AUTO ARC MW 4110 Owner's Manual

Om-112 875d

Hide thumbs Also See for AUTO ARC MW 4110:

Owner's manual (52 pages)

Table Of Contents

Table of Contents

Quick Links

AUTO

ARCJ

September

1990

FORM: OM-112

875D

Effective With Serial No. KA870779

MODEL:

MW 4110

MW 4230

OWNERS

MANUAL

IMPORTANT: Read and understand the entire

contents

of this

manual,

with

special emphasis

the

safety

material

throughout

the

manual,

before

MILLER ELECTRIC

Mig.

Co.

AM~G~Ud..Corr~any

Installing, operating,

maintaining

this

equipment.

This unit and these

Instructions

are

for

use

only by

persons

trained and

experienced

in the Safe

1079

Appleton,

WI 54912 USA

operation

welding equipment.

not

allow untraIned

persons

install,

Tel. 414-734-9821

operate,

maintain this

unit.

Contact your dIstributor

you

not

fuliy

understand these

Instructions.

18-112 943-A

Table of Contents

Need help?

Do you have a question about the AUTO ARC MW 4110 and is the answer not in the manual?

Questions and answers

Summary of Contents for AUTO ARC AUTO ARC MW 4110

Page 1 Effective With Serial No. KA870779 MODEL: MW 4110 MW 4230 OWNERS MANUAL IMPORTANT: Read and understand the entire of this with contents manual, MILLER ELECTRIC Mig. special emphasis material before safety throughout manual, AM~G~Ud..Corr~any Installing, operating, This unit and these...
Page 2 ARE UMITED TO THE REMEDY PROVIDED BY THIS LAW, original purchaser of this Welder. WARRANTY. TO THE EXTENT ENFORCEABLE UNDER MILLER ELECTRIC SHALL LAW, APPUCABLE of MILLERs EVENT BE LIABLE FOR CONSEQUENTiAL, INCIDENTAL breach of case any other duty...
Page 3: Table Of Contents
OM.1128750-e,gO RECEIVING-HANDLING Before record the Model unpacking equipment, check carton for any dam- Use the following Designa spaces age that may File any tion and Serial Style Number of your unit. The have occurred dunng shipment. infor claims for loss damage with the delivering...
Page 4 Page Section SECTION 6- SEQUENCE OF OPERATION Gas Metal 6-1. Welding (GMAW) 6-2. Shutting Down MAINTENANCE & TROUBLESHOOTING SECTION Routine Maintenance 7-2. Overload Protection 7-3. Replacing Drive Roll 7-4. Replacing Pressure Bearing 7-5. Wire Inlet Guide Replacing 7-6. Realigning Drive Housing 7-7.
Page 5: Introduction
WELDING OPERATION SECTION SAFETY RULES FOR OF ARC POWER SOURCE INTRODUCTION 1.1. welding cutting, (and chipping) protect eyes from radiant energy and metal. Replace flying cover We learn by experience. Learning safety through glass when broken, pitted, spattered. -3A.2. sonal child experience, like...
Page 6 menfas~ recommended in A6.O. Waterfilling below minute amounts just atmospheres ~,containing even perchloroØthylene. inerting. working level may substitufe trichioroethylene should be cleaned A container with unknown contents Fire Explosion Prevention Do NOT depend (see preceding paragraph). on sense Causes combustibles reached of fire and explosion are:...
Page 7 Prohibited use.~Never cylinder outlet from peo.ple ignition. Wipe contents use a away sources other than its intended NEVER ~with clean lintless support c~om. as a use, roller. Before Match regulator cylinder. connecting, check be knocked Locate cylinders they cannot that the label and regulator cylinder marking...
Page 8: Arc Welding
WELDING 1-3. .Viewirig weld. PrOvide face shields for all persons the weld. who will be looking rectly. Comply with this section. precautions 1-1, 1-2, Others See that all persons working wearing Welding, properly done, safe process, but area. flash goggles. careless invites trouble.
Page 9: Standards Booklet Index
HOTtiy electrically shock, Welding stray current possibly used with shielded power sources Do NOT GROUND tally. electrical conduit, pipe metal welding (SMAW) and similar proc orto carrying flammable eq~uipped liquid such fuel. with welding esses power on-off control devices. With such output equip Three-phase...
Page 10: General Information And
