MAC TOOLS MW 270 Plus Owner'S Manual Download Page 3

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TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

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1-1.

Symbol Usage

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1-2.

Arc Welding Hazards

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1-3.

Additional Symbols For Installation, Operation, And Maintenance

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1-4.

California Proposition 65 Warnings

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1-5.

Principal Safety Standards

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1-6.

EMF Information

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SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION

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2-1.

Symboles utilisés

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2-2.

Dangers relatifs au soudage à l’arc

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2-3.

Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

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2-4.

Proposition californienne 65 Avertissements

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2-5.

Principales normes de sécurité

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2-6.

Information EMF

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SECTION 3 − INTRODUCTION

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3-1.

Specifications

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3-2.

Welding Power Source Duty Cycle And Overheating

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3-3.

Welding Gun Duty Cycle And Overheating

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3-4.

Volt-Ampere Curves

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3-5.

Installing Welding Gun

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3-6.

Connecting To Weld Output Terminals

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3-7.

Installing Work Clamp

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3-8.

Setting Gun Polarity For Wire Type

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3-9.

Installing Wire Spool And Adjusting Hub Tension

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3-10. Installing Gas Supply

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3-11. Positioning Jumper Links

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3-12. Electrical Service Guide

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3-13. Selecting A Location And Connecting Input Power

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3-14. Threading Welding Wire

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3-15. Installing Optional Spool Gun Switch In Welding Power Source

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3-16. Connecting Spool Gun To Welding Power Source

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SECTION 4 − OPERATION

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4-1.

Controls

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4-2.

Weld Parameters

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SECTION 5 − MAINTENANCE AND TROUBLESHOOTING

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5-1.

Routine Maintenance

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5-2.

Supplementary Protectors

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5-3.

Replacing Drive Roll And Wire Inlet Guide

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5-4.

Removing Knob From Front Panel

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5-5.

Replacing Gun Contact Tip

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5-6.

Removing Nozzle, Contact Tip, And Adapter, Changing Liner, And Cleaning Gun Casing

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5-7.

Replacing Switch And/Or Head Tube

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5-8.

Welding Troubleshooting Table

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5-9.

Wire Drive/Gun Troubleshooting Table

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Summary of Contents for MW 270 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: ...ng Welding Gun 11 3 6 Connecting To Weld Output Terminals 12 3 7 Installing Work Clamp 12 3 8 Setting Gun Polarity For Wire Type 13 3 9 Installing Wire Spool And Adjusting Hub Tension 13 3 10 Installi...

Page 4: ...Weld Bead Characteristics 34 6 8 Troubleshooting Excessive Spatter 35 6 9 Troubleshooting Porosity 35 6 10 Troubleshooting Excessive Penetration 35 6 11 Troubleshooting Lack Of Penetration 36 6 12 Tro...

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: ...mm 185 lb 84 kg 023 045 in 0 6 1 2 mm 030 035 in 0 8 0 9 mm 030 045 in 0 8 1 2 mm m min D 36 1 2 in 927 mm While idling 6 Minutes Welding 4 Minutes Resting 3 2 Welding Power Source Duty Cycle And Ove...

Page 14: ...ous Welding SB1 1 8 93 0 10 Minutes Definition 023 To 045 in 0 6 To 1 1 mm Hard Or Flux Cored Wires 100 Duty Cycle At 200 Amperes Using CO2 100 Duty Cycle At 150 Amperes Using Mixed Gases 023 To 045 i...

Page 15: ...f 802 285 D 1 Drive Assembly 2 Gun Securing Knob 3 Gun End Loosen knob Insert gun end through opening until it bottoms against drive assembly Tighten knob 4 Gun Trigger Plug Insert plug into receptacl...

Page 16: ...th nut so that weld cable terminal is tight against copper bar Do not place anything between weld cable terminal and copper bar Make sure that the surfaces of the weld cable terminal and copper bar ar...

