MZ-1

SUBMERGED ARC WELDING TRACTOR

OPERATOR’S MANUAL
(PLEASE READ CAREFELLY BEFORE OPERATION)

CHENGDU HUAYUAN ELECTRIC EQUIPMENT CO., LTD.

 MZ-1 TRACTOR OPERATOR’S MANUAL

Safety Depends on You

Huayuan arc welding and cutting equipment is designed and built with safety in mind. However, your overall
safety can be increased by proper installation and thoughtful operation on your part.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE
SAFETY PRECAUTIONS CONTAINED THROUGHOUT.

Attention (very important)

1. Don`t let the tractor fall when it is on a slope position.
2. The tractor can`t be used in rain because its protection grade is IP21C.
3. Please don`t wear glove when guiding wire and changing wire reel.

Control box Cross arm rotation Across Hanging Wire Flux Flux hopper Head angle
locking handle & lift lock arm lock ring guide unit hopper switch lock

Head elevation
Control box angle adjustment

Wire feed rollers

Press wheel and

adjustment
handle
Wire reel

Upper corrective
wheel and handle

Cable jacket Head up-down

adjustment Lower
corrective wheel
Wiring board

Conductive rod
clamping unit
Clutch

Flux tube
Handle

Conductive rod

Wheel Column moving adjustment Conductive tip probe Flux hopper clamping nut

Figure 1 tractor construction

Purchase Date：
Serial Number：
Machine Model：
Purchase Place：

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Caut ions Arc and arc rays can hurt.

All performing welding workers ought to have health qualification from the authority organization to
prevent you and others from arc radiation and burn. It should be prevented for children to enter into
dangerous area as well.
Be careful reading the following important items and the welder safety byelaw from the authority
organization. Be sure that qualified professionals perform all installation, maintenances and repair
procedures.

1 Electric shock: The welding circuits are not insulated when welding. If you touch the
two output electrodes of the machine with your bare skin at the same time, it will lead to
electric shock, sometimes even fatal dangers. Users need to follow the items below to
avoid electric shocks:
 If possible, lay some insulating materials, which are dry and large enough, in your working field.
Otherwise, use the automatic or semiautomatic welding machine, DC welding machine as possible
as you can.
 Components in the automatic and semiautomatic welding machine such as the welding wire reel,
feed wheel, contact tip and welding head are all electric components. .
 Always be sure the machine has been connected perfectly to the work piece with the work cables

and should be as close as possible to the working area.

 The work piece should be grounded perfectly.
 Make sure that the insulating material of the electrode holder, the grounding clamp, the welding
cable and the welding head are not affected by damp, mildewed or spoilt, and be replaced
momentarily.
 Never dip the electrode in water for cooling.
 Never touch electric components of two welding machines at the same time, because this voltage is
supposed to be two times of welding voltage while the grounding mode is not clear.
 While working high above the ground or other places having the risk of falling, please be sure to
wear safety belt to avoid losing balance caused by electric shock.
2 Arc: Use an arc welding mask to protect your eyes and skin from sparks and the rays of
the arc, pay special attention to the filter glass, which must be conformable to the
national standard.
 Use clothing made from durable flame-resistant material or sailcloth to protect your skin from
hurting by the arc rays.
 Remind other nearby personnel before working lest arc rays hurt them by accident.
3 Fumes and Gases: Welding may produce fumes and gases hazardous to health. Avoid
breathing these fumes and gases. While working in limited room, use enough ventilation
and/or exhaust to keep fumes and gases away from the breathing zone, or use the
respirator. Do not weld at the same time when using of degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with these gases to form phosgene, a highly toxic gas,
 Some protective gases used in welding might displace the oxygen in the air, and can lead to hurt or
even death.
 Read and understand the manufacturer’s instructions for this equipment, and validate the health

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 MZ-1 TRACTOR OPERATOR’S MANUAL
certification of consumptive materials, make sure they are innocuous.

4 Spatter: Spatter can cause fire or explosion.

 Remove fire hazards from the welding area. Remember that spatter from welding
can easily go through small cracks and touch fire hazards. Protect all kinds of lines
going though welding area, including hydraulic lines in the wild.
 Where compressed gases are to be used in the field, special precautions should be used to prevent
explosion.
 When welding stops, make certain that no live part is touching the work piece or the work stage.
Accidental contact can create a fire hazard.
 Do not weld containers or lines, which are not proved to be innocuous.
 It is very dangerous to heat, cut or weld tanks or containers at entry holes. Does not start work until
the proper steps have been taken to insure that there is no flammable or toxic gas.
 Spatter might cause burn. Wear leather gloves, heavy shirt, cuffless trousers, high shoes and a cap
over your hair to prevent from burning by spatter. Wear the ear shield when performing sideways
or face up welding. Always wear safety glasses with side shields when being in a welding area.
 The welding cables should be as close to the welding area as possible, and the short, the better.
Avoid welding cables going through the building framework, lifting chains, AC or DC cables of
other welding machines and appliances. The welding current is strong enough to damage them
while having short circuit with them.
5 Cylinder: Damage of it might cause explosion.
 Make sure that the gas in the storage cylinder is qualified for welding, and the
decompression flow-meter, the adapter and the pipe are all in good condition.
 Make sure that the installation of cylinder is by the wall and bundled tightly by a chain.
 Be sure to put the cylinder in the working space with no crash or shake, and far from welding area.
 It is forbidden to touch cylinder with the welding clamp or the work cables.
 Avoid facing the cylinder while installing the decompression flow-meter or the gasometer.
 When not working, please tighten the valve.
6 Power: (For electrically powered welding and cutting equipment) Turn off input power
before installation, maintenances and repair, so that avoid accident.
 HUAYUAN welding equipment is Ι class safeguard equipment; please install the
equipment in accordance with the manufacturer’s recommendations by specific persons.
 Ground the equipment perfectly in accordance with the manufacturer’s recommendations.
7 Power:(For engine driven welding and cutting equipment)
 Work in ventilated place or outdoors.

 Do not add fuel near to fire or during engine starting or welding. When not working,
add fuel after engine is cooling down; otherwise, the evaporation of hot fuel would
result in dangers. Do not splash fuel out of the fuel tank, and do not start the engine
until complete evaporation of the outside fuel.
 Make sure that all the safeguard equipments, machine cover and devices are all in a
good condition. Be sure that arms, clothes and all the tools do not touch all the
moving and rotating components including V belt, gear and fan etc.
 Sometimes having to dismantle some parts of the device during maintenance, but must keep safety
awareness strongly every time.

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 MZ-1 TRACTOR OPERATOR’S MANUAL
 Do not put your hand close to fans and do not move the brake handle while operating.
 Please remove the connection between the engine and the welding equipment to avoid sudden
starting during maintenances.
 When engine is hot, it is forbidden to open the airtight cover of the radiator water tank to avoid hurt
by the hot vapor.
8 Electromagnetic: Welding current going though any area can generate electromagnetic,
as well as the welding equipment itself.
 Electromagnetic would affect cardiac pacemaker, the cardiac pacemaker users should
consult one’s doctor first.
 The effect of electromagnetic to one’s health is not confirmed, so it might have some negative
effect to one’s health.
 Welders may use following method to reduce the hazardous of electromagnetic:
a. Bundle the cable connected to the work piece and the welding cable together.
b. Do not enwind partially or entirely your body with the cable.
c. Do not place yourself between the welding cable and the ground (work piece) cable, if the welding
cable is by your left side, then the ground cable should be by your left side too.
d. The Welding cable and the ground cable are as short as possible.
e. Do not work near to the welding power source.
9 Lift Equipment: carton or wooden boxes package the welding machines supplied by
HUAYUAN. There is no lifting equipment in its wrapper. Users can move it to the
prospective area by a fork-lift truck, and then open the box.
 If having rings, the machine can be transited using rings. While HUAYUAN Welding
Machine Manufacture reminds users, there is possible risk to damage the welding
machine. It is better to push the welding machine moving in use of its rollers unless
special situations.
 Be sure that the appurtenances are all removed off when lifting.
 When lifting, make sure that there is no person below the welding machine, and
remind people passing by at any moment.
 Do not move the hoist too fast.

