ESAB A2 Multitrac Instruction Manual
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ESAB A2 Multitrac Instruction Manual

ESAB A2 Multitrac Instruction Manual

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A2 Multitrac
A2TF J1/ A2TF J1 Twin/
A2TG J1/ A2TG J1 4WD
Instruction manual
0449 165 160 2009-10-07
Valid for serial no. 940-xxx-xxxx

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  • Page 1 A2 Multitrac A2TF J1/ A2TF J1 Twin/ A2TG J1/ A2TG J1 4WD Instruction manual 0449 165 160 2009-10-07 Valid for serial no. 940-xxx-xxxx...
  • Page 2 ENGLISH ..........Rights reserved to alter specifications without notice.

  • Page 4: Table Of Contents

    ENGLISH 1 SAFETY ............2 INTRODUCTION .

  • Page 5: Safety

    SAFETY Users of ESAB welding equipment have the ultimate responsibility for ensuring that anyone who works on or near the equipment observes all the relevant safety precau- tions. Safety precautions must meet the requirements that apply to this type of weld- ing equipment.
  • Page 6 6. General precautions Make sure the return cable is connected securely. Work on high voltage equipment may only be carried out by a qualified electrician. Appropriate fire extinquishing equipment must be clearly marked and close at hand. Lubrication and maintenance must not be carried out on the equipment during operation.

  • Page 7: Electric Shock - Can Kill

    WARNING ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAUTIONS WHEN WELDING. ASK FOR YOUR EMPLOYER'S SAFETY PRACTICES WHICH SHOULD BE BASED ON MANU- FACTURER'S HAZARD DATA. ELECTRIC SHOCK - Can kill Install and earth the welding unit in accordance with applicable standards. Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.

  • Page 8: Introduction

    The A2TG J1/ A2TG J1 4WD automatic welding machines are designed for MIG/MAG welding of butt and fillet joints. All other applications are prohibited. They are intended for use in combination with PEK and ESAB's welding power sources LAF or TAF. Welding Method 2.2.1...

  • Page 9: Technical Data

    Technical data A2TF J1/ A2TG J1 A2TF J1 Twin (SAW) (MIG/MAG) Supply voltage 42 V AC 42 V AC Permissible load at 100 %: 800 A 600 A Wire dimensions: solid single wire 1.6-4.0 mm 0.8-2.5 mm cored wire 1.6-4.0 mm 1.2-3.2 mm solid twin wire 2x1.2-2.0 mm...

  • Page 10: Main Components A2Tf J1/ A2Tf J1 Twin (Saw)

    Main components A2TF J1/ A2TF J1 Twin (SAW) Carriage Contact tube Flux tube Carrier Wire feed motor 10. Guide pin Wire feed unit Wire guide Slide kit, manual Flux hopper Main Components A2TG J1/ A2TG J1 4WD (MIG/MAG) Carriage Slide kit, manual Wire guide Carrier Connector...

  • Page 11: Description Of Main Components

    Description of Main Components 2.8.1 Carriage The carriage is provided with 4-wheel drive. The carriage can be secured by way of the locking lever (1). 2.8.2 Carrier The control box, wire feed unit and flux hopper, among other things, are to be fitted on the carrier. 2.8.3 Wire Feed Unit / Wire Feed Unit with four-wheel Drive The unit is used for guiding and feeding the welding wire down into the contact...

  • Page 12: Installation

    INSTALLATION General The installation must be executed by a professional. WARNING Rotating parts can cause injury, take great care. Mounting 3.2.1 Wire drum (Accessories) Wire drum (1) is mounted on the brake hub (2). WARNING To prevent the reel sliding off the hub: Lock the reel in place by turning the red knob as shown on the warning label attached next to the hub.

  • Page 13: Connections

    Connections 3.4.1 General The PEK is to be connected by a qualified person. See instruction manual 0460 948 xxx, 0460 949 xxx, 0459 839 036. For the connection of welding power source LAF/ TAF, see separate instruction manual. 3.4.2 Automatic welding machine A2TF J1/ A2TF J1 Twin (Submerged arc welding, SAW) 1.
  • Page 14 3.4.3 Automatic welding machine A2TG J1 (Gas metal arc welding, MIG/MAG) 1. Connect the control cable (7) between the power source (8) and control box PEK (2). 2. Connect the return cable (11) between the power source (8) and work piece (9). 3.
  • Page 15 3.4.4 Automatic welding machine A2TG J1 4WD (Gas metal arc welding, MIG/MAG) 1. Connect the control cable (7) between the welding power source (8) and the PEK (2). 2. Connect the return cable (11) between the welding power source (8) and the work piece (9).

