Ausmig D260, User Manual

Page 1: ...M I G Welder n User Guide AUSMIG ...

Page 2: ...lectrical 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 Warran...

Page 3: ...age 4 page 7 Steel Stainless Steel Aluminium Non Ferrous Test of Operation Wire Tension Test Troubleshooting BASIC COMPACT LAYOUT BASIC COMPACT LAYOUT 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 Torch Connection Wire Drive Compartment Bottle Holder Transformer ...

Page 4: ...peed Control Remote Wire Drive Door Latch Removable Mounting Post Bottle Holder Digital Display Volts Amps Power Source Transformer Positive Connection 8 Metre Power Cable Remote Wire Drive Socket Power Switch Overheat Indicator Fuse 1 Amp Slow Blow Voltage Selection Negative Connection Earth Lead Clamp Gas Regulator MIG Welding Torch ...

Page 5: ...BOTTLE MOUNT Mount the bottle on the holder Secure bottle with the chain CORRECT GAS Stainless Steel Steel Aluminium Argon Shield Argon Shield Pure Argon ARGON MIX ARGON MIX Do not drop the bottle onto the machine 3 ...

Page 6: ...UN ASSEMBLY For Steel Stainless Steel liner A torch Check for any kinks Remove liner positioning nut A Lay gun and liner straight 4 LINER Ensure that the correct tip is fitted for the wire being used Disassemble torch head Unscrew Pull out A ...

Page 7: ...liner 2mm Cut excess liner leaving 2mm from the gun neck Screw positioning nut back tightly but over tension DO NOT GENTLY feed liner fully through the euro fitting of the torch 5 ...

Page 8: ...ead Slide nozzle on firmly Euro fitting Slide Together Do not allow the guide tube to touch rollers Leave 2mm gap between the two 6 Align the torch and Euro Fitting Screw in the collar until it bottoms Do not overtighten ...

Page 9: ... liner into brass spring neck tightly on the opposite end from the securing collet Unscrew liner positioning nut E Disassemble torch head GUN ASSEMBLY For Aluminium Non Ferrous GUN ASSEMBLY For Aluminium Non Ferrous Brass spring neck liner B B C D E Lay gun and liner out straight Remove steel liner if fitted 7 ...

Page 10: ...ert fully through until 2mm is protruding from the gun head Slide securing collet washer D through to the end of the euro fitting Screw back positioning nut E through the liner Do Not Overtighten DO NOT CUT EXCESS LINER YET 2mm B 8 ...

Page 11: ...ide tube from feed roller TIP use a piece of mig wire to hook and remove steel guide tube TORCH TEFLON LINER A Connect euro fitting to mig machine Re assemble torch head NOTE You MUST use aluminium contact tip ALUM 9 ...

Page 12: ...2mm Cut excess liner ensuring a 2mm space is left between roller and liner Remove torch to align brass tube LINER Using a hacksaw cut brass tube C to exactly the same length as the protruding liner 10 ...

Page 13: ... machine Check that 2mm gap is between the liner and the roller DO NOT let them touch 2 mm Slide the brass tube over the liner until 2 mm of the liner protrudes from the neck 11 Ensure a U Groove Roller is fitted Do not overtighten ...

Page 14: ...ire speed for your application Slow speed for Steel Fast for Aluminium The Switch is located on the back of the unit 15 Kg Wire Spool Spool hub Adjustment Locking Nut Locating Pin When fitting a spool of wire ensure that the locating lug is correctly aligned with the spool Do not overtighten the locking nut ...

Page 15: ... Drive Tensioner WIRE FEED ROLLERS WIRE FEED ROLLERS NOTE Liners should be blown through with compressed air every time a roll of wire is replaced Install the appropriate drive roller to match the selected wire 13 ...

Page 16: ...Feed wire through until it is 30mm into the guide tube 8 14 Return roller 1 then tensioner 2 1 2 ...

Page 17: ...ed until wire protrudes out from the gun head at approximately 300mm Twist tensioner until wire begins to roll through Plug into mains switch machine on Depress hold trigger down Adjust wire speed control knob to start wire drive rollers 1 2 3 4 5 6 9 8 7 15 ...

Page 18: ...y If wire slips through the rollers Not enough tension No wire movement Gun head Wire sways and runs through the rollers without slipping Hold wire WIRE TENSION TEST Continuous feed 16 3 3 5 Maximum Check setup if more is required ...

Page 19: ...REGULATOR ASSEMBLY Screw regulator onto gas bottle 17 Screw nut tail with gas hose connected to the regulator Remaining gas Flow rate Gas Outlet ...

Page 20: ...Slowly open the gas bottle valve 18 Screw in pressure adjustment knob until slight resistance is felt ...

Page 21: ... Adjust control knob according to 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 protect diaphragm inside the guage from damage TIP TIP 19 ...

Page 22: ...ronment you are working in After disconnecting the machine from its power source remove the side panels and with compressed air remove any dust from the transformer windings diode pack fans and switches etc Other Key components to inspect are Spool Post Check for Tension smooth operation Grease periodically Earth Lead Broken frayed cabling Damaged burnt clamp Torch Damaged lead Worn tip Diffuser T...

Page 23: ...REVERSE POLARITY 21 For wires that require reverse polarity exchange the two cables around Positive to negative Negative to positive Only available as standard equipment on TRAVELLER models Optional on compact machines ...

Page 24: ...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 tensioning Wire jumps off spool MIG WELDERS ARE A QUALITY AUSTRAL...