Page 1
MiOØrfi~
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#~41uI14Ft~4S4IV1
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I
I
~.w
April
1993
Form:
OM-157
745
Effective
With
Serial
No.
KD398640
OWNERS
MANUAL
Gold
SealTM
Model
5000
Read
and
follow
these
instructions
and
all
safety
blocks
carefully.
Have
only
trained
and
qualified
persons
install,
operate,
or
service
this
unit.
Call
your
distributor
if
you
do
not
understand
the
directions.
CV/DC
Welding
Power
Source/Wire
Feeder
For
FCAW
Welding
Or
GMAW
Welding
With
Optional
Gas
Valve
Rated
Output
Of
70
Amperes
At16Volts
DC,
20%
Duty
Cycle
Uses
115
VAC
Single-Phase
Input
Power
Motor
Overload
Protection
Basic
Model
Includes
Gun,
Standard
Model
Adds
Gas
Valve,
Deluxe
Model
Adds
Gas
Regulator/Flowmeter
U
Give
this
manual
to
the
operator.
For
help,
call
your
distributor
or:
MILLER
ELECTRIC
Mfg.
Co.,
P.O.
Box
1079,
Appleton,
WI
54912
414-734-9821
cover
8/92
ST.161
158
PRINTEDINUSA
Page 2
Page 3
J
U
MILLERS
TRUE
BLUETM
LIMITED
WARRANTY
EffectIve
January
1,
1992
(Equipment
withaserial
number
preface
of
KC
or
newer)
This
limited
werrenty
supersedes
sit
previous
MILLER
warrentlas
end
is
eaclunive
withnoother
gusrentees
or
warrenflea
espreseed
or
Implied.
al-
LIMITED
WARRANTYSubject
to
the
terms
end
conditions
below,
MILLER
Electric
Mlg.
Co.,
Appleton,
Wioconain,
werrents
to
its
original
retell
purcheser
thet
new
MILLER
equipment
sold
elfer
the
effective
dete
of
this
limited
werrenty
is
free
of
de
tects
in
meteriel
end
workmanship
et
the
timeitis
shipped
by
MILLER.
THIS
WAR
RANTY
IS
EXPRESSLY
IN
LIEU
OF
ALL
OTHER
WARRANTIES,
EXPRESS
OR
IMPLIED,
INCLUDING
THE
WARRANTIES
OF
MERCHANTABILITY
AND
FIT
NESS.
Within
the
werrenty
periods
listed
below,
MILLER
will
repeir
or
replece
eny
wer
rented
perle
or
components
thet
tell
due
to
such
defectsinmeteriel
or
workmanship.
MILLER
must
be
notified
in
writing
within
thirty
(30)
deys
of
such
detect
or
teiture,
et
which
time
MILLER
will
provide
instructions
on
the
werrenty
cleim
procedures
to
be
followed.
MILLER
shell
honor
werrenty
ctelme
on
werrented
equipment
listed
belowinthe
event
of
such
e
teilure
within
the
werrenty
time
periods.
All
werrenty
time
periods
stert
on
the
dete
thet
the
equipment
wee
deliveredtothe
originel
retell
purcheser,
end
ere
es
follows:
t.
S
Yeers
Perts
3
Yeers
Lebor
Originel
mein
power
rectifiers
2.
3
Yeers
Perts
end
Lebor
Treneformer/Rectilier
Power
Sources
*
Plesme
Arc
Cutting
Power
Sources
Semi-Autometic
end
Autometic
Wire
Feeders
Robots
3.
2
Yeers
Perte
end
Lebor
Engine
Driven
Welding
Generet
ore
)NOTE:
Engines
em
werrented
eeperetely
by
the
engine
menufecturer.)
4.
1
Yeer
Perte
end
Lebor
*
Motor
Driven
Guns
Process
Controllers
Water
Coolent
Systems
HF
Unite
*
Grids
Spot
Welders
*
Loed
Benko
SDX
Trenetormern
*
Running
Geer/Treilere
*
Field
Options
(NOTE:
Field
options
ere
covered
under
True
BIaenM
for
the
remeining
werrenty
period
of
the
product
they
ere
inatelled
in,
or
foreminimum
of
one
yeer
whichever
in
greeter.)
S.
6
Months
Bell
eries
6.
90
Deye
Perle
end
Lebor
MIG
Gune/TIG
Torches
*
Pleeme
Culling
Torches
*
Remote
Controls
4>
*
Acceeeory
Kite
*
Replecement
Perle
MILLERS
True
BtuenM
Limited
Werrenty
shell
not
epply
to:
1.
Iteme
furnished
by
MILLER,
but
menufectured
by
others,
such
es
engines
or
trede
ecceeeoriee.
These
items
ere
covered
by
the
menufeclurers
werrenty,
If
eny.
2.
Coneumeble
components;
euch
en
contect
tips,
culling
nozzles,
contectore
end
releye.
3.
Equipment
thet
hen
been
modified
by
eny
perty
other
then
MILLER.
or
equip
ment
thet
hee
been
improperly
inetelled,
improperly
opereted
or
mIsused
based
upon
induetry
etenderde,
or
equipment
which
hee
not
hed
reeeonebte
end
neceeeery
meintenence,
or
equipment
which
hoe
been
used
for
operetlon
outside
of
the
epeciticetione
for
the
equipment.
MILLER
PRODUCTS
ARE
INTENDED
FOR
PURCHASE
AND
USEBYCOMMER
CIAtJINDUSTRIAL
USERS
AND
PERSONS
TRAINED
AND
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
OF
WELDING
EOUIPMENT.
In
the
event
of
e
werrenty
claim
coveredbythis
werrenty.
the
eecluslve
remedies
shell
be,
et
MILLERS
option:
II)
repeir;or12)
replecement;
or,
where
euthorlzed
In
writing
by
MILLER
in
eppropriete
ceees,
)3)
the
reesoneble
cost
of
repelr
or
replece
ment
at
en
euthorized
MILLER
service
stetlon;
or
(4)
peyment
of
orcredlt
for
the
pur
chase
price
(less
reesonebte
deprecietion
besed
upon
ectuel
use)
upon
return
of
the
goode
et
customers
risk
end
espenee.
MILLERS
option
of
repeir
or
reptecement
will
be
FOB.,
Fectory
at
Appleton,
Wisconsin,
or
FOB.
et
e
MILLER
euthorlzed
ser
vice
facility
es
determined
by
MILLER.
