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
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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
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9
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10
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11
12
13
13
V. REPLACEMENT PARTS
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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
TABLE 1.2 Basic Torch Assemblies Available (see Fig. 5.1)*
* Basic torches do not include liners, contact tips/tubes, or nozzles. Mix and match the accessories listed in Fig. 1.4 and
1.4.1, 1.4.2, and 1.4.3 to customize a torch for your welding application.
Tables
Basic Assy./Length 10-ft. (3.0m) 12-ft. (3.6m) 15-ft. (4.5m) 25-ft. (7.5m)
MT-200cc 21091 21092 21093 --MT-400cc 21138 21139 21140 21141
1.3 REQUIRED EQUIPMENT
Heavy Duty Tips, Tubes and Nozzles improve the performance and extend the service life when used with
WIRE FEEDER
The MT-200cc and MT-400cc torch connects to any
high current applications, high spatter wires, pulsed arc
mig and when used in confined areas.
wire feeder equipped with a common (or Euro) style
connector. This quick-disconnect style connector includes power/wire, gas supply and trigger circuit connections. The required wire feeder accessories, which
Extra Heavy Duty (brass) Slide-on Nozzles provide
improved service life when subjected to extreme impact abuse.
include feed rolls and wire outlet guides, are shown in
the power source/wire feeder instruction booklet.
Extra Heavy Duty Threaded Nozzles and Heavy Duty
Tips and T ubes extend the rating of the MT -400cc from
1.4 TORCH ACCESSORY GUIDE & SELECTION -
400 amps to 500 amps @ 60% duty cycle.
Fig. 1.4, & T ables 1.4.1, 1.4.2 and 1.4.3.
Accessory Selection - Assembly Guide ..see Fig. 1.4
Standard Duty Tips and Nozzles provide good performance and service life for the majority of welding applications.
Contact Tips and Tubes.................... see T able 1.4.1
Nozzles (slip-on or threaded)............ see T able 1.4.2
Liners ............................................... see Table 1.4.3
Figure 1.4 Accessories Selection - Assembly Guide
To select correct accessories, choose tip based on wire and follow Guide Chart to determine nozzle and adaptors.
CONTACT TIPS
AND TUBES
STANDARD DUTY CONTACT TIPS
SHORT (S)
MEDIUM (M)
LONG (L)
.023" M or L .052" S or M
.030" M or L 1/16" S or M
.035" M or L 5/64" S or M
.045" - 3/64" S, M or L
HEAVY DUTY CONTACT TIPS
SHORT (S)
MEDIUM (M)
.045" - 3/64" M 1/16" M
.052"M 5/64" M
3/32" M
HEAVY DUTY CONTACT TUBES
SHORT (S)
MEDIUM (M)
.035" M 1/16" M
.045" - 3/64" M 5/64" S
.052" M 3/32" S
SEE TABLE
1.4.1
FOR PART
NUMBERS
SEE TABLE
1.4.1
FOR PART
NUMBERS
SEE TABLE
FOR PART
NUMBERS
1.4.1
SLIDE ON SELF INSULATED NOZZLES
STANDARD DUTY
#6 TAPERED #12
#8 #12 SPOT
#10
EXTRA HEAVY DUTY
THREADED NOZZLES
#8
#10
#12
#16 SPOT
SEE TABLE
1.4.2
FOR PART
NUMBERS
NOZZLES
SEE TABLE
1.4.2
FOR PART
NUMBERS
COLLET BODY
HEAVY DUTY
#8
#10
#12
#12 SPOT
TIP ADAPTOR
P/N 948785
P/N 17766 (.045" - 1/16")
P/N 948786 (5/64" - 3/32")
COLLET
P/N 17136
P/N 17135
TIP ADAPTOR
P/N 17983
EXTRA HEA VY
DUTY
#12 BRASS
STANDARD ACCESSORIES
ACCESSORIES FOR EXTENDED RATING *
P/N 17984
NOZZLE ADAPTOR
P/N 948793
P/N 17154
ADAPTORS
NOZZLE
ADAPTOR
P/N 999452
EXTRA HEA VY
DUTY
ADAPTOR
P/N 17318
MT-200cc
MT-400cc
PRIMARY USE OF ACCESSORIES
* Using Heavy Duty contact tips or tubes and Extra Duty threaded
nozzles will increase the rated capacity of the MT-400cc to 500 amps.
