Thermal Arc Fabricator 140 Service Manual Download Page 1

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Art # A-07923

FABRICATOR

PORTABLE MIG WELDING MACHINE

140

Service Manual

Revision No:

Issue Date:

Janua

y 25, 2008

Manual No.:

0-4992

Operating Features:

180

Summary of Contents for Fabricator 140

Page 1: ...Art A 07923 FABRICATOR PORTABLE MIG WELDING MACHINE 140 Service Manual Revision No AA Issue Date January 25 2008 Manual No 0 4992 Operating Features 180...

Page 2: ......

Page 3: ...Lebanon New Hampshire USA 03784 603 298 5711 www thermalarc com Copyright 2008 by Thermadyne Industries All rights reserved Reproduction of this work in whole or in part without written permission of...

Page 4: ...2 1 2 04 General 2 2 2 05 Machine Specifications 2 3 2 06 Volt Amp Curves 2 4 2 07 Duty Cycle 2 5 2 08 Fabricator 180A MIG Gun 2 6 2 09 Installing a New Wire Liner 2 7 2 10 MIG Gun Maintenance 2 7 SEC...

Page 5: ...on Guide 4 12 4 15 Gas Selection for Gas Metal Arc Welding 4 14 SECTION 5 BASIC TROUBLESHOOTING 5 1 5 01 Cleaning of the Unit 5 1 5 02 Cleaning of the Feed Rolls 5 1 5 03 Basic Troubleshooting 5 1 5 0...

Page 6: ...05 Power Supply 7 4 7 06 Wire Feeder Parts 7 6 7 07 Feed Plate Parts 7 8 7 08 Accessories 7 10 APPENDIX 1 OPTIONS AND ACCESSORIES A 1 APPENDIX 2 FABRICATOR 180 SYSTEM SCHEMATIC A 2 APPENDIX 3 FABRICA...

Page 7: ...ned spaces or damp locations do not use a welder with AC output unless it is equipped with a voltage reducer Use equipment with DC output 14 Wear a safety harness to prevent falling if working above f...

Page 8: ...quipment can cause fires and burns Accidental contact of electrode or welding wire to metal objects can cause sparks overheating or fire 1 Protect yourself and others from flying sparks and hot metal...

Page 9: ...armful exhaust gases 1 Use equipment outside in open well ventilated areas 2 If used in a closed area vent engine exhaust outside and away from any building air intakes WARNING ENGINE FUEL can cause f...

Page 10: ...offer clear science based advice on strategies to minimize or avoid potential risks To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or...

Page 11: ...Welding GMAW Increase Decrease Circuit Breaker AC Auxiliary Power Remote Duty Cycle Percentage Amperage Voltage Hertz cycles sec Frequency Negative Positive Direct Current DC Protective Earth Ground...

Page 12: ...i sous ten sion d s la mise en marche En soudage automatique ou semi automatique avec fil ce dernier le rouleau ou la bobine de fil le logement des galets d entrainement et toutes les pi ces m talliqu...

Page 13: ...vaillez dans un espace confin que s il est bien ventil sinon portez un respirateur adduction d air Les gaz protecteurs de soudage peuvent d placer l oxyg ne de l air et ainsi causer des malaises ou la...

Page 14: ...urs non huileux tels des gants en cuir une chemise paisse un pantalon revers des bottines de s curit et un casque AVERTISSEMENT LES ETINCELLES ET LES PROJECTIONS BRULANTES PEUVENT CAUSER DES BLESSURES...

Page 15: ...ls anti tincelles pour travailler sur un accumulateur 4 N utilisez pas une source de courant de soudage pour charger un accumulateur ou survolter momentan ment un v hicule 5 Utilisez la polarit correc...

Page 16: ...e Intensit de Courant Tension Hertz cycles sec Fr quence N gatif Positif Courant Continue DC Terre de Protection Ligne Connexion de la Ligne Source Auxiliaire Classement de Prise Source Auxiliaire Art...

Page 17: ...g to the Thermal Arc web site listed below and clicking on the Literature Library link http www thermalarc com 2 02 Equipment Identification The unit s identification number specification or part numb...

