Miller Electric Mw 4150 Users Manual O113336d_mil

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AUTO ARCJ~

May

1991

FORM:OM-113 336D

Effective With Serial No. KA898403

MODEL: AUTO ARCfi MW 4150

AUTO ARCfi MW 4200
SPW-1

OWNERS

MANUAL

IMPORTANT: Read and understand the entire contents of this manual, with
special emphasis on the safety material throughout the manual, before
installing, operating, or maintaining this equipment. This unit and these
instructions are for use only by persons trained and experienced in 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

MILLER ELECTRIC

Mfg. Co.

AMIerGroupLld..Company
Box 1079

Appleton,

WI

54912 USA

Tel. 414-734-9821

understand these instructions.
SB-087 313D

PRINTED IN U.S.A.

-~

~

ONE YEAR LIMITED WARRANTY
EFFECTIVE: FEBRUARY 17, 1989

This warranty

supersedes all previous AUTO ARC warranties and

MILLER Electric Mfg. Co. warrants to the
COVERAGE
for
buyer who purchases this AUTO ARC Welder (Welder)
that this
personal, family or household purposes (Consumer)
Welderwillbefreefromdefectsinmaterialandworkmanshipfor
a period of one year from the date of purchase. This warranty
covers only the original purchaser of this Welder. MILLER Electric does not authorize any party, including its authorized distributors, to offer any other warranty on behalf of MILLER Electric. Upon expiration of the warranty period, MILLER Electric
shall have

no further liability related to the Welder, except on
warranty claims made during the warranty period. No warranty
is made by MILLER with respect to engines, trade accessories
or other items manufactured by others. Such engines, trade accessories and other items are sold subject to the warranties of
their respective manufacturers, if any. All engines are warranted by their manufacturer for two years from date of original
purchase, except Deutz engines which have a one year, 2000
hour warranty.

MILLER shall be

required

to honor

warranty claims

on war-

ranted Equipment in the event of failure resulting from a defect
within the following periods from the date of delivery of Equipment to the original user:
1

A rc

2

we Id ers,

rnai

power sources,

power

re

an d

comporien

s

1 year

.

I iers

years

Ibr
3.
4.

5.

AU

welding guns, feeder/guns and torches
Replacement or repair parts, exclusive of labor
Batteries

90
.

60

days
days

is exclusive with

for the

no

other guarantees orwarranties expressed

or

implied.

purchase price (less reasonable depreciation based

upon actual use) upon return of the goods at Consumers risk
and expense. MILLERs option of repair or replacement will be
FOB., Factory at Appleton, WI or FOB. at a MILLER authorized service

facility, therefore,

no

compensation

for transporta

tion costs of any kind will be allowed. Upon receipt of notice of
apparentdefectorfailure, MILLER shall instructtheclaimanton
the

warranty claim procedures

to be followed.

THIS WARRANTY IS OFFERED IN LIEU OF ANY OTHER
EXPRESS WARRANTY; AND, EXCEPT TO THE EXTENT
PROHIBITED BY APPLICABLE LAW, THE DURATION OF
INCLUDING BUT NOT
IMPLIED WARRANTIES,
ALL
LIMITED TO THE IMPLIED WARRANTIES OF MERCHAN
TABILITYAND FITNESS FORAPARTICULAR PURPOSE, IS
LIMITED TO THE DURATION OF THIS WARRANTY.
ANY

EXPRESS WARRANTY NOT PROVIDED HEREIN

AND ANY IMPLIED WARRANTY. GUARANTY OR REPRE
SENTATION AS TO PERFORMANCE, AND ANY REMEDY

FOR BREACH OF CONTRACT WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR PARTICULAR PURPOSE,
WITH RESPECT TO ANY AND ALL EQUIPMENT FUR
NISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY
LLE

6 months
.

provided that MILLER is notified in
of such failure.

writing within thirty (30) days

WHAT IS NOT COVERED This warranty does not extend to
any Welder subjected to misuse, neglect, accident, or inwarranty repair by anyone except MILLER Electric or its authorized service stations. Further, thiswarranty only extends to the
original purchaser of this Welder.

p

In the case of MILLERs breach of warranty or any other duty
with respect to the quality of any goods, the exclusive remedies
therefore shall be, at MILLERs option (1) repair or (2) replacement or, where authorized in writing by MILLER in appropriate

(3) the reasonable cost of repair or replacement at an
authorized MILLER service station or (4) payment of or credit
cases,

-~

~

Some states do not allow limitations on how long an implied
warranty lasts, so the above limitation may not apply to you.
This warranty gives you specific legal rights, and you may also
have other rights which vary from state to state.
REMEDIES FOR A DEFECTIVE
THE PURCHASERS
WELDER, TO THE EXTENT PERMITTED BY APPLICABLE
LAW, ARE LIMITED TO THE REMEDY PROVIDED BY THIS
EXTENT ENFORCEABLE UNDER
APPLICABLE LAW, MILLER ELECTRIC SHALL IN NO
EVENT BE LIABLE FOR CONSEQUENTIAL, INCIDENTAL
OR SPECIAL DAMAGES ARISING OUT OF THE USE OF, OR
INABILITY TO USE, THE WELDER, WHETHER BASED ON
BREACH OF THIS WARRANTY, MILLER ELECTRICS NEG
LIGENCE OR OTHER TORT, OR ON ANY THEORY OF
STRICT LIABILITY.
WARRANTY. TO THE

j
A

ERRATA SHEET

After this manual was
to data

appearing

printed, refinements

in

equipment design occurred. This sheet lists exceptions

later in this manual.

AMENDMENT TO SECTION 7

MAINTENANCE & TROUBLESHOOTING

Amend Section 7-lA. ROUTINE MAINTENANCE: Fan Motor

This unit is

equipped with an
using SAE

every six months

exhaust fan and relies
20 oil.

on

forced draft for adequate

cooling.

The fan motor needs

oiling

OM-113 3360

5191

RECEIVING-HANDLING
Before unpacking equipment, check carton for any damage that may have occurred during shipment. File any
claims for loss or damage with the delivering carrier.
Assistance for filing or settling claims may be obtained
from the distributor and/or the equipment manufacturers Transportation Department.

Use the

spaces to record the Model Designa
Style Number of your unit. The infor
mation is located on the data card or the nameplate.
or

Model
________________________________

Serial
When requesting information about this equipment, al
ways provide the Model Description and Serial or Style
Number.

following

tion and Serial

or

Style

No.
____________________

Date of Purchase
_____________________

TABLE OF CONTENTS

Section No.
SECTION 1

Page

SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE

1-1.

Introduction

1

1-2.

General Precautions

1

1-3.

Arc

4

1-4.

Standards Booklet Index

Welding

5

SECTION 2- SAFETY PRECAUTIONS AND SIGNAL WORDS
2-1.

General Information And

2-2.

Safety

Alert

Symbol

And

Safety
Signal Words

6
6

SECTION 3SPECIFICATIONS

Volt-Ampere Curves
Duty Cycle

8

8

3-6.

Description
Supplied Equipment
Additional Required Equipment
Optional Equipment

10

3-7.

Consumable Parts

10

3-1.
3-2.
3-3.
3-4.
3-5.

SECTION 4INSTALLATION

8

8
9

OR RELOCATION

4-1.

Site Selection

10

4-2.

10

4-5.

Transporting Methods
Running Gear Installation
Optional SPW-1 Panel Installation
Shielding Gas Installation

4-6.

Work Cable

12

4-7.

Weld

14

4-3.
4-4.

4-8.
4-9.

4-10.
4-11.
4-12.

4-13.

No.

Assembly
Polarity Selection
MWG-200 Welding Gun Connections
Installation Of Optional Spool Gun
Welding Wire Spool Installation
Hub Tension Adjustment
Electrical Input Connections
Welding Wire Threading

11
11

12

14
14

16
16
16
18

Section No.

Page

SECTION 5OPERATOR

CONTROLS

5-1.

Power Switch And Pilot

5-2.

Thickness Volts Selector

5-3.

Fine

5-4.

Fan-On-Demand~

5-5.

Optional Spot/Pulse

SECTION 6

6-1.
6-2.
6-3.

SECTION 7

7-1.

Tuning

Wire

19

Light

Speed

19

20

Control

20

20

Panel Controls

SEQUENCE OF OPERATION
Gas Metal Arc Welding (GMAW)-Continuous And Gas Metal Arc
Welding-Pulsed Arc (GMAW-P)
Gas Metal Arc Welding (GMAW)-Spot (Models With Optional
SPW-1 Panel Only)
Shutting Down

21
22
23

MAINTENANCE & TROUBLESHOOTING

24

Routine Maintenance

7-2.

Replacing

7-3.

Drive

Drive Roll And Wire Inlet Guide

25
26

7-5.

Housing Realignment
Replacing Hub Assembly
Inspecting And Replacing Motor Brushes

7-6.

Overload Protection

27

7-7.

Thermal Overload Protection

28

7-8.

Printed Circuit Board

28

7-9.

Troubleshooting

7-4.

SECTION 8

Replacement

27

28

ELECTRICAL DIAGRAMS

Diagram
Diagram
Diagram
Diagram
Diagram

8-1.
8-2.

8-3.
8-4.
8-5.

Circuit

Diagram
Circuit Diagram
Circuit Diagram
Wiring Diagram
Circuit Diagram

For MW 4150 Models

30

For MW 4200 Models

31

For SPW-1 Panel

31

For SPW-1 Panel

32

For SPW-1 Panel Dual Timer/Pulser
33

Board PC5O

SECTION 9

26

WELDING TECHNIQUES & TROUBLESHOOTING
34

9-2.

Continuous Seam
Gas Metal Arc Welding (GMAW)
Gas Metal Arc Welding (GMAW)-Pulsed

9-3.

Gas Metal Arc Welding

36

9-1.

9-4.
9-5.
9-6.

SECTION 10

10-1.
10-2.
10-3.
10-4.

10-5.
10-6.

(GMAW)-Spot

37

Welds

Plug
Skip Welding
Troubleshooting

35

37
The Gas Metal Arc

Welding Process

37

AUTO BODY REPAIR APPLICATION

Pointers For

40

Procedure For

40

Welding Auto Body Sheet Metal
Welding Mild Steels
Procedures For Welding Door Panels
How To Prevent Glass Breakage And Spatter On Windows
Procedures For Welding Fenders And Quarter Panels
Welding Frames And High Strength (HSS) Steels

40
41

41
41

No.

Section No.

SECTION 11

Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure

Page
PARTS LIST

Assembly
w/Components
Drive Assembly, Wire

11-1. Main

42

11-2. Baffle, Air

44

11-3.

46

Panel, Rear w/Components
11-5. Panel, Front w/Components

47

11-6. SPW 1

50

11-4.

11-7. Circuit
11-8.

Spot

Panel

48

(Optional)

Card, Dual Timer/Pulser P050

Running

51

Gear

52

LIST OF CHARTS AND TABLES

Table 3-1.

Chart 3-1.
Chart 3-2.
Table 4-1.
Table 6-1.

Specifications
Volt-Ampere Curves
Duty Cycle
Input Conductor And

7

7
7

Fuse Size

17

Table 6-2.

Suggested Parameters For Continuous
Welding (GMAW)
Checking Weld Parameters

Table 7-1.

Maintenance Schedule

24

Table 7-2.

Troubleshooting

29

Gas Metal Arc
22
23

No.

SECTION 1
1-1.

SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE

INTRODUCTION

We learn

by experience. Learning safety through per
sonal experience, like a child touching a hot stove is
harmful, wasteful, and unwise. Let the experience of oth
ers

teach you.

search,

development, and field experience have
evolved reliable equipment and safe installation, opera
tion, and servicing practices. Accidents occur when
equipment is improperly used or maintained. The rea
son for the safe practices may not always be given.
based

sense, others may require
technical volumes to explain. It is wiser to follow the
are

Avoid

oily

or

on common

rules.

Read and understand these safe practices before at
tempting to install, operate, or service the equipment.
Comply with these procedures as applicable to the par
ticular equipment used and their instruction manuals, for
personal safety and for the safety of others.

should

clothing.

greasy

Hot metal such

Safe practices developed from experience in the use of
welding and cutting are described in this manual. Re

Some

or cutting, (and chipping) to protect the eyes
from radiant energy and flying metal. Replace cover
glass when broken, pitted, or spattered. See 1 -3A.2.

welding

never

A

spark may ignite them.

electrode stubs and

as

be handled without

workpieces

gloves.

Medical first aid and eye treatment. First aid facilities and
qualified first aid person should be available for each
shift unless medical facilities are close by for immediate
treatment of flash burns of the eyes and skin burns.
a

Ear

plugs

should be

worn

when

working

on

in a confined space. A hard hat should be
others work overhead.

overhead
worn

Flammable hair preparations should not be used
intending to weld or cut.

or

when

by

per

sons

B.

Toxic Fume Prevention

Severe discomfort, illness or death can result from
fumes, vapors, heat, or oxygen enrichment or depletion
that

welding (or cutting) may produce. Prevent them with
adequate ventilation as described in ANSI Standard

Failure to observe these safe practices may cause seri
ous injury or death. When safety becomes a habit, the

Z49.1 listed in Standards Index. NEVER ventilate with

equipment

oxygen.

can

be used with confidence.

These safe practices are divided into two Sections:
1-General Precautions, common to arc welding and cut

ting;

and 2-Arc

Welding (and Cutting) (only).

Reference standards: Published Standards on safety
are also available for additional and more complete pro
cedures than those

given

in this manual.

