ESAB A2 Multitrac Instruction Manual
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ESAB A2 Multitrac Instruction Manual

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A2 Multitrac                                  
A2TF J1/ A2TF J1 Twin/              
A2TG J1/ A2TG J1 4WD      
Instruction manual
Valid for: serial no. 940-xxx-xxxx
0449 165 160 GB 20200827

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Summary of Contents for ESAB A2 Multitrac

  • Page 1 A2 Multitrac                                   A2TF J1/ A2TF J1 Twin/               A2TG J1/ A2TG J1 4WD       Instruction manual Valid for: serial no. 940-xxx-xxxx 0449 165 160 GB 20200827...

  • Page 3: Table Of Contents

    Loading the welding wire (A2TG J1 4WD) ..........Changing the feed roller (A2TF J1 / A2TF J1 Twin, A2TG J1) .... 4.4.1 Single wire .................... 4.4.1.1 Twin wire (Twin-arc)................4.4.1.2 Flux-cored wire for knurled rollers (Accessories) ......Changing the feed rollers (A2TG J1 4WD) ........... 0449 165 160 © ESAB AB 2020...
  • Page 4 General ....................Daily ......................Periodic ....................TROUBLESHOOTING ................. General ....................Possible errors ..................ORDERING SPARE PARTS ................ DIMENSION DRAWING ..................28 SPARE PARTS LIST .................... 30 Rights reserved to alter specifications without notice. 0449 165 160 © ESAB AB 2020...

  • Page 5: Safety

    Safety Data Sheets (SDSs). Safety precautions Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who works on or near the equipment observes all the relevant safety precautions. Safety precautions must meet the requirements that apply to this type of equipment. The following recommendations should be observed in addition to the standard regulations that apply to the workplace.
  • Page 6 Protect your eyes and body. Use the correct welding screen and filter lens and wear protective clothing. • Protect bystanders with suitable screens or curtains. NOISE - Excessive noise can damage hearing Protect your ears. Use earmuffs or other hearing protection. 0449 165 160 - 6 - © ESAB AB 2020...
  • Page 7 There may be potential difficulties in ensuring electromagnetic compatibility of class A equipment in those locations, due to conducted as well as radiated disturbances. 0449 165 160 - 7 - © ESAB AB 2020...
  • Page 8 For further information contact the nearest ESAB dealer. ESAB has an assortment of welding accessories and personal protection equipment for purchase. For ordering information contact your local ESAB dealer or visit us on our website. 0449 165 160 - 8 - ©...

  • Page 9: Introduction

    The A2TG J1 / A2TG J1 4WD automatic welding equipment is designed for MIG/MAG welding of butt and fillet joints. All other applications are prohibited. Intended for use in combination with PEK and ESAB welding power sources LAF, TAF or Aristo 1000. NOTE! Aristo 1000 only together with PEK with serial no. 747-xxx-xxxx or later.

  • Page 10: Installation

    Rotating parts can cause injury, take great care. Main components A2TF J1 / A2TF J1 Twin (SAW) Carriage Wire feed motor Carrier Wire guide Wire feed unit Flux hopper Slide kit, manual Flux tube Contact tube Guide pin 0449 165 160 - 10 - © ESAB AB 2020...

  • Page 11: Main Components A2Tg J1 / A2Tg J1 4Wd (Mig/Mag)

    The horizontal and vertical position of the welding head is adjusted by way of linear slides. The angular motion can be freely adjusted using the rotary slide. 3.4.5 Contact tube / Connector Transfers welding current to the wire during welding. 0449 165 160 - 11 - © ESAB AB 2020...

  • Page 12: Wire Feed Motor

    Adjusting the brake hub The brake hub is adjusted at delivery. If readjustment is required, follow the instructions below. Adjust the brake hub so the wire is slightly slack when wire feed stops. 0449 165 160 - 12 - © ESAB AB 2020...

  • Page 13: Connections

    Turn both springs the same amount. Connections 3.7.1 General • The PEK must be connected by a qualified person. See separate instruction manual. • For connection of welding power source, see separate instruction manual. 0449 165 160 - 13 - © ESAB AB 2020...

