Miller Electric AUTO ARC MWG 160B User manual

February
1989
OWN
ERS
MANUAL
AUTOi~J
MILLER
ELECTRIC
MFG.
Co.
718 S.
BOUNDS
ST.
P.O.
Box
1079
APPLETON,
WI
54912 USA
ADDITIONAL COPY PRICE
35
CENTS
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
equip
ment.
This
unit
and
these
instructions
are
for
use
only
by
persons
trained and
experienced
in
the
safe
operation
of
welding equipment.
Do
not
allow
un
trained
persons
to
install,
operate,
or
maintain this
unit.
Contact
your
distributor
if
you
do
not
fully
understand these instructions.
FORM:
112934
Effective
With
Style
No.
JG-20
MODEL
AUTO ARC
MWG
160
MWG
160B
NWSA CODE
NO.
4579
PRINTED
IN
U.S.A.

ONEYEARLIMITEDWARRANTY
COVERAGE
-
Miller Electric
Mfg.
Co.
warrants
to
the
buyer
REMEDY
FOR
DEFECTIVE
WELDER
-
Upon receipt
of
any
who
purchases
this Auto Arc
Welder
(Welder)
for
personal,
defective
Welder.
Miller
Electric
will,
at
its
option, repair
or
(4
family
or
household
purposes
(Consumer)
that
this Welder
replace
the
defective Welder
at
its
expense,
refund
or
credit
~?
will
be
free
from defects
in
material
and
workmanship
for
a
the
purchase price
(less
reasonable
depreciation
based
on ac-
(
period
of
one
year
from the
date
of
purchase.
This
warranty
tual
use), or
reimburse
the
Consumer for
the
cost
of
repair
or
covers
only
the
original
purchaser
of
this
Welder.
Miller Electric
replacement
at
an
approved
Miller Electric
warranty
station,
does
not
authorize
any
party, including
its
authorized
provided
that the
purchaser
of
that Welder has followed
the
distributors,
to
offer
any
other
warranty
on
behalf
of
Miller
procedure
for
obtaining
warranty
performance
set
forth
below.
Electric.
Upon
expiration
of the
warranty
period,
Miller Electric
The Welder
so
repaired
or
used
as
a
replacement
will be
ship
~
shall have
no
further
liability
related
to
the
Welder,
except
on
ped
to
the
purchaser
of
the
defective
Welder,
with
transporta
(
warranty
claims
made
during
the
warranty
period.
tion
charges
prepaid
to
any
destination
in
the
continental
United
States
(transportation charges
on
shipments
to
Alaska
c~
THIS WARRANTY IS
OFFERED IN LIEU
OF
ANY
OTHER
or
Hawaii
will
be
paid
only
to
the
nearest
port
of
export).
~
EXPRESS
WARRANTY;
AND,
EXCEPT
TO
THE EXTENT
(4
PROHIBITED
BY
APPLICABLE
LAW,
THE
DURATION
OF
ALL
IMPLIED
WARRANTIES,
INCLUDING BUT NOT
THE
PURCHASERS
REMEDIES
FOR
A
DEFECTIVE
LIMITED
TO THE
IMPLIED
WARRANTIES OF
MERCHAN-
WELDER,
TO
THE
EXTENT PERMITTED BY
APPLICABLE
TABILITY AND FITNESS FOR
A
PARTICULAR