Page 18: ...arc welding Does not require the use of a shielding gas As delivered from the factory the Fabricator 140 is set up for 024 0 6mm diameter solid wire and the Fabricator 180 is set up for 030 0 8mm dia...

Page 19: ...4V 19 5 38V Output Current Range 30 140A 30 180A Duty Cycle Period Number of Output Voltage Values 4 6 Minimum Mains Circuit to suit factory fitted Plug Lead Weld Current Duty Cycle 15A 65A 40 21A 130...

Page 20: ...36 38 40 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 V out I out Fabricator 140 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 0 10 20 30 40 50 60 70 80 90 100 110 120 1...

Page 21: ...r 2 5 minutes out of every 10 minute period During the other 7 5 minutes of the 10 minute period the Fabricator 180 must idle and be allowed to cool The thermal cutout will operate if the duty cycle i...

Page 22: ...ator 180A MIG Gun has an operating capacity in excess of the capacity of the FABRICATOR and can be expected to give trouble free service Item Description Part No Size 1 Nozzle 21 50 11 23 023 0 6mm 11...

Page 23: ...or plug and the new raw end extends through the end of the conductor tube assembly 4 the outlet guide 10 in the connector plug must be securely tightened onto the liner to prevent its backward movemen...

Page 24: ...FABRICATOR 140 180 INTRODUCTION Manual 0 4992 2 8 January 25 2008...

Page 25: ...requires a 230VAC supply voltage The Fabricator 140 s power cord is equipped with a NEMA 5 15P plug and will only connect to a NEMA 5 15P receptacle The Fabricator 180 s power cord is equipped with a...

Page 26: ...m falling over If an optional portable mounting arrangement is used follow the instructions that are provided with it 2 Remove Cylinder Cap Remove the large metal cap on top of the cylinder by rotatin...

Page 27: ...ICATOR 140 180 January 25 2008 3 3 Manual 0 4992 1 Art A 07965 Cap 2 Shielding Gas Cracking 3 Shielding Gas Regulator and Flow Meter 4 Shielding Gas Shielding Gas 1 1 8 5 Gas Hose Figure 3 1 Gas Cylin...

Page 28: ...downstream of the regulator must be opened to obtain a true flow rate reading on the outlet gauge Welding power source must be triggered Close the valves after the pressure has been set Art A 07280 Fi...

Page 29: ...o the power source by first routing the switch lead through the access hole in the front panel followed by the gun cable see Figure 3 3 NOTE Turn the cable end to align the gas hose nipple on the conn...

Page 30: ...polarity DCEP 1 Open the door to the machine 2 Remove the polarity terminal knobs 3 Set up the polarity as per Table 3 1 above by removing the leads from the terminals and reversing them if necessary...

Page 31: ...n 3 09 Installing Wire Spool As delivered from the factory the unit is set for an 4 102mm spool Installation of 4 102mm Spool Assemble parts in sequence shown in Figure 3 6 from right to left 1 Spool...

Page 32: ...turn the spool 3 10 Feedrolls A feedroll consists of two different sized grooves As delivered from the factory the drive roll is installed for 023 0 6mm for the Fabricator 140 and 030 035 0 8mm 0 9mm...

Page 33: ...lines up with the hole in the spool When the spool of wire is in place replace the spool retaining pin NOTE The hub tension has been pre adjusted at the factory However if adjustment is required simp...

Page 34: ...t the proper groove is being used Fig 3 11 5 Pass the wire into the Gun Liner of the Gun Cable End Fig 3 11 6 Close the Pressure Arm Fig 3 11 7 Close the Pressure Adjust Device Tighten it to a snug co...

Page 35: ...Voltage Control Switch set to 1 0 1 2 3 4 5 6 OFF Art A 08338 Figure 3 13 Power ON 3 Set the wire feed speed to half way or 5 Art A 08339 Figure 3 14 Wire Speed Half way 4 Straighten the gun cable Re...

Page 36: ...FABRICATOR 140 180 INSTALLATION Manual 0 4992 3 12 January 25 2008...

Page 37: ...ctions and Warnings chapter included in this manual Neglect of these precautions may result in personal injury WARNING Make all connections to the power source including electrode and work cables as w...