ALTERNATE USE OF ACCESSORIES
6
Table 1.4.1 Recommended Contact Tips, Tubes and Adaptors
Standard Duty Heavy Duty* Heavy Duty*
Wire Contact Tips Contact Tips Contact Tubes
Sizes & Type Short
1
Medium
For Hard and Cored Wires
.023 (.6mm) - 20543 999742 - - - .030 (.8mm) - 20544 996994 - - - .035 (.9mm) - 996995 996996 - - - 17163
.040 (1.0mm) - 37287 37288 - - - .045 (1.2mm) 999578u 37290u 996998u - 37286u - 37292u
.052 (1.4mm) 948340u 2075349u - - 17778u - 17155u
1/16 (1.6mm) 948341u 37289u - - 37291u - 17157u
5/64 (2.0mm) - 2075230u - 948832u - 17159u -
3/32 (2.4mm) - - - 948833u - 17161u -
For Soft (Aluminum) Wires
.023 (.6mm) - 20543 999742 - - - .030 (.8mm) - 20544 996994 - - - .030 (.8mm) - 36884
.035 (.9mm) - 996995 996996 - - - -
.035 (.9mm) - 36885 --- - .040 (1.0mm) - 37287 37288 - - - 3/64 (1.2mm) - 996999 - - 17765 17164
3/64 (1.2mm) - 36886 --- - 1/16 (1.6mm) - 996997 - - 948835 - -
Tip Adaptor for 17983 (all diameters)+ 17984 (all diameters)+ Not Available
Slide-On Nozzles
Tip Adaptor for 948785 (all diameters)² 17766 (.045"-1/16")² Collet Body 17136
Threaded Nozzles 948786 (5/64"-3/32")² Collet 17135²
1 Short contact tips are generally recommended to give proper wire stick out for flux cored wire welding.
2 Medium contact tips are generally recommended to give proper wire stick out for spray transfer Mig welding.
3 Long contact tips are generally recommended to give good visibility and proper wire stick out for dip transferring welding.
* The use of Heavy Duty tips & tubes and Extra Heavy Duty threaded nozzles extends the rating of the MT-400cc to 500 amps @ 60% duty
cycle in CO2.
+ Use with Nozzle Adaptor (999452)
² Use with Nozzle Adaptor (948793) and Extra Heavy Duty Adaptor (17318)
u New ID for limproved arc performance on steel/flux cored wire.
Notched for improved arc starting and increased tip life.
2
--- - -
Long
3
Short
1
Medium
2
Short
1
Medium
2
T ABLE 1.4.2 Recommended Nozzles Accessories
Nozzle Slide-On, Self-Insulated* Threaded+
Standard Duty Heavy Duty Extra Heavy Extra Heavy
Description I.D. Standard Long-Lifeu Standard Long-Lifeu duty (Brass) Duty
#6 Tapered 3/8 998895 998895XL - - - #8 1/2 998893 998893XL 999471 999471XL - 948767
#10 5/8 998894 998894XL 999472 999472XL - 948768
#12 3/4 - - 999473 - 17350 948769
#12 Spot 3/4 17316§ - 999625 - - #16 Spot 1 - - - - - 999900
* Slide-on, self-insulated nozzles require adaptor 999452.
+ Threaded nozzles require adaptor 17318.
§ Requires 17293 Tip Adaptor (replaces standard tip adaptor) and 17321 Nozzle Insulator.
u Long-life nozzles are coated to reduce weld spatter adherence and extend life on nozzle.
7
TABLE 1.4.3 Recommended Liners Accessories
Wire Liner
Size & Type 10' 12' 15' 2 5 '
Hard Wires & Cored Wires
.023" (.6mm) 999743* 34929* - .030" (.8mm) 948850 17717 - .035" (.9mm) 2075237 17718 2075238 18235
.045" (1.2mm) 2075237 17718 2075238 18235
.052" (1.4mm) 2075239 17719 2075240 18236
1/16" (1.6mm) 2075239 17719 2085240 18236
5/64" (2.0mm) 2075245 17720 2075246 3/32" (2.4mm) 2075245+ 17720 2075246 -
Soft Wires (aluminum)
.035" (.9mm) 948862 33931 - 3/64" (1.2mm) 948863 34932 - 1/16" (1.6mm) 19065** - - -
* Requires support liner for .023" wire. Order P/N 999797 for 10 ft. or P/N 34930 for 12 ft.