Therefore
no
compensetion
or
reImburse
ment
for
transportation
costs
of
eny
kind
wilt
be
ellowed.
TO
THE
EXTENT
PERMITTED
BY
LAW,
THE
REMEDIES
PROVIDED
HEREIN
ARE
THE
SOLE
AND
EXCLUSIVE
REMEDIES.
IN
NO
EVENT
SHALL
MILLER
BE
LIABLE
FOR
DIRECT,
INDIRECt
SPECIAL,
INCIDENTALORCONSEOUENTIAL
DAMAGES
(INCLUDING
LOSS
OF
PROFIT).
WHETHER
BASED
ON
CON
TRACT,
TORT
OR
ANY
OTHER
LEGAL
THEORY.
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
ANY
IMPLIED
WAR
RANTY,
GUARANTY
OR
REPRESENTATION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
BREACH
OF
CONTRACT
TORT
OR
ANY
OTHER
LEGAL
THEORY
WHICH,
BUT
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
IN
CLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
AND
ALL
EOUIPMENT
FURNISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MtLLER.
Some
otetee
in
the
U.S.A.
do
not
allow
Ilmitetions
of
how
long
en
implIed
werrenty
lesto,
or
the
eaclusion
of
incidentel.
indirect.
opeciel
or
consequentlel
demeges,
so
the
ebove
limitationoreaciusion
may
not
apply
to
you.
This
werrenty
provides
spe
cific
legal
rights,
end
other
rights
may
be
available,
but
may
vary
from
statetostate.
In
Canada,
legislation
in
some
provinces
provides
for
certain
additional
warranties
or
remedies
other
than
as
staled
herein.
andtothe
entent
that
they
may
not
be
waived,
the
limitations
and
eaclusione
eat
out
abova
may
not
apply.
ThIs
Limited
Warranty
provides
specific
legal
rights,
and
other
rights
may
be
available,
but
may
vary
1mm
provincetoprovince.
F
-
RECEIVING-HANDLING
Before
unpack)ng
equipment,
ChBCk
carton
for
any
damage
that
may
haVB
occurred
dUr)ng
shipment.
File
any
C)aimS
for
)oss
or
damage
with
the
delivering
carrier,
Assistance
for
filing
or
setthng
c)aims
may
be
obta)ned
from
distributor
and/or
equipment
manufacturers
Transportation
Department.
When
requesting
information
about
this
equipment,
always
provide
Mode)
Designation
and
Serial
or
Style
Number.
Use
the
following
spaces
to
record
Model
Designation
and
Serial
or
Style
Number
of
your
unit.
The
information
is
located
on
the
rating
label
or
nameplate.
Model
_________
Serial
or
Style
No.
DateofPurchase
miller
5/92
Page 4
Page 5
ARC
WELDING
SAFETY
PRECAUTIONS
Read
all
safety
messages
throughout
this
manual.
Obey
all
safety
messages
to
avoid
injury.
Learn
the
meaning
of
WARNING
and
CAUTION.
A~
WARNING
ARC
WELDING
can
be
hazardous.
PROTECT
YOURSELF
AND
OTHERS
FROM
POSSIBLE
SERIOUS
INJURY
OR
DEATH.
KEEP
CHILDREN
AWAY.
PACEMAKER
WEARERS
KEEP
AWAY
UNTIL
CONSULTING
YOUR
DOCTOR.
In
welding,
as
in
most
jobs,
exposure
to
certain
hazards
occurs.
Welding
is
safe
when
precautions
are
taken.
The
safety
information
given
below
is
only
a
summary
of
the
more
complete
safety
information
that
will
be
found
in
the
Safety
Standards
listedonthe
next
page.
Read
and
follow
all
Safety
Standards.
HAVE
ALL
INSTALLATION,
OPERATION,
MAINTENANCE,
AND
REPAIR
WORK
PERFORMED
ONLY
BY
QUALIFIED
PEOPLE.
ELECTRIC
SHOCK
can
kill.
Touching
live
electrical
parts
can
cause
fatal
shocks
or
severe
burns.
The
electrode
and
work
circuit
is
electrically
live
whenever
the
output
is
on.
The
input
power
circuit
and
machine
internal
circuits
are
also
live
when
power
is
on.
In
semiautomatic
or
automatic
wire
welding,
the
wire,
wire
reel,
drive
roll
housing,
and
all
metal
parts
touching
the
welding
wire
are
electrically
live.
Incorrectly
installed
or
improperly
grounded
equipment
is
a
hazard.
1.
Do
not
touch
live
electrical
parts.
2.
Wear
dry,
hole-free
insulating
gloves
and
body
protection.
3.
Insulate
yourself
from
work
and
ground
using
dry
insulating
mats
or
covers.
4.
Disconnect
input
power
or
stop
engine
before
installing
or
servicing
this
equipment.
5.
Properly
install
and
ground
this
equipment
according
to
its
Owners
Manual
and
national,
state,
and
local
codes.
6.
Turn
oft
all
equipment
when
not
in
use.
7.
Do
not
use
worn,
damaged,
undersized,
or
poorly
spliced
cables.
8.
Do
not
wrap
cables
around
your
body.
9.
Ground
the
workpiece
to
a
good
electrical
(earth)
ground.
10.
Do
not
touch
electrode
while
in
contact
with
the
work
(ground)
circuit.
11.
Use
only
well-maintained
equipment.
Repair
or
replace
damaged
parts
at
once.
12.
Wear
a
safety
harness
to
prevent
falling
if
working
above
floor
level.
13.
Keep
all
panels
and
covers
securelyinplace.
/~p~
~2
-
ARC
RAYS
can
burn
eyes
and
skin;
NOISE
can
damage
hearing.
Arc
rays
from
the
welding
process
produce
intense
heat
and
strong
ultraviolet
rays
that
can
burn
eyes
and
skin.
Noise
from
some
processes
can
damage
hearing.
1.
2.
3.
4.
5.
Wear
a
welding
helmet
fitted
with
a
proper
shadeoffilter
(see
ANSI
Z49.1
listed
in
Safety
Standards)
to
protect
your
face
and
eyes
when
weldingorwatching.
Wear
approved
safety
glasses.
Side
shields
recommended.
Use
protective
screens
or
barriers
to
protect
others
from
flash
and
glare;
warn
others
nottowatch
the
arc.
Wear
protective
clothing
made
from
durable,
flame-resistant
material
(wool
and
leather)
and
foot
protection.
Use
approved
ear
plugs
or
ear
muffs
if
noise
level
is
high.
