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MAC TOOLS MW 185 Plus, Owner'S Manual

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OM-230 852 Page 30

SECTION 9 − MIG WELDING (GMAW) GUIDELINES

9-1.

Typical MIG Process Connections

Y

Weld current can damage
electronic parts in vehicles.
Disconnect both battery
cables before welding on a
vehicle. Place work clamp as
close to the weld as possible.

Wire Feeder/

Power Source

Workpiece

Gun

Regulator/
Flowmeter

Gas Hose

Shielding

Gas

Work Clamp

light mig 5/97 / Ref. 804 623-A

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Summary of Contents for MW 185 Plus

Page 1: ...hnical Support Contact Milweld Inc National Distributor P O Box 338 Hortonville WI 54944 0338 Tel 920 779 0916 Fax 920 779 0924 Processes Description MIG GMAW Welding Flux Cored FCAW Welding Arc Weldi...

Page 2: ......

Page 3: ...ecifications 9 4 2 Duty Cycle And Overheating 10 4 3 Volt Ampere Curves 10 SECTION 5 INSTALLATION 11 5 1 Installing Welding Gun 11 5 2 Installing Work Clamp 12 5 3 Process Polarity Table 13 5 4 Changi...

Page 4: ...ood Weld Bead Characteristics 34 9 8 Troubleshooting Excessive Spatter 35 9 9 Troubleshooting Porosity 35 9 10 Troubleshooting Excessive Penetration 35 9 11 Troubleshooting Lack Of Penetration 36 9 12...

Page 5: ...0 147 see Safety Standards D Properly install and ground this equipment according to its Owner s Manual and national state and local codes D Always verify the supply ground check and be sure that inpu...

Page 6: ...mbustibles such as a butane lighter or matches from your person before doing any welding D Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguishe...

Page 7: ...s computers and communicationsequipment D Have only qualified persons familiar with electronic equipment perform this installation D The user is responsible for having a qualified electrician prompt l...

Page 8: ...Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent...

Page 9: ...n la norme OSHA 29 CFR 1910 147 voir normes de s curit D Installer le poste correctement et le mettre la terre convenablement selon les consignes du manuel de l op rateur et les normes nationales prov...

Page 10: ...es poches telles qu un allumeur au butane ou des allumettes D Suivre les consignes de OSHA 1910 252 a 2 iv et de NFPA 51B pour travaux de soudage et pr voir un d tecteur d incendie et un ex tincteur p...

Page 11: ...ut provoquer des interf rences avec les quipe ments de radio navigation et de communica tion les services de s curit et les ordinateurs D Demander seulement des personnes qualifi es familiaris es avec...

Page 12: ...bpart Q and Part 1926 Subpart J de U S Government Printing Office Superinten dent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux r gionaux le t l phone de la r gion 5 Chicago est 31...

Page 13: ...um Open Circuit Voltage DC Amperes Input at Rated Load Output 230 V 50 60 Hz Single Phase KVA KW Weight W Gun Overall Dimensions 130 A 21 5 Volts DC 30 Duty Cycle At 60 Hz Input 20 Duty Cycle At 50 Hz...

Page 14: ...V OR Reduce Duty Cycle Minutes duty1 4 95 217 757 A 30 duty cycle at 130 amps 60 Hz 20 duty cycle at 130 amps 50 Hz 3 Minutes Welding 7 Minutes Resting 10 20 30 40 50 60 70 80 100 10 20 40 60 80 100 1...

Page 15: ...rew Welding gun must be inserted completely to prevent leakage of shielding gas 4 Gun Trigger Leads Insert leads one at a time through gun opening on front panel Connect female friction terminals to m...

Page 16: ...to clamp 4 Work Clamp 5 Screw 6 Work Clamp Tabs Bend tabs around work cable Slide insulating sleeves over handles 802 456 A Connection hardware must be tightened with proper tools Do not just hand tig...

Page 17: ...put terminal CHANGING POLARITY 5 4 Changing Polarity 1 Lead Connections For Direct Current Electrode Negative DCEN 2 Lead Connections For Direct Current Electrode Positive DCEP Always read and follow...

Page 18: ...gas hose connection and fitting on rear of welding power source 7 Flow Adjust Flow rate should be set when gas is flowing through welding power source and welding gun Open feedhead pressure assembly...

Page 19: ...ng Conductor 4 Input Power Cord 5 Disconnect Device switch shown in the OFF position 6 Disconnect Device Grounding Terminal 7 Disconnect Device Line Terminals Connect green or green yellow groundingco...

Page 20: ...t breaker with time current curves comparable to a Time Delay Fuse 2 Time Delay fuses are UL class RK5 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including...

Page 21: ...ux Nozzle MIG Nozzle Use with flux cored wire only Narrow design allows access in tight spaces and provides better visibility of puddle during welding Use with solid or flux cored wire Push nozzle ove...

Page 22: ...rive roll pressure Tighten knob enough to prevent slipping Cut off wire Close door Press gun trigger until wire comes out of gun Turn power on Be sure that Voltage range switch is set to range 1 2 3 4...

Page 23: ...nge also increases see weld setting label in welding power source or Section 6 2 as applicable 2 Power Switch 3 Voltage Switch The higher the selected number the thicker the material that can be welde...

Page 24: ...ty for DCEN Solid Wire ER70S 6 Set Polarity for DCEP Solid Wire ER70S 6 Set Polarity for DCEP Stainless Steel Set Polarity for DCEP Aluminum Set Polarity for DCEP Good for windy or outdoor application...