** Requires Support Liner, P/N 34930.
+ 45° curved wire guide (P/N 18243) recommended for 3/32" wire.
II. INST ALLATION
2.1 TORCH CONNECTIONS
2.1.1 AIR-COOLED MODELS
a. Install appropriate guide tube in wire feeder prior
to mounting torch. On wire feeders equipped with
quick-disconnect torch adapter, line up service and
trigger pins, insert and tighten retaining collar. (See
Table for guide tube part numbers in wire feeder
instruction booklet.)
b. The MT-200cc torch is supplied with liner and con-
tact tip for particular wire size and No. 8 nozzle
installed. If desiring to change these components
for another wire size as given in Table 1.4, refer to
the Maintenance section for instructions.
NOTE
The MT-200cc is rated to operate up to 300 amps
using CO2; 200 amps using mixed gases (60% duty
cycle).
b. The radiant energy of the arc can decompose chlo-
rinated solvent vapors, such as trichloroethylene
and perchloroethylene, to form phosgene, even
when these vapors are present in low concentrations. Do NOT weld where chlorinated solvents
are present in atmospheres in or around the arc.
c. Do NOT touch the electrode, contact tip or metal
parts in contact with them when power is ON; all
are electrically energized (HOT) and can cause a
possibly fatal shock. DO NOT allow electrode to
touch grounded metal; it will create an arc flash
that can injure eyes. It may also start a fire or
cause other damage.
d. When working in a confined space, be sure it is
safe to enter. The confined space should be tested
for adequate oxygen (at least 19%) with an approved oxygen measuring instrument. The confined space should not contain toxic concentrations
of fumes or gases. If this cannot be determined,
the operator should wear an approved air supplied
breathing apparatus.
III. OPERA TION
3.1 OPERATING SAFETY PRECAUTIONS
Comply with all ventilation, fire and other safety requirements for arc welding as established in the SAFETY
Section at the front of this manual.
Comply , also, with the following precautions:
a. Whenever welding above 250 amps, a No. 14 fil-
ter lens should be worn on your protective helmet.
Up to 250 amps, No. 11 or 12 filter lens is recommended.
Avoid gas leaks in a confined space, as the leaked
gas can dangerously reduce oxygen concentration in the breathing air.
DO NOT bring gas cylinders to confined spaces.
When leaving a confined space, shut OFF gas
supply at the source to prevent gas from leaking
into the space. Check the breathing atmosphere
in the confined space to be sure it is safe to reenter.
e. Never operate the equipment at currents greater
than the rated ampere capacity; over-heating will
occur.
8
f. Never operate equipment in damp, wet or confined
areas without suitable insulation for protection
against shock. Keep hands, feet and clothing dry
at all times.
g. Whenever the equipment is left unattended, turn
all control and power source switches and gas supplies OFF and open the main line switch.
h. Wear dark substantial clothing to protect exposed
skin from arc burn, sparks and flying hot metal.
NOTE
Correct torch position, and coating of an anti-spatter compound on all torch surfaces exposed to
spatter, reduces spatter accumulation.
IMPORTANT
Keep hoses, and cables from touching hot metal.
Do not lay torch down on hot metal.
c. To stop the arc, release the trigger.
i. Turn of f welding power before adjusting or replac-
ing electrodes, contact tips, nozzles, or contact tip
adaptors.
3.2 PRE-WELD REQUIREMENTS
Before welding, refer to feeder manual for pre-weld
requirements and checklist. Also check that:
a. Correct size liner , guide tube, contact tip and nozzle
are installed and uncontaminated by dirt or spat-
ter.
b. Wire is properly threaded through gun.
c. Nozzle is free from excessive spatter.
If all pre-weld requirements have been met for feeder
and torch, turn on all required power controls and proceed to weld.
IMPORTANT
For argon shield gas applications, copper nozzles
should be used in place of brass nozzles.
NOTE
Release the trigger, pull torch away from work only
far enough to prevent welding wire from freezing
in weld puddle. Gas will continue to flow for a short
period.
d. When putting torch down, comply with (Step c) and
CAUTION in next paragraph.
IMPORTANT
Never use torch as a hammer to remove spatter.
3.4 SHUTDOWN PROCEDURE
When welding is completed, shut down the equipment
as follows:
a. Shut OFF all power controls.
b. Turn off gas at source.
c. Place torch in safe location.
