2. INTRODUCTION & SPECIFICATIONS
IMPORTANT:
These instructions contain the information you require to prepare your machine for welding, together with maintenance and a trouble shooting
section. The instructions are not intended to teach you how to weld. If you have no experience, we recommend that you seek training from an expert source. MIG
welding is relatively easy, but does require a steady hand and supervised practice on scrap metal, as it is only with continued practice that you will achieve the
desired results.
Your Mightymig welder features a heavy duty high output transformer and forced air cooling to ensure the highest level of performance. Contoured grip torches run
cooler than any other and are comfortable in the hand, thus ensuring a steadier weld bead. Supplied with a hand held mask, disposable cylinder of CO
2
gas,
mini gas regulator, spool of mild steel wire and torch. Can also be connected to large, industrial CO
2
gas bottles using the optional adaptor kits AK9 or AK9/3. To weld
aluminium, order a roll of 0.8mm aluminium wire, a packet of 0.8mm contact tips, and a bottle of Argon gas. See our catalogue for details of welding accessories.
3. ASSEMBLY & PREPARATION
3.3.
Fitting the reel spindle and wire reel.
The welder is supplied with a mini spool of mild steel wire, but will
accept spools of up to 5kg without modification.
3.3.1. Align the reel spindle (fig.4. A) with the holes in the internal side panel and secure with two self tapping
screws (B). Place the wire reel (C) onto the spindle ensuring that the spool rotates anticlockwise with the
wire drawing off the bottom of the reel for the PM140XT and PM150XT (see fig.5) and clockwise, with the
wire drawing off the reel from the top for the EM130XT (see fig.7). Place the plastic reel ring nut (D) over
the end of the spindle followed by the reel spring (E). Push the ‘handwheel’ stub (F) into the end of the
spindle against the spring pressure and turn and release it to lock it in position.
3.3.2. Unscrew the wire feed pressure knob and lift the wire feed lever up to the right (fig. 6).
3.3.3. Straighten about 40-50mm of spool wire (
do not allow wire to uncoil
) and check that the wire end is
smooth and free from burrs. Gently push wire through the plastic guide and through the 6 or 8mm roller
groove and into the wire liner as indicated in fig.6
3.3.4. Hinge down the tension arm and secure with the wire feed knob. (See section 3.4 re wire tension.)
Model No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .EM130XT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PM140XT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PM150XT
Welding Current
. . . . . . . . . . . . . . . . . . . . . . . . . . . .35 - 130A . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 - 140A . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 - 150A
Wire Capacity-steel
. . . . . . . . . . . . . . . . . . . . . . . . .0.7 - 5.0kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.7 - 5.0kg . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.7 - 5.0kg
Wire Capacity-aluminium
. . . . . . . . . . . . . . . . . . . .0.5 - 2.0kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.5 - 2.0kg . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.5 - 2.0kg
Duty Cycle
. . . . . . . . . . . . . . . . . . . .100% @ 35A, 50% @55A . . . . . . . . . . . . . . . .100% @ 35A, 60% @ 50A . . . . . . . . . . . . . . . .100% @ 45A, 60% @ 55A
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20% @ 80A . . . . . . . . . . . . . . . .20% @ 90A, 15% @ 105A . . . . . . . . . . . . . . . . . . . . . . . . . .15% @ 115A
Penetration-steel
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2mm . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5 - 3.5mm . . . . . . . . . . . . . . . . . . . . . . . . . . .3.5 - 4.5mm
Penetration-aluminium
. . . . . . . . . . . . . . . . . . . . . . . . . .3mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5mm
Cooling System
. . . . . . . . . . . . . . . . . . . . . . . . . . . .Forced Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Forced Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Forced Air
Gas Type
. . . . . . . . . . . . . . . . . . . . . . .CO
2
/argon mix & argon . . . . . . . . . . . . . . . . . . .CO
2
/argon mix & argon . . . . . . . . . . . . . . . . . . .CO
2
/argon mix & argon
Torch
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Non-live . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Non-live . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Non-live
Power Input
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230V 1ph . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230V 1ph . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230V 1ph
Power Efficiency
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.8kVA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.0kVA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3kVA
1.3.
GAS SAFETY
#
Store gas cylinders in a vertical position only and ensure the storage area is correctly secured.
%
DO NOT store gas cylinders in areas where the temperature may exceed 50°C. DO NOT use direct heat on a cylinder. Always keep gas cylinders cool.
%
DO NOT attempt to repair or modify any part of a gas cylinder or valve and DO NOT puncture or damage a cylinder.
%
DO NOT obscure or remove any official labels on a cylinder. Always check the gas identity before use. Avoid getting gas cylinders oily or greasy.
%
DO NOT lift a cylinder by the cap, guard or valve. Always keep caps and guards in place and close valve when not in use.
3.1. Wheel
assembly for models PM140XT & PM150XT
3.1.1. Take the wheel axle and fit a wheel to one end.
Secure with a circlip. Pass the axle through the
lower part of the rear moulded frame then fit the
other wheel and circlip. Press fit the caps provided
into the recesses in each wheel.
3.2.
Connecting the gas cylinder (See Section 4.4
regarding gas types)
3.2.1. For the EM130XT attach the red gas cylinder belt to
the back of the welder by passing it through the
metal loops in the back panel just below the handle.
Place the lower end of the cylinder into the metal
hoop and fasten the belt around the cylinder as
shown in fig.2. For the PM140XT & PM150XT pass
the belt through either side of the rear moulded frame
as shown in fig.3. Hold the gas cylinder in place in
the recesses provided in the rear moulding and
fasten the belt around the cylinder.
3.2.2. Ensure that the regulator (fig. 1) is closed (knob turned fully clockwise) and then screw it onto the cylinder (finger tight only). Once the regulator has
opened the cylinder valve, indicated by the sound of gas escaping, screw it one full turn further, which is sufficient to seal the cylinder.
!
WARNING!
Excessive tightening of the regulator will over-compress the sealing washer and allow the gas to leak.
3.2.3. Push the gas tube into the quick connector on the regulator ( to remove tube, press collet in and pull the tube. See fig.1.)
Leave the regulator closed until the welder is fully set up and you are ready to weld.
3.2.4. When you are ready to commence welding switch the machine on and turn the regulator knob halfway for approx. 2l/min, and all the way for a max. flow of
approx. 4l/min.
3.2.5. Always remove the flow regulator after use if the machine is to be stored for any length of time.
fig. 5
fig. 6
fig.1
fig.2
fig. 3
fig. 4
fig.7
EM130XT.V3, PM140XT.V2, PM150XT.V2 - 3 - 130206