10 Noise: HUAYUAN Welding Machine Manufacture reminds users: Noise beyond the
limit (over 80 db) can cause injury to vision, heart and audition depending on oneself.
Please consult local medical institution. Use the equipment with doctor’s permission
would help to keeping healthy.

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CONTENTS
 Product introduction ……………………………………………… 6

 Welding machine installation ……………………………………… 8

 Tractor structure and panel ………………………………………… 8

 Operation principles ……………………………………………… 12

 Maintenance and repair ……………………………………………… 13

The general troubles and treatment methods ………………………… 14

The methods of inspecting motor …………………………………… 17

The methods of inspecting main control PCB ……………………… 18

The methods of inspecting the control cable ………………………… 18

The states of indicator lights ………………………………………… 19

The jump-lines on the PCB ………………………………………… 19

 The welding defects and preventions ………………………………… 21

 Diagram …………………………………………………………… 22

 Accessories ………………………………………………………… 22

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 MZ-1 TRACTOR OPERATOR’S MANUAL

SAFETY
For the electrical wires and terminals inside the Control Box over the safe voltage, only the trained personnel
should open the machine cover to check it.

 Product Introduction

1. Instruction on Model

Model: M Z — 1

Internal-used series number

Automatic Submerged Arc Welding

Name: Submerged Arc Welding Tractor

2. Application Field & Condition

1） This welding tractor, assembled with submerged arc welding machine power source, can
automatically weld under flux layer. It is mainly used for welding various steel plate structure with
groove or without groove, such as butt weld, fillet weld and lap weld etc, and these kinds of
welding seam can be at horizontal level or on inclined surface with inclination angle less than 10°
with horizontal level. This machine can weld the steel carbon structure steel, low alloy structure
steel, stainless steel, heat-proof steel and compound steel etc.

2）Environment condition
a. Power supply quality
The waveform of power supply voltage should be actual sinusoid wave, the fluctuation of
frequency can`t exceed its rated value ± 1%； the fluctuation of power supply voltage can`t
exceed its rated value ±10%.
b. Environment condition
The ambient air temperature range:
Welding: -10～+40℃；transport and store: -25～+55℃
Relative humidity level: at 40℃, ≦50%
at 20℃, ≦90%
The dust, corrosive gas and materials around working place should not exceed the normal
content and the machine should be used in the place with sea level less than 1000m, dry and
ventilation and be prevented from sunshine and raining.

3. Technical Specifications:

Item Parameter

The rated supply voltage 1~110V/50Hz (usually supplied by power source)

Suitable diameter of wire φ3.0, 4.0, 5.0, 6.0mm

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Rated welding current 1600A

Rated duty cycle 100%

Welding speed 0～155cm/min

Wire-feed speed 40～2000cm/min (can choose 135～675cm/min)

Wire feed method constant or alternate wire-feed

Adjustable range of up-down (The tractor’s column) 140mm

Horizontal adjustable range of (The tractor’s head) 93mm

The distance of tractor wheel 300mm

The distance of tractor axes 350mm

Horizontal rotated angle (the head round the column) ±90 °

Front-back sloped angle (the tractor`s head) ±30°

Left-right sloped angle (the tractor`s head) ±30°

Capacity of flux hopper 10L

Capacity of wire reel 25KG

Protection grade IP21C

Weight (without flux and wire) 90KG

External dimension 1010×510×930mm

4. External dimension:
930

3 50 30 0
580
3 60
1010

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 MZ-1 TRACTOR OPERATOR’S MANUAL

 Welding machine installation

断路器
此处若接触不好，将会有“手 动
送丝”正常但启动后不能送丝的
3～380V 焊接电源 故障。

MZV小车

10
送丝 10
行走 9
1 ～3

弧压采样 9
8
焊接电缆 控制电缆 行走
7
6
接地电缆

工件

Figure 2 The wiring connection drawing of SAW installation

1. The welding power source should be installed as per the requirements of corresponding instruction

manual.

2. Usually connect one terminal of welding cable with output terminal “+” of power source, connect the

other side with the conductive board of the tractor, and connect one terminal of ground cable with

terminal “－” of power source, connect the other side with workpiece. If the positive pole& negative pole

are connected mistakenly, the manual wire feeding and welding does not work.

If work with DC electrode negative type, the positive& negative line of output terminal should be

exchanged, connect the workpiece to positive pole of power source and connect the tractor with negative

pole. (Meanwhile, exchange the signal wire at the back of tractor voltmeter by professional person)

3. The multi-core control cable connects the “control” signal output terminal of power source with control

box connector of tractor firmly.

2
4. Connect the tractor with ground firmly by copper-core wire ≥Φ1.0mm

 Tractor structure and panel

1. Tractor structure (see figure 1)

1) Wire reel: have welding wire put into wire reel before welding orderly.

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 MZ-1 TRACTOR OPERATOR’S MANUAL
2) Control box: during submerged arc welding all control is operated through control box.

3) Box locking handle: loosen the handle, control box can be turned right or left.

4) Across arm lock: loosen two nuts fixed in across arm lock, the across arm can be moved forward and
backward, then lock the across arm in the required position.

5) Hanging ring: to lift the tractor.

6) Cross arm rotation& lift lock: loosen the handle, the cross arm can rotate around the column ±90°, and
adjust the height of the head to meet the different welding position requirements.

7) Flux hopper: Store the flux. adjust the switch below the hopper to control the flux flow.

8) Wire guide unit: pass the wire through the location hole on the top of wire guide unit before sending it to
conductive rod.

9) Head angle adjustment: loose this handle, the head can rotate around the cross arm to ±30°.

10)Wire feed rollers: This wheel is a wearing part. See the appendix figures.

11) Head elevation angle: it can adjust the elevation angle range ±30°by loosening head with the K6
inner six-corner spanner.

12) Press wheel and adjustment handle: adjust the press strength of the wire by this handle.

13) Upper corrective wheel and handle: correct the straightening strength of wire.

14) Lower corrective wheel: work with upper corrective wheel.

15) Conductive rod clamping unit: for connecting welding cable with conductive rod firmly. Please check
the joint connection condition regularly.

16) Conductive rod: customer can choose different length of conductive rod to change the length of
electrode and meet the different workpiece welding requirements. Customers can change its length by
themselves.

17)Probe: instruct and guide the welding arc moving along with required track.

18) Conductive tip: It belongs to wearing part and is used for conducting electricity. Notes: the
corresponding conductive tip should be selected to match with different diameter wires.

19) Flux hopper clamping nut: clamp the flux hopper and adjust the extension length of electrode to meet
the different welding positions of butt weld, fillet weld.

20) Flux tube: the flux flows to the welding area through this tube.

21) Head up-down adjustment: adjust handle to regulate the wire extension to meet the height change of
workpiece.

22) Column moving adjustment: adjust it to align the wire to welding seam.

23) Wheel: tractor travels depending on these wheels, the distance of wheel is 300mm and width is 30mm.

24) Clutch switch: Turn on this switch and tractor travels automatically while welding. Turn off this switch
to move the tractor to the welding position manually.

