Table of Contents
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perating Manual
CAT. 00308 8/1/09
MIG/FLUX C RE
WIRE WELDER
180FI
Tweco®
Style Torch
Infinite Wire Speed Control
Multiple Power SeHings
Thermal
verload Protection
Welds all types of:
•
Mild (Carbon)
•
Stainless
Steel
•
Alumi
n um
•
Cast Iron
Complete & Ready to Weld
Comes with: Operating Manual,
Set-Up Chart. Spool of Flux Cored
Wire,
Extra
Contact Tips, Chipping
Hammer & Brush Combo &
Welding
Face
Steel
Shield
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Summary of Contents for Forney MIG 180FI
- Page 1 perating Manual CAT. 00308 8/1/09 MIG/FLUX C RE WIRE WELDER 180FI Tweco® Style Torch Infinite Wire Speed Control Multiple Power SeHings Thermal verload Protection Welds all types of: • Mild (Carbon) Steel • Stainless Steel • Alumi n um • Cast Iron Complete &...
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Page 2: Warranty
ForneyIndustries 1830 LaPorte Avenue Fort Collins, 80521 1-800-521-6038 forneywelding.forneyind.com Purchaser Warranty:The original purchaser of the Forney Industries product. The warranty not transferable. Forney Industries products are intended for purchase and use by persons trained and experienced and maintenance of welding equipment. -
Page 3: Table Of Contents
TABLE F C NTENTS Align and Set the Drive Roller......14 Warranty ............. 2 Install the Welding Wire........14 Introduction............3 Set the Wire Drive Tension......16 Safety Summary..........4 Installing Aluminium Wire ....... 16 Safety Information........... 4 Change Polarity ..........17 Shock Hazards.......... -
Page 4: Safety Summary
TABLE OF CONTENTS • When you see one of the symbols shown SAFETY SUMMARY here, be alert to the possibility of personal Every welder respects the tools with which injury and carefully read the message that they work. They know that the tools repre- follows. -
Page 5: Shock Hazards
SH CK HAZARD into the power source if the ground prong on power cord plug is bent over, broken off, or missing. • Do not allow the welder to be connected to the power source or attempt to weld if the welder, welding cables, welding site, WARNING or welder power cord are exposed to any... -
Page 6: Fire Hazards
helmet and replace any cracked or bro- • Do not wear flammable hair preparations. ken filter lenses IMMEDIATELY. • Do not weld in an area until it is checked • Do not allow the uninsulated portion and cleared of combustible and/or flam- of the wire feed gun to touch the ground mable materials. -
Page 7: Fume Hazards
any other flammable material. LY TOXIC gas to form, along with other • Protect flammable walls, ceilings, and lung and eye-irritating gasses. Do not floors with heat resistant covers or weld or cut where these solvent vapors shields. can be drawn into the work area or •... -
Page 8: Additional Safety Information
ADDITI NAL SAFETY INF RMATI N anything other than its intended use. Do not use as a support or roller. For additional information concerning weld- • Do not locate cylinders in passageways ing safety, refer to the following standards or work area where they may be struck. and comply with them as applicable. -
Page 9: Welder Specifications
Table 2. Duty Cycle Ratings WELDER SPECIFICATI NS DESCRIPTI N Duty Maximum Required Cycle Welding Resting Your new MIG (GMAW) flux core (FCAW) Rating Time Time wire feed welder is designed for mainte- nance and sheet metal fabrication. The 1 minutes 9 minutes welder consists of a single-phase power 2.5 minutes... -
Page 10: Know Your Welder
precision welds. (Refer to the Suggested KN W Y UR WELDER Settings Chart on p.33 of this manual OR on Voltage the inside of the door of the welder.) Selector Handle Power Switch – This switch turns the welder Switch Wire ON and OFF. -
Page 11: Welder Installation
cle and the welder power cord without the use of WELDER INSTALLATI N adapters. Make certain that the extension is properly wired and in good electrical condition. P WER S URCE C NNECTI N Extension cords must be a #12 gauge cord at the smallest. -
Page 12: Installing The Handle
bottom of the handle in towards the face mask, while at the same time pushing upwards. (Alignment of the second tab is made easier by applying pressure to the point shown below.) 3. Once the handle tabs are properly seated in the face shield slots, install the handle cover by firmly pushing it into the recessed area on Figure 3. -
Page 13: Installing The Shielding Gas
lowing recommendations are based on the EQUIPMENT HAZARDS in the SAFETY electrical output characteristics and metal SUMMARY at the front of this manual. Secure thickness capabilities of this specific MIG your gas cylinder to the welding cart, or other welder. fixed support. -
Page 14: Align And Set The Drive Roller
turn open ALL THE WAY . Note: The drive roller has two wire size 2. Pull the trigger on the gun to allow the gas grooves built into it. When installing the drive to flow. KEEP THE TRIGGER PULLED. roller the number stamped on the drive roller Listen and feel for gas flowing from the for the wire size you are using should be fac- ing away from you. - Page 15 the end of the gun assembly. The purpose of the drive brake is to cause 2. Make sure the proper groove on the drive the spool of wire to stop turning at nearly roller is in place for the wire being installed. the same moment that wire feeding stops.