1
2
\
A~
WARNING
2
a
CAUTION
/
1
Safety
Alert
Symbol
______________
3
I
~
ELECTRIC
SHOCK
can
kill
MOVING
PARTS
can
Injure.
I
Do
not
touch
live
electrical
parts.
h
1…~I.
Keep
away
tram
moving
parts.
Disconnect
input
power
before
installingorservicing.
J~j
~
Keep
all
panels
and
covers
closed
I
when
operating.
5
2
SignalWord
WARNING
means
possible
death
or
serious
injury
can
happen.
CAUTION
means
possible
minor
injuryorequipment
damage
can
happen.
V
6
3
Statement
Of
Hazard
And
Result
NOTE
~
READ
SAFETY
BLOCKS
at
start
of
I
_____
Section
3-1
before
proceeding.
4
Safety
InstructionsToAvoid
Hazard
Turn
Off
switch
when
using
high
frequency.
5
Hazard
Symbol
(If
Available)
6
Safety
Banner
Read
safety
blocks
for
each
sym.
bol
shown.
7
NOTE
Special
instructions
for
best
oper
ation
not
related
to
safety.
Page 6
Page 7
FUMES
AND
GASES
can
be
hazardous
to
your
health.
Welding
produces
fumes
and
gases.
Breathing
these
fumes
and
gases
can
be
hazardous
to
your
health.
Keep
your
head
out
of
the
fumes.
Do
not
breath
the
fumes.
If
inside,
ventilate
the
area
and/or
use
exhaustatthe
arc
to
remove
welding
fumes
and
gases.
3.
If
ventilation
is
poor,
use
an
approved
air-supplied
respirator.
4.
Read
the
Material
Safety
Data
Sheets
(MSDSs)
and
the
manufacturers
instruction
for
metals,
consumables,
coatings,
and
cleaners.
5.
Work
in
a
confined
space
only
if
it
is
well
ventilated,
or
while
wearing
an
air-supplied
respirator.
Shielding
gases
used
for
welding
can
displace
air
causing
injury
or
death.
Be
sure
the
breathing
air
is
safe.
6.
Do
not
weldinlocations
near
degreasing,
cleaning,orspraying
operations.
The
heat
and
rays
of
the
arc
can
react
with
vapors
to
form
highly
toxic
and
irritating
gases.
7.
Do
not
weldoncoated
metals,
such
as
galvanized,
lead,
or
cadmium
plated
steel,
unless
the
coating
is
removed
from
the
weld
area,
the
area
is
well
ventilated,
and
if
necessary,
while
wearinganair-supplied
respirator.
The
coatings
and
any
metals
containing
these
elements
can
give
off
toxic
fumes
if
welded.
Chipping
and
grinding
cause
flying
metal.Aswelds
cool,
they
can
throw
off
slag.
PRINCIPAL
SAFETY
STANDARDS
Safety
in
Welding
and
Cutting,
ANSI
Standard
Z49.1,
from
American
Welding
Society,
550
N.W.
LeJeune
Rd,
Miami
FL
33126
Safetyand
Health
Standards,
OSHA
29
CFR
1910,
from
Superintendent
of
Documents,
U.S.
Government
Printing
Office,
Washington,
D.C.
20402.
Recommended
Safe
Practices
for
the
Preparation
for
Welding
and
Cutting
of
Containers
That
Have
Held
Hazardous
Substances,
American
Welding
Society
Standard
AWS
F4.1,
from
American
Welding
Society,
550
N.W.
LeJeune
Rd,
Miami,
FL
33126
National
Electrical
Code,
NFPA
Standard
70,
from
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
Safe
Handling
of
Compressed
Gases
in
Cylinders,
CGA
Pamphlet
P-i,
from
Compressed
Gas
Association,
1235
Jefferson
Davis
Highway,
Suite
501,
Arlington,
VA
22202.
Code
for
SafetyinWelding
and
Cutting,
CSA
Standard
Wi
17.2,
from
Canadian
Standards
Association,
Standards
Sales,
178
Rexdale
Boulevard,
Rexdale,
Ontario,
Canada
M9W1R3.
Safe
Practices
For
Occupation
And
Educational
Eye
And
Face
Protection,
ANSI
Standard
Z87.
1
,from
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
1.
2.
WELDING
can
cause
fire
or
explosion.
5.
Watch
for
fire,
and
keep
a
fire
extinguisher
nearby.
Sparks
and
spatter
fly
off
from
the
welding
arc.
The
flying
sparks
and
hot
metal,
weld
spatter,
hot
workpiece,
and
hot
equipment
can
cause
fires
and
burns.
Accidental
contact
of
electrode
orwelding
wire
6.
7.
Be
aware
that
welding
on
a
ceiling,
floor,
bulkhead,
or
partition
can
cause
fire
on
the
hidden
side.
.
Do
not
weld
on
closed
containers
such
as
tanks
or
drums.
to
metal
objects
can
cause
sparks,
overheating,
or
fire,
8.
Connect
work
cabletothe
workasclose
to
the
welding
area as
practical
to
prevent
welding
currentfrom
traveling
long,
possibly
.
1.
Protect
yourself
and
others
from
flying
sparks
and
hot
metal.
2.
Do
not
weld
where
flying
sparks
can
strike
flammable
material.
9.
unknown
paths
and
causing
electric
shock
and
fire
hazards.
Do
not
use
welder
to
thaw
frozen
pipes.
3.
Remove
all
flammables
within
35
ft
(10.7
m)
of
the
welding
arc.
If
this
is
not
possible,
tightly
cover
them
with
approved
covers,
10.
Remove
stick
electrode
from
holder
or
cut
off
welding
wire
at
contact
tip
when
not
in
use.
4.
Be
alert
that
welding
sparks
and
hot
materials
from
welding
can
11.
Wearoil-free
protective
garments
such
as
leather
gloves,
heavy
easilygothrough
small
cracks
and
openingstoadjacent
areas,
shirt,
cuffless
trousers,
high
shoes,
and
a
cap.
FLYING
SPARKS
AND
HOT
METAL
can
cause
injury,
1.
2.
Wear
approved
face
shield
or
safety
goggles.
Side
shields
recommended.
Wear
proper
body
protection
to
protect
skin.
CYLINDERS
can
explodeifdamaged.
3.
Keep
cylinders
away
from
any
welding
or
other
electrical
circuits.
1.
Shielding
gas
cylinders
contain
gas
under
high
pressure.
