Miller MW175 (MAC TOOLS) Owners manual

.

1~OLSfi

OM-210

July

Processes

089A

1998

MIG

Flux

(GMAW)

Cored

Welding

(FCAW)

Welding

Description

Arc
Feeder

MW135/MW175

And

GA16C2

Welding

Gun

Power

Source

And

_______

Wire

(

I

-

OWNERS

MANUAL

S

S

S

TABLE

OF

CONTENTS

The

following

used

interchangeably

throughout

MIG=GMAW

this

terms

manual:

-

SAFETY

are

SECTION

SECTION

SECTION

SECTION

SECTION

SECTION

SECTION
SECTION

SECTION

1

1-1.

Symbol

Arc

1-2.
1-3.

1-4.
1-5.

1.1

1.2

1.3

1

.4

1

.5

2-1.
2-2.

2-3.

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

3-4.

3-5.
3-6.
3-7.
3-8.
3-9.

4-1.
4-2.

4-3.

5-1.
5-2.

5-3.

5-4.

5-5.

5-6.

5-7.

7-1.
7-2.

7-3.

7-4.

7-5.

7-6.
7-7.

7-8.
7-9.
7-10.

7-11.

7-12.

7-13.

7-14.
7-15.

7-16.

Welding

Additional

Principal

Information

EMF

CONSIGNES

1.

Signification
Dangers
Dangers

Ia

maintenance

et

Principales

Information

-

2

SPECIFICATIONS

Specifications

Cycle

Duty
Volt-Ampere

INSTALLATION

3-

Installing
Changing
Process/Polarity
Installing

Selecting

Selecting

Electrical

Installing

Threading

OPERATION

4-

Controls

Parameters

Weld
Weld

Parameters

MAINTENANCE

5-

Routine

Overload

Changing

Circuit

Short

Replacing
CleaningOrReplacing
Troubleshooting

ELECTRICAL

6-

7-

MIG

Typical
Typical
Holding

Conditions

Gun

Movement

Poor

Weld

Weld

Good

Troubleshooting

TroubleshootingPorosity
Troubleshooting

Troubleshooting

TroubleshootingIncomplete
TroubleshootingBurn-Through
Troubleshooting
Troubleshooting

Common

PARTS

8-

PRECAUTIONS

Usage

Hazards

for

Symbols

Safety

des

relatifs

Installation,

Standards

SECURITE

DE

symboles

au

soudage

supplØmentaires

sØcuritØ

de

normes

les

sur

champs

And

Overheating

Curves

Welding

Gun

Polarity

Table

Gas

Supply

A

Location

A

Location

Service

Wire

Welding

Maintenance

Protection

Drive

Shutdown

Gun

WELDING

MIG

Process

MIG

Process

And

Positioning

That

Bead

Bead

MIG

And
And

Guide

And

Spool

Wire

For

120

For

230

&TROUBLESHOOTIN~

Roll

Or

Contact

Table

DIAGRAM

(GMAW)

Connections
Control

Affect

During

Characteristics

Characteristics



Excessive



Excessive



Lack

-

Waviness



Distortion

Shielding

LIST

GAl

Weld

Welding

-

READ

BEFORE

Operation,

-

LIRE

a

Iarc

relation

en

avec

ØlectromagnØtiques

Connecting
Connecting

For

230

Adjusting

VAC
VAC

Wire

Inlet

Tip

6C2

Input
Input

VAC

Model

Hub

Model

Model

Guida

Liner

Gun

GUIDELINE&

Tension

Settings

Bead

Gun

Shapa

Welding

spatter

Penetration

Penetration

Of

Fusion

Bead

Of

Gases

USING

Maintenance

and

UTILISATION

AVANT

Iinstallation,

For

Power
Power

For

fonctionnement

le

VAC

120

VAC

230

Model
Model

1

1

3

3

4

5

5

5

7

8

8

9
9

10
11

12
12
12
12

13

14
15

16
16

17

18
18

19
20

21
21
21
22
22

22

23
24

25
28
28
29
30
31
32

32

32
33
33
34

34

34

35

35

35

36

.38

WARRANTY

OM-21

0089A

.

SECTION

1

-

SAFETY

PRECAUTIONS

-

READ

BEFORE

USING

som

_nd_5/97

1-1

4A

Marks

A

Means

~

1-2

The

A

to

seethe

to

only

found
follow

Only

A

repair
During

A

circuits

automatic
metal

installed



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

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

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or

work

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there

.

Use

.

If
unit.



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servicing

to



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

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power

in

grounded



When

conductor



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replace



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

Do



Do

Symbol

Means
hazards
shown

a

special

Note~

Arc

symbols

attentiontoand

call

symbol,

the

avoid

a

summary

in

the

all

Safety

qualified

this

unit.

operation,

also

are

wire

welding,

touching

parts

or

improperly

touch

not

hole-free

dry,

yourself

covers

big

or

ground.

AC

not

use

is

a

dangeroffalling.

AC

output

AC

output

this

29

OSHA

install

Manual

verify

cord

off

not

not

ground

receptacle

making

first

inspect

cord

all

equipment

use

worn,

drape

disconnect

Usage

Warning!

with

the

in

safety

not

safety

Welding

shown

watch

hazard.

of

Safety

Standards.

persons

ELECTRIC

Touching

shocks
circuit
The

input

live

the

live

electrical

from

enough

output

ONLY

is

required,

input

power

equipment.

CFR

191

and
and

the

supply

wire

box

or

input



double-check

immediatelyifdamaged

damaged,

cables

Watch

this

procedure!

adjoining

message.

related.

Hazards

below

are

identify

and

out,

The

safety

the

more

Standards

should

everybody,

keep

SHOCK

electrical

live

or

severe

is

electrically

power

when

power

the

welding

grounded

insulating

input

over

wire

wire,

wire

parts.

work

and

to

prevent

in

areas,

damp

if

required

remote

use

or

Lockout/tagout

0.147

(see

ground

national,

ground

is

properly

that

cord

outlet.

connections,

power

when

not

undersized,

your

symbols.

followthe

listedinSection

install,

burns.

circuit

equipment

gloves

ground

for

stop

this

state,

plug

connections.

cord

in

body.

Out!