  • Page 16: Operation

    OPERATION General WARNING: Have you read and understood the safety information ? You must not operate the machine before then ! General safety regulations for the handling of the equipment can be found on page 5. Read through before you start using the equipment! Before welding start, check that the return cable is connected.

  • Page 17: Loading The Welding Wire (A2Tf J1/ A2Tf J1 Twin, A2Tg J1)

    Loading the welding wire (A2TF J1/ A2TF J1 Twin, A2TG J1) A2TF J1 (SAW) A2TF J1 Twin (SAW) A2TG J1 (MIG/MAG) 1. Mount the wire drum according to the instructions on page 12. 2. Check that feed roller (1) and contact jaw or contact tip (3) are of the correct dimension for the selected wire size.

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

    Loading the welding wire (A2TG J1 4WD) 1. Check that the feed rollers (1, 4) and the contact nozzle (7) are of the correct dimension for the wire size selected. NOTE! The feed rollers are marked with their respective groove diameter (D) on the opposite side of the roller.

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

    Changing the feed roller (A2TF J1/A2TF J1 Twin, A2TG J1) Single wire Release the knobs (3) and (4). Release the hand wheel (2). Change the feed roller (1). They are marked with their respective wire sizes. Twin wire (Twin-arc) Change the feed roller (1) with twin grooves in the same way as for single wire. NOTE! The pressure roller (5) must also be changed.

  • Page 20: Contact Equipment For Submerged Arc Welding

    Contact equipment for Submerged arc welding 4.6.1 For single wire 1.6 - 4.0 mm. Light duty (D20) Use automatic welding machine A2TF J1 (SAW) where the following are included: Wire feed unit (1), Connector D20 (2) Contact tip (3) (M12 thread). Tighten the contact tip (3) with a key in order to ensure that a good contact is achieved.

  • Page 21: Contact Equipment For Mig/Mag Welding

    Contact equipment for MIG/MAG welding 4.7.1 For single wire 1.6 - 2.5 mm (D35) Use automatic welding machine A2TG J1 (MIG/MAG) where the following are included: 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.

  • Page 22: Refilling With Flux Powder (Submerged Arc Welding)

    4.7.3 For single wire 1.0 - 2.4 mm (wire feed unit with four-wheel drive) Use automatic welding machine A2TG J1 4WD (MIG/MAG) where the following are included: Wire feed unit (5), Contact device D35 (6) Tighten the contact device (6) using the Allen screw (8).

  • Page 23: Transportation Of The Automatic Welding Machine

    Transportation of the Automatic Welding Machine Disengage the wheels by turning the locking lever (1). Make sure the safety chain (2) is properly fastened; this to prevent an accident happening, if for example the carrier is not adequately locked to the foot clamp of the carriage.

  • Page 24: Maintenance

    MAINTENANCE General Note: All warranty undertakings given by the supplier cease to apply if the customer attempts to rectify any faults on the machine during the warranty period. NB! Before doing any kind of maintenance work, make sure the mains is disconnected.

  • Page 25: Troubleshooting

    Use cables with a larger cross-section or use parallel cables. ORDERING OF SPARE PARTS Spare parts are ordered through your nearest ESAB representative, see back cover. When ordering spare parts, please state machine type and number as well as desig- nation and spare part number as shown in the spare parts list on page 29.

  • Page 26: 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 - 26 - dimdoc...
  • Page 27 A2TG J1/ A2TG J1 4WD Recommended adjusting Measure Butt joint Fillet joint 165 mm 165 mm 668 mm 668 mm 455 mm 455 mm - 27 - dimdoc...
  • Page 28 - 28 - sida...

