Related Manuals for MAC TOOLS MW135
Summary of Contents for MAC TOOLS MW135
- Page 1 OM-210 089B September 1998 Processes MIG (GMAW) Welding ® Flux Cored (FCAW) Welding Description Arc Welding Power Source And Wire Feeder MW 135 / MW 175 And GA16C2 Gun...
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Page 3: Table Of Contents
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ......The following terms are 1-1. -
Page 5: Section 1 − Safety Precautions - Read Before Using
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _nd_5/97 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Y Marks a special safety message. - Page 6 ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. D Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense D Always ventilate confined spaces or use visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.
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Page 7: Additional Symbols For Installation, Operation, And Maintenance
1-3. Additional Symbols for Installation, Operation, and Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables. -
Page 8: Emf Information
1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. Welding current, as it flows through welding cables, will cause electro- magnetic fields. -
Page 9: Section 1. Consignes De Securite − Lire Avant Utilisation
SECTION 1. CONSIGNES DE SECURITE − LIRE AVANT UTILISATION som _nd_Fre_4/97 Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Y Identifie un message de sécurité... - Page 10 LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris- voquer des brûlures dans les yeux et quent de provoquer des blessures ou sur la peau. même la mort. Le rayonnement de l’arc du procédé de soudage D Fermer l’alimentation du gaz protecteur en cas de génère des rayons visibles et invisibles intenses non utilisation.
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Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance
Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU DES ORGANES MOBILES peuvent D’EXPLOSION. provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou à D Rester à l’écart des organes mobiles comme le proximité... -
Page 12: Principales Normes De Sécurité
Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 P-1, de la Compressed Gas Association, 1235 Jefferson Davis High- way, Suite 501, Arlington, VA 22202. -
Page 13: Section 2 − Specifications
SECTION 2 − SPECIFICATIONS 2-1. Specifications A. 120 VAC Model Amperes Input at Maximum Open- Rated Welding Amperage Rated Load Output Weight Overall Circuit Voltage Output Range W/ Gun Dimensions 120 V, 60 Hz, Single-Phase Length: 19-1/8 in (489 mm) 90 A @ 19 Volts DC, 2.88 2.45... -
Page 14: Duty Cycle And Overheating
2-2. Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) A. 120 VAC Model opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. -
Page 15: Volt-Ampere Curves
2-3. Volt-Ampere Curves The volt-ampere curves show the A. 120 VAC Model minimum and maximum voltage and amperage output capabilities of the welding power source. Curves of other settings fall be- tween the curves shown. B. 230 VAC Model ssb1.1 10/91 − ST-802 082 / ST-802 089 OM-210 089 Page 11... -
Page 16: Section 3 − Installation
SECTION 3 − INSTALLATION 3-1. Installing Welding Gun Drive Assembly Gun Securing Thumbscrew Gun End Loosen thumbscrew. Insert gun end through opening until it bot- toms against drive assembly. Tighten thumbscrew. Gun Trigger Leads Insert leads, one at a time, through small grommet on front panel. -
Page 17: Installing Gas Supply
3-4. Installing Gas Supply Obtain gas cylinder and chain to running gear, wall, or other station- Tools Needed: ary support so cylinder cannot fall and break off valve. 5/8, 1-1/8 in Cylinder Valve Remove cap, stand to side of valve, and open valve slightly. Gas flow blows dust and dirt from valve. -
Page 18: Selecting A Location And Connecting Input Power For 120 Vac Model
3-5. Selecting A Location And Connecting Input Power For 120 VAC Model Rating Label Grounded Receptacle A 120 volt, 20 ampere individual 18 in branch circuit protected by time- (460 mm) delay fuses or circuit breaker is required. Plug From Unit Select extension cord of 14 AWG for up to 50 ft (15 m) or 12 AWG for 50 up to 200 ft (61 m). -
Page 19: Selecting A Location And Connecting Input Power For 230 Vac Model
3-6. Selecting A Location And Connecting Input Power For 230 VAC Model Rating Label Supply correct input power. Plug Receptacle Connect plug to receptacle. Line Disconnect Device 18 in (457 mm) of space for airflow See Section 3-7. Y Special installation may be required where gasoline or volatile liquids are present −... -
Page 20: Electrical Service Guide For 230 Vac Model
3-7. Electrical Service Guide For 230 VAC Model Input Voltage Input Amperes At Rated Output 19.5 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Min Input Conductor Size In AWG/Kcmil Max Recommended Input Conductor Length In Feet (Meters) 66 (20) Min Grounding Conductor Size In AWG/Kcmil Reference: 1996 National Electrical Code (NEC) -
Page 21: Threading Welding Wire
3-9. Threading Welding Wire Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Outlet Wire Guide Gun Conduit Cable Lay gun cable out straight. Tools Needed: Hold wire tightly to keep it from unraveling. 4 in (102 mm) 6 in (150 mm) Open pressure assembly. -
Page 22: Section 4 − Operation
SECTION 4 − OPERATION 4-1. Controls Voltage Switch The higher the selected number, the thicker the material that can be welded (see weld setting label in welding power source or Sections 4-2 and 4-3, as applicable). Do not switch under load. Voltage Switch - Purge “0”... -
Page 23: Weld Parameters For 120 Vac Model