Page 38: ...feed motor 2 The Voltage Control Switch sets the voltage level to theweldingterminalsasitisrotatedintheclockwise direction There are 4 positions available in the Fabricator140and6positionsintheFabric...

Page 39: ...ON FABRICATOR 140 180 January 25 2008 4 3 Manual 0 4992 Weldskill F A B R I C A T O R F A B R I C A T O R 180 80 0 1 2 3 4 5 6 OFF 1 2 4 3 5 6 8 9 Art A 07916 14 10 11 12 13 7 Figure 4 1 Fabricator Co...

Page 40: ...roper lenses installed See Safety Instructions and Warnings chapter included in this manual Neglect of these precautions may result in personal injury Travel at a speed necessary to maintain a bead wi...

Page 41: ...tal Molten Slag Solid Weld Metal Slag Art A 05104 Figure 4 3 FCAW Process 4 06 Basic Welding Technique General Two different welding processes are covered in this section with the intention of providi...

Page 42: ...times Always wear the welding helmet with proper filter lenses CAUTION Do not pull the welding gun back when the arc is established This will create excessive wire extension stickout and make a very p...

Page 43: ...n cause the desired change in the bead formation They are 1 Stickout distance between the end of the contact tube tip and the end of the electrode wire Keep this at about 3 8 10mm stickout as shown in...

Page 44: ...structions and Warnings chapter included in this manual 4 11 Welding Procedure 1 Maintain the tip to work distance stickout at 5 16 to 3 8 8 to 9mm at all times 2 For transverse and longitudinal nozzl...

Page 45: ...3 Leading 2 Increase 5 Larger 4 Ar CO2 mix Larger Bead 1 Increase 2 Decrease 3 Increase Smaller Bead 2 Decrease 2 Increase 3 Decrease Higher Narrower Bead 1 Decrease 2 Trailing 3 Increase Flatter Wid...

Page 46: ...5 CO2 023 0 6mm 030 0 8mm 023 0 6mm 030 0 8mm 75 Ar 25 CO2 25cfh Aluminum Aluminum 100 Ar 25cfh 030 0 8mm 035 0 9mm Steel Flux Core E71T GS None Required 030 0 8mm 035 0 9mm Steel ER70S 6 Solid or har...

Page 47: ...7 1 7 3 1 2 1 1 2 1 1 5 2 4 4 4 3 1 1 1 1 1 4 2 2 7 3 2 4 1 1 1 1 1 5 1 4 1 5 1 1 1 1 1 1 1 5 2 3 5 3 2 2 5 5 3 5 3 2 2 5 3 5 2 5 2 1 5 3 5 2 1 7 1 4 2 1 4 1 3 1 4 1 5 1 1 2 3 4 4 4 4 4 4 4 4 4 4 4 3...

Page 48: ...CO2 025 0 6mm 030 0 8mm 035 0 9mm Aluminum Aluminum 100 Ar 25cfh 030 0 8mm 035 0 9mm Steel Flux Core E71T GS None Required 045 1 2mm 030 0 8mm 035 0 9mm Steel ER70S 6 Solid or hard 100 CO2 25cfh 023 0...

Page 49: ...8 3 1 4 1 1 1 1 1 1 6 1 4 1 6 1 5 1 1 1 1 1 1 1 6 1 9 3 5 6 5 10 5 3 7 4 3 7 10 6 4 5 3 5 5 5 4 3 3 3 3 2 4 5 5 2 5 2 2 3 1 7 3 5 2 1 6 1 5 1 4 2 1 5 1 4 1 4 1 2 1 6 1 5 1 3 1 3 5 5 10 5 5 6 5 5 5 5 5...

Page 50: ...our Good mechanical properties Greater than 3 32 See Note 1 Spray transfer 92 Argon 8 CO2 Flat HV Fillet Reduces undercutting Higher deposition rates and improved bead wetting Deep penetration and goo...

Page 51: ...has not fractured and that it is connected to the MIG torch adaptor 4 Welding in a windy environment a Shield the weld area from the wind or increase the gas flow 5 Welding dirty oily painted oxidized...

