MAG KD410407 Owner's manual
- Category
- Welding System
- Type
- Owner's manual
This manual is also suitable for
May
1993
Form:
OM-154500A
Effective
With
Serial
No.
K041
0407
MW15OK
OWNERS
MANUAL
IMPORTANT:
Read
and
understand
the
entire
contents
of
this
manual,
with
special
emphasis
on
the
safety
material
throughout
the
manual,
before
installing,
operating,
or
maintaining
this
equipment.
This
unit
and
these
instructions
are
for
use
only
by
persons
trained
and
experienced
in
the
safe
operation
of
welding
equipment.
Do
not
allow
untrained
persons
to
install,
operate,
or
maintain
this
unit.
Contact
your
distributor
if
you
do
not
fully
understand
these
instructions.
I
1~oIsfi
Coven
5/92-ST-155
683-A
PRINTED
IN
USA
SECTION
1
SPECIFICATIONS
Table
1-1.
Welding
Power
Source
Type
Of
Output
Rated
Weld
Output
Type
Of
Input
Power
Input
Amperes
At
Rated
Output
KVAJKW
Used
At
Rated
Output
Max.
Open-Circuit
Voltage
Control
Circuit
Voltage
At
Gun
Welding
Processes
Speed
Range
Wire
Diameter
Range
Overall
Dimensions
Weight
Direct
Current/Constant
Voltage
(DC/CV)
120
Amperes,
21
Volts
DC.
30%
Duty
Cycle
Single-Phase:
60
Hz:
At
230
Volts
AC
20A
4.7
kVAI3.9
kW
32
Volts
DC
24
Volts
DC
Specification
Description
Gas
Metal
Arc
(GMAW)
And
Flux
Cored
Arc
Welding
(FCAW)
47
To
690
ipm
(1.2
To
17.5
mpm)
.023
To
.035
in
(0.58
To
0.89
mm)
Length:
27
in
(686mm):
Width:
12
in
(305
mm);
Height:
22-1/2
in
(571
mm)
Net:
117
lb
(53
kg);
Ship:
120
lb
(54
kg)
Welding
Gun
Rated
Output
(Air
Cooled)
160
Ampe
res
At
60%
Duty
Cycle
Using
CO2
Shielding
Gas
Cable
Length
lOft
(3
m)
1-1.
Volt-Ampere
Curve
And
Duty
Cycle
Chart
.
a
CAUTION
GUN
BEYOND
DUTY
CYCLE
RATING
can
damage
gun.
use
gun
beyond
rated
amperage
when
using
CO2
shielding
gas.
gun
at
30%
duty
cycle
when
using
mixed
shielding
gas.
wfw~m81
10191
The
volt-ampere
curves
show
the
minimum
and
maximum
voltage
~
--
~
u~~
~
~
~
.
50
00
150
200 260
D.C.
AI~E6ES
-
-
and
amperage
output
capabilities
of
the
welding
power
source.
Curves
of
other
settings
fall
be
tween
the
curves
shown.
operate
within
a
ten
minute
period
Duty
cycle
is
how
long
the
unit
can
without
causing
overheating
or
damage.
This
unit
is
rated
at
30%
duty
cycle
allowing
welding
3
minutes
out
of
every
10
minutes.
This
gun
is
rated
at
60%
duty
cycle
when
using
CO2
shielding
gas
and
30%
when
using
mixed
shielding
gas.
,00
~
-
-
- -
00
~
so
7
.
-
-
-
- -
-
-
-
...
-
.
-
~
60
00
-
-
-
-
-
- -
.5
20
25
30
60
50
60
70
00
60
ISO
DJTY
CY~.L
S
so
bl.I
10
/91
55.124
625
/
sbl.3
10/91
SB-124
624
Figure
1-1.
Volt-Ampere
Curve
And
Duty
Cycle
Chart
!4
rp,
.
ERRATA
SHEET
June
9,
1993
FORM:
OM-154
500A
Use
above
FORM
number
when
ordering
extra
manuals.
After
this
manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this
manual.
CHANGES
TO
SECTION
5
ELECTRICAL
DIAGRAMS
Replace
Figure
5-1.
Circuit
Diagram
For
Welding
Power
Source
(see
Page
2
on
this
Errata
Sheet)
Replace
Figure
4-2.