They

are

listed

in the Standards Index in this manual. ANSI Z49.1 is the
most

-,

cadmium -,zinc-, mercury-, and

beryllium-bear

and similar materials, when welded (or cut) may pro
duce harmful concentrations of toxic fumes. Adequate

local exhaust ventilation must be used,
the

area as

well

plied respirator.

or each person in
the operator must wear an air-sup
For beryllium, both must be used.
as

Metals coated with

or

containing materials that emit toxic
coating is removed

fumes should not be heated unless

complete.

The National Electrical Code, Occupational Safety and
Health Administration, local industrial codes, and local
inspection requirements also provide a basis for equip
ment

Lead

ing

installation, use, and service.

from the work surface, the area is well ventilated and, if
necessary, while wearing an air-supplied respirator.

Work in

a

confined space

only while

and, if necessary, while wearing

an

it is

being

ventilated

air-supplied respira

tor.
1-2.

GENERAL PRECAUTIONS

Difterent

arc

and fluxes

welding processes, electrode alloys,
produce difterent fumes, gases, and

can

a confined space should be avoided.
Leaked gas in large quantities can change oxygen con
centration dangerously. Do not bring gas cylinders into a

Gas leaks in

radiation levels. In addition to the information in this
manual, be sure to consult flux and electrode manu

confined space.

facturers Material

to

Safety

Data Sheets

specific technical data and
concerning their material.
A.

(MSDS5) for
precautionary measures

Burn Prevention

Wear protective clothing-gauntlet gloves designed for
use in welding, hat, and high safety-toe shoes. Button

shirt collar and pocket flaps, and wear cuffless trousers
entry of sparks and slag.

to avoid

Wear helmet with

safety goggles and glasses with side
appropriate filter lenses or plates
cover glass). This is a MUST for

shields underneath,
(protected by clear

Leaving

confined space, shut OFF gas

supply

at source

prevent possible accumulation of gases in the space if
downstream valves have been accidentally opened or
left open. Check to be
re-entering it.

sure

that the space is safe before

Vapors from chlorinated solvents can be decomposed
by the heat of the arc (or flame) to form PHOSGENE, a
highly toxic gas, and other lung and eye irritating prod
ucts. The ultraviolet (radiant) energy of the arc can also
decompose trichloroethylene and perchloroethylene va
pors to form phosgene. DO NOT WELD or cut where sol
vent vapors can be drawn into the welding or cutting at
mosphere or where the radiant energy can penetrate to
OM-113 336

Page

1

atmospheres containing

trichloroethylene
C.

Fire and

or

minute

even

of

amounts

perchioroethylene.

Explosion

ment as recommended in A6.O.

(see preceding paragraph). Do NOT depend
smell

or

rial; misuse of compressed gases and cylinders; and

Hollow

short circuits.

welding

flying sparks

falling slag

or

can

through cracks, along pipes, through windows

or

pass

doors,

through wall or floor openings, out of sight of
goggled operator. Sparks and slag can fly 35 feet.
and

To prevent fires and

the

explosion:

Avoid

are

in area, do NOT weld

practicable,

paint spray

on sense

of

to determine if it is safe to weld or cut.

castings or containers must be vented before
or cutting. They can explode.
or cut

may contain flammable dust, gas,

liquid vapors (such

or

where the air

gasoline).

as

Gas

Compressed

Equipment
with

precautions. Comply

precautions

in this

manual, and those detailed in CGA Standard P-i, SAFE
HANDLING OF COMPRESSED GASES IN CYLIN

DERS, listed ii in Standards Index.

short circuits.

If combustibles

sight

Standard

Keep equipment clean and operable, free of oil, grease,
(in electrical parts) of metallic particles that can

the work if

below

Explosive atmospheres. Never weld

D.

and

cause

Waterfilling just
inerting.

A container with unknown contents should be cleaned

Prevention

Causes of fire and explosion are: combustibles reached
by the arc, flame, flying sparks, hot slag or heated mate

BE AWARE THAT

level may substitute for

working

or

rooms,

dip tanks, storage areas, venti

lators. If the work cannot be moved,

move

at least 35 feet away out of reach of

sparks

combustibles
and heat;

or

Pressure

1.

cut. Move

to an area free of combustibles.

Regulators

Regulator relief valve is designed to protect only the
regulator from overpressure; it is not intended to protect
any downstream equipment. Provide such protection
with

one or more

relief devices.

protect against ignition with suitable and snug-fitting,
fire-resistant

covers or

Never connect

shields.

a

regulator

Walls

touching

combustibles

on opposite sides should
(or cut). Walls, ceilings, and floor near
work should be protected by heat-resistant covers or

not be welded on

shields.
Fire watcher must be

standing by with suitable fire extin
guishing equipment during and for some time after weld
ing or cutting if:
appreciable combustibles (including building
construction) are within 35 feet

a.

b.

appreciable

combustibles

feet but

be

can

are

further than 35

ignited by sparks

openings (concealed

c.

or

visible)

in floors

or

walls

sparks

Leaks-if gas leaks externally.
Excessive Creep-if delivery pressure continues to rise
with downstream valve closed.

Faulty Gauge-if gauge pointer does not move off stop pin
pressurized, nor returns to stop pin after pressure

when

release.

Repair. Do NOT attempt to repair. Send faulty regulators
repair to manufacturers designated repair center,
where special techniques and tools are used by trained
personnel.

Cylinders

2.

combustibles
or

Remove faulty regulator from service immediately for re
pair (first close cylinder valve). The following symptoms
indicate a faulty regulator:

for

within 35 feet may expose combustibles to

d.

cylinder containing gas
regulator was designed.

to a

other than that for which the

metal

adjacent

partitions

can

to

be

walls, ceilings, roofs,

ignited by radiant

or

Cylinders must be handled carefully to prevent leaks and
damage to their walls, valves, or safety devices:

conducted heat.

Avoid electrical circuit contact with

cylinders including

Hot work

permit should be obtained before operation to
ensure supervisors approval that adequate precautions

third rails, electrical wires, or welding circuits. They can
produce short circuit arcs that may lead to a serious acci

have been taken.

dent.

After work is done, check that

area

is free of

sparks,

and flames.

glowing embers,

empty container that held combustibles, or that can
produce flammable or toxic vapors when heated, must
be welded

been cleaned

as

cut, unless container has first
described in AWS Standard A6.O, listed
on or

7 in Standards Index.

This includes:
bles

trogen

or

or

OM-113 336

a

water

carbon dioxide, and

Page

2

DOT marking must be on each cylinder. It is an
of safety when the cylinder is properly han

dled.

Identifying gas content. Use only cylinders with name of
gas marked on them; do not rely on color to identify gas
content. Notify supplier if unmarked. NEVER DEFACE
or

thorough steam or caustic cleaning (or a
washing, depending on the combusti
solubility) followed by purging and inerting with ni

solvent

or

assurance

An

never

ICC

(See 1-3C.)

using protective equip-

is

alter name, number, or other
illegal and hazardous.

markings on

a

cylinder.

It

Empties: Keep valves closed, replace caps securely;
keep them separate from FULLS and return
promptly.
mark MT;

Prohibited

use.

Never

use a

cylinder

or

other than its intended use, NEVER
roller.

its contents for

as a

support

or

outlet away from

people

and

sources

of

ignition. Wipe

with a clean lintless cloth.

Match

Locate

or secure

cylinders

so

cannot be knocked

they

over.

Passageways and work areas. Keep cylinders
where they may be struck.

clear of

areas

Transporting cylinders.

With

crane, use a secure sup
cradle. Do NOT lift cylinders off

port such
the
or

a

as a platform or
ground by their valves

or

caps,

or

by chains, slings,

magnets.

Do NOT expose cylinders to excessive heat, sparks,
slag, and flame, etc. that may cause rupture. Do not al
low contents to exceed 130F.

Cool with water spray

where such exposure exists.

Protect

cylinders particularly valves from bumps, falls,
falling objects, and weather. Replace caps securely
when moving cylinders.
Stuck valve. Do NOT

cylinder

valve that

can

hammer

wrench to open a
not be opened by hand. Notify

use a

gases. Never try to mix any gases in

a

cylinder.

cylinder.

Cylinder fittings should never be modified or exchanged.

use.

Never

use

hose other than that

designed

for the specified gas. A general hose identification rule
is: red for fuel gas, green for oxygen, and black for inert
gases.
Use ferrules

or

clamps designed for the hose (not ordi
substitute) as a binding to connect

nary wire or other
hoses to fittings.
No copper

tings

to

tubing splices.
splice hose.

Use

only

standard brass fit

Avoid

long runs to prevent kinks and abuse. Suspend
hose off ground to keep it from being run over, stepped
on, or otherwise damaged.
Coil

threaded

con

wrench.

Adapters. Use a CGA adapter (available from your sup
plier) between cylinder and regulator, if one is required.
use two wrenches to tighten adapter marked RIGHT and
LEFT HAND threads.

Regulator outlet (or hose) connections may be identified
by right hand threads for oxygen and left hand threads
(with grooved hex on nut or shank) for fuel gas.
Pressurizing Steps:

5.

regulator of residual gas through suitable vent be
opening cylinder (or manifold valve) by turning ad
justing screw in (clockwise). Draining prevents exces
sive compression heat at high pressure seat by allowing
seat to open on pressurization. Leave adjusting screw
engaged slightly on single-stage regulators.
Drain

regulator

while

opening cylinder

valve.

Open cylinder valve slowly so that regulator pressure in
creases slowly. When gauge is pressurized (gauge
reaches regulator maximum) leave cylinder valve in fol
lowing position: For oxygen, and inert gases, open fully
to seal stem against possible leak. For fuel gas, open to
less than one turn to permit quick emergency shutoff.
Use pressure charts (available from your supplier) for
safe and efficient, recommended pressure settings on

regulators.
Check for leaks on first pressurization and regularly
there-after. Brush with soap solution (capfull of Ivory Liq
uid* or equivalent per gallon of water). Bubbles indicate
leak. Clean off soapy water after test; dried soap is com
bustible.

excess

hose to prevent kinks and

Protect hose from

tangles.
E.

damage by sharp edges,

and

Examine hose

regularly for leaks,

User

by

sparks, slag, and open flame.

Responsibilities

leaky or defective equipment from service im
mediately for repair. See User Responsibility statement
in equipment manual.
Remove

wear, and loose con

nections. Immerse pressured hose in water; bubbles in
dicate leaks.

Repair leaky or worn hose by cutting
ing (1-2D3). Do NOT tape.

area

out and

splic

F.

Leaving Equipment

Close gas
G.

4.

assembling

retighten using properly fitting

Stand to side of

Hose

Prohibited

connections. When

nections, clean and smooth seats where necessary.
Tighten. If connection leaks, disassemble, clean, and

fore

Never refill any

3.

Tighten

or

your supplier.

Mixing

regulator to cylinder. Before connecting, check
regulator label and cylinder marking area, and
that the regulator inlet and cylinder outlet match. NEVER
CONNECT a regulator designed for a particular gas or
gases to a cylinder containing any other gas.
that the

supply

Unattended

at source and drain gas.

Rope Staging-Support

Proper Connections

Clean cylinder valve outlet of impurities that may clog
orifices and damage seats before connecting regulator.

Except for hydrogen,

crack valve

momentarily, pointing

Rope staging-support should not be used for welding
cutting operation; rope may burn.

or

*Trademark of Proctor & Gamble.
OM-113 336

Page

3

Viewing the weld. Provide face shields for all persons

ARC WELDING

1-3.

Comply with precautions in 1-1, 1-2, and this section.
Arc Welding, properly done, is a safe process, but a
careless operator invites trouble. The

equipment carries
high currents at significant voltages. The arc is very
bright and hot. Sparks fly, fumes rise, ultraviolet and in

frared energy radiates, weidments are hot, and com
pressed gases may be used. The wise operator avoids

unnecessary risks and protects himself and others from
accidents. Precautions are described here and in stan
dards referenced in index.
A.

Burn Protection

Comply

with

The

1-2.

welding
visibly bright.
damage eyes, penetrate lightweight clothing, reflect
from light-colored surfaces, and burn the skin and eyes.
Its radiation

can

Skin burns resemble acute sunburn, those from gasshielded

arcs are more severe

and

painful. DONT GET

BURNED; COMPLY WITH PRECAUTIONS.
Protective

1.

Bare skin

protection. Wear dark, substantial clothing.
Button collar to protect chest and neck and button pock
ets to prevent entry of sparks.

Eye

are

wearing

sure

that

screen

flaps

or

Toxic Fume Prevention

B.

Comply

with

precautions

in 1 -2B.

Generator engine exhaust must be vented to the outside
air. Carbon monoxide can kill.
Fire and
with

Prevention

Explosion
precautions

in 1 -2C.

Equipments rated capacity. Do not overload arc welding
equipment. It may overheat cables and cause a fire.
Loose cable connections may overheat
fire.

or

flash and

cause a

an arc on a

cylinder

brittle

that

a

ture or lead to such a

long-sleeve clothing (particularly for gas-shielded
arc) in addition to gloves, hat, and shoes (1 -2A). As nec
essary, use additional protective clothing such as leather
jacket or sleeves, flame-proof apron, and fire-resistant
leggings. Avoid outer garments of untreated cotton.

2.

starting to weld, make
bay doors are closed.

Never strike

Wear

See that all persons

Before

sel. It creates

Clothing

area.

goggles.

Comply

is intense and

at the weld.

looking directly

Others working in
flash

C.

precautions in
arc

who will be

area

or

other pressure ves
violent rup

can cause a

rupture under rough handling.

Compressed Gas Equipment

D.

Comply

with

precautions

in 1 -2D.

Shock Prevention

E.

