MasterCraft MIG 140 Instruction Manual Download Page 16 | Manualshive

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IMPOR

TANT INFORMA

TION

12

MIG 140 INVERTER WELDER 058-9305-6

General use

The Mastercraft

Maximum

®

portable MIG 140 Inverter Welder uses 120 V AC single phase,

60 Hz with a 16 A time delayed fuse or circuit breaker. This welder is ideal to weld carbon steel and
stainless steel used in hobby and light duty applications.

Guidelines for proper usage and description

Removing from carton

1. Unpack the carton, bags or Styrofoam containing the welder and accessories.
2. Check the contents with the packaging content list

page 17

-

18.

After unpacking the welder unit, inspect for any damage that may have occurred during transit.
Check for loose, missing or damaged parts. A shipping damage claim must be filed with carrier.

Welder kit components

Electrode cable connection

This connection is located on the lower front panel and connects the cable of the electrode holder
with the welder during the stick welding mode.

Electrode holder

The holder is used for holding the electrode during stick welding.

Ground cable connection

This connection is located in the lower front panel and connects the ground cable and clamp to the
welder.

Gas hose

This hose connects the welder to the gas regulator.

Gas regulator

This regulator is installed on the shielding gas cylinder to regulate gas flow during MIG welding of
solid wires.

Gas test switch

This switch checks whether shielding gas flows through the gas shroud of the welding gun.

Ground cable with clamp

The ground cable with clamp provides grounding connection for the work piece.

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Summary of Contents for MIG 140

Page 1: ...058 9305 6 MIG 140 INVERTER WELDER INSTRUCTION MANUAL ...

Page 2: ...and this instruction manual thoroughly before using the product It contains important information for your safety as well as operating and maintenance advice Keep this instruction manual for future use Should this product be passed on to a third party this instruction manual must be included MIG 140 INVERTER WELDER 058 9305 6 ...

Page 3: ...the wire tension Press the trigger on the gun Turn the drive tension adjustment knob 1 clockwise and increase the drive tension until the wire feeds smoothly without slipping page 26 steps 1 2 MC 589305 15 1 2 MC 589306 12 MC 589305 09 IGBT INVERTER WIRE FEED WELDER SOUDEUSE DEVIDOIR INVERSEUR IGBT 4 5 6 7 8 9 10 V V POWER ALIMENTA TION SPOOL GUN PISTOL ET À BOBINE MIG MI G STICK BAGUE TTE 4 STEP ...

Page 4: ... 32 refer to welding techniques Stick welding STEP 1 Plug in the electrode holder cable 1 into the electrode cable connection and attach the electrode 2 in the electrode holder 3 pages 19 20 steps 1 3 MC 589305 27 1 IGBT INVERTER WIRE FEED WELDER SOUDEUSE DEVIDOIR INVERSEUR IGBT 4 5 6 7 8 9 10 V V POWER ALIMENTATION SPOOL GUN PISTOLET À BOBINE MIG MIG STICK BAGUE TTE 4 STEP TEST GAS WIRE FIL V WOR...

Page 5: ...ng it by 1 8 and maintain the gap throughout the weld page 37 steps 1 5 MC 589306 12 MC 589305 09 IGBT INVERTER WIRE FEED WELDER SOUDEUSE DEVIDOIR INVERSEUR IGBT 4 5 6 7 8 9 10 V V POWER ALIMENTA TION SPOOL GUN PISTOL ET À BOBINE MIG MI G STICK BAGUE TTE 4 STEP TEST GAS WIR E FIL V WORK MARCHE ALARM MD 4 5 6 7 8 9 10 MIG MI G 2 STE P 058 9305 MX MIG 140 INVERTER 1 MC 589306 12 MC 589305 39 1 8 1 2...