Wiring
Diagram
For
Welding
Power
Source
(see
Page
3
on
this
Errata
Sheet)
CHANGES
TO
SECTION
6
PARTS
LIST
Change
Parts
List
as
follows:
Dia.
Part
Replaced
--
Mkgs.
No.
With
Description
Quantity
14-46
123
768
162
245
..
CAPACITOR,
(qty
chg
deleted
C2)
(Effw/KD436311)
1
14-47
108
105
022
160
..
CLAMP,
(qty
chg)
(Eff
w/KD43631
1)
1
~First
digit
represents
page
no
digits
following
dash
represent
item
no.
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
SB-163
084
Figure
5-1.
Circuit
Diagram
For
Welding
Power
Source
Eftective
With
Serial
No.
KD436311
OM.1
54
500A
Page
2
0
UI
0
0
-u
SC-163
085
Figure
4-2.
WirIng
Diagram
For
Welding
Power
Source
Effective
With
Serial
No.
KD436311
2-1.
Installing
Work
Clamp
1
Insulator
2
Bolt
3
Smaller
Hole
4
Work
Clamp
Tabs
Tools
Needed:
Bend
tabs
around
work
cable.
7/16
in
3/8
in,
5
Work
Cable
From
Unit
6 Nut
R&.
57.025
190-C
Figure
2-1.
Installing
Work
Clamp
2-2.
Installing
Gas
Supply
A~
WARNING
Tools
Needed:
Obtain
gas
cylinder
and
chain
to
running
gear,
wall,
or
other
station
ary
support.
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
(CO2
shown)
4
CO2
0-Ring
SECTION
2
INSTALLATION
Keep
cylinders
away
from
welding
and
other
Shut
off
shielding
gas
supply
when
not
in
use.
CYLINDERS
can
explode
if
damaged.
BUILDUP
OF
SHIELDING
GAS
can
harm
health
or
kill.
~
electrical
circuits.
Never
touch
cylinder
with
welding
electrode.
Always
secure
cylinder
to
running
gear,
wall,
or
other
stationary
support.
wam4.1
9/91
A.
Installing
Safety
Chain
Cri
mp
onto
open
end
of
chain.
5
Cylinder
Bracket
For
Large
Gas
Cylinder
6
Gas
Fitting
ST-ISO
791
Figure
2-2.
Installing
Safety
Chain
B
.
Installing
Regulator/Fiowmeter
5
Regulator/Flowmeter
Install
so
face
Is
vertical.
6
Gas
Hose
Connection
lnstallgas
hose
between
flowmeter
and
welding
power
source.
Flow
rate
Is
set
to
20
cTh
(cubic
feet
per
hour).
Tools
Needed:
.~-
1-1/8,
5/8
In
ub3.1
12(92
-
81.154
563
/
81-154
623
Figure
2-3.
InstallIng
SupplIed
Regulator/Flowmeter
OM-154
500
Page
2
2-3.
Gun
Polarity
For
Wire
Type
2-4.
Installing
Welding
Gun
Table
2.1.
Electrical
Service
Requirements*
Swaml.1
2/93
1
Polarity
Changeover
Label
2
Polarity
Jumper
Links
Always
read
and
follow
wire
man
ufacturers
recommended
polarity.
There
are
two
jumper
links
(1
Set)
across
each
set
of
terminals.
Be
sure
to
move
each
set
of
links
when
changing
polarity.
3
Pilot
Light
(See
Section
4-1)
Close
door.
Loosen
securing
knob.
Insert
end
through
front
panel
opening
until
it
bottoms
against
drive
assembly.
Tighten
knob.
4
Gun
Trigger
Plug
Insert
into
receptacle
and
tighten
threaded
collar.
Close
door.
Input
Voltage
230
Input
Amperes
At
Rated
Output
20
Recommended
Standard
Fuse
Or
Circuit
Breaker
Rating
In
Amperes
30
Input
Conductor
Size
In
AWG/Kcmil2
14
Max
Input
Conductor
Length
In
Feet
(Meters)3
65
(20)
Grounding
Conductor
Size
In
AWG/KcmiI4
14
These
values
are
calculated
from
the
1990
edition
of
the
National
Electrical
Code
(NEC).
I
Recommended
fuse
or
circuit
breaker
size
is
that
closest
to
150%
of
rated
input
amperage
of
the
welding
power
source.