St~ndard ~rorn ANSI Z49.2, FIRE PREVENTION IN Compressed Association, 1235 Jef OF CUTTING WELDING PROC ferson Davis Suite 501, Highway, Arlington, ESSES obtainable from the American National 22202. Standards Institute, 1430 Broadway, York, CSA Standard W117.2, CODE FOR SAFETY NV 10018. WELDING CUTTING obtainable from AWS Standard...
Page 11: Specifications
SPECIFICATIONS SECTION 3- Table 3-1. SpecificatIons Power Source Welding input At Rated Load Max. Electrode Control Single-Phase Electrode Weight Rated Wire Open. Circuit Model Wire Feed Diameter Weld Output Circuit Voltage Amperes Speed Capability At Gun Voitage 11SV 230V )(VA Ship Amperes 70-400...
Page 12: Volt-Ampere
~Referio VOLT-Aii~lPERE Cycle 3-1. CURV~S (Chart 3-1) Duty Charts (Chart 3-2) to determine various output of the welding duty power source RATED OUTPUT cycles. IMPORTANT: Decreasing welding amperes increases show the minimum and maxi volt-ampere curves duty cycle. capabilities of the voltage output amperage...
Page 13: Description
CAUTION: EXCEEDING THE RATED AM weldi~ig factory equipped with power source PERAGE WITH OR FAILING TO RE (3 m) input power cord and built-in gas valve. WELDING DUCE THE AMPERAGE OR DUTY CYCLE WHEN USING A MIXED SHIELDING 3-5. ADDITIONAL REQUIRED EQUIPMENT (Fig result In damage...
Page 14: Optional Equipment
~Jlre Spool OPTIONAL EQUIPMENT 3-6. Selection of the wire is correct welding important This unit with styles equipped running Metal Arc Welding (GMAW). There types many ordered with the unit, running gear. gear run- wire from which choose, but certain wires best Owners Manual...
Page 15: Site Selection
4-1. SITE SELECTION (FIgure 3-1) Reguttor/Flowm.eter (Customer Supplied) (Fig. ure4-1) Select installation site which provides following: With the cylinder securely installed, remove Correct input supply (see unit nameplate) cylinder cap, stand side of power cylinder valve, and open valve slightly. When gas flows from...
Page 16: Gun Polarity
su~pIied Slide piece insulating sleeve onto Lockout/taggingprocedures consist of removing work cable. input from plug receptacle, padlocking power line disconnect switch position, open remov fuses from fuse box, shutting off and red Place work cable inside the handle of the work tagging circuit breaker other...
Page 17: Welding
WELDING 4-5. GUN INSTALLATION insert the connector, and (Figures receptacle, rotate collar clckwise. 4-4) fully WARNING: ELECTRIC SHOCK kill. 4-6. WELDING WIRE SPOOL INSTALLATION not touch live electrical parts. (Figure 4-4) Shutdown welding powersource, and discon Open left side door. nect input employing lockout/tagging...
Page 18: Welding
4110 models have duty cycle (2 minutes WARNING: ELECTRIC SHOCK kill. minutes be used for welding); every therefore, touch live, electrical parts. supplied cord and attached with NEC plug comply not connect input conductor standards for 20% duty cycle. that the building sure ground...
Page 19 WELDING dnv~e WIRE rolipressurØ puncture just tightly enough cause prevent HOT SURFACES wounds; can cause severe the wire from slipping against drive roll dur on or burns. ing operation. until instructed trigger press gun CAUTION: EXCESSIVE DRIVE ROLL TEN. SION equipment damage cause...
Page 20: Section 5-Operator Controls
SECTION OPERATOR CONTROLS Fine Tuning/ Wire Speed Power Control Switch Thicknessivoits Switch Gun Switch T8-112 g43-A Receptaci. Figure Operator Controls 5-1. ARCING POWER SWITCH (Figure 5-1) CAUTION: damage contact 5-1. surfaces. POWER of THICKNESS! change position VOLTS switch while welding under load.
Page 21 SECTION 6- SEQUENCE OF OPERATION WARNING: ELECTRIC SHOCK kill; Wear dry insulating gloves clothing. MOVING PARTS serious Injury; can cause polarity changeover links desired sure IMPROPER AIRFLOW AND EXPOSURE TO position (see Section 4-4). ENVIRONMENT damage Internal parts. not touch live electrical Select welding...
Page 22: Shutting Down