Page 6: ...UIDE TECHNICAL SPECIFICATIONS 3 4 SAFETY GUIDELINES 5 9 KEY PARTS DIAGRAM 10 11 IMPORTANT INFORMATION 12 18 ASSEMBLY INSTRUCTIONS 19 28 OPERATING INSTRUCTIONS 29 42 MAINTENANCE 43 TROUBLESHOOTING 44 45 MAIN CIRCUIT CHART 46 EXPLODED VIEW 47 PARTS LIST 48 WARRANTY 49 50 ...

Page 7: ...RATED WORKING VOLTAGE 18 5 V RATED DUTY CYCLE 30 EFFICIENCY 85 POWER FACTOR 0 75 INSULATION CLASS H ENCLOSURE PROTECTION IP 21 S COOLING TYPE FAN COOLED WIRE USED 0 023 0 035 0 58 0 89 mm MIG wire 0 030 0 035 0 76 0 89 mm flux core wire WIRE DIAMETER 0 023 0 58 mm 0 030 0 76 mm 0 035 0 89 mm ELECTRODE DIAMETER 1 16 1 58 mm 5 64 1 98 mm DIMENSIONS L x W x H 21 39 64 x 12 39 64 x 17 19 64 55 x 32 x ...

Page 8: ...058 9305 6 CURRENT SPECIFICATION SPOOL GUN OPTIONAL SPECIFICATION DUTY CYCLE TIME 10 MINUTES WELDING CURRENT IN AMPS 30 90 100 49 CONNECTOR 4 pin quick connect power connection MOTOR VOLTAGE 24 V DC WIRE SPEED 590 min RATING 90 A w CO2 gas 65 A A Ar gas ...

Page 9: ...ate this information Note The word Note is used to inform the reader of something he she needs to know about the tool PERSONAL SAFETY These precautions are intended for the personal safety of the user and others working with the user Please take time to read and understand them DANGER Potential hazard that will result in serious injury or loss of life WARNING Potential hazard that could result in ...

Page 10: ...CSA W117 2 American Welding Society standard A6 0 Do not expose the welder to rain Always disconnect the power supply when working on internal components Do not touch the PC board without being properly grounded with a wrist strap Place the PC board in a static proof bag while shipping Make sure harmful arc rays are shielded from view of other personnel Risk of electric shock Do not touch electric...

Page 11: ...plosions in hidden areas cracks or areas that are out of vision Use a fire extinguisher in the work area Do not have any items that are combustible such as lighters or matches Connect the work lead to the weld area as close as possible to prevent any unknown unintended paths of electrical current from causing electrical shock and fire hazards To prevent any unintended arcs after welding cut off th...

Page 12: ...sing the welder Use only recommended parts for replacement Keep hands and fingers away from moving parts such as drive roll or fan while the welder is in use Avoid contacting or touching welding wire work piece ground connection or electrode from another welder Do not drape cables over or around the body Do not point MIG gun toward yourself or other personnel Consult a doctor before using the elec...

Page 13: ...standard proper gloves and protective clothing such as leather shirt coat pants and insulated footwear to prevent the skin from being exposed to hot metals UV and IR rays while welding Do not overheat or overuse the welder to prevent it from being heated Allow proper cooling time between duty cycles Always use this welder in the rated duty cycle to prevent excessive heat and failure Ensure that al...

Page 14: ...ent indicator 13 MIG gun trigger connection 6 Spool gun MIG Selector 14 MIG gun 7 Gas test switch 15 Ground cable with clamp 8 Power cord 16 Grounding cable connection MC 589305 01 IGBT INVERTER WIRE FEED WELDER SOUDEUSE DEVIDOIR INVERSEUR IGBT 4 5 6 7 8 9 10 V V POWER ALIMEN TATION SPOO L GUN PISTO LET À BOBI NE MIG M IG STICK BAG UETT E 4 STE P TEST GAS 058 9305 MX MIG 140 INVERTER WIRE V WORK M...

Page 15: ...AM 11 MIG 140 INVERTER WELDER 058 9305 6 Welder back panel No Description No Description 1 Inert gas connection 2 Power switch GAS INPUT ENTRÊE DE GAZ 110V 120V 1PH OFF ON MARCHE ARRÊT POWER PUISSANCE 2 MC 589306 03 1 ...