Article
630-12(a)
of
NEC
allows
fuse
or
circuit
breaker
sizing
up
to
200%
of
rated
input
amperage.
2
Input
conductor
size
is
for
insulated
copper
wire
with
75C
rating
with
not
more
than
three
single
current-carrying
conductors
in
a
cable
or
raceway
(Table
31
0-16
of
NEC).
3
Maamum
length
is
to
prevent
more
than
a
3%
voltage
drop
between
service
entrance
and
input
terminals
of
the
welding
power
source
(Articles
210-19(a)
and
215-2(b)
of
NEC).
4
The
grounding
conductor
shall
be
colored
or
identified
as
specified
in
the
NEC.
Grounding
conductor
size
for
cop
per
wire
is
not
required
to
be
larger
than
input
conductor
(Article
250-95
of
NEC).
S~92.F
a
WARNING
ELECTRIC
SHOCK
can
kill.
~\
Do
not
touch
live
electrical
parts.
Turn
Off
welding
power
source,
and
disconnect
input
power
before
inspecting
or
installing.
Figure
2-4.
Gun
Polarity
Connections
R&.
ST-149831C
1
Gun
Securing
Knob
2
Drive
Assembly
3
Gun
End
Figure
2-5.
Gun
Connections
2-5.
Connecting
Input
Power
Ret
ST.149
629-B
OM-154
500
Page
3
a
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Turn
OFF
welding
power
source,
and
disconnect
input
power
before
inspecting
or
installing.
Have
only
qualified
electrician
install
unit.
Installation
must
meet
National
Electrical
Code
and
all
other
codes.
sw~m31
10/91
Have
only
qualified
persons
make
this
installation.
I
t8
in
(457
mm)
Open
Space
At
Front
And
Rear
For
Good
Airflow
2
Rating
Label
Supply
correct
input
power.
3
230
Volts
AC
Wall
Receptacle
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
and
grounding
conductor
in
conduit
or
equivalent
between
wall
receptacle
and
deenergized
line
disconnect
device.
Be
sure
grounding
conductor
goes
to
an
earth
ground.
6
Line
Disconnect
Device
Of
Proper
Rating
Obtain
and
install
switch
and
wall
receptacle.
7
Overcurrent
Protection
Select
type
and
size
using
Table
2-1.
Install
into
deenergized
line
disconnect
device
(fused
dis
connect
switch
shown).
8
Input
Power
Plug
Turn
Off
unit
Power
switch,
and
connect
plug
to
wall
receptacle.
ub2.2
3/92*
-
ST.149
830-B
Figure
24.
Location
And
Input
Power
Connections
OM-154
500
Page
4
2-6.
Threading
And
Feeding
Welding
Wire
AA
WARNING
CYLINDERS
can
explode
if
damaged.
Keep
cylinders
away
from
welding
and
other
electrical
circuits.
Never
touch
cylinder
with
welding
electrode.
Always
secure
cylinder
to
running
gear,
wall,
or
other
stationary
support.
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
The
welding
wire,
drive
rolls,
drive
assembly,
and
all
metal
parts
touching
the
welding
wire
are
electrically
live
when
welding
or
feeding
wire
using
gun
trigger.
Tools
Needed:
WELDING
WIRE
can
cause
puncture
wounds.
Do
not
press
gun
trigger
until
instructed
to
do
so.
Do
not
point
gun
toward
any
part
of
the
body,
other
people,
or
any
metal
when
threading
welding
wire.
HOT
SURFACES
can
burn
skin.
Allow
gun
to
cool
before
touching.
swam5.1
10191
/
swam2
1
9/91
1
Wire
Spool
2
1-lub
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
and
pull
6
in
(150
mm)
of
wire
from
spool.
3
Pressure
Adjustment
Open
pressure
assembly
4
Wire
Inlet
Guide
5
Drive
Roll
6
Wire
Outlet
Guide
Thread
wire
through
inlet
guide,
along
drive
roll
groove,
and
into
outlet
guide.
Close
pressure
assembly.
Lay
gun
cable
out
straight.
7
Nozzle
8
Contact
Tube
Remove
nozzle
and
contact
tube.
9
Gun
Trigger
Turn
On
unit,
press
gun
trigger,
and
feed
2
in
(55
mm)
of
wire
out
of
gun.