  • Page 29: 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...
  • Page 30 Item Ordering no. Denomination Notes 0461 233 880 Automatic welding machine A2TF J1, SAW 0449 100 883 Carriage 0449 154 880 Carrier 0449 152 880 Slide travel kit, manual 90 mm 0449 150 900 Wire feed unit complete 0460 504 880 Control box 0449 153 900 Cable kit...
  • Page 31 Item Ordering no. Denomination Notes 0461 233 881 Automatic welding machine A2TF J1 Twin, SAW 0449 100 883 Carriage 0449 154 880 Support 0449 152 880 Slide travel kit, manual 90 mm 0449 150 901 Wire feed unit complete Twin 0460 504 880 Control box 0449 153 900...
  • Page 32 Item Ordering no. Denomination Notes 0461 234 880 Automatic welding machine A2TG J1, MIG/ MAG 0449 100 883 Carriage 0449 154 880 Carrier 0449 152 880 Slide travel kit, manual 90 mm 0449 150 902 Wire feed unit complete 0460 504 880 Control box 0449 153 900 Cable kit...
  • Page 33 Item Ordering no. Denomination Notes 0461 234 881 Automatic welding machine A2TG J1 4 WD, MIG/ MAG 0449 100 883 Carriage 0449 154 880 Carrier 0449 152 880 Slide travel kit, manual 90 mm 0449 150 903 Wire feed unit complete 4 WD 0460 504 880 Control box...
  • Page 34 Item Ordering no. Denomination Notes 0449 100 883 Carriage 0449 087 001 Cover 0333 087 005 Y-Flange unit 0415 857 001 Rubber wheel 0211 102 962 Roll pin 0461 241 880 Motor cable L=1.9 m 0461 242 880 Pulse transducer cable L=2,1 m 0449 205 880 Guide arm complete...
  • Page 35 - 35 - h449100s...
  • Page 36 Item Ordering no. Denomination Notes 0449 154 880 Carrier 0413 671 001 Chain attachment 0413 597 001 Safety chain 0163 139 002 Bushing 0162 414 002 Insulating tube 0413 528 001 Column 0413 540 001 Clamp 0413 530 880 0146 967 880 Brake hub 0413 532 001 Attachment...
  • Page 37 - 37 - f449154s...
  • Page 38 Item Ordering no. Denomination Notes 0449 152 880 Slide travel kit Manual 0413 518 880 Slide 90 mm 0413 506 880 Circular slide - 38 - f449152s...
  • Page 39 Item Orderingno. Denomination Remarks 0413 518 880 Slide 0413 519 001 Slide profile 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 - 39 - f413518s...
  • Page 40 Item Ordering no. Denomination Notes 0413 506 880 Rotary slide 0413 507 001 Flange 0413 508 001 Tensioning ring 0413 509 001 Flange 0219 504 405 Bellleville spring T = 0.6 0193 571 105 Locking piece 0193 570 123 Locking lever - 40 - f413506s...
  • Page 41 Item Ordering no. Denomination Notes 0449 150 900 Wire feed unit complete (Right) 0147 639 882 Wire feed unit 0413 072 881 Bearing housing 0215 701 210 Wedge, flat 0413 517 001 Bracket for motor 0812 312 001 Motor with pulse transducer 0218 810 183 Insulated Hand wheel 0413 510 001...
  • Page 42 Item Ordering no. Denomination Notes 0449 150 901 Wire feed unit complete (Right) UP, Twin 0147 639 886 Wire feed unit Twin 0413 072 881 Bearing housing 0215 701 210 Wedge, flat 0413 517 001 Bracket for motor 0812 312 001 Motor with pulse transducer 0218 810 183 Insulated Hand wheel...
  • Page 43 Item Ordering no. Denomination Notes 0449 150 902 Wire feed unit complete (Right) MIG/ MAG 0147 639 882 Wire feed unit 0413 072 881 Bearing housing 0215 701 210 Wedge, flat 0413 517 001 Bracket for motor 0812 312 002 Motor with pulse transducer 0218 810 183 Insulated Hand wheel...
  • Page 44 Item Ordering no. Denomination Notes 0449 150 903 Wire feed unit complete (Right) 4WD, MIG/ MAG 0456 424 902 Wire feed unit 0457 460 881 Contact device MTW 600, L=250 0461 238 881 Solenoid valve and cable 0156 800 002 Wire liner 0333 754 001 Hose...