The

used

throughout

possible

information

complete

operate,

especially

can

parts

The

whenever

live

and

is

on.

drive

reel,

are

electrically

is

and

using

physical

any

movement

if

the

welding

output

engine

Safety

Standards).

equipment

and



check

connected

is

connected

attach

for

damage



bare

use.

or

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possible

hazards.
related

given

safety

children,

kill.

can

electrode

the

machine

In

semiautomatic

roll

housing,

live.

hazard.

a

body

protection.

dry

insulating

contact

is

process.

control

before

input

power

according

local

codes.

and

be

to

ground

proper

or

wiring

poorly

are

possible

hazards

this

manual

When

instructions

below

information

Read

1-4.

maintain,

cause

and

output

internal

and

Incorrectly

with

confined,

if

present

installing

according

that

sure

terminal

to

a

properly

grounding

bare

wiring

kill.

can

cables.

spliced

are

you

and

and

away.

fatal

work

is

on.

all

mats

the

or

to

input

or

on

or

its

Out!

group

symbols

avoid

to

earth

grounding

a

separate

touch

not

another

only

at

a

all

work

worktable

not

weld

of

symbols

SHOCK,

the

electrode

electrode

well-maintained

once.

safety

panels

cable

as

work

clamp

with

any

connect

output

This

ELECTRIC
Consult

actions



If

with



is

Do

or



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parts



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

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

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or



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contact



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single

SIGNIFICANT

Off

inverter,

touching



your

welding

the

in

a

an

nearby.

the

weld

highly

weld

not

area,

an

on

according

FUMES

Welding

these
health.

head

ventilate

is

Material

and

confined

air-supplied

oxygen

air

is

in

The
toxic

plated

the

air-supplied

these

input

power

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capacitors

before

r

if

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

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remove

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ventilation

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manufacturers

cleaners,

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wearing

person

lower

breathing



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operations.

form



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cadmium

weld

wearing
containing

inside,

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means

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related

and

hazards.

of

the

workpiece



do

cable

if

you

from

and

with

near

metal

more

DC

unit

if

covers

good

weld

the

when

object.

than

terminal.

VOLTAGE

Maintain

harness

inverters.

disconnect

to

parts.

any

ANb

produces

fumes

the

of

out

the

area

and

fumes

use

poor,

Safety

instructions

degreasers.

space

respirator.

level

heat

and

coated

steel,

elements

and

is

fumes

irritating

unless

well

respirator.

Welding

safe.

locations

on

area

Warning!

PARTS,

instructions

not

use

in

are

different

a

equipment.

according

working

securely

metal-to-metal

as

connected

not

electrode

one

input

instructions

GASES

and

gases

fumes.

and/or

gases.

an

approved

Data

for

metals,

only

and

causing

near

degreasing,

of

rays

gases.

metals,

the

ventilated,

can

give

Watch

HOT

and

below

is

required,

work

clamp

with

contact

machine.

Repair

manual.

to

floor

above

in

place.

practical.

to

or

exists

power,

Maintenance

in

can

fumes

and

be

can

breathe

not

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exhaust

use

air-supplied

Sheets

consumables,

if

well

it

is

have

Always

gases

or

injury

the

can

arc

such

as

coating

and

The

coatings

off

toxic

PARTS

for

necessary

ground

work

or

the

work,

or

level.

contact

workpiece

work

after

and

be

hazardous

replace

to

cable

removal

discharge

hazardous.

gases.

the

at

damaged

workpiece

to

Breathing

fumes.

the

respirator.

(MSDSs)

ventilated,

trained

a

can

displace

Be

death.

react

with

removed

if

necessary,

and

fumes

or

any

welded.

if

cleaning,

galvanized,

is

possible

hazards.

it

directly

cable.

ground,

prevent

to

any

of

input

Section

to

your

to

arc

the

and

coatings,

while

or

watch-
air

and

the

sure

spraying

to

vapors

or

lead,

from

the

while

metals

OM-210

089

Page

1



Wear

a

welding

face

your

and

Z87.1



Wear

approved

helmet.



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protective

warn

glare;

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area

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burns.

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weld

all

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aware

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Standards).

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shirt,

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ARC

Arc

rays

visible

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can

weld.

helmet

and

eyes

listed

in

safety

screens

others

not

clothing

and

WELDING

Welding

drums,

can

fly

hot

workpiece,

explosion,

doing

and

where

flammables

possible,

welding

small

and

fire,

that

fire

on

are

keep

welding

on

the

closed

properly

cable

prevent

and

paths

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to

electrode

when

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trousers,

combustibles,

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FLYING



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RAYS

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glasses

barriers

or

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to

made

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closed

on

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and

contact

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tightly

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any

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within

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cracks

fire

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on

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hidden

side.

containers

prepared

to

the

work

current

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causing

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frozen

from

in

use.

electric

garments

shoes,

high

such

doing

METAL

chipping,

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throw

can

approved

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welding

process

(ultraviolet

and

skin.

a

proper

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with

side

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durable,

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protection.

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35

and

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containers,

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arc.

welding

hot

equipment

fire.

or

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strike

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ft

(10.7

m)

them

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F4.1

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the

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BUILDUP

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approved

OF

off

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air-supplied

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can

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kill

in

or

use.

use

.

HOT

PARTS



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not

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torch.

MAGNETIC



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FIELDS

wearers

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approved

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parts

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protection

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mechanical

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associated

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compressed

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cylinders

or

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cylinders

drape

allow

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weld

on

correct

only

designed

parts

face

away

protective

or

connected

and

follow

equipment,

CYLINDERS

Shielding

pressure.

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gas

process,

slag,

in

an

upright

rack

from

away

a

welding

welding

a

pressurized

shielding

for

the

in

good

from

valve

in

cap

for

use.

instructions

cylinders

gas

If

damaged,

cylinders

be

sure

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gas

open

position

to

prevent

any

torch

over

electrode

cylinder

gas

specific

condition.

outlet

over

place

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and

can

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contain

a

are

normally

to

treat

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flames,

by

falling

or

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a

gas

to

touch



cylinders,

application;

when

opening

valve

except

on

compressed

publication

cylinder

part

carefully.

from

sparks,

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tipping.

other

cylinder.

cylinder.

any

explosion

regulators,

maintain

when

P-i

burns

on

gun

pacemakers.

doctor before

or

equipment

if

noise

level

if

damaged.

under

gas

can

explode.

of

the

welding

excessive

and

arcs.

to

a

stationary

electrical

circuits.

will

result.

hoses,

them

cylinder

cylinder

cylinders,

gas

listed

in

valve.