4-2. Weld Parameters For 120 VAC Model 205406A Welding Guide Settings are approximate. Adjust as required. WIRE THICKNESS WIRE GAS FLOW WELDING WIRE STICKOUT (Inches/ POLARITY VOLTAGE SPEED TO WELD: (Cubic Ft/Hr) TYPE\SIZE (Inches) Gauge) HB−28 .022” or C DCEP 3−4 Auto Body 24 GA. -
Page 24: Weld Parameters For 230 Vac Model
4-3. Weld Parameters For 230 VAC Model 205424A Welding Guide Settings are approximate. Adjust as required. WIRE THICKNESS WIRE GAS FLOW WELDING WIRE STICKOUT (Inches/ POLARITY VOLTAGE SPEED TO WELD: (Cubic Ft/Hr) TYPE\SIZE (Inches) Gauge) .022” HB−28 (.024) or C Auto Body DCEP 4.5−5.5... -
Page 25: Section 5 − Maintenance &Troubleshooting
SECTION 5 − MAINTENANCE &TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace Repair or Clean unreadable replace tighten weld labels. cracked terminals. weld cable. 6 Months Blow out or vacuum inside. During heavy service, clean monthly. 5-2. -
Page 26: Changing Drive Roll Or Wire Inlet Guide
5-3. Changing Drive Roll Or Wire Inlet Guide Inlet Wire Guide Securing Screw Inlet Wire Guide Loosen screw. Slide tip as close to drive rolls as possible without touching. Tighten screw. Drive Roll The drive roll consists of two differ- ent sized grooves. -
Page 27: Cleaning Or Replacing Ga16C2 Gun Liner
5-5. Cleaning Or Replacing GA16C2 Gun Liner Turn off welding power source/wire feeder. 3/8 in Remove nozzle, contact tip, and liner collet. 3/8 in Remove liner Gun/feeder connector Blow out gun casing. To Reassemble Gun: Install contact tip. Insert new liner. Install collet onto liner and tighten into gun/feeder connector using wrench. -
Page 28: Troubleshooting Table
5-6. Troubleshooting Table Trouble Remedy No weld output; wire does not feed; fan Secure power cord plug in receptacle (see Section 3-5). does not run. does not run. Replace building line fuse or reset circuit breaker if open. Place Power switch in On position (see Section 4-1). Check circuit breaker CB (CSA model), and reset if necessary (see Section 5-2). -
Page 29: Section 6 − Electrical Diagram
SECTION 6 − ELECTRICAL DIAGRAM ST-205 400 Figure 6-1. Circuit Diagram For 120 VAC Model OM-210 089 Page 25... - Page 30 Overload Feed Motor ST-210 011-B Figure 6-2. Circuit Diagram For 120 VAC CSA Model OM-210 089 Page 26...
- Page 31 ST-205 423-B Figure 6-3. Circuit Diagram For 230 VAC Model OM-210 089 Page 27...
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Page 32: Section 7 − Mig Welding (Gmaw) Guidelines
SECTION 7 − MIG WELDING (GMAW) GUIDELINES 7-1. Typical MIG Process Connections Y Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible. Regulator/ Flowmeter Wire Feeder/... -
Page 33: Typical Mig Process Control Settings
7-2. Typical MIG Process Control Settings NOTE These settings are guidelines only. Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. Test welds to be sure they comply to specifications. Material thickness determines weld parameters. 1/8 or Convert Material .125 in Thickness to... -
Page 34: Holding And Positioning Welding Gun
7-3. Holding And Positioning Welding Gun NOTE Welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trigger, be sure wire is no more than 1/2 in (13 mm) past end of nozzle, and tip of wire is positioned correctly on seam. Hold Gun and Control Gun Trigger Workpiece... -
Page 35: Conditions That Affect Weld Bead Shape
7-4. Conditions That Affect Weld Bead Shape NOTE Weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed (weld current), and voltage. ° Push ° Perpendicular Drag GUN ANGLES AND WELD BEAD PROFILES Short Normal Long... -
Page 36: Gun Movement During Welding
7-5. Gun Movement During Welding NOTE Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads works better. Stringer Bead − Steady Movement Along Seam Weave Bead −... -
Page 37: Troubleshooting − Excessive Spatter
7-8. Troubleshooting − Excessive Spatter Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead. S-0636 Possible Causes Corrective Actions Wire feed speed too high. Select lower wire feed speed. Voltage too high. Select lower voltage range. Electrode extension (stickout) too long. -
Page 38: Troubleshooting − Excessive Penetration
7-10. Troubleshooting − Excessive Penetration Excessive Penetration − weld metal melting through base metal and hanging underneath weld. Excessive Penetration Good Penetration S-0639 Possible Causes Corrective Actions Excessive heat input. Select lower voltage range and reduce wire feed speed. Increase travel speed. 7-11. -
Page 39: Troubleshooting − Burn-Through
7-13. Troubleshooting − Burn-Through Burn-Through − weld metal melting completely through base metal resulting in holes where no metal remains. S-0640 Possible Causes Corrective Actions Excessive heat input. Select lower voltage range and reduce wire feed speed. Increase and/or maintain steady travel speed. 7-14. -
Page 40: Common Mig Shielding Gases
7-16. Common MIG Shielding Gases This is a general chart for common gases and where they are used. Many different combinations (mixtures) of shielding gases have been developed over the years. The most commonly used shielding gases are listed in the following table. - Page 41 Notes OM-210 089 Page 37...
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Page 42: Section 8 − Parts List
SECTION 8 − PARTS LIST Hardware is common and not available unless listed. ST-802 066 Figure 8-1. Main Assembly OM-210 089 Page 38... - Page 43 Item Dia. Part Mkgs. Description Quantity Figure 8-1. Main Assembly ....+203 563-1 . . . PANEL, top (gray) ..........
- Page 44 Item Dia. Part Mkgs. Description Quantity Figure 8-1. Main Assembly (Continued) ..... 129 696 . . . CONTACTOR, input (120 VAC model) .
- Page 45 Item Part Description Quantity Figure 8-2. Complete Assembly (GA16C2 Gun) 187 708 ... . . 110 793 HANDLE ASSEMBLY ..........
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