  • Page 45 Item Orderingno. Denomination Remarks 0147 639 882 Straightener (right mounted) 0156 449 001 Clamp 0212 900 001 Spacer screw 0215 201 209 O-ring D11.3x2.4 0218 400 801 Pressure roller arm 0218 810 181 Handwheel 0218 810 182 Handwheel 0332 408 001 Stub shaft 0153 148 880 Roller 0415 498 001 Thrust roller carrier 0212 902 601 Spacer screw...
  • Page 46 Item Ordering no. Denomination Notes 0147 639 886 Straightener (right mounted) 0156 449 001 Clamp 0156 530 001 Clamp half 0212 900 001 Spacer screw 0215 201 209 O-ring D11.3x2.4 0218 400 801 Pressure roller arm 0218 810 181 Handwheel 0332 408 001 Stub shaft 0218 524 580 Pressure roller Twin...
  • Page 47 Item Orderingno. Denomination Notes 0413 072 881 Bearing housing with stub shaft 0413 073 002 Searing housing 0190 726 003 Ball bearing 0334 575 001 Stub shaft 0215 701 014 Betaining ring 0334 576 001 Spacer - 47 - f413072s...
  • Page 48 Item Orderingno. Denomination Remarks 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 - 48 - f332994s...
  • Page 49 Item Ordering no. Denomination Notes 0153347880 Flux valve 0153348001 Outlet 0153349001 Shaft 0211102938 Roll pin d 3x20 - 49 - h153347s...
  • Page 50 Item Ordering no. Denomination Notes 0333 852 881 Connector Twin L=275 A6 UP 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 - 50 - f333852s...
  • Page 51 Item Ordering no. Denomination Notes 0417 959 881 Contact equipment L=275mm 0443 372 001 Screw 0219 504 307 Beleville spring T = 1.1 0443 344 881 Pipe L = 275 - 51 - f417959s...
  • Page 52 Item Ordering no. Denomination Notes 0153 299 880 Flux nozzle 0153 290 002 Pipe holder 0153 296 001 Pipe bend 0153 425 001 Wheel - 52 - f153299s...
  • Page 53 Item Ordering no. Denomination Notes 0145 787 880 Fine wire straightener for twin wire 0145 788 001 Case 0145 789 001 Roller 0145 790 001 Roller 0145 791 001 Searing bushing 0190 240 103 Bearing bushing D12/10 0145 792 001 Screw 0145 793 001 Runner 0145 796 002 Screw 0145 794 001 Knob...
  • Page 54 Item Orderingno. Denomination Remarks 0030 465 389 Connector 0145 226 001 Insulating sleeve 0190 680 313 O-ring OR 15.3x2.4 0190 680 303 O-ring OR 5.3x2.4 0190 680 405 O-ring OR 22.2x3 0334 278 880 Insert tube 0334 279 001 Spiral 0146 099 001 Plug 0145 534 882 Contact tube 0145 227 882 Gas nozzle...
  • Page 55 Item Ordering no. Denomination Notes 0456424902 Feed unit 0455046003 Gear housing 0368749881 Pressure device 0458997001 Shaft 0459001880 Pressure arm 0458999001 Shaft 0458993001 Spring 0215702706 Locking washer 0458722001 Shaft 0380351001 Wire guide nipple 0455072001 Intermediate nozzle D13 (W) 0469837880 Outlet nozzle 0457365001 Current connection 0455048001...
  • Page 56 Item no. Ordering no. Denomination Notes 0457 460 881 Contact device MTW 600, 250 mm 0457 457 002 Cooling jacket 0457 455 002 Contact tube 0457 456 001 Insulation sleeve 0457 451 001 Gas nozzle 0457 452 001 Spatter protection 0457 453 001 Centering sleeve 0457 617 001...
  • Page 57 Item Orderingno. Denomination Notes 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 - 57 - f461238s...
  • Page 58 ESAB Romania Trading SRL ESAB VAMBERK s.r.o. SOUTH AFRICA ESAB Mexico S.A. Bucharest Vamberk ESAB Africa Welding & Cutting Ltd Monterrey Tel: +40 316 900 600 Tel: +420 2 819 40 885 Durbanvill 7570 - Cape Town Tel: +52 8 350 5959...

This manual is also suitable for:

A2tf j1A2tf j1 twinA2tg j1A2tg j1 4wd

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