INSTRUCTIONS for
MT-200cc, MT-400cc & MT-400ccEHD*
F-15-085-C
April, 1998
MIG WELDING TORCH
WITH COMMON CONNECTOR
*Extra Heavy Duty (EHD)
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation
and safe practices for arc welding equipment, we urge you to read our booklet, "Precautions and Safe Practices for
Arc Welding, Cutting and Gouging." Form 52-529. Do NOT permit untrained persons to install, operate, or maintain
this equipment. Do NOT attempt to install or operate this equipment until you have read and fully understand these
Instructions. If you do not fully understand these Instructions, contact your supplier for further information. Be
sure to read the Safety Precautions on page 3 before installing or operating this equipment.
Be sure this information reaches the operator.
You can get extra copies through your supplier.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained, and repaired in accordance with the instructions provided. This equipment must be checked periodically. Malfunctioning equipment should not be used. Parts that are
broken, missing, worn, distorted, or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone or written request for service advice be
made to the Authorized Distributor from whom purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.
The user of this equipment shall have the sole responsibility for any malfunction which results from improper use,
faulty maintenance, damage, improper repair, or alteration by anyone other than the manufacturer or a service facility
designated by the manufacturer.
TABLE OF CONTENTS
I. INTRODUCTION
1.1 Scope
.................................................................................................................
1.2 Features/Benefits
1.3 Required Equipment
1.4 Torch Accessory Guide & Selection
II. INSTALLATION
2.1 Torch Connections
2.1.1 Air-Cooled Models
III. OPERATION
.................................................................................................................
3.1 Operating Safety Precautions
3.2 Pre-Weld Requirements
3.3 Welding Procedures
3.4 Shutdown Procedure
V SERVICE
......................................................................................................................
4.1 Service Procedure
4.2 Inspect and Service Torch Regularly
4.3 Nozzles
............................................................................................................
4.4 Wire Feed Liner (except 0.023-in. liner)
4.5 0.023-in. Wire Feed Liner
4.6 Curved Wire Guide
4.7 Torch Switch
4.8 Handle and Cable Assembly
..........................................................................................................
...............................................................................................
..........................................................................................
...................................................................
............................................................................................................
.............................................................................................
.............................................................................................
............................................................................
....................................................................................
..........................................................................................
.........................................................................................
.............................................................................................
...............................................................
..........................................................
................................................................................
..........................................................................................
....................................................................................................
............................................................................
5
5
6
6
6
8
8
8
8
8
9
9
9
9
9
10
10
10
11
12
13
13
V. REPLACEMENT PARTS
............................................................................................
2
13
SAFETY PRECAUTIONS
WARNING: These Safety Precautions are for
your protection. They summarize precautionary information from the references listed in
Additional Safety Information section. Before
performing any installation or operating procedures, be
sure to read and follow the safety precautions listed below
as well as all other manuals, material safety data sheets,
labels, etc. Failure to observe Safety Precautions can result
in injury or death.
PROTECT YOURSELF AND OTHERS --
Some welding, cutting, and gouging
processes are noisy and require ear
protection. The arc, like the sun, emits
ultraviolet (UV) and other radiation and
can injure skin and eyes. Hot metal can cause burns.
Training in the proper use of the processes and equipment is essential to prevent accidents. Therefore:
1. Always wear safety glasses with side shields in any work
area, even if welding helmets, face shields, and goggles
are also required.
2. Use a face shield fitted with the correct filter and cover
plates to protect your eyes, face, neck, and ears from
sparks and rays of the arc when operating or observing
operations. Warn bystanders not to watch the arc and
not to expose themselves to the rays of the electric-arc
or hot metal.
3. Wear flameproof gauntlet type gloves, heavy long-sleeve
shirt, cuffless trousers, high-topped shoes, and a welding helmet or cap for hair protection, to protect against
arc rays and hot sparks or hot metal. A flameproof apron
may also be desirable as protection against radiated
heat and sparks.
4. Hot sparks or metal can lodge in rolled up sleeves,
trouser cuffs, or pockets. Sleeves and collars should be
kept buttoned, and open pockets eliminated from the
front of clothing
5. Protect other personnel from arc rays and hot sparks
with a suitable non-flammable partition or curtains.
6. Use goggles over safety glasses when chipping slag or
grinding. Chipped slag may be hot and can fly far.
Bystanders should also wear goggles over safety glasses.
FIRES AND EXPLOSIONS -- Heat from
flames and arcs can start fires. Hot slag
or sparks can also cause fires and explosions. Therefore:
1. Remove all combustible materials well away from the
work area or cover the materials with a protective nonflammable covering. Combustible materials include wood,
cloth, sawdust, liquid and gas fuels, solvents, paints and
coatings, paper, etc.