Page 16: ...ts A shipping damage claim must be filed with carrier Welder kit components Electrode cable connection This connection is located on the lower front panel and connects the cable of the electrode holder with the welder during the stick welding mode Electrode holder The holder is used for holding the electrode during stick welding Ground cable connection This connection is located in the lower front...

Page 17: ... This switch is located on the back panel to turn the welder ON or OFF In the OFF position there is no power supply to the MIG gun or electrode holder circuit of the welder In the ON position power is supplied to the main transformer and control circuit Always turn the power switch OFF and unplug the welder before performing any maintenance Power ON indicator This indicator is located on the upper...

Page 18: ... an arc is being drawn 2T 4T selector This selector is located on the upper front panel and used to select either 2T mode or 4T mode 2T mode This is called two tact mode in which the welding current flows only when the welding torch is kept on the work piece In this mode simply touch the work piece with the torch and hold the trigger to start the arc Continue holding the trigger while welding Rele...

Page 19: ...d coated with a layer of flux During the process of welding electrical current flows between the electrode rod and the grounded metal work piece The intense heat of the arc between the rod and the grounded metal melts the electrode and the flux The most popular electrodes are mentioned below Torch travel Refers to the movement of the welding torch along the weld joint Travel direction Refers to th...

Page 20: ...s et solidement en place Keep all doors covers and panels closed and securely in place Le fil de soudure et les pièces motrices sont peut être a la tension de soudage Ne touchez pas le fil oules parties motrices à mains nues ou avec des outils lorsque la detente est sous pression Do not touch wire or drive parts with bare hands or tools when trigger is depressed 2 4 5 1 DCEN DCEN FLUX CORE WIRE FI...

Page 21: ... Gas hose 3 m 1 5 MIG gun 1 6 Electrode holder with welding cable 1 7 MIG nozzle 1 IGBT INVERTER WIRE FEED WELDER SOUDEUSE DEVIDOIR INVERSEU R IGBT 4 5 6 7 8 9 10 V V POWER ALIMENTATION SPOOL GUN PISTOLET À BOBINE MIG MIG STICK BAGUETTE 4 STEP TEST GAS 058 9305 MX MIG 140 INVERTE R WIRE FIL V WORK MARCHE ALARM MD 4 5 6 7 8 9 10 MIG MIG 2 STEP 250 300 350 400 0 10 50 100 150 200 20 30 40 50 ...

Page 22: ...MATION 18 MIG 140 INVERTER WELDER 058 9305 6 8 Wire spool with gas shielded welding wire 0 45 kg 2 9 Contact tip 0 030 2 10 Hexagonal wrench 1 11 Electrode 10 12 Owner s manual 1 No Material name Quantity Illustration ...

Page 23: ...er the welder s power plug in any way Do not use any adapters between the welder s power cord and the electrical outlet Make sure the power switch is turned OFF before connecting the power cord to a properly grounded 120 V AC 60Hz single phase 16 A power source MC 589305 04 fig A 1 IGBT INVERTER WIRE FEED WELDER SOUDEUSE DEVIDOIR INVERSEUR IGBT 4 5 6 7 8 9 10 V V POWER ALIMENTATION SPOOL GUN PISTO...

Page 24: ...G 2 STEP 058 93 05 MX MIG 140 INVER TER MC 589305 07 fig D 1 IGBT INVERTER WIRE FEED WELDER SOUDEUSE DEVIDOIR INVERSEUR IGBT 4 5 6 7 8 9 10 V V POWER ALIMENTATION SPOOL GUN PISTOLET À BOBINE MIG MIG STICK BAGUETTE 4 STEP TEST GAS WIRE FIL V WORK MARCHE ALARM MD 4 5 6 7 8 9 10 MIG MIG 2 STEP 058 930 5 MX MIG 140 INVERT ER 2 MC 589305 08 fig E IGBT INVERTER WIRE FEED WELDER SOUDEUSE DEVIDOIR INVERSE...