Do not allow protruding welding wire to touch a
grounded metal surface.
When the POWER is ON, and torch trigger is depressed, the electrode wire becomes electrically
HOT. Do NOT touch the wire as it may cause a
possibly fatal shock. Do NOT allow wire to touch
grounded metal surfaces other than the work to
be welded.
3.3 WELDING PROCEDURE
a. On each new application, weld trial pieces of simi-
lar metal to determine any necessary welding adjustments.
b. When the trigger is squeezed, weld wire feeds
continuously into the arc and the resulting weld
puddle is protected by the shielding gas. Protect
the arc from strong drafts which can disrupt shielding gas coverage and cause porous welds.
d. Coil or drape hose and cable without sharp bends.
IV. SERVICE
4.1 SERVICE PROCEDURE
Always shut OFF all power and gas supplies before attempting inspection, maintenance, or repair
unless otherwise instructed here. Remove main
line fuses or lock and red tag switches.
If power source is ON, electrode wire becomes electrically HOT when gun trigger is pressed, and drive
rolls start. Keep fingers clear of drive rolls. Do
NOT touch wire or metal parts contacting it or allow wire to touch grounded metal. It may cause
possibly fatal shock, fire or other damage. (See
Operating Safety Precautions in preceding section,
item 3.1).
9
Equipment which is not functioning properly should not
be used until all required repairs have been completed
and the equipment has been tested to ascertain that it
is in proper operating condition.
Inspection, troubleshooting, and repair of this equipment as indicated in this manual may ordinarily be undertaken by a competent person having at least general experience in the maintenance and repair of equipment of this nature.
No such maintenance or repair should ever be undertaken by anyone not having such qualifications.
grounded metal, it would create an arc flash. If it
should touch the body , it could cause a fatal shock.
d. Periodically remove any weld spatter or foreign
matter which has accumulated around the nozzle
orifice and contact tip. To ease spatter removal,
spray a thin film of anti-spatter compound on contact tip and nozzle before welding and reapply the
compound after cleaning of tip and nozzle.
e. Replace contact tip if worn.
f. Remove any accumulation around trigger that may
make it stick, or cause short circuits.
It is recommended that worn parts be replaced with
parts manufactured and sold by ESAB Welding & Cutting Products.
Except for inspection, troubleshooting, and repairs indicated in this manual, it is recommended that all other
servicing be done by an authorized service facility.
Contact the Distributor from whom purchased for assistance.
If so advised, the unit should be sent to the authorized
service facility, adequately packaged, in the original
shipping container, if possible, and shipped prepaid,
with a statement of the observed deficiency. Return
transportation charges are to be paid by Buyer. In all
cases other than when warranty is applicable, repairs
will be made at current list price for the replacement
part(s) plus a reasonable labor charge.
4.2 INSPECT AND SERVICE TORCH REGULARLY
a. Clean accumulated dirt from all areas, particularly
electrical parts where metallic particles can cause
short circuits. Blow out liner with compressed air
when changing wire. Compressed air should NOT
exceed 30 psig (2.1 bar).
b. Tighten loose hardware including all gas and elec-
trical connections. (Loose power connections overheat during welding).
c. Regularly inspect insulation on equipment for pos-
sible damage or wear. Check for frayed and
cracked insulation. Before using equipment again,
make necessary repairs or replace all worn or damaged insulation, hoses, cables, conduit, and connectors.
T o avoid shock, do not depress trigger while handling contact tip or nozzle parts or while disassembling torch.
4.3 NOZZLES
IMPORTANT
Do not hammer torch or nozzle to remove spatter.
Spatter can be removed from the inside of the nozzle
with a hand reamer or file. Adherence of spatter can
be minimized and removal made easier by coating the
inside of the nozzle with No. 65 Nozzle Anti-Spatter
Compound.
4.4 WIRE FEED LINER (Except 0.023-in liner, see
Section 4.4)
To remove liner for cleaning or replacement, proceed
as follows:
1. Remove nozzle, contact tip, tip adaptor and front
insulator.
2. Loosen the setscrew in the curved wire guide and
remove the liner retaining nut (21073) from the
central adaptor block (21067), and then lay the
torch cable out relatively straight.
3. Push on the liner extending from the front end of
the torch. Y ou should then be able to grab the end
of the liner at the adaptor block by hand and pull it
out of the torch keeping the cable relatively straight
while pulling.