Exposed hot conductors or other bare metal in the weld
ing circuit, or in ungrounded, electrically-HOT equip
ment can fatally shock a person whose body becomes a
conductor. DO NOT STAND, SIT, LIE, LEAN ON, OR
a wet surface when welding, without suitable

TOUCH

and Head Protection

protection.
Protect eyes from exposure to
electric arc without protection.

NEVER look at

arc.

an

To

protect against shock:

Wear

helmet

Welding
no.

shield

or

containing

12 or denser must be used when

face before

striking

or

filter plate shade

welding.

Place

over

arc.

Protect filter plate with

Cracked

a

a

dry duckboard,
clear

broken helmet

worn; radiation can pass

cover

plate.

shield should NOT be

or

through

to cause burns.

or loose filter plates must be replaced
Replace clear cover plate when broken,
spattered.

IMMEDIATELY.

Flash

or

goggles with side shields

helmet to

give

MUST be worn under the

protection

to the eyes should the
helmet not be lowered over the face before an arc is
struck. Looking at an arc momentarily with unprotected

eyes

some

(particularly

a

high intensity gas-shielded arc)

retinal burn that may leave
in the field of vision.

cause a
area

3.

Protection of

Enclosed

can

Nearby Personnel

area.

round the

operation with low-reflective, non-combusti
ble screens or panels. Allow for free air circulation, par

ticularly

at floor level.

OM-113 336

Page

4

or

body protection. Keep

rubber mat when

not be avoided.

through

Sweat,

dampness

or sweat

the

sea

body.

voltage will exist between the electrode and any con
ducting object in the work circuit. Examples of conduct
ing objects include, but are not limited to, buildings, elec
trical tools, work benches, welding power source cases,
workpieces, etc. Never touch the electrode and any
metal object unless the welding power source is off.
A

Grounding

1.

permanent dark

For production welding, a sepa
enclosed bay is best. In open areas, sur

welding

rate room or

a

and

water, or moisture be
tween body and an electrically HOT part or grounded
metal reduces the electrical resistance, and could en
able dangerous and possibly lethal currents to flow
can

Cracked, broken,

pitted,

dry insulating gloves

body and clothing dry. Never work in damp area without
adequate insulation against electrical shock. Stay on a

Arc

the

Equipment

welding equipment

must be

grounded according

to

the National Electrical Code, and the work must be
grounded according to ANSI Z49.1 Safety In Welding
And

Cutting.

When

installing,

connect the frames of each unit such as

welding power source, control, worktable, and water cir
culator to the building ground. Conductors must be ade
quate to carry ground currents safely. Equipment made

ANSI Standard Z49.2, FIRE PREVENTION IN
THE USE OF CUTTING AND WELDING PROC
ESSES obtainable from the American National
Standards Institute, 1430 Broadway, New York,

6.

NY 10018.

from the
22202.
12.

CSA Standard W117.2, CODE FOR SAFETY IN
WELDING AND CUTTING obtainable from the
Canadian Standards Association, Standards
Sales, 178 Rexdale Boulevard, Rexdale, Ontario,
Canada M9W 1 R3.

13.

NWSA booklet, WELDING SAFETY BIBLIOG
RAPHY obtainable from the National Welding

AWS Standard A6.0, WELDING AND CUTTING
CONTAINERS WHICH HAVE HELD COMBUS

7.

TIBLES obtainable from the American

Society,
8.

Welding

550 N.W. LeJeune Rd, Miami, FL 33126.

NFPA Standard 51, OXYGEN-FUEL GAS SYS

TEMS FOR WELDING, CUTTING, AND ALLIED
PROCESSES obtainable from the National Fire
Protection Association,
Batterymarch Park,

Quincy,

Welding Society Standard AWSF4.1,
RECOMMENDED SAFE PRACTICES FOR THE
PREPARATION FOR WELDING AND CUTTING
OF CONTAINERS AND PIPING THAT HAVE

14.

American

CODE obtainable from the National Fire Protec

Batterymarch Park, Quincy,

Protection

HELD HAZARDOUS

from the American

Association,

Batterymarch

Park,

American

Broadway,

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
use

of this

equipment.

SAFETY
WORDS

The

following safety

used

B.

1430

tify

Safety

alert

SYMBOL

AND

and

signal

symbol

SIGNAL

words

are

throughout this manual to call attention to and iden

different levels of hazard and special instructions.

a

This

safety

alert

symbol

is used with the

signal

words WARNING and CAUTION to call atten

tion to the

The

nameplate of this unit uses international symbols for
labeling the front panel controls. The symbols also ap
pear at the appropriate section in the text.

ALERT

2-2.

General

followed for the safe and effective

Standards Institute,
New York, NY 10018.
National

SAFETY PRECAUTIONS AND SIGNAL WORDS

GENERAL INFORMATION AND SAFETY

2-1.

550 NW.

ANSI Standard Z88.2, PRACTICE FOR RESPI
RATORY PROTECTION, obtainable from the

15.

MA 02269.

SECTION 2

SUBSTANCES, obtainable

Welding Society,

Miami, FL 33126.

LeJeune Rd,

CGA Pamphlet P-i, SAFE HANDLING OF COM
PRESSED GASES IN CYLINDERS obtainable

11.

A.

MA

NFPA Standard 51B, CUTTING AND WELDING
PROCESSES obtainable from the National Fire

Quincy,

Street, Philadel

MA 02269.

tion Association,
02269.
10.

1900 Arch

Supply Association,
phia, PA 19103.

NFPA Standard 70, NATIONAL ELECTRICAL

9.

Compressed Gas Association, 1235 Jef
Highway, Suite 501, Arlington, VA

ferson Davis

safety

statements.

a

WARNING statements identify procedures or
practices which must be followed to avoid seri
ous personal injury or loss of life.

a

CAUTION statements identify procedures or
practices which must be followed to avoid minor
personal injury or damage to this equipment.

The installation,

operation, maintenance, and trouble
welding equipment requires practices
and procedures which ensure personal safety and the
safety of others. Therefore, this equipment is to be in
stalled, operated, and maintained only by qualified per
shooting

sons

of

arc

in accordance with this manual and all

applicable

codes such as, but not limited to, those listed at the end
of Section 1
Safety Rules For Operation Of Arc Weld

ing

Power Source.

OM-113 336

Page

6

IMPORTANT statements identify special instructions
necessary for the most efficient operation of this equip
ment.

electrically HOT by stray current may shock, possibly fa
tally. Do NOT GROUND to electrical conduit, or to a pipe
carrying ANY gas or flammable liquid such as oil or fuel.
Three-phase connection. Check phase requirements of
equipment before installing. If only 3-phase power is
available, connect single-phase equipment to only two
wires of the 3-phase line. Do NOT connect the equip
ment ground lead to the third (live) wire, or the equip
ment will become electrically HOT-a dangerous condi
tion that can shock, possibly fatally.
Before

welding, check ground for continuity. Be sure
conductors are touching bare metal of equipment
frames at connections.

esses

power switch is turned ON. Never touch the
electrode unless the welding power source is
off.

Safety

7.

Safety

Fully

insulated electrode holders should be used. Do

NOT

use

protruding

devices such

interlocks and circuit breakers

as

shunted out.

or

Before installation, inspection,

or

remove

service, of equipment,

line fuses

(or lock

or

red-

prevent accidental turning ON of power.
tag switches)
Disconnect all cables from welding power source, and
to

pull all 115 volts line-cord plugs.
Do not open power circuit or change polarity while weld
ing. If, in an emergency, it must be disconnected, guard
against shock burns, or flash from switch arcing.

Leaving equipment

unattended.

disconnect all power to

F.

screws.

shut OFF and

Always

equipment.

power

near

the

source.

Protection For Wearers of Electronic Life

Sup

port Devices (Pacemakers)

Connectors
insulated

Fully
lock-type connectors should
join welding cable lengths.

be used to

Cables

4.

Devices

should not be disconnected

welding

3.

used with shielded

arc

Power disconnect switch must be available

Electrode Holders

holders with

sources

power

welding (SMAW) and similar proc
may not be equipped with welding power
output on-off control devices. With such equip
ment the electrode is electrically HOT when the
metal

shut OFF all power and

If a line cord with a ground lead is provided with the
equipment for connection to a switchbox, connect the
ground lead to the grounded switchbox. If a three-prong
plug is added for connection to a grounded mating re
ceptacle, the ground lead must be connected to the
ground prong only. If the line cord comes with a threeprong plug, connect to a grounded mating receptacle.
Never remove the ground prong from a plug, or use a
plug with a broken off ground prong.
2.

Welding

Magnetic fields from high currents can affect pacemaker
operation. Persons wearing electronic life support
equipment (pacemaker) should consult with their doctor
before going near arc welding, gouging, or spot welding
operations.

Frequently inspect cables for wear,

cracks and

damage.
IMMEDIATELY REPLACE those with excessively worn
or damaged insulation to avoid possibly-lethal shock
from bared cable. Cables with damaged areas may be
taped to give resistance equivalent to original cable.

1-4.

For

dry, free of oil
metal and sparks.

cable

from hot

and grease, and

protected

information, refer to the following standards

Terminals and other exposed parts of electrical units
should have insulating covers secured before operation.

2.

NIOSH, SAFETY AND HEALTH IN ARC WELD

metal

D.C. 20402.

power

arc

sources

for

use

with the gas

welding (GMAW), gas tungsten

3.

arc

are

and similar processes nor
equipped with devices that permit on

off control of the

welding power output. When so
equipped the electrode wire becomes electri
cally HOT when the power source switch is ON
and the welding gun switch is closed. Never
touch the electrode wire or any conducting ob
ject in contact with the electrode circuit unless
the welding power source is off.
b.

Equipment without output on/off
contactor)

control

(no

OSHA, SAFETY AND HEALTH STANDARDS,
29CFR 1910, obtainable from the Superinten
dent of Documents, U.S. Government Printing
Office, Washington, D.C. 20402.

welding (GTAW)
mally

Superintendent of Documents,
Printing Office, Washington,

U.S. Government

Equipment with output on/off control (contactor)

Welding

or

applicable:

ING AND GAS WELDING AND CUTTING ob

Electrode
a.

as

ANSI Standard Z49.1, SAFETY IN WELDING
AND CUTTING obtainable from the American
Welding Society, 550 N.W. LeJeune Rd, Miami,

tainable from the
6.

comply

FL 33126.

Terminals And Other Exposed Parts

5.

more

their latest revisions and
1.

Keep

STANDARDS BOOKLET INDEX

4.

ANSI Standard Z87.1, SAFE PRACTICES FOR
OCCUPATION AND EDUCATIONAL EYE AND
FACE PROTECTION obtainable from the Ameri
can National Standards Institute, 1430 Broad
way, New York, NY 10018.

5.

ANSI Standard Z41 .1, STANDARD FOR MENS
SAFETY-TOE FOOTWEAR obtainable from the

Standards

American

National

Broadway,

New York, NY 10018.

Institute,

OM-113 336

1430

Page

5

SECTION 3

Table 3-1.
Rated

M

SpecificatIons

At Rated Load Output
60 Hz Single-Phase

Input

~ Ci~cuit
Voltag e
Duty Cycle

SPECIFICATIONS

Amperes

Voltage

Electrode
Wire
Feed

Electrode
Wire
Diameter

At Gun

Speed

Capability

Control
Circuit

At

200V

230V

460V

575V

kva

kw

26.5

24

12

9.6

5.5

4.8

150
At
23 Volts
DC

60to486

24

Amperes
32

Volts
DC

.023/.025 in. (0.6 mm)

ipm

.030 in.
.035 in.

to 12.3

(1.5
mpm)

Dimensions

(0.8 mm)
(0.9 mm)

Weight

A: Width

Net

Ship

205 lbs.*

215 lbs.~

(93 kg)

(98 kg)

13-1/2 in.

(343 mm)
B:

Length
27 in.

(686 mm)
C:

Height
30 in.

(762 mm)
*Add 2-3/4 lbs. (1.25 kg) for units with spot
~Add 5 lbs. (2.27 kg) for units with spot panel.

Figure

Chart 3-1.

3-1. Overall Dimensions

Chart 3-2.

Volt-Ampere Curves

Duty Cycle

RATED OUTPUT,
200
.

-

~

-

Cl)
w

-

-

-

w

0

6 I~I3H

>

5
4
3
2

C)
0

1LOW

0.
160

0
-J

-~

w

100
30
SB.146 888

40

60

Z DUTY

60

70

60

90100

CYCLE
SB-I 46 687

OM-113 336

Page

7

VOLT-AMPERE CURVES (Chart 3-1)

3-1.

(~3*
The

volt-ampere

This unit is

RATED OUTPUT

show the

curves

voltage

and amper

age output capabilities of the unit. Voltage and amper
age adjustment is provided by the FINE TUNING WIRE
SPEED control. Curves of other setting fall between the
curves

shown.

With the

use

of the

DESCRIPTION

3-3.

volt-ampere

curves, it is

determine the weld amperage at any
age.

possible
particular load volt-

to

a single-phase constant voltage dc arc weld
ing power source and wire feeder system. This unit is de
signed for Gas Metal Arc Welding (GMAW) with short
circuit or spray transfer. It is designed primarily for use as
a dc Electrode Positive/Reverse Polarity machine.

Rated weld output is 150 amperes, 23 volts dc, at 60%

duty cycle.
Models with the optional SPOT/PULSE WELD PANEL
provide the controls for regulating spot weld time/pulse
on time, burnback time, and pulse off time.
SUPPLIED EQUIPMENT (Figure 3-2)

3-4.

DUTY CYCLE

3-2.

