WELDING can cause fire or explosion.
Sparks and spatter fly off from the welding arc. The
flying sparks and hot metal, weld spatter, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode or welding wire
to metal objects can cause sparks, overheating, or
fire.
1. Protect yourself and others from flying sparks and hot metal.
2. Do not weld where flying sparks can strike flammable material.
3. Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
4. Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.
7. Do not weld on closed containers such as tanks or drums.
8. Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
11. Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
FLYING SPARKS AND HOT METAL can
cause injury.
Chipping and grinding cause flying metal. As welds
cool, they can throw off slag.
1. Wear approved face shield or safety goggles. Side shields
recommended.
2. Wear proper body protection to protect skin.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
1. Protect compressed gas cylinders from excessive heat,
mechanical shocks, and arcs.
2. Install and secure cylinders in an upright position by chaining
them to a stationary support or equipment cylinder rack to
prevent falling or tipping.
3. Keep cylinders away from any welding or other electrical circuits.
4. Never allow a welding electrode 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 away from valve outlet when opening cylinder valve.
7. Keep protective cap in place over valve except when cylinder is
in use or connected for use.
8. Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
PRINCIPAL SAFETY STANDARDS
Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American Welding
Society Standard AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501,
Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard,
Rexdale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 1430
Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51B, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Ref. sr1 2/92
TABLE OF CONTENTS
SECTION 1 – SPECIFICATIONS
SECTION 4 – MAINTENANCE & TROUBLESHOOTING
1-1. Volt-Ampere Curve And Duty Cycle Chart
1
4-1. Overload Protection
6
. . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Drive Assembly Maintenance
7
. . . . . . . . . . . . . . . . . .
SECTION 2 – INSTALLATION
4-3. Gun Maintenance
8
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Installing Work Clamp
2
4-4. Troubleshooting
8
. . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Installing Gas Supply
2
. . . . . . . . . . . . . . . . . . . . . . . .
2-3. Connecting Input Power
2
SECTION 5 – ELECTRICAL DIAGRAM
9
. . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . .
2-4. Gun Polarity For Wire Type
3
. . . . . . . . . . . . . . . . . . .
2-5. Installing Welding Gun
3
SECTION 6 – PARTS LIST
. . . . . . . . . . . . . . . . . . . . . . .
2-6. Threading And Feeding Welding Wire
4
Figure 6-1. Main Assembly
11
. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6-2. MWG-160M Gun
12
. . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 – OPERATION
5
. . . . . . . . . . . . . . . . . . . . . . .