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 MZ-1 TRACTOR OPERATOR’S MANUAL
25) Handle: for moving the tractor.

26) Wiring board and cable jacket: connect the cable of power source with wiring board firmly and pack it
by cable jacket.

2. The tractor’s control panel and functions

Power indicator
light
Voltmeter

Power switch
Ammeter

Welding Speed
Output control

6.Wire-feed speed
Wire-feed mode

Start
Manual/auto
Stop Wire feed inch arc volt/ welding speed Left/right travel

Figure 3. Front control panel of the tractor

2.1 Ammeter: display the actual welding current.

2.2 Voltmeter: display actually welding voltage or walking-motor voltage, which is Controlled by the

selection switch arc volt./welding speed.

2.3 Power indicator light：Indicate if the tractor is energized.

2.4 Power switch：the power source main switch of control box.

2.5 Output control: adjust the output welding current on the constant current mode; adjust the output

welding voltage on the constant voltage mode. Rotate this knob clockwise and the output will be

increased.

2.6 Wire-feed speed: adjust feed speed of different diameter wires. Rotate the knob clockwise and the

wire-feed speed will be increased.

To adjust the welding current when the welding source works with a constant voltage characteristic,

rotates the knob clockwise and the welding current will be increased. To adjust the welding voltage

with a constant current characteristic , rotates the knob clockwise and the welding voltage will be

reduced.

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 MZ-1 TRACTOR OPERATOR’S MANUAL

Attention: The knobs of the wire-feed speed and output control should be cooperated, because the

dynamic characteristic of the machine is not ideal constant current or constant voltage characteristic,

adjusting the wire-speed can cause the output change naturally. To adjust the output current/voltage

carefully, in order to obtain the ideal welding parameter.

2.7 Start button: Press this button, start the welding.

2.8 Stop button: After finishing welding press this button, welding will stop immediately.

2.9 Wire-Feed inch: This switch is used to adjust welding wire up or down. When welding wire touches

the workpiece, the wire feeding will stop automatically.

2.10 Arc voltage/ Welding speed: when the knob switches to ‘Arc voltage’ position, voltmeter displays

the arc voltage; when switches to ‘Welding speed’ position, voltmeter displays voltage of the

traveling-motor.

2.11 Welding speed: To adjust the travel speed of the welding tractor. The tractor travels distance per

minute at different voltage as follows. This data is only for your reference, because the data differs

from each tractor.

Table 1 Relationship between welding speed and voltage value showed in voltmeter

Voltage (V) 10 20 30 40 45 50 55 60 65 70 80 90 100

Speed cm/min 10 20.2 30.4 40.6 45.8 51 57 62 68 73 82 93.4 106

2.12 Left/ right control: To change the direction of the welding tractor travel.

Notice: When changing the direction of tractor traveling, make sure the tractor has already stopped. In

normal condition, the traveling speed should be lower than the indicated voltage value 60V. When it is higher

than 60V, the tractor traveling direction must be changed under emergency, the tractor speed should be

reduced first through adjusting the welding speed, or turn off the power switch to prevent occurring

unexpected incident, then the traveling direction can be changed.

2.13 Manual/auto switch: Switching to the ‘auto’ position and pressing the start button, the tractor will

travel automatically, the machine will strike arc and start welding at same time; when switching to

‘manual’ position, the tractor travel speed(welding speed) can be preset for welding.

2.14 Wire-feed mode: when the output of welding machine is dropping characteristic, recommend to

select the constant current mode. When the thin wire is used to weld, the machine output is constant voltage

characteristic, the wire feed mode should be constant voltage mode.

Note: The wire feed mode has been fixed already in the control box under constant current in factory,

user should only have the ZD5 welding source function switch under submerged arc welding and dropping

characteristic position while welding. If user want to use the constant voltage function of submerged arc

welding, please have the wire feed mode switched to constant voltage characteristic, and the power source

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 MZ-1 TRACTOR OPERATOR’S MANUAL

should also be under constant voltage characteristic.

 Operation principles
The power supply of circuit mainly depends on the main power source 110V/AC supply, which passes
through fuse 1.5A/220V, power switch and connects through control circuit, then after rectifying it passes
through filter circuit and supply power to control power source. The direct current that is not filtered supplies
directly for the DC servomotor.
The control power source is a standard switched power source, which outputs two independent 25V and
one 16V direct current. One 25V outputs a 15V voltage regulation signal through LM7815, which is used for
the whole system; 25V is used for the systematic relays at the same time. Another 25V DC supply is for the
manual wire feed of sampling arc voltage. When it is manual wire feed, apply this voltage to both poles
(negative and positive). The 16V DC supply is for the sampling circuit of welding current, and is used to
isolate with the electric connection of main welding circuit to ensure system safety.
The command signals sent out by the control panel or the remote control box are gathered to the
program control circuit at first. These signals are judged its rationality by the program control circuit again,
then the correct command signal is sent to each performance circuit that perform the action such as starting,
feeding wire, returning wire, traveling, stopping etc.
When turn on the switch of INCH UP, the voltage checking circuit send out an output checking voltage
under corresponding condition (the machine does not work for welding). When the program circuit checks out
the arc signal of voltage checking circuit, it sends a wire feed command to the feed wire/return wire logic
control circuit. When welding wire touches the workpiece, Arc voltage disappears, the voltage checking
circuit shows the short circuit signal at once, the program control circuit send out the command of braking, at
this moment the welding wire will touch the workpiece gently. There will be no wire feed action if the switch
of INCH UP is turned on again at this moment.
When turn on the switch of INCH DOWN, the program control circuit send the command signal to the
feed wire circuit which has the feeding motor rotation reversed, and the wire begins to return. If the machine
is working for welding at this moment, the control program circuit will not perform the command signal of
returning wire.
The program control circuit is regulated that the wire feed can work only while the arc voltage is normal,
otherwise only return wire (INCH UP, for being offered an additional 25V voltage, arc voltage is thought to
be normal at this moment) can work.
The voltage checking circuit is to check whether there is voltage existing between the (+) pole and the (-)
pole, and isolate the sampling voltage with linear characteristic, allow the voltage to be reverse –-change
polarity. Again, this isolated voltage signal is sent to the program control circuit to supply the alternate
wire-feed, meanwhile it sends out the order through the program control circuit, transports a group of control
voltage to both poles for manual wire feed.
The current checking circuit is used to adjust the current signal from the welding power output, in order
to avoid the signal distortion caused by line loss. Meanwhile, it is used to check circuit and send out the
existing current signal to the program control circuit. The current sampling circuit adopts a group of
independent supply power, which isolates the control circuit from the main welding circuit. When the polarity
of welding is changed, any altering action is unnecessary.

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 MZ-1 TRACTOR OPERATOR’S MANUAL

启动
手动 退 方向
送丝 /退 丝 控制
丝电 路 给定
控制 逻辑 电源

电极
整
滤波 控制 电源 电 压 隔离 反 馈 电压 检 电压 线
流
电 压 状态 指 示 测电 路 性隔 离
桥

15 V/2 5V
焊枪
启 动 按钮 焊 接 状态 控 制
程 序 控制 电路

停止 按 钮 电 流 状态 指 示
送 丝按 钮
16 V
电流表
电 流 检测 显示

电 源给 定 送丝 给 定 电压 表
电 流 信号 输 入
电 源给 定

主 电 路 手 动送 丝 电路

Figure 4 control system

◆ Maintain and Repair

Attention: Only qualified technicians should perform troubleshooting work on the
machine. If for any reason you do not understand the test procedures or are unable to
perform the tests/repairs safely, contact our service department for technical
assistance.