4. Be sure to wear proper eye and face protection.
Blow out metallic chips, grit, etc. from the liner and
the handle and cable assembly with compressed
air.
With any repairs, make sure that metallic parts do
not protrude from insulation. Damaged insulation
can expose the conductor. If it should touch
NOTE: Direct the initial blast of air away from the
parts to clear moisture that occasionally accumulates in compressed air lines.
10
5. Inspect the small gas sealing O-ring (646988) on
the adaptor block. Replace it if damaged. Make
sure the O-ring is properly located in the groove.
6. Remove all burrs from the O.D. of the liner's bare
spring end (particularly if installing a new liner) to
prevent snagging while pushing the liner through
the cable.
7. With the torch cable laying straight, insert the bare
end of the liner into the adaptor body . Then push
the liner slowly through the cable. T o prevent possible kinking of the liner, it is recommended to push
it in no more than 150 mm (6-in.) at a time. An
occasional slight whip-snapping of the inlet flex
support will also facilitate liner installation as illustrated below.
b. Remove any sharp burrs on end (O.D. and I.D.)
of the spring liner. Burrs could cause wire to
bind during the feeding or the liner to sag during reinstallation into the torch.
SETSCREW
5-6 MM
(3/16" - 1/4")
11. Install tip adaptor wrench tight to seat the liner.
Then tighten the setscrew in the curved wire guide
with the supplied 5/64-in. (2mm) hex key . Do NOT
overtighten.
12. Install and tighten proper size contact tip with a
pair of pliers.
8. After seating the liner ferrule against the adaptor
block, reassemble liner retaining nut to the adaptor block and tighten firmly with a wrench.
9. If installing a used liner, it should extend beyond
the end of the curved wire guide 3/8 to 7/16-in (9
to 11mm). If short rotate the torch handle in the
counter clockwise direction as illustrated below
(white arrow) to force the liner to extend more. If
liner is extending excessively, then rotate the
handle in the clockwise direction (dark arrow).
10. If installing a new replacement liner, it should be
extending several inches past the curved wire
guide. Proceed as follows:
a. Snip off excess liner with a sharp cutting tool
so that the liner extends 3/16-in. to 1/4-in.
(5-6mm) from the face of the nozzle adaptor.
13. Install push-on nozzle. A slight rotating motion will
help slide the nozzle past the friction rings and Oring.
4.5 0.023-IN. WIRE FEED LINERS
T o install liner and support liners into the torch, use the
following procedure (refer to Figure 4.4).
1. Remove nozzle, contact tip, tip adaptor (998869)
and front insulator (999474). Back out setscrew
in wire guide until it is flush with wire guide
O.D. (This setscrew must remain in wire guide to
prevent loss of shielding gas.)
2. Remove Liner Retaining Nut (21073), this nut will
be replaced with a different retaining nut (211 19),
later in the procedure.
3. Lay torch out straight and insert support liner
(999797) from inlet end of torch. Seat liner end
fitting firmly into torch inlet.
4. Snip off excess support liner protruding from wire
guide so that it is flush with end of wire guide.
5. Remove the support liner and cut off an additional
1/2-in. (13mm). Deburr and reinstall in torch. At
this point, you may need to screw-on the new retaining nut (21 1 19) to temporarily hold the support
liner in place.
11
INNER LINER
SUPPORT LINER
DO NOT TIGHTEN
THIS SETSCREW
LINER
RETAINING
NUT
ADAPTOR BLOCK
SUPPORT
LINER
TORCH
WIRE GUIDE
1/2"
INNER LINER
END FITTING
Figure 4.4 - Installing 0.023-in. Inner and Support Liners
INNER LINER
6. With torch laying straight, insert inner liner (999743)
from torch wire guide end. Push liner in all the
way until the small brass liner fitting seats firmly
against the end of the wire guide. Reinstall front
insulator and tip adaptor.
7. Excess liner should be extending from torch inlet
end, and beyond the liner retaining nut. You can
now firmly tighten the nut to the adaptor block with
a wrench. Leaving 5/16-in. (8mm) of inner liner
extending from liner retaining nut, snip off excess
and deburr.
8. Install contact tip and tighten with a pair of pliers.
9. Install nozzle. A slight rotating motion may be required for sliding the nozzle past the friction rings
and O-ring.