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Page 16: Set The Wire Drive Tension
SET THE WIRE DRIVE TENSI N 15. Connect the welder power cord to the ac power source. Turn the welder ON by set- ting the VOLTAGE switch to the voltage (heat) setting recommended for the gauge metal that is to be welded. Refer to the WARNING label mounted on the cover, inside the drive compartment, for recommended volt-... -
Page 17: Change Polarity
CHANGE P LARITY 2. Attach the ground clamp to the work piece, making sure that it is cleaned of This welder allows you the capability to dirt, oil, rust, scale, oxidation, and paint at change the welding current polarity. You may the point of connection. -
Page 18: Peration
TUNING IN THE WIRE SPEED PERATI N This is one of the most important parts of MIG welder operation and must be done Operation of this welder consists of selecting before starting each welding jobor whenever and adjusting operating controls for optimum any of the following variables are changed: voltage (welding heat) and wire speed set- heat setting wire diameter, or wire type. -
Page 19: Learning To Weld
for a given heat setting by selecting hugher or work best for you. Refer to WELDING POSI- lower wire speed settings. Repeat this tune-in TIONS - p.21) procedure if you select a new heat setting, a Position the Gun to the Work Piece There different diameter wire, or a different type of welding wire. -
Page 20: Welding Techniques
On a fillet weld joint, the nozzle is generally moved steadily and at the right speed along positioned in such a manner so as to split the weld joint. Moving the gun too fast, too the angle between the horizontal and vertical slow, or erratically will prevent proper fusion members of the weld joint. -
Page 21: Welding Positions
There are two basic types of weld beads, the 2. The HORIZONTAL POSITION (Figure 15) stringer bead and the weave bead. is next in difficulty level. It is performed very much the same as the flat weld except that 1. The STRINGER BEAD (Figure 12) is angle B (see HOLDING THE GUN - p.19) is formed by traveling with the gun in a straight such that the wire, and therefore the arc... -
Page 22: Multiple Pass Welding
N TE: WHEN USING SELF-SHIELDING FLUX-CORE WIRE it is very important to thoroughly chip and brush the slag off each completed weld bead before making another WARNING pass or the next pass will be of poor quality. Hot slag can cause fires and serious injury from burns! Be sure to wear protective cloth- ing and eye gear when using the Overhead Position. - Page 23 Punch and Fill, and Lap (see Figure 20). tune in the wire speed as if you were Each has advantages and disadvantages welding the same thickness material with depending on the specific application as well a continuous bead. as personal preference. 3.
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Page 24: Maintenance
Always use a contact tip stamped with the MAINTENANCE same diameter as the wire it will be used GENERAL with. This welder has been engineered to give Note: Due to inherent variances in flux-cored many years of trouble-free service providing welding wire, it may be necessary to use a that a few very simple steps are taken to contact tip one size larger than your flux core... -
Page 25: Testing For A Shorted Nozzle
Failure to keep the nozzle adequately cleaned 6. Remove gun liner holding clamp by can result in the following problems: A removing two self tapping screws and SH RTED nozzle results when spatter two bolts with nuts. buildup bridges the insulation in the nozzle, 7. -
Page 26: Preventive Maintenance
edge of the Cable Holding Clamp. ( The goal is to make sure that the end of the gun liner will be visible after the Cable Holding Clamp is assembled. This will make installing the welding wire much easier. ) 19. - Page 27 TABLE 4 – TR UBLESH TING TR UBLE P SSIBLE CAUSE P SSIBLE REMEDY Dirty, porous, brittle weld 1. Plugged welding nozzle 1. Clean or replace nozzle. 2. No shielding gas 2. Tank empty, flow restricted or 3. Wrong type of gas regulator set too low.
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Page 28: Wiring Diagram
WIRE FEED WELDER WIRING DIAGRAM CM13 GAS/NO GAS CHANGE r ·- ·- · · < L ·- ·- ·- ·J f - - - - - " " " r ·- ·- ·; : w l loiiN T T T -j\- L ·- ·- ·- ·J ..JjL... -
Page 29: Parts List
S2-S3 SWITCH SCHALTER COMM UTATEUR CONMUTADOR COMMUTATOR£ BRENNER BOUTON LSADOR DE LA PULSANTE TORCH TRIGGER SCHALlER TORCHE ANTORCHA. TORC TRANSF OR ADOR TRANSFORM TRANSF ORMATOR TiRANSFORMATEUR TRASFORMATORE CHOKE IMPEOANZ IMPEDANCE PEDANCIA M PEDENZA... - Page 30 WIRE FEED WELDER PARTS LIST FIG # OEM # FORNEY # DESCRIPTION 21690175 85233 FRONT PLASTIC TRIM 22710037 85261 E0795 P.C. BOARD 220/240V + FUSE "CSA" 04600145 85207 MOTOR D.37 + PINION 22210014 85233 THERMOSTAT 100° 10A 22400038 85258 RECTIFIER PMS 8/4/1 F...
- Page 32 WIRE FEED WELDER GUN PARTS LIST IG # OEM # ORNEY # DESCRIPTION 04600163 85296 HANDLE ASSY., BLUE 23005332 85190 GAS VALVE 23005145 85191 SWAN NECK WITH INSULATING COVER 23005091 85377 SWAN NECK LINER 23005285 85192 ISOLATING COVER FOR NECK 23005146 85295 TW1 TORCH DIFFUSER...
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- Page 38 Forney Industries, Inc. 1-800- 21-6038 www.forneyind.com...
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Questions and answers
My forney 180FI has a very small plastic hose to connect to the argon tank but I can't find anyone that knows what kind of regulator it is designed to connect to or how to connect it.
The Forney MIG 180FI requires a regulator that matches the cylinder's connection type. If the cylinder has male regulator connecting threads instead of female, a special compressed gas cylinder adaptor is needed to connect the regulator properly.
This answer is automatically generated