If
damaged,acylinder
can
explode.
Since
gas
cylinders
are
normally
part
of
the
welding
process,
be
sure
to
treat
them
carefully.
Protect
compressed
gas
cylinders
from
excessive
heat,
mechanical
shocks,
and
arcs.
4.
5.
6.
7.
Never
allow
a
welding
electrode
to
touch
any
cylinder.
Use
only
correct
shielding
gas
cylinders,
regulators,
hoses,
and
fittings
designed
for
the
specific
application;
maintain
them
and
associated
parts
in
good
condition.
Turn
face
away
from
valve
outlet
when
opening
cylinder
valve.
Keep
protective
cap
in
place
over
valve
except
when
cylinder
is
in
use
or
connected
for
use.
2.
Install
and
secure
cylinders
in
an
upright
position
by
chaining
8.
Read
and
follow
instructions
on
compressed
gas
cylinders,
them
to
a
stationary
support
or
equipment
cylinder
rack
to
associated
equipment,
and
CGA
publication
P-i
listed
in
Safety
prevent
falling
or
tipping.
Standards.
Cutting
And
Welding
Processes,
NFPA
Standard
51
B,
from
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
Page 8
Page 9
TABLE
OF
CONTENTS
SECTION
1
SPECIFICATIONS
1-1.
Volt-Ampere
Curve
And
Duty
Cycle
Chart
1
SECTION
2INSTALLATION
2-1.
Installing
Work
Clamp
2
2-2.
Gun
Polarity
For
Wire
Type
2
2-3.
Installing
Welding
Gun
3
2-4.
Connecting
Input
Power
3
2-5.
Threading
And
Feeding
Welding
Wire
.
3
2-6.
Installing
Gas
Supply
5
SECTION
3OPERATION
6
SECTION
4-
MAINTENANCE
&
TROUBLESHOOTING
4-1.
Overload
Protection
7
4-2.
Drive
Assembly
Maintenance
8
4-3.
Gun
Maintenance
9
4-4.
Troubleshooting
10
SECTION
5
ELECTRICAL
DIAGRAMS
11
SECTION
6
PARTS
LIST
Figure
6-1.
Main
Assembly
13
Figure
6-2.
Drive
Assembly,
Wire
15
Figure
6-3.
GA-i
6C1
Gun
16
OM.1
57
745
4/93
Page 10
Page 11
Page 12
Page 13
SECTION
1
SPECIFICATIONS
Table
1-1.
Welding
Power
Source
a
CAUTION
30
25
20
15
g
5
0
I0
Specifications
Description
Type
Of
Output
Constant
Voltage/Direct
Current
(CV/DC)
Rated
Weld
Output
70
Amperes,
16
Volts
DC,
20%
Duty Cycle
Type
Of
Input
Power
Single-Phase;
60
Hz;
At
115
Volts
AC
Input
Amperes
At
Rated
Output
15
A
KVA/KW
UsedAtRated
Output
2.2
kVN2
kW
Max.
Open-Circuit
Voltage
29
Volts
DC
Control
Circuit
Voltage
At
Gun
24
Volts
DC
Welding
Processes
Flux
Cored
Arc
(FCAW)
And
Gas
Metal
Arc
Welding
(GMAW)
Speed
Range
AtNoLoad
22
To
286
ipm
(0.6
To
7.3
mpm)
Wire
Diameter
Range
.023
To
.035
in
(0.58
To
0.89
mm)
Overall
Dimensions
Length:
16-1/2
in
(419
mm);
Width:
9-1/2
in
(241
mm);
Height:
17
in
(432
mm)
Weight
Net:
53
lb
(24
kg);
Ship:
65
lb
(29
kg)
Welding
Gun
Rated
Output
(Air
Cooled)
160
Amperes
At
60%
Duty Cycle
Using
CO2
Shielding
Gas
Cable
Length
10
ft
(3
m)
1-1.
Volt-Ampere
Curve
And
Duty
Cycle
Chart
U
SING
GUN
BEYOND
DUTY
CYCLE
RATING
can
damage
gun.
Do
not
use
gun
beyond
rated
amperage
when
using
CO2
shiel
ding
gas.
Use
gun
at
30%
duty
cycle
when
using
mixed
shielding
gas.
~arn8.1
10/91
The
volt-ampere
curves
show
the
minimum
and
maximum
voltage
and
amperage
output
capabilities
of
the
welding
power
source.
Curves
of
other
settings
fall
be
tween
the
curves
shown.
Duty
cycle
is
how
long
the
unit
can
operate
within
a
ten
minute
period
without
causing
overheating
or
damage.
This
unit
is
rated
at
20%
duty
cycle
DC
AMPERES
allowing
welding
2
minutes
out
of
every
10
minutes.
This
gun
is
rated
at
60%
duty
cycle
when
using
CO2
shielding
gas
and
30%
when
using
mixed
shielding
gas.
5
20
25
30
40
50 60
70
80 90
00
DUTY
CYCt.E
~
ssbl.1
10/91
/sbl.3
10/91
SB-157
146/SB.121
475
Figure
1-1.
Volt-Ampere
Curve
And
Duty
Cycle
Chart
OM-157
745
Page
1
Page 14
Page 15
2-1.
Installing
Work
Clamp
Figure
2-1.
Installing
Work
Clamp
2-2.
Gun
Polarity
For
Wire
Type
a
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Turn
Oft
welding
power
source,
and
disconnect
input
power
before
inspectingorinstalling.
SwOrnl.1
2/93
1
Polarity
Changeover
Label
1
2
Polarity
Jumper
Links
STRAIGHTIREVERSE
For
Flux
~
POLARITY POLARITY
For
Solid
L
Always
read
and
follow
welding
~
~{~
I
Steel
Or
wire
manufacturers
recom
(FCAW
~
Wires
mended
polarity.
Cored
Wires
J
Aluminum
IGMAWI
Processi
L
S.~.P
Processi
Close
door.
DCEN
OCEP
GUN
POLARITY
CHANGEOVER
S-116
599-Cl
SECTION
2
INSTALLATION
1
Insulator
2
Bolt
3
Smaller
Hole
4
Work
Clamp
Tabs
Bend
tabs
around
work
cable.
5
Work
Cable
From
Unit
6
Nut
Tools
Needed:
~
3/8,
7/16
in
Ret.
ST-025
190-C
2
Tools
Needed:
C~~~JzztC
3/8
in
C
)1
_______
I
~)
I 1
1
1
1
I
1
-
Ref.
