September 1990 FORM: OM-112 875D

AUTO ARCJ Effective With Serial No. KA870779

MODEL: MW 4110
MW 4230

OWNERS MANUAL
IMPORTANT: Read and understand the entire contents of this manual, with MILLER ELECTRIC Mig. Co.
special emphasis on the safety material throughout the manual, before AM~G~Ud..Corr~any

Installing, operating, or maintaining this equipment. This unit and these 1079
Instructions are for use only by persons trained and experienced in the Safe Appleton, WI 54912 USA

operation of welding equipment. Do not allow untraIned persons to install, Tel. 414-734-9821

operate, or maintain this unit. Contact your dIstributor If you do not fuliy
understand these Instructions.

18-112 943-A

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 ONEYEAR LIMITED WARRANTY
EFFECTIVE: FEBRUARY 11, 1989

This warranty supersedes alt previous AUTO ARC warranties and is exclusive with no otherguarantees orwarranties expressed or implied.

COVERAGE MILLER Electric Mfg. Co. warrants to the

-
for the purchase price (less reasonable depreciation based
buyer who purchases this AUTO ARC Welder (~WeIder) for upon actral use) upon return of the goods at Consumers risk
personal, family or household purposes (Consumer) that this and expense. MILLERs option of repair or replacement will be
Welderwill be free from defects in material and workmanship for F.O.B., Factory at Appleton, WI or FOB, at a MILLER autho
a peflod of one year from the date of purchase. This warranty rized service facility, therefore, no compensation for transporta
covers only the onginal purchaser of this Welder. MILLER Elec tion costs of any kind will be alowed. Upon receipt of notice of
tric does not authorize any party, including its authorized dis apparentdefect orfailure, MILLER shall instruct the claimant on
tributors,to offer any other warranty on behalf of MILLER Elec the warranty claim procedures to be followed.
tric. Upon expiration of the warranty period. MILLER Electric
shall have no further liability related to the Welder, except on THIS WARRANTY IS OFFERED IN LIEU OF ANY OTHER
warranty claims made during the warranty period. No warranty EXPRESS WARRANTY; AND, EXCEPT TO THE EXTENT
is made by MILLER with respect to engines, trade accessories PROHIBITED BY APPLICABLE LAW. THE DURATION OF
orotheritems manufactured by others. Such engines, trade ac ALL IMPUED WARRANTIES. INCLUDING BUT NOT
cessories and other items are sold subject to the warranties of LIMITED TO THE IMPUED WARRANTIES OF MERCHAN
their respective manufacturers, if any. All engines are war TABIUTY AND FITNESS FOR A PARTiCULAR PURPOSE. IS
ranted by their manufacturer for two years from date of original UMITED TO THE DURATION OF THIS WARRANTY.
purchase, except Deu~ engines which have a one year, 2000
hour warranty.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR REPRE
MILLER shall be required to honor warranty claims on war SENTATION AS TO PERFORMANCE, AND ANY REMEDY
ranted Equipment in the event of failure resulting from a defect FOR BREACH OF CONTRACT WHICH. BUT FOR THIS
within the following periods from the date of delivery of Equip PROVISION, MIGHT ARISE BY IMPUCATION, OPERATION
ment to the original user: OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
1. Arc welders, power sources, and components INCLUDING ANY IMPUED WARRANTY OF MERCHANT
1 yew
ABIUTY OR OF FITNESS FOR PARTICULAR PURPOSE.
...

2. Original main power rectifiers 3 years

WITH RESPECT TO ANY AND ALL EQUIPMENT FUR
(labor 1 year only)
3. All NISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY
welding guns, feeder/guns and torches 90 days
MILLER.
4. Replacement or repair parts, exclusive of labor .
60 days
5. Batteries 6 months
Some states do not allow limitations on how long an implied
provided that MILLER is notified in writing within thirty (30) days warranty lasts, so the above limitation may not apply to you.
of such failure. This warranty gives you specific legal rights, and you may also
have other rights which vary from state to state.
WHAT IS NOT COVERED This warranty does not extend to
any Welder subjected to misuse, neglect, accident, or in- THE PURCHASERS REMEDIES FOR A DEFECTIVE
warranty repair by anyone except MILLER Electric or its autho WELDER, TO THE EXTENT PERMITrED BY APPLICABLE
rizedservicestations. Further, thiswarrantyonlyextendstothe LAW, ARE UMITED TO THE REMEDY PROVIDED BY THIS
original purchaser of this Welder. WARRANTY. TO THE EXTENT ENFORCEABLE UNDER
APPUCABLE LAW, MILLER ELECTRIC SHALL IN NO
In the case of MILLERs breach of warranty or any other duty EVENT BE LIABLE FOR CONSEQUENTiAL, INCIDENTAL
with respect to the quality of any goods, the exclusive remedies OR SPECIAL DAMAGES ARISING OUT OF THE USE OF. OR
therefore shall be, at MILLERs option (1) repair or (2) replace- INABILITY TO USE, THE WELDER, WHETHER BASED ON
mentor, where authorized in wflnng by MILLER in appropriate BREACH OF THIS WARRANTr~ MILLER ELECTRICS NEG
cases, (3) the reasonable cost of repair or replacement at an LIGENCE OR OTHER TORT, OR ON ANY THEORY OF
authorized MILLER service station or (4) payment of or credit STRICT LIABIUTY.

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 -
OM.1128750-e,gO

RECEIVING-HANDLING

Before unpacking equipment, check carton for any dam- Use the following spaces to record the Model Designa
age that may have occurred dunng shipment. File any tion and Serialor Style Number of your unit. The infor
claims for loss or damage with the delivering carrier. mation is located on the data card or the nameplate.
Assistance for filing or settling claims may be obtained
frorrt the distributor and/or the
equipment manufactur- Model __________________________________________

ers Transportation Department.

Serial or Style No. ______________________________

When requesting information about this equipment, al

ways provide the Model Description and Serial or Style Date of Purchase ______________________________

Number.

TABLE OF CONTENTS

Section No. Page No.

SECTION 1 SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE

1-1. Introduction 1
1-2. General Precautions 1
1-3. Arc Welding 4
1-4. Standards Booklet Index 5

SECTION 2-SAFETY PRECAUTIONS AND SIGNAL WORDS

2-1. General Information And Safety 6

2-2. Safety Aert Symbol And Signal Words 6

SECTION 3 SPECIFICATIONS

3-1. Volt-Ampere Curves 8

3-2. Duty Cycle 8
3-3. Description 9
3-4. Supplied Equipment 9
3-5. Additional Required Equipment 9
3-6. Optional Equipment 10
3-7. Consumable Parts 10

SECTION 4INSTALLATION

4-1. Site Selection 11

4-2. Shielding Gas Installation 11
4-3. Work Clamp installation 11
4-4. Gun Polarity Selection Procedure 12
4-5. Welding Gun Installation 13
4-6. Welding Wire Spool Installation 13
4-7. Electrical Input Connections 13
4-8. Welding Wire Installation 14

SECTION 5-OPERATOR CONTROLS

5-1. Power Switch 16

5-2. ThicknessNo Its Switch 16
5-3. Fine Tuning/Wire Speed Control 16
5-4. Welding Gun Receptacle 16

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 Section No. Page No.

SECTION 6- SEQUENCE OF OPERATION

6-1. Gas Metal Arc Welding (GMAW) 17

6-2. Shutting Down 18

SECTION 7- MAINTENANCE & TROUBLESHOOTING

7-1 Routine Maintenance 20

7-2. Overload Protection 21
7-3. Replacing Drive Roll 21
7-4. Replacing Pressure Bearing 22
7-5. Replacing Wire Inlet Guide 22
7-6. Realigning Drive Housing 22
7-7. Circuit Board Replacement 22
7-8. Welding Gun Inspection And Upkeep 23
7-9. Contact Tube Replacement 24
7-10. Gun Liner Replacement 24
7-11. Troubleshooting 25

SECTION 8- ELECTRICAL DIAGRAMS

Diagram 8-1. Circuit Diagram For MW 4110 Models 27

Diagram 8-2. Circu~ Diagram For MW 4230 Models 27

Diagram 8-3. Circuit Diagram For MW 4110 Motor Control Board PCI 28
Diagram 8-4. Circuit Diagram ForMW 4230 Models
Motor Control Board PCi 28
Diagram 8-5. Wiring Diagram For MW 4110 Models 29
Diagram 8-6. Wiring Diagram For MW 4230 Ampere Models 30

SECTION 9 WELDING TECHNIQUES & TROUBLESHOOTING

9-1. Gas Metal Arc Welding (GMAW) Continuous Seam

- 31
9-2. Troubleshooting The Gas Metal Arc Welding (GMAW) Process ....
32

SECTION 10 AUTO BODY REPAIR APPLICATION

10-1. Pointers For Welding Auto Body Sheet Metal 36

10-2. Procedure For Welding Mild Steels 36
10-3. Procedures For Welding Door Panels 36
10-4. How To Prevent Glass Breakage And Spatter On Windows 37
10-5. Procedures For Welding Fenders And Quarter Panels 37
10-6. Welding Frames And High Strength (HSS) Steels 37

SECTION 11 PARTS LIST

Figure 11-1. Main Assembly (Auto Arc MW 4230 Illustrated) 38

Figure 11-2. Drive Assembly, Wire 41
Figure 11-3. Circuit Card, Motor Control PCi 42
Figure 11-4. Circuit Card, Motor Control PCi 44
Figure 11-5. Exploded View 01 GA-16C Gun 46

LIST OF CHARTS AND TABLES

Table 3-1. Specifications 7

Chart 3-1. Volt-Ampere Curves 8
Chart 3-2. Duty Cycle 8
Table 4-i. Line Disconnect Or Supply Circuit Fuse Size 14
Table 6-1. Suggested Settings For Welding 18
Table 7-i. Maintenance Schedule 20
Table 7-2. Troubleshooting 26

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 SECTION 1 - SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE

1.1. INTRODUCTION welding or cutting, (and chipping) to protect the eyes

from radiant energy and flying metal. Replace cover
We learn by experience. Learning safety through per
sonal experience, like a child touching a hot stove is
glass when broken, pitted, or spattered. See 1 -3A.2.
harmftil, wasteful, and unwise. Letthe experienceof Oth Avoid oily or greasy clothing. A spark may ignite them.
ers teach you.
Hot metal such as electrode stubs and workpieces
Safe practices developed from experience in the use of should never be handled without gloves.
welding and cutting are described in this manual. Re Medical first aid and eye treatment. First aid facilities and
search, development, and field experience have a qualified first aid person should be available for each
evolved reliable equipment and safe installation, opera shift unless medical facilities are close by for immediate
tion, and servicing practices. Accidents occur when treatment of flash burns of the eyes and skin burns.
equipment is improperly used or maintained. The rea
son for the safe practices may not always be given.
Ear plugs should be worn when working on overhead or

Some are based on common sense, others may require in a confined space. A hard hat should be worn when

technical volumes to explain. It is wiser to follow the others work overhead.

rules. Flammable hair preparations should not be used by per

Read and understand these safe practices before at
sonsintending to weld or cut.
tempting to install, operate, or service the equipment. B. Toxic Fume Prevention
Comply with these procedures as applicable to the par
Severe discomfort, illness or death can result from
ticular
equipment used and their instruction manuals, for
fumes, vapors, heat, or oxygen enrichment or depletion
personal safety and for the safety of others. that welding (or cutting) may produce. Prevent them with
Failure to observe these safe practices may cause seri adequate ventilation as described in ANSI Standard
ous injury or death. When safety becomes a habit, the Z49.1 listed in Standards Index. NEVER ventilate with
equipment can be used with confidence. oxygen.
These safe practices are divided into two Sections: Lead-, cadmium-, zinc-, mercury-, and beryllium-bear
1-General Precautions, common to arc welding and cut ing and similar materials, when welded (or cut) may pro
ting; and 2-Arc Welding (and Cutting) (only). duce harmful concentrations of toxic fumes. Adequate
local exhaust ventilation must be used, or each person in
Reference standards: Published Standards on safety
the area as well as the operator must wear an air-sup
are also available for additional and more complete pro
cedures than those given in this manual. They are listed
plied respirator. For beryllium, both must be used.
in the Standards Index in this manual. ANSI Z49.1 is the Metals coated with or containing materials that emit toxic
most complete. fumes should not be heated unless coating is removed
from the work surface, the area is well ventilated and, if
The National Electrical Code, Occupational Safety and
necessary, while wearing an air-supplied respirator.
Health Administration, local industrial codes, and local
inspection requirements also provide a basis for equip Work in a confined space only while it is being ventilated
ment installation, use, and service. and, if necessary, while wearing an air-supplied respira
tor.
1-2. GENERAL PRECAUTIONS Gas leaks in a confined space should be avoided.

Different arc welding processes, electrode alloys, Leaked gas in large quantities can change oxygen con
and fluxes can produce different fumes, gases, and centration dangerously. Do not bring gas cylinders into a
radiation levels. In addition to the information in this confined space.
manual, be sure to consult flux and electrode manu Leaving confined space, shut OFF gas supply at source
facturers Material Safety Data Sheets (MSDSs) for toprevent possible accumulation of gases in the space if
specific technical data and precautionary measures downstream valves have been accidentally opened or
concerning their material. left open. Check to be sure that the space is safe before
A. Burn Prevention re-entering it.

Wear protective Vapors from chlorinated solvents can be decomposed

clothing-gauntlet gloves designed for
use in welding, hat, and high safety-toe shoes. Button by the heat of the arc (or flame) to form PHOSGENE, a
shirt collar and pocket flaps, and wear cuffless trousers highly toxic gas, and other lung and eye irritating prod
ucts. The ultraviolet (radiant) energy of the arc can also
to avoid entry of sparks and slag.
decompose trichloroethylene and perchloroethylene va
Wear helmet with safety goggles and glasses with side pors to form phosgene. DO NOT WELD or cut where sol
shields underneath, appropriate filter lenses or plates vent vapors can be drawn into the welding or cutting at
(protected by clear cover glass). This is a MUST for mosphere or where the radiant energy can penetrate to
OM-112 875 Page 1

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 atmospheres ~,containing even minute amounts of menfas~ recommended in A6.O. Waterfilling just below
trichioroethylene or perchloroØthylene. working level may substitufe for inerting.
C. Fire and Explosion Prevention A container with unknown contents should be cleaned
(see preceding paragraph). Do NOT depend on sense of
Causes of fire and explosion are: combustibles reached
smell or sight to determine if it is safe to weld or cut.
by the arc, flame, flying sparks, hot slag or heated mate
nal; misuse of compressed gases and cylinders; and Hollow castings or containers must be vented before
stiorf circuits. welding or cutting. They can explode.
BE AWARE THAT flying sparks or falling slag can pass Explosive atmospheres. Never weld or cut where the air
through cracks, along pipes, through windows or doors, may contain flammable dust, gas, or liquid vapors (such
and through wall or floor openings, out of sight of the as gasoline).

goggled operator. Sparks and slag can fly 35 feet. D. Compressed Gas Equipment
To prevent fires and explosion: Standard precautions. Comply with precautions in this
Keep equipment clean and operable, free of oil, grease, manual, and those detailed in CGA Standard P-i SAFE ,

and (in electncal parts) of metallic particles that can HANDLING OF COMPRESSED GASES IN CYLIN
cause short circuits. DERS, listed 11 in Standards Index.