PURPOSE,
IS
LAW,
ARE
LIMITED
TO
THE
REMEDY PROVIDED BY
THIS
WARRANTY:
AND,
TO THE
EXTENT
ENFORCEABLE
LIMITED TO
THE
DURATION OF THIS
WARRANTY.
UNDER APPLICABLE
LAW,
MILLER ELECTRIC
SHALL IN
4
Some
states
do
not
allow limitations
on
how
long
an
implied
NO
EVENT BE LIABLE
FOR
CONSEQUENTIAL,
INCIDENTAL
~
warranty
lasts,
so
the
above limitation
may
not
apply
to
you.
OR
SPECIAL
DAMAGES ARISING OUT
OF
THE USE
OF,
OR
(4
This
warranty
gives
you
specific
legal rights,
and
you may
also
INABILITY
TO
USE,
THE
WELDER,
WHETHER
BASED ON
have
other
rights
which
vary
from
state to
state.
BREACH
OF THIS
WARRANTY,
MILLER
ELECTRICS
NEGLIGENCE
OR
OTHER
TORT,
OR
ON
ANY
THEORY OF
STRICT LIABILITY.
Except
as
specified
below,
Millers
warranty
does
not
apply
to
components having
normal
useful
life
of
less
than
one
(1)
year,
such
as
spot
welder
tips,
relay
and
contactor
points,
Some
states
do
not
allow the exclusion
or
limitation
of
con
~
parts
that
come
in
contact
with
the
welding
wire
including
sequential
or
incidental
damages,
so
the
above
limitations
may
~
nozzles and nozzle insulators
where
failure does
not
result
from
not
apply
to
you.
defect
in
workmanship
or
material.
Miller
shall
be
required
to
honor
warranty
claims
on
war-
PROCEDURE
FOR
OBTAINING
WARRANTY
PERFORMANCE
~
ranted
Equipment
in
the
event of
failure
resulting
from
a
defect
As
soon as
any
defect
in
a
Welder becomes
known,
the
pur
within
the
following
periods
from the
date
of
delivery
of
Equip-
chaser of
the Welder
must,
within
thirty
(30)
days,
notify
an
ment
to the
original
user:
approved
Warranty
Station
or
Miller Electric
in
writing
of the
~
1.
Arc
welders,
power
sources,
and
components
1
year
period.
return
the Welder
to
Miller
Electric at the
following
ad-
defect. The
purchaser
must
then,
within
the
one
year
warranty
2
Original
main
power
rectifiers 3
years
dress:
(labor
-
1
year
only)
3. All
welding
guns,
feeder/gunsand plasma
torches...
BOdeyS
Miller
Electric
Mfg.
Co.
4.
Replacement
or
repair
parts,
exclusive of
labor
..
60
days
718
South
Bounds
Street
WHAT
IS NOT
COVERED
-
This
warranty
does
not
extend
Box 1079
Appleton,
Wisconsin
54912
to
any
Welder
subjected
to
misuse,
neglect,
accident,
or
in-
warranty
repair
by
anyone
except
Miller
Electric.
Further,
this
All
transportation
charges
to
Warranty
Station
or
Miller
Electric
~Q
warranty
only
extends to those
purchasing
the
Welder for
per-
must
be
prepaid.
sonal,
family
or
household
purposes.
Commercial
and
in
dustrial
users are
given
a
different
warranty.

