Sealey MIGHTYMIG100 - Manual (Page 6)

6.6.4 Push the liner lock ring (2) firmly towards the brass nut and withdraw the liner from the nut. With the torch cable as straight as possible pull the liner from
the torch cable.
6.6.5 Insert the new liner into the torch cable and secure it in the wire drive unit by replacing the torch cable clamp. See fig.11. Insert the other end of the liner
through the locking ring and fully into the brass nut in the torch head. See 2 in fig.12.
6.6.6 Check that the torch inner parts are properly seated in their respective mouldings then close the torch by inserting the tongue on the switch moulding
(fig.12-5) into the slot at the front of the other moulding. Swing the switch moulding downwards and forwards until both parts have closed around the torch
cable. Slide the ribbed ring (fig.12-1) onto the end of the torch handle and turn it clockwise to lock.
PROBLEM POSSIBLE CAUSE REMEDY
Weld current interrupted Overheating protection activated due to overload Protection automatically resets when transformer has cooled (approx. 15 min)
No weld current Rectifier blown Replace rectifier
No weld current Bad connection between clamp and workpiece Clean or grind contact surface and weld area
Break in earth lead Repair or replace earth lead
Break in torch lead Repair or replace
Feed motor not working Gear damaged or worn Replace gears
Motor defective Replace motor (Contact service agent)
Wire does not feed, feed roller rotates Pressure roller improperly adjusted Adjust tension
Dirt, copper, dust, etc. have collected in torch liner Clean the liner from the machine forward. Use compressed air. If too much dirt
Gas cup (nozzle) or tip defective Replace gas cup (nozzle) and/or tip. Check roller tension (Section 3)
Deformed wire Adjust roller tension
Wire feeds unevenly Dirt, etc, in liner Clean the liner from the machine forward using compressed air
Gas cup (nozzle) or tip defective Replace gas cup (nozzle) and/or tip
Gas cup (nozzle) spattered Clean or replace gas cup (nozzle)
Feed roller groove clogged Clean feed roller
Feed roller groove deformed Replace feed roller
Pressure roller tension incorrect Adjust tension
Unstable arc Incorrect settings Check settings
Impurities in weld area Clean and/or grind workpiece
Worn or defective gas cup (nozzle) Replace gas cup (nozzle)
Porous weld Rusty/dirty joints Clean or grind the workpiece
Torch too far from, or at wrong angle to, workpiece Gas cup to workpiece should be 8-10mm. Torch angle approx 75°
Wire sticking in gas cup (nozzle) Worn or defective gas cup (nozzle) Replace gas cup (nozzle)
Wire deformed Check roller tension
Wire speed too slow Increase wire speed
Irregular weld head Torch incorrectly held Use correct torch angle
Wire weaving in weld pool Check roller tension and adjust
Weld bead too narrow and raised Weld current too low Increase power and wire speed
Weld speed too fast Move torch slower and weave a little more
Weld bead too wide Weld current too high Increase power and wire speed
Weld speed too slow Move torch faster and weave less
Poor penetration Weld current too low Increase current and wire speed
Arc too long Bring torch closer to workpiece
Excessive penetration Weld current too high Decrease current and wire speed
Weld speed too slow Move torch faster
Incorrect distance of torch to workpiece Torch distance should be 8-10mm
7. TROUBLESHOOTING
NOTE: It is our policy to continually improve products and as such we reserve the right to alter data, specifications and component parts without prior notice.
IMPORTANT: No liability is accepted for incorrect use of this product.
WARRANTY: Guarantee is 12 months from purchase date, proof of which will be required for any claim.
INFORMATION: For a copy of our latest catalogue and promotions call us on 01284 757525 and leave your full name and address, including postcode.
01284 757500
01284 703534 [email protected]
Sole UK Distributor, Sealey Group,
Kempson Way, Suffolk Business Park ,
Bury St. Edmunds, Suffolk,
IP32 7AR
www.sealey.co.uk
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Original Language Version MIGHTYMIG100 Issue: 2 - 26/02/10