If combustibles are in area, do NOT weld or cut. Move 1. Pressure Regulators

the work if practicable, to an area free of combustibles.
Regulator relief valve is designed to protect only the
Avoid paint spray rooms, dip tanks, storage areas, venti regulator from overpressure; it is not intended to protect
lators. If the work cannot be moved, move combustibles
any downstream equipment. Provide such protection
at least 35 feet away out of reach of sparks and heat; or with one or more relief devices.
protect against ignition with suitable and snug-fitting,
fire-resistant covers or shields. Never connect a regulator to a cylinder containing gas
other than that for which the regulator was designed.
Walls touching combustibles on opposite sides should
Remove faulty regulator from service immediately for re
not be welded on (or cut). Walls, ceilings, and floor near
work should be protected by heat-resistant covers or pair (first close cylinder valve). The following symptoms
shields. indicate a faulty regulator:

Fire watcher must be Leaks-if gas leaks externally.

standing by with suitable fire extin
Excessive Creep-if delivery pressure continues to rise
guishing equipment during and for some time afterweld
with downstream valve closed.
ing or cutting if:
Faulty Gauge-if gauge pointerdoes not move off stop pin
a. appreciable combustibles (including building when pressurized, nor returns to stop pin after pressure
construction) are within 35 feet release.
b. appreciable combustibles are further than 35 Repair. Do NOT attempt to repair. Send faulty regulators
feet butcan be ignited by sparks for repair to manufacturers designated repair center,
where special techniques and tools are used by trained
c. openings (concealed orvisible) in floors orwalls
within 35 feet may expose combustibles to personnel.
sparks 2. Cylinders
d. combustibles adjacent to walls, ceilings, roofs, Cylinders must be handled carefully to prevent leaks and
or metal partitions can be ignited by radiant or
damage to their walls, valves, or safety devices:
conducted heat.
Avoid electrical circuit contact with cylinders including
Hot work permit should be obtained before operation to third rails, electrical wires, or welding circuits. They can
ensure supervisors approval that adequate precautions produce short circuit arcs that may lead to a serious acci
have been taken. dent. (See 1-3C.)
After work is done, check that area is free of sparks, ICC or DOT marking must be on each cylinder. It is an
glowing embers, and flames. assurance of safety when the cylinder is properly han
dled.
An empty container that held combustibles, or that can
produce flammable or toxic vapors when heated, must Identifying gas content. Use only cylinders with name of
never be welded on or cut, unless container has first gas marked on them; do not rely on color to identify gas
been cleaned as described in AWS Standard A6.O, listed content. Notify supplier if unmarked. NEVER DEFACE
7 in Standards index. or alter name, number, orother markings on a cylinder. It
is illegal and hazardous.
This includes: a thorough steam orcausticcleaning (or a
solvent or water washing, depending on the combusti Empties: Keep valves closed, replace caps securely;
bles solubility) followed by purging and inerting with ni mark MT; keep them separate from FULLS and return
trogen or carbon dioxide, and using protective equip- promptly.
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 Prohibited use.~Never use a cylinder or its contents ior outlet away from peo.ple and sources of ignition. Wipe
other than its intended use, NEVER as a support or ~with a clean lintless c~om.
roller.
Match regulator to cylinder. Before connecting, check
Locate or secure cylinders so they cannot be knocked that the regulator label and cylinder marking area, and
over. thatthe regulator inlet ~nd cylinderoutlet match. NEVER
CONNECT a regulator designed for a particular gas or
Passageways and work areas. Keep cylinders clear of
gases to a cylinder containing any other gas.
areas~where they may be struck.
lighten connections. When assembling threaded con
Transporting cylinders. With a crane, use a secure sup
nections, clean and smooth seats where necessary.
port such as a platform or cradle. Do NOT lift cylinders off
the ground by their valves or caps, or by chains, slings,
Tighten. If connection leaks, disassemble, clean, and
retighten using properly fitting wrench.
or magnets.
Do NOT expose cylinders to excessive heat, sparks, Adapters. Use a CGA adapter (available from your sup
plier) between cylinder and regulator, if one is required.
slag, and flame, etc. that may cause rupture. Do not al
use two wrenches to tighten adapter marked RIGHT and
low contents to exceed 130F. Cool with water spray
LEFT HAND threads.
where such exposure exists.

Protect cylinders particularly valves from bumps, falls,

Regulator outlet (or hose) connections may be identified
by right hand threads for oxygen and left hand threads
falling objects, and weather. Replace caps securely
when
(with grooved hex on nut or shank) for fuel gas.
moving cylinders.
Stuck valve. Do NOT use a hammer orwrench to open a
5. Pressurizing Steps:
cylinder valve that can not be opened by hand. Notify Drain regulator of residual gas through suitable vent be
your supplier. fore opening cylinder (or manifold valve) by turning ad
Mixing gases. Never try to mix any gases in a cylinder. justing screw in (clockwise). Draining prevents exces
sive compression heat at high pressure seat by allowing
Never refill any cylinder. seat to open on pressurization. Leave adjusting screw
engaged slightly on single-stage regulators.
Cylinder fittings should never be modified or exchanged.
3. Hose
Stand to side of regulator while opening cylinder valve.

Prohibited use. Never use hose otherthan that designed Open cylinder valve slowly so that regulator pressure in
creases slowly. When gauge is pressurized (gauge
for the specified gas. A general hose identification rule
reaches regulator maximum) leave cylinder valve in fol
is: red for fuel gas, green for oxygen, and black for inert
lowing position: For oxygen, and inert gases, open fully
gases.
to seal stem against possible leak. For fuel gas, open to
Use ferrules or clamps designed for the hose (not ordi less than one turn to permit quick emergency shutoff.
nary wire or other substitute) as a binding to connect
Use pressure charts (available from your supplier) for
hoses to fittings.
safe and efficient, recommended pressure settings on
No copper tubing splices. Use only standard brass fit regulators.
tings to splice hose.
Check for leaks on first pressurization and regularly
Avoid long runs to prevent kinks and abuse. Suspend there-after. Brush with soap solution (capfull of Ivory Liq
hose off ground to keep it from being run over, stepped uid* or equivalent per gallon of water). Bubbles indicate
on, or otherwise damaged. leak. Clean off soapy water after test; dried soap is com
bustible.
Coil excess hose to prevent kinks and tangles.
E. User ResponsibilIties
Protect hose from damage by sharp edges, and by
sparks, slag, and open flame. Remove leaky or defective equipment from service im

Examine hose regularly for leaks, wear, and loose con mediately for repair. See User Responsibility statement
in equipment manual.
nections. Immerse pressured hose in water; bubbles in
dicate leaks. F. Unattended
Leaving Equipment
Repair leaky or worn hose by cutting area out and splic Close gas supply at source and drain gas.
ing (1-2D3). Do NOT tape.
G. Rope Staging-Support
4. Proper Connections
Rope staging-support should not be used for welding or
Clean cylinder valve outlet of impurities that may clog
cutting operation; rope may burn.
orifices and damage seats before connecting regulator.
Except for hydrogen, crack valve momentarily, pointing Trademark of Proctor & Gamble.

OM.112 875 Page 3

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 1-3. ARC WELDING .Viewirig the weld. PrOvide face shields for all persons
who will be at the weld.
looking di rectly.
Comply with precautions in 1-1, 1-2, and this section.
Arc Welding, properly done, is a safe process, but a Others working in area. See that all persons are wearing
careless operator invites trouble. The equipment carries flash goggles.
high currents at significant voltages. The arc is very Before starting to weld, make sure that screen flaps or
bright and hot. Sparks fly, fumes rise, ultraviolet and in bay doors are closed.
traredenergy radiates, weldments are hot, and com
B. Toxic Fume PreventIon
pressed gases may be used. The wise operator avoids
unnecessary risks and protects himself and others from Comply with precautions in 1-2B.
accidents. Precautions are described here and in stan
Generator engine exhaust must be vented to the outside
dards referenced in index.
air. Carbon monoxide can kill.
A. Burn Protection
C. Fire and Explosion Prevention
Comply with precautions in 1-2. in 1 -2C.
Comply with precautions
The welding arc is intense and
visibly bright, Its radiation rated capacity. Do not overload arc welding
Equipments
can damage eyes, penetrate lightweight clothing, reflect It may overheat cables and cause a fire.
equipment.
from light-colored surfaces, and burn the skin and eyes.
Skin burns resemble acute sunburn, those from gas- Loose cable connections may overheat or flash and
cause a tire.
shielded arcs are more severe and painful. DONT GET
BURNED; COM PLY WITH PRECAUTIONS. Never strike an arc on a cylinder or other pressure ves
sel. It creates a brittle area that can cause a violent rup
1. Protective Clothing ture or lead to such a rupture under rough handling.
Wear long-sleeve clothing (particularly for gas-shielded
D. Compressed Gas Equipment
arc) in addition to gloves, hat, and shoes (1-2A). As nec
Comply with precautions in 1 -2D.
essary, use additional protective clothing such as leather
jacket or sleeves, flame-proof apron, and fire-resistant E. Shock Prevention
leggings. Avoid outer garments of untreated cotton.
Exposed hot conductors or other bare metal in the weld
Bare skin protection. Wear dark, substantial clothing. ing circuit, or in ungrounded, electrically-HOT equip
Button collar to protect chest and neck and button pock ment can fatally shock a person whose body becomes a
ets to prevent entry of sparks. conductor. DO NOT STAND, SIT, LIE, LEAN ON, OR
2. and Head Protection TOUCH a wet surface when welding, without suitable
Eye
protection.
Protect eyes from exposure to arc. NEVER look at an
To protect against shock:
electric arc without protection.
Wear dry insulating gloves and body protection. Keep
Welding helmet shield
containing a filter plate shade
or
body and clothing dry. Neverwork in damp area without
no. 12 or denser must be used when welding. Place over
face before striking arc.
adequate insulation against electrical shock. Stay on a
dry duckboard, or rubber mat when dampness or sweat
Protect filter plate with a clear cover plate. can not be avoided. Sweat, sea water, or moisture be
tween and an electrically HOT part or grounded
body
Cracked or broken helmet or shield should NOT be
metal reduces the electrical resistance, and could en
worn; radiation can pass through to cause burns.
able dangerous and possibly lethal currents to flow
Cracked, broken, loose filter plates must be replaced
or through the body.
IMMEDIATELY. Replace clear cover plate when broken, A voltage will exist between the electrode and any con
pitted, or spattered. ducting object in the work circuit. Examples of Conduct
Flash goggles with side shields MUST be worn underthe ing objects include, but are not limited to, buildings, elec
heitnet to give some protection to the eyes should the trical tools, work benches, welding power source cases,
helmet not be lowered over the face before an arc is workpieces, etc. Never touch the electrode and any
struck. Looking at an arc momentarily with unprotected metal object unless the welding power source Is of f.
eyes (particularly a high intensity gas-shielded arc) can 1. Grounding the Equipment
cause a retinal bum that may leave a permanent dark
in the field of vision. Arc welding equipment must be grounded according to
area
the National Electrical Code, and the work must be
3. Protection of Nearby Personnel to ANSI Z49.1 Safety In Welding
grounded according
Enclosed welding For production welding, a sepa
area.
And Cutting.
rate room or enclosed bay is best. In open areas, sur When installing, connect the frames of each unit such as
round the operation with low-reflective, non-combusti welding power source, control, worktable, and water ci r
ble screens or panels. Allow for free air circulation, par culatorto the building ground. Conductors must be ade
ticularly at floor level. quate to carry ground currents safely. Equipment made
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 electrically HOTtiy stray current may shock, possibly fa -
Welding power sources used with shielded
tally. Do NOT GROUND to electrical conduit, orto a pipe metal arcwelding (SMAW) and similar proc
carrying ANY gas or flammable liquid such as oil or fuel. esses may not be eq~uipped with welding power

Three-phase connection. Check phase requirements of output on-off control devices. With such equip
ment the electrode is electrically HOT when the
equipment before installing. If only 3-phase power is
available, connect single-phase equipment to only two power switch is turned ON. Never touch the
electrode unless the welding power source is
wires of the 3-phase line. Do NOT connect the equip
off.
ment ground lead to the third (live) wire, or the equip
ment will become electncally HOT-a dangerous condi 7. Safety Devices
tion that can shock, possibly fatally.
Safety devices such as interlocks and circuit breakers
Before welding, check ground for continuity. Be sure should not be disconnected or shunted out.
conductors are touching bare metal of equipment Before installation, inspection, or service, of equipment,
frames at connections. shut OFF all power and remove line fuses (or lock or red-
If a line cord with a ground lead is provided with the tag switches) to prevent accidental turning ON of power.
equipment for connection to a switchbox, connect the Disconnect all cables from welding power source, and
ground lead to the grounded switchbox. If a three-prong pullall 115 volts line-cord plugs.
plug is added for connection to a grounded mating re Do not open power circuit or change polarity while weld
ceptacle, the ground lead must be connected to the ing. If, in an emergency, it must be disconnected, guard
ground prong only. If the line cord comes with a three- against shock bums, or flash from switch arcing.
prong plug, connect to a grounded mating receptacle.
Never remove the ground prong from a plug, or use a Leaving equipment unattended.Always shut OFF and
disconnect all power to equipment.
plug with a broken off ground prong.
Power disconnect switch must be available near the
2. Electrode Holders
welding power source.
Fully insulated electrode holders should be used. Do F. ProtectIon For Wearers of Electronic Life
NOT
Sup
use holders with protruding screws.
port Devices (Pacemakers)
3. Connectors
Magnetic fields from high currents can affect pacemaker
Fully insulated lock-type connectors should be used to operation. Persons wearing electronic life support
join welding cable lengths. equipment (pacemaker) should consult with their doctor
before going near arc welding, gouging, or spot welding
4. Cables
operations.
Frequently inspect cables forwear, cracks and damage.
IMMEDIATELY REPLACE those with excessively worn 14. STANDARDS BOOKLET INDEX
or damaged insulation to avoid possibly-lethal shock
For more information, refertothefollowing standards or
from bared cable. Cables with damaged areas may be their latest revisions and comply as applicable:
taped to give resistance equivalent to original cable.
1. ANSI Standard Z49.1, SAFETY IN WELDING
Keep cable dry, free of oil and grease, and protected AND CUTTING obtainable from the American
from hot metal and sparks.
Welding Society, 550 N.W. LeJeune Rd, Miami,
5. Terminals And Other FL 33126.
Exposed Parts
Terminals and other exposed parts of electrical units 2. NIOSH, SAFETY AND HEALTH IN ARC WELD
should have insulating covers secured before operation. ING AND GAS WELDING AND CUTTING ob
tainable from the Superintendent of Documents,
6. Electrode U.S. Government Printing Office, Washington,
a. Equipment with output on/ott control (contactor) D.C. 20402.

