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Operating Manual

CAT. 00308 8/1/09

MIG/FLUX CORE

WIRE WELDER

180FI

Tweco

Style Torch

Infinite Wire Speed Control

Multiple Power S

Hings

Thermal Overload Protection

ds all types of:

•

Mild (Carbon) Stee

•

Stainless

•

lumi

num

•

Cast

ron

Complete & Ready to Weld

Comes with: Operating Manual,
Set-Up Chart. Spool of Flux Cored
Wire

Extra

Contact Tips, Chipping

Hammer & Brush Combo &

ding

Face

Shie

Summary of Contents for MIG 180FI

Page 1: ...e Speed Control Multiple Power SeHings Thermal Overload Protection Welds all types of Mild Carbon Steel Stainless Steel Aluminum Cast Iron Complete Ready to Weld Comes with Operating Manual Set Up Cha...

Page 2: ...Avenue Fort Collins co 80521 1 800 521 6038 forneywelding forneyind com 6 Purchaser 1 Warranty The original purchaser of the Forney Industries product The warranty is not transferable Forney Industrie...

Page 3: ...stalling the Feet 12 Selecting Shielding Gas 12 Installing the Shielding Gas 13 Check the Gas Flow 13 Align and Set the Drive Roller 14 Install the Welding Wire 14 Set the Wire Drive Tension 16 Instal...

Page 4: ...welder Failure to comply with these instructions could result in personal injury and or property damage RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE Note The following safety alert symbols identify...

Page 5: ...ay Do not attempt to plug the welder into the power source if the ground prong on power cord plug is bent over broken off or missing Do not allow the welder to be connected to the power source or atte...

Page 6: ...clothing that contains oil grease or other flammable substances Do not wear flammable hair preparations Do not weld in an area until it is checked and cleared of combustible and or flam mable material...

Page 7: ...erchloroethylene can be decomposed by the heat of an electric arc or its ultraviolet radiation These actions can cause PHOSGENE a HIGH LY TOXIC gas to form along with other lung and eye irritating gas...

Page 8: ...fails to return to the stop pin after pressure is released WARNING This product contains chemicals including lead or otherwise produces chemicals known to the State of California to cause cancer birt...

Page 9: ...ents the maximum welding time allowed The balance of the 10 minute cycle is required for cooling Your new welder has a duty cycle rating of 25 at the rated output This means that you can weld for 2 5...

Page 10: ...gun Voltage Selectors The voltage selectors control the weld heat There are six voltage heat selections available on this welder Lower voltage less heat is achieved by set ting the Voltage Selector Sw...

Page 11: ...mance an extension cord should not be used unless absolutely nec essary If necessary care must be taken in selecting an extension cord appropriate for use with your specific welder Select a properly g...

Page 12: ...he front screw holes on the bottom of the welder The curved face of the front feet should face the front of the welder 3 Insert the two Phillips head screws includ ed in the accessories bag into the h...

Page 13: ...stand and fol low all the COMPRESSED GASSES AND EQUIPMENT HAZARDS in the SAFETY SUMMARY at the front of this manual Secure your gas cylinder to the welding cart or other fixed support 1 Remove the pro...

Page 14: ...hand turning the spool counter clockwise Be careful not to allow the wire to come out of the rear end of the gun without hold ing onto it or it will unspool itself Put the end of the wire into the ho...

Page 15: ...oller or will not be able to feed at all If TOO LITTLE tension is applied the spool of wire will want to unspool itself Readjust the drive brake tension as necessary to correct for either problem 7 Af...

Page 16: ...d hand tighten securely 21 Install the nozzle on the gun assembly For best results coat the inside of the nozzle with anti stick spray or gel 22 Cut off the excess wire that extends past the end of th...

Page 17: ...tor on the inside of your welder A For Gasless FCAW welding mount the Ground Clamp ring terminal to the mounting post and the Torch ring terminal to the mounting post B For MIG GMAW welding mount the...