5/16"
LINER RECEPTACLE
3. Remove the handle end cap (20885), wire guide
insulator (21065) unless the insulator is being replaced. The insulator should be replaced if torch
has been in service for an extended period.
4. Place the wire guide in a vise. Using an adjustable wrench, turn the torch body counterclockwise
to unscrew the wire guide.
5. Reassemble components in reverse order.
NOTE: When assembling a new curved wire guide,
ADAPTOR
SUPPORT BODY
ADAPTOR NUT
do NOT apply teflon tape or other lubricants
on the pipe threads. The threads should be
dry since the torch body threads have a film of
conductive material already applied. Assemble
the torch body to the wire guide by hand, and
then use a wrench to tighten to the desired
position.
4.6 CURVED WIRE GUIDE
To replace the curved wire guide (21064) proceed as
follows:
1. Remove the nozzle, contact tip, tip adaptor, nozzle
adaptor, front insulator, liner and shoulder ring.
2. Remove the switch housing (998858) (refer to
Section 4.6) which will expose a hex-section on
the torch body .
12
4.7 TORCH SWITCH
IMPORTANT: During the first switch replacement.
The housing should be removed and
the switch lead positions observed.
When the switch and other switch
parts are reassembled, the leads
should be returned to the original position.
To replace switch (2075220), press lever (2075214)
down then remove metal clamp (2075219) from housing (998858) by sliding it towards the rear of the torch
handle. After lifting the lever away from the handle,
remove the switch from the mounting lugs on the underside of the lever. Y ou can then disconnect the leads
from the old switch and reconnect to the new switch.
Make sure the switch is properly positioned on the
mounting lugs of the lever and then reassemble lever
and clamp. The switch is properly assembled when
you press and release the lever and hear two distinct
clicks.
4.8 HANDLE AND CABLE ASSEMBLY (See Figure
5.1)
The handle and cable assembly includes the power
cable switch leads, and gas and wire passages. The
outer jacket should be examined periodically for signs
of minor damage which may be repaired by the customer. If severe damage occurs, causing torch malfunctions, the handle and cable assembly should be
replaced.
V . REPLACEMENT PARTS
5.1 GENERAL
All replacement parts are keyed in figure 5.1. Other
replacement parts by part number and part name. Do
not order by part number alone.
The following illustrations of the equipment identify each
replacement part by part number, description and quantity used (in parentheses, if more than one).
MOLDED
RUBBER KEYS
If you desire to have the switch assembly located on
the top side of the torch handle for thumb operation of
switch, disassemble as described above but you must
also remove the plastic housing from the handle and
cut off the molded-in rubber keys (located on the underside where illustrated) with a wire cutter or some
other sharp instrument. Spread the housing apart so
that it can slide upward off the handle. Disconnect the
switch and then reconnect on the top side of handle so
that the leads can be tucked neatly into the handle
cavity . Reassemble the housing from the opposite side.
Reassemble switch components as described in the
preceding paragraph.
Some assemblies are available as a unit or as individual parts. These parts are listed below such assemblies. When any of the assembly parts is a subassembly , its individual parts are listed below it, indented
another space.
Attaching hardware items are listed below the part they
attach. They may not be shown. Order them separately.
5.2 ORDERING
To assure proper operation, it is recommended that
only genuine ESAB parts be used with this equipment.
To order replacement parts:
a. Give the part number, description and quantity of
each part required.
b. Give part number and description of equipment on
which the parts are to be used.
c. Indicate any special shipping instructions.
13
1
11
10
12
13
20
9
9A
19
7
3
4
6
17
5
14
15
16
18
21A **
14
21B **
22 **
23 **
Fig. 5.1 - Replacement Parts - MT-200cc & MT-400cc Basic Torch Assemblies
Not Included With
Basic Torch
** Denotes Items
Replacement Parts List for Figure 5.