(Chart 3-2)
following equipment is supplied
power source and requires customer
sembly:

with the

The
The

duty cycle

that

a

welding

is the percentage of
power source can be

a

ten minute

operated

at

period
a given

output without overheating and damaging the unit. This
power source is rated at 60 percent duty cycle
when operated at 150 amperes. The unit can be oper
ated at 150 amperes for six consecutive minutes, but it
must operate at no load for the remaining four minutes to
allow proper cooling. If the welding amperes decrease,
the duty cycle increases.

welding

A.

Duty Cycle

the output of the

chart

welding

(Chart 3-2)

cylinder

receptacle (200/230

Wall

C.

Work cable, work clamp, and

CAUTION:
EXCEEDING
CYCLE
DUTY
RATINGS will damage the welding power
source.

Do not exceed indicated duty cycles.

volt models

MWG-200 gun with 5/8 in. (16 mm) nozzle and

Drive rolls for .023/.025, .030, and .035 in. (0.6,
0.8, and 0.9 mm) hard wire.

The

welding power source is factory equipped with 9 ft.
(2.7 m) power cord (with plug on 200/230 volt models),
gas valve, and facilities for a Spool gun.

Bar

Wall

Receptacle

Page

8

only).

jack plug.

Spreader

OM-113 336

and

duty
E.

Figure

rack

two contact tubes for each wire size.

cycles.

a

gas

B.

to determine

power source at various

with

or as

bracket.

D.

Refer to the

Running gear

welding

installation

3-2.

Supplied Equipment

Bracket

3-5.

ADDITIONAL REQUIRED EQUIPMENT (Fig
ure

3-3)

C. Gas Hose
Measure distance from gas cylinder to welding power
Obtain good quality 5/8 in. (16 mm) outside di

The additional equipment required to complete the Gas
Metal Arc Welding (GMAW) setup can be obtained from

source.

your local

thread

A.

Gas

welding supplies

distributor.

D. Wire

Cylinder

Two types of gas

are

generally

used with Gas Metal Arc

Welding (GMAW) of thin gauge sheet steel. Carbon
dioxide (002) is the gas recommended for use with this
welding power source/gun combination. A mixture of 75
percent argon and 25 percent carbon dioxide also gives
favorable results. Obtain a cylinder of selected shielding
gas from your supplier.
B.

Regulator/Flowmeter

Regulator/flowmeters provide a constant shielding gas
pressure and flow rate during the welding process. Be
cause gases have different properties, each regulator!
flowmeter is designed to be used with a specific gas or
mixture of gases. Regulator/flowmeters cannot be
changed from one gas to another unless the proper
adapters are installed. Obtain the proper regulator/flowmeter for the

ameter, S.A.E. gas hose, and install 5/8-18 right-hand
fittings on both ends of hose.

Spool

For GMAW Process

Selection of the correct welding wire is important in Gas
Metal Arc Welding (GMAW). There are many types to
choose from, but certain wires are best suited for weld
ing thin gauge sheet steel. The American Welding Soci

ety (AWS) classification for GMAW wires is usually indi
cated on the label of the wire spool. Two AWS wire
are E7OS-6 and E705-3. The
E7OS-6 provides a more fluid (wetter) weld puddle and a
flatter bead than E7OS-3. Obtain a spool of selected
wire.

classes recommended

E.

Personal

When

using

Safety Equipment

this

welding

power source,

wear a

helmet, fitted with the proper filter lens,

to

welding

protect the

eyes from the

welding arc. Also wear protective clothing,
safety glasses, and gloves to prevent injury.
F.

type of gas used.

Offset/Punching

Tool

(Figure 3-4)

repair of automotive sheet steel is
OffsetlPunching tool is used. This tool
pose, rotating head.

The

easier when
has

a

an

dual pur.

damaged area is cutaway and the jaws of the offset
portion of the head are placed over the sheet steel.
When pressure is applied to the handles, the tool indents
a small offset in the sheet steel. A new piece of sheet
steel, cut to size, is placed in position to overlap the off
set portion. The new piece of sheet steel is welded into
place, sanded, filled with body putty, and finish sanded.
The

Gas

Cylinder

The head of the tool

can

be rotated one-half turn to be

punching tool. The punching tool expedites
riveting operations. The use of this tool will keep material
use and finishing time to a minimum.
used

Helmet

as a

Wire

Spool
Gloves

Li. /

1.

I

Gas Hose

Safety

Regulator/Flowmeter

Glasses

Figure

3-3. Additional

Required Equipment

Figure

3-4.

Offset/Punching

Tool

OM-113 336

Page

9

OPTIONAL EQUIPMENT

3-6.

The

following equipment

can

capabilities of the basic unit
tions:
A.

be obtained to extend the
or

to suit

special applica

The

following parts are subject to wear or damage in

mal

use:

SPW-1, Spot, Pulse, Continuous Panel (in

A.

Contact tubes

cludes three spot nozzles) (for installation
Section 4-4)

B.

Nozzles

C.

Gun liner

D.

Drive rolls.

B.

Spool

C.

Gun cable holder

D.

25 ft.

nor

see

gun

(7.6 m) power cord extension.

SECTION 4

SITE SELECTION

4-1.

CONSUMABLE PARTS

3-7.

INSTALLATION OR RELOCATION

(Figure 4-1)

a

WARNING: FIRE OR EXPLOSION can result
from placing unit on or over combustible
surfaces; RESTRICTED AIRFLOW can
cause overheating and possible damage to
internal parts.
Do not locate unit overcombustible surfaces.
Maintain at least 18 inches (457 mm) of
unrestricted space on all sides of unit, and
keep underside free of obstructions.
Do not place any filtering device over the in
take air passages that provide airflow for
cooling this unit.
if any type of
used at intake air passages.

Warranty is void

4-2.

filtering

device is

TRANSPORTING METHODS

SB-087 313-0

welding power source is equipped with a lifting eye
moving the unit during installation. Weight capacity of
the lifting eye only allows for supporting the welding

This

for

power

Figure
Select

an

4-1. Location

installation site which

4~

~.

Correct input power supply (see unit nameplate)

2.

Shielding

3.

Adequate ventilation and fresh

4.

No flammables

5.

A clean and

6.

supply

dry

air

supply

that avoids extremes of heat

cold

7.

Proper airflow around

8.

Adequate space for opening side

unit

access doors
for installation, maintenance, and repair func
tions.

mounting

secure

holes

the unit

on

Disconnect input power conductors from
deenergized supply line BEFORE moving
welding power source.
FALLING EQUIPMENT can cause serious
personal injury and equipment damage.

Use equipment of
the unit.

OM-113 336

provide the capability to install and
a running gear or in a permanent

Page

10

adequate capacity

to lift

If lifting or moving this unit with lift forks under
the base, be sure that lift forks are long
enough to extendbeyond opposite side of the
base.

lift forks too short

can

damage

internal

parts if tips of the lift forks penetrate the unit
base, or may cause personal injury and/or

equipment damage

location.

kill.

Do not touch live electrical parts.

Using
Base

can

Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other heavy
accessories or devices.

area

Proper temperature
or

WARNING: ELECTRIC SHOCK

provides the following:

1.

gas

source.

if unit falls off the lift forks.

RUNNING GEAR INSTALLATION

4-3.

(Figure 4-2)

5.

WARNING: UNCONTROLLED TILTING OR
TIPPING of unit can result in personal injury

a

or

equipment damage.

6.

Use equipment of adequate capacity to lift the
unit.
If using lift forks to handle this unit, be sure the
lift forks are long enough to extend out of the
opposite side of the base.

Do not place any part of the
unit while it is suspended.

body

cylinder rack onto welding power source
using 5/16-18 x 3/4 cap screws and asso
ciated hardware (see Figure 4-2).
Remove the two front cap screws in top of welding
power source wrapper and discard. Install run
ning gear handle onto wrapper using 1/4-20 x 3/4
cap

7.

under the

screws as

shown in

Install

cylinder

power

source as

x

8.

Place blocks under frame of unit before

Install

base

3/4 cap

Install

4-2.

bracket onto rear panel of welding
shown in Figure 4-2 using 1/4-20

screws

safety

Figure

and

existing

chain onto

holes in

rear

panel.

cylinder bracket.

installing

running gear.

4-4.

OPTIONAL SPW-1

PANEL

INSTALLATION

(Figure 4-3)
Install the two 4 in.

1.

er

(102 mm)

bar onto the front

source

base

a

shown in

casters and

spread
welding power
Figure 4-2 using 3/8 in.

corners

of the

a

hardware.
Blockthe unit up securely in middleto ease instal
lation of rear wheel/gas cylinder rack assembly.

3.

Slide axle
er on

on

through cylinder rack,

each end of axle with

a

and install

kill.

welding

power source, and dis

input power employing lockout/tag
ging procedures before inspecting or install.
connect

ing.
Lockout/tagging procedures consist of remov
ing input power plug from receptacle, pad
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off
and red-tagging circuit breaker or other discon
necting device.

a

3/4 in. flat wash

each side of wheel.

Secure wheels in place with supplied

4.

can

Do not touch live electrical parts.

Shut down

2.

wheel

WARNING: ELECTRIC SHOCK

retaining

rings.

Cylinder

Safety
chain

Flat
Washers

Cylinder
Rack

Axle

.wheel

Nut

Washer

Cap
Nut

Screw
Flat
Washers

Spreader
Bar

Casters

SC-049 808-E

Figure

4-2.

Running

Gear Installation
OM-113 336 Page 11

IMPORTANT: SPW- 1 Spot Panel will not provide spot
capabilities for the Spool gun. Retain all hardware re
moved during this procedure for reinstallation. All direc
tions, such as left or right, are with respect to the operafor facing the front panel.
Remove module

1.

hand

corner

WARNING: PRESSURIZED CYLINDERS can
rupture causing serious personal injury and
loss of life; FALLING CYLINDERS can cause
serious injury and equipment damage.

a

Keep cylinders away from welding

plate from upper rightpanel.

cover

of front

Never allow

wiring harness clamped to air baffle. Re
wiring harness from first clamp and careful
ly pull end of wiring harness with connectors
it will come
through opening in front panel
through approximately 2 in. (51 mm).

4.

Connect receptacle RC55 from SPW-1 panel to
PLG2. Be sure the connectors are locked togeth
er

plug PLG2.

front

panel,

Step

1.

Regulator/Flowmeter (Customer Supplied) (Fig
4-4)

ure

1.

cylinder correctly installed, remove cylin
Figure 4-4). Stand to one side of the
cylinder valve, and open the valve slightly. When
gas flows from cylinder, close valve. This proce

With the

der cap (see

(see Figure 4-3).

Install SPW-1

5.

electrode to touch any

welding

port.
B.

Disconnect jumpered connector from

a

Always fasten cylinder securely to running
gear bracket, a wall, or other stationary sup

move

3.

other

cylinder.

Locate

2.

or

electrical circuits.

panel into upper right corner of
secure using screws removed in

gets rid of any dust or dirt that may have
cumulated around the valve seat.
dure

and

2.

regulator/flowmeter must be properly
equipped with a stem, nut connectors, and gasket
for use with either CO2 cylinders or Argon/CO2
cylinders.

The

IMPORTANT: A
leaks. Do not
3.

ac

gasket should be installed to prevent
lubricants or sealing agents.

use

Install gas regulator onto gas cylinder valve; keep
the face of the regulator/flowmeter gauge in the

position, and tighten
cylinder.

vertical

stem nut

securely

onto gas

Plug _....~
PLG2

4.

A

shielding gas output fitting is provided at the
of the welding power source for making gas

rear

connections. Attach

Receptacle

one

end of the gas hose to

this output fitting. Attach other end of the gas hose
to the regulator/f lowmeter.

RC55

SPw-1

._~

WORK CABLE ASSEMBLY

4-6.

Spot Panel

(3 m) cable with a lug attached to one end is
supplied with the unit. To install the work clamp and jack
plug onto the cable, proceed as follows:

A 10 ft.

A.
1.

Work

Clamp Installation (Figure 4-5)

Insert the end of the work cable with the terminal

lug

on

it

through

one

of two supplied

insulating

sleeves.

FIgure

4-3. SPW-1 Panel Installation

SHIELDING GAS INSTALLATION

4-5.

2.

Lay the work cable inside the handle of the
clamp which has the flattest inner surface.

3.

Align

work

the smaller hole in the work

clamp handle
lug. Se
clamp with the

with the hole in the work cable terminal
A.

Gas

Cylinder (Customer Supplied) (Figure 3-3)

cure

the terminal

supplied
Secure gas cylinder to

running gear using safety chain
on cylinder bracket. If the running gear is not to be used,
chain cylinder to wall or other stationary support to pre
vent the cylinder from falling over and breaking off the
valve.
OM-113 336

Page

12

4.

5.

lug

to the work

nut and bolt.

Bend the tabs on the end of the work clamp han
dle around the work cable.
sleeve

Slide the

insulating

the work

clamp handle.

on

the work cable

over

Regulator

Gas Hose
Connection
(5/8.18 Male

CO2

Washer

Fitting Required)

Gas Hose
Connection
(5/8-18 Male

CO2 Cylinder

CO2 Installation
Figure
6.

Slide the

4-4.

remaining insulating
clamp handle.

Argon Installation
Typical Regulator/Flowmeter

sleeve

over

the

6

6.

Twist tie wire

wire is twisted and

Cut off looped ends of tie wire.

8.

Bend the twisted tie wire over and along the side
(C) of uninsulated portion of cable.

9.

Wrap the strip of copper foil tightly around uninsu
lated portion of cable and twisted tie wire (D).

10.
Step

tight

(B) until entire tie

around insulation of cable.

7.