Page 18: ...NING IN THE WIRE SPEED This is one of the most important parts of MIG welder operation and must be done before starting each welding jobor whenever any of the following variables are changed heat sett...

Page 19: ...tempt to make any repairs on valuable equipment until you have satisfied yourself that your practice welds are of good appearance and free of slag or gas inclusions What you fail to learn through prac...

Page 20: ...s Direction and Speed A solid weld bead requires that the welding gun be moved steadily and at the right speed along the weld joint Moving the gun too fast too slow or erratically will prevent proper...

Page 21: ...still allowing slow enough travel speed to achieve good penetration A good starting point for angle B is about 30 degrees DOWN from being perpendicular to the work piece Figure 15 Horizontal Position...

Page 22: ...a bevel on the edge of one or both pieces of the metal being joined When this is done a V is created between the two pieces of metal that will have to be welded closed In most cases more than one pas...

Page 23: ...f the three spot weld meth ods In this method a hole is punched or drilled into the top piece of metal and the arc is directed through the hole to pene trate into the bottom piece The puddle is allowe...

Page 24: ...e while allowing the wire to pass through it smoothly Always use a contact tip stamped with the same diameter as the wire it will be used with Note Due to inherent variances in flux cored welding wire...

Page 25: ...liner and remove wire from gun assembly 5 Lay gun cable and gun handle straight out in front of unit 6 Remove gun liner holding clamp by removing two self tapping screws and two bolts with nuts 7 Take...

Page 26: ...cleaning cleaning the nozzle and occasionally retight ening screws there is no periodic mainte nance recommended for your welder Figure 22 Gun Assembly TROUBLESHOOTING The following TROUBLESHOOTING in...

Page 27: ...3 Wrong type or size wire 4 Poor ground connection 5 Wrong size contact tip 6 Loose gun connection or faulty gun assembly 7 Wrong welding polarity set 8 Dirty or rusty welding wire 1 Blow inside of m...

Page 28: ...J I GAS I I _ I l Ct l13 J l NO GAS I I I l J F1 F2 THERM OSTAT THERM OSTAT TIHERM OSTAT TERM OSTATOS TERM OSTATI M WIRE FEEDING M OTOR DRAHTVORSCHUB MOTOR MOTEUR D EN TRAINEMEN T DU FI L EQUIPO ARRA...

Page 29: ...CONMUTADOR COMMUTATOR 54 TORCH TRIGGER BRENNER SCHALlER BOUTON TORCHE PU LSADOR DE LA ANTORCHA PULSANTE TORC I A T1 TRANSFORM ER TRANSF ORMATOR TiRANSFORMATEUR TRANSF OR ADOR TRASFORMATORE XL CHOKE I...

Page 30: ...1 18 22205164 85251 SWITCH 17A CM 13 CS017M0 1 19 21605036 85293 CABLE CLAMP PG21 BLAC 1 20 20220120 85226 POWER CABLE 3X12AWG 2 5M 50A 6 50P 1 21 21690179 85237 SWITCH KNOB 38 1 22 22200039 85250 GRE...

Page 31: ...w 0 4 1...

Page 32: ...SWAN NECK LINER 1 85192 ISOLATING COVER FOR NECK 2 85295 TW1 TORCH DIFFUSER 1 60170 0 024 CONTACT TIP 1 60171 0 030 CONTACT TIP 1 60172 0 035 CONTACT TIP 1 85316 TORCH GAS NOZZLE 1 85313 FAST ON CONT...

Page 33: ......

Page 34: ...32 y 5 3 2 J 6 7 I I I I I _ j B I 4 12 11...

Page 35: ...ics Fine tune the arc to match travel speed and torch angl e by adjusting the wire speed to achi e ve a smooth sounding arc After installing new wire spool make sure welding I I M IN 2 r wire is inser...

Page 36: ...34 NOTES...

Page 37: ...I I S I N C E 1932...

Page 38: ...Forney Industries Inc 1 800 521 6038 www forneyind com...

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