6-2. SHUTTING DOWN valve. Close gas cylinder CONCENTRA11ON OF WARNING: HIGH Stop welding. SHIELDING GAS harm heafth kill. Shut off gas supply when Place POWER switch position. use. Table 6-1. Suggested Welding SettIngs MW 4110 Models GMAW Material ThIckness OPerator Shielding Control ~_______...
Page 23 GMAW And FCAW MW 4230 Models Material Thickness Wire Wire )Derator Type, Control Shielding Diameter Gas, 1/8 In. 3/16 In. 1/4 In. And Flow Rate (Inch) Settings (6.4 mm) (4.8 mm) (3.2 mm) Range .023 Feed 100% Speed* E7OS-6 Range .030 Feed Speed...
Page 24: Routine Maintenance
TROUBLESHOOTING SECTION MAINTENANCE & ROUTINE MAINTENANCE clean, airstream (Table 7-1) outer enclosure, or vac use a suction for the cleaning operation. dusty dirty IMPORTANT: the labels Ever, six months inspect clean the unit monthly. conditions present, this unit legibility. precautionary labels must maintained...
Page 25: Overload Protection
OVERI~.OAD 7-2. PROTECTION Lbckoutitaggingproceduresconsistof removing from input plug powr receptacle, padlocking Short Circuit Shutdown line disconnect switch in open position, remov fuses from fuse box, off and red shutting The unit is protected from damage to contact tube circuit breaker tagging other disconnecting...
Page 26: Replacing Pressure Bearing
inlet.~uide securing REPLACING PRESSURE BEARING (Figure Loosen wire 7.4. screw. 7-1) from drive housing, and in Remove inlet guide stall guide. WARNING: ELECTRIC SHOCK kill. touch live electrical parts. should be installed IMPORTANT: Wire inlet guide them. the drive rolls possible without touching...
Page 27: Welding Gun Inspection And Upkeep
.~Hub Support Standoff Wire Drive Mounting Motor Control Board PCI Wire Drive Motor Ref. SO-log 354-E Figure 7-2. Motor Control Board PCi Replacement WARNING: ELECTRIC SHOCK kill. Remove wrapper. touch live electrical parts. Remove terminal from terminal header housing PCi. Shut down welding powersource, and discon...
Page 28: Gun Liner Replacement
accumu~ation Remove around the switch. Remove nozzle... Cutoff any portion of the electrode wire which Repair all hose and cab replace required tends end of tube. beyond give particular attention to frayed I~ng. insulation and where it cracked enters area Remove contact tube and replace...
Page 29: Troubleshooting
install corftact tube. Itis assumed that the installed accord upitwas properly Section of this is familiar manual, operator Reinstall nozzle. function of with the controls; welding power source Reinstall gun wire drive assembly. working properly, and that the trouble is related process.
Page 30 Table 7-2. TroubleshootIng TROUBLE PROBABLE CAUSE REMEDY No weld wire does Power Secure receptacle. output; cord plug plug secure feed. wall receptacle. circuit Line fuse circuit breaker Replace line fuse reset breaker. open. Section Thermal overload. Allow cooling period (see 7-2).
Page 31 ELECTRICAL SECTION 8 DIAGRAMS Circuit No. SB-119 059 Diagram Diagram 8-1. Circuit For MW 4110 Models Diagram No. SB-119 063-C Circuit Diagram Diagram 8-2. CircuIt For MW 4230 Models Diagram OM-112 875 Page...
Page 32: Motor Control Board Pci
Circuit SC-i Diagram 37 798 Diagram 8-3. Circuit Diagram For MW Control Board PCI 4110 Motor No. SC-i 37 801 Circuit Diagram For MW 4230 Models Motor Control Board PCI Diagram 8-4. Circuit Diagram OM-112 Page...
Page 33 1 3 2 - B S C - 1 1 9 D i a g r a m C O R D W i r i n g M o d e l s 4 1 1 0 D i a g r a m W i r i n g 8-5.
Page 34 7 4 4 - C S C - i D i a g r a m W i r i n g M o d e l s M W - 4 2 3 0 D i a g r a m W i r i n g 8-6.
Page 35 TROUBLESHOOTING ~SECTION WELDING TECHNIQUES & CAUTION: WELDING CURRENT the helmet and before lowering pressing the gun seam age vehicle and other elec components trigger. tronic components. Disconnect both battery cables before weld vehicle. on a Place work the weld clamp close possible avoid...
Page 36: Welding Gun
Direction of Arc Tray Direction of Arc Travel Backhand Forehand Technique Technique 9-4. Gun Positions Figure LongitudInal The vertical up and/or vertical down drag technique generally techniques describe plete weld penetration. in the vertical the direction of travel when the welding be done when...