Step

4

Installation

Insert a 3/8 in. (9.5 mm) diameter rod through
looped ends of tie wire.

is

Step

SB-109 492-A

5.

other work

Step

Argon Or
Argon Mix Cylinder

Fitting Required)

Push the

jack plug

onto cable over copper foil

(E).

3

AU

U

B~
Steps

1 and 5
0250

Figure
B.

Jack

4-5. Work

Clamp

Installation

Plug Installation (Figure 4-6)

The supplied jack plugs are used to connect the weld
cables to the weld output receptacles. Install jack plugs
onto weld cables as follows:
1.

Remove 3/4 in. (19

mm)

of insulation from

~

one

end of each weld cable.
2.

Clamp cable in a vise with the uninsulated end ex
tending upward out of vise approximately 1-3/4 in.
(44 mm).

3.

Place steel tie wire

mately 1/4
4.

Make

a

in.

FP

(item A, Figure 4-6) approxi
(6 mm) from end of insulation.

half turn around cable

ends of tie wire

together.

S~0023

bringing looped
Figure 4-6. Jack Plug Installation
OM-113 336

Page

13

Insert the 1/4-20 setscrews into center and bot-

11.

torn holes in

and

jack plug,

tighten (E).

1.

Open

2.

Loosen the

Remove cable from vise, and insert jack plug into
insulating sleeve. Slide insulating sleeve over

12.

jack plug

and cable until hole in

lines up with

rernaining

Insert the 8-32

13.

hole in

insulating

hole in

self-tapping
sleeve into

insulating sleeve
jack plug (F).

screw

IMPORTANT:

connector

securing

knob

Wire

guides
as

should be installed

close to the drive rolls

so

as

that

possi

(F) through

jack plug,

and

tight-

gun/feeder connector, which includes
guide, through the access hole in the weld-

Insert the

3.

ing power source front panel and into the drive as
sembly as illustrated in Figures 4-7 and 4-8.

WELD POLARITY SELECTION

POSITIVE

1

4.

Tighten the gun/feeder connector securing

5.

Close and

B.

secure access

Gun Switch Connection

WARNING: ELECTRIC SHOCKcan kill; ARC
ING can burn skin or damage electrical connections.

a

gun/feeder

the tip of the guide is
ble without touching.

outlet

NEGATIVE

door.

(see Figure 4-7).

en.

4-7.

access

knob.

door.

(Figure 4-8)

GUN
TRIGGER

Do not touch live electrical parts.
Shut down welding power source before mak
ing any twistlock plug connections.
The GUN TRIGGER
Do not

change position oftwistlockplug
welding.

Secure twistlock
before welding.

IMPORTANT:
secure

them in

plug

Rotate

in selected

jack plugs 1/4
receptacles,

1.

Connect

2.

Connect jack

receptacle

turn clockwise to

jack plug on weld cable from
POSITIVE (+) weld output receptacle.

TIVE

plug

while

unit into

() weld output receptacle.

IMPORTANT: For Electrode

GER receptacle, insert connector, and rotate threaded
collar fully clockwise. When the gun switch is closed, the
welding power source contactor energizes, shielding

gas flows, and wire feeds.

~

ELECTRIC SHOCK

WARNING:

can

Shut down

welding

welding pow

welding

power source, and dis

input power employing lockout/tag
ging procedures before inspecting or install-

ing.
Lockout/tagging procedures consist of remov
ing input power plug from receptacle, pad
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off
and red-tagging circuit breaker or other discon

kill.

power source, and dis-

input power employing lockout/tagging procedures before inspecting or installconnect

necting device.

ing.
Lockout/tagging procedures consist of removing input power plug from receptacle, padlocking line disconnect switch in open position,
removing fuses from fuse box, or shutting off
and red-tagging circuit breaker or other disconnecting device.

kill.

connect

Do not touch live electrical parts.

Shut down

can

Do not touch live electrical parts.

er source at

MWG-200 WELDING GUN CONNECTIONS

~

WARNING: ELECTRIC SHOCK

Do not connect two guns to this
the same time.

Negative/Straight Polarity

Connections, reverse cable connections to weld output
receptacles; electrode becomes negative.
4-8.

INSTALLATION OF OPTIONAL SPOOL GUN

4-9.
~

from work cable into NEGA-

receptacle is provided for making

switch control connections. Align the keys on the gun
switch connector with the keyway on the GUN TRIG-

If two guns are connected to this welding power
source, both electrode wires will be energized
when either gun is operated.

A.

Shielding Gas Connections

IMPORTANT: Use pure argon
wire welding.

shielding gas

for alumi

num

A.

Gun/Feeder Connector Installation (Figures 4-7
And

4-8)

Connect the

IMPORTANT: The outlet guide is provided as part of the
gun

assembly.

OM-113 336

Page

14

shielding gas

hose from the

Spool Gun to
supply.

the gas regulator/flowmeter on the shielding gas
The connector has 5/8-18 right-hand threads.

Hub
Wire Outlet
Guide

Drive Roll
Cover
Front Panel
Of Unit

Monocoil
Liner

Hex Nut

Gun/Feeder
Connector

Spool

Compression
Spring
Retainer

Gun/Feeder
Connector
Securing Knob

Ring

Figure

4.7.

SA.o72 573.A

Gun/Feeder Connector And Wire Spool Installation

B

A

Figure

4-8.

C

Welding Gun Connections
OM-113 336

Page

15

B.

Weld Cable Connections

3.

Insert Spool Gun welding cable plug into POSITIVE (+)
weld output receptacle with flat side facing the recep
tacle key. Rotate plug clockwise 1/4 turn.
C.

SPOOL GUN

Slide spool of wire onto hub
bottom of spool.

hub. Slide
back

making

receptacle RC3 is provided for

connections between the

welding power source
Spool Gun. To connect the gun, align keyway,
insert gun plug into receptacle, and rotate threaded col
lar fully clockwise. When gun switch is closed, the con
tactor energizes, shielding gas flows, and wire feeds.

flange

of hub.

5.

Compression spring is not required for 12 in. (305
mm) spools. For 8 in. (203 mm) spools, use com
pression spring. Reinstall retaining ring onto hub.

6.

Close and

SPOOL
GUN

A 3-socket SPOOL GUN

that wire feeds off

Rotate spool until hole in spool aligns with pin in
spool onto hub until it seats against

4.

Receptacle Connection (Figure

4-9)

so

secure access

door.

4-11.

HUB TENSION ADJUSTMENT

a

WARNING: ELECTRIC SHOCK

(Figure 4-7)
can

kill.

Do not touch live electrical parts.

and the

Shut down

welding power source, and dis
input power employing locko ut/tag
ging procedures before inspecting or install
ing.
connect

Lockout/tagging procedures consist of remov
ing input power plug from receptacle, pad
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off
and

red-tagging
necting device.

circuit breaker

or

other discon

Check the hub tension by slowly pulling the wire toward
freely, but the hub
tension should be sufficient to keep the wire taut and pre
the feed roll. The wire should unwind

S-0037

vent backlash when the wire

Figure

4-9. Front View Of 3-Socket

Receptacle

Spool

With Socket Locations

The sockets on the SPOOL GUN receptacle
nated as follows:
Socket A:

Gun

are

desig

feeding

ceases.

ment is

required, loosen or tighten the hex
of the spindle support shaft accordingly.
4-12.

If

adjust

nut on the end

ELECTRICAL INPUT CONNECTIONS

o

+24 volts ac, 60 Hz.

INPUT

Socket B:

Welding power source contactor control;
+24 volts closes contactor; 0 volts opens contactor.
Socket C:

4-10.

a

+24 volts ac, 60 Hz.

WELDING

WIRE

SPOOL

WARNING: ELECTRIC SHOCK

Shut down

INSTALLATION

J~

WARNING:

ELECTRIC SHOCK

can

kill.

welding

power source, and dis

input power employing lockout/tag
ging procedures before inspecting or install

ing.

Lockout/tagging procedures consist of remov
ing input power plug from receptacle, pad
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off
and red-tagging circuit breaker or other discon

1.
2.

Open

OM-113 336

device.

left side access door.

Remove
Page

retaining ring.
16

power source, and dis

Lockout/tagging procedures consist of remov
ing input power plug from receptacle, pad
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off
and red-tagging circuit breaker or other discon
necting device.

connect

necting

welding

input power employing locko ut/tag
ging procedures before inspecting or install
ing.

Do not touch live electrical parts.
Shut down

kill.

connect

(Figure 4-7)

______

can

Do not touch live electrical parts.

A.

Electrical

Operate

Input Requirements

the

welding power source from a single-phase,
power supply. The input voltage must match
one of the electrical input voltages shown on the input
data label on the unit nameplate. Contact the local elec
60 Hertz,

tric

ac

utility for

information about the type of electrical

ser

vice available, how proper connections should be made,
and inspection required.

B.

Jumper

Link Installation

(Figures 4-10

And

4-11)

Wall Receptacle And Power Cable Connections

C.

(Figure 4-12)

WARNING:

Read and follow safety informa
tion at beginning of entire Section 4-12 be
fore proceeding.

a

WARNING:

ELECTRIC SHOCK

can

kill.

Do not touch live electrical parts.

Jumper links are

used to allow the

equipment to operate
from different line voltages. The jumper links may be in a
bag attached to the input terminal board or installed on
the input terminal board for the highest voltage shown on
the

input voltage

Install a fusible line disconnect switch in the
circuit to the welding power source.

input

Use Table 4-1 as a guide in selecting appropri
input conductor and fuse size.

ate

label.

Connect input conductors to the welding
power source before connecting to single-

1.

Remove the wrapper.

2.

Compare position of jumper links on the input
terminal board (see Figure 4-10) to the voltage
link arrangement on input voltage label (see Fig
ure 4-11).

phase input power.
Read and follow safety information at begin
ning of entire Section 4-12 before proceed

ing.
The line disconnect switch provides a safe and
convenient means to completely remove all
electrical power from the welding power source
whenever necessary to inspect or service unit.

Air
Baffle

equipped with a three-conductor power
requiring 200 or 230 volts input are
equipped with a three-prong polarized plug and wall re
ceptacle. The wail receptacle should be installed in a
convenient location by a competent electrician. Install
the wall receptacle with the grounding terminal at the
top, allowing the power cable to hang downward without
undue bending or twisting.
All models are

cable. Models

Input Voltage

Models

Label

having an electrical input voltage above 230
prewired power cables with three conductors.

volts have
Terminal
Board

Input

The black and white conductors must be connected to
RefS0-072507-L

Figure

4-10.

Input Terminal Board

Location

the line disconnect switch, and the green conductor
must be connected to a proper ground (see Figure 4-12).
Use

a

grounding method that is acceptable
inspection authority.

to the local

electrical

CAUTION: INCORRECT INPUT VOLTAGE
JUMPER LINK PLACEMENT can damage
unit.

a

Position jumper links as shown on the input
label (see Figures 4-10 and 4.11).

voltage

Store unused jumper links

across

Table 4-1.

In put

Input Conductor
Size

IMPORTANT: If the input voltages stated on nameplate
rating label are different from those in Figure 4-11,

or

check the

3.

input voltage
Department.

Install

jumper

label in the unit

or

call

Factor,

links onto the

input terminal board
input line voltage.

Reinstall wrapper.
200V

(AWG)

Ground Conductor
Size (AWG)
Fuse Size
In

to match the available
4.

Voltage

And Fuse Slze*

200

230

460

575

10

10

14

14

10

10

14

14

40

35

20

15

linked

terminals.

Service

Input Conductor

Amperes

*Conductor size is based on the 1990 Edition of the National
Electrical Code (NEC) specifications for allowable ampacities
of insulated copper conductors, having a temperature rating of
167F (75C), with not more than three single current-carrying
conductors in a raceway (Article 310 of NEC). (The ground
conductor is not counted as a current-carrying conductor.)

230V

SA-117 070

*Fuse size is based

on not more

than 200 percent of the rated
source (Article 630 of

input amperage of the welding power

Figure

4-11.

Input Voltage

Label

NEC).

S~0092/9~90

OM-113 336

Page

17

a

WARNING:

ELECTRIC SHOCK

Do not connect an input (white
ductor to the ground term mal.
Do not connect the ground
to an input line terminal.

can

or

kill.

black)

(green)

Open

1.

left side

access

door.

con

Install

2.

Incorrect input connections can result in an
electrically energized welding power source
chassis. The ground terminal is connected to
the welding power source chassis and is for
grounding purposes only.

Ground Conductor

welding

wire

spool according

to Section

4-10.

conductor

IMPORTANT:

Spooled

wire has

a tendency to unravel
spool. Maintain a firm grip on
wire during the threading operation.

when loosened from the
the

3.

Unreel and

straighten approximately

6 in.

(152

mm) of wire from wire spool.
Cutoff any wire that is bent, and

4.

or

remove

any burrs

sharp edges.

Line Disconnect

Switch

Release pressure spring on drive roll assembly,
pivot upper drive roll up and away from lower
drive roll.

5.

and

Route

6.

welding

wire into wire inlet

guide, along
guide

lower drive roll groove, and into wire outlet

(see Figure 4-7).

L2 Line
Conductor
Li Line
Conductor

4-13.

Pivot upper drive roll down onto lower drive roll.

8.

Reinstall pressure spring. Be
wire is in groove of drive rolls.

9.

Lay gun cable assembly out as straight and flat as
possible.

10.

Energize welding power source. If power source
has spot welding capabilities, place the Selector
switch in the CONTINUOUS position.

sure

that

welding

Wall
SA-112 075-A

Receptacle

Figure

7.

4-12. Wall

Receptacle And Power Cable
Connections

WELDING WIRE THREADING

Depress and hold the gun trigger until the wire
approximately 1/4 in. (6 mm) out the gun

11.