Turn
Off
unit
and
reinstall
contact
tube
and
nozzle.
10
Adjusting
Pressure
Turn
On
unit
and
check
drive
roll
pressure
by
feeding
wire
against
a
wood
board
or
concrete
surface;
wire
should
feed
steadily
without
slipping.
Tighten
pressure
adiustrnent
if
nec
essary.
Close
door.
~9/16in
R&.
ST.
149
632-C
/
S.0627.A
Figure
2-7.
FeedIng
Welding
Wire
3
9
5
6
OM-154
500
Page
5
SECTION
3
OPERATION
M
OVING
PARTS
can
cause
injury.
Keep
away
from
pinch
points
such
as
drive
rolls.
Keep
all
doors,
panels,
covers,
and
guards
closed
and
securely
in
place.
I
~
4
I
~
~
~
READ
SAFETy
BLOCKS
at
beginning
of
manual
before
proceeding.
1
2
3
/
~
1
Insulating
Gloves
2
Safety
Glasses
With
Side
Shields
3
Welding
Helmet
glasses
with
side
shields,
and
a
Wear
dry
insulating
gloves,
safety
welding
helmet
with
a
correct
shade
of
filter
(see
ANSI
Z49.1).
sb3i
10/91
ARCING
can
damage
switch.
Do
not
change
Voltage
Adjustment
switch
position
while
welding.
Arcing
inside
switch
can
damage
contacts,
causing
switch
to
fail.
Figure
3-1.
Safety
Equipment
1
Wire
Speed
Adjustment
Control
Use
control
to
select
a
wire
feed
speed.
As
Voltage
Adjustment
switch
setting
increases,
wire
speed
range
also
increases.
The
numbers
around
the
control
are
not
a
wire
feed
speed
(see
Table
3-1).
2
Voltage
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.
4
Work
Clamp
Use
wire
brush
or
sandpaper
to
clean
metal
at
weld
joint
area.
Connect
work
clamp
to
clean,
paint-free
location
on
workpiece.
as
close
as
possible
to
weld
area.
Tools
Needed:
Rf.
$1150
192-A/Ru.
81.150253a
Figure
3-2.
Controls
OM.154
500
Page
6
Table
3-1.
Suggested
Welding
Settings
Wire
Type,
Shielding
Gas,
And
Flow
Rate
Wire
Diameter
(inch)
Operator
Control
settings
Material
Thickness
1/4
in.
(6.4
mm)
3/16
in.
(4.8
mm)
1/8
in.
(3.2
mm)
14
ga.
16
ga.
18
ga.
22
ga.
24
ga.
E7OS-6
CO2
20
cfh+
.023
Voltage
4
3
2
2
1
1
1
Wire
Speed*
100
80 70
60
55
45
35
.030
Voltage
4
4
3
2
2
1
1
Wire
Speed*
80
75
60
60
50 40
30
.035
Voltage
4 4
3
2
1
1
1
Wire
Speed*
65 60 50
40 30
20
15
E7OS-6
75%
Aroon
25%
CO2
20
cfh+
.023
Voltage
4
3
2
2
1 1
1
Wire
Speed*
100
90
80
70
60
50
40
.
030
Voltage
4
3
3
2
2
1
1
Wire
Speed*
.
90
80
70
60
50
45
30
.035
Voltage
4
3
3
3
2
2
1
Wire
Speed*
75
70
60
50
40 33
25
E71T-GS
Flux
Core
.030
Voltage
3
3
2
1 1
1
Wire
Speed*
40 65
45
40
30 20
.035
Voltage
3 3
2
1 1
1
Wire
Speed*
60 50
40
30 20
10
ER
308
Stainless
Steel
Tn-Mix
20
cfh+
.023
Voltage
4
4
3
3
3
2
1
Wire
Speed*
100
100
90
85
75
70
60
.030
Voltage
4
4
3
3
2
2
Wire
Speed*
75 75
65
60
55
50
.035
Voltage
4
4
3
Wire
Speed*
60 60 50
Aluminum
Argon
30
cfii+
.030
Voltage
4
3
3
2
1 1
Wire
Speed*
90
85 80 90 90 85
.035
Voltage
4
4
3
2 2
1
Wire
Speed*
85
85 85
90
90
80
*
Do
not
change
Voltage
Adjustment
switch
position
while
welding.