MT-200cc Basic Torch Assembly, 10-Ft., 21091 MT-400cc Basic Torch Assembly,10-Ft., 21138
MT-200cc Basic Torch Assembly, 12-Ft., 21092 MT-400cc Basic Torch Assembly, 12-Ft., 21139
MT-200cc Basic Torch Assembly, 15-Ft., 21093 MT-400cc Basic Torch Assembly, 15-Ft., 21140
MT-400cc Basic Torch Assembly, 25-Ft., 21141
ITEM QTY. PART
NO. REQ'D. NO. DESCRIPTION
1 1 Handle and Cable Assembly:
21094 10-Ft., MT-200 (includes Handle 20829 and Cable 21097)
21095 12-Ft., MT-200 (includes Handle 20829 and Cable 21098)
21096 15-Ft., MT-200 (includes Handle 20829 and Cable 21099)
21142 10-Ft., MT-400 (includes Handle 20948 and Cable 21146)
21143 12-Ft., MT-400 (includes Handle 20948 and Cable 21147)
21144 15-Ft., MT-400 (includes Handle 20948 and Cable 21148)
21145 25-Ft., MT-400 (includes Handle 20948 and Cable 21149)
3 1 2062294 Terminal, Supplied in Pkg. of 10
(included with Item 1)
4 1 951880 Central Adaptor Block
(Includes 2-female wire connectors,
Item 5 & 6)
5 1 21073 Liner Retaining Nut (see Item 4)*
6 1 18406 O-Ring (see Item 4)
7 1 21074 Adaptor Support Screw
9 1 21069 Adaptor Support
9A 1 21068 Adaptor Nut
10 1 21070 Bayonet Ring
11 1 21071 Cable Support Sleeve
12 1 998858 Switch Housing, MT-200
1 2075745 Switch Housing, MT-400
13 1 20885 End Cap, MT-200
1 2075215 End Cap, MT-400
14 1 21065 Wire Guide Insulator, MT-200
1 999475 Wire Guide Insulator, MT-400
15 1 185W31 Shoulder Ring
16 1 21064 Curved Wire Guide, MT-200 (Includes #8-32 x 3/16"
Setscrew & a supplied (5/64" Hex Key)
1 18234 Curved Wire Guide, MT-400 (Includes #8-32 x 3/16"
Setscrew & a supplied 5/64" Hex Key)
17 1 2075220 Switch
18 1 999474 Front Insulator
19 1 2075214 Lever
20 1 2075219 Clamp
21A** 1 999452 Nozzle Adaptor (Includes O-Ring & 2-Friction Ring)
21B** 1 17983 Tip Adaptor
22** 1 - Contact Tip (See Figure 1.4 & Table 1.4.1)
23** 1 - Nozzle (See Figure 1.4 & Table 1.4.2)
* For all wire liners except .023" wire
which uses Liner Retaining Nut 21119
** Denotes Items not included with Basic Torch
15
ESAB Welding & Cutting Products, Florence, SC Welding Equipment
COMMUNICATIONS GUIDE - CUSTOMER SERVICES
A. CUSTOMER SERVICE QUESTIONS: Telephone (803) 664-5540/Fax: (800) 634-7548
Order Entry Product Availability Pricing Hours: 8:30 AM to 5:00 PM EST
Order Changes Saleable Goods Returns Delivery
Shipping Information
B. ENGINEERING SERVICE: Telephone: (803) 664-4416 / Fax : (800) 446-5693
Welding Equipment Troubleshooting Hours: 7:30 AM to 5:00 PM EST
Warranty Returns Authorized Repair Stations
C. TECHNICAL SERVICE: Telephone: (800) ESAB-123/ Fax: (803) 664-4452
Part Numbers Technical Applications Hours: 8:00 AM to 5:00 PM EST
Performance Features Technical Specifications Equipment Recommendations
D. LITERATURE REQUESTS: Telephone: (803) 664-5501 / Fax: (803) 664-5548
E. WELDING EQUIPMENT REPAIRS: Telephone: (803) 664-4469 / Fax: (803) 664-5557
Repair Estimates Repair Status Hours: 7:30 AM to 3:30 PM EST
F. WELDING EQUIPMENT TRAINING:
Telephone: (803)664-4428 / Fax: (803) 664-4476
Training School Information and Registrations Hours: 7:30 AM to 4:00 PM EST
G. WELDING PROCESS ASSISTANCE:
Telephone: (803) 664-4248 / Fax: (803) 664-4454 Hours: 7:30 AM to 4:00 PM EST
H. TECHNICAL ASST. CONSUMABLES:
Telephone: (800) 934-9353 Hours: 7:30 AM to 5:00 PM EST
Hours: 7:30 AM to 4:00 PM EST
IF YOU DO NOT KNOW WHOM TO CALL
Telephone: (800) ESAB-123/ Fax: (803) 664-4452/Web: http://www.esab.com
Hours: 7:30 AM to 5:00 PM EST
F-15-085-C 4/98 Printed in U.S.A.
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