(Figure 4-7)

feeds

a

WARNING:
ELECTRIC SHOCK can kill;
MOVING PARTS can cause serious injury.

nozzle. If wire feeds

more

than 1/4 in. out nozzle,

cut wire off to 1/4 in.

Do not touch live electrical parts.

Keep away from moving parts.
Do not energize welding power source
feeder until instructed to do so.

The
with

welding wire and all metal parts
it are energized while welding.

WELDING

WIRE

can

cause

wounds; HOT SURFACES

or

12.

Deenergize welding

13.

Adjust hub tension according

power

source.

wire

in contact

puncture

to Section 4-11, if

necessary.

Close and

14.

secure access

door.

can cause severe

burns.
Do not press gun

trigger until instructed to

do

so.

IMPORTANT: For a smoother weld start, be sure weld
ing wire extends 1/4 in. (6 mm) out of contact tube and
has

Do not point gun toward any part of the body,
any conductive surface, or other personnel
when threading welding wire.
Allow gun to cool before
OM-113 336 Page 18

touching.

a

sharp end.

SECTION 5

OPERATOR CONTROLS

Selector
Switch

Pulse Off
Time Control

Positive

(+) Weld
Receptacle

Fine

Tuning

Wire Speed
Control

Gun

Trigger

Weld Cable
Power Switch

Spool Gun
Receptacle

Pilot

Light

Thickness Volts

Receptacles And
Selector Plug
OPTIONAL
Ref. SB.087 313.D

Figure
5-1.

POWER SWITCH AND PILOT LIGHT

5-1.

Operator

(Figure

Controls

IMPORTANT: When the POWER switch is in the ON po

sition, the pilot light comes on, but the fan motor does not
run unless the internal components are already warm.

5-1)

ON

POWER

The fan motor is

thermostatically controlled and only op
cooling is required (see Section

erates when additional

e

5-4).

00FF

5-2.

Placing the POWER switch in the ON position energizes
welding power source. The pilot light comes on
indicates that the unit is

Placing

welding power

source

power.

and turns off the

VOLTS

and

the POWER switch in the OFF position shuts

down the

light.

receiving input

position

(Figure 5-1)

THICKNESS

the

whenever the POWER switch is in the ON

THICKNESS VOLTS SELECTOR

pilot

a

CAUTION: ARCING can damage
and receptacle contact surfaces.

jack plug

Do not change THICKNESS VOLTS selector
plug position while welding or under load.
OM-113 336 Page 19

Arcing

causes

the contact surfaces to become

Placing Selector switch

pitted. Eventually continuity is lost and the selec
tor plug no longer works to select output range.

tion and

2.

Spot

Position

jack plug and recep
input to the weld. The

SPOT

tacles provide a selection of heat
higher the numbered receptacle, the hotter the weld.

....

Placing Selector switch in SPOT position and de
pressing the gun trigger feeds welding wire for the
length of time set on the SPOT TIME control.

IMPORTANT: After installing selector plug into THICK
NESS VOLTS receptacle, rotate plug 1/4 turn clockwise
to secure in place. When

removing plug from receptacle,
plug 1/4 turn counterclockwise while withdrawing
from receptacle.

it

FINE TUNING WIRE SPEED CONTROL

5-3.

ure

Pulse Position

3.

PULSE

(Fig

5-1)

(~o
-1

Placing Selector switch in PULSE position and
depressing the gun trigger feeds welding wire for
the length of time set on the PULSE ON TIME
control. At the end of the pulse on time, welding

FINE TUNING
WIRE SPEED

wire stops feeding for the length of time set on the
PULSE OFF TIME control. The welding wire con

The FINE TUNING WIRE SPEED control provides
selection of the speed at which welding wire feeds into
the weld.

Rotating

tinues to

the FINE TUNING WIRE SPEED

control clockwise increases wire feed

posi

depressing
trigger feeds welding
wire for as long as the gun trigger remains closed.

The THICKNESS VOLTS selector

rotate

in CONTINUOUS

the gun

pulse feed

and off for the selected

on

times until the gun trigger is released. The pulse
option provides better control of the heat input to

speed.

the weld

The scale around the FINE TUNING WIRE SPEED con
trol is calibrated in percent and does not indicate the ac

ing

on

thin gauge metals,

thereby decreas
melt-throughs.

distortion and the likelihood of

tual wire feed speed.

B.

IMPORTANT: The FINE TUNING WIRE SPEED control
may be adjusted while welding.

The SPOT TIME/PULSE ON TIME control enables the
operator to select from 0.5 to 4 seconds of pulse time for

IMPORTANT: In the PULSE mode, the FINE TUNING
WIRE SPEED control must be set at 50 percent or less
when

using THICKNESS VOLTS taps

5 and 6.

The fan motor is

may not
are

cool

are warm.

Under normal

loading,

assem

the fan motor

The fan motor turns off when Ti and SR3
when the unit POWER switch is turned off.

run.

or

Normally-open

thermostats TP1 and TP2, and relay
CR2 control the fan motor.
5-5.

OPTIONAL
TROLS

IMPORTANT:

SPOT/PULSE

PANEL

operation. Rotating the control clockwise
pulse off time. The control scale is calibrated
and does not indicate actual pulse off time.
D.

increases
in

percent

Burn back Time Control

e.~. ~
BURNBACK TIME

stopping

The Selector switch enables the operator to select
or pulsed wire feed operation.

tinuous, spot,

Continuous Position

CONTINUOUS

wire

The BURNBACK TIME control

justing

provides a means of ad
period (up to a maximum of 0 25 sec
welding wire remains electrically ener
wire feeding has stopped.

the time

onds) that the
gized after the

By adjusting

this control

neither freeze in the weld
con

puddle

the

nor

welding

wire

will

in the contact tube

into the contact tube, decrease the burnback time

Ro

tate the control clockwise to increase the burnback time,

and rotate the control counterclockwise to decrease the
brated in

surrounding

percent and does

back time.
20

properly,

of the gun. If the welding wire freezes to the work, in
crease the burnback time. If the welding wire burns back

burnback time. The scale

Page

time.

The PULSE OFF TIME control enables the operator to
select from 0.25 to i second of pulse off time for pulse

(Figure 5-1)

Selector Switch

OM-113 336

on

In the PULSE

circuit breaker in the motor control circuit
feed.

1.

spot/pulse

Pulse Off Time Control

CON

mode, the FINE TUNING
WIRE SPEED control must be set at 50 percent or less.
Exceeding the 50 percent control setting may trip the

A.

0.25 to 2 seconds for pulse operation.

control clockwise increases spot/pulse on
time. The control scale is calibrated in percent and does

controlled and does

when main transformer Ti and/or rectifier

bly SR3

or

Time Control

Rotating the

C.

thermostatically

not turn on with the unit POWER switch. The fan motor
runs

spot operation

not indicate actual

FAN-ON-DEMAND~

5-4.

Spot Time/Pulse On

not

the control

represent

an

is

cali

actual burn

SECTION 6

f%~

SEQUENCE OF OPERATION

WARNING:

ELECTRIC SHOCK can kill;
MOVING PARTS can cause serious injury;
IMPROPER AIRFLOW AND EXPOSURE TO
ENVIRONMENT can damage internal parts.

a~

IMPORTANT: Be

sure

that work cable is installed into

NEGATIVE () weld output receptacle and weld cable
from unit is installed into POSITIVE (+) weld output re

ceptacle (see Section 4-7).

Do not touch live electrical parts.

Keep away from moving parts.

2.

Wear

Keep all covers
operating.

3.

Thoroughly

Warranty
operated

and panels in place while

is void if the

welding

is
with any portion of the outer enclosure
source

power

skin; NOISE

can

FUMES AND GASES
your health.

Keep your head
Ventilate to

can

of

workpiece.

Disconnect both
on a vehicle.

battery cables before

Disconnect vehicle
ing on a vehicle.

body protection.

computer(s) before weld

Place work clamp as close to the weld
sible to avoid long electrical paths.

harm

Be sure all weld circuit connections
and tight.

out of the fumes.

keep from breathing fumes and

weld

ing

damage

seriously

area

components.

hearing.
Wear correct eye, ear, and

joint

WELDING CURRENT can dam
vehicle
computers and other electronic
age

ARC RAYS, SPARKS, AND HOT SURFACES
burn eyes and

clean

CAUTION:

a

removed.

can

dry insulating gloves and clothing.

as

are

pos

clean

Connect work clamp to clean, bare metal at work-

4.

gases.

piece.
If ventilation is

breathing

inadequate,

use

approved
Select and obtain proper welding wire, and thread
instructed in Section 4-13 of this Manual.

5.

device.

as

WELDING

WIRE

can

cause

puncture

If applicable, place the Selector switch on the op
tional SPW-1 Panel in the CONTINUOUS posi
tion if continuous welding, and place the switch in

6.

wounds.

Do not point gun toward any part of the body,
any conductive surface, or other personnel.

the PULSE

HOT
cause

METAL, SPATTER, AND SLAG

position

if

pulse welding (see Section

5-5).

can

fire and burns.
If pulse welding, rotate the SPOT TIME/PULSE
ON TIME and PULSE OFF TIME control to de
sired settings (see Section 5-5).

7.

Watch for fire.

Keep

fire

a

extinguisher nearby,

how to

use

Do not

use near

and know

it.

Set

8.

Allow work and

flammable material.

equipment

to cool before

handling.
MAGNETIC FIELDS FROM HIGH CURRENTS
affect pacemaker operation.

can

Wearers should consult their doctor before
or spot weld

going near arc welding, gouging,
ing operations.
See Section 1

Rules For Operation Of
Arc Welding Power Source for basic welding
safety information.
-

Safety

voltage

a

condition with the THICKNESS

VOLTS selector plug that is appropriate for the
base metal thickness and type of shielding gas
(see Section 5-2 and Table 6-1).
IMPORTANT: It is important that the selected voltage be
appropriate for type of weld and thickness of material.
Be sure that the weld bead is thoroughly fused with the
base metal along the total length of the bead. If the weld
bead does not

weld

voltage.

penetrate the base metal, increase the

If the

edges

of the bead cut into the base

metal, decrease weld voltage.
Rotate the FINE TUNING WIRE SPEED control

9.

to 50. The control can be

6-1.

a
1.

GAS METAL ARC WELDING (GMAW)-CON
TINUOUS AND GAS METAL ARC WELDINGPULSED ARC (GMAW-P)

while

Install and connect unit

to section 4.

required

at the source.

Turn

11.

Adjust shielding gas pressure, and purge
ing gas hose as follows:
a.

according

as

10.

WARNING: Read and follow safety informa
tion at beginning of entire Section 6 before

proceeding.

adjusted

welding.
on

shielding gas

Open left
spring on

side

access

drive roll

shield

door, release pressure

and pivot upper
drive roll up and away from lower drive roll.

assembly,

OM-113 336

Page

21

Table 6-1.

Suggested

Parameters For Continuous Gas Metal Arc

Voltage Adjustment
Receptacle

1

2

3

4

5

6

Gauges

22-18

18-16

16-14

14-12

12-10

10 or
Heavier

Inches

.035+

.047+

.059+

.067+

.104+

.134+

Millimeters

.8+

1.2+

1.5+

1.9+

2.6+

3.4+

*Amperage For
(0.8 mm) Wire

30-55

55-85

85-105

105-130

130-150

150-180

*Amperage for
(0.9 mm) Wire

35-65

65-95

95-115

115-140

140-180

175-220

Metal
Thickness

.030 in.

.035 in.

*Amperage
~

values

are

obtained

by adjusting

WARNING: ELECTRIC SHOCK

can

the FINE TUNING WIRE SPEED Control.

kill.

cracking sounding

(When optimum arc length
frying bacon).

Do not touch live electrical parts.
Do nottouch

16.

welding wire orany metal part in
welding.

welding wire and all metal parts in contact
with it carry weld current whenever the gun trig
ger is depressed.

Energize welding power source, and depress
gun trigger for approximately 15 seconds to adjust regulator/flowmeter and to purge the gas
hose.

6-2.

GAS METAL ARC WELDING (GMAW)-SPOT
(Models With Optional SPW-1 Panel Only)

a

WARNING: Read and follow safety informa
tion at beginning of entire Section 6 before

Deenergize welding power

source.

d.

Close drive roll housing

follows:

as

Close and

secure

12.

Wear

13.

Energize welding

14.

Be

Wear

dry insulating gloves and clothing.

components.
Disconnect both
ing on a vehicle.

battery

cables before weld

side access door.

power

lens

Disconnect vehicle computer(s) before weldon a vehicle.

ing

ac-

Place work clamp as close to the weld as pos
sible to avoid long electrical paths.

source.

Be

welding wire extends approximately 1/4
in. (6 mm) out gun nozzle, position gun over joint,
lower welding helmet, and depress gun trigger.
sure

The

to Section 4.

CAUTION: WELDING CURRENT can damage
vehicle computers and other electronic

spring.

welding helmet with proper filter
cording to ANSI Z49. 1.

IMPORTANT:

according

IMPORTANT: Be sure the work cable is installed into
NEGATIVE () weld output receptacle and weld cable
from unit is installed into POSITIVE (.4-) weld output re
ceptacle (see Section 4-7).

Pivot upper drive roll down onto lower drive roll,
and reinstall pressure

proceeding.
Install and connect unit

2.

c.

as nec-

essary.

1.

IMPORTANT: Shielding gas flow rate of 15 to 25 cfh is
typical. Welding out of position at high wire feed speeds
or welding in a drafty environment will require more
shielding gas.

is

pulse welding, readjust SPOT TIME/PULSE

If

ON TIME and PULSE OFF TIME control

The

e.

arc.

reached, arc will sound like

contact with it while

b.