Welding power sources for use with the gas 3. OSHA, SAFETY AND HEALTH STANDARDS,
metal arc welding (GMAW), gas tungsten arc 29CFR 1910, obtainable from the Superinten
dent of Documents, U.S. Government Printing
welding (GTAW) and similar processes nor
mally are equipped with devices that permit on Office, Washington, D.C. 20402.
off control of the welding power output. When so 4. ANSI Standard Z87.1, SAFE PRACTICES FOR
equipped the electrode wire becomes electri OCCUPATION AND EDUCATIONAL EYE AND
cally HOT when the power source switch is ON FACE PROTECTION obtainable from the Ameri
and the welding gun switch is closed. Never can National Standards Institute, 1430 Broad
touch the electrode wire or any conducting ob
way, New York, NY 10018.
ject in contact with the electrode circuit unless
5. ANSI Standard Z41 .1, STANDARD FOR MENS
the welding power source is off.
SAFETY-TOE FOOTWEAR obtainable from the
b. Equipment without output on/oft control (no American National Standards Institute, 1430
contactor) Broadway, New York, NY 10018.
OM-112 875 Pa9e 5

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 6. ANSI St~ndard Z49.2, FIRE PREVENTION IN ~rorn the Compressed Gas Association, 1235 Jef
THE USE OF CUTTING AND WELDING PROC ferson Davis Highway, Suite 501, Arlington, VA
ESSES obtainable from the American National 22202.
Standards Institute, 1430 Broadway, New York,
NV 10018. 12. CSA Standard W117.2, CODE FOR SAFETY IN
WELDING AND CUTTING obtainable from the
7. AWS Standard A6.0, WELDING AND CUTTING
Canadian Standards Association, Standards
~CONTAlNERS WHICH HAVE HELD COMBUS
Sales, 178 Rexdale Boulevard, Rexdale, Ontario,
TIBLES obtainable from the American Welding
Canada M9W 1 R3.
Society, 550 N.W. LeJeune Rd, Miami, FL 33126.
8. NFPA Standard 51, OXYGEN-FUEL GAS SYS 13. NWSA booklet, WELDING SAFETY BIBLIOG
TEMS FOR WELDING, CUTTING, AND ALLIED RAPHY obtainable from the National Welding
PROCESSES obtainable from the National Fire Supply Association, 1900 Arch Street, Philadel
Protection Association, Batterymarch Park, phia, PA 19103.

Quincy, MA 02269.
14. American Welding Society Standard AWSF4.1,
9. NFPA Standard 70, NATIONAL ELECTRICAL RECOMMENDED SAFE PRACTICES FOR THE
CODE obtainable from the National Fire Protec PREPARATION FOR WELDING AND CUTTING
tion Association, Batterymarch Park, Quincy, MA OF CONTAINERS AND PIPING THAT HAVE
02269. HELD HAZARDOUS SUBSTANCES, obtainable
NFPA Standard 51 B, CUTTING AND WELDING from the American Welding Society, 550 N.W.
10.
LeJeune Ad, Miami, FL 33126.
PROCESSES obtainable from the National Fire
Protection Association, Batterymarch Park,
15. ANSI Standard Z88.2, PRACTICE FOR RESPI
Quincy, MA 02269. RATORY PROTECTION, obtainable from the
11. CGA Pamphlet HANDLING OF COM
,
American National Standards Institute, 1430
PRESSED GASES IN CYLINDERS obtainable Broadway, New York, NY 10018.

SECTION 2- SAFETY PRECAUTIONS AND SIGNAL WORDS

2-1. GENERAL INFORMATION AND SAFETY 2-2. SAFETY ALERT SYMBOL AND SIGNAL

A.
WORDS
General

Information presented in this manual and on various la The following safety alert symbol and signal words are
bels, tags, and plates on the unit pertains to equipment used throughout this manual to call attention to and iden
design, installation, operation, maintenance, and tify different levels of hazard and special instructions.
troubleshooting which should be read, understood, and This safety alert symbol is used with the signal
followed for the safe and effective use of this equipment.

The nameplate of this unit uses international symbols for

a words WARNING and CAUTION to call atten
tion to the safety statements.
labeling the front panel controls. The symbols also ap
pear at the appropriate section in the text. WARNING statements identify procedures or
B. Safety a practices which must be followed to avoid seri
ous personal injury or loss of life.
The installation, operation, maintenance, and trouble
shooting of arc welding equipment requires practices
CAUTION statements identify procedures or
and procedures which ensure personal safety and the
safety of others. Therefore, this equipment is to be in a practices which must be followed to avoid minor
personal injury or damage to this equipment.
stalled, operated, and maintained only by qualified per
Sons ifl accordance with this manual and all applicable
codes such as, but not limited to, those listed at the end IMPORTANT statements identify special instructions
of Section 1 Safety Rules For Operation Of Arc Weld necessary for the most efficient operation of this equip-
ing Power Source. merit.

OM-112 875 Page 6

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 SECTION 3- SPECIFICATIONS

Table 3-1. SpecificatIons

Welding Power Source

Max.
input At Rated Load Electrode
Single-Phase Control
Rated Electrode Wire Weight
Model Open. Circuit
Weld Output Circuit Wire Feed Diameter
Amperes At Voltage
Voitage At Gun Speed Capability
11SV 230V )(VA KW Net Ship
90 Amperes
70-400 ipm .023 in. 88 lbs. 95 lbs.
MW 4110 @ 18 Volts DC 30 20 10 3 2.2
(1.8-10.2mpm) (0.6mm) (40kg) (43kg)
20%DutyCycle 24 Volts
DC
l20Amperos
MW 4230 47-690 ipm .023 thru .035 in. 94 lbs. 101 lbs.
@ 21 Volts DC 32 20 4.7 3.9
30% Duty Cycle (1.2-17.5mpm) (0.6thruo.9mm) (43kg) (46kg)

MWG-160 Gun

Ampere Rating
With CO Wire Cabie Cooling
DIameter Length Metho
60% Duty C~cie
.023 in.
l6oAmpores lOft. (3.0 m) Air
(0.6 mm)

15 In. (381 mm)

19 In. (483 mm)

TB- 1 12 943-A

Figure 3-1. Overall Dimensions

OM-112 875 Pago 7

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 3-1. VOLT-Aii~lPERE CURV~S (Chart 3-1) ~Referio the Duty Cycle Charts (Chart 3-2) to determine
the output of the welding power source at various duty
(3* RATED OUTPUT cycles.

The volt-ampere curves show the minimum and maxi IMPORTANT: Decreasing welding amperes increases
mum voltage and amperage output capabilities of the duty cycle.
unit ft~om the minimum and maximum settings of the
CAUTION: EXCEEDING DUTY CYCLE
FINE TUNING/WIRE SPEED control.
a RATINGS will damage
source.
welding power

Do not exceed indicated duty cycles.

Chart 3-1. Volt-Ampere Curves

Chart 3-2. Duty Cycle

A. MW 4110 Models
50

A. MW 4110 Models
40
I 5C

125
~,30
I-
-J
100
0 (I)
> w
~20 75
0 Lii
0~
x
I0
50
a
0
d ~

S8.l10 683

B. MW 4230 Models 2~
0
40
10 15 20 25 30 40 50607080 100
i~ DUTY CYCLE
SA109 428
30
B. MW 4230 Models

206 - -

20

Ca 160
a

10

100

90 .~
90 ~
0 %

0 60 100 160 200 70

250 %

D.C. A~P~ES 60
SB-124 625

I .6 40 90 100

wry cye.E x S8.124 624

3-2. DUTY CYCLE

A. Welding Power Source (Chart 3-2)

The MW 4110 is rated at 20 percent duty cycle; there B. Welding Gun
fore, the unit can be operated at rated load for two con
The duty cycle of a welding gun is the percentage of a ten
secutive minutes out of ten, but it must idle for the re
minute period that a gun can be operated at a given load.
maining eight minutes to allow proper cooling. This gun is rated at 60% duty cycle using CO2 shielding
The MW 4230 is rated at 30 percent duty cycle; there gas. This means that the gun can be operated six min
fore, the unit can be operated at rated load for three con utes out of every ten with the CO2 shielding gas. The re
secutive minutes, but it must idle forthe remaining seven maining four minutes the gun should be idle to permit
minutes to allow proper cooling. proper cooling.
OM-112 875 Page 8

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 CAUTION: EXCEEDING THE RATED AM
a PERAGE WITH CO~ OR FAILING TO RE
DUCE THE WELDING AMPERAGE OR DUTY
The weldi~ig power source is factory equipped with
ft. (3 m) input power cord and built-in gas valve.
a 10

CYCLE WHEN USING A MIXED SHIELDING

3-5. ADDITIONAL REQUIRED EQUIPMENT (Fig
GAS can result In damage to the gun.
ure 3-3)
Do not exceed rated amperage when using
Co2.
Reduce duty cycle when using mixed shield
ing gases such as carbon dioxide and argon.

3-3. DESCRIPTION

The MW 4110 is single-phase, constant voltage, dc arc

a

welding power and wire feed system designed

source
for Gas Metal Arc Welding (GMAW) using a MWG-1 60
gun and .023 in. (0.6 mm) welding wire. Rated weld out
put is 90 amperes, 18 volts dc, at 20% duty cycle.
The MW 4230 is a single-phase, constant voltage, dc arc
welding power source and wire feed system for Gas Met
al Arc Welding (GMAW) using a MWG-1 60 gun and .023
through .035 in. (0.6 through 0.9 mm) welding wire.
Rated weld output is 120 amperes, 21 volts dc, at 30%
duty cycle.
All units are protected against short circuit overload
(contact tube shorting to work) and overheating. If either
condition occurs, the unit automatically shuts down.

3-4. SUPPLIED EQUIPMENT (FIgure 3-2)

Figure 3-3. AdditIonal Supplies Required

Contact yoursupplier or see the yellow pages of the local

telephone book for the location of the nearest welding
supply company to obtain the necessary equipment.
A. Gas Cylinder
Two types of gas are generally used with Gas Metal Arc
Welding (GMAW) of thin gauge sheet steel. Carbon
dioxide (C02) is the gas recommended for use with this
welding power source/gun combination. A mixture of 75
percent argon and 25 percent carbon dioxide also gives
favorable results. Obtain a cylinderof selected shielding
gas. When welding power source is installed on running
gear, a 20 lb. cylinder is the largest that can be used.
B. Regulator/Flowmeter
Regulator/f lowmeters provide a constant shielding gas
pressure and flow rate dunng the welding process. Be
cause gases have different properties, each regulator!
flowmeter is designed to be used with a specific gas or
mixture of gases. Regulator/flowmeters cannot be
Figure 3-2. Supplied Equipment changed from one gas to another unless the proper
adapters are installed. Be sure to obtain the proper regu
Equipment supplied with the welding power source and lator/fiowmeter for the type of gas used.
requiring customer installation or assembly is listed be
low: C. Gas Hose

1.
Measure distance from gas cylinder to welding power
Welding gun with 1/2 in. (13 mm) seam nozzle
and two contact tubes. source. Obtain good quality 5/8 in. (16 mm) O.D., S.A.E.
gas hose, and install 5/8-18 right-hand thread fittings on
2. Work clamp. both ends of hose.

OM-112 875 Page 9

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 D. Spool Of ~Jlre 3-6. OPTIONAL EQUIPMENT

Selection of the correct welding wire is important in Gas This unit be equipped with two styles of running
can
Metal Arc Welding (GMAW). There are many types of
gear. Ifrunning gear was ordered with the unit, see run-
wire from which to choose, but certain wires are best
fling gear Owners Manual for installation procedures.
suited for welding thin gauge sheet steel. The American
Welding Society (AWS) classification for GMAW wires is
usually indicated on the label of the wire spool. Two AWS 3-7. CONSUMABLE PARTS
wire classes recommended are E7OS-6 and E7OS-3.
The following parts are subject to wear under normal
The E7OS-6 provides a more fluid (wetter) weld puddle
usage:
and a flatter bead; however, E7OS-6 is acceptable for
use with this welding power source. Obtain a spool of se 1. Contact tubes
lected wire.
2. Contact tube adapters (170 Ampere Model Guns
E. Personal Safety Equipment
Only)
When using this welding power
source, wear a welding
3. Nozzle
helmet, fitted with the proper filter lens, to protect the
eyes from the welding arc. Also important is wearing pro 4. Drive Rolls
tective clothing, safety glasses, and gloves to prevent in
jury. Spare parts should be available at all times.

SECTION 4 INSTALLATION

Cap
Flowmeter

Gas Cylinder
Valve

CO2 Cylinder

CO2 Washer

CO2 Installation

Fiowmeter Cap
Regulator

Argon or Argon Mix

Cylinder

SB-109 492
Argon Installation

Figure 4-1. TypIcal Regulator/Flowmeter Installation

OM-112 875 Page 10

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 4-1. SITE SELECTION (FIgure 3-1) B. Reguttor/Flowm.eter (Customer Supplied) (Fig.
-

ure4-1)
Select an installation site which provides the following:
1. With the cylinder securely installed, remove the
1. Correct input power supply (see unit nameplate) cylinder cap, stand to one side of cylinder valve,
and open valve slightly. When gas flows from cyl
2. Shielding gas supply inder, close valve. This procedure blows Out dust
3... or dirt that may have accumulated around the
Adequate ventilation and fresh air supply
valve seat.
4. No flammables
2. The regulator/f Iowmeter must be properly
5. A clean and dry area equipped with stem, nut connectors, and gasket
a
for use with either CO2 cylinders or inert gas type
6. Proper temperature that avoids extremes of heat cylinders.
or cold
IMPORTANT: A gasket should be installed to prevent
7. Proper airflow around unit leaks. Do not use lubricants or sea/mg agents.