Safety

or

spot

can

is

high

heat,

and

and

is

.

in

OM-210

089

Page

2

1-3

Additional

Symbols

for

Installation,

Operation,

and

Maintenance



Do

not

is

properly

FIRE

overload

sized,

FALLING

OVERUSE

STATIC



Do
combustible

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building

rated,

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gear,

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support

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using

long

unit.

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starting

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EXPLOSION

OR

install

not

install

not

wiring

and

UNIT

lifting

cylinders,

gas

equipment

unit.

lift

forks

enough

can

cooling

current

weld

to

block

not

(ESD)

or

place

surfaces.

unit

near



be

protected

can

to

eye

of

adequate

to

move

to

extend

cause

period;

or

again.

filter

or

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unit

flammables.

sure

power

to

cause

lift

unit

or

any

unit,

beyond

follow

reduce

airflow

damage

hazard.

over,

on,

supply

unit.

this

handle

injury

NOT

only,

accessories.

other

capacity

to

forks

be

sure

opposite

OVERHEATING

rated

duty

cycle

duty

unit.

to

PC

boards.

near

or

system

running

lift

and

are

of

side

cycle.

before

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promptly

installation.

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notified

If

equipment

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keep

shielding

MOVING

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closed

RADIATION

H.F.



High-frequency

navigation,

communications



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electronic

is

user

responsible

correct

any

FCC

the

by

at

once.

the

installation

high-frequency

spark

to

gaps

minimize

at

PARTS

from

away

all

doors,

and

securely

safety

qualified

only

equipment

for

interference

about

regularly

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Page

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SECTION

2-

SPECIFICATIONS

2-1.

A.

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Amperage

Range

30

Solid/

Stainless

.023.030



0.8

(0.6

175

mm)

mm)

Maximum

Circuit

Flux

in

.030

(0.8

Maximum

Circuit

in

.030-.035

(0.8

DC

28

Cored/

Aluminum

-

0.9

DC

30

Flux

Cored/

Aluminum



0.9

Open-

Voltage

.035

mm)

Open-

Voltage

mm)

Amperes

Rated

Load

120

V,

Single-Phase

20*

~fl

Amperes

Load

Rated

230

V,

Single-Phase

19.5

in

Input

60

24

Input

50/60

at

Output

Hz,

at

Output

Hz,

Wire

Wire

160

160

~A

2.88

2.40*

Feed

-870

~A

4.49

Feed

-954

Speed

1PM

Speed

1PM

KW

2.45

2.04*

Range

(4.1

KW

3.83

Range

(4.1

22.5

-24

Weight

WI

67

(30

No

At

m/min)

Weight

W/

70

(31.8

At

No

m/min)

Gun

Gun

lb

kg)

Load

lb

kg)

Load

Overall

Dimensions

Length:

(489

Width

(267

Height:

(368

Overall

Dimensions

Length:

(489

Width:

(267

Height.

(368

19-1/8

mm)

10-1/2

mm)

14-1/2

mm)

19-1/8

mm)

10-1/2

mm)

14-1/2

mm)

in

in

in

in

in

in

OM-210

089

Page

9

2-2.

Duty

Cycle

And

Overheating

A.

120

VAC

Model

Minutes

3

~5

30%dutycycle

Welding

Duty

minutes

load

If

unit

opens,

fan

runs.

unit

to

duty

A

Exceeding

damage

Cycle

that

without

overheats,

output

Wait

cool.

cycle

is

percentage

unit

can

overheating.

stops,

fifteen

Reduce

before

welding.

duty

unit

or

of

cooling

void

and

10

for

or

can

weldatrated

thermostat(s)

and

minutes

amperage

cycle

gun

S

warranty.

80

50

Minutes

50

Resting

CYCLE

4,)

30

90

at

amps

7

.~5

~.)

DUTY

%

B.

230

VAC

Model

Minutes

3

%

DUlY CYCLE

30%dutycycle

20%

duty

cycle

Welding

130

at

amps,

130

at

amps,

7

Hz

60

50

Minutes



Hz

Resting

OM-210

089

Page

S



SA-802

4/95

dutyl

10

SA-802

090

091

/

2-3.

A.

Volt-Ampere

12OVAC

Model

30

27.5

25

22.5

20

17.5

15

12.5

10

7.5

2.5

0

0

Curves

the

show

The

volt-ampere

minimum

and

amperage

of

the

of

Curves

the

tween

RANGE

4

3

RANGE

RANGE

RANGE

80

20

40

60

100

AMPS

120

2

I

140

160

180

and

welding

other

curves

curves

maximum

output

power

settings

shown.

voltage

capabilities

source.

fall

be

B.

230

VAC

Model

Cl)

0

0

-J

U

a

3W

25-

20-

15-

10-

A-

5-

~-.------..

~

~

-~----------------~

RANGE

RANGE
RANGE

RANGE

0

50

100

150

4

3

2

1

DC

LOAD

AMPS

ssbl.1

10/91

-ST-802

OM-210

082/ST-802

089

089

Page

11

SECTION

3-

INSTALLATION

3-1.

3-2.

Installing

Welding

Changing

Polarity

Gun

S6e

40~

L~_~

nualibt

'

Drive

1

2

3

Loosen

end

toms

Tighten

4

Insert

small

Connect

to

Polarity

Close

Assembly

Gun

Securing

Gun

End

thumbscrew.

through

against

thumbscrew.

Gun

Trigger

leads,

grommet

female

matching

is

not

door.

Connections

Lead

Current

(DCEP)

Lead

2

Connections

Current

(DCEN)

and

door.

read

see

Always

manufacturers

larity,

Close

Thumbscrew

opening

drive

Leads

oneata

time,

on

friction

male

terminalsinunit.

important.

Electrode

Electrode

and

recommended

Section

Insert

until

it

assembly.

through

front

panel.

terminals

Ref.

ST-802

For

Direct

Positive

For

Direct

Negative

follow

3-3.

gun

bot

wire

po

S

024

3-3.

GMAW

ing

gas

FCAW

no

shielding

OM-210

2

Process/Polarity

Process



Soild

wire

with



Self-shielding

gas

089

Page

wire

12

Table

shield-



u~

DCEP

DCEN

Fk~.