  • Page 14: Automatic Welding Equipment A2Tf J1 / A2Tf J1 Twin

    (1). Connect the measurement cable (12) between the power source (8) and workpiece (9). Automatic welding equipment Control cable Return cable Power source Welding cable Work piece Measurement cable 0449 165 160 - 14 - © ESAB AB 2020...

  • Page 15: Automatic Welding Equipment A2Tg J1

    (1). Connect the measurement cable (12) between the power source (8) and workpiece (9). Automatic welding equipment Control cable Return cable Power source Welding cable Work piece Measurement cable 0449 165 160 - 15 - © ESAB AB 2020...

  • Page 16: Automatic Welding Equipment A2Tg J1 4Wd

    Connect the measuring cable (12) between the welding power source (8) and the work piece (9). Automatic welding equipment Control cable Return cable Power source Welding cable Work piece Measurement cable 0449 165 160 - 16 - © ESAB AB 2020...

  • Page 17: Operation

    Locate the end of the wire in the feed roller (1) groove. Set the wire tension on the feed roller with the knob (4). NOTE! Do not tension more than is required to achieve an even feed. 0449 165 160 - 17 - © ESAB AB 2020...

  • Page 18: Loading The Welding Wire (A2Tg J1 4Wd)

    Locate the end of the wire in the feed roller (1) groove. Feed the wire through the intermediate nozzle (3). Locate the end of the wire in the other feed roller (4) groove. Feed the wire through the outlet nozzle (9). 0449 165 160 - 18 - © ESAB AB 2020...

  • Page 19: Changing The Feed Roller (A2Tf J1 / A2Tf J1 Twin, A2Tg J1)

    A special stub shaft is required for the pressure roller (order no. 0212 901 101). • Tighten the pressure screw (4) with moderate pressure to ensure that the flux-cored wire does not deform. 0449 165 160 - 19 - © ESAB AB 2020...

  • Page 20: Changing The Feed Rollers (A2Tg J1 4Wd)

    Contact tip (3) (M6 thread) • Fine-wire feed unit (5) • Guide tubes (4, 6) Tighten the contact tip (3) with a key in order to ensure that a good contact is achieved. 0449 165 160 - 20 - © ESAB AB 2020...

  • Page 21: Accessories

    Wire feed unit (1) • Connector D35 (2) • Contact tip (3) (M10 thread) Tighten the contact tip (3) with a key in order to ensure that a good contact is achieved. 0449 165 160 - 21 - © ESAB AB 2020...

  • Page 22: For Single Wire < 1.6 Mm (D35)

    Select a wire guide insert of the correct dimension for the type of wire to be used. See the instruction manual for contact device MTW 600 (0449 006 xxx). 0449 165 160 - 22 - © ESAB AB 2020...

  • Page 23: Refilling With Flux Powder

    Make sure the safety chain (2) is properly fastened. This prevents accidents, for example if the carrier is not adequately locked to the foot clamp of the carriage. NOTE! Use the lifting eye bolt (3) when lifting the equipment. 0449 165 160 - 23 - © ESAB AB 2020...

  • Page 24: Conversion Of A2Tf J1 / A2Tf J1 Twin (Submerged Arc Welding) To

    Welding) to MIG/MAG welding Assemble in accordance with the instructions accompanying the conversion kit. 4.11 Conversion of A2TF J1 (Submerged Arc Welding) to Twin-arc Assemble in accordance with the instructions accompanying the conversion kit. 0449 165 160 - 24 - © ESAB AB 2020...

  • Page 25: Maintenance

    ○ Reassemble in the reverse order. • Tensioning the chain from the trolley's front axle to the drive motor and gearbox. ○ Tension the chain by moving the drive motor and gearbox. 0449 165 160 - 25 - © ESAB AB 2020...

  • Page 26: Troubleshooting

    Poor electrical connection. Action Clean and tighten all electrical connections. Cause 3.2 Cross-sectional area of welding cables is too small. Action Use cables with a larger cross-section or use parallel cables. 0449 165 160 - 26 - © ESAB AB 2020...

  • Page 27: Ordering Spare Parts

    Spare parts and wear parts can be ordered through your nearest ESAB dealer, see esab.com. When ordering, please state product type, serial number, designation and spare part number in accordance with the spare parts list.