8. Adequate space for opening side access doors 3. Install gas regulator/flowmeter onto gas cylinder
for installation, maintenance, and repair func valve; keep the face of the regulator/flowmeter
tions. gauge in vertical position, and tighten stem nut
securely to gas cylinder valve.
Base mounting holes provide the capability to install and
the unit on a running gear or in a permanent loca 4. A shielding gas output fitting is provided at the
secure
tion. rear of the welding power source for making gas
connections. Attach one end of the gas hose to
this output fitting. Attach other end of the gas hose
WARNING: FIRE OR EXPLOSION can result
a from placing unit on or over combustible
surfaces; RESTRICTED AIRFLOW can cause
to the regulator/f Iowmeter.

overheating and possible damage to Internal 4-3. WORK CLAMP INSTALLATION (Figure 4-2)
parts. A 10 ft. (3 m) work cable with lug extends out of the front
Do not locate unit over combustible surfaces. panel. Install work clamp onto the work cable as follows:

Maintain at least 18 inches (457 mm) of WARNING: ELECTRIC SHOCK can kill.
unrestricted space on a/i sides of unit, and keep
underside free of obstructions.
a Do not touch live electrical parts.

Shutdown welding powersource, anddiscon

Do not place any filtering device over the in
nect input power employing lockout/tagging
take air passages that provide airflow for coo/mg
procedures before installing work clamp.
this unit.
Lockout/tagging procedures consist of removing
Warranty is void if any type of filtering device is input power plug from receptacle, padlocking
used at intake air passages. line disconnect switch in open position, remov
ing fuses from fuse box, or shutting off and red
tag9ing circuit breaker or other disconnecting
4-2. SHIELDING GAS INSTALLATION device.

Step 6
WARNING: PRESSURIZED CYLINDERS can
a rupture causing serious personal Injury and
loss of life; FALLING CYLINDERS can cause
serious Injury and equipment damage.

Keep cylinders away from welding or other Step 2

electrical circuits.

Never allow a welding electrode to touch any

cylinder. Step 4

Step 3
Always fasten cylinder securely to running
gearbracket, a wall, orotherstationary support.

A. Gas Cylinder (Customer Supplied) (Figure 4-1)

Chain the cylinder to a wall or other stationary support to
prevent the cylinderfrom failing over and breaking oft the Steps 1 and 5
valve. If optional running gear is used, secure gas cylin S.0250

der to running gear with supplied chain. Figure 4.2. Work Clamp Installation

OM-112 875 Page 11

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 1. Slide one piece of su~pIied insulating sleeve onto Lockout/taggingprocedures consist of removing
work cable. input power plug from receptacle, padlocking
line disconnect switch in open position, remov
2. Place work cable inside the handle of the work ing fuses from fuse box, or shutting off and red
clamp with the flattest inner surface. tagging circuit breaker or other disconnecting
device.

3. Align the smaller hole in the work clamp handle The welding power source has jumper links that allow
with the hole in the work cable terminal lug. Se the userto select the polarity of the unit. The jumper links
cure the terminal lug to the work clamp with the can be positioned for Reverse Polarity (DCEP) or
supplied nut and bolt. Straight Polarity (OCEN) welding (see Figure 4-3).
The unit was shipped with the links positioned for Re
4. Bend the tabs on the end of the work clamp
around the work cable.
verse Polarity (DCEP) welding using solid steel wire with
the Gas Metal Arc Welding (GMAW) process. If using
flux cored wire (without adding a shielding gas) and the
5. Slide insulating sleeve on work cable over work
Flux Cored Arc Welding (FCAW) process, position links
clamp handle. for Straight Polarity (DCEN). Straight Polarity (DCEN)
can also be used for welding with solid wire on very thin
6. Slide remaining insulating sleeve over other work
metal.
clamp handle.
The jumper links are located behind the access door.
The polarity changeover label (Figure 4-3) is located
4-4. GUN POLARITY SELECTION PROCEDURE next to the polarity changeover board on the center
baffle of the unit. If it is necessary to change jumper link
(FIgure 4-3)
positions, proceed as follows:

WARNING: ELECTRIC SHOCK

1. Open left side access door.

a Do not touch live electrical parts.

can kIll.
2. Loosen hardware securing jumper links to polar

Shut down welding powersource, and discon

ity changeover board.
nect input power employing lockout/tagging 3. Reposition jumperlinks as necessary, andtighten
procedures before inspecting or changing jumper link securing hardware.
connections.
4. Close and secure access door.

P STRAIGHT REVERSE
I POLARITY POLARITY
For Solid

Cored
Wires,~ (
For Flux

(FCAW
process) )
Steel Or
Aluminum
Wires
(GMAW)

Polarity Changeover
L DCEN DCEP
J process)

Label GUN POLARITY CHANGEOVER

S-116 599
I

Polarity Changeover
Board

Hub

Gun/Feeder
Connector

Gun/Feeder Connector
Securing Knob

FIgure 4-3. Gun Polarity Selection

OM-112 875 Page 12

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 4-5. WELDING GUN INSTALLATION (Figures 4.3 GUN receptacle, insert the connector, and rotate collar
And 4-4) fully clckwise.
WARNING: ELECTRIC SHOCK can kill.
a Do not touch live electrical parts.
4-6. WELDING
(Figure 4-4)
WIRE SPOOL INSTALLATION

Shutdown welding powersource, and discon 1. Open left side door.

nect input power employing lockout/tagging
procedures before inspecting or installing. 2. Remove retaining pin from hub.

Lockout/tagging procedures consist of removing 3. Slide spool of wire onto hub so that wire feeds off
input power plug from receptacle, padlocking bottom of spool. Do not loosen wire from spool.
line disconnect switch in open position, remov
ing fuses from fuse box, or shutting ott and red- 4. Rotate spool until hole in spool aligns with pin in
tagging circuit breaker or other disconnecting hub. Slide spool onto hub until it seats against
device.
back flange of hub.

A. Gun/Feeder Connector Installation (Figures 4-3

5. Reinstallretaining pin onto hub in a position which
And 4-4) prevents wire spool from moving in or out.
6. Close and secure access door.
IMPORTANT: The outlet guide is provided as part of the
gun assembly.
4-7. ELECTRICAL INPUT CONNECTIONS
1. Open access door. WARNING: ELECTRIC SHOCK can kill.
2. Loosen the gun/feeder connector securing knob. a Do not touch live electrical parts.

IMPORTANT: Wire guides should be installed so that Shutdown welding power source, and discon
the nect input power employing lockout/tagging
tip of the guide is as close to the drive rolls as possi
ble without procedures before inspecting or installing.
touching.
Lockout/tagging procedures consist of removing
3. Insert gun/feeder connector through access hole input power plug from receptacle, padlocking
in front panel and into drive assembly until gun/fe line disconnect switch in open position, remov
eder connector is flush drive ing fuses from fuse box, or shutting ott and red-
against assembly.
tagging circuit breaker or other disconnecting
4. Tighten the gun/feeder connector securing knob. device.

5. Close and secure access door.

A. Electrical Input Requirements
B. Gun Switch Connection (Figure 5-1) The National Electrical Code (NEC) (Article 630B., 1987
The WELDING GUN receptacle is provided for making Edition) provides standards for amperage handling ca
switch control connections. Align the keys on the gun pability of supply conductors based on the duty cycle of
switch connector with the keyways in the WELDING the welding power source.

Front Panel
Pressure Roll Assembly
(Shown in Open Position)
Hub Pin

Gun

Wire
Spool I

Retaining
Pin
Wire inlet
Guide
SA-109 356-s

FIgure 4-4. WeldIng Gun And Wire Spool installation

OM-112 875 Page 13

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 The MW 4110 models have a 20% duty cycle (2 minutes WARNING: ELECTRIC SHOCK
of every 10 minutes can be used for welding); therefore,
the supplied cord and attached plug comply with NEC
~a can kill.

Do not touch live, electrical parts.

Do not connect an input conductor to the
standards for 20% duty cycle. Be sure that the building
ground terminal in the line disconnect device.
supply and receptacle comply with NEC standards and
Do not connect the ground conductor to an
any additional state and local codes.
input line terminal.
The MW 4230 (230 Volts only) models have a 30% duty Incorrect input connections can result in an
cycle (3 minutes of every 10 minutes can be used for electrically energized welding power source
welding); therefore, the supplied cord and ring terminals chassis. The ground terminal is connected to
the welding power source chassis and is for
comply with NEC standards for 30% duty cycle.
grounding purposes only.
IMPORTANT: The supply wiring for the welding power
source must be capable of handling a 15 ampere load for
the MW4 110 models, anda 20 ampere load for the MW Models requiring 230 volts input have prewired power
4230 models. The welding power source must be the cables with three conductors and ring terminals. Check
only load connected to the supply circuit. Poor unit per the nameplate for input voltage requirement, and con
formance or frequently opening line fuses or circuit nect the conductors to a properly grounded and pro
breakers can result from an inadequate or improper tected line disconnect device capable of handling 230
VAC at 20 amperes (see Figure 4-5). The black and
supply.
white conductors must be connected to the line terrrii
B. input Conductor ConnectIons For MW 4110 nals, and the green conductor must be connected to a
Models proper ground. Use a grounding method that is accept
able to the local electrical inspection authority.
MW 4110 models are equipped with a cord and three-
Ground Conductor
prong polarized plug. Check nameplate for input voltage
requirement, and
connect the
plug to .a properly
grounded and protected (fuses or circuit breakers) 115
VAC receptacle capable of handling 15 amperes.

C~ Input Conductor Connections For MW 4230

Models (Table 4-1 And
Figure 4-4)
WARNING: ELECTRIC SHOCK
a Do not touch live electrical parts.
can kill.

Install a fusible line disconnect switch in the

input Circuit to the welding power source.
Read and follow safety information at begin
ning of entire Section 4-7 before proceeding.
The line disconnect switch provides a safe and
convenient means to completely remove all
electrical power from the welding power source Input Power
From Welding
whenever it is necessary to inspect or service Source
the unit. (230 Volt Models Only)

S9.124 654.~
Table 4-1 provides guidelines for selecting the proper
size line fuses. Figure 4.5. Power Cable Connections
(230 Volt Models Only)

Table 4-1. Line Disconnect Or Supply Circuit

Fuse Size 4-8. WELDING WIRE INSTALLATION

A. Threading Welding WIre (Figure 4-4)

Model Fuse Size
In Amperes* WARNING: ELECTRIC SHOCK can kill;

MW411O 30
a MOVING PARTS can cause serious injury.
Do not touch live electrical parts.

MW 4230 30 Keep away from moving parts.

Do not energize welding powersource until in
*Fuse size is based on not more than 200 per structed to do so.
cent of the rated input amperage of the welding The welding wire and all metal parts in contact
power source (Article 630 of NEC). s-oogv~-ea with it are energized while welding.

OM-112 875 Pago 14

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 WELDING WIRE can cause puncture dnv~e rolipressurØ just tightly enough to prevent
wounds; HOT SURFACES can cause severe the wire from slipping on or against drive roll dur
burns.
ing operation.
Do not press gun trigger until instructed to do
so CAUTION: EXCESSIVE DRIVE ROLL TEN.
SION can damage equipment and cause
Do not point gun toward any part of the body,
poor wire feedIng.
any conductive surface, or other personnel
when threading welding wire. Do not overtighten drive roll pressure adjust
ment knob.
Allow gun to cool before touching.
10. Lay gun cable assembly out as straight and flat as
1. Open and secure left side access door. possible.
2. install welding wire spool according to Section WARNING: ELECTRIC SHOCK can kill.
4.6.
Do not touch live electrical parts.
3. Loosen pressure adjustment knob, pivot pres- The welding wire is electrically energized when-
sure adjustment arm free of cover, and pivot pres- ever the gun trigger is depressed.
sure roll assembly away until it is in an open posi-
WELDING WIRE can cause puncture
tion (see Figure 4-4).
wounds.
~ CAUTION: LOOSE WELDING WIRE can Do not point gun toward any part of the body,
cause Injury, other personnel, or any conductive surface
when threading welding wire.
Keep firm hold on wire during installation,
removal, and threading operations. 11. Energize welding power source.

Spooled wire has a tendency to unravel rapidly 12. Depress and hold the gun trigger until the wire
when loosened from the spool. feeds approximately 1/4 in. (6 mm) out the gun
nozzle. if wire feeds more than 1/4 in. out nozzle,
4. Unreel and straighten approximately 6 in. (152 cut wire off to 1/4 in.
mm) of wire from wire spool.
13. Deenergize welding power source.
5. Cut oft any wire that is bent, and remove any burrs
14. Adjust hub tension according to Section 4-8B, if
or sharp edges.
necessary.
6. Route welding wire into wire inlet guide, along
15. Close and secure left side access door.
drive roll groove, and into wire outlet guide in gun
feeder/connector. IMPORTANT: Fora smoother weld start, be sure weld-
7. Pivot pressure roll assembly downward onto iflg wire extends 1/4 in. (6 mm) out end of contact tube
drive roll, making sure that wire is riding in drive and has a sharp end.
roll groove.
B. Hub Tension Adjustment
8. Pivot pressure adjustment arm up until the wash-
Check hub tension by slowly pulling the wire toward the
er on the adjustment arm is seated on top of the
drive roll. The wire should unwind freely, but hub tension
cover.
should be sufficient to keep the wire taut and prevent
9. Rotate the pressure adjustment knob in a clock- backlash when wire feeding ceases. If adjustment is re
wise direction until the drive roll and pressure quired, loosen or tighten the hex nut on the end of the
bearing are tight against the welding wire. Adjust spindle support shaft accordingly.

OM-112 875 Page 15

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 SECTION 5- OPERATOR CONTROLS

Fine Tuning/
Wire Speed
Power
Control
Switch

Thicknessivoits
Switch

Gun Switch
Gun T8-112 g43-A
Receptaci.

Figure 5-1. Operator Controls

5-1. POWER SWITCH (Figure 5-1) CAUTION: ARCING can damage contact

POWER
a surfaces.
Do not change position of THICKNESS!
VOLTS switch while welding or under load.
-e Arcing causes the contacts to become pitted and
eventually inoperative.
Placing the POWER switch in the ON position energizes
the welding power source. Placing the POWER switch in
the OFF position shuts down the welding power source.
5-3. FINE TUNING/WIRE SPEED CONTROL (Fig
5-2. THICKNESSNOLTS SWITCH (Figure 5-1)
ure 5-1)

WIRE SPEED FINE TUNING

2

olo
The FINE TUNING/WIRE SPEED control provides se
lection of the speed at which welding wire feeds into the
weld. Rotating the FINE TUNING/WIRE SPEED control
clockwise increases wire feed speed.