Welding (GMAW)

welding

wire is not

energized

all weld circuit connections

are

clean

tight.

Connect work clamp to clean, bare metal at work-

3.

piece.

until

the gun trigger is pressed; therefore, the operator can
accurately position gun on weld joint before lowering
helmet and pressing gun trigger.

sure

and

Select and obtain proper welding wire, and thread
instructed in Section 4-13 of this manual.

4.

as

Set spot weld parameters (weld voltage, wire
speed, spot weld time, burnback time) as

5.

feed
15.

Readjust FINE TUNING

WIRE SPEED control

as

follows:

necessary.
a.

IMPORTANT: Adjust the wire speed to keep weld spatter at a minimum while maintaining a steady, quickOM-113 336 Page 22

Obtain sample piece of metal the same type, but
approximately twice the thickness of final work

piece,

and clean surface to be welded.

b.

Place Selector Switch

on

optional SPW-1 panel

Make several

f.

in CONTINUOUS

position, and set welding volt
age and wire feed speed parameters according
to Steps 8 thru 15 in Section 6-1. (Set voltage
and wire feed

practice spot welds to determine if
correctly. (Refer to
weld.)

weld parameters are set
Table 6-2 to check sample

To spot weld, place gun nozzle directly on workpiece, hold gun motionless, and depress gun

speed for metal thickness of sam

ple metal.)

trigger. When trigger is depressed, welding wire
will feed for the length of time
SPOT TIME/PULSE ON TIME

IMPORTANT: Use in CONTINUOUS position serves as
coarse adjustment of unit for SPOTmode operation. Arc

and

shielding gas

set

on

length and weld puddle can not be observed with spot
welding nozzle installed on gun. Several pieces of
double thickness metal maybe required to coarse adjust

Control.

IMPORTANT:

The welding wire is not energized until
trigger is pressed; therefore, the operator can
accurately position gun on weld joint before lowering
helmet and pressing gun trigger.
the gun

unit.
c.

After

voltage

have

been

and wire feed

speed parameters

set, deenergize welding power
source, remove continuous welding nozzle from

IMPORTANT: The gun trigger must be held closed until
the SPOT TIME/PULSE ON TIME control has timed Out,

gun, and replace nozzle with appropriate spot
nozzle.

completing

welding

Obtain sample pieces of metal the

d.

and thickness of final

Place

same

type

workpiece.
source

6.

released

SHUTTING DOWN

The correct burnback time allows the

back into the contact tube, decrease burnback time. If
the wire burns back into the contact tube, it may be nec

1.

Stop welding.

2.

Shut down

3.

Turn off

a

essary to replace the contact tube in the gun. (See gun
Owners Manual for contact tube replacement proce

welding

Table 6-2.

Appearance

Dark blue circle

or

Checking

small protruside of

Voltage

are set

at the source.

supply

when not in

use.

Weld Parameters

Correction Procedure

and wire feed

parameters

source.

WARNING:
HIGH CONCENTRATION OF
SHIELDING GAS can harm health or kill.

Cause

on reverse

power

shielding gas

Shut off gas

dure.)

sion visible

trigger is

workpiece.

wire to burn back just free of the weld puddle. If the weld
ing wire freezes to the workpiece at the end of the weld
cycle, increase burnback time. If the welding wire burns

Weld

If the

settings.
6-3.

IMPORTANT:

spot weld cycle.

After all weld parameters have been set, prepare
weld joint (see Sections 9 and 10), and weld final

in SPOT mode,

BURNBACK TIME controls to desired

the

before the cycle is complete, the cycle stops, and the unit
resets for another weld cycle.

welding power
and rotate SPOT TIME/PULSE ON TIME and

e.

the

speed
correctly.

None.

weld.

Small

burn-through

on reverse

side of weld.

Excessive
verse

Voltage

and wire feed

speed DecreaseSPOTTIME/PULSEONTIMEControI
setting.

parameters are set correctly,
but spot time too long.

burn-through

on re-

Welding voltage

set too

high.

side of weld.

No dark blue circle
trusion

on reverse

or small proside of weld,

but when welded pieces are
pulled apart, a small hole is torn
in bottom piece of metal.
No dark blue circle
trusion

on reverse

or small proside of weld,

Voltage

Repeat Steps 5a thru f in Section 6-2 to
voltage and wire feed speed parameters.

reset

speed Increase SPOT TIME/PULSE ON TIME Control
correctly, but setting.

and wire feed
set

parameters
spot time too short.

Welding voltage

set too low.

Repeat Steps 5a thru f in Section 6-2 to
voltage and wire feed speed parameters.

reset

and when welded

pieces are
pulled apart, there is minimal
penetration into lower piece of
metal.
OM-113 336 Page 23

SECTION 7

MAINTENANCE & TROUBLESHOOTING

ROUTINE MAINTENANCE

7-1.

IMPORTANT:

Every six months inspect the labels on
legibility. All precautionary labels must be
maintained in a clearly readable state and replaced
this unit for

when necessary. See Parts List for part number of
precautionary labels.

a

Every six months, blow out or vacuum dust and dirt from
welding power source. Remove the out
er enclosure, and use a clean, dry airstream or vacuum
suction for the cleaning operation. If dusty or dirty condi
tions are present, clean the unit monthly.
the inside of the

WARNING:

ELECTRIC SHOCK

can

C.

Inspection

a

kill.

Do not touch live electrical parts.

Shutdown

welding powersource, and discon
input power employing lockout/tagging
procedures before inspecting, maintaining, or
servicing.
nect

Lockout/tagging procedures consist of removing
input power plug from receptacle, padlocking
line disconnect switch in open position, remov
ing fuses from fuse box, or shutting off and redtagging circuit breaker or other disconnecting
device.
MOVING PARTS

can cause

serious

Allow

before

Maintenance to be

door.

1.

Open

2.

Inspect gun for broken areas, cracks, and loose
parts; tighten, repair, and replace as required.

3.

Repair or replace, as required, all hose and cable;
give particular attention to frayed and cracked in

side

access

sulation and

injury.

burns.

areas

where hose and cables enter

Remove grease and

4.

grime from components,

moisture from electrical parts and cable.

servicing.

Do not depress gun trigger while
maintenance on gun.

proceeding.

equipment.

can cause severe

cooling period

Upkeep

WARNING: Read and follow safety informa
tion at beginning of entire Section 7-1 before

Every six months, inspect the gun, hoses, and cables. If
dusty or dirty conditions are present, inspect the unit
monthly. Inspection should consist of the following:

Keep away from moving parts.
HOT SURFACES

and

performing

a

performed only by qualified

CAUTION: FLYING DIRT AND METAL CHIPS

injure personnel

can

and

damage equip

ment.

only in a safe direction away
from personnel and equipment when cleaning
with compressed air.
Point gun liner

persons.
Table 7-1. Maintenance Schedule
Maintenance

Blow out the gun wire guide liner with com
pressed air when changing wire. This will remove

heavy service environ-

any metal chips and dirt that may have

5.

Frequency*
Every

month.

Units in

Check labels, weld
cables, clean internal parts and
drive rolls.
6 months.

Check all labels (see
TANT block, Section
spect gun and cables
7-iC). Clean drive rolls

IMPOR

7-1).

In

(Section
(Section

Internal

a

Cleaning

WARNING: Read and follow safety informa
tion at beginning of entire Section 7-1 before

proceeding.

OM-113 336

Page

24

door.

Of Drive Rolls

WARNING: Read and follow safety informa
tion at beginning of entire Section 7-1 before

proceeding.
can cause

serious

injury.

Do not allow drive rolls to rotate at high speed
if compressed air is used forcleaning the drive
roll assembly.

This unit is equipped with an exhaust fan and relies on
forced draft for adequate cooling. The fan motor requires

B.

access

HIGH ROTATIONAL SPEED can cause dam
age to drive rolls and injure personnel.

Fan Motor

maintenance other than periodic cleaning according

side

Keep away from moving parts.

of service is based cii units operated 40
hours per week. Increase frequency of maintenance if
usage exceeds 40 hours per week.

no

secure

MOVING PARTS

*Frequency

to Section 7-lB.

Cleaning

a

7-iD).

A.

Close and

6.
D.

Every

accumu

lated.

ments:

It is necessary to remove the drive rolls for proper clean
ing of the wire grooves (see Section 7-2 for removal and
installation

instructions). Use

a

wire brush to clean rolls.

IMPORTANT: Failure to properly maintain the drive rolls
result in a buildup of wire particles which decreases
the efficiency of the wire feeding operation.
can

REPLACING DRIVE ROLL AND WIRE INLET

7-2.

GUIDE

b.

(Figure 7-1)

Release pressure
drive roll

As

a result of wear or a change in wire size, it may be
necessary to replace the drive rolls and wire inlet guide.
Proceed as follows:

c.

d.

spring from spring pin

on

cover.

Remove cotter

pin from drive roll cover pivot pin.

Remove pivot pin, thereby
from drive assembly.

freeing

drive roll

cov

er

a

WARNING:

ELECTRIC SHOCK

can

kill.

e.

Do not touch live electrical parts.

Shut down

welding powersource,

and discon

f.

nect

input power employing lockouVtagging
procedures before inspecting, maintaining, or
seivicing.
input power plug from receptacle, padlocking
lir~ disconnect switch in open position, remov

a.

1.

Drive Roll

b.

a.

and

c.

secure

left side

access

door.

facing

insulator). Be

motor

with gear

of the

cover

sure to

align

rear

Align key

in drive roll shaft with

keyway

taining ring

and

front side of

cover.

bearing through hole
side of drive roll cover, through drive roll,

proceeding.

Open

cover

(side facing

the

in drive

roll, and route end of drive roll shaft without

WARNING: Read and follow safety informa
tion at beginning of entire Section 7-2 before

Disassembly

Install drive roll into drive roll

section of drive roll

clearance hole in drive roll with the two shaft
clearance holes in drive roll cover.

device.

a

Push drive roll shaft out drive roll cover until
cover. Be sure that key re
mains in slot in drive roll shaft.

Assembly

ing fuses from fuse box, or shutting off and redtagging circuit breaker or other disconnecting

Replacing Upper

retaining ring and flanged bearing from

end of drive roll shaft.

drive roll falls from

2.

Lockout/tagging procedures consist of removing

A.

Remove
one

re

in rear

and out

Reinstall flanged bearing and retaining ring re
moved in Step le onto end of drive roll shaft.
Lower
Drive Roll
Shaft And Key

Wire Drive
Motor

Brush

(2)

Wire
Inlet
Guide

Drive Roll
Cover spring
Pin

Cotter
Pin

Brush

Cap (2)

Motor
Insulator
Lower
Drive Roll
Lower Drive
Roll Shaft
Self-Locking Nut

Gun/Feeder
Connector

Retaining
Ring

Flanged

Bearing

Drive Roll
Cover
Pivot Pin

FIgure

Weld Cable
Terminal
Nut

Opening

Drive
Roll

7-1.

Replacing

Drive Rolls And Motor Brushes
OM-113 336 Page 25

d.

Reinstall drive roll
roll

e.

f.

spring

Replacing

1.

pin

Close and

5.

on

secure access

drive roll cover, and
door.

a

b.

If

Lockout/tagging procedures consist of removing
input power plug from receptacle, padlocking
line disconnect switch in open position, remov
ing fuses from fuse box, or shutting off and redtagging circuit breaker or other disconnecting

from

roll up,

awayfrom

lower drive roll.
nut from end of lower drive

remove

drive roll. Be

sure

that

key

remains in slot in drive roll shaft.

Assembly
Install drive roll onto lower drive roll shaft

align
key

in drive roll clearance hole with

ing keyway

in drive roll shaft.

with gear section

(Drive roll

facing

device.

the motor

c.

Adjust horizontal position of lower drive roll

or

out as necessary. To move the drive roll in to
wards the motor insulator, rotate the self-lock

ing

necessary proceed

comes

as

the drive rolls. This ad
but if

readjustment

be

follows:

door.

1.

Open

2.

mounting bolts and the weld terminal nut,
securing wire drive housing to the air baffle.

access

Loosen

Slide drive

3.

wire

can

housing upward or downward until the
straight through the guides while

be fed

seated in the drive roll.

nut onto drive roll shaft.

in

is made with mounting holes of
provide adjustment of the wire

guides up or down in relation to
justment has been factory set,

insulator.)

Reinstall

housing

sufficient clearance to

must be installed

b.

self-locking

kill.

welding powersource, and discon
input power employing lockout/tagging
procedures before inspecting, maintaining, or
servicing.

The wire drive

applicable, pivot upper drive

roll shaft, and

can

Shutdown

proceeding.

self-locking

(Figure

Do not touch live electrical parts.

WARNING: Read and follow safety informa
tion at beginning of entire Section 7-2 before

Remove

REALIGNMENT

WARNING: ELECTRIC SHOCK

Lower Drive Roll

If applicable, release pressure spring
spring pin on drive roll cover.

a.

door.

access

nect

a.

2.

side

4-7)

Disassembly

c.

secure

HOUSING

DRIVE

7-3.

pivot pin.

onto

spring pin

over

close and

a

pivot pin into drive

or changing lower drive roll, proceed
7-2B; otherwise, reengage pressure

installing

to Section

B.

and

assembly.

Reinstall cotter
If

cover

4.

Tighten mounting

5.

Close and

bolts and weld terminal nut.

secure access

door.

REPLACING HUB ASSEMBLY (Figure 7-2)

7-4.

nut clockwise. To move the drive roll out

away from the center panel of the unit, rotate the
nut counterclockwise.

