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The following safety alert symbol and signal words are used throughout this manual to call attention to and identify
different levels of hazard and special instructions.

WARNING

WARNING statements identify procedures or practices which must be followed to avoid serious personal
injury or loss of life.

CAUTION

CAUTION statements identify procedures or practices which must be followed to avoid minor personal
injury or damage to this equipment.

IMPORTANT:  statements identify special instructions necessary for the most efficient operation of this equipment.

ARC WELDING SAFETY PRECAUTIONS

WARNING

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.
In welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The
safety information given below is only a summary of the more complete safety information that will be found in the
Safety Standards listed on the next page. Read and follow all Safety Standards.

HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY
QUALIFIED PEOPLE.

ARC WELDING can be hazardous.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks
or  severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing, and
all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.

1. Do not touch live electrical parts.

2. Wear dry, hole-free insulating gloves and body protection.

3. Insulate yourself from work and ground using dry insulating mats

or covers.

4. Disconnect input power or stop engine before installing or

servicing this equipment.

5. Properly install and ground this equipment according to its

Owner’s Manual and national, state, and local codes.

6. Turn off all equipment when not in use.
7. Do not use worn, damaged, undersized, or poorly spliced cables.
8. Do not wrap cables around your body.
9. Ground the workpiece to a good electrical (earth) ground.

10. Do not touch electrode while in contact with the work (ground)

circuit.

11. Use only well-maintained equipment. Repair or replace

damaged parts at once.

12. Wear a safety harness to prevent falling if working above floor

level.

13. Keep all panels and covers securely in place.

ARC RAYS can burn eyes and skin;
NOISE can damage hearing.

Arc rays from the welding process produce intense
heat and strong ultraviolet rays that can burn eyes and
skin. Noise from some processes can damage
hearing.

1. Wear a welding helmet fitted with a proper shade of filter (see

ANSI Z49.1 listed in Safety Standards) to protect your face and
eyes when welding or watching.

2. Wear approved safety glasses. Side shields recommended.
3. Use protective screens or barriers to protect others from flash

and glare; warn others not to watch the arc.

4. Wear protective clothing made from durable, flame-resistant

material (wool and leather) and foot protection.

5. Use approved ear plugs or ear muffs if noise level is high.

FUMES AND GASES can be hazardous
to your health.

Welding produces fumes and gases. Breathing these
fumes and gases can be hazardous to your health.

1. Keep your head out of the fumes. Do not breath the fumes.
2. If inside, ventilate the area and/or use exhaust at the arc to

remove welding fumes and gases.

3. If ventilation is poor, use an approved air-supplied respirator.
4. Read the Material Safety Data Sheets (MSDSs) and the

manufacturer’s instruction for metals, consumables, coatings,
and cleaners.

5. Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Shielding gases used for
welding can displace air causing injury or death. Be sure the
breathing air is safe.

6. Do not weld in locations near degreasing, cleaning, or spraying

operations. The heat and rays of the arc can react with vapors to
form highly toxic and irritating gases.

7. Do not weld on coated metals, such as galvanized, lead, or

cadmium plated steel, unless the coating is removed from the
weld area, the area is well ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.

Summary of Contents for MW150K

Page 1: ...carefully Have only trained and qualified persons install operate or service this unit Call your distributor if you do not understand the directions Give this manual to the operator For help call you...

Page 2: ...undersized or poorly spliced cables 8 Do not wrap cables around your body 9 Ground the workpiece to a good electrical earth ground 10 Do not touch electrode while in contact with the work ground circu...

Page 3: ...de to touch any cylinder 5 Use only correct shielding gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in good condition 6 Turn face...

Page 4: ...Gun Rated Output Air Cooled 160 Amperes At 60 Duty Cycle Using CO2 Shielding Gas Cable Length 10 ft 3 m 1 1 Volt Ampere Curve And Duty Cycle Chart CAUTION USING GUN BEYOND DUTY CYCLE RATING can damage...

Page 5: ...e in bracket and chain 3 Chain 4 Snap Crimp onto open end of chain 5 Cylinder Bracket For Large Gas Cylinder 6 Gas Fitting ST 160 791 1 2 3 Tools Needed 4 5 6 Figure 2 2 Installing Safety Chain B Inst...

Page 6: ...door Ref ST 149 629 B 2 4 1 3 Figure 2 5 Gun Connections 2 5 Connecting Input Power Table 2 1 Electrical Service Requirements Input Voltage 230 Input Amperes At Rated Output 20 Recommended Standard F...

Page 7: ...tacle 4 Input Conductors 5 Grounding Conductor Select size and length using Table 2 1 Conductor rating must comply with national state and lo cal electrical codes Install and connect input conduc tors...

Page 8: ...e Spool 2 Hub Tension Nut Grasp spool in one hand and turn while using a wrench to adjust nut When a slight force is needed to turn spool tension is set Loosen wire from spool and cut off bent wire an...

Page 9: ...oltage Adjustment switch position while welding Arcing inside switch can damage contacts causing switch to fail READ SAFETY BLOCKS at beginning of manual before proceeding WARNING 1 1 Insulating Glove...

Page 10: ...oltage Adjustment Switch Use switch to select an arc voltage The higher the selected number the thicker the material that can be welded see Table 3 1 3 Power Switch Use switch to turn unit On and Off...

Page 11: ...80 3 60 3 50 3 90 3 70 3 60 2 45 2 40 3 90 3 65 3 50 3 80 3 85 2 2 1 1 1 70 60 55 45 35 2 2 1 1 60 50 40 30 2 1 1 1 40 30 20 15 2 2 1 1 1 80 70 60 50 40 2 2 1 1 60 50 30 45 2 2 1 3 50 40 33 25 1 1 1...

Page 12: ...r Clean and check wire drive parts replace as necessary Every 3 months Tape or replace cracked cables clean and tighten connections Replace unreadable labels Every 6 months Blow out or vacuum inside o...

Page 13: ...ARNING Turn Off and unplug unit 1 Wire Spool 2 Gun Contact Tube Cut welding wire off at contact tube Retract wire onto spool and secure 3 Pressure Roll Arm 4 Cotter Pin 5 Pin 6 Screw 7 Bearing Remove...

Page 14: ...ut liner off Reinstall gun so that liner is as close as possible to drive rolls without touch ing Thread welding wire see Section 2 6 Close door Ref ST 149 629 C Ref ST 155 509 Tools Needed 3 8 in 3 2...

Page 15: ...nlet guide or liner if dirty or plugged 4 3 4 4 Replace drive roll or pressure bearing if worn or slipping 4 3 Secure gun trigger plug in receptacle or repair leads or replace trig ger switch 2 4 Chec...

Page 16: ...OM 154 500 Page 13 Figure 5 2 Wiring Diagram For Welding Power Source SC 163 085...

Page 17: ...RTS LIST ST 155 497 B Figure 6 1 Main Assembly 1 2 3 4 5 6 7 18 9 10 11 12 13 14 20 21 22 23 24 8 15 16 17 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 26 27 49 50 51 52 53...

Page 18: ...572 Bracket 52 Rear Panel w Cmpts 128 751 Gas Valve 605 227 Nyl Nut gas valve 152 118 Cord Set 111 443 Bushing cord set 147 443 Rear Panel 146 619 Bezel 147 548 Speed Nut 156 339 Bottle Retainer 602 3...

Page 19: ...Notes...

Page 20: ......

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