Wire
Speed
Adjustment
value
in
table
is
a
starting
value
only,
and
Wire
Speed
Adjustment
control
setting
can
be
fine
tuned
during
welding.
i-cTh
=
cubic
ft
per
hour
OM.154
500
Page
7
SECTION
4-
MAINTENANCE
&
TROUBLESHOOTING
AA
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
.
Turn
Off
welding
power
source,
and
disconnect
input
power
before
inspecting,
maintaining,
or
servicing.
HOT
PARTS
can
cause
severe
burns.
Allow
cooling
period
before
maintaining
or
servicing.
~
M
OVING
PARTS
can
cause
Injury.
Keep
away
from
moving
parts.
~b
Keep
away
from
pinch
points
such
as
drive
rolls.
*~
.
Maintenance
and
troubleshooting
to
be
performed
only
by
qualified
persons.
swarn8
2
2193
Table
4-1.
Maintenance
Schedule
Time
Maintenance
Before
each
use.
Tighten
all
connections.
Check
gun
and
clean
nozzle.
After
each
spool
of
wire.
Blow
out
gun
liner.
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
of
unit.
4-1.
Thermal
Overload
Protection
If
rectifier
SR2
overheats,
thermostat
TP1
opens
stopping
all
weld
output.
If
this
condition
occurs,
the
pilot
light
next
to
the
gun
polarity
jumper
link
terminals
goes
out
and
the
fan
motor
runs.
Allow
unit
to
cool
about
15
minutes
before
trying
to
weld.
4-2.
Overload
Protection
£~
WARNING
A.
Short
Circuit
Shutdown
READ
Sectio
SAFETY
n
4
befor
BLOCKS
at
start
of
e
proceeding.
If
contact
tube
is
shorted
and
sticks
to
workpiece,
the
unit
shuts
down,
but
fan
runs.
To
resume
operation,
release
gun
trigger,
turn
Off
unit,
and
remove
contact
tube
from
workpiece.
Check
contact
tube
and
replace
if
damaged.
Turn
On
unit
to
continue
operation.
OM154
500
Page
8
B.
Motor
Fuse
Fl
4-3.
Drive
Assembly
Maintenance
READ
Sectio
SAFETY
n
4
befor
BLOCKS
at
start
of
e
proceeding.
Turn
Off
and
unplug
unit.
I
Wire
Spool
2
Gun
Contaci
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
2
7
Beaflng
Remove
bearing
as
shown.
Install
new
bearing
and
secure
with
screw.
Reinstall
arm
Onto
pin
and
secure
with
cotter
pin.
8
Screw
9
Drive
Roll
Remove
dflve
roll
as
shown.
Use
a
wire
brush
to
clean
drive
roll.
Push
drive
roll
onto
shaft
and
rein
stall
screw
and
washers.
10
Wire
Inlet
Guide
Tools
Needed:
~
Remove
guide
by
pressing
on
barbed
area
or
cutting
off
one
end
near
housing
and
pulling
it
Out
of
hole.
Push
new
guide
into
hole
from
rear
until
it
snaps
in
place.
Thread
welding
wire
(see
Section
2-6).
Close
door.
R~ST.15O193.C/ST.I55578
Figure
4-1.
Fuse
Fl
Location
Figure
4-2.
Drive
Assembly
Maintenance
OM-154
500
Page
9
4-4.
Gun
Maintenance
____________________________________________________________________________
ewemlO.t
10/91
Turn
Off
and
unplug
unit.
1
Wire
Spool
Cut
welding
wire
off
at
contact
tube.
Retract
wire
onto
spool
and
se
cure.
2
Gun
Securing
Knob
Loosen
knob
and
remove
gun
and
trigger
plug.
3
Nozzle
4
Contact
Tube
5
Head
Tube
6
Liner
Collet
Disassemble
gun
as
shown.
7
Liner
Pull
liner
from
this
end.
Blow
gun
casing
out
with
compressed
air.
Insert
new
liner
into
gun
casing
until
even
with
end
of
head
tube.
Install
collet
onto
liner.
Install
contact
tube
and
nozzle.
Insert
gun
into
feeder
and
mark
where
liner
touches
drive
roll.
Re
move
gun
and
cut
liner
off.
Rein
stall
gun
so
that
liner
is
as
close
as
possible
to
drive
rolls
without
touching.