2. Hot sparks or hot metal can fall through cracks or
crevices in floors or wall openings and cause a hidden
smoldering fire or fires on the floor below. Make certain
that such openings are protected from hot sparks and
metal.“
3. Do not weld, cut or perform other hot work until the
workpiece has been completely cleaned so that there
are no substances on the workpiece which might produce flammable or toxic vapors. Do not do hot work on
closed containers. They may explode.
4. Have fire extinguishing equipment handy for instant use,
such as a garden hose, water pail, sand bucket, or
portable fire extinguisher. Be sure you are trained in its
use.
5. Do not use equipment beyond its ratings. For example,
overloaded welding cable can overheat and create a fire
hazard.
6. After completing operations, inspect the work area to
make certain there are no hot sparks or hot metal which
could cause a later fire. Use fire watchers when necessary.
7. For additional information, refer to NFPA Standard 51B,
"Fire Prevention in Use of Cutting and Welding Processes", available from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
ELECTRICAL SHOCK -- Contact with live
electrical parts and ground can cause
severe injury or death. DO NOT use AC
welding current in damp areas, if movement is confined, or if there is danger of
falling.
1. Be sure the power source frame (chassis) is connected
to the ground system of the input power.
2. Connect the workpiece to a good electrical ground.
3. Connect the work cable to the workpiece. A poor or
missing connection can expose you or others to a fatal
shock.
4. Use well-maintained equipment. Replace worn or damaged cables.
5. Keep everything dry, including clothing, work area, cables,
torch/electrode holder, and power source.
6. Make sure that all parts of your body are insulated from
work and from ground.
7. Do not stand directly on metal or the earth while working
in tight quarters or a damp area; stand on dry boards or
an insulating platform and wear rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the power.
9. Turn off the power before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on next page)
for specific grounding recommendations. Do not mistake
the work lead for a ground cable.
ELECTRIC AND MAGNETIC FIELDS —
May be dangerous. Electric current flowing through any conductor causes localized Electric and Magnetic Fields
(EMF). Welding and cutting current creates EMF around welding cables and
welding machines. Therefore:
1. Welders having pacemakers should consult their physician before welding. EMF may interfere with some pacemakers.
2. Exposure to EMF may have other health effects which are
unknown.
3. Welders should use the following procedures to minimize
exposure to EMF:
A. Route the electrode and work cables together. Secure
them with tape when possible.
B. Never coil the torch or work cable around your body.
C. Do not place your body between the torch and work
cables. Route cables on the same side of your body.
D. Connect the work cable to the workpiece as close as
possible to the area being welded.
E. Keep welding power source and cables as far away
from your body as possible.
11/95
3
FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in confined spaces. Do
not breathe fumes and gases. Shielding gases can cause asphyxiation.
Therefore:
1. Always provide adequate ventilation in the work area by
natural or mechanical means. Do not weld, cut, or gouge
on materials such as galvanized steel, stainless steel,
copper, zinc, lead, beryllium, or cadmium unless positive
mechanical ventilation is provided. Do not breathe fumes
from these materials.
2. Do not operate near degreasing and spraying operations. The heat or arc rays can react with chlorinated
hydrocarbon vapors to form phosgene, a highly toxic
gas, and other irritant gases.
3. If you develop momentary eye, nose, or throat irritation
while operating, this is an indication that ventilation is not
adequate. Stop work and take necessary steps to improve ventilation in the work area. Do not continue to
operate if physical discomfort persists.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below)
for specific ventilation recommendations.
CYLINDER HANDLING -- Cylinders, if
mishandled, can rupture and violently
release gas. Sudden rupture of cylinder, valve, or relief device can injure or
kill. Therefore:
1. Use the proper gas for the process and use the proper
pressure reducing regulator designed to operate from
the compressed gas cylinder. Do not use adaptors.
Maintain hoses and fittings in good condition. Follow
manufacturer's operating instructions for mounting regulator to a compressed gas cylinder.
2. Always secure cylinders in an upright position by chain
or strap to suitable hand trucks, undercarriages, benches,
walls, post, or racks. Never secure cylinders to work
tables or fixtures where they may become part of an
electrical circuit.
3. When not in use, keep cylinder valves closed. Have
valve protection cap in place if regulator is not connected. Secure and move cylinders by using suitable
hand trucks. Avoid rough handling of cylinders.
4. Locate cylinders away from heat, sparks, and flames.
Never strike an arc on a cylinder.
5. For additional information, refer to CGA Standard P-1,
"Precautions for Safe Handling of Compressed Gases in
Cylinders", which is available from Compressed Gas
Association, 1235 Jefferson Davis Highway, Arlington,
VA 22202.
