834
OPTIONAL
item
Part
Item
Part
No.
No.
Description
No.
No.
Description
34
057358
35
147569
36
108358
37
137800
38
125
847
113 149
079
747
39
072817
40
087156
41
155056
155
054
026
701
42
152214
038618
43
090087
44
112583
45
123770
117
116
46
123768
47
108105
48
005656
49 117014
50
147572
51 147315
52
128
751
605 227
152 118
111
443
147
443
146 619
147548
154005
154
596
53
147578
8
7
2
2
17
Nozzle,
flat
spot
Trigger
Switch
Assembly
Terminal
Cable
Sleeve
Liner,
.030.035
Collet,
.035
0-Ring.
.500
Connector
Housing
Plug
& Pins
Terminal
Clamp
ST-lb
832-0
Figure
6-2.
GA-16C
Gun
(Fig
6-1
Item
61)
OM-154
500
Page
12

Suggested
Welding
Settings
Wire
Type,
Shielding
Gas,
And
Flow
Rate
Wire
Diameter
(inch)
Operator
Control
Settings
Material
Thickness
1/4 in.
(6.4 mm)
3/16
in.
(4.8
mm)
1/8
in.
(3.2
mm)
14
ga.
16
ga.
18
ga.
22
ga.
24
ga.
E7OS-6
CO2
20
c~h+
023
Voltage
4
3
2
2
1 1
1
Wire
Speed

100
80
70
60
55
45 35
.030
Voltage
4
4
32
2
1
1

Wire
Speed
80
75
60 60
50
40
30

.035
Voltage
4
3
~________
2
1
1
1

Wire
Speed
65
60
50 40 30
20 15
.
E7OS-6
75%
ArOon
25%
C02
20
cfh+
.023
Voltage
4
3
2 2
1
1
1
Wire
Speed

100
90 80
70
60
50
40
.030
Voltage
4
3
3
2 2
1
1

Wire
Speed
90
80
70
60
50
45
30
.035
Voltage
4
3
3 3 2
2
1

Wire
Speed
75
70 60 50 40 33
25

E71T-GS
Flux
Core
.030
Voltage
33
2
1
1 1


Wire
Speed
40 65
45
40 30 20
 
.035
Voltage
33
2
1 1 1
 
Wire
Speed
60 50 40 30
20
10


ER
308
Stainless
Steel
Tn-Mix
20
cfh+
.023
Voltage
4
4
3 3
3 2
1

Wire
Speed
100
100
90
85 75
70 60

.030
Voltage
4
4
3
3
2
2


Wire
Speed
75 75
65 60
55 50
.035
Voltage
4 4
3
Wire
Speed
60 60
50
  


Aluminum
Argon
3Ocfh+
.030
Voltage
4
3 3
2
1
1


Wire
Speed
90
85
80
90
90
85


.035
Voltage
4 4
3 2 2
1


Wire
Speed
85
85 85 90 90 80


*
Do
not
change
VOLTAGE
ADJUSTMENT
switch
position
while
welding.
WIRE
SPEED ADJUSTMENT
value
in
table
is
a
starting
value
only,
and
WIRE
SPEED ADJUSTMENT
control
setting
can
be
fine
tuned
during welding.
+cfh = cubic
ft
per
hour
OM-154
500
Page
13