Page 37 ~..Posslble Correct~ve Causes Actions nozzle: shieldin Remove from the Inadequate spatter g gas coverage. Check gas hoses for leaks. Eliminate drafts blowing into (from fans, doors, etc.) open welding arc. 5/16 in. from worlcpiece. Place nozzle 114 tO (6-8 Increase flow displace all air from the weld...
Page 38 Corrective Causes Actions Clean weld surfaces of oil, impurities (grease, moisture, rust, paint, dirt, etc.) prior welding. Select adjust FINE TUNING/ higher voltage range WIRE SPEED control. technique. When weaving technique dwell momentarily using side walls of the groove. Provide improved at root joints.
Page 39 Cracks Weld Metal Possible Causes Corrective Actions Material thick. Joint design improper joint preparation. preparation must be ade the b~):\om of the groove while provide quate access wire characteris maintaining welding extension proper tics. Select Heat input high causing excessive lower voltage and reduce wire...
Page 40 SECTION 10- AUTO BODY REPAIR APPLICATION CAUTION: WELDING CURRENT Clamp metal place, and prepare spot vehicle and other electronic computers weld. components. Place the VOLTAGE ADJUSTMENT switch in the Disconnect cables before weld both battery position. vehicle. on a Install the nozzle the gun.
Page 41 Car-and door panel reinforcement, break .welded place. body manufacturers have the outer welded in different places. it will be necessary the we(~ panels detet~nine where the welds inspect body Grind the old off the hem flange remove in each After the old panel removed, cated...
Page 42 (I) m C, -l 0 z Cl) -I 11-3 8 9 7 ~ B 1 1 - 4 S D - 1 1 2 & i l l u s t r a t e d ) 4 2 3 0 ( A u t o A s s e m b l y M a i n...
Page 43 Quantity Model Item Dia. Part Description Mkgs. MW 4110 MW 4230 Figure 11-1. Main Assembly GA-16C GUN, (Fig 11-5) 089899 LATCH 112814 LABEL,AutoArcMW4llO(Ieftside) LABEL, Auto Arc MW 4230 (left side) 134 464 LABEL, warning general precautionary WRAPPER +111 833 LABEL,AutoArcMW4llO(rightside) 112813 127991 LABEL,...
Page 44 Quantity Model Item Dia. Part Description Mkgs. MW 4110 4230 Figure 11-1. Main Assembly (Continued) ~~44 PLG1 113494 CORDSET,pwr300Vl4ga3/c7ft PLG1 127933 CORDSET,pwr300Vl2ga3/c6ft BUSHING, strain relief .240/.510 ID .875 hole 112 811 LABEL, Auto Arc emblem 116 996 VALVE, 115VAC custom port 128 751 23OVAC...
Page 45 Item Part Description Quantity 11-2. DrIve Wire (Fig 11-1 Item Figure Assembly, WIRE DRIVE, 126 838 (consisting 090416 PIN,hinge HOUSING, wire drive SCREW, mach sti phflh 10-24 .625 BEARING, ball LEVER, roll pressure 604 741 PIN, cotter-hair .042 .937 ~PlN,springCS.187x1.000 010224 058 549 GUIDE,...
Page 46 SA-137 11-3. CircuIt Motor Control PCi Figure Card, OM-112 Page...
Page 47 Dia. Part Description Quantity Mkgs; CircuIt 137 797 Figure 11-3. Card, Motor Control (Fig 11-1 Item Cl ,2 100VDC 035 833 CAPACITOR, polye film .033uf 097 488 CAPACITOR, .l5uf 50V cer mono C4,6 CAPACITOR,cerdisc.Oluf500V 031 677 CAPACITOR, tantlm 5.6uf 35VDC 000 348 CAPACITOR, tantim .47uf 35V...
Page 48 SA-137 Figure 11-4. Circuit Card, Motor Control OM-112 875 Page...
Page 49 Part Dia. Description Quantity Mkgs. 137 800 Figure 11-4. CIrcuit Card, Motor Control (Fig 11-1 item 035 833 CAPACITOR, poiye film .033uf IOOVDC 097 488 CAPACITOR, .15u1 50V cer mono C4,6 CAPACITOR, disc .01 uf 500V 031 677 CAPACITOR, elcttt 5.6uf 35V0C 000 348 CAPACITOR,...
Page 50 ~-1o SC-uo B32-C Figure 11-5. Exploded View Of GA-16C Gun OM-112 875 Page...
Page 51 1 I 1 1 3 I 1 2 1 1 1 1 2 1 1 4 tern Part Quantity Description 110 720 Of GA-16C Gun (Fig 11-1 Item Figure 11-5. Exploded View 110793 HANDLE ASSEMBLY 110 795 TUBE, head (consisting 110780 NUT,MlOxl 110 779...

This manual is also suitable for:

Auto arc mw 4230Mw 4110Mw 4230

AUTO ARC MW 4110 Owner's Manual

Quick Links

Need help?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for AUTO ARC AUTO ARC MW 4110

Summary of Contents for AUTO ARC AUTO ARC MW 4110

This manual is also suitable for:

Table of Contents