EQUIPMENT MAINTENANCE -- Faulty or improperly maintained equipment can cause
injury or death. Therefore:
1. Always have qualified personnel perform the installation, troubleshooting, and maintenance work. Do not
perform any electrical work unless you are qualified to
perform such work.
2. Before performing any maintenance work inside a power
source, disconnect the power source from the incoming
electrical power.
3. Maintain cables, grounding wire, connections, power
cord, and power supply in safe working order. Do not
operate any equipment in faulty condition.
4. Do not abuse any equipment or accessories. Keep
equipment away from heat sources such as furnaces,
wet conditions such as water puddles, oil or grease,
corrosive atmospheres and inclement weather.
5. Keep all safety devices and cabinet covers in position
and in good repair.
6. Use equipment only for its intended purpose. Do not
modify it in any manner.
ADDITIONAL SAFETY INFORMATION -- For
more information on safe practices for electric arc welding and cutting equipment, ask
your supplier for a copy of "Precautions and
Safe Practices for Arc Welding, Cutting and
Gouging", Form 52-529.
The following publications, which are available from the
American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, are recommended to you:
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
5. AWS C5.5 - "Recommended Practices for Gas Tungsten
Arc Welding“
6. AWS C5.6 - "Recommended Practices for Gas Metal Arc
Welding"“
7. AWS SP - "Safe Practices" - Reprint, Welding Handbook.
8. ANSI/AWS F4.1, "Recommended Safe Practices for
Welding and Cutting of Containers That Have Held
Hazardous Substances."
This symbol appearing throughout this manual
means Attention! Be Alert! Your safety is
involved.
The following definitions apply to DANGER, WARNING,
CAUTION found throughout this manual:
Used to call attention to immediate hazards which, if not avoided, will result in
immediate, serious personal injury or loss
of life.
Used to call attention to potential hazards which could result in personal injury
or loss of life.
Used to call attention to hazards which
could result in minor personal injury.
4
I. INTRODUCTION
1.1 SCOPE
This manual provides installation, operation, service
and parts information for the MT-200cc, MT -400cc and
MT-400ccEHD air-cooled welding torch. For information on the equipment with which the torch is used,
such as power sources and wire feeders, refer to the
instruction manuals for that equipment.
1.2 FEATURES/BENEFITS
l assembles or packages available - the MT-200cc,
MT400cc "ready-to-weld" torch comes ready to
hook up to any wire feeder with a common (Eurostyle) connector.
—or, the MT-400cc EHD torch packages which
include unassembled liner, heavy duty contact
tip(s) or tube(s), and extra-heavy duty threaded
nozzle.
l lightweight extended performance - see Specifi-
cation Table 1.1.
l self-insulated slide-on nozzle design - one piece
design with insulator firmly crimped inside the
nozzle is less susceptible to burn-up.
—or, heavy-duty threaded nozzles that extend capacity .
l two-piece tip adaptor - reduces consumable costs
l heavy duty torque crimped cable design - elimi-
nates premature failure of soldered cables due to
constant flexing and subsequent work hardening
and breakage of copper conductor strands.
l contact tips, or heavy-duty contact tubes - many
of which are interchangeable with the MT-200 and
MT-400 models.
l rugged, one piece composite cable assembly-
strong lightweight and easy to manipulate,
providing outstanding comfort and flexibility welders demand.
l flame retardant design - self-extinguishing ma-
terial of high impact resistance for long life and
durability.
l enclosed torch micro-switch - provides sure long
life for millions of cycles; because the micro-switch
is enclosed, no manual cleaning of exposed contacts is required to keep the torch working.
l reversible torch screw - enables weldier to change
the trigger location (top or bottom) to the position
of his choice.
l "easy fix" design - thread-in wire guide, slide to-
gether trigger housing, and replaceable one-piece
handle and cable assembly, allowing for quick and
easy repair.
TABLE 1.1 Torch Specifications
Rated Current Capacity* Wire Sizes Available
Model CO2 Mixed Gases Accommodated Lengths
MT-200cc 300 amps 200 amps .023" to 1/16" 10', 12' or 15'
MT-400cc 400 amps 275 amps .023" to 3/32" 10', 12', 15' or 25'
MT-400cc EHD 500 amps 375 amps .035" to 3/32" 15' (a)
(a) The MT-400cc EHD torch uses HD (Heavy Duty) tips or tubes and EHD (Extra Heavy Duty) threaded nozzles to increase
current capacity to 500 amps. Using these accessories will increase the capacity of any MT-400cc torch to 500 amps (see
Fig. 1.4).
* @ 60% duty cycle (10 min. base)
5
Loading...