Page 25: ...the proper sized grooves of the drive roll must be placed in the wire drive compartment before installing the wire 3 Insert the end of the wire into the hole 1 on the outside edge of the wire spool and bend the wire to hold it in place Remove the wire spool from the wire drive compartment fig I Note If the wire is already installed in the welder roll the wire back onto the wire spool by manually r...

Page 26: ... the below chart to select the roll groove based on the wire diameter 6 Attach the drive roll onto the drive roll shaft and tighten the drive roll onto the shaft using the wrench Note When installing the drive roll the number stamped on the drive roll should face the user 7 Close the wire drive compartment MC 589305 13 fig J 2 1 MC 589305 14 fig K 1 2 Wire diameter Roll groove 0 023 0 6 0 030 0 9 ...

Page 27: ...g the power cord from the AC power source before installing the wire Remove the wire or wire spool that is rusty This welding unit is not designed to weld work pieces thinner than 24 gauge Doing so may burn the work piece Before installing remove the old wire from the MIG gun assembly to prevent the wire from being jammed inside the gun liner Do not remove the welding nozzle when the MIG gun trigg...

Page 28: ...his time 3 Remove the adjustment knob 1 roll plate 2 and spring 3 from the hub 4 in the wire compartment Slide the wire spool 5 over the hub and secure the spring roll plate and knob sequentially fig M Note The welder can use both 4 spool and 8 spool The adjustment knob is designed to adjust the pressure tension of the wire spool 4 Place the spool on the hub with the wire passing from the bottom o...

Page 29: ...e wire with the correct groove in the drive roll 14 Fix the drive tension arm above the drive roll 15 Tighten the drive tension adjusting knob until the tension roller applies enough force on the wire to prevent it from slipping out of the drive roll 16 Plug in and turn the welder ON Set the welding voltage control to the voltage setting recommended for the gauge of the work piece Refer to the set...

Page 30: ... clamp or any grounded material during the drive tension setting process If not followed arcing will occur Do not apply back pressure on the wire without a glove Failure to comply may result in injury fig O MC 589305 18 1 WARNING Potential hazard that could result in serious injury or loss of life Do not use damaged shielding gas cylinder Doing so may cause explosion of the cylinder Never expose t...

Page 31: ...S MC 589305 19 fig P 1 IGBT INVERTER WIRE FEED WELDER SOUDEUSE DEVIDOIR INVERSEUR IGBT 4 5 6 7 8 9 10 V V POWER ALIMENTATION SPOOL GUN PISTOLET À BOBINE MIG MIG STICK BAGUETT E 4 STEP TEST GAS 058 93 05 MX MIG 140 INVER TER WIRE FIL V WORK MARCHE ALARM MD 4 5 6 7 8 9 10 MIG MIG 2 STEP MC 589305 20 fig Q 250 300 350 400 0 10 50 100 150 200 20 30 40 50 1 2 MC 589305 21 fig R 250 300 350 400 0 10 50 ...

Page 32: ...d will not be obtained Avoid unnecessary gas loss by closing the cylinder valve when finished welding Preparing the work piece 1 Make sure the surface of work piece is free from dirt rust scale oil or paint Or it will create brittle and porous weld 2 Use a metal grinder to bevel the edges of metal pieces 1 if the metal pieces to be joined are thick or heavy The correct bevel should be around 60 de...

Page 33: ...k Do not cut off the grounding prong or alter the welder s power plug in any way and do not use any adapters between the welder s power cord and the electrical outlet Make sure the power switch is turned OFF before connecting the power cord to a properly grounded 120 V AC 60Hz single phase 16 A power source Angle A 60 degrees Angle B 30 45 degrees Angle A is the angle between the nozzle and the wo...