When the equipment goes wrong, please check according to the following steps in case of authorizing.

The first step: Confirm the trouble reasons

Reading table 1 " the general trouble and treatment method", this table shows the general trouble
appearing probably and common treatment method, find out the trouble most close to the actual conditions in
tabulating.

The second step: Check the outside parts

Read the checking method 1 ‘The method of inspecting motor’, according to the methods of checking
the wire-feed motor and travel motor to judge whether they are damaged.

The third step: check the main control board.

Read the table 4 “indicating working status”, check the status of indicator lights, confirm all indicator
lamps status while trouble occurs and write down. The trouble is repaired by the professional under
authorizing

All above-mentioned methods are unable to solve the troubles, or users are unable to do
above-mentioned methods, please contact the local retail trader, or contact the service apartment of

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 MZ-1 TRACTOR OPERATOR’S MANUAL
HUAYUAN Company of China directly.

Table 2. The general trouble and treatment methods

TROUBLE Checking items Analyzing and conclusion

Checking the welding control cable

A． To measure the resistance between the 7 and 8 lines of the
welding control cables, the value ought to be about If there is no trouble in control
GZ1 infinite. cable, the power source can be in
Indicator light trouble
doesn’t illuminate If fuse has damaged, replace a 3A，
while turn on the B. Check fuse
Φ5×20 fuse
machine
C． Open machine top cover and observe the indicator on the 110V1~110V2 are on PCB board
main control PCB, if all of them don’t illuminate, the test CN7, the main control PCB is
value of the resistances between 110V1～110V2 are zero. damaged.
D. The plug SK1 and SN7 connection is loose Reconnect these plugs.
Don’t start again after turning off
A. To stop later, others are normal
GZ2 the machine in 20 seconds.
The wire is returning B. VA,VS lights on ,others light off. The wire feed is normal. The main control PCB is damaged
after turning on the
machine C．Same to above B. But there is no wire feed. The switch of wire feed is damaged

A. VE,VJ can work at same time. There is no wire feed while The main control PCB is damaged
GZ3 welding （the H bridge is damaged）
Can’t feed and return B VE,VJ indicator lamps don't illuminate at the same time, but The middle point line of wire feed
wire it is normal while welding. switch doesn’t get through, it must
be checked.
A． The voltmeter displays 20v value and stop working while The contacts of the wire feed switch
welding wire touches the workpiece. are linked together.
GZ4 The logical circuit of the main
B． VJ light off，VE light on
Feeding wire after control PCB is damaged
turning on the The contacts of the start button is
C． Welding power source is started
machine linked together.
The logical circuit is damaged,
D. VJ light on, but VE off
change the main control board.
GZ5 Test the resistance value of INCU~SGND on the CN7, and no
The circuit does not get through.
No manual wire feed, resistance value change occurs with the operating of switch.
but others work Motor drive circuit is damaged,
Otherwise
normally. change the main control board

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 MZ-1 TRACTOR OPERATOR’S MANUAL
GZ6
When the wire The voltage checking circuit in the
The welding wire surface should be clean. Otherwise, VG light
touches the work main control is damaged, and the
on and VH light off while feeding wire manually.
piece, it doesn’t stop main control PCB must be changed.
automatically.
A．VL light is FGW+ to CW104 ﹥ 1KΩ
on while
FGW- to CW104 upper position ﹥4. 7KΩ
GZ7 starting
The connection lines of FGW does
The wire Feed speed machine.
not get through, check it and repair.
is not adjustable Measure the
The resistance value between FGWD to
while welding; but resistance
CW104 is not adjustable.
manual wire feed is after power
normal off.
The logical circuit is damaged.
B．VB light is on and VL is off while starting
Replace the main control board.

*GZ8
A. R122 or D28 is not damaged Q102（C1318）is damaged.
Both the welding and
manual wire feed are
maximum and Replace resistor of 100 Ω or
B．R122 or D28 is damaged.
non-adjustable 1N4007 diode

A. Check as per GZ7 A, FGW don`t connect Please check it

GZ9
Voltage checking circuit is
Both the welding and
B. Change the VV to CV, then it comes into normal. damaged, change the main PCB
manual wire feed are
board
minimum and
unstable. C. D107 is normal. Change CW103 (3296-502)

A. The power indicator lamp works normally, but the

GZ10
voltmeter didn't display the 20V value, return wire Voltage checking circuit of main
No wire feed. After
normally. The value between work~tort of CN7 is 100Ω control board is damaged
starting machine
while power off(Only return wire)
there is no wire feed
or and only return B. The value of meter is more than 105Ω(only return wire) CN7 has problem

wire.
C. The fuse is broken when start the machine (no wire-feed) Motor is damaged or short circuit

The start button contacts loosely, or

A． VB light off while starting
CN7 contact loosely.
GZ11
The line between PEN1, PEN2 and
There is no voltage
B． VB VK light on，but no output voltage. power source does not get through,
display after starting
it must be checked.
machine, but manual
The logical circuit of the main
wire feed and return C． VB light on, but VK light off
control PCB is damaged.
wire is normal.
The WORK line of CN7 cannot
D．VG light off after starting
connect with 13th pin of SK1.

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 MZ-1 TRACTOR OPERATOR’S MANUAL
One connection line on the upper
GZ12 VE, VJ indicating lamps does not illuminate. After short circuit
contact of the wire feed switch does
No manual wire feed, the middle contact and upper contact of the wire feed switch,
not get through, and this must be
but others are normal there is wire feed.
checked.
A. Start the pgw+～CW103 upper contact is more PGW connection has trouble, it
machine the than 1K must be checked.
VL light on, Pgwd ～ CW103 upper contact
turn off the resistance value is not adjustable
machine, PGW-～CW103 upper contact is more PGW connection has trouble, it
and test the than 4.7K must be checked.
resistance PGW+～SK1.2
value by use PGW+～SK1.3
GZ13
of
The voltage output is PGW+～SK1.4
multimeter
not adjustable
The logical circuit of the main
VJ light on after starting machine control PCB is damaged. Replace
it.
B. VK light on, VJ light off, the index of ammeter does CRT+ ～ SK1.11 or CRT- ～ SK1.12
VL light off not move. has trouble, it must be checked.
Current checking circuit is
The index of ammeter shakes damaged, replace the main control
PCB
A. When Start/ Stop, VK light on. Power off, take apart CN7, *RL2 is under trouble, change
power source turn off. relay(DS2Y-S-DC24V)
GZ14 The logical circuit of the main
B. When Start/Stop, VK always light on, and VB, VC light
Cannot turn off the control PCB is damaged. Replace
on.
power source it.
C. VB always light on, the value of STAT/SGND resistance The start button is damaged, change
is less than 10Ω it (BX2DA142 green)
A. The VC light off when stop, no stop for the value of The stop button is damaged or either
STOP/SGND after power off. STOP or SGND line is broken
GZ15
The power source The logical circuit of the main

can`t stop after B. The VC light on when stop, but VK always light on control PCB was damaged. Replace

starting it.

C. The VC light on when stop and VK light on normally Main power source has problem

GZ16 Tractor drive circuit is under

No condition
Tractor doesn’t move trouble, change main control board
The circuit from SGND to manual
GZ17
Power off , then test the value of MENB/SGND under manual switch has trouble, or the switch
It doesn`t move under
mode, which is more than 10. (KN1-203) is damaged, it must be
manual mode
checked.