ST-159
619-A
Figure
2-2.
Gun
Polarity
Connections
OM-157
745
Page
2
Page 16
Page 17
2-3.
Installing
Welding
Gun
2-4.
Connecting
Input
Power
Connect
unitto
a
properly
grounded
115
VAC
receptacle
of
a
20
ampere
individual
branch
circuit
protected
bytime-delay
fusesorcircuit
breakers.
Selectanextension
cord
of
12
AWG
for
up
to
75
ft
(23
m)
or
10
AWG
for
up
to
140
ft
(46 m).
2-5.
Threading
And
Feeding
Welding
Wire
a
WARNING
ELECTRIC
SHOCK
can
kill.
S
Do
not
touch
live
electrical
parts.
The
welding
wire,
drive
rolls,
drive
assembly,
and
all
metal
parts
touching
the
welding
wire
are
electrically
live
when
weldingorfeeding
wire
using
gun
trigger.
1
Gun
Securing
Nut
2
Drive
Assembly
3
Gun
End
Loosen
securing
nut.
Insert
end
through
front
panel
opening
until
it
bottoms
against
drive
assembly.
Tighten
nut.
4
Gun
Trigger
Leads
Insert
leads,
oneata
time,
through
grommet
on
front
panel.
Connect
leads
to
matching
leadsinunit.
Close
door.
Ref.
ST.159
619-A/
Ret.
ST-159
216
Tools
Needed:
~
5/l6in
Figure
2-3.
Gun
Connections
S
HOT
SURFACES
can
burn
skin.
Allow
gun
to
cool
before
touching.
WELDING
WIRE
can
cause
puncture
wounds.
Do
not
press
gun
trigger
until
instructedtodo
so.
Donotpointguntowardanypartofthebody,other
people,
or
any
metal
when
threading
welding
wire.
.~_
~
-
~
C
YLINDERS
can
explode
if
damaged.
Keep
cylinders
away
from
welding
and
other
electrical
circuits.
Always
secure
cylinder
to
running
gear,
wall,
or
Never
touch
cylinder
with
welding
electrode.
other
stationary
support.
swarn5.1
10/91
/
swarn2.1
9/91
OM-157
745
Page
3
Page 18
Page 19
2
3
6
(150
mm)
Pull
and
hold
wire;
cut
off
end.
Tools
Needed:
~
9/l6in
1
Wire
Spool
2
Hub
Tension
Nut
Grasp
spool.
Turn
while
using
wrench
to
adjust
nut.
When
a
slight
force
is
needed
to
turn
spool,
ten
sion
is
set.
3
Welding
Wire
4
Inlet
Wire
Guide
5
Pressure
Adjustment
Knob
6
Drive
Roll
7
Outlet
Wire
Guide
8
Gun
Conduit
Cable
Lay
gun
cable
out
straight.
Close
and
tighten
pressure
assembly,
and
let
go
of
wire.
ON
POWER
00FF
Set
switch.
-*=~
Remove
gun
nozzle
and
contact
tube.
Press
gun
trigger
until
wire
comes
out
of
gun.
Reinstall
contact
tube
and
nozzle.
Feed
wiretocheck
drive
roll
pressure.
lighten
knob
enough
to
prevent
slipping.
Cut
off
wire.
Close
and
latch
door.
Figure
2-4.
Feeding
Welding
Wire
Ref.
ST-161
157/
Ret.
ST-159
615-Al
Ret.
ST.159
216
/
S-0627-A
Hold
wire
tightly
to
keep
it
from
unraveling.
Open
pressure
assembly.
4
in~
(102
mm)
Push
wire
thru
guides
into
gun;
continuetohold
wire.
1111
II
-~
~~r~J/
OM-157
745
Page
4
Page 20
Page 21
2-6.
Installing
Gas
Supply
£~
WARNING
CYLINDERS
can
explode
if
damaged.
Keep
cylinders
away
from
welding
and
other
electrical
circuits.
Never
touch
cylinder
with
welding
electrode.
Always
secure
cylindertorunning
gear,
wall,
or
other
stationary
support.
3
Tools
Needed:
1-1/8,5/8
in
BUILDUP
OF
SHIELDING
GAS
can
harm
health
or
kill.
Shut
off
shielding
gas
supply
when
not
in
use.
warn4.1
9/91
Obtain
gas
cylinder
and
chain
to
running
gear,
wall,
or
other
station
ary
support
so
cylinder
cannot
fall
and
break
off
valve.
1
Cap
2
Cylinder
Valve
Remove
cap,
standtoside
of
valve,
and
open
valve
slightly.
Gas
flow
blows
dust
and
dirt
from
valve.
Close
valve.
3
CO2
Cylinder
4
0-Ring
5
Regulator/Flowmeter
If
not
supplied,
obtain
proper
regu
lator/flowmeter
for
use
with
CO2
gas.
Install
onto
gas
cylinder
so
that
face
is
vertical.
Flow
rate
for
supplied
regulator/
flowmeter
is
set
to
20
cfh
(cubic
feet
per
hour).
6
Gas
Rose
Connection
Obtain
and
install
gas
hose.
ssb31*
12/92
ST-154
583
/
ST-154
823
Figure
2-5.
InstallationOfDeluxe
Model
Regulator/Flowmeter
6
OM-157
745
PageS
Page 22
Page 23
SECTION
3
OPERATION
a
WARNING
1
Power
Switch
Use
switch
to
turn
unitOnand
Off.
=~
READ
SAFETY
BLOCKS
at
beginning
of
manual
before
proceeding.
MOVING
PARTS
can
cause
injury.
ARCING
can
damage
switch.
Keep
away
from
pinch
points
suchasdrive
rolls.
Keep
all
doors,
panels,
covers,
and
guards
closed
and
securely
in
place
Do
not
change
ThicknessNoltage
switch
position
while
welding.
Arcing
inside
switch
can
damage
contacts,
causing
switch
to
fail.
1
2
3
/
~S8
Figure
3-1.
Safety
Equipment
1
Insulating
Gloves
2
Safety
Glasses
With
Side
Shields
3
Welding
Helmet
Wear
dry
insulating
gloves,
safety
glasses
with
side
shields,
and
a
welding
helmet
with
a
correct
shadeoffilter
(see
ANSI
Z49.1).
sb3.1
10/91
2
Wire
Speed
Control
Use
controltoselectawire
feed
speed.
As
Voltage
switch
setting
increases,
wire
speed
range
also
increases.
