M.I.G. Welder

TROUBLE SHOOTING

Symptom Possible Causes & Solution

User Guide

AUSMIG

REVERSE POLARITY

21

DANGER OFELECTROCUTION

BEWAREOF SMOKEAND STEAM

DO NOT USE NEAR FLAMMABLEOR EXPLOSIVE MATERIAL

BEWARE OFRAYS FROMTHE ARC

WARNINGWARNING:Protect yourself and others. Read and understand this manual.ELECTRIC SHOCK: Can kill.FUMES AND GASES: Can be dangerous to your health.ARC RADIATION: Can injure eyes and burn skin.

* Read and understand your employer's safety practices.* Keep your head out of fumes.* Use enough natural ventilation, or both, at the

fume source to keep fumes and gases from the breathing zone andthe general area

* Wear correct eye, ear and body protection.* Do not touch live electrical parts.* Refer to AS 1674 and WTIA Technical Note 7 or the manufacturer's

recommendations for further information.

* Do not change voltage selection while the torch trigger is depressed.* Wiring ! Select the correct primary power plug to suit the MIG

purchased.

* Disconnect MIG from power supply prior to servicing machine.

Rev:2.5

*IMPORTANT NOTICE*AUSMIG MIG welders are covered by a Conditional Warranty.Some Important Conditions of this Warranty are ;* The Warranty Card Must Be Filled Out And Returned To The

Manufacturer. (If you do not have a warranty card please contactyour local Distributor.)

* Any UNAUTHORISED Tampering Or Repairs To This Machine WillVoid The Warranty. Repairs To Ausmig MIG Welders Are Only To BePerformed By The Manufacturer Or Service Agent With WrittenAuthorisation.

1

CONTENTS

Bottle Mount page 3Correct Gas

Regulator Assembly

Spool Assembly

Reverse Polarity

Wire Feed Rollers

Gun Assemblypage 3

page 17

page 12

page 21

page 15

page 16

page 22

page 13

page 4

page 7- Steel / Stainless Steel

- Aluminium & Non-Ferrous

Test of Operation

Wire Tension Test

Troubleshooting

BASIC COMPACT LAYOUTBASIC COMPACT LAYOUT

Typical Control Settings

Fuse 1 Amp Slow Blow

Power Switch

Wire Speed Control

OverHeat Indicator

Votlage Selection

Earth Lead Connection

Gas Regulator

Earth lead & Clamp

MIG Welding Torch

Euro Fitting TorchConnection

Wire DriveCompartment

Bottle Holder

Transformer

2

TIP ..

19

BASIC LAYOUT : TRAVELLERBASIC LAYOUT : TRAVELLER

Wire DriveCompartment

Euro Fitting TorchConnection

Wire DriveHanging Bracket

Wire Speed Control

Remote WireDrive

Door Latch

RemovableMounting Post Bottle Holder

Digital DisplayVolts & Amps

Power Source

Transformer

PositiveConnection

8 MetrePower Cable

Remote WireDrive Socket

Power Switch

Overheat Indicator

Fuse 1 AmpSlow Blow

Voltage Selection

NegativeConnection

Earth Lead& Clamp

Gas Regulator

MIG Welding Torch

BOTTLE MOUNTBOTTLE MOUNT

Mount the bottleon the holder

Securebottle withthe chain

CORRECT GAS

Stainless Steel

Steel

Aluminium

Argon Shield

Argon Shield

Pure Argon

(ARGON MIX)

(ARGON MIX)

Do not drop the bottleonto the machine

3

GUN ASSEMBLY- For Steel / Stainless SteelGUN ASSEMBLY- For Steel / Stainless Steel

liner (A)

torch

Checkforanykinks

Remove linerpositioningnut.. *A*

Lay gun andliner straight

REGULATOR ASSEMBLY

4

LINER

Ensure that the correcttip is fitted for thewire being used.

17

Disassembletorch head..

Unscrew

Pull out

A

liner.

2mm

Cut excess liner leaving2mm from the gun neck

Screw positioningnut back tightly but

over tension.DO NOT

GENTLY feedliner fully throughthe euro fitting ofthe torch

WIRE TENSION TEST

5

Re -assembletorch head

Slide nozzle on firmly

Euro fitting

*Slide Together*

Do notallow theguide tubeto touchrollers.Leave 2mmgap betweenthe two.

6

Align the torchand Euro Fitting.

Screw in the collaruntil it “bottoms”.Do not overtighten

Startup Procedure

15

TORCH

TEFLONLINER (A)

BRASSNECKLINER

BRASSTUBE

SECURINGCOLLET

LINERPOSITIONINGNUT

A

Teflonliner (A)

Screw liner into brass springneck tightly on the oppositeend from the securing collet

Unscrew linerpositioningnut (E)

Disassembletorch head

GUN ASSEMBLY- For Aluminium & Non-Ferrous

GUN ASSEMBLY- For Aluminium & Non-Ferrous

Brass springneck liner (B)

(B)

(C)

(D)

(E)

Lay gun and linerout straight

Remove steelliner if fitted

7

WIRE FEED ROLLERS

NOTE

GENTLY feed theconnected insertfully through until2mm isprotruding fromthe gun head

Slide securingcollet & washer (D)through to the end of the euro fitting

Screw back positioningnut (E) through the liner*Do Not Overtighten*

DO NOT CUTEXCESS LINER YET!!