The scale around the FINE TUNING/WIRE SPEED con

percent arid does not indicate the ac
trol is calibrated in
DO NOT OPERATE tual wire feed speed.
SWITCH UNDER LOAD
IMPORTANT: The FINE TUNING/WIRE SPEED con

The THICKNESSNOLTS switch provides a selection of trol may be adjusted while welding.
four welding voltages:

MW4I1O MW4230 5-4. WELDING GUN RECEPTACLE (Figure 5-1)

Model Model
Thin 20 20 Volts DC Connect gun switch to this receptacle according to Sec
1 Very Volts DC
2 Thin 23 Volts DC 23 Volts DC tiOn 4-5. When the gun switch Is closed, the contactor in
3Thicker 25 Volts DC 27 Volts DC the welding power source energizes, shielding gas
4 Thickest 29 Volts DC 32 Volts DC flows, and wire feeds.
OM-112 875 Page 16

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 SECTION 6- SEQUENCE OF OPERATION

WARNING: ELECTRIC SHOCK can kill; 3. Wear dry insulating gloves and clothing.
a MOVING PARTS can cause serious Injury;
IMPROPER AIRFLOW AND EXPOSURE TO 4. Be sure polarity changeover links are in desired
ENVIRONMENT can damage Internal parts. position (see Section 4-4).
Do not touch live electrical parts. 5. Select welding wire and shielding gas (see Table
6-1). Thread welding wire according to Section
Keep away from moving parts. 4-8. Install shielding gas according to Section 4-2.
Keep all covers and panels in place while
6. Connect work
operating.
clamp to clean, bare metal at work-
piece.
Warranty is void if the welding power source is
7. Set weld parameters using the THICKNESS1
operated with any portion of the outer enclosure
removed. VOLTS switch and FINE TUNING/WIRE SPEED
control appropriate for the base metal thickness
ARC RAYS, SPARKS, AND HOT SURFACES and type of shielding gas (see Table 6-1).
canburn eyes and skin; NOISE can damage
hearing. 8. Close regulator/flowmeter flow adjustment knob,
and slowly open the gas cylinder valve.
Wear correct eye, ear, and body protection.
9. Purge shielding gas line as follows:
FUMES AND GASES can seriously harm
your health. WARNING: ELECTRIC SHOCK kill; ARC
Keep your head out of the fumes. a RAYS can burn eyes.
Do not touch live electrical parts.
can

Ventilate to keep from breathing fumes and

gases. Keep the welding wire isolated from the work
clamp or any conductive surface when not weld
If ventilation is inadequate, use approved ing.
breathing device. The welding wire is electrically energized when
ever the gun trigger is depressed.
WELDING WIRE can cause puncture
wounds.
a. Release drive roll pressure.
Do not point gun toward any part of the body,
any conductive surface, or other personnel. b. Place Line Disconnect switch in the ON posi
tion.
HOT METAL, SPATTER, AND SLAG can
cause fire and burns. c. Place POWER switch on the welding power
Watch for fire. sourcein the ON position.

Keep a fire extinguisher nearby, and know d. Depress gun trigger for approximately 15 sec
how to use it. onds to allow for adjustment of regulator/flow-
meter and to purge gas hose of air.
Do not use near flammable material.
IMPORTANT: Gas pressure of 6 pounds or flow rate of
Allow work and equipment to cool before
15 Cfh are typical. Welding out of position at high wire
handling.
feed speeds, or welding in a drafty environment will re
MAGNETIC FIELDS FROM HIGH CURRENTS quire more shielding gas.
can affect pacemaker operation.
Wearers should consult their doctor before e. Place POWER switch on welding power source
going near arc welding, gouging, orspot welding in OFF position, and retighten drive roll pres
operations. sure according to Section 4-8.

See Section 1 Safety Rules For Operation Of

-
10. Wear welding helmet with proper filter lens ac
Arc Welding Power Source for basic welding cording to ANSI Z49.1.
safety information.
11. Place POWER switch on welding power source in
ON position, and begin welding.

6-1. GAS METAL ARC WELDING (GMAW)

12. Adjust hub tension and drive roll pressure as nec

essary (see Section 4-8).

1. Install and connect unit according to Section 4.
13. Adjust FINE TUNING/WIRE SPEED control as
2. Prepare weld joint (see Sections 9 and 10). necessary.
OM-112 875 Page 17

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 6-2. SHUTTING DOWN 3. Close gas cylinder valve.
WARNING: HIGH CONCENTRA11ON OF
1. Stop welding. SHIELDING GAS can harm heafth or kill.
2. Place POWER switch in OFF position. Shut off gas supply when not in use.

Table 6-1. Suggested SettIngs For Welding

MW 4110 Models -
GMAW

Shielding Gas OPerator Material ThIckness

And Flow Rate Control ~_______

Settings 12 ga. 14 ga. 16 ga. 18 ga. 20 ga. 22 ga. 24 ga.

Range 4 3 2 2~ 1 1 1
co2
20cfh+
Feed Speed* 70% 55% 48% 43% 25% 10% 6%

75% Argon Range 3 3 2 1 1

25% CO2
20 cfh+ Feed Speed* 80% 60% 70% 60% 50%

*AdjuSt FINE TUNING/WIRE SPEED control as required.

+cth = cubic feet per hour

OM.112 875 Page 18

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 MW 4230 Models - GMAW And FCAW

Wire Type, Wire )Derator Material Thickness

Shielding Gas, Diameter Control 1/4 In. 3/16 In. 1/8 In.
And Flow Rate (Inch) Settings (6.4 mm) (4.8 mm) (3.2 mm) 14 ga. 16 ga. 18 ga. 22 ga. 24 ga.

Range 4 3 2 2 1 1 1
.023
,~. Feed
100% 80% 70% 60% 55% 45% 35%
Speed*
E7OS-6
Range 4 4 3 2 2 1 1
Co2 .030
Feed
80% 75% 60% 60% 50% 40% 30%
Speed
20 Cl h+
Range 4 4 3 2 1 1 1
.035
Feed
65% 60% 50% 40% 30% 20% 15%
Speed* ~_______

Range 4 3 2 2 1 1 1
.023
Feed
Speed* 100% 90% 80% 70% 60% 50% 40%
E7OS-6
Range 4 3 3 2 2 1 1
75% Argon
.030
25% CO2 Feed
90% 80% 70% 60% 50% 45% 30%
Speed
20 Cl h+
Range 4 3 3 3 2 2 1
.035
Feed
75% 70% 60% 50% 40% 33% 25%
Speed*
Range 3 3 2 1 1 1
.030 -

Feed
E7IT-GS 40% 65% 45% 40% 30% 20%
Speed
Flux Core Range 3 3 2 1 1 1
.035
Feed
60% 50% 40% 30% 20% 10%
Speed
Range 4 4 3 3 3 2 1
.023
Feed
Speed 100% 100% 90% 85% 75% 70% 60%
ER 308
Stainless Range 4 4 3 3 2 2
Steel .030
Tn-Mix Feed
75% 75% 65% 60% 55% 50%
Speed
20 cf h+
Range 4 4 3
.035
Feed
Speed 60% 60% 50%

Range 4 3 3 2 1 1
.030
Aluminum Feed
90% 85% 80% 90% 90% 85%
Speed
Argon
20 Cf h+ Range 4 4 3 2 2 1
.035
Feed
Speed* 85% 85% 85% 90% 90% 80%

Adjust FINE TUNING/WIRE SPEED control as required.

+cfh = cubic feet per hour
IMPORTANT: it in doubt, set THICKNESS/VOLTS switch for voltage desired and set FINE TUNING/WIRE
SPEED to 50. The weld can be started and fine tuned during operation. It input voltage is low, a higher
THICKNESSNOLTS setting may be required to obtain desired weld.

OM-112 875

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 SECTION 7- MAINTENANCE & TROUBLESHOOTING

7-1 ROUTINE MAINTENANCE (Table 7-1) outer enclosure, and use a clean, dry airstream or vac
uum suction for the cleaning operation. If dusty or dirty
IMPORTANT: Ever, six months inspect the labels on
conditions are present, clean the unit monthly.
this unit for legibility. All precautionary labels must be
maintained in a clearly readable state and replaced C. Inspection And Upkeep
when necessary. See Parts List for part number of
WARNING: Read and follow safety informa
precautionary labels.
a tlon at beginnIng of entire SectIon 7-1 before
proceeding.
WARNING: ELECTRIC SHOCK can kill.
a Do not touch live electrical parts. Every six months, inspect the gun, hoses, and cables. If
dusty or dirty conditions are present, inspect the unit
Shutdown welding powersource, and discon
monthly. Inspection should consist of the following:
nectinputpoweremp!oying !ockouttagging pro
cedures before inspecting, maintaining, or se,v
1. Open side access door.
icing.
Lockout/tagging procedures consist of removing 2. Inspect gun for broken areas, cracks, and loose
input power plug from receptacle, padlocking parts; tighten, repair, and replace as required.
line disconnect switch in open position, remov
ing fuses from fuse box, or shutting off and red- 3. Repairor replace, as required, all hose and cable;
tagging circuit breaker or other disconnecting give particular attention to frayed and cracked in
device. sulation and areas where hose and cables enter
MOVING PARTS can cause serious injury. equipment.
Keep away from moving parts. 4. Remove grease and grime from components,
HOT SURFACES can cause severe burns. moisture from electrical parts and cable.
Allowcooling period before servicing. CAUTION: FLYING DIRT AND METAL CHIPS
Maintenance to be performed only by qualified
persons.
a can
ment.
Injure personnel and damage equip

Point gun liner only in a safe direction away

Table 7-1. Maintenance Schedule from personnel and equipment when cleaning
with compressed air.
Frequency Maintenance
5. Blow out the gun wire guide liner with com
Every month. Units in heavy service environ
ments: Check labels, weld ca pressed air when changing wire. This will remove
bles, clean internal parts. any metal chips and dirt that may have accumu
lated.
Every 6 months. Check all labels (see IMPOR
TANT block, Section 7-1). Clean 6. Close and secure side access door.
internal parts (see Section
7-1B).
D. Cleaning Of Drive Rolls

WARNING: Read and follow safety Informa

Frequency of service is based on units operated 40
hours per week. Increase frequency of maintenance if a beginning of entire Section 7-1 before
tion at
proceeding.
usage exceeds 40 hours per week
MOVING PARTS can cause serious injury.
Keep away from moving parts.
A. Fan Motor
HIGH ROTATIONAL SPEED can cause dam
This unit is equipped with an exhaust fan and relies on age to drive rolls and Injure personnel.
forced draft for adequate cooling. The fan motor is Do not allow drive rolls to rotate at high speed
manufacturedwith lifetime sealed bearings and requires if compressed air is used for cleaning the drive
no maintenance. roll assembly.

B. Internal Cleaning It is necessary to remove the drive rolls for proper clean
WARNING: Read and follow safety lnfomia ing of the wire grooves (see Section 7-3 for removal and
4~ tion at beginning of entire SectIon 7-1 before
proceeding.
installation instructions). Use a wire brush to clean rolls.

IMPORTANT: Failure to properly maintain the drive rolls

Every sixmonths blow out or vacuum dust and dirt from can result in a buildup of wire particles which decreases
the inside of the welding power source. Remove the the efficiency of the wire feeding operation.

OM-112 875 Page 20

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 7-2. OVERI~.OAD PROTECTION - Lbckoutitaggingproceduresconsistof removing
input powr plug from receptacle, padlocking
A. Short Circuit Shutdown line disconnect switch in open position, remov
ing fuses from fuse box, or shutting off and red
The unit is protected from damage due to contact tube
tagging circuit breaker or other disconnecting
short by optical coupler OC1 on motor control circuit device.
board PCi. If the contact tube is shorted to the work-
MOVING PARTS can cause serious Injury.
piece while welding, the unit
completely shuts down. To
re~ume operation, remove contact tube fromworkpiece, Keep away from moving parts.
and continue welding.
1. Open left side access door.
B. Thermal Overload Protection
2. Loosen pressure adjustment knob, pivot pres
Rectifier SR2 is protected from overheating bya normal sure adjustment arm free of cover, and pivot pres
ly-closed thermostat TP1 in the relay CR1 and contactor sure roll assembly away until it is in an open posi
CR2 control circuitry. Should overheating occur, TP1 tion.
would open causing CR1 and thereby the contactor to 3. Remove the drive roll securing bolt in the end of
drop out (deenergize) thereby stopping all weld output.
the motor shaft, and remove the drive roll from the
The thermostat automatically closes when the unit cools
shaft.
down. Allow a cooling period before continuing opera
tion. 4. Slide new drive roll onto motor shaft until the drive
roll bottoms against shoulder of motor shaft.

7-3. REPLACING DRIVE ROLL (Figure 7-1) 5. Reinstali securing bolt, and tighten.
As a result of wear or a change in wire size, it may be 6. Pivot pressure roll assembly downward onto
necessary to replace the drive roll and wire inlet guide. drive roll, making sure thatwelding wire is riding in
Proceed as follows: drive roll groove.

7. Pivot pressure adjustment arm up until the wash

WARNING: ELECTRIC SHOCK can kill.
a Do not touch live electrical parts.
er on
cover.
the adjustment arm is seated on top of the

Shutdown welding powersource, and discorl

8. Adjust drive roll pressure according to Section
nect input power employing locko ut/tagging pro
cedures before 4-8.
inspecting, maintaining, or serv
icing. 9. Close and secure side access door.

Pressure
ill Cover

Pressure
Adjustment
Arm

SB.091 19O.~

Figure 7-1. DrIve Roll And Pressure Bearing Replacement

OM-112 875 Page 21

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 7.4. REPLACING PRESSURE BEARING (Figure 4. Loosen wire inlet.~uide securing screw.

7-1)
5. Remove inlet guide from drive housing, and in

WARNING: ELECTRIC SHOCK can kill. stall new guide.

