MIG 140Si
OWNER’S MANUAL
WARNING:
Read carefully and understand all
ASSEMBLY AND OPERATION
INSTRUCTIONS
before operating. Failure to follow the safety rules and other
basic safety precautions may result in serious personal injury.
Item# 44725
Page 1: ...MANUAL WARNING Read carefully and understand all ASSEMBLY AND OPERATION INSTRUCTIONS before operating Failure to follow the safety rules and other basic safety precautions may result in serious personal injury Item 44725 ...
Page 2: ... Gun 44453 for welding aluminum with 4 spools of aluminum wire Welding with flux core wire gives the operator the flexibility to use this wire feed welder for mobile applications including outdoor applications Flux core wire does not require the use of a separate shielding gas which can be blown away by the wind in outdoor applications Since flux core welding does not use shielding gas the operato...
Page 3: ...g in free from flammable materials Always keep a fire extinguisher accessible to your welding environment Always have a qualified person install and operate this equipment Make sure the area is clean dry and ventilated Do not operate the welder in humid wet or poorly ventilated areas Always have your welder maintained by a qualified technician in accordance with local state and national codes Alwa...
Page 4: ... excessive heat and failure 1 4 Specific Areas of Danger Caution or Warning Electrical Shock Electric arc welders can produce a shock that can cause injury or death Touching electrically live parts can cause fatal shocks and severe burns While welding all metal components connected to the wire are electrically hot Poor ground connections are a hazard so secure the ground lead before welding Wear d...
Page 5: ...ing Warn people in your welding area when you are going to strike an arc so they can protect themselves Fire Hazards Do not weld on containers or pipes that contain or have had flammable gaseous or liquid combustibles in them Welding creates sparks and heat that can ignite flammable and explosive materials Do not operate any electric arc welder in areas where flammable or explosive materials are p...
Page 6: ...e cylinder upright to a cart or stationary object Keep cylinders away from welding or electrical circuits Use the proper regulators gas hose and fittings for the specific application Do not look into the valve when opening it Use protective cylinder cap whenever possible 1 5 Proper Care Maintenance and Repair Always have power disconnected when working on internal components Do not touch or handle...
Page 7: ...reaker The MIG 140SI features an infinite voltage control for fine turning of the welding arc It also features a spot weld timer thermal overload protection and is spool gun ready The MIG 140Si is capable of MIG welding steel and stainless steel with the correct shielding gas Use the optional Quick Draw Spool Gun 44453 for best results when MIG welding aluminum This unit welds between 24 gauge and...
Page 8: ...TOR When normal MIG welding this switch should be turned in MIG position When using the spool gun the switch should be in spool gun position SPOT TIME ADJUSTMENT The Spot Time Adjustment allows you to set a time from 0 1 sec to 9 9 seconds for consistent spot welds MIG TORCH The welding wire is driven through the welding cable and torch to the work piece It is attached to the drive system The trig...
Page 9: ...ain the bolt sets down into the retaining groove on the back of the MIG torch 1 4 Connect the 5 Pin trigger connection on the MIG torch to the 5 Pin trigger receptacle on the front panel 1 5 Connect the ground cable to the Negative weld output connection for MIG welding If welding with self shielded flux core connect the ground cable to the Positive weld output connection and move the Weld Power C...
Page 10: ...3 The trigger connection is the 5 Pin snap on connector 2 3 We recommend removing the MIG torch when the Spool Gun is connected to avoid accidental arcing Loosen the wing nut retaining bolt and slide the MIG torch out of the front of the machine Disconnect the 5 Pin trigger connection on the front of the machine 2 4 Carefully slide the gas connector and the weld power connection through the weld c...
Page 11: ...trical Shock High voltage danger from power source Consult a qualified electrician for proper installation of receptacle This welder must be grounded while in use to protect the operator from electrical shock Do not remove grounding prong or alter the plug in any way Do not use any adapters between the welder s power cord and the power source receptacle Make sure the POWER switch is OFF when conne...
Page 12: ...end it over to hold the wire in place Remove the spool of wire from the drive compartment of the welder 3 4 Remove the drive roller by turning the drive roll knob 3 counter clockwise Carefully slide the drive roll assembly off of the drive shaft This drive roll assembly consist of three pieces The outer drive roll inner drive roll and a key Take care to keep from misplacing the key 3 5 Based on th...
Page 13: ... Remove the nozzle and contact tip from the end of the torch assembly 4 2 2 Make sure the proper groove on the drive roller is in place for the wire installed If not change the drive roller as described in Section 3 4 2 3 Remove the packaging from the spool of wire and then identify the leading end of the wire secured on the edge of the spool DO NOT UNHOOK IT AT THIS TIME 4 2 4 Place the spool on ...
Page 14: ...ent portion of the wire using a wire cutter 4 2 9 Loosen the tension adjusting knob holding the drive tension arm in place and lift the tension arm up off the drive roller 4 2 10 Insert the wire into the inlet guide tube feed it across the drive roller and into the torch assembly about six inches Make certain that the welding wire is actually going into the torch liner If not the wire will jam up ...