TABLE
OF
CONTENTS
Section
No.
Page
No.
SECTION
1

INTRODUCTION
1-1.
General
Information And
Safety
1
1-2.
Receiving-Handling
1
1-3.
Description
1
1-4.
Duty
Cycle
1
SECTION
2
INSTALLATION
2-1.
Gun/Feeder
Connector Installation
2
2-2.
Gun
Trigger
Connections
2
2-3.
Changing
Wire
Size 2
SECTION
3
SEQUENCE
OF
OPERATION
3-1.
Gas
Metal Arc
Welding
(GMAW)
3
3-2.
Flux
Cored
Arc
Welding
(FCAW)
3
3-3.
Shutting
Down
4
SECTION
4
MAINTENANCE
4-1.
Inspection
And
Upkeep
4
4-2.
Contact
Tube
Replacement
5
4-3.
Liner
Replacement
5

SECTION 1
-
INTRODUCTION
Ampere Rating
60/~
Duty
Cycle
Wire
Diameter
Cable
Length
Cooling
Method
Weight
Net
I
Ship
I
2.8
lbs.
(1.3
kg)
5.4 lbs.
(2.4
kg)
160
Amperes
With
CO2
0.023
in.
(.6
mm)
0.030
in.
~.8
mm)
10
ft.
(3.05
m)
Air
Figure
1-1.
Specifications
1-1.
GENERAL
INFORMATION
AND SAFETY
A.
General
Information
presented
in this
manual and
on
various
la
bels,
tags,
and
plates
on
the unit
pertains
to
equipment
design,
installation,
operation,
maintenance,
and
troubleshooting
which should be
read, understood,
and
followed
forthe
safe
and effective
use
of this
equipment.
B.
Safety
The
installation,
operation,
maintenance,
and
troubleshooting
of
arc
welding equipment requires
prac
tices and
procedures
which
ensure
personal safety
and
the
safety
of
others.
Therefore,
this
equipment
is
to
be
installed,
operated,
and maintained
only by qualified
persons
in
accordance
with
this
manual and
all
applica
ble
codes such
as,
but
not limited
to,
those
listed at the
end of
Section
1
-
Safety
Rules For
Operation
Of
Arc
Welding
Power
Source.
Safety
instructions
specifically
pertaining
to
this unit
ap
pear
throughout
this manual
highlighted by
the
signal
words
WARNING
and
CAUTION
which
identify
differ
ent
levels
of
hazard.
WARNING statements
include
installation,
operation,
and
maintenance
procedures
or
practices
which
if
not
carefully
followed
could
result
in
serious
personal
injury
or
loss of life.
CAUTION
statements
include
installation,
operation,
and maintenance
procedures
or
practices
which
if
not
carefully
followed
could result
in minor
personal
injury
or
damage
to
this
equipment.
A third
signal
word, IMPORTANT
highlights
instruc
tions
which
need
special emphasis
to
obtain the
most
ef
ficient
operation
of this
equipment.
1-2.
RECEIVING-HANDLING
Before
installing
this
equipment,
clean all
packing
mate
rial from
around
the
unit and
carefully
inspect
for
any
damage
that
may
have
occurred
during shipment.
Any
claims
for
loss
or
damage
that
may
have
occurred
in
transit must
be
filed
by
the
purchaser
with
the
carrier.
A
copy
of
the bill of
lading
will
be furnished
by
the
manu
facturer
on
request
if
occasion
to
file
claim
arises.
When
requesting
information
concerning
this
equip
ment,
it is essential
that
Model
Description
and
Style
Number
of the
equipment
be
supplied.
1-3.
DESCRIPTION
This
unit
is
an
air-cooled
semiautomatic
Gas
Metal
Arc
Welding
(OMAW)
or
Flux
Cored
Arc
Welding (FCAW)
gun.
The
MWG
160 gun
is
shipped ready
to
feed 0.023
in.
(0.6
mm)
welding
wire.
The MWG
160B
gun
is
shipped
ready
to
feed 0.030
in
(0.8 mm)
welding
wire.
To
change
wire
size,
see
Section
2-3.
1-4. DUTY
CYCLE
The
duty
cycle
of
a
welding
gun
is the
percentage
of
a
ten
minute
period
that
a
gun
can
be
operated
at
a
given
load.
This
gun
is
rated
at
60%
duty
cycle
using
CO2
shielding
gas.
This
means
that the
gun
can
be
oper
ated
six
minutes
out
of
every
ten
with
the
CO2
gas
shielding.
The
remaining
four
minutes the
gun
should
be
idle
to
permit
proper
cooling.
4A
CAUTION: EXCEEDING
THE
RATED
AM
PERAGE WITH
CO2
OR FAILING
TO
RE
DUCE THE
WELDING
AMPERAGE OR
DUTY
CYCLE
WHEN
USING
A MIXED
SHIELDING
GAS
can
result
In
damage
to
the
gun.

Do
not
exceed rated
amperage
when
using
C02.

Operate
at
30%
duty cycle
when
using
mixed
shielding
gases.
112934 Paael

SECTION
2

INSTALLATION
2-1.
GUN/FEEDER
CONNECTOR INSTALLATION
(Figure
4-1)
a
WARNING:
ELECTRIC
SHOCK
can
kill.

Do
not
touch live electrical
parts.