Page 25: ...5 60 5 50 5 60 5 50 5 40 5 50 4 35 6 90 6 60 6 50 6 80 6 50 6 40 6 60 5 35 6 70 7 50 7 90 7 50 5 40 6 40 7 70 7 40 7 50 7 60 6 35 7 80 7 60 7 50 7 40 1 35 3 50 2 50 4 40 3 35 4 40 6 60 4 50 3 40 6 50...

Page 26: ...t or vacuum inside During heavy service clean monthly Or 7 2 Overload Protection 802 441 1 SupplementaryProtector CB1 CB1 protects unit from overload If CB1 opens unit shuts down Reset supplementary p...

Page 27: ...rive roll 1 4 turn to closed slot 4 Drive Roll The drive roll consists of two different sized grooves The stamped markings on the end surface of the drive roll refers to the groove on the opposite sid...

Page 28: ...t 1 8 in 3 mm of liner sticks out Hand tighten outlet guide and then tighten two full turns more Cut liner off so that 3 4 in 19 mm sticks out of head tube Install gas diffuser adapter contact tip and...

Page 29: ...ghten head tube into cable connector Place head tube in vice and tighten until nuts are tight Remove from vice Reposition handle and install switch housing Secure with handle locking nut Y Turn Off we...

Page 30: ...tighten if necessary Low weld output Connect unit to proper input voltage or check for low line voltage Place voltage switch in desired position see Section 6 1 Electrode wire feeding stops during wel...

Page 31: ...OM 230 852 Page 27 Notes...

Page 32: ...OM 230 852 Page 28 SECTION 8 ELECTRICAL DIAGRAM Figure 8 1 Circuit Diagram...

Page 33: ...OM 230 852 Page 29 228 180 A...

Page 34: ...ons Y Weld current can damage electronic parts in vehicles Disconnect both battery cables before welding on a vehicle Place work clamp as close to the weld as possible Wire Feeder Power Source Workpie...

Page 35: ...ters 035 in Recommendation Wire Speed Approx 1 8 or 0 125 in 0 001 in 1 ampere 0 125 in 125 A Wire Size Amperage Range 0 023 in 0 030 in 0 035 in Select Wire Size Wire Size 0 023 in 0 030 in 0 035 in...

Page 36: ...e is positioned correctly on seam NOTE 1 Hold Gun and Control Gun Trigger 2 Workpiece 3 Work Clamp 4 Electrode Extension Stickout 1 4 to 1 2 in 6 To 13 mm Hold a shorter stickout when welding with sol...

Page 37: ...avel speed thickness of base metal wire feed speed weld current and voltage NOTE Slow FILLET WELD ELECTODE EXTENSIONS STICKOUT ELECTRODE EXTENSIONS STICKOUT GUN ANGLES AND WELD BEAD PROFILES 10 10 GUN...

Page 38: ...ment Along Seam 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode S 0054 A 3 1 2 9 6 Poor Weld Bead Characteristics 1 Large Spatter Deposits 2 Rough Uneven Bead 3 S...

Page 39: ...in weld metal S 0635 Possible Causes Corrective Actions Insufficient shielding gas at welding arc Increase flow of shielding gas at regulator flowmeter and or prevent drafts near welding arc Remove s...

Page 40: ...welding power source 9 12 Troubleshooting Incomplete Fusion Incomplete Fusion failure of weld metal to fuse completely with base metal or a preceeding weld bead S 0637 Possible Causes Corrective Actio...

Page 41: ...Excessive heat input Use restraint clamp to hold base metal in position Make tack welds along joint before starting welding operation Select lower voltage range and or reduce wire feed speed Increase...

Page 42: ...ough so it does not touch wire feed rolls Dirty or damaged kinked liner Replace liner Wire feeds but no gas flows Gas cylinder empty Replace empty gas cylinder Gas nozzle plugged Clean or replace gas...

Page 43: ...OM 230 852 Page 39 Notes...

Page 44: ...Hardware is common and not available unless listed 804 624 A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 34 32 31 49 43 48 47 46 45 44 51 50 36 35 42 41 40 38 39 37...

Page 45: ...GA 3 C 7ft SPT 3 jkt 1 16 111 443 BUSHING strain relief 1 17 137 761 NUT gas valve 1 18 196 064 MOTOR fan 1 19 409 953 001 BLADE fan cooling 1 20 226 069 TRANSFORMER power assy 1 21 208 015 HANDLE car...

Page 46: ...25 GUIDE wire inlet 1 50 227 010 LABEL weld chart 1 51 204 711 LATCH 1 52 217 585 CONTACTOR 1 53 203 572 LABEL warn gen precaution EN FR models only 1 54 LABEL nameplate order by model and serial numb...

Page 47: ...ing 1 5 169 718 TUBE head 1 6 169 738 NUT locking handle 1 7 169 719 NUT jam 1 8 079 975 O RING 187 ID x 103CS rbr 1 9 194 010 LINER monocoil 023 025 wire x 15ft consisting of 1 9 194 011 LINER monoco...

Page 48: ...ing Gear Cylinder Rack For One Small Gas Cylinder 100 lb 45 kg max 194 776 Small Running Gear Cylinder Rack For One Small Gas Cylinder 75 lb 34 kg max 195 957 H 10 Replacement Gun 10 ft length 030 035...

Page 49: ...Notes...

Page 50: ...Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual...

Page 51: ...ents such as contact tips cutting nozzles contactors relays brushes slip rings or parts that fail due to normal wear 2 Items furnished by manufacturer but manufactured by others such as engines or tra...

Page 52: ...erial Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Owner s Manuals Circuit Diagrams...

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