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MAC TOOLS MW135 - User Manual

MAC TOOLS MW135
46 pages
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Processes
OM-210 089B
September 1998
MW 135 / MW 175
And GA16C2 Gun
Arc Welding Power Source And Wire
Feeder
Description
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
®

Table of Contents

Questions and Answers

  • B
    Brian BeckerAug 2, 2025
    What to do if MAC TOOLS MW135 has no weld output, wire does not feed, and the fan does not run?
    • C
      Courtney ChavezAug 2, 2025
      First, ensure the power cord is securely plugged into the receptacle. Then, check the building line fuse and replace it or reset the circuit breaker if it's open. Make sure the power switch is in the On position. Finally, for CSA models, check the circuit breaker CB and reset it if needed.
  • Z
    Zachary AlexanderAug 8, 2025
    Why is there low weld output on my MAC TOOLS Welding System?
    • J
      Jacqueline WalkerAug 8, 2025
      The low weld output might be caused by incorrect input voltage. Connect the unit to the proper input voltage or check for low line voltage. Also, ensure the voltage switch is in the desired position.
  • E
    Elizabeth ButlerAug 14, 2025
    What to do if MAC TOOLS MW135 Welding System electrode wire feeding stops during welding?
    • M
      Margaret BeasleyAug 14, 2025
      If the electrode wire feeding stops during welding, try the following: * Straighten the gun cable or replace any damaged parts. * Adjust the drive roll pressure. * Change to the proper drive roll groove. * Readjust the hub tension. * Replace the contact tip if it is blocked. * Clean or replace the wire inlet guide or liner if it is dirty or plugged. * Replace the drive roll or pressure bearing if it is worn or slipping. * Secure the gun trigger leads or repair them. * Check the circuit breaker CB or CB2 and reset if necessary. * Check and clear any restrictions at the drive assembly and liner.
  • S
    Samantha HortonAug 19, 2025
    What to do if MAC TOOLS MW135 has no weld output but wire feeds?
    • D
      Darren HolmesAug 20, 2025
      If there is no weld output but the wire feeds, ensure the work clamp has good metal-to-metal contact. Replace the contact tip. Also, check for proper polarity connections.
  • X
    xholmesAug 27, 2025
    What to do if MAC TOOLS MW135 Welding System has no weld output, wire does not feed, but fan motor continues to run?
    • J
      Joshua YoungAug 27, 2025
      If there is no weld output and the wire does not feed, but the fan motor continues to run, it might be due to thermostat S3 being open due to overheating. Allow the fan to run so the thermostat closes when the unit has cooled. Also, ensure the gun trigger leads are secure.

Summary

Safety Precautions

Symbol Usage

Explains the meaning and application of various warning symbols used in the manual.

Arc Welding Hazards

Details critical hazards like electric shock, arc rays, fire, explosion, gases, hot parts, and magnetic fields associated with arc welding.

Additional Symbols and Standards

Covers additional symbols for installation/operation and lists principal safety standards.

EMF Information

Discusses electromagnetic fields, their potential effects, and mitigation strategies.

Specifications

Model Specifications

Lists technical specifications for 120 VAC and 230 VAC models, including output, input, and dimensions.

Duty Cycle and Overheating

Explains duty cycle percentages and indicators of overheating for the welding unit.

Volt-Ampere Curves

Illustrates the minimum and maximum voltage and amperage output capabilities of the welding power source.

Installation

Gun and Gas System Setup

Instructions for installing the welding gun, changing polarity, and setting up the gas supply.

Wire Spool and Input Power Connection

Covers installing the wire spool, adjusting hub tension, and connecting input power for 120/230V models.

Threading Welding Wire

Step-by-step guide for feeding welding wire through the machine and gun assembly.

Operation

Controls and Settings

Explains the function of each control knob and switch on the welding unit.

Weld Parameters for 120;230 VAC Models

Provides recommended weld parameters (wire size, gas, voltage, speed) for various materials and applications.

Maintenance and Troubleshooting

Routine Maintenance and Overload Protection

Outlines scheduled maintenance tasks and explains the unit's overload protection system.

Gun and Wire Feed System Maintenance

Details procedures for changing drive rolls, wire guides, contact tips, and gun liners.

Troubleshooting Common Issues

A table listing common welding problems and their corresponding solutions and remedies.

Electrical Diagrams

120 VAC Model Diagrams

Provides detailed electrical circuit diagrams for the 120 VAC and 120 VAC CSA models.

230 VAC Model Diagram

Offers a detailed electrical circuit diagram for the 230 VAC model.

MIG Welding Guidelines

Process Setup and Connections

Illustrates typical MIG process connections and lists common shielding gases and their applications.

Welding Technique and Parameters

Guides on setting parameters, gun positioning, movement, bead characteristics, and weld quality.

Troubleshooting Weld Defects

Covers common weld defects like spatter, porosity, penetration, fusion, burn-through, waviness, and distortion with solutions.

Parts List

Main Assembly Parts

Lists all components and part numbers for the main welding machine assembly.

Optional Drive Rolls

Details the available optional drive rolls and their compatible wire diameters.

GA16 C2 Gun Assembly Parts

Lists all components and part numbers for the GA16C2 welding gun.

MAC TOOLS MW135 Specifications

General IconGeneral
BrandMAC TOOLS
ModelMW135
CategoryWelding System
LanguageEnglish

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