Facing

with

POLAR~TV

Polarity



Reverse



Straight

Interior

door

open

CHANGEOVER

polarity

Polarity

Panel

Bectrodo

DcEP

Podtrve

Sold

W~,

Connect

put

Connect

output

Cable

to

terminal

to

terminal

To

Gun

positive

negative

Cable

(+)

()

out-

Connections

Connect

terminal

Connect

terminal

CableToWork

to

negative

to

positive

()

(+)

output

output

3-4.

Installing

Gas

ri~~H

4

5

Supply

Argon

Gas

chain

station

cannot

side

valve.

Gas

Gas

fitting

cfh

(cubic

wire

man

Sup

to

fall

of

Gas

gas

on

flow

Obtain

Needed:

Tools

~

5/8,1-1/8in

running

ary

and

1

2

Remove

valve,

flow

Close

3

4

2

3

Install

5

6

Connect

hose

gas

rear

7

Typical

feet

ufacturers

rate.

8

cylinder

gas

gear,

so

support

off

break

Cap

Cylinder

cap,

and

open
dust

blows

valve.

Cylinder

Regulator/Flowmeter

faceisvertical.

so

Regulator/Flowmeter

Connection

Hose

Welding

Connection

Hose

customer

between

hose

connection,

of

welding

Flow

Adjust

flow

hour).

per

CO2

Adapter

and

other

or

wall,

cylinder

valve.

Valve

to

stand

valve

slightly.

from

dirt

and

Power

Source

supplied

regulator/llowmeter

and

source.

power

is

20

rate

Check

recommended

(Customer

plied)

9

Install

2

regulator/flowmeter

0-Ring

adapter

(Customer

with

Supplied)

0-ring

and

between

CO2

cylinder.

//

:j00000000000

]OOaODtJD0000
]cIOiJcI0000000

]OEJD~JDDDDDDD

]DOD0000

]UcJ00000
]DOD0000

1~DI~

oaool

3

Gas

CO2

6

ST-802

OM-210

028/

089

ST-802

Page

086

13

3-5.

Selecting

I

A

Location

And

Connecting

Input

18

Power

in

For

120

VAC

Model

Rating

2

Grounded

A

120

volt,

branch

circuit

fuses

delay

required.

3

Plug

Select

extension

for

to

up

50

to

up

A

Special
required

volatile

see

Section

Label

20

or

From

ft

50

(15

ft

200

installation

liquids

NEC

20.

Receptacle

ampere

protected

circuit

Unit

cordof14

12

or

m)

(61

m).

where

gasoline

are

Article

511

individual

time-

by

breaker

AWG

AWG

may

present

CEC

or

is

for

be

or



OM-210

089

Page

.

14

S

3-6.

Selecting

Location

A



And

Connecting

Input

Power

VAC

1

Rating

Supply

2

Plug

3

Receptacle

Connect

Line

4

See

Section

Special

A

required

volatile

see

Section

Model

Label

correct

plug

Disconnect

3-7.

installation

liquids

NEC

20.

input

power.

to

receptacle.

Device

where

gasoline

are

511

Article

may

present

CEC

or

be

or



230

For

4

Li

Always

A

grounding

conductor

=

GNDIPE

connect

first.

Do

not

A

where

move

it

could

or

operate

tip.

unit

ssb2.2

1/94

OM-2i0

-

Ref.

089

ST-802

Page

179

15

3-7.

Electrical

Service

Guide

For

230

VAC

Model

Input

Input

Amperes

Max

Recommended

Mm

Input

Max

Recommended

Mm

Grounding

Reference:

3-8.

Voltage

At

Rated

Conductor

Conductor

National

1996

Installing

Output

Standard

Size

In

Input

Electrical

Wire

Fuse

AWG/Kcmil

Conductor

Size

In

Code

Spool

Or

Circuit

Length

AWG/KcmiI

(NEC)

And

Breaker

Feet

In

(Meters)

Adjusting

Rating

Hub

In

Amperes

Tension

66

230

19.5

30

14

(20)

14

S-0092-J

OM-210

089

Page

.

16

3-9.

Threading

Tools

Needed:

Welding

Wire

1

2

3

4

5

6

7

Lay

Wire

Spool

Welding

Wire

Inlet
Pressure

Roll

Drive

Outlet

Conduit

Gun

cable

gun

Wire

Guide

Adjustment

Guide

Wire

Cable

out

Knob

straight.

Open

pressure

assembly.

-4

Pull

Hold

it

~6in~

(150

hold

and

wire;

wire

from

unraveling.

mm)

cut

tightly

end.

off

to

keep

Push

wire

thru

continue

guides

hold

to

ON

INPUT

POWER

-e

into

wire.

I

gun;

and

Close

assembly,

Press

gun

of

out

gun.

tighten

let

and

trigger

pressure

of

go

until

wire.

wire

comes

-4

Reinstall

contact

Remove

tip

and

gun

nozzle.

nozzle

and

contact

-4

tip.

Feed

Tighten

Cut

wire

knob

off

to

wire.

check

enough

Close

drive

to

and

ReL

roll

prevent

latch

ST-802

Turn

1111

power

I

II

on.

(~!.

pressure.

slipping.

door.

Ref.

ST-205

081

I

OM-210

089

Page

837

17

SECTION

4-OPERATION

4-1.

,

Controls

~

1

Voltage

The

higher

the

thicker

welded

(see

welding

power

4-2

and

4-3,

switch

under

2

Voltage

Position

In

purge

there

is

no

3

Wire

Use

control

As

speed.

increases,

increases

welding

power

4-2

or

4-3,

Switch

the

selected

the

material

weld

source

as

applicable).

load.

Switch

position,

weld

output.

Control

Speed

to

selectawire

Voltage

wire

speed

weld

(see

source

as

applicable).

that

setting

Sections

or

-

Purge

fan

runs

switch

range

setting

Sections

or

number,

be

can

label

Do

not

0

but

feed

setting

also

label

in

in

II~

/P~ST~

I

R

a.,

/

7/

~

44~:

3~

OM-210

089

Page

.

Ref.

S~2O5

18

4-2.