Thread
welding
wire
(see
Section
2-6).
Close
door.
Ref.
ST.149
929-C
I
Ref.
ST.155
509
4-5.
Troubleshooting
-
READ
SAFETY
BLOCKS
at
start
of
~
1
Section
4
before
proceedIng.
____
READ
SAFETY
BLOCKS
at
Start
of
Section
4
before
proceeding.
FLYING
METAL
CHIPS
AND
DIRT
can
cause
injury
and
damage
equipment.
Point
gun
away
from
people
and
in
a
safe
direction
when
blowing
out
with
compressed
air
Tools
Needed:
3/8
in
3
5
6
7
Figure
4-3.
Gun
Maintenance
WeldIng
Trouble
No
weld
output;
wire
does
not
feed.
---S.
Rem!dy
Secure
power
cord
plug
in
receptacle.
Section
Motor
fuse
Fl
open,
replace
fuse.
Replace
building
line
fuse
or
reset
circuit
breaker
if
open
Secure
gun
trigger
plug
in
receptacle
or
repair
leads,
or
replace
trigger
switch.
No
weld
output:
wire
does
not
feed;
fan
~
-
motor
continues
to
run
and
pilot
light
is
off.
No
weld
output;
wire
feeds.
Low
weld
oiL
Thermostat
TP1
open
(overheating).
Allow
fan
to
run;
the
thermo-
~
...~
4-1
stat
closes
when
the
unit
has
cooled.
J
-~
Connect
work
clamp
to
get
good
metal
to
metal
contact.
F
-
Figure
3-2
Replace
contact
tube.
F--
-1
-~
-
Connect
unit
to
proper
Input
voltage
or
check
for
low
line
voltage.
}
-
2-5
OM-154
500
Page
10
2~O
SECTION
5
ELECTRICAL
DIAGRAMS
Figure
5-1
-
Circuit
Diagram
For
Welding
Power
Source
Section
4-4
--a
--a
--.~
---~
--a
--~
--.
--.~
2-6
2-6
4-4
4-3,
4.4
4.3
2-4
4-2
4-3,
4-4
S8-153
629
Wire
Drive/Gun
Trouble
Electrode
wire
feeding
stops
during
-.
welding.
Remedy
-a
Straighten
gun
cable
and/or
replace
damaged
parts.
Adjust
drive
roll
pressure.
Readjust
hub
tension.
Replace
contact
tube
if
blocked.
Clean
or
replace
wire
inlet
guide
or
liner
if
dirty
or
plugged.
Replace
drive
roll
or
pressure
bearing
if
worn
or
slipping
Secure
gun
trigger
plug
in
receptacle
or
repair
leads,
or
replace
trigger
switch.
Check
and
replace
Fl.
Check
and
clear
any
restrictions
at
drive
assembly
and
liner
Have
nearest
Factory
Authorized
Service
Station/Service
Distrib
utor
check
drive
motor.
T~NTT~AL
~oo
~U.Ts
220
~TS
1~O4
OM-154
500
Page
11
S2
RC3
POWER
CORD
(PLO
I)
SC-153
644
Figure
4-2.
WIring
Diagram
For
Welding
Power
Source
SECTION
6
PARTS
LIST
p.
U,
>1
.0
E
0
0
0
4
C
0
U-
1-
~O)
C.,
~
U,
C.,
C.,.
Co
CJ
C~1
U,
C.,
U,
Co
r
0)~
/
U,
I.
IA
/
/
/
/
if,
OM-154
500
Page
13
Parts
For
Main
Assembly
NOTE:
All
items
indented
by
a
got(s)
are
included
with
the
item
listed
directly
above.