Shut
down
welding
po
wersource
and
discon
nect
input
power
employing
lockout/tagging
procedures
before
installing,
inspecting,
or
servicing
gun.
Lockout/tagging procedures
consist of
remov
ing
input
power
plug
from
receptacle,
padlocking
line
disconnect
switch
in
open
posi
tion,
removing
fuses
from fuse
box,
or
shutting
off
and
red-tagging
circuit breaker
or
other dis
connecting
device.
1.
Loosen
gun/feeder
connector
securing
knob
on
wire drive
assembly.
2.
Insert
gun
into
wire drive
assembly
until
gun/feeder
connector
hex
stop
is flush
against
wire drive
as
sembly.
IMPORTANT:
The
gun
liner
should
be
as
close
as
pos
sible
to
the
drive rolls
without
touching
them.
3.
Tighten
gun/feeder
connector
securing
knob.
2-2.
GUN TRIGGER
CONNECTIONS
(Figure
4-1)
A.
MWG
160
Gun
Align
the
keyway
on
the
gun
switch
connector
with
the
keyway
on
the
Trigger
Control
receptacle.
Insert
the
connector
and
rotate
the threaded collar clockwise.
B.
MWG16OBGun
1.
Locate the
two leads
hanging
free
from
gun
cable.
2.
Route
leads
through
small
access
hole
on
front
panel.
3.
Securely
connect
leads
to
matching
leads behind
panel.
4.
Close
and
secure
side
access
door.
2-3.
CHANGING
WIRE
SIZE
The
MWG
160
gun
is
shipped
ready
to
feed
0.023
in.
(0.6
mm) welding
wire.
The
MWG
1
60B
gun
is
shipped
redytofeed
0.030
in.
(0.8 mm)
welding
wire.
The
MWG
160
gun
can
be
converted
to
feed
0.035
in.
(0.9
mm)
wire.
Only
the
contact
tube needs
to
be
changed
to
per
mit
either
gun
to
feed
the
larger
wire.
a
WARNING:
ELECTRIC SHOCK
can
kill.

Do
not
touch live electrical
parts.

Shut down
wire
feeder
and
welding
power
source
and disconnect
input
power
employing
lockout/tagging
procedures
before
installing,
inspecting,
or
servicing
gun.
Lockout/tagging
procedures
consist
of
remov
ing
input
power
plug
from
receptacle,
padlocking
line disconnect switch
in
open
posi
tion,
removing
fuses from
fuse
box,
or
shutting
off
and
red-tagging
circuit breaker
or
other
dis
connecting
device.
HOT
SURFACES
can cause severe
burns.

Allow
cooling period
before
servicing.
1.
Remove
nozzle.
2. Cut
off
any
portion
of
the
electrode
wire
which
ex
tends
beyond
end
of
contact
tube.
a
CAUTION: LOOSE
WELDING WIRE
can
cause
Injury.

Keep
a
firm
hold
on
the
wire
during
installa
tion,
removal,
and
threading
operations.
Spooled
wire
has
tendency
to
unravel
rapidly
when
loosened from
the
spool.
3.
Retract
wire
onto
wire
spool.
4.
Remove
contact
tube,
and install
new
contact
tube.
5.
Reinstall
nozzle.
6.
Thread wire
and
resume
operation.
112934
Page
2

SECTION
3-
SEQUENCE
OF
OPERATION
a
WARNING:
ELECTRIC SHOCK
can
kill.

Do
not
touch
live
electrical
parts.
ARC
RAYS,
SPARKS,
AND
HOT
SURFACES
can
burn
eyes
and
skin;
NOISE
can
damage
hearing.

Wear
correct
eye,
ear,
and
body
protection.
FUMES
AND
GASES
can
seriously
harm
your
health.

Ventilate
to
keep
from
breathing
fumes and
gases.

If
ventilation
is
inadequate,
use
approved
breathing
device.
WELDING
WIRE
can cause
puncture
wounds.

Do
not
point
gun
toward
any
part
of the
body
or
other
personnel.
HOT
METAL,
SPATTER,
AND
SLAG
can
cause
fire
and
burns.

Watch forfie.

Have
a
fire
extinguisher
nearby,
and know
how
to
use
it.

Allow work and
equipment
to
cool before han
dling.
MAGNETIC
FIELDS
FROM
HIGH
CURRENTS
can
affect
pacemaker operation.

Wearers
should consult with their doctor
be
fore
going
near arc
welding, gouging,
or
spot
welding
operations.
See Section 1
-
Safety
Rules
For
Operation
Of
Arc
Welding
Power
Source
for
basic
welding
safety
information.
CAUTION: EXCEEDING
THE RATED AM
PERAGE WITH
CO2
OR FAILING TO
RE
DUCE THE WELDING AMPERAGE
OR
DUTY
CYCLE
WHEN
USING
A MIXED
SHIELDING
GAS
can
result
in
damage
to
the
gun.