Weld

Parameters

For

120

VAC

Model

Welding

TO

Auto

Lawnmower

Waaons,

Wo~k,

Tailpipes,

Wheelbarrows,
Decks,

Galvanized

Sides,

Tailpipes,

Fencing,

Trailers,

Wheelbarrows,

Brackets

Bailers,

Trailer

Brackets,

Farm

Basketball

Stainless
Counter

Guide

WELD:

Body

Tricycles

Auto

Door

Bicycles

Basketball

Roofing,

Garage

Motorcycles

Lawnmower

Trailer

Grain

ombines,

Hitches,

Axles

Equipmeni

Rimsand

Steel

Tops,

Equipment

Aluminum

=

Carbon

CO2

=

C25

Argon

Handles,

Brackets,

Lawnmower

Posts,

Door

Frames,

Garage

Waaons,

Door

A

Frames,

Fryers,

Kitchen

Dioxide
25%

+

Duct

Trailer

Tracks,

Decks,

Door

~umpers

Hinge

Frames,

Brackets

Carbon

Settings

THICKNES

(Inches/

Gauge)

.022

24

3/64

18

1/16

16

1/8

11GA.

3/16

7

1/16

16

1/8

11

1/16

16

Dioxide

are

GA.

GA.

GA.

GA.

GA.

GA.

GA.

approximate.

WIRE

TYPE\SIZE

HB28

(.024)

HB-28

HB28

Fabshield

HB-28
HB-28
HB-28

Fabshield
Fabshield

HB-28
HB28

HB-28

Fabshield
Fabshield

HB28
HB28

HB-28
Fabshield
Fabshield

Solid

Stainless

(.030)

5356

Adjust

(.024)
(.030)

21B

(.024)
(.030)

(.035)

21B

21B

(.024)

(.030)

(.035)

21B

21

B

(.024)

(.030)

(.035)

21B

21

B

(.035)

as

(.035)

(.035)
(.045)

(.035)

(.045)

(.035)

(.045)

required.

GAS

or

C25

co2

or

C25

CO2

or

C25

CO2

orC25

CO2

or

CO2

C25

CO2orC25



CO2orC25

orG25

CO2

CO2orC25

or

C25

CO2

or

C25

CO2

CO20rC25



C25

C25

ARGON

GAS

(Cubic

20

20

20

20
20
20





20
20
20

20

20
20





20

20

20

FLOW

Ft/Hr)

POLARIT~

DCEP

DCEP
DCEP
DCEN
DCEP

DCEP

DCEP

DCEN

DCEN
DCEP
DCEP
DCEP
DCEN
DCEN
DCEP

DCEP

DCEP

DCEN

DCEN

DCEP

DCEP

DCEP

205406A

WELDING

VOLTAGE

23
23

2-3

34

45

34

3-4
3
6-7

4-5

45

4

4-5

8

WIRE

STICKOU

(Inches)

1/4

1/4

5/16

1/4
5/16
5/16
5/16

1/4

1/2

5/16

1/2

1/2

1/4

3/4

1/2

1/2

1/2

1/2

3/4

5/16

1/2

1/4

WIRE

SPEEI

1

34

2

34

2

1

2

3-4

2



2

1

2-3

1

3
3
3

2
2

4

4

4

3

4

2

6

4

1

205

406-A

OM-210

089

Page

19

4-3.

Weld

Parameters

For

230

VAC

Model

Welding

Guide

TO

WELD:

Auto

Body

Lawnmower

Waaons,

Worl<,

Tailpipes,

Wheelbarrows,

Decks,

Galvanized

Sides,

Tailpipes,

Fencing,

Trailers,

Wheelbarrows,

Brackets

Bailers,

Trailer

Brackets,

Farm

Basketball

Stainless
Counter

Equipment

Aluminum

CO2

C25

TRI-MIX=

Tricycles

Auto

Bicycles

Basketball

Garage

Motorcycles

Lawnmower

Trailer

Grain

Combines,

Hitches,

Axles

Equipmen~

Steel

Tops,

=

Carbon

=

Argon

90%

Handles,

Duct

Door

Brackets,

Lawnmower

Posts,

Roofing,

Door

Tracks,

Frames

GarageDoor

Waaons,

bumpers

Door

A

Frames,

Rims

and

Fryers,

Kitchen

Dioxide

Carbon

25%

+

HELIUM

Trailer

Decks,

Hinge

Frames,

Brackets

+

Settings

THICKNES

(Inches!

Gauge)

24

18

16

16

11

3/16tol/4

.187to.250

16

14

Dioxide

7-1/2%

.022

3/64

1/16

1/8

11

3/16

.187

io

1/4

.250

1/16

1/8

1/16

3/32

1/8

11

1/4

ARGON

are

GA.

GA.

GA.

GA.

GA.

GA.

GA.

GA.

GA

approximate.

WIRE

TYPE\SIZE

HB28(.024)

HB-28
HB28

Fabshield

HB-28
HB-28
HB-28

Fabshield

Fabshield

HB-28
HB-28

HB28

Fabshield
Fabshield

HB28

HB28(.030)

HB28

Fabshield

Fabshield

Solid

Stainless

(.030)

5356

5356

5356

5356

+

2-1/2%

Adjust

(.024)

(.030)

21B

(.035)

(.024)

(.030)

(.035)

21B

(.035)

21B

(.045)
(.024)
(.030)

(.035)

21B

(.035)

21B

(.045)
(.024)

(.035)

21B

(.035)

21B

(.045)

(.035)

(.035)

(.035)

(.035)

CARBON

as

required.

CO2

CO2orC25

CO2orC25

CO2orC25

CO2orC25
CO2

CO2

CO2
CO2

CO2

CO2orC25

CO2

DIOXIDE

GAS

orC25

or

or

or

or

or

or



TRIMIX

TRI-MIX

TRI-MIX

ARGON

ARGON

ARGON

ARGON

C25

C25
C25
C25

C25

C25

GAS

(Cubic

20

20
20

20
20

20

20
20
20

20
20
20

20

20

20

20

20

20

20

FLOW

Ft/Hr)









POLARIT~

DCEP
DCEP
DCEP
DCEN
DCEP
DCEP
DCEP

DCEN
DCEN
DCEP

DCEP

DCEP

DCEN
DCEN

DCEP

DCEP

DCEP

DCEN

DCEN

DCEP

DCEP

DCEP

DCEP

DCEP

DCEP

DCEP

205424A

WELDING

VOLTAGE

3or4
3or4

5

9

9

10

WIRE

STICKOU1

(Inches)

1/4
1/4

5/16

1/4

5/16

5/16

5/16

1/2

1/2

5/16

3/8
3/8

1/2

1/2
1/2

1/2

1/2
1/2

3/4

3/8

3/8

3/8

1/2

1/2

1/2

1/2

205

.

