5.1. Wire feed unit
Check the wire feed unit at regular intervals. The feed roller wire guide plays an important part in obtaining consistent results. Poor wire
feed affects welding. Clean the rollers weekly, especially the feed roller groove, removing all dust deposits.
5.2. Torch
Protect the torch cable assembly from mechanical wear. Clean the liner from the machine
forwards by using compressed air. If the liner is clogged it must be replaced.
5.3. Changing Feed Roller
(
IMPorTAnT:
Adjust the feed roller to the corresponding wire size.)
There are two grooves
on the feed roller, 0.6mm and 0.8mm. Always use the groove on the outside of the roller, (the
groove nearest to you). To remove the feed roller, undo the two screws and remove the plastic
cover (fig 6). Clean and turn, or if damaged change the feed roller and replace the plastic
cover accordingly.
5.4. Contact Tip
(to remove tip follow steps in 3.3.6 to replace 3.3.9 a & b very carefully).
The contact tip is a consumable item and must be replaced when the hole becomes
enlarged or oval. The contact tip
MuST
be kept free from spatter to ensure an unimpeded flow of gas.
5.5. Gas Cup
(to remove cup follow steps in 3.3.6. and to replace 3.3.9. a & b very carefully).
The gas cup must also be kept clean and free from spatter. Build up of spatter inside the gas cup can cause a short circuit at the
contact tip which will result in either the fuse blowing on the printed circuit card, or expensive machine repairs. To keep the contact tip
free from spatter, we recommend the use of Sealey anti-spatter spray (MIG/722307) available from your Sealey Dealer.
5.6. Replacing the Liner
Wind the wire back on to the spool and secure it. Unscrew the torch from the machine and undo the brass nut. The liner should now
be visible. Pull it out and replace with a new one.
5.7. Changing gears
An inexperienced welder can allow spatter to build up in the tip and shroud. In severe cases this can block the feed causing gear
stripping in the drive motor. To check if the gears are worn depress the button on the torch with the set switched on. If the gears are
worn, a grating sound will be heard coming from the wire feed motor, you may also observe the feed roller vibrating instead of rotating.
Should this be the case, open the gearbox, remove the worn or damaged gears and replace with new ones.
5.8. Changing Fuses
The fuse is located on the auxiliary transformer and is mainly blown for the following reasons:
Spatter collecting in the gas cup, causing contact tip to short circuit.
Wire tension is too great.
A sudden surge of current.
5. MaINTENaNCE
6 . TROUBLESHOOTING
Roller
Plastic cover
fig 6
PROBLEM
POSSIBLE CaUSE
SOLUTION
1. Power source stops
Overheating protection activated due to overload
Protection automatically resets when transformer has cooled
(about 15mins)
2. No weld current, fuse blowing
in 13 amp plug
Rectifier blown
Replace rectifier
3. No weld current
Bad conncection current between clmp and wprkpeice
Break in earth lead
Brek in torch lead
Clean or grind contact surface and weld area
Repair or replace earth lead
Repair or replace torch
4. Feed motor not working, lamp
is on
Fuse blown
Gear damage or worn
Motor defective
Replace fuse 1.5amp (Chapter 5)
Replace gears (Chapter 5)
Replace motor (contact service agent)
5. Wire does not feed, feed roller
rotates
Pressure roller improperly adjusted
Dirt, copper, duct, etc, has collected in torch liner
Gas cup (nozzle) or tip defective
Deformed wire
Adjust tension
Clean the liner from the machine forward. Use compressed air.
If too much dirt, replace the liner. (Chapter 5)
Replace gas cup (nozzle) and/or tip. (Chapter 5)
Check roller tension and adjust it fi necessary (Chapter 3)
6. Wire feeds unevenly
Dirt, etc, in wire
Gas cup (nozzle) or tip defective
Gas cup (nozzle) spattered
Feed roller groove clogged
Feed roller grove deformed
Pressure roller tension improper
Clean the liner from the machine forward. Use compressed air.
Replace gas cup (nozzle) and/or tip. (Chapter 5)
Clean or replace gas cup (nozzle) (Chapter 5)
Clean feed roller. (Chapter 5)
Replace feed roller (Chapter 5)
Adjust tension (Chapter 3)
7. Unstable arc
Incorrect setting
Impurities in weld area
Worn or defective gas cup (nozzle)
Check settings. (Chapter 4)
Clean and/or grind workpiece. (Chapter 4)
Replace gas cup (nozzle). (Chapter 5)
8. Porous weld
No gas
Gas cup clogged
Draft blowing away shielding gas
Rusty or dirty joints
Torch too far from or at wrong angle to work
Gas leak
Faulty Electrovalve
Open gas cylinder, regulate gas flow
Clean or replace cup. (Chapter 5)
Screen off welding site or increase gas flow
Clean or grind the workpeice. (Chapter 4)
The distance from gas cup to workpeice should be 8-10mm
Check hoses, connections and torch assembly. (Chapter 6)
Press the gas cup in correct position
Clean out or replace
9. Electrode sticking in gas cup (nozzle) Worn or defective gas cup (nozzle)
Electrode deformed
Wire speed too slow
Replace gas cup (nozzle). (Chapter 5)
Check roller tension. (Chapter 3)
See recommendation for wire speed
10. Irregular weld head
Torch incorrectly held
Wire weaving in weld pool
Use correct torch angle
Check roller tension and adjust as needed. (Chapter 3)
11. Weld bead too narrow and
raised
Weld current too low
Weld speed too high
Increase power and wire speed. (Chapter 4)
Move torch slower and weave a little more
12. Weld bead too wide
Weld current too high
Weld speed too low
Arc too long
Decrease power and wire speed. (Chapter 4)
Move torch faster and weave less
Bring torch closer to workpiece
13. Poor penetration
Weld current too low
Arc too long
Increase power and wire speed. (Chapter 4)
Bring torch closer to workpiece
14. Excessive penetration
Weld current too high
Weld speed too slow
Incorrect distance of torch too workpiece
Decrease power and wire speed. (Chapter 4)
Move torch faster
Torch distance should be 8-10mm
15. Fuse blowing
Tension too great
Gas cup contract tip clogged
Releace tension. (Chapter 3)
Clean gas cup and contact tip. (Chapter 5)
Original Language Version
SUPERMIG185.V2,195, 220.V5, 235.V4 Issue: 3 - 09/03/10