  • Page 28: Dimension Drawing

    DIMENSION DRAWING DIMENSION DRAWING A2TF J1 / A2TF J1 Twin Recommended adjusting Measure Butt joint Fillet joint 165 mm 165 mm 668 mm 668 mm 455 mm 455 mm 0449 165 160 - 28 - © ESAB AB 2020...
  • Page 29 DIMENSION DRAWING A2TG J1 / A2TG J1 4WD Recommended adjusting Measure Butt joint Fillet joint 165 mm 165 mm 668 mm 668 mm 455 mm 455 mm 0449 165 160 - 29 - © ESAB AB 2020...

  • Page 30: Spare Parts List

    Denomination Notes 0461 233 880 A2 Multitrac SAW A2TF J1 SAW 0461 233 881 A2 Multitrac SAW Twin A2TF J1 Twin SAW 0461 234 880 A2 Multitrac MIG/ MAG A2TG J1 MIG/ MAG 0461 234 881 A2 Multitrac MIG/ MAG A2TG J1 4WD MIG/ MAG    ...
  • Page 31 0449 153 900 Cable kit L= 1.6 m 0460 909 881 Pulse transducer cable 0461 249 881 Motor cable 0461 239 880 Arc welding cable                             0449 165 160 - 31 - © ESAB AB 2020...
  • Page 32 0449 153 900 Cable kit L= 1.6 m 0460 909 881 Pulse transducer cable 0461 249 881 Motor cable 0461 239 880 Arc welding cable                             0449 165 160 - 32 - © ESAB AB 2020...
  • Page 33 0449 153 900 Cable kit L= 1.6 m 0460 909 881 Pulse transducer cable 0461 249 881 Motor cable 0461 239 880 Arc welding cable                             0449 165 160 - 33 - © ESAB AB 2020...
  • Page 34 0449 153 900 Cable kit L= 1.6 m 0460 909 881 Pulse transducer cable 0461 249 881 Motor cable 0461 239 880 Arc welding cable                             0449 165 160 - 34 - © ESAB AB 2020...
  • Page 35 0449 108 001 Plate 0219 504 302 Spring washer 0413 539 002 Clamp 0193 570 131 Locking lever 0163 139 002 Bushing 0162 414 002 Insulating pipe 0413 527 001 Plate 0449 165 160 - 35 - © ESAB AB 2020...
  • Page 36 SPARE PARTS LIST                                 0449 165 160 - 36 - © ESAB AB 2020...
  • Page 37 0156 442 002 Clamp screw R21 M8 0334 185 886 Box girder beam complete 0413 525 001 Insulating tube 0413 317 001 Handle 0218 301 113 Lifting eye bolt 0162 414 004 Insulating tube 0449 165 160 - 37 - © ESAB AB 2020...
  • Page 38 SPARE PARTS LIST 0449 165 160 - 38 - © ESAB AB 2020...
  • Page 39 0449 152 880 Slide travel kit Manual 0413 518 880 Slide 90 mm 0413 506 880 Circular slide                                                             0449 165 160 - 39 - © ESAB AB 2020...
  • Page 40 0413 524 001 Bearing bushing 0413 521 001 Runner 0413 522 001 Lead screw 0334 537 002 Crank 0413 523 001 Axis 0190 240 107 Bearing                         0449 165 160 - 40 - © ESAB AB 2020...
  • Page 41 0413 509 001 Flange 0219 504 405 Bellleville spring T = 0.6 0193 571 105 Locking piece 0193 570 123 Locking lever                                 0449 165 160 - 41 - © ESAB AB 2020...
  • Page 42 0333 094 880 Clamp for Flux tube 0332 948 001 Flux tube 0332 994 883 Flux container 0413 318 001 Holder 0449 475 001 Bar 0462 132 880 Protecting cover 0449 528 001 Protection plate 0449 165 160 - 42 - © ESAB AB 2020...
  • Page 43 0145 787 880 Fine wire straightener 0146 967 880 Brake hub 0413 532 002 Attachment 0154 734 001 Clamp 0457 713 001 Bar 0462 132 880 Protecting cover 0449 528 001 Protection plate 0449 165 160 - 43 - © ESAB AB 2020...
  • Page 44 L = 2,25 m, D 14/ 6.3 0193 761 002 Hose clamp 0147 336 880 Hose coupling 0449 475 001 Bar 0462 132 880 Protection cover 0449 528 001 Protection plate 0449 165 160 - 44 - © ESAB AB 2020...