The
numbers
around
the
control
are
not
a
wire
feed
speed
(see
rear
cover).
3
ThicknessNoltage
Switch
Use
switchtoselect
an
arc
voltage.
Use
Low
to
weld
thin
materialand
High
to
weld
thicker
material
(see
rear
cover).
Use
wire
brush
or
sandpaper
to
clean
metalatweld
joint
area.
Use
chipping
hammer
to
remove
slag
after
welding.
Connect
work
clamp
to
clean,
paint-free
location
on
workpiece,
as
close
as
possible
to
weld
area.
Figure
3-2.
Controls
5T-159
017IRet.
ST-157
049
OM-157
745
Page
6
Page 24
Page 25
SECTION
4-
MAINTENANCE&
TROUBLESHOOTING
-
A~
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Turn
Oft
welding
power
source,
and
disconnect
input
power
before
inspecting,
maintaining,
or
servicing.
HOT
PARTS
can
cause
severe
burns.
Allow
cooling
period
before
maintaining
or
servicing.
4f
M
OVING
PARTS
can
cause
injury.
Keep
away
from
moving
parts.
Keep
away
from
pinch
points
suchasdrive
rolls.
Maintenance
and
troubleshooting
to
be
performed
only
by
qualified
persons.
swarnS
2
2/93
Table
4-1.
Maintenance
Schedule
Time
Maintenance
Before
each
use.
Tighten
all
connections.
Check
gun
and
clean
nozzle.
After
each
spool
of
wire.
Blow
out
gun
liner.
Clean
and
check
wire
drive
parts;
replace
as
necessary.
Every
3
months.
Tapeorreplace
cracked
cables:
clean
and
tighten
connections.
Replace
unreadable
labels.
Every
6
months.
Blow
out
or
vacuum
insideofunit.
4-1.
Overload
Protection
READ
Sectio
SAFETY
BLOCKS
at
start
of
n
4
before
proceeding.
Thermostat
TP1
protects
the
unit
from
damage
due
to
overheating.
If
main
transformer
Ti
gets
too
hot,
TPi
opens
and
weld
output
stops.
The
fan
keeps
running
to
cool
the
transformer.
Wait
several
minutes
before
trying
to
weld.
A.
Overheating
B.
Motor
Fuse
Fl
Turn
Off
and
unplug
unit.
Unlatch
door,
remove
handle,
and
remove
door/wrapper.
1
Fuse
Fl
(See
Parts
List
For
Rating)
If
this
fuse
opens,
the
wire
drive
motor
does
not
run.
Push
on
fuseholder
and
twist
to
open.
Replace
fuse.
Reinstall
wrapper
and
handle,
and
latch
door.
1T~~1ZJfl
1/4,3/Bin
ST-159
618/Ret.
ST-I
52
031
Tools
Needed:
Figure
4-1.
Fuse
Fl
Location
OM-157
745
Page
7
Page 26
Page 27
4-2.
Drive
Assembly
Maintenance
I~4s.
READ
SAFETY
BLOCKS
at
start
of
7
______
Section
4
before
proceeding.
Turn
Off
and
unplug
unit.
1
Wire
Spool
Cut
welding
wire
off
at
contact
tube.
Retract
wire
onto
spool
and
secure.
2
Pressure
Roll
Arm
3
Cotter
Pin
4
Pin
5
Screw
6
Bearing
Remove
bearing
as
shown.
Install
new
bearing
and
secure
with
screw.
Reinstall
arm
onto
pin
and
secure
with
cotter
pin.
7
Setscrew
8
Smooth
Groove
For
Hard
Wire
9
Drive
Roll
Remove
drive
roll
as
shown.
Useawire
brushtoclean
drive
roll.
Push
drive
roll
onto
shaft
with
de
sired
groove
in.
Turn
drive
roll
so
one
setscrew
faces
flat
side
of
shaft,
and
tighten
both
setscrews.
10
Knurled
Groove
For
Flux-
Cored
Wire
11
Wire
Inlet
Guide
Remove
guide
by
pressing
on
barbed
area
or
cutting
oft
one
end
near
housing
and
pulling
it
out
of
hole.
Push
new
guide
into
hole
from
rear
until
it
snaps
in
place.
Thread
welding
wire
(see
Section
2-5).
Close
door.
Tools
Needed:
5/6~1
Ret.
ST-159
615-A
/
ST-154
199
Figure
4-2.
Drive
Assembly
Maintenance
OM-157
745
Page
8
Page 28
Page 29
4-3.
Gun
Maintenance
3/8,
5/16
in
Figure
4-3.
Gun
Maintenance
swarrilOl
10/91
Turn
Off
and
unplug
unit.
1
Wire
Spool
Cut
welding
wire
off
at
contact
tube.
Retract
wire
onto
spool
and
secure.
2
Gun
Securing
Nut
Disconnect
trigger
leads.
Loosen
nut
and
remove
gun
and
trigger
leads.
3
Nozzle
4
Contact
Tube
5
Head
Tube
6
Liner
Collet
Disassemble
gun
as
shown.
7
Liner
Pull
liner
from
this
end.
Blow
gun
casing
out
with
compressed
air.
Insert
new
liner
into
gun
casing
until
even
with
end
of
head
tube.
Install
collet
onto
liner.
Install
contact
tube
and
nozzle.
Insert
gun
into
feeder
and
mark
where
liner
touches
drive
roll.
Re
move
gun
and
cut
liner
off.
Reinstall
gun
so
that
liner
is
as
close
as
possible
to
drive
rolls
without
touching.
Thread
welding
wire
(see
Section
2-5).
Close
door.
READ
SAFETY
BLOCKS
at
start
of
1
Section4before
proceeding.
FLYING
METAL
CHIPS
AND
DIRT
can
cause
injury
and
damage
equipment.
Point
gun
away
from
people
and
in
a
safe
direction
when
blowing
out
with
compressed
air.
2
3
4
5
7
Tools
Needed:
Rot.
57-159
619-A
/
Rot.
ST-155
509
OM-157
745
Page
9
Page 30
Page 31
4-4.
Troubleshooting
READ
SAFETY
BLOCKS
at
start
of
Section4before
proceeding.
Table
4-2.
Welding
Trouble
Table
4-3.
Wire
Drive/Gun
Trouble
Welding
Trouble
No
weld
output;
wire
does
not
fee~
-,
Remedy
Secure
power
cord
plug
in
receptacle.
Motor
fuse
Fl
open,
replace
fuse.