If it should become necessary to replace part or all of the
assembly, reinstall the new hub assembly as

hub

follows:

IMPORTANT:

Be

that upper and lower drive roll
meshed
and the drive roll grooves are
are
properly
gears
when
horizontal
aligned
adjusting
position of lower drive
sure

shaft in order

roll.
d.

Reengage
drive roll

e.

If

pressure

spring

over

spring pin

on

wire inlet

replacing

guide, proceed
secure

side

access

Wire Inlet Guide

1.

Loosen wire

2.

Remove wire

3.

Install

new

guide securing
guide from

wire

left side of drive

screw.

drive

housing.

guide through mounting hole
housing (see Figure 7-1).

in

IMPORTANT: Wire guide should be installed as close to
the drive rolls as possible without touching them.
4.

Tighten

OM-113 336

Page

wire
26

a.

Fiber Washer

b.

Brake Washer

c.

Hub

d.

Brake Washer

e.

Fiber Washer

f.

Keyed Washer

g.

Spring

h.

Flat Washer

to Section

door.

Replacing

single support

given:

cover.

7-20; otherwise, close and

C.

Slide the following items onto the

1.

guide securing

setscrew.

2.

Rotate hex nut onto support shaft. Hex nut should
only until a slight drag is felt while turn

be rotated

ing

hub.

welding

3.

Install

4.

Reinstall

wire

according

retaining ring

to Section 4-13.

onto hub.

Retaining
Ring

Hex Nut

Keyed

Washer

Washer

Spring
Hub
Fiber Washer

Brake Washer

*COmpreSsion
Spring

*

Used With 8 In.

Fiber Washer

(203 mm) Spools.

Pef. SD.072 509G

Figure
7-5.

INSPECTING
BRUSHES

REPLACING

AND

7-2. Hub

MOTOR

Assembly
OVERLOAD PROTECTION

7-6.

(Figure 7-1)

WARNING: ELECTRIC SHOCK
.

WARNING: ELECTRIC SHOCK

can

kill.

Shutdown

Do not touch live electrical parts.

Shutdown

welding powersource,

Lockout/tagging procedures Consist of removing
power plug from receptacle, padlocking

input

2.

Remove the brush caps (two).

3.

Remove brushes.

4.

access

door.

A.

Circuit Breaker CB1

WARNING: Read and follow safety informa
tion at beginning of entire Section 7-6 before

proceeding.

The drive motor is

Examine brushes. Replace brushes if they are
chipped or broken or if less than 1/4 in. (6 mm) of

welding power
5.

Install brushes, and

secure

with caps.

protected from damage

due to

over

by circuit breaker CB1, located under the access
door. Should an overload on CB1 occur, the contactorW
load

coil would open

brush material remains.

or

device.

a

Open

and discon

Lockout/tagging procedures consist of removing
input power plug from receptacle, padlocking
line disconnect switch in open position, remov
ing fuses from fuse box, or shutting off and redtagging circuit breaker or other disconnecting

servicing.

1.

welding powersource,

procedures before inspecting, maintaining,
servicing.

input power employing lockout/tagging
procedures before inspecting, maintaining, or
nect

line disconnect switch in open position, remov
ing fuses from fuse box, or shutting off and redtagging circuit breaker or other disconnecting
device.

kill.

input power employing lockout/tagging

nect

and discon

can

Do not touch live electrical parts.

If CB1 opens,

thereby stopping

all output from the

source.

manually

reset the circuit breaker as fol

lows:

a

CAUTION: DISASSEMBLY OF THE MOTOR
FIELD MAGNETS can result in personal in
jury and equipment damage.
Limit drive motor

repairs

to brush

1.
2.

replace

6.

Close and

secure access

door.

access

door.

Check for jammed wire

or clogged gun liner, and
problem. If motor overload occurs repeat
edly, repair or replace the motor or liner.

correct

ment.

The field magnets are very strong. If disassem
bly is attempted, injury to fingers and hands may
result from the rotor being drawn back into the
motor. The field magnets are matched sets, and
operation may be affected if the magnets are
tampered with. Warranty is void if the motor is
tampered with.

Open

3.

Check for binding drive gear
rolls, and correct problem.

4.

Reset circuit breaker CB1

or

drive

(depress button); it
cooling period before

may be necessary to allow
the breaker can be reset.

a

5.

Close and

door.

6.

Resume

secure access

misaligned

operation.
OM-113 336

Page

27

B.

Circuit Breaker CB2

7-9.

TROUBLESHOOTING

a

WARNING: ELECTRIC SHOCK

WARNING: Read and follow safety informa
tion at beginning of entire Section 7-6 before

a

proceeding.

Circuit breaker CB2 protects the 24 volts ac winding of
transformer Ti from overload. CB2 is located under the
door. Should CB2 open, the contactor W coil
would open thereby stopping all output from the welding

kill.

can

Do not touch live electrical parts.

access

power
7-7.

source.

If CB2 opens,

manually reset the

Shutdown

welding powersource, and discon
input power employing lockout/tagging
procedures before inspecting, maintaining, or
servicing.
nect

breaker.

THERMAL OVERLOAD PROTECTION

Rectifier

SRi

is

protected from overheating by

Lockout/tagging procedures consist of removing
input power plug from receptacle, padlocking

a

normally-closed thermostat TP3 wired in series with
relay CR1 and contactor W coil circuit. Should overheat
ing occur, TP3 would open causing CR1 and thereby the
contactor to drop out (deenergize) and the wire drive
motor to stop, thereby stopping all weld output. If this
condition occurs, it will be necessary to allow a cooling
period before resuming operation.
7-8.

a

line disconnect switch in open position, remov
ing fuses from fuse box, or shutting off and redtagging circuit breaker or other disconnecting
device.

MOVING PARTS

HOT SURFACES

PRINTED CIRCUIT BOARD REPLACEMENT

WARNING:

ELECTRIC SHOCK

can

Allow

kill.

welding powersource,

serious

injury.

moving parts.

can cause severe

burns.

cooling period before servicing.

Troubleshooting

Do not touch live electrical parts.
Shutdown

can cause

Keep away from

to

be

performed

only

by

qualified persons.
and discon

input power employing lockout/tagging
procedures before inspecting, maintaining, or
nect

servicing.

Lockout/tagging procedures consist of removing
input power plug from receptacle, padlocking
line disconnect switch in open position, remov
ing fuses from fuse box, or shutting off and redtagging circuit breaker or other disconnecting
device.

It is assumed that the unit

ing

to Section 4 of this

with the function of
was

a

CAUTION:

(ESD)

ELECTROSTATIC DISCHARGE

damage circuit boards.
Put on properly grounded wrist strap
FORE handling circuit boards.

manual, the operator is familiar
source

and that the trouble is not related

welding process.

BE
The

following table is designed

remedies for

some

this

Perform work

with the circuit

only at a

static-safe work

area.

INCORRECT INSTALLATION or misaligned
plugs can damage circuit board.
sure

that

plugs

are

properly

installed and

aligned.
EXCESSIVE PRESSURE
board.
Use

Page

28

welding power

forming

these

diagnose

and provide

of the troubles that may
source.

diagram

ing procedures.

to

Use this table in

while

performing

develop

can

break circuit

in

conjunction

troubleshoot

If the trouble is not remedied after per

procedures,

contact the nearest

Authorized Service Station. In all

cases

dures and instructions.

Factory

of equipment

malfunction, strictly follow the manufacturers

minimal pressure and gentle move
when disconnecting or connecting
board plugs and removing or installing board.

only

ment

OM-113 336

installed accord

can

Transport circuit boards in proper staticshielding carriers or packages.

Be

properly

controls, the welding power

working property,

to the

was

proce

Table 7-2.

Troubleshooting

TROUBLE

PROBABLE CAUSE

No weld output; wire does not

Line Disconnect Switch in OFF

feed.

position.

REMEDY
Place Line Disconnect Switch in ON

position.

.

Improper electrical input

con-

See Section 4-12 for proper

input

connections.

nections.

Input voltage jumper links
position.

not in

See Section 4-12 for proper

jumper

link

position.

proper

Line

fuse(s)

Check and

open.

Main rectifier SRi

overheating

replace

open line fuses.

Allow rectifier to cool down

(see Section 7-7).

(thermal shutdown).
Gun

switch,

or

gun

switch

See gun Owners

Manual.

leads.

No weld output; wire feeds.

POWER switch Si.

Replace Si.

Switch control relay CR1.

Replace CR1.

THICKNESS VOLTS plug not

Secure connection.

secure

in

receptacle.

Work clamp connection loose
or incomplete due to rust, paint,
etc. on surface of

Low weld output.

Check work connection for good metal-to-metal
contact.

workpiece.

Contact tube.

See gun Owners

Low

Check for proper

input voltage.

Input voltage jumper

link

in

Manual.

input voltage.

SeeSection4-i2forproperjumperlinkposition.

wrong position.
Electrode

wire

stops feeding

Circuit breaker CB2.

Check and reset CB2 if necessary (see Section

welding.

7-6).

Sharp or excessive bend in gun
cables or liners,

Straighten gun cables and/or replace
gun Owners Manual).

Incorrect hub tension.

Readjust

~

while

Contact

hub tension

(see Section 4-li).

See gun Owners

Manual.

Friction in gun.

See gun Owners

Manual.

Gun liner dirty, restricted.

See gun Owners

Manual.

See gun Owners

Manual.

tube

opening

re-

liners (see

stricted; burnback of wire into
tube.
.

Broken

or

damaged gun

liner.

Worn drive rolls.

Replace drive

Drive rolls

misaligned.

Realign

Excessive

loading of

drive

mo-

rolls

drive rolls

(see Section 7-2).

(see Sections

Clear restriction in drive

7-2 and

7-3).

assembly.

tor.

Drive motor brushes.

Check and

replace

brushes if necessary

(see

Section 7-5).
Check and replace motor if necessary.

Drive Motor M.

Gun
or

Unit shuts down while

welding.

trigger

switch

inoperative

See gun Owners

Manual.

leads broken.

Fan motor FM.

Check and replace FM if necessary.

OM-113 336

Page

29

Table 7.2.

TROUBLE
No open-circuit

Troubleshooting (Continued)

PROBABLE CAUSE

REMEDY

THICKNESS VOLTS plug not

voltage.

secure

in

Secure

plug

in

receptacle.

receptacle.

Contactor W points.

Contact nearest Factory Authorized Service Sta
tion.

Gun switch.

See gun Owners

Transformer Ti.

Manual.

Contact nearest Factory Authorized Service Sta
tion.

Plug

PLG2 not

secure

in recep-

Secure PLG2 into RC55.

tacle RC55

(models with option
al Spot Weld Panel only).

Wire does not feed; open circuit
voltage normal.

Circuit breaker CB1

or

Reset CB1

CB2.

Rectifier SR2.

or

CB2 (see Section 7-6).

Contact nearest Factory Authorized Service Sta
tion.

Wire feed motor M.

Replace M.

weld timer does not time
(models with SPW-1 panel).

SPW-1
PC5O.

panel

Authorized Service Station.

Pulsed wire feed operation not

SPW-i

panel

available.

PC5O.

Spot
out

SECTION 8

or

or

circuit board

circuit board

See Section 7-8, and contact nearest

Factory

See Section 7-8, and contact nearest
Authorized Service Station.

Factory

ELECTRICAL DIAGRAMS

3

64-

84
230V.
TE I

q

~

POSITIVE

NEGATIVE

Circuit Diagram No. SB-121 827

Diagram
OM-113 336

Page

30

8.1. Circuit

Diagram

For MW 4150 Models

AC

B
5C3

:3

4

<
PLOP

SI

230V.

TE I

PLG2

POSITIVE

NEGATIVE

Circuit

Diagram

8-2. Circuit

Diagram

Diagram

No. SB-i 37 373

Diagram

No. A-ago 568-A

For MW 4200 Models
OFF
Ti ME

PLO 51

68f~1~69
S

~
CONT.

V


C)

>~

H~

I

Z

o

0

a)
a)
Co
-J

IC))
+1
C
(31C~U1C7I
O~
~ -J

Iflg~
Wa)

Ox
R69

Figure

11-7. Circuit

~O

~

D

0)0)0)
~

0)0)0)

0)
N)

a)-J

SB~O97 696~A

Card, Dual Tlmer/Pulser PC5O

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-113 336 Page 51

1
2

Dia.

Part
No.

Mkgs.

Figure
1

108940

2

025193

3

604 423

4

5

057478
022617

6

602389

7

602387

8
9

602384
070 799

10
11

602250
052693

12

052692

13

121 614

14

601 944

15

602211

16

601 869

17

008999
052691

18
19

602213

20

601 871

Quantity

Description
11-8.

Running Gear

SCREW, cap stl hexwhd .250-20 x .750
HANDLE, running gear
GRIP, handle .875 ID x 4.500
BRACKET, support tank
CHAIN, cyl racks (consisting of)
HOOK, S blunt 1.500 in
CHAIN, weldless 2/0 x 27 in
SNAP, chain
WHEEL, rubolene 10 in dia
WASHER, flat stl SAE .750
RACK, cylinder
AXLE, running gear (consisting of)
RING, retaining ext .750 shaft x .082
SCREW, cap sti hexhd .312-18 x .750
WASHER, lock stl split .312
NUT, stl hex jam 312-18
CASTER, plastic swvl 4 in dia
ANGLE, spreader cyl rack
WASHER, lock stl split .375
NUT, stl hex jam .375-16

4

1

2
1
1

1
I
1
1
4
1
1

2
4
4

4

1

5

11

~~15

14

~17
SC-049 808-E

Figure

11-8.

Running Gear

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-113 336

Page

52

I



---

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