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 MZ-1 TRACTOR OPERATOR’S MANUAL
The circuit from MAUT to manual
A. Power off , then test the value of MENB/MAUT under switch has trouble, or the switch
GZ18 auto mode, which is more than 10Ω. (KN1-203) is damaged, it must be
It moves under repaired.
manual mode The tractor drive circuit is under
B. Power off, then test the value of MENB/MAUT under
trouble, replace the main control
auto mode, which is less than 10Ω.
board
GZ19
The tractor drive circuit is under
The tractor doesn`t
No condition trouble, replace the main control
stop when on auto
board
mode
A. Power off , then test the value of upper contact from The circuit is under trouble, CN7 or
MGWH to CW201, which is more than 10Ω CW201 must be checked
B. Power off, then test the value of upper contact from
GZ20 The circuit is under trouble, CN7 or
MGWH to MGWD, which is more than 4.7K and cannot
The tractor is out of CW201 must be checked
be adjusted
control when move
The tractor drive circuit is under
C. All above test is normal trouble, replace the main control
board
A. Power off , then test the value of upper contact from The circuit is under trouble, CN7 or
MGWL to CW201, which is more than 10Ω CW201 must be checked
GZ21 B. Power off , then test the value of upper contact from
The circuit is under trouble, CN7 or
The speed of tractor MGWL to MGWD, which is more than 4.7K and cannot
CW201 must be checked
is slow and can`t be adjusted
adjust C. All above test is normal The tractor drive circuit is under
trouble, replace the main control
board

Warning
The trained personnel by Huayuan Company can perform serves and repairs. It’s dangerous to
repair by yourself and also harm for its credits of Huayuan Company. For you safety, please read
carefully about the notes of this manual.

Checking method 1: the methods of inspecting tractor motor

A. Checking method: to make sure if the wire feed motor and walking motor can be
revolved when supply the DC current directly.
Checking Requirement: a DC current battery, electrical wires.
Checking steps:
 Pull out the plug of the wire feed motor or walking motor.
 Supply a 12VDC directly between the No.1 and 2 terminals of the motor with the wire.

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 MZ-1 TRACTOR OPERATOR’S MANUAL
 Check whether the outside wire around motor is in trouble: if motor run at low rate, change the
wires of No.1 and No.2, the motor run in reverse. It shows the motor works well, or that be in
trouble.
B. If the wire feed motor has fault, replace it.
Required tool: inner six-corner spanner K6; straight screwdriver 150mm
 Use inner six-corner spanner K6 to remove the head
 Loose motor clamping nut, take the motor down
 Remove the two guide line on the back of motor, pay attention to its direction and mark it.
 Test the naked motor by use of checking method A, and confirm if the motor has fault again. If the
motor works well, that means the guide line connected to motor is short circuit, please repair or
change it.
 If confirm the motor is broken, replace it by a new motor.
 Install the motor and screw down the nut.
 Connect the two guide line as the mark.
C. If the walking motor has fault, replace it.
 Turn the tractor 90°.
 Remove the bottom base by straight screwdriver.
 Remove 4 pcs M6 screws by K5 spanner.
 Remove motor installation plate, and take down motor.
 Remove the two motor lines and pay attention to the direction and mark it.
 Test the naked motor by use of checking method A, and confirm if the motor has fault again. If the
motor works well, that means the guide line connected to motor is short circuit, please repair or
change it.
 If the motor is broken, replace it by a new motor.
 Connect the two motor lines
 Install the motor into machine by K5 spanner
 Install the bottom base

Checking method 2: inspecting methods of the main control PCB

Sometime it seems that some wrong occurs in the main control PCB, but the PCB may be not in trouble.
Avoid repairing or replacing the PCB, please check it by the following steps.
 Make sure the PCB is in trouble, according to the conclusion of table 2 The general trouble and
treatment methods or there are some apparent damages on the PCB.
 Check if the plug of the PCB is loose or broken.
 if troubles have not been solved, replace the PCB. Replace it according to flowing steps.
1. Turn off both the switch of the tractor and the power source.
2. Use a screwdriver to unscrew the control panel of the control box, and take it down.
3. Unscrew 4pcs M5 nuts for installing the PCB with spanner, and take the plug-in apart.
4. Take out the damaged PCB and replace a new one, and install the plug-in well.
5. Cover the panel, turn on the machine, if the troubles are solved, it confirms that the troubles
are in the PCB and its plug-in
6. Install the original one again. If the problem occurs again, then the problem indeed occurs in
PCB. If no problem occurs, the plug-in should be checked again, the problem may be caused
in plug-in.

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 MZ-1 TRACTOR OPERATOR’S MANUAL
7. if the trouble cannot be solved with new PCB, it confirms that it is not caused by the PCB. The
trouble must be checked again or Contact the retail trader or the service apartment of
HUAYUAN COMPANY.
Attention: Prevent static electricity while replacing the PCB. Pack up the damaged
PCB and remark “Damaged PCB” onto it, and post it to the service apartment of
HUAYUAN COMPANY.

Checking method 3: The methods of inspecting the control cable

There are 12-14 wires in the control cable, 10 wires of them are used actually as signal lines. The
numbers are 1, 2, 3, 4, 5, 6, 7, 8, 11, 12 respectively. These 10 lines must be well conducted. If one of
them does not get through, the system will be unable to work normally. Meanwhile, it must ensure that
there is no damage to the insulation layer of wires.

Table 3 The states of indicator lights

State
Number
Turn on the Return wire Feed wire Start to Stop Burn back
machine welding
A on on on on on
B on
C on
D
E on on
F on
G on on on
H on on on
J on
K on on
L on
S on on on on

Figure 5: The indicator lights location on the PCB

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 MZ-1 TRACTOR OPERATOR’S MANUAL

VA (No we ld ing ) VJ( ma nua l w ir e-f eed )

VD (ha vin g cur ren t)
VH( Vo lt of ar c) V L(W eld in g)

VG( Ha vin g A RC ) VE (di rec ti on

of fe edi ng ) VB (S tar t) V C(S to p)

VS (S top pin g
VF( au xil iar y set ) st at e)
VK (t urn on
t he ma chi ne )

Figure 6. The jumper wire on the PCB

L a rg e va l ue t o g iv e w h i le st o p pi n g a r c
c on t r ol th e g i v in g s i g na l o f so u rc e
E n di n g a r c t o g i ve wh i l e s to p p in g a r c

b r ak i n g w hi l e n o c u rr e n t o ut p u t
J u st b ra k in g af t er en d i ng ar c
S1
c o n tr o l t h e s up p l y p ow e r w i th th e St a rt / s to p b u t to n
c on t r ol l in g th e
d el a y t o s h ut o ff th e su p pl y po w er af t e r s to p p in g m o t or
w al k i ng
b r ak i n g a cc o r di n g t o d e te r mi n e
c o nt r o l t he b ra k e w it h st a rt i n g o r s t op p in g

u ni n st a l l t he e nd i ng a rc pa r t s
in s t al l t h e e a nd i n g a rc p ar t s
c on t r ol l in g ex t ro
u ni n st a l l t he s tr i ki n g a r c p a rt s
p ar t s
i ns t al l th e s t r ik i ng a rc pa r t s
S2
d e la y t o st o p t he s up p ly p ow e r w h en pr e ss i n g t he s to p b u t to n co nt r ol t he po we r o n/ of f
s h ut o ff su p p ly po w er a t o nc e wh e n p r es s in g t h e s t op b ut t on
s t op wi r e f e ed w he n p r e ss i ng t he bu t to n
s t op wi r e f e ed w he n s t o pp i ng a rc c on t ro l t h e w i re f ee d

Note: Two jumper wires close to each other can't be installed at the same

time, namely the positive line and negative line can't be installed at the same

time within one group, and one of them must be installed in one time.

