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MT-200, MT-400 & MT-400EHD* These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation This equipment will perform in conformity with the description thereof contained in this manual and accomp ing labels and/or inserts when installed, operated, maintained, and repaired in accordance with the instructions pro- vided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts that are broken, missing, worn, distorted, or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone or written request for service advice be made to the Authorized Distributor from whom it was purchased. This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The user of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty maintenance, damage, improper repair, or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer. TABLE OF CONTENTS I.INTRODUCTION 1.1Scope 1.2Features/Benefits 1.3Required Equipment 1.4Torch Accessory Guide & Selection II.INSTALLATION 2.1Torch Connections 2.1.1Air-Cooled Models III.OPERATION 5.Do not use equipment beyond its ratings. For example, and from ground. 1.Always provide adequate ventilation in the work area by 2.Do not operate near de-greasing and spraying opera- hydrocarbon vapors to form phosgene, a highly toxic 3.If you develop momentary eye, nose, or throat irritation 4.Refer to ANSI/ASC Standard Z49.1 (see listing below) 5.WARNING:This product, when used for welding or 1.Always have qualified personnel perform the installa- 2.Before performing any maintenance work inside a power 3.Maintain cables, grounding wire, connections, power 4.Do not abuse any equipment or accessories. Keep tibles du secteur où l’on exécute des soudures ou des comprend notamment le bois, les vêtements, la sciure, g. Empêchez l’apparition de toute humidité, notamment sur vos vêtements, à la surface de l’emplacement de I. INTRODUCTION and parts information for the MT-200, MT-400 and MT- (a)The MT-400 EHD torch uses HD (Heavy Duty) tips or tubes and EHD (Extra Heavy Duty) threaded nozzles to increase current capacity to 500 amps. Using these accessories will increase the capacity of any MT-400 torch to 500 amps (see Fig. *@ 60% duty cycle (10 min. base) Rated Current Capacity*Wire SizesAvailable ModelCO2Mixed GasesAccommodatedLengths MT-200300 amps200 amps.023" to 1/16"10', 12' or 15' MT-400400 amps275 amps.023" to 3/32"10', 12', 15' or 25' MT-400 EHD500 amps375 amps.035" to 3/32"15' (a) of which are interchangeable with the MT-200 and MT-400 models. strong lightweight and easy to manipulate, providing outstanding comfort and flexibility weld- TABLE 1.2 Basic Torch Assemblies Available (see Fig. 5.1)* *Basic torches do not include liners, contact tips/tubes, or nozzles. Mix and match the accessories listed in Tables 1.4.1, 1.4.3 to customize a torch for your welding application. 1.3REQUIRED EQUIPMENT (See Fig. 1.3) 1.3.1W ire Feeder Connector Assembly - P/N Provides quick connect and disconnect of the MT-200 or MT-400 to a MIG-35, or Digimig Wire Basic Assy./Length10-ft. (3.0m)12-ft. (3.6m)15-ft. (4.5m)25-ft. (7.5m) MT-200998888948921998887 --- MT-40099946994892299947018232 Feeder. It includes power cable, gas hose, and 1.4TORCH ACCESSORY GUIDE & SELECTION - Fig. 1.4, & Tables 1.4.1, 1.4.2 and 1.4.3. Standard Duty Tips and Nozzles provide good perfor- mance and service life for the majority of welding Heavy Duty Tips, Tubes and Nozzles improve the per- high current applications, high spatter wires, pulsed arc pact abuse. Extra Heavy Duty Threaded Nozzles and Heavy Duty Tips and Tubes extend the rating of the