Page 34: ...ire speed using the wire speed control 3 Hold the torch in one hand and allow the nozzle to rest on the edge of the work piece farther from the user and at angle A or angle B Refer operating instructions page 28 CAUTION Potential hazard that may result in moderate injury or damage to equipment Always maintain a distance between the nozzle and work piece If not the arc may sputter thereby affecting...

Page 35: ...peed decreases the sound that the arc makes will change from a sputtering sound to a high pitched buzzing sound If the wire speed is decreased too much the arc will again make a sputtering sound The correct setting is the point where the high pitched buzzing sound is achieved 7 Use the wire speed control to slightly increase or decrease the heat and penetration by selecting higher or lower wire fe...

Page 36: ...ddle visibility Note For a fixed heat setting when the speed is increased a decrease in penetration and a narrowing of the finished weld bead will result WARNING Potential hazard that could result in serious injury or loss of life Prolonged exposure to the welding arc can cause blindness and burns Do not perform any welding while standing kneeling or lying on the grounded area Failure to comply co...

Page 37: ...and enough travel speed For this position the torch nozzle should be kept at an angle of 30 degrees with respect to the work piece fig c Stringer bead Weave bead The stringer bead is formed by travelling with the torch in a straight line while keeping the wire and nozzle centered over the weld joint fig Z The weave bead is made by weaving the wire from side to side while moving with the torch It c...

Page 38: ... difficult welding position For this position angle A should be maintained at 60 degrees Maintaining this angle will reduce falling of molten metal into the nozzle fig e Angle B should be zero so that the wire is aiming directly into the weld joint If excessive dripping of the weld puddle occurs select a lower heat setting Stick welding operation Selection of electrode 1 Select the appropriate typ...

Page 39: ... small electrode The bead will be high and irregular fig g The arc will be difficult to maintain On selection of a large electrode The arc will burn through light metals The bead will undercut the work piece The bead will be flat and porous fig h The rod may stick to work piece Note Rate of travel over the work piece also affects the weld To ensure proper penetration and enough rod deposit the arc...

Page 40: ...mperage for light and thin metals 2 Try the intended weld on scrap metal to ensure the proper amperage determination Welding techniques Holding the electrode 1 Hold the electrode in a way that is most comfortable to work 2 Hold the electrode 1 perpendicular to the work piece 2 when striking the initial arc fig i 3 To allow good penetration with minimal spatter hold the electrode at an angle of 10 ...

Page 41: ...piece when they stick together Note A stuck electrode will cause a short circuit and the thermal overload protection will shut the welder OFF 4 Make sure the arc is accompanied by a crisp cracking sound as it indicates a proper arc 5 Move the electrode 1 downwards along required direction to lay a weld bead fig k DANGER Potential hazard that will result in serious injury or loss of life Prolonged ...

Page 42: ... weld speed The bead will be wide and tall fig o This results in the occurrence of cold joints and slag inclusions Stringer bead Weave bead The stringer bead is formed by travelling with the electrode in a straight line while keeping it centered over the weld joint fig l The weave bead is made by weaving from side to side with the electrode It can be used when needed to weld the metal over a wider...

Page 43: ... undercut the work piece The slag will be difficult to remove from the edges of the weld Guidelines for a good weld bead A solid weld bead requires that the electrode be moved slowly and steadily along the weld seam Moving the electrode rapidly or erratically will prevent proper fusion or create an uneven bead MC 589305 45 fig p MC 589305 46 fig q WARNING Potential hazard that could result in seri...

Page 44: ...rty metal scale on the finished weld Welding position 1 Flat position This position is easiest and most commonly used It is best to weld in the flat position to achieve good results fig r 2 Horizontal position It is same as flat weld except the electrode angle which should be about 30 degrees with respect to the work piece This prevents the weld puddle from running downward while allowing slow eno...

Page 45: ...nt The multiple pass beads can be laid in three passes into a T fillet joint and a lap fillet joint as shown fig u Spot welding There are three methods of spot welding 1 Burn through method In this method two overlapped metal pieces are welded together by burning through the top piece and into the bottom piece It is better to choose large diameter wire for this method Self shielding flux core wire...