Page 52: ...utlet guides a Wire will rub against the misaligned guides and reduces wire feedability 5 Liner blocked with slag a Slag is produced by the wire passing through the feed roller if excessive pressure i...

Page 53: ...Increase joint angle or gap C Shielding gas incorrect C Change to a gas which gives higher penetration 3 Lack of fusion Voltage too low Increase voltage by increasing voltage selection switch positio...

Page 54: ...preheating part to be welded or cool slowly 7 Cold weld puddle A Faulty rectifier unit A Have an Accredited THERMAL ARC Service Agent to test then replace the faulty component B Loose welding cable c...

Page 55: ...lty control PCB B Have an Accredited THERMAL ARC Service Agent investigate the fault 4 Wire feeds when the MIG Gun trigger switch is depressed but arc can not be established Poor or no work lead conne...

Page 56: ...FABRICATOR 140 180 BASIC TROUBLESHOOTING Manual 0 4992 5 6 January 25 2008...

Page 57: ...from the positive Polarity Change Over terminal 5 Open the PRESSURE ADJUST DEVICE so the wire will not feed 6 With the Primary Line Disconnect in the OFF position plug the input power cord into the p...

Page 58: ...mately 4 VDC to 20 VDC C Remove the jumper and the meter from J6 and re install MIG gun plug P6 This completes the Spool Gun Control Test If the above steps were correct proceed to the next section Ou...

Page 59: ...terminals J3 to JFM If voltage measures at 120 VAC for Fabricator 140 or 230 VAC for Fabricator 180 replace the fan D Green AC LED is on fan turns OVERTEMP LED is on 1 The unit is overheated a Allow t...

Page 60: ...the unit 2 Defective solenoid a Replace the solenoid C AC LED is on and the fan is on When the MIG gun switch is closed gas flows feed roll does not turn output voltage is measures 21 VDC 1 Defective...

Page 61: ...side cover 1 Disconnect and isolate the black wire from the negative capacitor terminal A Refer to Figure 6 1 2 Disconnect and isolate the transformer wire from terminal AC1 Refer to Figure 6 1 3 Usin...

Page 62: ...ion T1 Secondary Voltage 1 15 2 18 3 21 4 25 Fabricator 180 Voltage Control Switch SW1 position T1 Secondary Voltage 1 17 2 19 3 21 4 23 5 26 6 31 6 13 C1 C2 Test Procedure Use a Capacitor Tester if a...

Page 63: ...illustration and a corresponding list of parts which contains a breakdown of the equipment into assemblies subassemblies and detail parts Most parts of the equipment are listed except commercially ava...

Page 64: ...i Part Number Helvi Part Number Helvi Part Number 1 1 Bezel Front Molding F140 180 W7004018 2 1 Bushing Torch F140 180 W7004016 3 1 Panel Front Fab140 W7004044 3 1 Panel Front Fab180 W7004045 4 1 Clam...

Page 65: ...iption Description Part Number Part Number Part Number Part Number Part Number 1 1 Clamp Cable D20 F140 180 W7004003 1 1 Clamp Cable M25X1 5 Fab180 W7004013 2 1 Bezel Rear Molding F140 180 W7004019 3...

Page 66: ...8 Rectifier 140A Fab140 W7004032 4 1 D1 D8 Rectifier 180A Fab180 W7004033 5 1 Panel Top Side F140 180 W7004042 6 1 SOL 1 Solenoid Valve 110V60Hz Fab140 W7004036 6 1 SOL 1 Solenoid Valve 230V60Hz Fab18...

Page 67: ...PARTS LISTS FABRICATOR 140 180 January 25 2008 7 5 Manual 0 4992 1 2 3 4 5 6 7 8 9 10 11 12 Art A 08258...

Page 68: ...014 2 1 Handle F140 180 W7004012 3 1 Panel Internal F140 180 W7004048 4 1 Drive Roll 023 030 035 0 6 0 8 0 9mm 7977036 5 1 Wire Feed Plate Fab140 W7004054 5 1 Wire Feed Plate Fab180 W7004055 6 1 Screw...