Do
not exceed
rated
amperage
when
using
CO2.

Operate
at
30%
duty
cycle
when
using
mixed
shielding
gases.
IMPORTANT:
For
welding
wire
threading,
drive roll ad
justment,
welding
power
source,
or
wire
feeder control
in
formation,
see
the
appropriate
Owners Manual.
3-1.
GAS
METAL ARC
WELDING
(GMAW)
IMPORTANT:
Read the
warning
in
formation
at
the
be
ginning
of
Section
3-
SEQUENCE OF
OPERATION
be
fore
operating.
1.
Ensure that
proper
electrical
connections
have
been
made
to
the
welding
power
source
and
wire
feeder.
2.
Ensure
that
proper
shielding
gas
is
connected
to
shielding
gas
valve.
3.
Ensure
that
welding
wire
has
been
properly
threaded and that
correct
initial
tensions have been
set
on
drive rolls.
4.
Turn
on
shielding
gas
supply.
5. Place controls
on
the
welding
power
source
and
wire feeder
in
required position
for
the
welding
setup.
6.
Energize welding
power
source
and wire
feeder.
IMPORTANT:
When
installing
new
equipment,
or
after
prolonged
shutdown,
allow
shielding
gas
to
flow
con
tinuously
for
at
least
one
minute
prior
to
welding
to
purge
the
shielding
gas
line. To
avoid
wasting
wire while
purg
ing,
loosen
pressure
adjustment
knob
on
drive
assem
bly,
and
pivot
free
from
cover.
7.
Press
Purge
button
on
the wire
feeder
(if
applica
ble)
or
open
drive
roll
cover
and
press
gun
switch
to
purge
gas
line.
8.
Close
drive
roll
cover
and
adjust
tension.
9.
Actuate
the
gun
trigger
or
Jog
button
on
the wire
feeder
(if applicable)
to
run
wire
out
beyond
end of
gas
nozzle.
Cut
wire
off
so
it sticks
out
approxi
mately
1/4 to
3/8
in.
(6.4
to
9.5
mm)
from
nozzle.
10. Hold end
of
gas
nozzle
approximatey
1/2
in.
(12.7
mm)
from
workpiece.
11.
Press the
gun
trigger.
Gas
will
start to
flow,
wire will
start
to
feed,
and the
arc
will be
established.
If
wire
slippage
is
noticed,
tighten
drive
roll
pressure
ad
justment
1/4
turn at
a
time
until
slippage
stops.
Do
not
overtighten.
12.
After the
controls
on
the
welding
power
source
and
wire feeder have been
adjusted
for normal
opera
tion,
welding
power
source
and wire
feeder
will
function
automatically
whenever the
gun
trigger
is
pressed.
Releasing
the
trigger
will extinguish
the
arc
and
cause
wire feed
and
gas
flow
to
stop.
3-2.
FLUX
CORED
ARC WELDING
(FCAW)
IMPORTANT:
Read
the
warning
information
at
the
be
ginning
of Section
3-
SEQUENCE
OF
OPERATION
be
fore
operating.
1.
Ensure
that
proper
electrical
connections have
been
made
to
the
welding
power
source
and
wire
feeder.
2.
Ensure
that
welding
wire
has
been
properly
threaded and that
correct initial
tensions have
been
set
on
drive rolls.
a
112934
Pac,A3