MT-400 from 400 amps to 500 amps @ 60% duty cycle. Accessory Selection - Assembly Guide..see Fig. 1.4 Contact Tips and Tubes....................see Table 1.4.1 Nozzles (slip-on or threaded)............see Table 1.4.2 Liners...............................................see Table 1.4.3 Figure 1.4 Accessories Selection - Assembly Guide MT-200 MT-400 STANDARD DUTY SEE TABLE FOR PART .023" M or L .052" S or M .030" M or L 1/16" S or M .035" M or L 5/64" S or M SHORT (S) SEE TABLE FOR PART #6 TAPERED #12 #8 #12 SPOT EXTRA HEAVY HEAVY DUTY STANDARD ACCESSORIES SEE TABLE FOR PART HEAVY DUTY CONTACT TIPS EXTRA HEAVY DUTY SHORT (S) .045" - 3/64" M 1/16" M .052"M 5/64" M 3/32" M SEE TABLE FOR PART HEAVY DUTY CONTACT TUBES SHORT (S) .035" M 1/16" M .045" - 3/64" M 5/64" S .052" M 3/32" S SEE TABLE FOR PART PRIMARY USE OF ACCESSORIES ALTERNATE USE OF ACCESSORIES ACCESSORIES FOR EXTENDED RATING NOZZLE ADAPTOR EXTRA HEAVY ADAPTOR TIP ADAPTOR TIP ADAPTOR ADAPTOR *Using Heavy Duty contact tips or tubes and Extra Duty threaded nozzles will increase the rated capacity of the MT-400 to 500 amps. II. INSTALLATION 1.Install the proper feed roll (see Table 1.3) to the 1Short contact tips are generally recommended to give proper wire stick out for flux cored wire welding. 2Medium contact tips are generally recommended to give proper wire stick out for spray transfer Mig welding. 3Long contact tips are generally recommended to give good visibility and proper wire stick out for dip transferring welding. *The use of Heavy Duty tips & tubes and Extra Heavy Duty threaded nozzles extends the rating of the MT-400 to 500 amps @ 60% du +Use with Nozzle Adaptor (999452) Use with Nozzle Adaptor (948793) and Extra Heavy Duty Adaptor (17318) Notched for improved arc starting and increased tip life. Table 1.4.1 Recommended Contact Tips, Tubes and Adaptors Standard DutyHeavy Duty*Heavy Duty* WireContact TipsContact TipsContact Tubes Sizes & TypeShort For Hard and Cored Wires .023” (.6mm)-20543999742---- .030” (.8mm)-20544996994---- .035” (.9mm)-996995996996---17163 .040” (1.0mm)-3728737288---- .045” (1.2mm)999578 -37286 -37292 .052” (1.4mm)948340 --17778 -17155 1/16” (1.6mm)948341 --37291 -17157 5/64” (2.0mm)-2075230 -948832 -17159 3/32” (2.4mm)---948833 -17161 For Soft (Aluminum) Wires .023” (.6mm)-20543999742---- .030” (.8mm)-20544996994---- .030” (.8mm)-36884 ----- .035” (.9mm)-996995996996---- .035” (.9mm)-36885 ----- .040” (1.0mm)-3728737288---- 3/64” (1.2mm)-996999--1776517164 3/64” (1.2mm)-36886 ----- 1/16” (1.6mm)-996997--948835-- TABLE 1.4.2 Recommended Nozzles Accessories NozzleSlide-On, Self-Insulated*Threaded Standard DutyHeavy DutyExtra HeavyExtra Heavy DescriptionI.D.StandardLong-Life StandardLong-Life duty (Brass)Duty #6 Tapered3/8”998895998895XL---- #81/2”998893998893XL999471999471XL-948767 #105/8”998894998894XL999472999472XL-948768 #123/4”--999473-17350948769 #12 Spot3/4”17316 -999625--- #16 Spot1”-----999900 *Slide-on, Self-Insulated Nozzles require Adaptor 999452. +Threaded Nozzles require Extra Heavy Duty Adaptor 17318 and Nozzle Adaptor 948793. Requires 17293 Tip Adaptor (replaces standard tip adaptor) and 17321 Nozzle Insulator. Long-life nozzles are coated to reduce weld spatter adherence and extend life on nozzle. III. OPERATION -200 is rated to operate up to 300 amps ; 200 amps using mixed gases (60% duty -400 is rated to operate up to 400 amps us- ; 250 amps using mixed gases (60% duty WireLiner Size & Type10'12'15'25' Hard Wires & Cored Wires .023"(.6mm)999743*34929*-- .030"(.8mm)94885017717-- .035"(.9mm)207523717718207523818235 .045"(1.2mm)207523717718207523818235 .052"(1.4mm)207523917719207524018236 1/16"(1.6mm)207523917719208524018236 5/64"(2.0mm)2075245177202075246- 3/32"(2.4mm)2075245+177202075246- Soft Wires (aluminum) .035"(.9mm)94886233931-- 3/64"(1.2mm)94886334932-- 1/16"(1.6mm)19065**--- TABLE 1.4.3 Recommended Liners Accessories *Requires support liner for .023" wire. Order P/N 999797 for 10 ft. or P/N 34930 for 12 ft. **Requires Support Liner, P/N 34930. +45° curved wire guide (P/N 18243) recommended for 3/32" wire. Figure 2.1 - MT-200 or MT-400 Torch and Wire Feed Connector Shown Attached to MIG-35 Wire Feeder CONNECTOR MT-200 OR MT-400 TORCH (Part of Wire Feeder HOT. Do NOT touch the wire as it may cause a servicing be done by an authorized service facility. service facility, adequately packaged, in the original shipping container, if possible, and shipped prepaid, To avoid shock, do not depress trigger while han- IMPORTANT Never use torch as a hammer to remove spatter. 3.4SHUTDOWN PROCEDURE unless otherwise instructed here. Remove main rolls start. Keep fingers clear of drive rolls. Do parts manufactured and sold by ESAB Welding & Cut- 4.3NOZZLES IMPORTANT Do not hammer torch or nozzle to remove spatter. with a hand reamer or file. Adherence of spatter can inside of the nozzle with No. 65 Nozzle Anti-Spatter 4.4WIRE FEED LINER (Except 0.023-in liner, see To remove liner for cleaning or replacement, proceed 1.Remove nozzle, contact tip, tip adaptor and front insulator. 4.Be sure to wear proper eye and face protection. 8.After seating the liner ferrule fully into the cable 10.If installing a new replacement liner, it should be guide. Proceed as follows: a.Snip off excess liner with a sharp cutting tool so that the liner extends 3/16-in. to 1/4-in. (5- 6mm) from the face of the nozzle adaptor. b.Remove any sharp burrs on end (O.D. and I.D.) of the spring liner. Burrs could cause wire to 11.Install tip adaptor wrench tight to seat the liner. NOTE:When assembling a new curved wire guide, on the pipe threads. The threads should be conductive material already applied. Assemble 4.7TORCH SWITCH IMPORTANT: Fig. 5.1 - Replacement Parts - MT-200 & MT-400 Basic Torch Assemblies Basic Torch 8 2 23 ** 15 17 1312 ITEMQTY.PART NO.REQ'D.NO.DESCRIPTION 11Handle and Cable Assembly: 99889010-Ft., MT-200 (includes Handle 20829 and Cable 21097) 1771512-Ft., MT-200 (includes Handle 20829 and Cable 21098) 99888915-Ft., MT-200 (includes Handle 20829 and Cable 21099) 94807510-Ft., MT-400 (includes Handle 20948 and Cable 21146) 1771612-Ft., MT-400 (includes Handle 20948 and Cable 21147) 94807615-Ft., MT-400 (includes Handle 20948 and Cable 21148) 1823325-Ft., MT-400 (includes Handle 20948 and Cable 21149) 222062294*Terminal, (Supplied in Pkg. of 10) 32950400*Clamp (Supplied in Pkg of 10) 41948069*Plug Housing 522062344*Plug Terminal (Supplied in Pkg of 10) 62493552*O-Ring .489ID x .070 Neopr 70A MT-200 Basic Torch Assembly, 10-Ft., 998888MT-400 Basic Torch Assembly, 10-Ft., 999469 MT-200 Basic Torch Assembly, 12-Ft., 948921MT-400 Basic Torch Assembly, 12-Ft., 948922 MT-200 Basic Torch Assembly, 15-Ft., 998887MT-400 Basic Torch Assembly, 15-Ft., 999470 MT-400 Basic Torch Assembly, 25-Ft., 18232 Figure 5.2 - Replacement Parts - Wire Feeder Connector Assembly (for Mig-35/Digimig Wire Feeders) -- P/N 2075378 W. F. CONNECTOR - 2075380 CONNECTOR - 2075366 GAS HOSE ASS'Y - 2075381 NIPPLE - 11N22 Items included with WIRE FEEDER CONNECTOR ASS'Y (ESAB) - 2075378 PO Box 100545 Florence SC 29501-0545 F-12-778H 06/99 Printed in U.S.A. A.CUSTOMER SERVICE QUESTIONS: Order EntryProduct AvailabilityPricingDelivery