Replace
building
line
fuse
or
reset
circuit
breaker
if
open.
Secure
gun
trigger
leads
or
repair
leads,
or
replace
trigger
switch.
No
weld
output;
wire
does
not
feed;
fan
--
motor
continues
to
run,
and
pilot light
turns
off.
Section
-~
2-4
-~
~
--
--
-a
2-3
No
weld
output;
wire
feeds.
Thermostat
TP1
open
(overheating).
Allow
fan
to
run;
the
thermo
stat
will
close
when
the
unit
has
cooled.
---p.
4-lA
Low
weld
output.
Replace
contact
tube.
Connect
work
clamp
to
get
good
metal-to-metal
contact.
H
Figure
3-2
4-3
-ru-~
Connect
unit
to
proper
input
voltage
or
check
for
low
line
voltage.
--L
2-4
Wire
Drive/Gun
Trouble
Remedy
Section
Electrode
wire
feeding
stops
during
-~
-~
4-3
welding.
2-5
2-5
-~
4-3
-~
4-2,4-3
4.2
2-3
-~
4-lB
4-2,4-3
---~
--
Straighten
gun
cable
and/or
replace
damaged
parts.
Adjust
drive
roll
pressure.
Readjust
hub
tension.
Replace
contact
tubeifblocked.
Clean
or
replace
wire
inlet
guide
or
liner
if
dirty
or
plugged.
Replace
drive
roll
or
pressure
bearing
if
worn
or
slipping.
Secure
gun
trigger
leads
or
repair
leads,
or
replace
trigger
switch.
Check
and
replace
Fl.
Check
and
clear
any
restrictions
at
drive
assembly
and
liner.
Have
nearest
Factory
Authorized
Service
Station
check
drive
motor.
OM-157
745
Page
10
Page 32
Page 33
SECTION
5-
ELECTRICAL
DIAGRAMS
Figure
5-1.
Circuit
Diagram
For
Welding
Power
Source
2
CR
I
I
L
PLC
I
69N.
z
ST-157
378
OM-157
745
Page
11
Page 34
Page 35
SI
S2
8A(FM-2~V.)
~~1
--j
P2
WORK
SPLIcE
GND
POWER
CORD
SC-157
379-A
Figure
5-2.
Wiring
Diagram
For
Welding
Power
Source
Page 36
Page 37
SECTION
6
PARTS
LIST
>
E
a,
U,
U,
4
(a
a)
L.
IL.
C0
c~:J
C,,
CD
Lf)~
LI~
OM-157
745
Page
13
Page 38
Page 39
Item
Dia.
Part
No.
Mkgs.
No
-~
Description
1
010909..
2
010910..
3
073355..
4
111998..
5
111929..
6....
CR1
120706..
7
120675..
8....
FM
111931..
9
005656..
10
053297..
11
Fl
*012663..
12....
VR1
087156..
13
R2
117116..
14
Ci
109039..
15
161439..
16
108105..
17
134834..
18
149322..
29....
GS1
116996..
120077..
20
157190..
21
Ri
119653..
22
605227..
23
157187..
24
089899..
25
157376..
26
134464..
27
+157188..
28
PLG1
113494..
29
111644..
30
019663..
31
....
TP1
120638..
32
Ti
157389..
33
157447..
34
Z
118457..
35
010368..
36
111443..
37
S2
157305..
38
39
.40
41
42
.43
Si
44
..45....SR2....
46
..47....TE1....
48
49
50
51
52
53
Figure
6-1.
Main
Assembly
Quantity
NUT,
SB
slflkg
hex
.375-16
1
WASHER,
flatstl
SAE
.375
2
SPRING,
cprsn
.625
OD
x
.093
wire
x
1
.000
1
PIN,
cotter
hair
.l2Odia
x
2.375
Ig
x
.500
shaft
HUB,
spool
1
RELAY,
end
24VAC
DPDT
1
BRACKET,
mtg
motor
fan
1
MOTOR,
fan
115V
50/60Hz
2600RPM
.i8i8dia
shaft
BLADE,
fan
6
in
4wg
3odeg
.175
bore
CW
1
HOLDER,
fuse
crtg
in-line
1
FUSE,
mintr
gI
slo-blo
3A
1
VARISTOR,
10
joule
68VDC
1
RESISTOR,
WWfxd
20W
50
ohm
1
CAPACITOR,
elctlt
46000uf
35VDC
1
STRIP,
comb
rmr
.012
x
1.500x9.000
CLAMP,
capacitor
2.500dia
1
HOSE,
SAE
.187
ID
x
.410
OD
(order
by
ft)
3ft
CLAMP,
hose
.405-.485clp
dia
slfttng
2
VALVE,
115VAC
2
way
custom
port
1/8
orf
(std
&
deluxe
model)
BLANK,
snap-in
nyl
sq
1.250
(basic
model
only)
1
CASE
SECTION,
front/base/rear
1
RHEOSTAT,
WW
25W
25
ohm
1
NUT,
nyl
hex
jam
.75ONPST
(std
&
deluxe
model)
PANEL,
side
1
LATCH,
slide
1
HANDLE,
lifting
1
LABEL,
warning
general
precautionary
WRAPPER
1
CORD
SET,
125V
5-15P
l4ga
3/c
7ft
1
BUSHING,
strain
relief
.370/430
ID
x
.875mtg
hole
MOUNT,
nprn
15/16
OD
4
THERMOSTAT,
NC
1
TRANSFORMER,
pwr
main
115
(consisting
of)
1
COIL,
pwr
main
1
STABILIZER
1~
CLAMP,
grd
200A
1
BUSHING,
strain
relief
.240/.510
ID
x
.875mtg
hole
1
SWITCH,
rocker
DPDT
15A
125VAC
600
325..
CABLE,
weld
cop
strd
No.
6
(orderbyft)
1
5ft
026
843..
INSULATOR,
vinyl
blk
2
119
697..
GA-l6Ci
GUN,
(Fig
6-3)
1
025
338..
BUSHING,
nyl
univ
23/32
hd
dia
.625mtg
hole
1
097
922..
KNOB,
pointer
1
153
698..
SWITCH,
rocker
SPST
16A
125VAC
NAMEPLATE,
(order
by
model
and
serial
number)
1
119
264..
RECTIFIER,
si
iph
100A
200PIV
1
010
047..
TUBING,
stl
.625
OD
x
1
2ga
wall
x
1.000
1
122
385..
TERMINAL
ASSEMBLY,
chgov
(consisting
of)
1
601
835....