424-A

WIRE

PEE

1

4.55.5

2

2

2

2

2

3
3
2

2

4

4

4

2

3

4-5.5

455.5

1

1

1

3

4

1

2

3

4

45

4-5.5

4.55.5

45
55.~

~i~T

4.55.~

45

78

4_S

45

4.5-5.:

6-7

67

9-10

OM-210

089

Page

.

20

SECTION

5-

MAINTENANCE

&TROUBLESHQOTING

5-1.

Routine

Maintenance

5-2.

Overload

VAC

120

And

Protection

VAC

230

(CSA)

Models

120

VAC

3

(CSA)

2

Model

Circuit

1

Circuit
feed

breaker

Circuit

2

Model)

CB1
CB1

Circuit

3

Model)

Circuit
feed
breaker

Reset

Breaker

breaker

from

motor

opens,

Breaker

protects

opens,

Breaker

breaker

from

motor

opens,

breaker.

wire

unit

unit

wire

CB

CB

protects

overload.

stops

CB1

from

shuts

CB2

CB2

protects

overload.

stops

If

circuit

feeding.

(CSA

overload.

down.

(CSA

If

circuit

feeding.

wire

If

wire

OM-210

Ref.

ST-802

089

081

Page

21

5-3.

Changing

Tools

Needed:

Drive

Roll

Or

Wire

Inlet

Guide

Inlet

1

2

Loosen
drive

touching.

3

4

3

The

ent

markings

drive

opposite

groove

the

Section

ing

woodruff

and

4

Secure

shown.

Wire

screw.

rolls

Guide

Slide

as

Screw
InletWireGuide

Tighten

Drive

Roll

drive

roll

sized

proper

drive

not

Drive

consists

grooves.

the

on

roll

referstothe

side

closesttothe

groove

NOTE:

3-9).

rolls,

isonthe

key

in

the

Roll

drive

of

old

Securing

roll

Securing

tip

possible

screw.

of

The

end

surface

groove

the

drive

motor

thread

to

when

make

motor

drive

with

close

as

without

two

stamped

roll.

shaft

chang

sure

roll.

Screw

screw

to

differ

of

the
the

on

The

is

(see

the

shaft,

as

.

5-4.

F1

Replacing

Tools

Needed:

Gun

Contact

Tip

Ref.

ST-802

024/

ST-802

139

.

Turn

A

1

2

Cut

Remove

Remove
contact

2

Off

replacing

Nozzle
Contact

Tip

off

welding

nozzle.

contact

Reinstall

tip.

power

contact

wire

tip

at

and

nozzle.

Ret.

before

tip.

contact

install

ST-149

tip.

new

326-A

OM-210

089

Page

22

5-5.

Cleaning

Or

Replacing

GAl

6C2

Gun

Liner

Turn

off

welding

source/wire

feeder.

power

Remove

contact

liner

nozzle,

tip,

collet.

and

Gun/feeder

Tools

V

Needed:

3/8

in

1~

Blow

casing.

gun

out

Remove

To

Reassemble

Install

contact

Insert

new

Install

collet

into

gun/feeder

wrench.

Cut

liner

is

end

possible

Install

nozzle.

off

as

without

liner

tip.

liner.

onto

near

close

Gun:

and

liner

connector

colletsothat

to

drive

rolls

touching.

OM-210

089

Page

23

5-6.

Troubleshooting

Table

P~*~*H*~

weld

No

not

does

No

weld

continues

motor

No

weld

Low

weld

Electrode

welding.

output;

run.

output;

output;

output.

wire

Trouble

wire

wire

to

run.

wire

feeding

does

does

feeds.

not

not

stops

feed;

feed;

during

Secure

fan

Replace

Place

Check

fan

Thermostat

Section

Secure

Connect

Replace

Check

Connect

Place

Straighten

Adjust

Change

Readjust

Replace

Clean

Replace

Secure

Check

Check

Have

power

building

Power

circuit

2-2).

gun

work

contact

for

proper

unit

voltage

gun

drive

to

proper

hub

contact

or

replace

drive

gun

circuit

and

clear

nearest

cord

plug

line

switchinOn

breaker

S3

open

leads

trigger

clamp

tip

polarity

to

proper

switch

cable

roll

pressure

drive

tension

tip

wire

roll

or

leads

trigger

breaker

any

Factory

in

receptacle

fuse

CB

(CSA

reset

or

position

model),

circuit

(see

(overheating).

Section

(see

to

get

(see

input

desired

in

and/or

roll

(see

if

blocked

inlet

pressure

CBorCB2

restrictionsatdrive

Authorized

metal

good

Section

connections

voltage

position

replace

Section

(see

groove

Section

(see

or

guide

bearing

or

repair

5-4).

leads

(depending

Service

(see

breaker

Section

and

Allow

3-1).

to

metal

(see

check

or

(see

damaged

3-9).

Section

(see

3-8).

Section

if

liner

dirtyorplugged

if

worn

(see

assembly

Agent

Remedy

Section

reset

fan

to

Section

for

Section

parts.

5-4).

or

Section

on

3-5).

if

open.

4-1).

if

necessary

thermostat

run;

contact.

3-2).

low

line

4-1).

5-3).

slipping

3-1).

Model),

and

drive

check

voltage.

(see

Section

(see

and

reset

liner

(see

motor.

(see

closes

Section

if

Section

Section

when

5-3

5-3).

necessary

or

3-9

5-2).

unit

Section

(see

or

has

Section

Section

cooled

5-5).

5-5).

(see

5-2).

OM-210

089

Page

.

24

P

SECTION

6-

ELECTRICAL

DIAGRAM

I~

I~

I~

INPUT

120V

RANVE

REV~.J

-

IO1R~

F

I1O1~

FACING

BASE

~

LEADS

ROTA1OI

~CI1

(aiDSa~D)

FROM

S

:~

VALVE

101

--

OPEN

CIA

GILT

V~TASE



19



22

2



3

25



4

29

Bi
B2

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CR1

LEGEND

~.IRE

MOTOR,

MOTOR,

CAPACITOR,

CB

J1

Ki

CIRCUIT

OUTPUT

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FAN

/

53000

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REC11FIER

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AY.

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TRANSFORMER

30

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VOLTS

6-1.

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Li

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51

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S3

Ti

Diagram

RELAY,

REACTOR,

GAS

RHEOSTAT,

RESISTOR.

SWiTCH,

SWiTCH.