1. Design of welding procedures

The design of logical control circuits is to control the welding current, the given circuit of welding
power source; procedure of feeding wire, procedure of traveling etc. Seeing figure 5 the positions of them are
enlarged already but their relative positions do not change. For easy explaining, count from lower to upper,

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 MZ-1 TRACTOR OPERATOR’S MANUAL
S1 and S2 are divided into 12345678 eight jumper wires, which are divided into four groups. Namely 1,2 one
group; 3,4 one group; 5,6 one group; 7,8 one group, only one jumper wire of each group is allowed to be
installed. Its installation way is showed with four codes, S1: 1357 expresses that S1 should install four lines,
they are wire No. 1, 3, 5, 7 respectively. The following examples can well illustrate the installation of the
program control circuit.
A．Striking arc parts or ending arc parts has been already installed. The jumper wire code is S2: xx5x or
xxx7, x means uncertainty. And the 5th or the 7th of S2 can be confirmed.
B．Striking arc parts or ending arc parts has not been installed yet. The jumper wire code is S2: xx6x or
xxx8, x means uncertainty. And the 6th or the 8th of S2 can be confirmed.
C．The selection of ending arc mode: feeding wire stops immediately, the power source delays to cut off.
The jumper wire code is S2: 24xx, and 2 means that the wire feed stops at once when pressing the stop button,
4 means that the power source delays to cut off when pressing the stop button.
D．The selection of ending arc mode: feeding wire stops and return the wire immediately, the power
source delays to cut off. The jumper wire code is S2: 14xx, 1 means that the wire feed or return wire stops
when ending arc, 4 means that the power source delays to cut off when pressing the stop button.
E． The selection of ending arc mode. feeding wire stops and return the wire immediately, the power
source cut off at once. The jumper wire code is S2: 13xx, 1 means that wire feed and return wire stops when
ending arc. 3 means that the power source cut off at once when pressing the stop button.
F． The selection of tractor traveling mode. Tractor starts to travel when pressing the start button, and
stops traveling when pressing the stop button. The jumper wire code is S1: 136x, 1 means to control brake
through the start/stop button, 3 means to cut off the power of tractor when turn off the power source, 6 means
to brake the tractor immediately when ending arc.
G．The selection of tractor traveling mode. The tractor travels only after current getting through, and
brakes immediately after ending arc. The jumper wire code is S2: 236x, 2 means to control the brake of
tractor according to the third group jumper wire, and the selection in third group is 6 at this moment. The
braking of tractor can depend on the current, namely tractor brakes once there is no output current. 3 means
that the power supply of motor begins after starting machine and comes to an end after stopping machine.
H．The selection of tractor traveling mode. The tractor travels only after current getting through, and
stops when pressing the stop button. The jumper wire code is S2: 246x, 2 means to control the brake of tractor
according to the third group jumper wire, and the selection in third group is 6 at this moment. The braking of
tractor can depend on the current, namely the tractor will not travel if there is no output current. 4 means that
the power supply to tractor stops after pressing stop button.
I． The selection of tractor traveling mode. Tractor starts to travel after starting machine, and stops
traveling after ending arc. The jumper wire code is S2: 2357, 2 means to control the brake of tractor
according to the third group jumper wire, and the selection in third group is 6 at this moment, namely tractor
brakes after ending arc. 3 means the power supply of motor stops once there is no output voltage. 7 means
that the given signal of power source switches to ending arc after pressing stop button. For this situation,
ending arc parts must be installed, then No. 7 jumper line must be installed.

J． The machine setting before leaving factory: S1=1468, its means that tractor travels immediately

when starting the welding, braking promptly when stopping. The maximum given value of power source after
ending arc is S2 =1468, its means that after stopping back burning, the wire feeder brakes and returns wire
immediately, the power delays to cut off.

2、The selection of wire feed mode

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 MZ-1 TRACTOR OPERATOR’S MANUAL
A． The selection of welding parameters. According to the structure of workpiece and material type, to
decide the welding current and voltage, to choose the suitable welding wire. In principle, the thin welding
wires adopts the constant voltage. Thick wires adopts constant current. It is easy to change the
characteristic of wire feeder, and have the characteristic selection switch in control box panel set under
required state. Special attention: have the output characteristic of power source converted to the same
characteristic with wire feeder.
B． If the polarity of welding needs to be changed, in addition to the exchanged installation of output
welding cable, the installation for two signal wires of voltage display selection switch must be
exchanged.
Note: This change must be done by professional person under permission from Huayuan Company.

 Introduction about submerged arc welding materials and technologies

1. Welding flux
The function of welding flux is to ensure a good welding seam shape, besides its molten slag covering
the molten pool can prevent oxygen, nitrogen in air from entering molten pool. The welding flux has a
metallurgical reaction with liquid metal, which can remove the impurities in metal like oxygen, hydrogen,
sulfur, phosphorus, and add to the required alloy, then a welding seam metal with good mechanical
property or special property can be obtained.
According to the alkaline level, welding flux can be divided into alkaline flux, acid flux and neutral
flux. According to the chemical property, it can be divided into oxidizing flux (inclusive of SiO2,MnO or
Feo largely), weak oxidizing flux and inert flux (inclusive of Al2O3, CaO, MgO, CaF2, but almost no
SiO2,MnO or Feo).
Table 4 Common welding flux usage and matched wire
Suitable
Welding Welding flux
Usage Matched wire current
flux type granularity(MM)
type
HJ130 Low carbon steel, common low 0.45～2.5 H10Mn2 AC/DC
alloy steel current
HJ131 Ni alloy 0.3～2 Ni wire AC/DC
current
HJ150 Roller surfacing 0.45～2.5 2Cr13、3 Cr2W8 DC
current
HJ172 High Cr iron steel 0.3～2 Steel wire DC
current
HJ173 Mn-A1 high alloy steel 0.25～2.5 Steel wire DC
current
HJ230 Low carbon steel, common low 0.45～2.5 H08MnA、H10Mn2 AC/DC
alloy steel current
HJ250 Low alloy high tensile steel 0.3～2 Steel wire DC
current
HJ251 Heat resistant steel 0.3～2 Cr-Mo steel wire DC
current
HJ260 Stainless steel, roller surfacing 0.3～2 Stainless wire DC
current

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 MZ-1 TRACTOR OPERATOR’S MANUAL
HJ330 Low carbon steel and common 0.45～2.5 H08MnA、H10Mn2 AC/DC
low alloy steel current
Mn-Mo 、 Mn-Si and Ni AC/DC
HJ350 Low alloy and high tensile steel 0.2～1.4
high tensile steel wire current
HJ430 Low carbon steel and common 0.45～2.5 H08A、H10MnA AC/DC
low alloy steel current
HJ431 Low carbon steel and common 0.45～2.5 H08A、H10MnA AC/DC
low alloy steel current
HJ432 Low carbon steel and common 0.2～1.4 H08A AC/DC
low alloy steel(thin plate) current
HJ433 Low carbon steel 0.45～2.5 H08A AC/DC
current
H08MnAH10MnMoA AC/DC
SJ101 Low alloy structural steel 0.3～2
H08Mn2MoA、H10Mn2 current
H08MnA 、 H10Mn2 、 AC/DC
SJ301 Common structural steel 0.3～2
H08MnMoA current

