Forney MIG 180FI Operating Manual Download Page 5

5

 

 

SHOCK  HAZARD

 

 

WARNING

 

ELECTRIC  SHOCK  CAN  KILL! 

To  reduce

 

the risk of death or serious injury from shock, 
read,  understand,  and  follow  the  following 
safety  instructions.  In  addition,  make  certain 
that anyone else  who uses this  welding 
equipment, or who is a bystander in the 
welding  area  understands  and  follows  these 
safety  instructions  as  well.

 

 

• 

IMPORTANT! 

TO  REDUCE THE  RISK 

OF DEATH,  INJURY,  OR  PROPERTY 
DAMAGE,  DO  NOT ATTEMPT  OPERA-

 

TION  of this  welding equipment until you 
have  read  and  understand  the  following 
safety  summary.

 

• 

Do not, in any manner, come into physi- 

cal contact  with any part of the  welding

 

current  circuit.  The  welding  current  circuit 
includes:

 

a. the work piece or any conductive

 

material  in contact  with  it,

 

b. the  ground  clamp,

 

c. the  electrode  or  welding  wire,

 

d. any metal parts  on the electrode 

holder, or  wire feed gun.

 

• 

Do not weld in a damp area or come in

 

contact with a moist or  wet surface.

 

• 

Do not attempt to weld if any part of 

clothing or body is  wet.

 

• 

Do not allow the welding equipment to

 

come in contact with water or moisture.

 

• 

Do  not  drag  welding  cables,  wire  feed 

gun,  or  welder  power  cord  through  or 
allow  them to  come into contact with

 

water  or  moisture.

 

• 

Do not touch welder, attempt to turn 

welder on or off if any part of the body or 
clothing is moist or if you are in physical

 

contact with  water or moisture.

 

• 

Do  not  attempt  to  plug  the  welder  into  the 

power  source  if  any  part  of  body  or  cloth- 
ing  is  moist,  or  if  you  are  in  physical  con- 
tact with  water  or moisture.

 

• 

Do not connect welder  work piece clamp 

to or  weld  on  electrical conduit.

 

• 

Do not alter power cord or power cord 

plug in any way.

 

• 

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 attempt to weld if 
the welder,  welding  cables,  welding  site, 
or welder power cord are exposed to any 
form of  atmospheric  precipitation,  or  salt 
water spray.

 

• 

Do not carry coiled welding cables around 

shoulders, or any other part of the body, 
when they are plugged into the welder.

 

• 

Do not  modify any  wiring, ground 

connections, switches, or  fuses  in this 
welding  equipment.

 

• 

Wear  welding gloves  to  help insulate 

hands  from  welding  circuit.

 

• 

Keep all liquid containers far enough

 

away from the welder and work area so 
that if spilled, the liquid can not possibly

 

come in contact with any part of the

 

welder or  electrical  welding circuit.

 

• 

Replace any  cracked  or  damaged  parts 

that are insulated or act as insulators

 

such as welding cables, power cord,  or 
electrode  holder  IMMEDIATELY.

 

 

FLASH  HAZARDS

 

 

WARNING

 

ARC  RAYS  CAN  INJURE  EYES AND

 

BURN SKIN! 

To reduce the risk of injury 

from  arc  rays,  read, understand,  and  follow 
the  following  safety  instructions.  In  addition, 
make certain that anyone else that uses  this 
welding equipment, or is a bystander in the 
welding  area  understands  and  follows  these 
safety  instructions  as  well.  Headshields  and 
filter should conform  to ANSI Z87.1  stan- 
dards.

 

 

• 

Do not look at an electric arc without proper 
protection. A welding arc is extremely bright 
and intense and, with inadequate or no eye 
protection, the retina can be burned, leav- 
ing a permanent dark spot in the field of 
vision. A shield or helmet with a number 10 
shade filter lens (minimum) must be used.

 

• 

Do not strike a welding arc until all 
bystanders and you (the welder) have

 

welding shields and/or helmets in place.

 

• 

Do not wear a cracked or broken

 

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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