A~ Do not touch live electrical parts. IMPORTANT: Wire inlet guide should be installed as
Shutdown we/ding powersource, anddiscon close to the drive rolls as possible without touching them.
nect input power employing locko uttagging pro
cedures before inspecting, maintaining, or serv 6. lighten wire inlet guide securing screw.
icing.
Lockoutitagging procedures consist of removing 7. Thread welding wire through wire drive assembly
input power plug from receptacle, padlocking and gun according to Section 4-8.
line disconnect switch in open position, remov
ing fuses from fuse box, or shutting off and red- 8. Close and secure side access door.
tagging circuit breaker or other disconnecting
device.
7-6. REALIGNING DRIVE HOUSING (FIgure 7-2)
MOVING PARTS can cause serIous Injury.
Keep away from moving parts.
WARNING: ELECTRIC SHOCK can kill.

1. Open left side access door.

a Do not touch live electrical parts.
Shutdown welding powersource, and discon
2. Loosen pressure adjustment knob, pivot pres nect input power employing lockout/tagging pro
sure adjustment arm free of cover, and pivot pres cedures before inspecting, maintaining, orserv
sure roll assembly away until it is in an open posi icing.
tion. Lockout/tagging procedures consist of removing
input power plug from receptacle, padlocking
3. Remove cotter pin from pressure lever hinge pin. line disconnect switch in open position, remov
4. Remove pressure lever assembly from
ing fuses from fuse box, or shutting off and red
hinge pin.
tag9ing circuit breaker or other disconnecting
device.
5. Remove securing screw from pressure bearing,
and remove pressure bearing from pressure lever MOVING PARTS can cause serious Injury.
assembly. Keep away from moving parts.
6. Install new pressure bearing, and reinstall secur
ing screw. The wire drive housing is made with mounting holes of
sufficient clearance to provide adjustment of the wire
7. Reinstall pressure lever assembly onto hinge pin. guides up or down in relation to the drive rolls. This ad
8. Reinstall cotter pin onto end of
justment has been factory set, but if readjustment be
hinge. comes necessary proceed as follows:

9. Pivot pressure roll assembly downward onto

drive roll, making sure that welding wire is riding in 1. Remove wrapper from unit.
drive roll groove.
2. Loosen mounting screws and the weld terminal
10. Pivot pressure adjustment arm up until the wash stud hardware securing wire drive housing to cen
er on the adjustment arm is seated on top of the ter baffle.
cover.
3. Slide drive housing up or down until the wire can
11. Adjust drive roll pressure according to Section be fed straight through the wire inlet guide and
4-8. into the wire outlet guide while wire is seated in
drive roll groove.
12. Close and secure side access door.
4. lighten mounting screws and weld terminal stud
7-5. REPLACING WIRE INLET GUIDE (FIgure 7-1) hardware.

1. Open left side access door. 5. Reinstall wrapper.

2. Loosen pressure adjustment knob, pivot pres

sure adjustment arm free of cover, and pivot pres 7.7. CIRCUIT BOARD REPLACEMENT (Figure
sure roll assembly away until it is in an open posi 7.2)
tion.
If circuit board PCi is at fault for a problem with the unit,
3. Cut off welding wire at point where it enters wire replace the board using the following procedure. Do not
inlet guide, and pull wire out nozzle-end of weld attempt board repair. Contact the nearest Factory Au
ing gun. thorized Service Station for correct replacement part.
OM-112 875 Page 22

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 -

.~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. 1. Remove wrapper.

a Do not touch live electrical parts.
can

2. Remove terminal housing from terminal header

Shut down welding powersource, and discon RC1 on PCi.
nect input power employing lockout/tagging
3. Note board mounting position, release PCi from
procedures before inspecting, maintaining, or
servicing. support standoff s, and remove PCi from center
baffle in unit.
Lockout/tagging procedures consist of removing
input power plug from receptacle, padlocking 4. Install new PCi onto center baffle, and reconnect
line disconnect switch in open position, remov terminal housing onto terminal header RC1 on
ing fuses from fuse box, or shutting off and red- new PCI. Be sure that all pins on RC1 mate with
tagging circuit breaker or other disconnecting socket in terminal housing.
device.
5. Reinstall wrapper onto unit.
MOVING PARTS can cause serious injury.
Keep away from moving parts. 7-8. WELDING GUN INSPECTION AND UPKEEP

Usage and shop conditions will determine frequency

CAUTION: ELECTROSTATIC DISCHARGE
a (ESD) can damage circuit boards.
and type of maintenance required.
WARNING: ELECTRIC SHOCK can kill.
Put on
BEFORE
properly grounded wrist
hand/mg circuit boards.
st rap
a Do not touch live electrical parts.

Transport circuit boards in proper static- Shutdown welding po wersource, and discon
shielding carriers or packages. nect input poweremploying locko ut/tagging pro
cedures before inspecting, maintaining, orseri
Perform work only at a static-safe work area.
icing.
INCORRECT INSTALLATION or misaligned Lockout/tagging procedures consist of removing
plugs can damage circuit board. input power plug from receptacle, padlocking
Be that plugs line disconnect switch in open position, remov
sure are properly installed and
aligned. ing fuses from fuse box, or shutting off and red
tagging circuit breaker or other disconnecting
EXCESSIVE PRESSURE can break circuit device.
board.
MOVING PARTS can cause serious Injury.
Use only minima/pressure and gentle move
ment when disconnecting or connecting Keep away from moving parts.
board plugs and removing or installing board.
1. Inspect gun every three months or as use war
rants for broken areas, cracks and loose parts:
IMPORTANT: A/I directions, such as left or right, are
with respect to the operator facing the unit front panel. tighten, repair and replace as required.
Retain all hardware removed during this procedure for 2. Carefullyremove any weld spatter or dirt which
reinstallation unless specifically told otherwise. has accumulated around the nozzle opening.

OM-112 875 Pago 23

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 3 Remove any accumu~ation around the switch. 1. Remove nozzle...

4 Repair replace as required all hose and cab

or 2. Cutoff any portion of the electrode wire which ex

I~ng. give particular attention to frayed and tends beyond end of tube.
cracked insulation and area where it enters 3. Remove contact tube and replace with new con
equipment. tact tube.

5 Remove grease and grime from components and 4. Replace nozzle, and resume operation.
moisture from electrical parts and cables.
7-10. GUN LINER REPLACEMENT (Figure 7-3)
CAUTION: FLYING DIRT AND METAL CHIPS
a can
ment.
Injure personnel and damage equip
a WARNING: ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
S Point gun liner only in a safe direction away
from personnel and equipment when cleaning
Shutdown welding powersource, and discon
with compressed air. nect input power employing lockout/tagging
procedures before inspecting, maintaining, or
6 Blow out gun casing or liner with compressed air servicing.
whenever the wire or liner is removed. Lockout/tagging procedures Consist of removing
input power plug from receptacle, padlocking
line disconnect switch in open position, remov
7-9. CONTACT TUBE REPLACEMENT (Figure
ing fuses from fuse box, or shutting off and red-
7-3)
tagging circuit breaker or other disconnecting
WARNING: ELECTRIC SHOCK can kill. device.
a Do not touch live electrical parts. MOVING PARTS can cause serIous Injury.
Shutdown welding po wersource, and discon Keep away from moving parts.
nect input power employing 10cko ut/tagging pro
cedures before inspecting, maintaining, orserv 1. Remove nozzle.
icing. 2. Cut off any portion of the electrode wire which ex

Lockout/tagging procedures consist of removing tends beyond end of contact tube.

input power plug from receptacle, padlocking
CAUTION: LOOSE WELDING WIRE
line disconnect switch in open position, remov
ing fuses from fuse box, or shutting off and red a cause Injury.
can

tagging circuit breaker or other disconnecting Keep firm hold on wire during installation,
device. removal, and threading operations.
MOVING PARTS can cause serious injury. Spooled wire has a tendency to unravel rapidly
when loosened from the spool.
Keep away from moving parts.
3. Remove contact tube.

Nozzle 4. Retract wire onto wire spool.

5. Disconnect gun assembly from wire drive asse m
bly.
Contact Tube
6. Remove liner colIet.
7. Lay cable assembly out flat and straight (no coils
in the cable/conduit).
Head Tube
8. Pull out the liner from gun/feeder adapter end of
Gun/Feeder gun assembly.
Trigger Adapter
CAUTION: FLYING DIRT AND METAL CHIPS
a can Injure personnel and damage equip
ment.
Point gun liner only in a safe direction away
from personnel andequipment when cleaning
with compressed air.

9. Blow out gun casing or liner with compressed air

Uner whenever the wire or liner is removed.
Coliet
10. Insert new liner into gun/feeder adapter end of
gun. The liner should be flush with end of head
tube.
SB.11O 831-A
11. Install collet and be sure liner is still flush with end
7-3. MWG-160 Gun Parts of head tube.
Figure
Replacement 12. Cut oft liner 1/16 in. (1.6 mm) from collet.
OM.112 875 Page 24
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 13. install corftact tube. Itis assumed that the upitwas properly installed accord

14. Reinstall nozzle. ihg to Section 4 of this manual, the operator is familiar
with the function of controls; the welding power source
15. Reinstall gun to wire drive assembly. was working properly, and that the trouble is not related

16. Thread welding wire according to Section 4-8, to the welding process. The following table is designed

and resume operation. to diagnose and provide remedies for some of the troub
les that may develop in this welding power source.
7-11~ 1ROUBLESHOOTING (Table 7.2)
Use this table in conjunction with the circuit diagram
WARNING: ELECTRIC SHOCK kill.
a Do not touch live electrical parts.
can while performing troubleshooting procedures. If the
trouble is not remedied after performing these proce
dures, the nearest Factory Authorized Service Station
Shut down wire feeder and welding power should be contacted. In all cases of equipment malfunc
source, and disconnect input power employing tion, the manufacturers recommendations should be
lockout/tagging procedures before inspecting,
maintaining, or servicing. strictly followed.

Lockout/tagging procedures consist of removing CAUTION: IMPROPER INPUT FUSES OR

input power plug from receptacle, padlocking
line disconnect switch in open position, remov
fuses from fuse box, or shutting off and red
a CIRCUIT BREAKERS can damage unit and!
or Input supply.
ing
tagging circuit breaker or other disconnecting Be sure replacement input fuse amperage ca
device. pacity matches that listed in Table 4-1 for the
model used. Use fuse of same size and type.
MOVING PARTS can cause serious injury.
Use circuit breaker with amperage capacity
Keep away from moving parts.
that matches Table 4-1 for the model used.
HOT SURFACES can cause severe burns.
Correct overload problem before replacing fuse
Allow cooling period before servicing. or resetting circuit breaker.
Troubleshooting to be performed only by quati
lied persons.

OM-112 875 Page 25

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 Table 7-2. TroubleshootIng
TROUBLE PROBABLE CAUSE REMEDY

No weld output; wire does not Power cord plug not secure in Secure plug in receptacle.
feed. wall receptacle.
.

Line fuse or circuit breaker Replace line fuse or reset circuit breaker.
open.
Thermal overload. Allow a cooling period (see Section 7-2).
Gun switch connection not Se- Secure gun switch connector in receptacle RC3.
cure.

Gun switch, or gun switch leads Replace gun switch (if applicable) or repair
open. switch leads.

Power switch S2. Replace S2.

Switch control relay CR1. Replace CR1.
No weld output; wire feeds. Work clamp connection loose Remakeworkconnectionensuringgoodmetalto
or incomplete due to rust, paint, metal contact.
etc., on surface of workpiece.
Contact tube. Replace contact tube (see Section 7-9).
Low weld output. Low input line power. Connect unit to proper input voltage or check for
low line voltage.

Electrode wire stops feeding Sharp or excessive bend in gun Straighten gun cable and/or replace liner (see
while welding. cable or liner. Section 7-10).

Incorrect drive roll pressure. Adjust drive roll pressure (see Section 4-8).
Incorrect hub tension. Readjust hub tension (see Section 4-8).
Contact tube opening re- Replace contact tube (see Section 7-9).
stricted; burnback of wire into
tube.

Friction in gun. Check wire passage; clean, replace parts as re

quired (see Sections 7-9 and 7-10).
Gun casing liner dirty or Clean or replace liner (see Section 7-10).
plugged.
~
Broken or damaged casing or Replace damaged parts (see Section 7-10).
liner.

Drive roll or pressure roll worn Replace drive roll or pressure bearing as re
or slipping. quired (see Sections 7-3 and 7-4).
Gun trigger switch or wire leads Replace switch; check connections.
broken.

.
Excessive loading of drive mo- Clear restriction in drive assembly.
tor.

Drive motor. Contact nearest Factory Authorized Service Sta

tion.

Motor Drive Board PCi. Replace PCI according to Section 7-7.

OM-112 875 Page 26

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 SECTION 8 ELECTRICAL DIAGRAMS

Circuit Diagram No. SB-119 059

Diagram 8-1. Circuit Diagram For MW 4110 Models

230

Circuit Diagram No. SB-119 063-C

Diagram 8-2. CircuIt Diagram For MW 4230 Models

OM-112 875 Page 27

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 Circuit Diagram No. SC-i 37 798

Diagram 8-3. Circuit Diagram For MW 4110 Motor Control Board PCI

Circuit Diagram No. SC-i 37 801

Diagram 8-4. Circuit Diagram For MW 4230 Models Motor Control Board PCI

OM-112 875 Page 28

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 P2
132-B
SC-1 9
No.

CORD
Diagram
Wiring

Models
41 0
MW
For

Diagram
Wiring
8-5.

Diagram

PC3

S2
0 N) cn (I,

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 74 -C
23
SC-i
No.

Diagram
Wiring

Models
MW-4230
For

Diagram
Wiring
8-6.

Diagram

0 N) -J UI -ł (0

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 ~SECTION 9 .- WELDING TECHNIQUES & TROUBLESHOOTING

CAUTION: WELDING CURRENT can dam before lowering the helmet and pressing the gun
a age vehicle components and other elec
tronic components.
seam

trigger.

~ Disconnect both battery cables before weld

ing on a vehicle.
Place work clamp as close to the weld as
possibleto avoid long electrical paths.

Be sure gun to power source as well as cable

connections to work clamp are clean and
tight.
To minimize risk, disconnect the computer(s)
from the vehicle.

9-1. GAS METAL ARC WELDING (GMAW) - TA-057 469-119

CONTINUOUS SEAM Gun Position

Figure 9-2.