1
089
899
Latch
2
134
464
Warning
Label
3
+151
565
Wrapper
126
838
Drive
Assembly
4
124817
DriveHousing
5
090 416
Hinge
Pin
6
151
828
Cotter
Hair
Pin
7
112031
PressureLever
8
090 443
Bearing
111
622
Spacer
9
092237
Knob
10
090415
Spring
11
085244
CuppedWasher
12
085242
Fastener
13
010
224
Spring
Pin
14
058
549
Wire
Guide
15
126652
Knob
16
149332
HoseClamp
17
134834
Hose
18
154
828
Drive
Roll
19
126653
NylWasher
20
111
912
Insulator
21
147573
Bracket
22
126
651
Nyl
Shldr
Washer
23
048
573
Light
24
058428
Hub
25
057 745
Spring
26
058628
Brake
Washer
27
010191
FiberWasher
28
057971
Keyed
Washer
29
057 543
Spring
30
605941
Washer
31
058
427
Retaining
Ring
32
085980
Nut
33
134
201
Stand-Off
Support
34 057
358
Bushing
35
147569
Baffle
36
108
358
Contaclor
37
157
044~
Circuit
Card
38
*125
847
Fuse,
slo-blo
12A
113
149
Housing,
14
pin
079
747
Terminal
39
072817
Relay
40
087
156
Varistor
41
155
056
Rectifier
155
054
Thermostat,
NC
026
701
Insulation
42
152
214
Terminal
Assembly
038618
Link
43
090
087
Drive
Motor
44
112583
Insulator
45
123
770
Resistor
Assembly
117
116
Resistor
46
123
768
Capacitor
47
108105
Clamp
48
Base
w/Running
Gear
152872
Base
147893
Axle
090
693
Wheel,
8
in
602
250
Washer.
.750
flat
121
614
Retaining
Ring
109318
Caster.
2.500
49
117014
Fan
Motor
50
005656
Fan
Blade
51
147572
Bracket
52
Rear
Panel
w/Cmpts
128751
Gas
Valve
605
227
.
Nyl
Nut,
gas
valve
152118
CordSet
111
443
Bushing,
cord
set
147443
RearPanel
146619
Bezel
147
548
Speed
Nut
156339
Bottle
Retainer
602
389
5
Hook
156340
Cha,n
602 384
Snap,
chain
53
147
315
Stabilizer
54
147313
Transformer
146943
Coil
55
147
576
Lower
Panel
56
Front
Panel
w/Cmpts
072 623
Potentiometer
097
922
Knob
048
482
Receptacle
w/Sockets
079534
Terminal
111
897
Rotary
Switch,
4posn
127023
Knob
116
830
~Rocker
Switch,
DPST
147
442
Front
Panel
146619
Bezel
147548
Speed
Nut
154005
Handle
154
596
Cap,
Handle
153
448
Nameplate
004
214
Bushing,
2.000mtg
111
644
Bushing,
.875mtg
57
600 325
Cable
58
026
843
Insulator
59
010368
Clamp
60
110
720
GA-16C
Gun,
(Fig
6-2)
153
714
Regulator/Flowmeter
154
829
Hose
Kit
112
863
Adapter
Fitting
113129
PVCTubing
089
120
Hose
Clamp,
.375450
+When
ordering
a
component
originally
dis
playing
a
precautionary
label,
the
label
should
also
be
ordered,
*Recommended
Spare
Parts,
Be
sure
to
provide
Model
and
Serial
Number
when
ordering
replacement
parts.
item
Part
No.
No.
Descriotion
1
110793
Handle
Assembly
110795
Head
Tube
2
110780
Nut
3
110779
Jacket
4
110781
Stop
5
128878
Adapter
6
154819
Spring
7
154826
Contact
Tube,
.023
7
154825
Contact
Tube,
.030
7
154824
Contact
Tube,
.035
8
154
822
Nozzle,
1/2
orf
8
154821
Nozzle,3/$orf
8
1
54820
Nozzle,
flat
spot
9
110794
TriggerSwitchAssembty
10
080 565
Terminal
11
110792
Cable
12
110797
Sleeve
13
154823
Liner,
.030-,035
14
120715
CoIIet,.035
15
079
974
0-Ring,
500
16
110796
Connector
17
079
878
Housing
Plug
&
Pins
079
535
Terminal
18
048834
Clamp
item
Part
I
I
Item
Part
I
Item
Part
No.
No.
-
Description
I I
No.
No.
Description
No.
No.
Description
.1
14.
17
18
ST.11O
832-0
OPTIONAL
Figure
6-2.
GA-16C
Gun
(Fig
6-1
Item
60)
OM-154
500
Page
14
-
1
-
2
-
3
-
4
-
5
-
6
-
7
-
8
-
9
-
10
-
11
-
12
-
13
-
14
-
15
-
16
-
17
-
18
-
19
-
20
MAG KD410407 Owner's manual
- Category
- Welding System
- Type
- Owner's manual
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