2. Welding wire
The applied welding wire in submerged arc welding is different for different types of welding metals.
Usually, there are carbon structural steel, alloy structural steel, high alloy steel, various nonferrous metal
welding wires and special alloy wires used for surfacing. The allied welding wire surface should be smooth
enough, so that it can be feed smoothly. It is better to choose the wire coated with copper, which can not
only prevent rust, but also improve the contact status between wire and conductive tip. If there is oil stain
and rust on wire, it must be cleaned, or they will be brought into welding seam and cause blow holes, and
affect mechanical property of welding seam.
Table 5 steel wire diameter and allowed deviation（mm）：
Wire diameter（mm） 2.0 2.5 3.0 3.2 4.0 5.0 6.0 6.5 7.0 8.0 9.0
Allowed deviation -0.12 -0.16 -0.20
general precision
Allowed deviation high -0.06 -0.08 -0.10
precision
Table 6 current range for various diameter wires
Wire diameter 2.0 2.5 3.0 4.0 5.0 6.0
（mm）
Current 200～400 250～450 350～600 500～800 700～1000 800～1200
range(A)

3. Parameters of affecting welding seam shape size

A. Welding technology parameters

1)Welding current
Welding current I increases, productivity improves, and deposition R, molten depth H enlarges. If I is
too large, it will cause burning through and overlarge heat-affecting zone. If I is too small, it will cause
insufficient molten depth and deformed welding seam. Under normal welding conditions and no change
made to other conditions, welding seam molten depth H is almost direct ration to welding current I.

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 MZ-1 TRACTOR OPERATOR’S MANUAL
H=Km X I
Km is proportion coefficient, it changes with the change of current type, polarity, wire diameter and
welding flux chemical composition.

For thick wire submerged arc welding, Km ≈ 1mm/100A. For thin wire submerged arc welding, Km

≈1.3mm/100A.
2)arc voltage
Arc voltage is direct ration to arc length. If no change made to other conditions, with the increase of
arc voltage welding seam molten width increases apparently, but molten depth and excess weld metal
decreases a little.

3)welding speed
Welding speed has a great effect on molten depth and width. When the welding speed is low(eg. Single
wire submerged arc welding speed is less than 670mm/min), with the increase of welding speed, arc
column inclines, and this is beneficial for backward flowing of molten metal, molten depth increase a
little, but usually the increase of welding speed can reduce molten depth, width and excess weld metal.
When welding speed increases to a certain level, molten depth and width will reduce greatly due to the
decrease of energy input.

B. Welding technology
Both the inclined angle of welding wire and workpiece angle have a great effect on welding seam
shape.
The inclination direction of wire includes forward and backward inclination. If the inclination
direction and angle is different, the force and heat function of arc to molten pool is different, thereby it
has a different effect on welding seam shape. When welding wire inclines backward at a certain angle,
the arc force to push the metal in molten pool backward is reduced, the metal on the molten pool bottom
become thick, so molten depth reduces, but the pre-heat effect of arc to base metal forward increases, so
molten width enlarges.
Inclination welding of workpiece includes upslope welding and downslope welding, which have a
different effect on welding seam shape. When it is upslope welding, it is easy to occur overlarge excess
weld metal, undercut on both sides, deformed welding seam etc. In practice, upslope welding should be
avoided as much as possible. The effect of downslope welding is contrary to upslope welding. When the
inclination angle is less than 6°～ 8°, the molten depth and excess weld metal all reduce, molten width
increases a little, welding seam shape is improved. But if welding angle is too big, it will cause
incomplete fusion, welding bead and other flaws.

C. Structure
1) Groove shape
Under same conditions, if groove width and depth is increased, then molten depth will decrease a
little, and excess weld metal, deposition ratio reduces greatly.
2) Welding seam gap
For butt welding, the change of welding seam gap can be used to adjust excess weld metal and fusion
ratio. Too large gap will cause solder skips easily.
Table 7 the influence of welding seam gap to butt welding seam size（wire Ф5mm flux HJ330）
：

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 MZ-1 TRACTOR OPERATOR’S MANUAL
Plate Parameters Molten depth Molten width Excess weld Fusion ratio %
thickness （mm） （mm） metal（mm）
(mm) Weldi Arc Weldi Gap size（mm）
ng voltag ng 0 2 4 0 2 4 0 2 4 0 2 4
curre e speed
nt （V） （cm/
（A） min）
12 700 32～ 50 7.5 8.0 7.5 20 21 20 2.5 2.0 1.0 74 64 57
～ 34 134 5.6 6.0 5.5 10 11 10 2.0 - - 71 61 46
750
20 700 36～ 20 10 9.5 10 27 27 27 3.0 2.0 2.5 60 57 52
～ 38 33.4 11 11.5 11 23 22 22 3.5 2.5 1.5 63 58 49
750 134 6.5 7.0 7.0 11 11 10 2.5 - - 72 61 45
30 700 40～ 20 10.5 11 10.5 34 33 35 3.5 3.0 2.5 61 59 55
～ 42 33.4 12 12 11 30 29 30 3.0 2.0 1.5 67 63 69
750 134 7.5 7.5 7.5 12 12 12 1.5 - - 77 72 60

4. butt joint single side welding

For automatic submerged arc welding, a groove can be made or not on workpiece. A groove does not
only ensure molten depth, sometimes also meet other technology purposes. Butt joint single welding can
take following methods: weld on welding flux backing plate, weld on permanent backing plate or locking
bottom, weld on temporary backing plate and impending welding etc.
1) weld on welding flux copper backing plate. It takes copper backing plate with groove, to which
welding flux is filled. During welding the welding flux plays the role of backing plate, also protecting
copper backing plate, which will be avoided to get direct effect of arc. Groove plays the role of
shaping back welding seam.
2) Weld on permanent backing plate or locking bottom plate. When welding workpiece is allowed to
keep permanent backing plate, the workpiece under 10mm in thickness can adopt permanent backing
plate single welding method. The workpiece above 10mm in thickness can adopt locking bottom
welding method.
3) Impending welding. When the workpiece is well assembled and has no gap, it can adopt impending
welding without backing plate. When this method is used for single side welding, workpiece can be
fused completely. Usually molten depth does not surpass two-thirds of plate thickness, or it is easy to
weld through. This method is only suitable for welding the joint which is not required to fuse
completely.
4) Weld on welding flux backing. For this welding method, the quality of welding seam shape mainly
depends on the backing strength, evenness of welding flux, and the evenness of welding seam
assembling.
Table 8 welding conditions of butt joint single welding on welding flux backing
Plate Assembling Wire Welding Arc voltage Welding Granularity of
thickness gap diameter current （V） speed welding flux
（mm） （mm ） （mm） （A） （cm/min） backing
2 0～1.0 1.6 120 24～28 73 fine

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 MZ-1 TRACTOR OPERATOR’S MANUAL
3 0～1.5 1.6 275～300 28～30 56.7 fine
2.0 275～300 28～30 56.7
3.0 400～425 25～28 117
4 0～1.5 2.0 375～400 28～30 66.7 fine
4.0 525～550 28～30 83.3
5 0～2.5 2.0 425～500 32～34 58.3 fine
4.0 575～625 28～30 67.5
6 0～3.0 2.0 475 32～34 50 Normal
4.0 600～650 28～32 67.5
7 0～3.0 4.0 650～750 30～34 61.7 Normal
8 0～3.5 4.0 725～775 30～36 56.7 Normal