2mm

(B)

8 13

WIRE SPOOL ASSEMBLYRemove steel guidetube from feed roller

TIP.. use a piece of migwire to hook andremove steel guidetube

TORCH

TEFLONLINER (A)

Connect euro fittingto mig machine

Re -assembletorch head

NOTE

You MUST use aluminium contact tip

ALUM

9

TOGGLE SWITCH

2mm

Cut excess liner ensuring a2mm space is leftbetween roller and liner

Remove torch to alignbrass tube

LINER

Using a hacksaw, cut brasstube (C) to exactly the same lengthas the protruding liner

10 11

Reconnecteuro fittingto mig machine

Check that 2mm gap is betweenthe liner and the roller. DO NOTlet them touch.

2 mm

Slide the brass tube over theliner until 2 mm of theliner protrudes from the neck

11

Ensure a “U”Groove Rolleris fitted.

* Do not overtighten*

WIRE SPOOL ASSEMBLYWIRE SPOOL ASSEMBLY

TIP..

12

NOTE

9

TOGGLE SWITCHTOGGLE SWITCH

Steel

Alum

Select the appropriatewire speed for yourapplication.

Slow speed for Steel.Fast for Aluminium.

The Switch is locatedon the back of the unit.

15 Kg Wire Spool

Spool hubAdjustment

Locking NutLocating Pin

When fitting a spool of wire, ensure that thelocating lug is correctly aligned with the spool.Do not overtighten the locking nut.

ReleaseWire-DriveTensioner

WIRE FEED ROLLERSWIRE FEED ROLLERS

NOTE

Liners should be blown through withcompressed air every time a roll ofwire is replaced .

Install theappropriatedrive roller tomatch the selected wire.

13

A

GUN ASSEMBLY- For Aluminium & Non-Ferrous

Feed wire throughuntil it is 30mminto the guide tube

814 7

Return roller 1then tensioner 2

1

2

Startup ProcedureStartup Procedure

Keep trigger depresseduntil wire protrudes outfrom the gun head atapproximately 300mm

Twist tensioner until wire beginsto roll through

Plug into mains, switch machine onDepress &hold trigger down

Adjust wirespeed controlknob to startwire drive rollers

1 234

56

98 7

15

16

Twist tensioneraccordingly.

If wire slipsthrough therollers.. Notenough tension

No wiremovement..

Gun head

Wire swaysand runsthrough therollers withoutslipping

Hold wire

WIRE TENSION TEST

Continuousfeed..

16 5

3 ~ 3.5 MaximumCheck setup if more

is required.

GUN ASSEMBLY- For Steel / Stainless Steel

REGULATOR ASSEMBLY

Screw regulatoronto gas bottle

17

Screw nut & tailwith gas hose connectedto the regulator.

Remaining gas

Flow rate.

Gas Outlet.

BOTTLE MOUNT

CORRECT GAS

Slowly open the gas bottle valve.

18 3

Screw in pressure adjustment knobuntil slight resistance is felt.

NOTE:The more the control knobis screwed in, the higher the flow rate

Adjust control knob accordingto the desired flow rate

STEEL

STAINLESS STEEL

ALUMINIUM

10 - 15 l / min

10 - 15 l / min

15 - 25 l / min

When exchanging bottles,be sure to turn flow rate

control knob all the way to the left to protectdiaphragm inside the guage from damage.

TIP ..TIP ..

19

BASIC LAYOUT : TRAVELLER

1

CONTENTS

BASIC COMPACT LAYOUT

Typical Control SettingsTypical Control Settings

20

Use low voltage selection and lowwire speed for light and thinmaterials.

Increase voltage and wire speedas material thickness increases.

MACHINE MAINTENANCE

DO NOT OPERATE THE WELDER WITHTHE SIDE PANELS REMOVED.

Grinding Dust is the greatest enemy of any machineand the frequency for cleaning your machine isdependant on the environment you are working in.After disconnecting the machine from its power source,remove the side panels, and with compressed air removeany dust from the transformer windings, diode pack, fansand switches etc.

Other Key components to inspect are :

Spool Post ~ Check for Tension / smooth operationGrease periodically

Earth Lead ~ Broken / frayed cablingDamaged / burnt clamp

Torch ~ Damaged leadWorn tip / Diffuser / Tip holder / Nozzle

Do not touch components or wiringwhile panels are removed.

Drive System ~ Tension (Average setting 3)Drive rollers - check for wearGuide tube alignment / wear*DO NOT LUBRICATE*

REVERSE POLARITYREVERSE POLARITY

21

For wires that require reverse polarity,exchange the two cables around .Positive (+) to negative (-),Negative (-) to positive (+).Only available as standardequipment on TRAVELLER models;Optional on compact machines .

WARNING

TROUBLE SHOOTINGTROUBLE SHOOTING

Symptom Possible Causes & SolutionPossible Causes & Solution

Too porous,

bubbly..Faulty gun

Windy area

Faulty gauge

Insufficient or out of gas

Rusty or Contaminated material

Dirty linerNo liner

Large build-up (3-phase only)

phase out

or

diode out

Incorrect polarity

Poor power

Long extension

leadLoss of powerWire speed

too fastNo Penetration Loose cables

Incorrect polarity

Tighten rollers

Exceeded duty cycle

Thermal protection cutout

Loss of primary power

Wrong size rollers

Not enough wire

tension

Wrong size tip

Liner cut too short

Wire Slips

Machine not

running

Wire burning

through to the

tip

(sticks to it)

Dirty liner

Dirty liner

Incorrect roller

size

22

Spool hub

needs tensioningWire jumps off

spool

MIG WELDERS ARE A QUALITY

AUSTRALIAN MADE PRODUCT.

FOR MORE INFORMATION PLEASE CONTACT,

AUSLINK WELDING EQUIPMENT P/L

23 RESEARCH DRIVE CROYDON

PH 03 9761.4915 FAX 03 9761.4916

AUSMIG

Blown Fuse

Liner is kinked