THERMOSTAT,

TRANSFORMER,

For

120

VALVE

BRAKE

FILTER

CAP

ROTARY.

POWER,

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16

OHM,

BLEEDING,

5

ON/OFF

OVER

POWER

Model

50W

POSI11ON.

TEMPERATURE

OHM.

25A

lOW

OM-210

089

Page

25

ST-205

400

50

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25A

DN

OM-2l0

089

Page

.

011

ST-210

VAC

CSA

6-2.

Figure

26

Circuit

Diagram

For

120

Model

___

~

LE#~

~JOC

]

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Ba~

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--_____

_____

_____

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a

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~

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K2

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r

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Figure

6-3.

Circuit

Diagram

For

230

VAC

Model

OM-210

089

Page

27

ST-205

423

SECTION

7-

MIG

WELDING

(GMAW)

GUIDELINES

F!!

7-1.

Typical

Flowmeter

Shielding

Gas

~

MIG

Process

Regulator!

Connections

Wire

Power

Feeder!

Source

Gun

Weld

A

electronic

Disconnect

cables
vehicle.

as

possible.

Workpiece

close

current

before

Place

parts

both

to

can

damage

in

vehicles.

welding

work

weld

the

battery

on

a

clamp

as

Work

Clamp

light

mig

5/967

ST-801

/

909

OM-210

089

Page

28

7-2.

Typical

MIG

Process

Control

Settings

NOTE

L~

Material

parameters.

These

settings

position,

shielding

specifications.

thickness

determines

are

guidelines

etc.

gas,

weld~z~

only.

affect

or

125

in

4,



90

30

40145



180

50

Range

A

A

A

Amperage

4,

Material

settings.

Test

and

wire

welds

type,

to

Convert

Thickness

Amperage

(.001

.125

Select

be

=

in

in=125A

Wire

joint

sure

Material

to

(A)

1

ampere)

Size

design,

comply

they

fitup,

to

Wire

Size

.023

.030

.035

in

in

in

Set

Recommendation

in

3.5

per

2

in

per

1.6

in

per

Low

voltage:

High

voltage:

midway

voltage

ampere

ampere

ampere

arc

.

wire

is

between

3.5x125

1.6

stubs

unstable

high/low

Wire

(Approx.)

2x125

125

x

into

work

(spatter)

Speed

A=437

A=250

A

=

200

voltage.

ipm

ipm

1pm

Select

(Amperage)

Abased

125

material

=

1pm

Select

Wire

inch

Speed

on

1/8

thickness

minute

per

Voltage

in

OM-210

Ref.

089

ST-802

Page

083

29

7-3.

Holding

And

Positioning

Welding

Gun

NOTE

EIIII~

End

Welding

pressing

and

View

Of

tip

4

Work

wire

is

trigger,

of

wire

1

Angle

GROOVE

energized

be

sure

is

positioned

()

Side

WELDS

when

gun

wire

is

correctly

ViewOfGun

trigger

more

no

on

S

Angle

is

pressed.

than

seam.

1/2

in

Before

(13

1

2

3

4

5

lowering

mm)

past

Hold

Gun

Trigger

Workpiece

Work

Electrode

(Stickout)

13mm)

Cradle

on

Workpiece

Clamp

Gun

helmet

of

end

Control

and

Extension

1/4to1/2

Rest

and

and

nozzle,

Gun

To

in

(6

Hand

S

End

View

S

Of

Work

Angle

FILLET

WELDS

Side

ViewOfGun

Angle

S-0421-A

OM-210

089

Page

30

7-4.

Conditions

That

Affect

Weld

Bead

Shape

N

OTE

(weld

extension

current),

trave~

feed

electrode

speed

bead

~

Weld

(stickout),

and

Perpendicular

shape

travel

voltage.

ANGLES

GUN

depends

speed,

I~,41Oo

AND

Push

on

gun

thickness

WELD

BEAD

of

angle,

base

PROFILES

direction

meta~

Drag

of

wire

y

Short

Normal

Long

ELECTRODE

EXTENSIONS

(STICKOUT)

~I&c~&c~~c

Short

FILLET

Slow

WELD

ELECTRODE

Normal

Normal

GUNTRAVELSPEED

EXTENSIONS

Long

(STICKOUT)

()

Fast

C)

S-0634

OM-210

089

Page

31

7-5.

N

Gun

OTE

Movement

~

During

Normally,

howeve,

multiple

Welding

a

single

for

wide

stringer

stringer

groove

beads

bead

weld

works

is

satisfactory

or

joints

better.

for

bridging

most

across

narrow

gaps,

g

roove

a

weave

weld

joints;

bead

or

7-6.

Poor

1

~

Weld

Bead

~4~(4~(

Characteristics

1

Stringer

2

1

Movement
Weave

2

Movement

Weave

3

Use

weave

wide

area

electrode.

1

Large

2

Rough,

3

Slight

Bad

4

Poor

5

Overlap

Penetration



Bead

Steady

Seam

Along

BeadSideToSide

Patterns

in

Spatter

Uneven

Crater

Along

patterns

one

Deposits

During

Seam

to

pass

Bead

cover

Welding

of

S-0054-A

a

the

7-7.

OM-210

Good

089

Page

Weld

32

Bead

r~L/3

Characteristics

2

34

5

S-0053-A

1

Fine

Spatter

2

3

Welding

Weld

in

1/8

being

No

4

Good

5

Metal

5

Uniform

Moderate

a

new

(3.2

welded.

Overlap

Bead

Crater

bead

or

thickness

mm)

Penetration

During

layer

into

for

in

each

metals

Base

S-0052-B

7-8.

Troubleshooting



Excessive

Spatter

Excessive

cool

to

solid

Spatterscattering

form

near

weld

bead.

of

molten

metal

particles

that

S-0636

Wire

feed

Voltage

Electrode

Workpiece

Insufficient

welding

Dirty

7-9.

speed

too

extension

Possible

high.

Causes

too

high.

(stickout)

too

long.

dirty.

shielding

wire.

gas

at

welding

Troubleshooting

Possible

Causes

Select

Select

Use

Remove

welding.

arc.



Increase

Use

Eliminate

Porosity

lower

lower

shorter

all

flow

clean,

wire

voltage

electrode

grease,

of

welding

dry

pickup

Porosity

in

feed

speed.

range.

extension

oil,

shielding

wire.

of

oil

or



small

weld

metal.