Page 69: ...PARTS LISTS FABRICATOR 140 180 January 25 2008 7 7 Manual 0 4992 1 2 3 4 5 6 7 8 9 11 12 10 13 Art A 08259...

Page 70: ...Part Number Part Number 1 1 Motor Pinion F140 180 W7004200 2 1 Arm Pressure F140 180 W7004201 3 1 Pressure Roll F 140 180 W7004202 4 1 Key Drive Spacer F140 180 W7004203 5 1 Screw Fix Drive Roll F140...

Page 71: ...PARTS LISTS FABRICATOR 140 180 January 25 2008 7 9 Manual 0 4992 Art A 08276_AB 1 8 8 8 8 See Appendix 1 and 4 for more options 4 7a 7b 7c 7d 7e 6 6 10 11 11 11 12 3 5 12 12 12 2 2 4 7...

Page 72: ...Ref Ref Des Des Des Des Des Description Description Description Description Description Part Number Part Number Part Number Part Number Part Number 1 1 Alternative Firepower Regulator 0781 9851 2 1 T...

Page 73: ...2723 Medalist 1400 Series HRF Flowmeter Regulator Argon Argon CO2 mix gases Victor Regulator Flowmeter CO2 0781 2725 Medalist 1400 Series HRF Flowmeter Regulator CO2 gas CONSUMABLES Feedroll Kits Feed...

Page 74: ...AC 1PH 60Hz SW1 FAN V V M M TS1 COM COM GUN SW YELLOW GREEN B1 B TS1 T1 TS1 T1 WIRE SPEED WIRE SPEED TS1 DIODE HEATSINK 3 TS1 DIODE HEATSINK 3 CB1 CB1 SOL1 SOL1 GND GND OVERTEMP OVERTEMP J4 J4 T1 T1 1...

Page 75: ...4W 5 2 CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS uF Chk App TITLE Last Modified Size SCHEMATIC INDUSTRIAL PARK 2 WEST LEBANON NH 03784 603 298 5711 A THERMADYNE COMPANY RevCode Tuesday July 24 200...

Page 76: ...V V M M TS1 COM COM GUN SW FAN 120 VAC 60Hz SW1 PCB1 WHT BLK GRN YELLOW GREEN AC AC J3 J3 J5 J5 1 2 3 4 5 6 7 8 OVERTEMP OVERTEMP CB1 CB1 SW1 SW1 R L1 4 3 2 1 L1 L1 T1 T1 1 2 3 4 J2 J2 A1 A B1 B F1 F1...

Page 77: ...4W 5 2 CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS uF Chk App TITLE Last Modified Size SCHEMATIC INDUSTRIAL PARK 2 WEST LEBANON NH 03784 603 298 5711 A THERMADYNE COMPANY RevCode Tuesday July 24 200...

Page 78: ...35 045 0 9 1 2mm Hard Wire 7977731 Feed Roll 030 035 0 8 0 9mm Soft Wire 7977732 Feed Roll 030 035 0 8 0 9mm Cored Wire 7977264 704277 Feed Roll 045 1 16 1 2 1 6mm Cored Wire W7004022 Size visible whe...

Page 79: ......

Page 80: ...herwise shall not exceed the price of the goods upon which such liability is based No employee agent or representative of Thermal Arc is authorized to change this warranty in any way or grant any othe...

Page 81: ...d components including but not limited to relays switches contactors solenoids fans electric motors 1 year 1 year PLASMA WELDING EQUIPMENT WARRANTY PERIOD LABOR Ultima 150 Original Main Power Magnetic...

Page 82: ......

Page 83: ...trict Shanghai PR 200052 Telephone 86 21 69171135 Fax 86 21 69171139 Thermadyne Asia Sdn Bhd Lot 151 Jalan Industri 3 5A Rawang Integrated Industrial Park Jln Batu Arang 48000 Rawang Selangor Darul Eh...

Page 84: ...World Headquarters Thermadyne Holdings Corporation Suite 300 16052 Swingley Ridge Road St Louis MO 63017 Telephone 636 728 3000 FAX 636 728 3010 Email sales thermalarc com www thermalarc com...

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