Forney MIG 180FI Operating Manual Download Page 7

7

 

 

any  other  flammable  material.

 

• 

Protect  flammable  walls,  ceilings,  and 

floors  with  heat resistant covers or 
shields.

 

• 

Check welding area to make sure it

 

is free of sparks, glowing metal or slag, 
and  flames  before  leaving  the  welding 
area.

 

 

FUME  HAZARDS

 

 

WARNING

 

FUMES,  GASSES, AND  VAPORS  CAN 
CAUSE  DISCOMFORT,  ILLNESS,  AND

 

DEATH! 

To  reduce  the  risk  of  discomfort,  ill- 

ness,  or  death,  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.

 

 

• 

Do not weld in an area until it is checked 

for adequate  ventilation  as  described  in 
ANSI standard  #Z49.1.  If  ventilation  is 
not adequate  to  exchange all fumes  and 
gasses generated  during  the  welding

 

process with  fresh air, do not  weld unless 
you (the  welder) and all bystanders are

 

wearing  air-supplied  respirators.

 

• 

Do not heat metals coated with, or that 

contain,  materials  that  produce  toxic

 

fumes  (such  as  galvanized  steel),  unless 
the coating is removed. Make  certain  the

 

area is  well ventilated, and the operator 
and  all  bystanders  are  wearing  air-sup-

 

plied  respirators.

 

• 

Do not weld, cut, or heat lead, zinc, cad- 

mium,  mercury,  beryllium,  or  similar  met-

 

als  without  seeking  professional  advice

 

and inspection of  the ventilation of the 
welding  area.  These  metals  produce 
EXTREMELY TOXIC  fumes  which  can 
cause  discomfort,  illness,  and  death.

 

• 

Do not weld or cut in areas that are near 

chlorinated  solvents.  Vapors  from  chlori- 
nated  hydrocarbons,  such  as  trichloroeth- 
ylene  and  perchloroethylene,  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 gasses.  Do  not 
weld or cut  where  these solvent vapors 
can be drawn into the  work area or 
where  the  ultraviolet  radiation  can  pene- 
trate  to  areas containing even very small 
amounts  of  these  vapors.

 

• 

Do not weld in a confined area unless it 

is being ventilated  or  the operator  (and 
anyone else in the area) is  wearing an 
air-supplied  respirator.

 

• 

Stop  welding  if  you  develop  momentary  

eye, nose, or throat irritation as this indi-

 

cates  inadequate  ventilation.  Stop  work

 

and  take necessary steps  to  improve 
ventilation in the  welding area. Do not

 

resume  welding  if  physical  discomfort

 

persists.

 

 

COMPRESSED  GASSES AND 
EQUIPMENT HAZARDS

 

 

WARNING 

IMPROPER 

HANDLING  AND  MAINTENANCE  OF 
COMPRESSED  GAS  CYLINDERS  AND 
REGULATORS  CAN RESULT  IN  SERIOUS

 

INJURY OR  DEATH! 

To reduce the risk of 

injury or death  from

 

compressed  gasses  and  equipment  hazards,

 

read,  understand,  and  follow  the  following 
safety  instructions.  In  addition,  make  certain 
that anyone else  who uses this  welding 
equipment or a bystander in the  welding area 
understands  and  follows  these  safety  instruc- 
tions as  well.

 

 

• 

Do not use  flammable gasses with  MIG 

welders.  Only  inert  or  nonflammable 
gasses are  suitable  for  MIG  welding. 
Examples are Carbon  Dioxide, Argon, 
Helium,  etc.  or mixtures of more than one 
of these gasses.

 

• 

Do not attempt to mix gasses or refill a 

cylinder yourself.  Do  not  expose  cylin- 
ders to excessive heat,  sparks,  slag  and 
flame, etc.  Cylinders  exposed  to  temper- 
atures above  130°F  will require  water 
spray cooling.

 

• 

Do not expose cylinders to  electricity of 

any  kind.

 

• 

Do not use a cylinder or its contents for

 

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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