The gun can be moved along the seam in a steady move

ment known as the drag technique (see Figure 8-3), or it
can be oscillated a few degrees beyond each side of the
seam. The travel speed will be regulated by the type of
weld bead required, the thickness of the material, weld
FIgure 9-1. ContInuous Seam ing current selected and the technique used. However,
the average speed is 15 to 20 inches per minute (0.4-0.5

The ability to produce a good bead while using the Con-S

mpm).
tinuous Seam Gas Metal Arc process is dependent on
several factors. One of the most important, after wire
and shielding gas selection, is the way the gun is held. a aa sw
Cradle the gun in one hand and rest the side of the hand
on the workpiece (avoid doing this on hot material); use TA-057 469-16

other hand to hold gun and control the gun trigger. Posi
FIgure 9-3. WeldIng Techniques
tion the gun either towatti or away from the body at a 45
to 60 degree lead angle (see Figure 8-2). This will give a
Other welding techniques that affect the weld character
good view of the arc and make it easier to follow the
istics in the GMAW welding process include the back
seam while wearing a helmet. Maintain a 1/4 to 5/16 inch
hand and forehand technique, and the vertical up and
(6-8 mm) distance from the bottom of the gun nozzle to
vertical down positions. In the backhand technique the
the workpiece during the arc starting and welding period.
Do not pull the gun back from the seam when the arc gun is positioned so that the electrode wire is feeding in
the opposite direction of arc travel. The filler metal is be
starts, as this will create a long wire extension and result
in a poor weld. ing fed into the weld metal previously deposited. In the
forehand technique the gun is angled so that the elec
The welding wire is not energized until the trigger is trode wire is fed in the same direction as the arc travel.
pressed. Therefore the welding wire can be extended The backhand technique generally yields a more stable
1/4 inch (6mm) beyond the gun nozzle and placed on the arc and less spatter on the workpiece.

OM-112 875 Page 31

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 Direction of Arc Tray Direction of Arc Travel

Backhand Technique Forehand Technique

Figure 9-4. LongitudInal Gun Positions

The vertical up and/or vertical down techniques describe plete weld penetration. The drag technique is generally
the direction of arc travel when the welding must be done employed when welding in the vertical position, but
in the verticalposition. In both of these techniques gun when bridging a gap, the arc can be oscillated from one
is
positioning extremely important because the arc must side of the work to the other.
be kept on the leading edge of the puddle to ensure corn-

Vertical Up Vertical Down

Figure 9-5. Welding In The Vertical Up And Vertical Down Position

9-2. TROUBLESHOOTING THE GAS METAL ARC WELDING (GMAW) PROCESS

A. Porosity

.4

FIgure 9-6. PorosIty

OM-112 875 Page 32

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 ~..Posslble Causes Correct~ve Actions

1. Inadequate shieldin g gas coverage. Remove spatter from the gun nozzle:

Check gas hoses for leaks.

Eliminate drafts (from fans, open doors, etc.) blowing into the
..
,- welding arc.

Place nozzle 114 tO 5/16 in. (6-8 mm) from worlcpiece.

Increase gas flow to displace all air from the weld zone.

Decrease excessive gas flow to avoid turbulence and the en

trapment of air in the weld zone.

Hold gun at end of weld until molten metal solidifies. .

Check for frozen CO2 regulator/f lowmeter.

2. Wrong gas. Use welding grade shielding gas.
3. Dirty welding wire. Use clean and dry welding wire.

Eliminate pick up of oil or lubricant on welding wire from feeder

or conduit.

4. Workpiece dirty. Remove all grease, oil, moisture, rust, paint, undercoating, and
dirt from work surface before welding.

Use a more highly deoxidizing welding wire.

5. Welding wire extend s too far out of nozzle. Welding wire should extend 114 in. (6 mm) out of nozzle.

B. ExcessIve Spatter

Possible Causes CorrectIve Actions

1. Excessive spatter when using CO2 shield- Select lower voltage range or adjust FINE TUNING/
ing gas. WIRE SPEED control.

C. incomplete Fusion

Figure 9-7. Incomplete Fusion

OM-112875P~.

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 Causes Corrective Actions

Clean weld surfaces of impurities (grease, oil, moisture, rust,

paint, dirt, etc.) prior to welding.
Select higher voltage range or adjust FINE TUNING/
WIRE SPEED control.

technique. When using a weaving technique dwell momentarily on the

side walls of the groove.

Provide improved access at root of joints.

Keep electrode directed at the leading edge of the puddle.

Provide proper gun angle (see Section 7.1).

FIgure 9-8. Lack of Penetration

Possible Causes CorrectIve Actions

1. Improper joint preparation. Material too thick. Joint preparation and design must be ade
quate to provide access to the bottom of the groove while
maintaining proper welding wire extension and arc characteris
tics.

2. improper weld technique. Maintain normal gun angle to achieve maximum penetration
(see Section 7-1).
.

Keep arc on leading edge of the puddle.

3. Insufficient heat input. Select higher voltage range and wire speed.

Reduce the travel speed.

Be sure welding wire extends 1/4 in. (6 mm) out of nozzle.

E. Excessive Penetration (Burn-Through)

~
Figure 9-9. ExcessIve Penetration

Possible Causes Corrective Actions

1. Excessive heat input. Select lower voltage range and reduce wire speed.

Increase travel speed.

OM-112 875 Page 34

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 F. Cracks in Weld Metal

Possible Causes Corrective Actions

1. improper joint preparation. Material too thick. Joint preparation and designmust be ade
quate to provide the b~):\om of the groove while
access to
maintaining proper welding wire extension and arc characteris
tics.
~.

2. Heat
input too high causing excessive Select lower voltage range and reduce wire speed.
shrinkage and distortion.

Increase travel speed.

G. Wavinessof Bead

~.
~

Figure 9-10. Waviness of Bead

Possible Causes Corrective Actions

1. Welding wire extends too far out of nozzle. Welding wire should extend 1/4 in. (6 mm) out of nozzle.

2. Unsteady hand. Support hand on solid surface.

H. Humping

Figure 9-11. Humping

Possible Causes Corrective Actions

1. Excessive heat input. Select lower voltage range or increase travel speed.

Weld in small segments and allow to cool between welds.

OM-112 875 Page 35

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 SECTION 10- AUTO BODY REPAIR APPLICATION

CAUTION: WELDING CURRENT can dam 20. Clamp the new metal in place, and prepare to spot
a age vehicle computers and other electronic
components.
weld.

21. Place the VOLTAGE ADJUSTMENT switch in the

Disconnect both battery cables before weld
ing on a vehicle.
3 position.
Place work 22. Install the spot nozzle on the gun.
clamp as close to the weld as
possible to avoid long electrical paths. 23. With theshielding gas and power source turned
-Be sure gun to power source aswell as cable on,place the spot nozzle and press firmly against
connections to work clamp are clean and the new material about 1/2 to 3/4 in. (12-18mm),
tight. from the edge. Fit up must betightto assure good,
To minimize risk, disconnect the computer(s) repeatable spot welds.
from the vehicle.
24. Begin spot welding from the center out on each
side. Distortion may occur if welding begins at the
corners.
10-1. POINTERS FOR WELDING AUTO BODY
SHEET METAL 25. Space spot welds 1 to 1/2 in. (25-38 mm) apart
around repair. Spot welds should be about 3/16
Before using this equipment to weld on a finished piece
in. (5 mm) in diameter.
of work, make a few practice welds on a sample piece of
material the same as that of the finished workpiece. IMPORTANT: Do not make continuous welds around
Whenever possible, weld in the fiat position since this is the repair as this will promote distortion and warpage.
the easiest position to learn. Be sure that the material to
be welded is clean and free of paint and rust. The work 26. After welding, remove the clamp and grind spot
cable clamp must be attached to the parts being welded. flush to surface.
Clean surface to ensure proper grounding and to com
27. Smooth the joints with body filler and finish.
plete the current path.
Use a .023 in.(0.6 mm) E7OS-6 wire and argon/carbon 10-3. PROCEDURES FOR WELDING DOOR PAN
dioxide shielding gas. ELS

Use direct current IMPORTANT: Every experienced autobody repairman

straight polarity (electrode negative)
for reduced burn will have his own method of performing the folio wing pro
through. Check position of gun polarity
changeover jumper links according to information found cedures. However, this information is presented to show
in a separate section previously covered in this manual. how, in most cases, this welding po wer source can make
If necessary, reposition jumper links. the job easier and less time consuming.
IMPORTANT: For maximum penetration on thicker ma If the door is severely damaged, but the damage is pri
terials such as 18 gauge
(1.22 mm) and thicker, recon marily in the outer panel, or skin, the door can be easily
nect for direct current reverse polarity (work lead to repaired without necessarily installing a whole new door.
negative, electrode wire to positive).
1. Remove exterior molding and hardware. It is not
necessary to remove window regulator, remote
10-2. PROCEDURE FOR WELDING MILD STEELS control mechanisms, lock or runs.

The following are some basic guidelines that can be 2. Remove door assembly, and place on flat surface
used when using this welding power source to weld mild withedge of door extending over edges of surface
or high strength steels: to provide room to work.

17. Use a power wire brush or sanderto remove paint

to bare metal in the area to be repaired. Two to Door Skin
three inches (51-76mm) on either side of the weld Damage
area should be cleaned for applying body filler af I
ter welding is completed.
Inner Door
18. Remove damaged
metal using hand cutters,
shears, or a power hand grinder equipped with a
cutting wheel.
In nor Door
19. Fit a new piece of sheet steel over the section Flange
S-04 t8
which was removed. The new material should
overlap the cut away section by one inch (25 mm). FIgure 10-1. Cutaway Of Door Panel Damage
OM-112 875 Page 36

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 3. If door t~s an outer panel reinforcement, break .welded ir~ place. Car-and body manufacturers have the
the we(~ panels welded in different places. so it will be necessary
the old
toinspect the body to detet~nine where the welds are lo
4. Grind off the hem flange and remove
cated in each case. After the old panel is removed, the
panel. inner panels must be carefully checked, straightened or
5. Repair any damage to the inner panel. replaced.
Continuous Seam
6. Position the new outer panel over door and bend
the end flange over the inner flange.
7. Spot weld outer panel reinforcement to new door
panel.
8. Spot weld new hem flange to inner panel.
9. Metal finish exterior surface, paint and assembly
interior trim and hardware. Pulsed Seam
Weld. Spot Welds S .0420

Figure 10-3. AutomotIve Body Sections

Assembled With ContInuous Seam, Pulsed,
And Spot Welds

The new outer panel can then be placed and held in posi
tion by vice-grips or c-clamp. When welding, start at the
center and proceed first in one direction and then the
other. In order to ensure reduced distortion due to heat,
weld only a section of 2 or3 in. (51-76mm) at a time. It is
important to constantly check the over all temperature of
S-0419
the sheet steel around the welding area, because it is in
this concentrated heat area that warpage and distortion
Figure 10-2. Hem Flange Removal will begin. Leave a gap and then weld another short sec
tion. When the weld is completed it can be hammered
down, filled with body putty and sanded.
10-4. HOWTOPREVENTGLASS BREAKAGE AND
SPATTER ON WINDOWS
10-6. WELDING FRAMES AND HIGH STRENGTH
Spatter and excessive heat can become problems when (HSS) STEELS
welding near windows. Protect the windows by keeping The new HSS steels are used on many of the new econ
them covered and as far away from the heat zone as
omy compact cars. HSS steels can be found in the steel
possible. When welding must be performed near win
gussets, brackets, floor pans, and support members of
dows, the windows should be covered and protected
these new models. HSS steelsare thinner for weight re
from excessive heat by using wet rags. A putty like sub
duction and are heat sensitive. As heat is applied, the
stance which reduces heat transfer is available through
If burn
strength decreases and cracking can occur, therefore
your welding supplier. through and spatter be the heat affected zone must be kept as small as possi
come problems, ensure that the correct voltage tap is
ble. For this reason the GMAW welding process has be
being used forthe size material being welded. Use an ar come the preferred method for welding HSS steels, and
gon and CO2 gas mixture and check travel speed.
the oxacetylene welding or brazing processes, with its
wider heat affective area, are normally not recom
10-5. PROCEDURES FOR WELDING FENDERS
mended.
AND QUARTER PANELS

When a complete panel must be replaced it will be nec

essary to remove the bolts securing the panel to the rest

of the structure, or to cut through the spot welds if the
panel is welded in place. In most cases afrontfenderwill
be bolted in place, while the other panels will be either
spot welded or continuous seam welded. The alignment
of front fenders is usually simple because the bolt holes
are often elongated so that the position of the new front
fender can be shifted and correctly aligned. Generally all
other panels are welded into place.

If the whole panel is to be replaced, the old panel must be

removed by cutting along the weld if welded by continu
ous seam, or by drilling out the spot welds if it is spot Figure 10-4. ApplIcation Of Body Putty
OM-112 875 Page 37

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 (I) m C, -l 0 z -I -I Cl) r Cl) -I

11-3 1 -4 897~B
28 29 30
Fig& SD-1 2
27

26

25

24

23

22

21

20

19
ilustraed)
4230
18
MW
Arc
(Auto
Asembly
Main
1 -1.
Figure

11-5 59
61 60 52
Fig
0

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 Quantity
Model
Item Dia. Part
No. Mkgs. No. Description MW 4110 MW 4230

