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D/F MAC Instruction Manual

Air cooled mig barrels
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Instruction Manual 653AM
MAC/MAT Long
Revised 06/2014
D/F MACHINE SPECIALTIES, INC.
MIG & TIG Welding Products, Consumables & Accessories
1750 Howard Drive, North Mankato, MN 56003
Phone: (507) 625-6200 Fax: (507) 625-6203
www.dfmachinespecialties.com
AIR COOLED MIG BARRELS
Model MAC - Collet Action (Slip-In Tip)
Model MAT - Threaded Current Tip
Shielding Gas Connection is in the Vertical
Barrel Length - 8.625"
INSTRUCTIONS, PARTS & SPECIFICATIONS MANUAL

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Summary of Contents for D/F MAC

  • Page 1 1750 Howard Drive, North Mankato, MN 56003 Phone: (507) 625-6200 Fax: (507) 625-6203 www.dfmachinespecialties.com AIR COOLED MIG BARRELS Model MAC - Collet Action (Slip-In Tip) Model MAT - Threaded Current Tip Shielding Gas Connection is in the Vertical Barrel Length - 8.625”...
  • Page 2 “MIG” (GMAW) & “TIG” (GTAW) weld- ing products, consumables and accessories. D/F offers several types of manual Air or Water-Cooled “MIG” welding tools, and with the increased use of automated and robotic welding systems, a demand has been created for welding tools of the highest quality, durability and interchangeability.

  • Page 3: Table Of Contents

    What is the Proper Use of the Nozzle Thread Chaser Tap? ..........9 (Table I) Gas Nozzles, (Tables II) Current Tips ............10 Air-Cooled Machine Barrel Model MAC - Parts ............11 Air-Cooled Machine Barrel Model MAT - Parts ............12 (Table 3) Casings, (Table 4) Liners, (Table 5) Recommended Spare Parts ....13 Air-Cooled Machine Barrel - Remote Mounting &...
  • Page 4 SAFETY MEASURES - **PLEASE READ!** Welding is not particularly hazardous when certain safety practices are followed. Anyone using this equipment should be thoroughly trained in safe welding practices. Failure to observe safe practices may cause serious injury. Handling welding torches presents no dan- ger if the appropriate safety regulations are strictly adhered to.

  • Page 5: Introduction, Ordering Information

    Two models are available. The model MAC features a slip-in current tip fastened by a collet nut. The wire diameter range includes .030”-1/16” with a current capacity of 175-275 amperes in CO The model MAT uses a threaded type current tip.

  • Page 6: Required Tools List For Disassembly & Assembly

    Never use another wrench to apply more torque to this wrench. D/F Nozzle Thread Chaser Taps (Front & Rear) - This is used to re-tap damaged threads that have been improperly cleaned or cross threaded.

  • Page 7: Required Tools List For Disassembly & Assembly

    REQUIRED TOOLS LIST FOR DISASSEMBLY & ASSEMBLY...

  • Page 8: How Do I Cut, Fit, And Install A New Liner

    HOW DO I CUT, FIT, AND INSTALL A NEW LINER? Be sure the MIG Gun cable is arranged in a straight line, free from twists, when installing or removing a wire liner. Remove the old liner by first removing the MIG gun’s contact tip. Pull the old wire liner out of the conduit/casing assembly from the feeder connector or feeder adapter plug end.

  • Page 9: What Is The Proper Use Of The Nozzle Thread Chaser Tap

    WHAT IS THE PROPER USE OF THE NOZZLE THREAD CHASER TAP? All D/F Nozzles are hand checked for fit before and after plating, and checked again before shipping. If a nozzle has been installed on a new complete torch, they have also been hand checked while being assembled.

  • Page 10: (Table I) Gas Nozzles, (Tables Ii) Current Tips

    TABLE 1 - GAS NOZZLES Gun Model Ref. Nozzle Type O.D. I.D. Code No. CA-C/CA-T Copper Tapered 63/64” 5/8” 10362 Copper Straight 1” 3/4” 10340 Copper Full Taper 63/64” 5/8” 10359 Copper Straight 5/8” 7/16” 10374 Use with Nozzle Body 13198 1-1/16”...