Page 17: ...inal 3 Negative Black Output Terminal Always read and follow wire manufacturer s recommended polarity Close door Ref 802 285 D Ref ST 192 432 3 2 3 9 Installing Wire Spool And Adjusting Hub Tension Wh...

Page 18: ...ylinder cannot fall and break off valve 1 Cap 2 Cylinder Valve Remove cap stand to side of valve and open valve slightly Gas flow blows dust and dirt from valve Close valve 3 Cylinder 4 Regulator Flow...

Page 19: ...ut voltage available at site 1 Jumper Links Access Door Open door 2 Jumper Link Label Check label only one is on unit 3 Input Voltage Jumper Links Move jumper links to match input voltage Close and se...

Page 20: ...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 60 amp and UL class H 65 amp and above 4 Conductor data...

Page 21: ...line ter minal 1 Rating Label Supply correct input power 2 Plug 3 Receptacle Connect plug to receptacle 4 Black And White Input Conductor L1 And L2 5 Green Or Green Yellow Grounding Conductor 6 Input...

Page 22: ...contact tip Turn On WOOD Press gun trigger until wire comes out of gun Reinstall contact tip and nozzle Feed wire to check drive roll pressure Tighten knob enough to prevent slipping Cut off wire Clo...

Page 23: ...switch plug Retain jumper plug by placing looped lead over unit wiring harness 8 Switch Plug Connect switch plug to wiring har ness switch plug 9 Jam Nut Remove top jam nut from switch switch is equip...

Page 24: ...existing gas hose above barbed fitting at wire drive housing Install supplied hose clamp onto end of hose at wire drive housing and insert either of the two output barbed ends of diverter valve into h...

Page 25: ...rols 1 Wire Speed Control The scale around the control is per cent not wire feed speed 2 Voltage Control The higher the selected number the thicker the material that can be welded see welding guide an...

Page 26: ...045 1 1 mm 045 1 1 mm 023 0 6 mm 030 0 8 mm 035 0 9 mm 035 0 9 mm 030 0 8 mm 047 1 2 mm 030 0 8 mm 035 0 9 mm 047 1 2 mm Selecting Wire Gas and Control Settings 10 20 30 40 50 60 70 80 90 WIRE SPEED W...

Page 27: ...80 3 60 3 52 2 22 5 100 4 64 5 38 4 28 4 12 4 50 4 54 3 52 4 54 VOLTA GE 1 2 3 4 5 6 10 20 30 40 50 60 70 80 90 WIRE SPEED Wire Size Stock No V Grooved 024 030 035 202925 024 045 407230 004 V Knurled...

Page 28: ...coat of oil or grease to drive motor shaft 5 2 Supplementary Protectors Ref 802 285 D Y Turn Off unit 1 Supplementary Protector CB1 CB1 protects main circuit board PC1 if drive motor shorts or fails I...

Page 29: ...ze and type 4 Drive Roll Securing Screw Secure drive roll with screw as shown Tools Needed 2 1 3 4 5 4 Removing Knob From Front Panel Y Turn Off power 1 Front Panel 2 Knob 3 Spring Clip 4 Control Shaf...

Page 30: ...g Gun Contact Tip Ref 800 797 C Y Turn Off power before replacing contact tip 1 Nozzle 2 Contact Tip Cut off welding wire at contact tip Remove nozzle Remove contact tip and install new contact tip Re...

Page 31: ...tip check and match wire size Head Tube Tools Needed 5 8 7 16 in Lay gun cable out straight before installing new liner Remove nozzle contact tip and adapter Unscrew and remove liner Blow out gun cas...

Page 32: ...to new head tube Hand tightenhead 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 lo...

Page 33: ...speed Readjust front panel settings see Section 4 1 Change to correct size drive roll see Section 5 3 Readjust drive roll pressure see Section 3 14 Replace inlet guide contact tip and or liner if nec...

Page 34: ...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 G...

Page 35: ...meters 035 in Recommendation Wire Speed Approx 802 280 F 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...

Page 36: ...13 mm past end of nozzle and tip of wire 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 5 Crad...