Figure 11-1. Main Assembly

1 110 720 GA-16C GUN, (Fig 11-5) 1 1

~2 089899 LATCH 2 2
3 112814 LABEL,AutoArcMW4llO(Ieftside) 1
3 127 738 LABEL, Auto Arc MW 4230 (left side) 1
4 134 464 LABEL, warning general precautionary 1 1
5 +111 833 WRAPPER 1 1
6 112813 LABEL,AutoArcMW4llO(rightside) 1
6 127991 LABEL, Auto Arc MW 4230 (right side) 1
7 SR2 119 263 RECTIFIER, si diode (consisting of) 1
TP1 601 066 THERMOSTAT, NC open 167F close 140F I
7 SR2 124 062 RECTIFIER, Si diode (consisting of) 1
TPI 117 275 THERMOSTAT, NC open 186F close 166F 1
8 VR1 087 156 VARISTOR, 10 joule 68VDC 1 1
9 010124 TUBING,stl.5000DxllgawaIlxl.250 1
9 010 529 TUBING, stl .625 OD x .156 wall x .875 1
10 113 447 FOOT, mtg stab 1 1
11 604 657 SCREW, cap sti hex hd .375-16 x 1.250 1 1
12 602 213 WASHER, lock stl spIlt .375 1 1
13 010910 WASHER,fIatstISAE.375 1 1
14 111 912 INSULATOR, housing drive I I
15 Figll-2 DRIVEASSEMBLY,wire 1 1
16 089 120 CLAMP, hose .375-.450 clp dia slfttng 2 2
17 604 550 HOSE, nprn brd No. 1 (order by ft) 3ft 3ft
18 010 909 NUT, sti sit 1kg hex .375-16 1 1
19 010910 WASHER,flatstlSAE.375 2 2
20 073 355 SPRING, cprsn .625 OD x .093 wire x 1.000 1 1
21 111998 PIN,cotterhair.120x2.375 1 1
22 111929 HUB,spool 1 1
23 126839 BAFFLE,center 1 1
24 CR1 072817 RELAY,encI24VACDPDT 1 1
25 108 342 BRACKET, mtg tan 1 1
26 FM 111 931 MOTOR, fan 120V 50/60 Hz 2600RPM 1
26 FM 117014 MOTOR,fan23OV5O/6OHz2600RPM .
1
27 005 656 BLADE, lan 6 in 4 wg 30 deg .175 bore CW 1 1
28 110 375 STAND-OFF SUPPORT, PC card 4 4
29 113 149 HOUSING, term hdr 14 pin 1 1
079 747 TERMINAL, contact hdr 24-18 wire 14 14
30 PCi 137797 CIRCUIT CARD, motor control (Fig 11-3) 1
30 PCi 137800 CIRCUIT CARD, motor control (Fig 11-4) I
31 CR2 129696 CONTACTOR,defprp25AlP24VACcoil 1
31 CR2 108 358 CONTACTOR, def pip 25A 2P 24VAC coil 1
32 116 619 TERMINAL ASSEMBLY, chgov (consisting of) 1 1
33 601 835 NUT, brs hex 10-32 8 8
34 038 887 STUD, pn bd brsl0-32 x 1.375 4 4
35 116 620 TERMINAL BOARD, chgov 1 1
36 038 618 LINK, jumper term bd pn 2 2
37 M 090 087 MOTOR, gear 24VDC 1 1
38 112 583 INSULATOR, motor to housing drive 1 1
39 R2 117 116 RESISTOR, WW fxd 20W 50 ohm 1
39 123 770 RESISTOR ASSEMBLY, (consisting of) 2
R2-5 117 116 RESISTOR, WWfxd 20W 50 ohm 2
40 Cl 109 039 CAPACITOR, elctlt 46000uf 35VDC 1
40 Cl ,2 123 768 CAPACITOR, elctit 70000uf 35VDC 2
41 108 105 CLAMP, capacitor 2.500 dia 1 2
42 128007 PANEL,rear 1 1
43 605 227 NUT, nyl hex jam .750 NPST 1 1

OM-112 875 Page 39

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 Quantity
Model
Item Dia. Part
No. Mkgs. No. Description MW 4110 I MW 4230

Figure 11-1. Main Assembly (Continued)

~~44 PLG1 113494 CORDSET,pwr300Vl4ga3/c7ft 1

44 PLG1 127933 CORDSET,pwr300Vl2ga3/c6ft 1
45 111 443 BUSHING, strain relief .240/.510 ID x .875 mtg hole I 1
46 112 811 LABEL, Auto Arc emblem 1 1
47 GS1 116 996 VALVE, 115VAC 2 way custom port 1/8 orf 1
47 GS1 128 751 VALVE, 23OVAC 2 way custom port 1/8 orf 1
48 Z 112 635 STABILIZER 1
48 Z 123 609 STABILIZER 1
49 111827 BASE 1 1
50 Ti 113 515 TRANSFORMER, pwr main 115V (consisting of) 1
112 049 COIL, pwr main 1
50 Ti 123 962 TRANSFORMER, pwr main 230V (consisting of) 1
123749 COIL,pri/sec 1
51 SI iii 897 SWITCH, rotary (consisting of) 1 1
52 127023 ~KNOB,pointer 1 1
53 Ri 072 623 POTENTIOMETER, C sitd sit l/T 2W 1000 ohm 1 1
54 111 831 PANEL,front i
54 116835 PANEL,front 1
55 RC3 048 282 RECEPTACLE w/SOCKETS, (consisting of) 1 1
079 534 TERMINAL, female lskt 14-18 wire 4 4
56 111 644 BUSHING, strain relief .370/.430 ID x .875 mtg hole 1 1
57 026843 INSULATOR 2 2
58 010368 CLAMP,grdlOOA 1 1
59 S2 111 997 SWITCH, SPST bA 25OVAC 1
59 S2 116830 SWITCH, DPST 1OA25OVAC 1
60 097 922 KNOB, pointer 1 1
61 137217 NAMEPLATE,AutoArcMW4liO 1
61 137 218 NAMEPLATE, Auto Arc MW 4230 1
113 280 HOSE, gas (consisting of) 1 1
089 120 CLAMP, hose .375- .450 clp dia slitting 2 2
113 129 TUBING, PVC .250 ID x .062 waIl (order by ft) 4ft 4ft
112 863 FITTING, adapter hose kit 1 1

+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-112 875 Page 40

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 Item Part
No. No. Description Quantity

Figure 11-2. DrIve Assembly, Wire (Fig 11-1 Item 15)

1 126 838 WIRE DRIVE, (consisting of) 1

2 090416 PIN,hinge 1
3~ 124 817 HOUSING, wire drive 1
4 114 415 SCREW, mach sti phflh 10-24 x .625 1
5 111 523 BEARING, ball 1
6 112 031 LEVER, pressure roll 1
7 604 741 .
PIN, cotter-hair .042 x .937 1
8 010224 ~PlN,springCS.187x1.000 1
9 058 549 GUIDE, wire inlet 1/16 1
10 085 242 FASTENER, pinned 1
11 085 244 .

WASHER, cupped stl .328 ID x .812 00 x .125 lip I

12 090 415 SPRING, compression .720 OD x 1.250 1
13 092 237 KNOB, ad justment tension 1
14 126652 KNOB,plstcT2.000lgx.312-18 1
15 604538 WASHER,flatstlSAE.312 5
16 126 653 WASHER, flat nyl .312 ID x .625 OD x .Og4thk 1
17 602 238 WASHER, fiat-SAE 3/16 1
18 602 203 WASHER, lock-split No. 10 3
19 090105 SCREW,cap-hexhd5mmx22mm 3
20 090 106 SCREW, cap-hex hd 6mm x 16mm 1
21 602 207 WASHER, lock-split 1/4 1
22 602 240 WASHER, flat-std 1/4 1
23 112 749 ROLL, drive Auto Arc U groove .023-.030 wire 1
24 126 651 WASHER, shldr nyl .437 OD x .328 ID x .7O3shldr 1
25 602 211 WASHER, lock sti Split .312 1
26 128 129 SCREW, cap sti hexhd .312-18 x 1.750 1

262515 1

Includes
Items
4thrul3

13-~
12-j
11

(.

8 ~19
23

)
9 22
21
~2O SB.091 190.E

Figure 11-2. Drive Assembly, Wire

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

OM-112 875 Page 41

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 SA-137 796

Figure 11-3. CircuIt Card, Motor Control PCi

OM-112 875 Page 42

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 Dia. Part
Mkgs; No. Description Quantity

PCi 137 797 Figure 11-3. CircuIt Card, Motor Control (Fig 11-1 Item 30)

Cl ,2 035 833 CAPACITOR, polye film .033uf 100VDC 2

C3 097 488 CAPACITOR, cer mono .l5uf 50V I
C4,6 059 122 CAPACITOR,cerdisc.Oluf500V 2
C5 031 677 CAPACITOR, tantlm 5.6uf 35VDC 1
C7 000 348 CAPACITOR, tantim .47uf 35V 1
C8 111 944 CAPACITOR, elctlt 68uf 35VDC 1
C9 044 176 CAPACITOR, cerdisc.Oluf 100 VDC 1
ClO 028 290 CAPACITOR, elctlt luf 5OVDC 1
Cli 031 670 CAPACITOR, cer disc .O5uf 500VDC I
CR1 099 018 RELAY, end 24VDC SPDT 1
Dl ,3,6,8 026 202 DIODE, rect 1A 400V 4
D2 037 243 DIODE, zener 18V 1W 1
D4,7 037084 DIODE,zener4.7V1W 2
D5 028 351 DIODE, sig .020A 75V 1
Fl *125 847 FUSE, mintrgl sb blo 12A 1
089 835 CLIP, fuse 15A .250 dia 2
OC1 114712 IC,interfacellCi 1
01 039 355 TRANSISTOR, WT 15MA 40V I
02 114 714 TRANSISTOR, PNP 200MA 80V 1
03 114 713 TRANSISTOR, NPN 500MA 80V 1
Ri 092 525 RESISTOR, MF .25W 2K ohm 1
R2 009 173 POTENTIOMETER, cermet trmr 201T .5W 5K ohm 1
R3 082 178 POTENTIOMETER,cermettrmr25lr.5W 10K ohm 1
R4 035825 RESISTOR,CF.25WlKohm 1
R5,i0 004 592 RESISTOR, WW fxd 3W 150 ohm 2
R6 072 560 RESISTOR, MF .25W 1K ohm 1
R7 035 830 RESISTOR, MF .25W 6.81K ohm 1
R8 035 887 RESISTOR, CF .25W 3.3K ohm 1
R11,12 035824 RESISTOR,CF .25W 270 ohm 2
R13 030 025 RESISTOR, C .5W 100 ohm 1
R14 035 823 RESISTOR, CF .25W 100 ohm 1
R15 039331 RESISTOR,CF.25W4.7Kohm 1
A 16,21 035 827 RESISTOR, CF .25W 10K ohm 2
R17 039328 RESISTOR,CF.25W1.5Kohm 1
R18 039 334 RESISTOR, CF .25W 27K ohm 1
R19 030843 RESISTOR,ClW6800hm 1
R20 039 335 RESISTOR, CF .25W 47K ohm 1
RC1 113 148 TERMINAL, hdr 14 pin 1
SCR1,2 125486 THYRISTOR, SCA 15A200V 2
SRi 093 747 RECTIFIER, integ 30A 400V 2
TI 111 910 TRANSFORMER,pulse 1
VR1 093331 IC,Iinear337T I

Recommended Spare Parts.

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

OM-112 875 P

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 SA-137 799

Figure 11-4. Circuit Card, Motor Control PCi

OM-112 875 Page 44

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 Dia. Part
Mkgs. No. Description Quantity

Pci 137 800 Figure 11-4. CIrcuit Card, Motor Control (Fig 11-1 item 30)

Cl ,2 035 833 CAPACITOR, poiye film .033uf IOOVDC 2

C3 097 488 CAPACITOR, cer mono .15u1 50V 1
C4,6 059 122 CAPACITOR, cer disc .01 uf 500V 2
C5 031 677 CAPACITOR, elcttt 5.6uf 35V0C 1
C7 000 348 CAPACITOR, tantlm .47uf 35V 1
C8 111 944 CAPACITOR, elctlt 68uf 35V0C 1
C9 044 176 CAPACITOR, cer disc .Oiuf 1000VDC I
ClO 028 290 CAPACITOR, elcttt luf 5OVDC 1
Cli 031 670 CAPACITOR, cer disc .O5uf 500VDC 1
CR1 099 018 RELAY, end 24VDC SPOT 1
Di ,3,6,8 026 202 DIODE, rect 1A 400V 4
D4,7 037 084 DIODE, zener 4.7V 1W 2
D5 028 351 DIODE, sig .020A 75V I
*
Fl 125 847 FUSE, mintr gI $10 blo 1 2A 1
089 835 CLIP, fuse 15A .250 dia 2
OC1 114712 IC,interfacellCl 1
Qi 039 355 TRANSISTOR, UJT 15MA 40V 1
02 114714 TRANSISTOR, PNP200MA8OV 1
Q3 114 713 TRANSISTOR, NPN 500MA 80V 1
Ri 092 525 RESISTOR, CF .25W 2K ohm 1
R2 082 178 POTENTIOMETER, cermet trmr 25/T .5W 10K ohm 1
R5,10 004 592 RESISTOR, WW fxd 3.25W 150 ohm 2
R6 072 560 RESISTOR, MF .25W 1K ohm 1
R7 035 830 RESISTOR, MF .25W 6.81K ohm 1
R8 035 887 RESISTOR, CF .25W 3.3K ohm 1
Ril,12 035824 RESISTOR,CF.25W270ohm 2
R13 030 025 RESISTOR, C .5W 100 ohm 1
R14 035 823 RESISTOR, CF .25W 100 ohm 1
R15 039 331 RESISTOR, CF .25W 4.7K ohm I
R16,21 035 827 RESISTOR, CF .25W 10K ohm 2
Ri 7 039 328 RESISTOR, CF .25W 1.5K ohm 1
R18 039 334 RESISTOR, CF .25W 27K ohm 1
R19 030843 RESISTOR,ClW68Oohm 1
R20 039 335 RESISTOR, CF .25W 47K ohm 1
R22 039 106 RESISTOR, CF .25W 470 ohm 1
P23 009 173 POTENTIOMETER, cermet trmr 20/T .5W 5K ohm 1
RC1 113148 TERMINAL,hdrl4pin 1
SCR1,2 125846 THYRISTOR, SCR 15A200V 2
SRi 093 747 RECTIFIER, integ 30A 400V 2
TI 111 910 TRANSFORMER, pulse 1
VR1 093 331 IC, linear 337T 1

*
Recommended Spare Parts. .

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

OM-112 875 Page 45

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 9

1 ~-1o
1

11
16
17

12

18

19

SC-uo B32-C

Figure 11-5. Exploded View Of GA-16C Gun

OM-112 875 Page 46

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4
2
3
I
1

tern Part
No. No. Description Quantity

110 720 Figure 11-5. Exploded View Of GA-16C Gun (Fig 11-1 Item 1)

1 110793 HANDLE ASSEMBLY 1

2 110 795 TUBE, head (consisting of) 1
110780 NUT,MlOxl 2
4 110 779 JACKET, head tube
5 110781 ~STOP,nozzle
6 128 878 ADAPTER, head tube/nozzle
7 110782 SPRING,nozzle
8 112 743 TUBE, contact Auto Arc .024 (.06 mm)
9 112 747 NOZZLE, Auto Arc 1/2 ort
10 110794 TRIGGERSWITCHASSEMBLY
11 080 565 TERMINAL, frict fern .110 x .016 22-18 wire
12 110 792 CABLEJCONDUIT, lOft
13 110797 SLEEVE, rbr
14 112 745 LINER, Auto Arc lOft (consisting of)
15 110 784 COLLET, liner .023-.030 wire
16 079 974 0-RING, .500 ID x .103 CS rbr
17 110 796 CONNECTOR, gun/feeder
18 079 878 HOUSING PLUG & PINS, (consisting of)
079 535 TERMINAL, male 1 pin sz 16 18-14 wire
19 048 834 CLAMP, cable strain relief 1

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

OM-112 875 Pa;e

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