Page 46: ...long each side of the lap joint seam Select the wire diameter heat setting and tune in the wire speed to lay a continuous bead fig x Instructions to be followed for spot welding 1 Select the wire diameter and heat setting recommended above for the intended method of spot welding 2 Tune in the wire speed as if a continuous weld is to be performed 3 Hold the nozzle piece completely perpendicular to ...

Page 47: ... F 120 F and relative humidity of less than 90 It is recommended to repack the welder when transporting or storing the welder Before storage clean the welder and its accessories and seal the plastic bag containing the accessories WARNING Potential hazard that could result in serious injury or loss of life Unplug the welder before performing any maintenance or service Only use the welder after repl...

Page 48: ...stantial temperature is too high 5 The welder is used over the rated duty cycle 1 Turn the power supply OFF and check the power source Restart the welder when power supply returns to normal state 2 Turn the power supply OFF and check the power source Restart the welder when power supply returns to normal state 3 Make sure the welder is placed in a properly ventilated area 4 The welder will automat...

Page 49: ...hange the power cable 3 Increase the input voltage 4 Clean or replace the liner and keep the torch cable straight Pilot arc does not form 1 Earth cable is not connected 2 Work piece is greasy dirty or rusty 1 Connect the earth cable 2 Clean the grease or the rust off the work piece Shielding gas does not flow 1 The torch is not connected properly 2 The gas pipe is bent or blocked 3 The gas system ...

Page 50: ...3 5 4 1 2 J1 2 1 3 4 D1 2 1 3 4 D2 2 1 3 4 D6 2 1 3 4 D8 VCC R16 G C T3 G C E T6 R3 R1 R18 R20 G1 E1 G2 E2 NTC1 D3 D4 D9 D7 C5 C6 C13 NTC2 AC 1 AC 2 3 4 Z1 C14 1 2 CN2 1 2 3 FAN FAN1 DB PM 02 ZKB PowerMIG 90 MB ALARM POWER WORK 1 2 3 VOLTAGE 1 2 3 WIRE FEED PowerMIG 200 KZB SW2 G1 E1 G2 E2 3 R22 C18 3 R23 C19 QF QF1 2 2 C1 C11 R10 C15 1 2 3 4 5 6 7 8 1CN6 1 2 3 4 5 6 7 8 2CN4 SW4 M M1 B2 SW3 C20 C...

Page 51: ...EXPLODED VIEW 47 MIG 140 INVERTER WELDER 058 9305 6 1 2 3 4 6 7 8 9 10 5 11 12 13 14 15 16 17 18 19 22 23 24 26 25 27 28 29 30 31 32 33 34 20 21 35 36 37 38 MC 589305 57 ...

Page 52: ...me 1 26 Welding mode selector switch 1 8 Door 1 27 2T 4T Power switch ON OFF 3 9 Door latch 1 28 Potentiometer knob 2 10 Wire spool seat 1 29 Trigger switch 1 11 Wire spool bolt 1 30 Quick connector 2 12 Spool spring 1 31 Base pads 4 13 Wire spool cover 1 32 Case base 1 14 Wire spool adjust nut 1 33 Main PC board 1 15 Insulated connector 2 34 Fan 1 16 Front panel 1 35 Back panel 1 17 Front panel c...

Page 53: ...ants vacuum bags blades belts sandpaper bits fluids tune ups or adjustments e this warranty will not apply where damage is caused by repairs made or attempted by others i e persons not authorized by the manufacturer f this warranty will not apply to any product that was sold to the original purchaser as a reconditioned or refurbished product unless otherwise specified in writing g this warranty wi...

Page 54: ...s warranty applies only to the original purchaser and may not be transferred Neither the retailer nor the manufacturer shall be liable for any other expense loss or damage including without limitation any indirect incidental consequential or exemplary damages arising in connection with the sale use or inability to use this product Notice to consumer This warranty gives you specific legal rights an...

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