3.
Place controls
on
the
welding
power
source
and
wire
feeder
in
required positions
for
the
welding
setup.
4.
Actuate
gun
trigger
or
Jog
button
on
the
wire
feeder
to
run
wire
out
beyond
the
nozzle.
Cut
wire off
so
it
sticks
out
approximately
0.25 in.
(6.4 mm).
5. Hold the
gun
approximately
0.50
in.
(12.8
mm)
from
the
workpiece.
6.
Press the
gun
trigger.
Wire
will
start
to
feed
and
the
arc
will
be established.
If wire
slippage
is
noticed,
tighten
drive roll
pressure
adjustment
1/4 turn
at
a
time until
slippage
stops.
Do
not
overtighten.
7. After the
controls
on
the
welding
power
source
and
wire
feeder
have
been
adjusted
for
normal
opera
tion,
welding
power
source
and
wire
feeder
will
function
automatically
whenever
the
gun
trigger
is
pressed. Releasing
the
trigger
will
extinguish
the
arc
and
stop
the wire from
feeding.
3-3.
SHUTIING
DOWN
1.
Stop
welding.
2.
Turn off
welding
power
source
and wire feeder.
3.
If
used,
turn
off the
shielding
gas
at
the
source.
a
WARNING: HIGH
CONCENTRATION
OF
SHIELDING GAS
can
harm
health
or
kill.

Shut
off
gas
supply
when
not
in
use.
SECTION
4-
MAINTENANCE
4-1.
INSPECTION
AND UPKEEP
Usage
and
shop
conditions
will
determine
frequency
and
type
of maintenance
required.
a
ELECTRIC
SHOCK
can
kIll.

Do
not touch
live
electrical
parts.

Shut
down
welding
powersource
and
discon
nect
input
power
employing lockouttagging
procedures
before
installing,
inspecting,
or
servicing
gun.
Lockoutitagging
procedures
consist of
remov
ing input
power
plug
from
receptacle,
padlocking
line disconnect
switch
in
open
posi
tion,
removing
fuses
from
fuse
box,
or
shutting
off and
red-tagging
circuit
breaker
or
other
dis
connecting
device.
HOT
SURFACES
can
cause severe
burns.

Allow
cooling
period
before
servicing.
6.
Blow
out
gun
casing
or
liner with
compressed
air
whenever
the
wire
or
liner is
removed.
1.
Inspect
gun
for
broken
areas,
cracks,
and
loose
parts;
tighten,
repair,
and
replace
as
required.
2.
Carefully
remove
any
weld
spatter
or
foreign
matter
which
may
accumulate around
the nozzle
opening.
3.
Remove
any
accumulation
around the
switch.
4.
Repair
or
replace
as
required
all
hose
and
cabling;
give
particular
attention
to
frayed
and
cracking
insu
lation and
areas
where hose
and
cabling
enter
equipment.
5.
Remove
grease
and
grime
from
components;
mois
ture
from
electrical
parts
and
cables.
a
CAUTION: FLYING
DIRT
AND METAL PAR
TICLES
can
Injure personnel
and
damage
equipment.

Point
gun
liner
only
in
a
safe direction
away
from
personnel
and
equipment
when
cleaning
with
compressed
air.
Tube
Tube
MWG
160B
Collet
Adapter
Figure
4-1.
Gun
Parts
Replacement
TB-hO 831
Ref. 18-121
447
112934
Page
4

4-2.
CONTACT
TUBE
REPLACEMENT
(Figure 4-1)
a
ELECTRIC
SHOCK
can
kill.

Do
not
touch live
electrical
parts.

Shutdown
welding
powersource
and discon
nect
input
power
employing lockout/tagging
procedures
before
installing,
inspecting,
or
servicing
gun.
Lockout/tagging procedures
consist of
remov
ing
input
power
plug
from
receptacle,
padlocking
line
disconnect switch
in
open
posi
tion,
removing
fuses from fuse
box,
or
shutting
off
and
red-tagging
a
circuit
breaker
or
other
dis
connecting
device.
HOT
SURFACES
can
cause
severe
burns.

Allow
cooling period
before
servicing.
1.
Remove
nozzle.
2.
Cut
off
any
portion
of the
electrode
wire
which
ex
tends
beyond
end of
contact
tube.
3.
Remove
contact
tube,
and
install
new
contact
tube.
4.
Reinstall
nozzle,
and
resume
operation.
a
LINER
REPLACEMENT
(Figure
4-1)
ELECTRIC
SHOCK
can
kill.

Do
not
touch live electrical
parts.

Shut down
welding
powersource
and discon
nect
input
power
employing
lockout/tagging
procedures
before
installing,
inspecting,
or
servicing
gun.
Lockout/tagging
procedures
consist of
remov
ing input
power
plug
from
receptacle,
padlocking
line
disconnect
switch
in
open
posi
tion,
removing
fuses
from fuse
box,
or
shutting
off
and
red-tagging
circuit breaker
or
other
dis
connecting
device.
HOT
SURFACES
can
cause
severe
burns.