  • Page 11: Air-Cooled Machine Barrel Model Mac - Parts

    AIR-COOLED MACHINE BARREL Model MAC - Slip-In Tip REF. CODE NO. DESCRIPTION 14335 14322 Washer 14712 Socket Set Screw 14111 Casing Adapter 16091 Inner Body Assembly 16202 Adapter Jam Nut Barrel Liner (see Table below) Alignment Tube (see Table below) 13205 Adapter - 1/4”...

  • Page 12: Air-Cooled Machine Barrel Model Mat - Parts

    AIR-COOLED MACHINE BARREL Model MAT - Threaded Tip REF. CODE NO. DESCRIPTION 14335 14322 Washer 14712 Socket Set Screw 14111 Casing Adapter 16091 Inner Body Assembly 16202 Adapter Jam Nut Barrel Liner (see Table below) Alignment Tube (see Table below) 13205 Adapter - 7/16”...

  • Page 13: (Table 3) Casings, (Table 4) Liners, (Table 5) Recommended Spare Parts

    TABLE 3 - LINERS Description Wire Size 2 Ft. 3 Ft. 4 Ft. 5 Ft. 6 Ft. 7 Ft. 8 Ft. 10 Ft. 12 Ft. 15 Ft. Hard .030” 14130 14131 14132 16818 16819 16820 12320 12321 12322 Hard/Cored .035”-.045” ** 16443 16444 16445...

  • Page 14: Air-Cooled Machine Barrel - Remote Mounting & Utilities

    AIR-COOLED MACHINE BARREL - REMOTE MOUNTING See Chart Below for Gas Hose Casings - Select from p. 13, Table 9 See Chart Below for Power Cable Mounting Dia. .625” 1” 2.750” Barrel 1.250” Dia. 8.625” 3.500” ORDERING INFORMATION - POWER CABLE CODE NO.

  • Page 15: Utility Station - Air-Cooled Barrels

    D/F TORCH CONNECTION 5.75” 1/0 or 2/0 Hose Power Cable 3.125” 3.75” 2.5” FROM LEFT: D/F TORCH CONNECTION CUSTOMER UTILITIES CONNECTION FROM RIGHT: CUSTOMER UTILITIES CONNECTION 1/0 or 2/0 Shielding Gas Power Cable (3/16” Hose Shank) Shielding Gas Gas Hose (3/16”...

  • Page 16: Wire Feeder Adapters & Inlets

    WIRE FEEDER ADAPTERS & INLETS ORDERING INFORMATION Direct Mount Remote Mount Adapter Each D/F gun is fully assembled and ready to in- Adapter Manufac- stall. In order to make the installation complete, Models Wire Diameter turer the code number, wire size & type, make/model...

  • Page 17: Troubleshooting

    TROUBLESHOOTING: POROSITY (SUMMARY) NOTE: Most POROSITY is caused by gas problems, followed by base metal contamination. Causes of Porosity Possible Solutions BASE METAL CONTAMINATION Impurities on base metal a. Remove contamination; clean surfaces b. Use of specific wire/gas mix for specific types of impurities FILLER METAL CONTAMINATION Impurities on filler metal (wire) a.
  • Page 18 TROUBLESHOOTING: SPATTER Possible Solutions Problems/Causes SPATTER Too fast or too slow wire feed for the arc voltage Set the wire feed rate and voltage in accordance with good weld- ing practices as recommended by a qualified welding engineer. Too long an arc Adjust the wire feed and voltage so that the arc is in accordance with good welding practice for the joint to be welded.
  • Page 19 TROUBLESHOOTING: GENERAL GUIDE Problems/Causes Possible Solutions ERRATIC WIRE FEED Slipping feed rolls Check that the feed roll size is correct for the wire size being used. Increase the drive roll pressure until the wire feed is even. Do not apply excessive pressure as this can damage the wire surface, causing copper coating to loosen from steel wires or metal shavings to be formed from soft wires like aluminum.
  • Page 20 Note complete weld parameters, including welding current (Amps), welding volt- Capacity of gun being exceeded age, wire feed speed, type and size of wire, type of gas and flow rate of gas and consult your local Authorized D/F Machine Specialties Distributor or contact the factory. Dirty connection Remove torch and inspect parts for dirt build-up.
  • Page 22 D/F or its authorized distributor as new merchandise. The barrel and cable assemblies are warranted by D/F to be free from manufacturing defects for 90 days after delivery by D/F, provided that the equipment is properly operated under conditions of normal use and that regular periodic maintenance and service is performed.

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