Page 15: ...mp or any grounded material during the drive tension setting process or arcing will occur 5 1 Press the trigger on the torch 5 2 Turn the drive tension adjustment knob clockwise until the wire seems to feed smoothly without slipping 6 GAS INSTALLATION Shielding gas cylinders and high pressure cylinders can explode if damaged so treat them carefully Never expose cylinders to high heat sparks open f...
Page 16: ... scale on the gauge NOTE Slowly open the cylinder valve by turning it counterclockwise until the cylinder pressure gauge registers on the first gauge of the regulator Turn the adjustment knob clockwise right slowly to increase gas flow to 20 cfm To reduce the gas flow turn the adjustment counterclockwise left The gas valve is located on the back panel of the welder and activated by the trigger Gas...
Page 17: ...OL The wire speed control adjusts the speed at which the wire is fed out of the welding torch The wire speed needs to be closely matched tuned in to the rate at which it is being melted off Some things that affect wire speed selection are the type and diameter of the wire being used the heat setting selected and the welding position to be used Refer to the label inside the welder side door for rec...
Page 18: ...e work piece See HOLDING THE TORCH section if you are uncertain of the angle at which you will be welding 7 4 Set the wire feed speed based on the thickness of material and the set up chart on the back side of the wire feeder door 7 5 Lower your welding helmet and pull the trigger on the torch and let the wire feed into the work piece to start an arc then begin to drag the torch toward you 7 6 LIS...
Page 19: ... take advantage of the greater weld puddle visibility Travel speed is the rate at which the torch is being pushed or pulled along the weld joint For a fixed heat setting the faster the travel speed the lower the penetration and the lower and narrower the finished weld bead Likewise the slower the travel speed the deeper the penetration and the higher and wider the finished weld bead 8 2 Types of w...
Page 20: ...t for angle B is about 30 degrees DOWN from being perpendicular to the work piece VERTICAL POSITION It is easier for many people to Pull the torch from top to bottom It can be difficult to prevent the puddle from running downward Pushing the torch from bottom to top may provide better puddle control and allow slower rates of travel speed to achieve deeper penetration When vertical welding angle B ...
Page 21: ...have to be welded closed In most cases more than one pass or bead will need to be laid into the joint to close the V Laying more than one bead into the same weld joint is known as a multiple pass weld The illustrations in following figure show the sequence for laying multiple pass beads into a single V butt joint NOTE WHEN USING SELF SHIELDING FLUX CORE WIRE it is very important to thoroughly chip...
Page 22: ...acceptable Always select the HIGH heat setting with the burn through method and tune in the wire speed prior to making a spot weld 2 The PUNCH AND FILL METHOD produces a weld with the most finished appearance of the three spot weld methods In this method a hole is punched or drilled into the top piece of metal and the arc is directed through the hole to penetrate into the bottom piece The puddle i...
Page 23: ...the trigger until a desired spot weld is made 6 Make spot welds on the actual work piece at desired locations MAINTENANCE Maintain your KLUTCH MIG 140Si It is recommended that the general condition of any KLUTCH MIG 140Si be examined before it is used Keep your KLUTCH MIG 140Si in good repair by adopting a program of conscientious repair and maintenance Have necessary repairs made by qualified ser...
Page 24: ...Too Much or Too Little Wire Tension See Installing The Wire Section Too Much or Too Little Drive Roll Tension See Setting Drive Roll Tension Section Drive Roll is Worn Replace Drive Roll Can Not Create An Arc Work Piece is Painted Or Rusty Remove All Paint And Rust Ground Clamp Is Connected Where There Is Paint Or Rust Remove All Paint And Rust So Ground Clamp Is Connected To Bare Metal Ground Cla...
Page 25: ...Page of 27 25 DIAGRAM PARTS LIST ...
Page 26: ...03 40 323 TRIGGER RECEPTACLE 1 18 1 2 08 02 0471 GROUND CABLE AND CLAMP 1 19 1 2 08 04 0120 MIG TORCH 1 20 2 30 08 188 CONTACT TIP 1 21 2 20 04 501 MIG NOZZLE 1 22 2 07 11 016 POTENTIOMETER KNOB 3 23 2 03 30 765 SPOT WELD ON OFF SWITCH 1 24 2 03 40 320 WELD GUN SELECTOR SWITCH 1 25 1 1 01 05 3039 FRONT PANEL 1 26 1 1 05 07 0114 FRONT PANEL PC BOARD 1 27 1 1 02 01 8831 MIDDLE BOARD 1 28 1 1 01 02 8...
Page 27: ...for Northern Tool Equipment welding carts and welding cabinets This warranty covers the absence of or defective parts 1 year Parts and Labor on MIG gun parts except those listed under normal wear items cables regulator plasma torch except those listed under normal wear items Any shipping related to warranty repair is the responsibility of the customer 1 year 3 year Please see your product informat...