Allow
cooling period
before
servicing.
1.
Remove
nozzle.
2.
Cut
off
any
portion
of the
electrode
wire which
ex
tends
beyond
end of
contact
tube.
3.
Remove
contact
tube.
a
CAUTION: LOOSE
WELDING
WIRE
can
cause
injury.

Keep
a
firm
hold
on
the wire
during
installa
tion, removal,
and
threading operations.
Spooled
wire
has
tendency
to
unravel
rapidly
when
loosened
from
the
spool.
4.
Retract
wire
onto
wire
spool.
5.
Disconnect
gun
assembly
from wire drive
assem
bly.
6.
Remove
liner
collet.
7.
Lay
cable
assembly
out
flat and
straight
(no
coils
in
the
cable/conduit).
8. Pull
out
the
liner
from
gun/feeder
connector
end of
gun
assembly.
4A
CAUTION:
FLYING
DIRT AND
METAL
PAR
TICLES
can
Injure
personnel
and
damage
equipment.

Point
gun
liner
only
in
a
safe
direction
away
from
personnel
and
equipment
when
cleaning
with
compressed
air.
9. Blow
out
gun
casing
or
liner
with
compressed
air
whenever
the
wire
or
liner is
removed.
10. Insert
new
liner
into
gun/feeder adapter
end
of
gun
assembly.
Liner
should
be flush
with end of
head
tube.
11.
Install
collet
onto
liner
and
into
gun/feeder
adapter.
Be
sure
liner
is
still
flush
with
end of head
tube.
12.
Reinstall
appropriate
contact
tube
and
nozzle.
13.
Cut
liner
off
at
gun/feeder
adapter
end
so
that
when
installed
in
wire drive
assembly
liner
is
as
close
as
possible
to
the
drive
rolls
without
touching.
14.
Reinstall
gun
to
wire
drive
assembly.
15. Thread
welding
wire
and
resume
operation.
112934
Page
5

Februaryl989
FORM:
112934
Effective
With
Style
No. JG-20
PARTS
LIST

8
1
Figure
A
-
Exploded
View
Of
MWG
160
Gun
TC-11O
832
5
3~
2
r
11
14
2
16
17
112934
Page
1

Description
Quantity
Figure
A
Exploded
View
Of
Gun
1
110793
1
2
110780
2
3
110779
1
4
110781
1
5
110795
1
6
110782
1
7
112743
1
7
112751
1
8
112747
1
8
113018
1
8
113022
1
8
113020
1
9
110794
1
10
079878
1
079535
4
10
047994
2
11
048834
1
12
112745
1
12 121
905
1
13
110784
1
13
120715
1
14
110796
1
15
079974
2
16
110797
1
17
110792
1

Optional Equipment
BE
SURE TO PROVIDE
MODEL
AND
STYLE
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
Item
No.
Part
No.
HANDLE
ASSEMBLY
NUT,MlOxl
JACKET,
head tube
STOP,
nozzle
TUBE,
head
SPRING
,nozzle
TUBE,
contact
.024
wire
(MWG
160)
TUBE,
contact
.030 wire
(MWG
1
60B)
NOZZLE,
slip
type
1/2
orifice
NOZZLE,
slip
type
3/8
orifice
NOZZLE,
spot-flat
NOZZLE,
spot
TRIGGER SWITCH ASSEMBLY
HOUSING PLUG & PINS
(MWG
160)
(consisting
of)
TERMINAL,
male
TERMINAL,
friction-female
(MWG
160B)
CLAMP,
cable
(MWG
160)
LINER,
.024
wire
10
ft.
(MWG
160) (consisting of)
LINER,
.030 wire
10
ft.
(MWG
160B) (consisting
of)
COLLET,
liner .024
wire
(MWG
160)
COLLET,
liner
.030
wire
(MWG
1
60B)
ADAPTER,
gun/feeder
0-RING,
1/2 ID
x
.103
SLEEVE,
rubber
CABLE,
lOft
112
934
Page
2