Page 37: ...ectrode extension stickout travel 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...

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 6 6 Poor Weld Bead Characteristics 1 Large Spatter Deposits 2 Rough Uneven Bead 3 S...

Page 39: ...Insufficient shielding gas at welding arc Increase flow of shielding gas at regulator flowmeter and or prevent drafts near welding arc Remove spatter from gun nozzle Check gas hoses for leaks Place no...

Page 40: ...on Incomplete Fusion failure of weld metal to fuse completely with base metal or a preceeding weld bead S 0637 Possible Causes Corrective Actions Workpiece dirty Remove all grease oil moisture rust pa...

Page 41: ...upport hand on solid surface or use two hands 6 15 Troubleshooting Distortion Distortion contraction of weld metal during welding that forces base metal to move Base metal moves in the direction of th...

Page 42: ...aged Check size of contact tip and cable liner replace if necessary Wire curling up in front of the wire feed rolls bird nesting Too much pressure on wire feed rolls Decrease pressure setting on wire...

Page 43: ...ecessary Wrong size gun liner or contact tip Match liner and contact tip to wire size and type Incorrect voltage setting for selected wire feed speed on welding power source Readjust welding parameter...

Page 44: ...OM 219 806 Page 40 Notes...

Page 45: ...OM 219 806 Page 41 SECTION 7 ELECTRICAL DIAGRAM 206 590 A Figure 7 1 Circuit Diagram For Welding Power Source...

Page 46: ...806 Page 42 SECTION 8 PARTS LIST 802 281 F Hardware is common and not available unless listed 18 19 21 20 16 15 14 13 12 11 8 7 6 5 4 3 2 1 9 Fig 8 2 10 Fig 8 3 17 Fig 8 4 22 Fig 8 5 Figure 8 1 Main A...

Page 47: ...11 CORD SET 250V 6 50p 8 10ga 3 c for 200 230 1 12 146 161 BASE 1 13 135 390 AXLE 1 14 186 758 WHEEL 2 15 121 614 RING retaining 2 16 209 870 CASTER swvl 4 00 in X 1 250 in poly olefin 2 17 Fig 8 4 PA...

Page 48: ...Page 44 802 284 D Hardware is common and not available unless listed 1 2 3 4 5 6 7 8 9 12 13 14 11 10 15 16 20 23 25 27 28 29 33 34 35 37 26 17 18 19 25 24 30 31 32 36 21 22 Figure 8 2 Center Baffle w...

Page 49: ...92 SUPPLEMENTARY PROTECTOR man reset 1P 10A 250V 1 20 PC1 171 986 CIRCUIT CARD ASSEMBLY control 1 21 038 618 LINK jumper term bd pri as req 22 TE1 188 910 TERMINAL ASSEMBLY pri 1ph double voltage 200...

Page 50: ...34 deg 1 3 M 188 706 MOTOR fan 230V 50 60 Hz 1 4 203 711 WINDTUNNEL 9in 1 5 216 396 VALVE 24 VAC 2 way custom port 1 8 orf w frict 1 6 203 478 PANEL rear 1 7 169 654 BRACKET support tank 1 8 188 441 C...

Page 51: ...07 077 KNOB 1 5 208 207 POTENTIOMETER CP flat 1 T 2W 1K linear wire feed speed 1 6 S2 226 602 SWITCH selector 7 position 1 228 166 SCREW 010 24X2 00 pan hd phl stl pld trilob thdfmg 3 7 S1 124 511 SWI...

Page 52: ...1 1 169 725 NOZZLE slip type 625 orf 125 recess 1 1 169 726 NOZZLE slip type 625 orf flush 1 1 169 727 NOZZLE slip type 625 orf 125 stickout 1 2 087 299 TIP contact scr 023 wire x 1 125 2 000 067 TIP...

Page 53: ...al performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor Description Part No Dia Mkgs Item...

Page 54: ...Notes...

Page 55: ...ch 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 trade acce...

Page 56: ...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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MAC TOOLS MW 270 Plus, Owner'S Manual

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