NUT,
brs
hex
10-32
8
038
887....
STUD,
pri
bd
brs
10-32
x
1.375
4
.116620....
TERMINALBOARD,chgov
1
038618....
LINK,
jumper
term
bd
pri
2
157
191
..
BAFFLE,air
1
131
336..
DRIVE
ASSEMBLY,
wire
(Fig
6-2)
1
059
712..
CLIP,
component
.437dia
mtg
adh
back
1
153
714..
REGULATOR/FLOWMETER,
dual
scale
(deluxe
model
only)
602
958..
FITTING,
brs
barbed
M
1/4tbg
x
1/4NPT
(deluxe
model
only)
1
*Recommended
Spare
Parts.
+When
ordering
a
component
originally
displaying
a
precautionary
label,
the
label
should
also
be
ordered.
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-157
745
Page
14
Page 40
Page 41
Item
Dia.
Part
No.
Mkgs.
No.
Description
..1..MOT..
..2
.5
..6
.7
..8
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
119
021
604 657
602
213
010
910
128
189
602
211
604
538
129
893
126
838
090
416
124
817
151
828
112 031
090 443
114
415
010
224
058
549
085
242
085
244
090 415
092
237
602
204
604 537
605
853
119
028
602
169
601
862
602
203
604
673
Figure
6-2.
Drive
Assembly,
Wire
1
1
1
1
1
3
1
3
1
2
1
1
1
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-157
745
Page
15
131
336
Figure
6-2.
Drive
Assembly,
Wire
(Fig
6-1
Item
53)
Quantity
1
MOTOR,
gear
12VDC
80RPM
SCREW,
.375-16x1.250
hexhd
sti
WASHER,
lock
stl
split
.375
WASHER,fIatstlSAE.375
SCREW,
.312-18
x
1.750
hexhd
sti
WASHER,
lock
stl
split
.312
WASHER,flatstlSAE.312
INSULATOR,
housing
drive
WIRE
DRIVE,
(consisting
of)
PIN,
hinge
HOUSING,
wire
drive
PIN,
cotter
hair
.042
x
.750
LEVER,
pressure
roll
BEARING,
ball
rdl
sgl
row
.315
x
.866
x
.447
SCREW,
10-24
x
.625
flathd-phl
stl
PIN,
spring
CS
.187
x
1.000
GUIDE,
wire
inlet
1/16
FASTENER,
pinned
WASHER,
cupped
stl
.328
ID
x
.812
OD
x
.125
SPRING,
cprsn
.720
OD
x
.072
wire
x
1.250
KNOB,
adj
tension
WASHER,
lock
stl
ext
tooth
No.
10
NUT,
stl
hex
full
.312-18
SCREW,
10-32
x
.750
rndhd-slt
stl
ROLL,
drive
V
groove
combination
SCREW,
set
8-32
x
.187
cup
pt
sch
stl
NUT,
stl
hex
10-32
WASHER,
lock
sti
split
No.
10
SCREW,
10-32
x
.625
flathd-slt
sti
2.
5
7
8
18-
12
16
28
27
22
13
14
26 25
15
24
7
SC.121
448.C
Page 42
Page 43
Part
No.
Description
119
697
Figure
6-3.
GA-16C1
Gun
(Fig
6-1
Item
40)
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
Quantity
Itern
No.
1
110793..
HANDLE
ASSEMBLY
2
110
795
..
TUBE,
head
(consisting
of)
3
110780....
NUT,
MiOxi
4
110
779
....
JACKET,
head
tube
5
110
781
....
STOP,
nozzle
6
....
128
878
....
ADAPTER,
head
tube/nozzle
7
110
782
....
SPRING,
nozzle
8
110786
10..
11
..12..
.13..
.14..
15..
16..
.17..
.18..
9
2
.110789..
.110794..
080565..
...110797..
120714..
120715..
079974..
...110796..
047994..
...110792..
TUBE
contact
030
wire
(quantity
of
1
included
with
gun)
3
NOZZLE,
slip
type
1/2
orE
1
TRIGGER
SWITCH
ASSEMBLY
1
TERMINAL,
frict
fern
.110x.016
22-18
wire
2
SLEEVE,
rbr
1
LINER,
rnonocoil
.030-.035
wire
w/collet
lOft
(consisting
of)
1
COLLET,
liner
.035
wire
1
0-RING,
.500
ID
x
.1O3CS
rbr
2
CONNECTOR,
gun/feeder
1
TERMINAL,
frict
fern
.250
x
.032
22-18
wire
2
CABLE/CONDUIT,
lOft
1
Ref.
SC-lb
832-0
10
11
12
18
17
Figure
6-3.
GA-16C1
Gun
OM-157
745
Page
16
Page 44
Page 45
SUGGESTED
PARAMETERS
FOR
WELDING
MILD
STEEL
PROCESS
WIRE
SIZE
AND
TYPE
WELDING
POLARITY
SETTINGS
STICK
OUT
SHIELDING
GAS
Material
Thickness
CONTROL
SETTINGS
Thinner
Than
20
ga
0.0359
in
(0.91
mm)
20-18
ga
0.0359-0.0478
in
(0.91
-1.21
mm)
17-15
ga
0.0538-0.0673
in
(1.36-1.71
mm)
14-13
ga
0.0747-0.0897
in
(1.89-2.28
mm)
12
ga
and
thicker
0.1046
in
+
(2.65
mm)
FCAW
0.030
in
(0.76
mm)
Flux
Cored
E-71T-GS
DCEN
1/2
in
(12.7
mm)
NA
Voltage
Adjustment
LOW
LOW
MEDIUM
MEDIUM
HIGH
Wire
Feed
Adjustment
Control
30
60
40
50
90
FCAW
0.035
in
(0.889
mm)
Flux
Cored
E-71T-GS
DCEN
1/2
in
(12.7
mm)
NA
Voltage
Adjustment
LOW
LOW
MEDIUM
MEDIUM
HIGH
Wire
Feed
Adjustment
Control
25
50
30
40
60
GMAW
0.023-0.025
in
(0.58-0.64
mm)
Solid
Steel
DCEP
1/4
in
(6.35
mm)
CO
2
Voltage
Adjustment
LOW
LOW
MEDIUM
MEDIUM/HIGH
Not
Recommended
Wire
Feed
Adjustment
Control
55
60
95
100
Not
Recommended
0
0
-.4
01
-4
Ref.
S-157
696
Page 46
Page 47
Page 48
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