  • Page 45 0147 336 880 Hose coupling 0449 011 001 Support 0449 009 002 Motor bracket 0449 009 001 Motor bracket 0163 139 002 Bushing 0162 414 002 Insulating tube                 0449 165 160 - 45 - © ESAB AB 2020...
  • Page 46 0153 148 880 Roller 0415 498 001 Thrust roller carrier 0212 902 601 Spacer screw 0415 499 001 Thrust roller carrier 0334 571 880 Contact clamp 0212 601 110 Nut 0449 165 160 - 46 - © ESAB AB 2020...
  • Page 47 0415 498 001 Thrust roller carrier 0212 902 601 Spacer screw 0219 501 013 Spring washer D18.1/10.2 0156 531 001 Clamp half 0212 601 110 Nut                 0449 165 160 - 47 - © ESAB AB 2020...
  • Page 48 0334 575 001 Stub shaft 0215 701 014 Retaining ring 0334 576 001 Spacer                                                                 0449 165 160 - 48 - © ESAB AB 2020...
  • Page 49 0332 994 883 Flux hopper complete 0332 837 001 Hopper for flux 0153 347 881 Flux valve 00203 017 80 Flux strainer 0443 383 002 Flux hose L = 500                 0449 165 160 - 49 - © ESAB AB 2020...
  • Page 50 0153 347 880 Flux valve 0153 348 001 Outlet 0153 349 001 Shaft 0211 102 938 Roll pin d 3 x 20                                                 0449 165 160 - 50 - © ESAB AB 2020...
  • Page 51 0333 772 001 Nozzle holder 0417 959 881 Contact equipment L = 275, Heavy Duty 0415 032 001 Guide pipe 0334 279 001 Spiral to connector L = 366                 0449 165 160 - 51 - © ESAB AB 2020...
  • Page 52 Qty Ordering no. Denomination Notes 0417 959 881 Contact equipment L = 275 mm 0443 372 001 Screw 0219 504 307 Beleville spring T = 1.1 0443 344 881 Pipe L = 275 0449 165 160 - 52 - © ESAB AB 2020...
  • Page 53 0153 299 880 Flux nozzle 0153 290 002 Pipe holder 0153 296 001 Pipe bend 0153 425 001 Wheel                                                         0449 165 160 - 53 - © ESAB AB 2020...
  • Page 54 0190 240 103 Bearing bushing D12/10 0145 792 001 Screw 0145 793 001 Runner 0145 796 002 Screw 0145 794 001 Knob 0145 795 001 Link 0151 287 001 Hose L = 600 0449 165 160 - 54 - © ESAB AB 2020...
  • Page 55 0334 279 001 Spiral 0146 099 001 Plug 0145 534 882 Contact tube 0145 227 882 Gas nozzle 0144 998 882 Water hose 0040 979 804 Extension L = 108, D20 0449 165 160 - 55 - © ESAB AB 2020...
  • Page 56 0457 365 001 Current connection 0455 048 001 Insulating tube 0455077003 Drive unit with pulse transducer 0459 441 880 Gear wheel 0459 440 001 Motor gear 0458 721 001 Locking nut 0449 165 160 - 56 - © ESAB AB 2020...
  • Page 57 0457 458 002 O-ring 0457 454 002 Wear insert (Steel spiral) L = 260, wire Ø 1.0-1.6 mm 0457 620 002 Wear insert (Brass tube) L = 258, wire Ø 2.0-2.4 mm 0449 165 160 - 57 - © ESAB AB 2020...
  • Page 58 0461 238 881 Solenoid valve with cable 0157 259 001 Contact 0262 612 802 Cable 0262 613 329 Cable 0193 054 002 Solenoid valve 42 V 0194 269 002 Bushing 0449 165 160 - 58 - © ESAB AB 2020...
  • Page 59 SPARE PARTS LIST 0449 165 160 - 59 - © ESAB AB 2020...
  • Page 60 For contact information visit esab.com ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone +46 (0) 31 50 90 00 http://manuals.esab.com...

This manual is also suitable for:

A2tf j1A2tf j1 twinA2tg j1A2tg j1 4wd

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