Corrective

(stickout).

moisture,

gas

lubricant

rust,

at

regulator/flowmeter

on

welding

cavities

holes

or

Corrective

paint,

undercoating,

wire

resulting

Actions

and/or

from

Actions

feeder

from

and

prevent

or

pockets

gas

dirt

drafts

liner.

from

work

near

surface

welding

before

arc.

S-0635

Insufficient

Wrong

gas.

Dirty

welding

Workpiece

Welding

wire

shielding

wire.

dirty.

extends

gas

too

at

welding

far

out

of

arc.

nozzle.

Increase

Remove

Check

gas

Place

nozzle

Hold

gun

Use

welding

Use

clean,

Eliminate

Remove

welding.

Use

a

more

Be

sure

flow

of

spatter

hoses

1/4to1/2

bead

near

grade

dry

welding

pick

up

all

grease,

highly

welding

shielding

from

for

gun

leaks.

end

at

in

gas

(6-13

shielding

wire.

of

oilorlubricant

oil,

moisture,

deoxidizing

wire

extends

at

regulator/flowmeter

nozzle.

from

mm)

until

change

on

welding

rust,

paint,

more

molten

wire

than

of

weld

gas;

not

welding

workpiece.

metaJ

different

to

from

wire

coatings,

(contact

in

1/2

(13

and/or

prevent

solidifies.

gas.

feeder

and

dirt

supplier).

mm)

beyond

or

from

drafts

liner.

work

nozzle.

near

surface

welding

before

arc.

OM-210

089

Page

33

7-10.

Troubleshooting

(

Excessive

Penetration

Possible

Good

Causes



Excessive

~

Penetration

Penetration

Excessive

and

Penetration

hanging

underneath



weld

weld.

Corrective

metal

melting

Actions

through

base

metal

S-0639

Excessive

7-11.

Improper

Improper

Insufficient

7-12.

heat

input.

Troubleshooting

~fl

I

I

LackofPenetration

Possible

preparation.

joint

weld

technique.

heat

input.

I

Good

Causes

Troubleshooting

Select

Increase

-

Lack

Of

~JW

Penetration

I

Material

maintaining

Maintain

Keep

Be

sure

Select

Reduce

-

Incomplete

lower

voltage

travel

speed.

Penetration

Lack Of
fusion

base

thick.

too

proper

normal

gun

on

arc

leading

wire

welding

wire

higher

travel

speed.

Fusion

and

range

between

metal.

Joint

welding

angle

edge

extends

feed

reduce

Penetrationshallow

weld

preparation

wire

of

0to15

of

weld

not

and/or

speed

metal

Corrective

and

extension

degrees

puddle.

more

select

wire

and

design

and

than

feed

must

arc

achieve

to

in

1/2

higher

speed.

Actions

access

provide

characteristics.

maximum

(13

mm)

beyond

voltage

range.

of

bottom

to

penetration.

nozzle.

groove

S-0638

while

.

Workpiece

Insufficient

Improper

welding

Possible

dirty.

heat

Causes

input.

technique.

Remove

all

welding.

Select

higher

Place

stringer

work

Adjust

Momentarily

on

arc

Keep

Use

correct

Incomplete

base

metal

oil,

grease,

voltage

in

bead

or

angle

hold

arc

leading

angle

gun

Fusion

or

moisture,

range

proper

widen

on

groove

edge

of

0



failure

a

preceeding

Corrective

rust,

paint,

and/or

adjust

location(s)atjoint

to

side

puddle.

15

degrees.

access

walls

groove

of

weld

to

of

weld

metal

weld

bead.

Actions

undercoating,

feed

wire

during

bottom

when

using

to

speed.

welding.

during

weaving

fuse

completely

and

dirt

welding.

technique.

from

work

with

surface

S-0637

before

OM-210

089

Page

34

7-13.

TroubleshootingBurn-Through

pletely

ris.

through

base

metal

S-0640

Excessive

7-14.

Welding

Unsteady

7-15.

Possible

heat

Causes

input.

Troubleshooting

wire

hand.

Possible

extends

Causes

too

far

out

of

Troubleshooting

~ase



Waviness

nozzle.



Distortion

metal

in

direction

the

the

weld

Select

Increase

Be

sure

Support

moves

bead.

lower

voltage

maintain

and/or

Of

Bead

Waviness

formed

joint

wire

welding

hand

of

solid

on

Distortioncontraction

base

metal

range

Of

extends

surface

reduce

and

travel

steady

Beadweld

base

by

not

or

to

move.

metal.

more

use

Corrective

feed

wire

speed.

that

metal

Corrective

than

1/2

hands.

two

of

weld

speed.

is

in

metal

Actions

not

Actions

(13

during

and

parallel

mm)

beyond

welding

does

nozzle.

that

not

forces

cover

S-0641

S-0642

Excessive

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heat

input.

Causes

restraint

Use

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tack

tower

Select

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travel

(clamp)

welds

voltage

segments

along

speed.

to

joint

range

hold

and

base

before

and/or

allow

Corrective

metal

in

starting

reduce

cooling

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position.

welding

feed

wire

between

operation.

speed.

welds.

OM-210

089

Page

35

7-16.

Common

MIG

Shielding

Gases

This

is

a

shielding

Argon

Globular

Single

HE

90%

table.

Argon

Tn-Mix3

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following

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general

have

gases

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25%

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All

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combinations

shielding

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gases

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listed

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Aluminum

All

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in

of

the

OM-210

089

Page

36

Nstu

C&$210

Page

37

SECTION

8-

PARTS

LIST

-23

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ItT

Hardware

available

not

is

common

unless

.

and

listed.

OM-210

089

Page

ST-802

066



8-1.

Figure

38

Main

Assembly

Item

No.

Dia.

Mkgs.

Part

No.

Figure

8-1.

Main

Description

Assembly

Quantity

.43

10

11

12
13

14

15
16

17

18
19

20

21
22

23

23

24
25

25

26
27

27

28
29
30
30

31

31
32

33

34

34A

35
36
37
38

39

40

41

42

44

45

46

47

48

49

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OM-210

089

Page

39

Item

No.

Dia.

Mkgs.

Part

No.

Figure

8-1.

Main

Assembly

Description

(Continued)

Quantity

49
50
51

52

53
54

56
57

57

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59
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61
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OM-210

089

Page

40

111111

U~

Item

No.

1

2

3

4

5
6

7

8
8

9

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OM-210

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