5. Butt joint double-side welding

1) Impending welding. No gap or a very little gap less than 1mm is left during assembling workpiece.
For the 1st side welding, the molten depth usually should be less than half of workpiece thickness,
and the molten depth for opposite side welding is required to reach 60% to 70% of workpiece
thickness, so that the workpiece is molten completely.
2) Weld on welding flux backing. For the 1st side welding, the most economic welding method is
reserve a gap but no groove opened, and the selected welding parameters must ensure that the

molten depth is more than 60% ~ 70% of workpiece thickness. For the opposite side welding, its
welding parameters can be the same as that of the 1st side welding, so that the workpiece can be
molten completely.
Table 9 welding conditions of butt joint impending & double-side welding without groove
Workpiec Wire Workpiece front-side welding Workpiece opposite-side welding
e diameter parameters parameters
thicknes （mm） Welding Welding Welding Welding Welding Welding
s current voltage speed current voltage speed
（mm） （A） （V） cm/min （A） （V） cm/min
6 4 380～420 30 58 430～470 30 55
8 4 440～480 30 50 480～530 31 50
10 4 530～570 31 46 590～640 33 46
12 4 620～660 35 42 680～720 35 41
14 4 620～660 37 41 730～770 40 38
15 5 680～720 34～36 63 850～900 36～38 43
17 5 800～850 35～37 60 900～950 37～39 43
18 5 850～900 36～38 60 900～950 38～40 40
20 5 850～900 36～38 42 900～1000 38～40 40
22 5 900～950 37～39 53 1000～ 38～40 40
1050

6. Fillet welding
1) Boat-shape welding
The both sides of workpiece for fillet welding is placed under 45°with vertical line, this is the best
condition for welding seam shape. This kind of welding method requires that the assembling gap of

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 MZ-1 TRACTOR OPERATOR’S MANUAL

joint is no more than 1 ~ 1.5mm, or the measure must be taken to prevent the los s of liquid metal.
2) Horizontal fillet welding
When the boat-shape welding is unsuitable for some workpieces, it can take horizontal fillet welding.
The corresponding position of welding wire and welding seam has a great effect on the quality of

horizontal fillet. Usually the inclination angle of welding wire within 20 ° ~ 30 ° , the actual

position of welding wire should be decided as per joint state. The cross section of each single pass

horizontal fillet is not more than 40 ~ 50mm ², that is, when the welding foot length is more than
8x8mm, it will cause metal spillover and undercut.

 The weld defects and preventions

1. The main welding defects and reasons

 Blow hole

a) Moisture, filth and oxidizing iron scrap in the flux, etc. all can cause blow holes in welding seam.

b) The insufficient covering of welding flux during welding causes the exposure of arc, which have air
involved in and causes the blow hole.

c) The molten slag is too viscous;

d) The arc magnetic blow causes the blow hole, which is usually produced at the end welding area of
thick plate.

e) The welding position is polluted by iron rust, oil stain or other filth.

 Crackle

a) Solidification crackle: For welding steel, the impurities such as the sulfur, phosphorus etc in the
welding seam causes solidification crackle while the welding seam solidifies.

b) Hydrogen-caused crackle: This kind of crackle is mostly formed in the heat-affect zone of welding
the low-alloy steel, middle-alloy steel and high-carbon steel.

 Slag inclusion

Slag inclusion caused in submerged arc welding is related to not only the slag detachability of welding
flux, but also the assembling state of workpiece, and welding technology parameters.

2. Prevention methods
Please take the following methods according to the quality demand of welding.

 Remove and clean oil, rust, moisture and other impurities on the surface of wire and on the both sides of

welding seam within the range of 20mm.

 The flux must be dried according to its operation regulation, store them under about 50°C temperature

for stand-by.

 The reclaimed flux must be prevented from pollution of the oxide, slag, water dust etc.

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 MZ-1 TRACTOR OPERATOR’S MANUAL

 the granular size of the flux must be suitable, the powder and dust should be cleaned up.

 The workpiece assembling gap for impending welding is not more than 0.8 ~ 1.0mm.

 When arc magnetic blows, the welding starts from the earth line side, and earth line must be connected

reliabely.

 Machine Diagram
1. Machine Schematic Diagram

2. Machine Wiring Diagram

 Accessories
 MZ-1 tractor 1 set
 Wire reel 1pc
 Conductive tip Φ3.0 Φ4.0 (Φ4.0 has been installed in tractor head already) each 1
 Flux tube 2 pcs
 Flux hopper (10L) 1pc
 Welding control cable 15m
 Welding cable 15m
 Work cable 3m
 Inner hexagon spanner M5, M6 each 1

 Drawing
1. Head
1 2 3 4 5 6

10 7

11
8
20
12 9
21

13

19

14

15

16 17

18

No. Name Specification Qty ERP Code

1 Welding gun holder Part of head, clamped to motor 1 203090000006
GB/T 70.1-2000 M8×75，for clamping the head
2 Inner hexnut 1
to motor and adjust the angel of head

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 MZ-1 TRACTOR OPERATOR’S MANUAL
3 Wire guiding plate For limiting the wire position when the wire feeds 1 212010600054
into wire feed system
4 Fixing axis of press wire rolls For fixing the press wire rolls and straighten rolls 2 204700000019
and straighten rolls holder holder. Press wire roll and straighten roll holder
should be able to revolve around the axis.
5 Axis-used elastic ring A type GB/T 894.1-1996 φ10 2
6 Locking hand wheel holder Support locking hand wheel, screw the two M6 2 212010600033
nuts down
It is used to adjust the top tight force of press wire
7 Elastic locking hand wheel roll, and it Can`t exchange with fixed locking 1 212010600029
hand wheel when using
8 Cap nut GB923-1988 M6 2 108020000048
9 Press wire rolls & straighten Supporting press wire rolls and straighten rolls 2 212010600028
rolls holder
10 Wire feeding rolls Connect with output axis of wire feed motor, 1 212010600023
supply the wire feed force.
11 Wire feed rolls ring For fixing the wire feed rolls position on the axis 1 212010600022
12 Nut assembly parts GB/T 9074.14 M5×20 1
13 Head press wire rolls Supply the press force to wire 1 212010600027
14 Head corrective wheel Supply corrective force together with corrective 1 212010600038
bearing and wire feed rolls
15 Electrode board At the cable connection place, screw down nut. 1 203090000008
16 Conductive rod head For guiding the wire and conduct electricity 1 212010600042
17 Lengthened Conductive rob Lengthen conductive rod, used for conducting 1 203080200035
Ⅱ
18 Conductive tip wearing part, used for conducting 1 106050000063
19 Cap nut GB923-1988 M8 1 108020000047
20 Fixed locking handle wheel For adjusting the straightening force 1 203090000009
21 Wire-straightening bearing GB/T 276-1994 6300 1 108050000020
2. Horizontal adjustment unit

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 MZ-1 TRACTOR OPERATOR’S MANUAL

1 3

4
2

6
5

9 8

No. Name Specification Qty ERP code

1 Column base For fixing the column 1 2030900001
GB/T 73-1985 M8x10 is used for preventing the
2 fixed nut column rotation, the nut should be screwed down 1 108010500023
when using
3 Protection shield 3 Move with column together 1
For connecting protection shield 1 and 2. It can 2
4 Protection shield 2
move flexibly
5 Protection shield 1 Fixed protection shield, for limiting the position of 2
shield 2
6 Horizontal adjusting handle Rotating this handle can adjust the horizontal 2 212010100029
position of the head
There is a keyway in it which supplies the moving
7 Front wheel 2 212010100001
force for tractor.
8 Handle For moving tractor 2 102010500731
9 Rear wheel Passive moving wheel 2 212010100001

The final explanation right is reserved to Huayuan Company!

If there is any change in the manual, please forgive not to inform separately!

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 MZ-1 TRACTOR OPERATOR’S MANUAL

Address: Wuhou National Science Park, Chengdu, China

Postcode: 610045

Tel: 0086-28-85012443, 85011951, 85013964

Fax: 0086-28-85033444

E-mail: [email protected]

http://www.hwayuan.com

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