0449 165 160 GB

A2 Multitrac
A2TF J1/ A2TF J1 Twin/

A2TG J1/ A2TG J1 4WD
Instruction manual
0449 165 160 GB 20230626 Valid for: serial no. 940-xxx-xxxx

TABLE OF CONTENTS
1 SAFETY ....................................................................................................... 5
1.1 Meaning of symbols ............................................................................... 5
1.2 Safety precautions ................................................................................. 5
2 INTRODUCTION .......................................................................................... 9
2.1 General .................................................................................................... 9
2.2 Welding method...................................................................................... 9
2.2.1 Submerged Arc Welding (SAW) ........................................................... 9
2.2.2 MIG/MAG welding ................................................................................ 9
2.3 Definitions ............................................................................................... 9
2.4 Horizontal welding.................................................................................. 9
3 INSTALLATION ............................................................................................ 10
3.1 General .................................................................................................... 10
3.2 Main components A2TF J1 / A2TF J1 Twin (SAW)............................... 10
3.3 Main components A2TG J1 / A2TG J1 4WD (MIG/MAG) ..................... 11
3.4 Description of main components.......................................................... 11
3.4.1 Carriage................................................................................................ 11
3.4.2 Carrier................................................................................................... 11
3.4.3 Wire feed unit ....................................................................................... 11
3.4.4 Manual slides ....................................................................................... 11
3.4.5 Contact tube / Connector ..................................................................... 11
3.4.6 Wire feed motor .................................................................................... 12
3.4.7 Guide pin .............................................................................................. 12
3.4.8 Flux hopper / Flux tube......................................................................... 12
3.5 Mounting ................................................................................................. 12
3.5.1 Wire drum (Accessories) ...................................................................... 12
3.6 Adjusting the brake hub ........................................................................ 12
3.7 Connections............................................................................................ 13
3.7.1 General................................................................................................. 13
3.7.2 Automatic welding equipment A2TF J1 / A2TF J1 Twin (Submerged 14
Arc Welding, SAW) ...............................................................................
3.7.3 Automatic welding equipment A2TG J1 (Gas metal arc welding, 15
MIG/MAG) ............................................................................................
3.7.4 Automatic welding equipment A2TG J1 4WD (Gas metal arc welding, 16
MIG/MAG) ............................................................................................
4 OPERATION ................................................................................................ 17
4.1 General .................................................................................................... 17
4.2 Loading the welding wire (A2TF J1 / A2TF J1 Twin, A2TG J1)........... 17
4.3 Loading the welding wire (A2TG J1 4WD)............................................ 18
4.4 Changing the feed roller (A2TF J1 / A2TF J1 Twin, A2TG J1) ............ 19
4.4.1 Single wire ............................................................................................ 19
4.4.1.1 Twin wire (Twin-arc)........................................................................... 19
4.4.1.2 Flux-cored wire for knurled rollers (Accessories) .............................. 19
4.5 Changing the feed rollers (A2TG J1 4WD) ........................................... 20
0449 165 160 © ESAB AB 2023

TABLE OF CONTENTS
4.6 Contact equipment for Submerged Arc Welding ................................ 20

4.6.1 For single wire 1.6–4.0 mm – Light duty (D20) .................................... 20
4.6.2 For twin wires 2×1.2–2.0 mm – Light Twin (D35) ................................. 20
4.6.2.1 Accessories ....................................................................................... 21
4.6.2.2 Adjustment of the wires for twin-arc welding ..................................... 21
4.7 Contact equipment for MIG/MAG welding............................................ 21
4.7.1 For single wire 1.6–2.5 mm (D35) ........................................................ 21
4.7.2 For single wire < 1.6 mm (D35) ............................................................ 22
4.7.2.1 Accessories ....................................................................................... 22
4.7.3 For single wire 1.0–2.4 mm (wire feed unit with four-wheel drive) ....... 22
4.8 Refilling with flux powder ...................................................................... 23
4.9 Transportation ........................................................................................ 23
4.10 Conversion of A2TF J1 / A2TF J1 Twin (Submerged Arc Welding) to 24
MIG/MAG welding ...................................................................................
4.11 Conversion of A2TF J1 (Submerged Arc Welding) to Twin-arc ......... 24
5 MAINTENANCE ........................................................................................... 25
5.1 General .................................................................................................... 25
5.2 Daily ......................................................................................................... 25
5.3 Periodic ................................................................................................... 25
6 TROUBLESHOOTING ................................................................................. 26
6.1 General .................................................................................................... 26
6.2 Possible errors ....................................................................................... 26
7 ORDERING SPARE PARTS ........................................................................ 27

DIMENSION DRAWING ....................................................................................... 28
SPARE PARTS LIST ............................................................................................ 30
Rights reserved to alter specifications without notice.
0449 165 160 © ESAB AB 2023

1 SAFETY
1 SAFETY
1.1 Meaning of symbols
As used throughout this manual: Means Attention! Be Alert!
DANGER!
Means immediate hazards which, if not avoided, will result in immediate,
serious personal injury or loss of life.
WARNING!
Means potential hazards which could result in personal injury or loss of life.
CAUTION!
Means hazards which could result in minor personal injury.
WARNING!
Before use, read and understand the instruction manual
and follow all labels, employer´s safety practices and
Safety Data Sheets (SDSs).
1.2 Safety precautions

Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who
works on or near the equipment observes all the relevant safety precautions. Safety
precautions must meet the requirements that apply to this type of equipment. The following
recommendations should be observed in addition to the standard regulations that apply to
the workplace.
All work must be carried out by trained personnel well-acquainted with the operation of the
equipment. Incorrect operation of the equipment may lead to hazardous situations which can
result in injury to the operator and damage to the equipment.
1. Anyone who uses the equipment must be familiar with:
○ its operation
○ location of emergency stops
○ its function
○ relevant safety precautions
○ welding and cutting or other applicable operation of the equipment
2. The operator must ensure that:
○ no unauthorised person is stationed within the working area of the equipment
when it is started up
○ no-one is unprotected when the arc is struck or work is started with the
equipment
3. The workplace must:
○ be suitable for the purpose
○ be free from drafts
0449 165 160 -5- © ESAB AB 2023

1 SAFETY
4. Personal safety equipment:

○ Always wear recommended personal safety equipment, such as safety glasses,
flame-proof clothing, safety gloves
○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which
could become trapped or cause burns
5. 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 extinguishing equipment must be clearly marked and close at
hand
○ Lubrication and maintenance must not be carried out on the equipment during
operation
WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions
when welding and cutting.
ELECTRIC SHOCK - Can kill

• Install and ground the unit in accordance with instruction manual.
• Do not touch live electrical parts or electrodes with bare skin, wet gloves or
wet clothing.
• Insulate yourself from work and ground.
• Ensure your working position is safe
ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health
• Welders having pacemakers should consult their physician before welding.
EMF may interfere with some pacemakers.
• Exposure to EMF may have other health effects which are unknown.
• Welders should use the following procedures to minimize exposure to
EMF:
○ Route the electrode and work cables together on the same side of
your body. Secure them with tape when possible. Do not place your
body between the torch and work cables. Never coil the torch or work
cable around your body. Keep welding power source and cables as
far away from your body as possible.
○ Connect the work cable to the workpiece as close as possible to the
area being welded.
FUMES AND GASES - Can be dangerous to health
• Keep your head out of the fumes.
• Use ventilation, extraction at the arc, or both, to take fumes and gases
away from your breathing zone and the general area.
ARC RAYS - Can injure eyes and burn skin
• Protect your eyes and body. Use the correct welding screen and filter lens
and wear protective clothing.
• Protect bystanders with suitable screens or curtains.
NOISE - Excessive noise can damage hearing
Protect your ears. Use earmuffs or other hearing protection.
0449 165 160 -6- © ESAB AB 2023

1 SAFETY
MOVING PARTS - Can cause injuries

• Keep all doors, panels and covers closed and securely in place. Have only
qualified people remove covers for maintenance and troubleshooting as
necessary. Reinstall panels or covers and close doors when service is
finished and before starting engine.
• Stop engine before installing or connecting unit.
• Keep hands, hair, loose clothing and tools away from moving parts.
FIRE HAZARD
• Sparks (spatter) can cause fire. Make sure that there are no inflammable
materials nearby.
• Do not use on closed containers.
HOT SURFACE - Parts can burn
• Do not touch parts bare handed.
• Allow cooling period before working on equipment.
• To handle hot parts, use proper tools and/or insulated welding gloves to
prevent burns.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
CAUTION!
This product is solely intended for arc welding.
WARNING!
Do not use the power source for thawing frozen pipes.
CAUTION!
Class A equipment is not intended for use in residential
locations where the electrical power is provided by the
public low-voltage supply system. There may be
potential difficulties in ensuring electromagnetic
compatibility of class A equipment in those locations,
due to conducted as well as radiated disturbances.
0449 165 160 -7- © ESAB AB 2023

1 SAFETY
NOTE!
Dispose of electronic equipment at the recycling
facility!
In observance of European Directive 2012/19/EC on
Waste Electrical and Electronic Equipment and its
implementation in accordance with national law,
electrical and/or electronic equipment that has reached
the end of its life must be disposed of at a recycling
facility.
As the person responsible for the equipment, it is your
responsibility to obtain information on approved
collection stations.
For further information contact the nearest ESAB dealer.
ESAB has an assortment of welding accessories and personal protection equipment

for purchase. For ordering information contact your local ESAB dealer or visit us on
our website.
0449 165 160 -8- © ESAB AB 2023

2 INTRODUCTION
2 INTRODUCTION
2.1 General
The A2TF J1 / A2TF J1 Twin automatic welding equipment is designed for Submerged Arc
Welding (SAW) of butt and fillet joints.
The A2TG J1 / A2TG J1 4WD automatic welding equipment is designed for MIG/MAG
welding of butt and fillet joints.
All other applications are prohibited.
Intended for use in combination with PEK and ESAB welding power sources LAF, TAF or
Aristo 1000.
NOTE!
Aristo 1000 only together with PEK with serial no. 747-xxx-xxxx or later.
2.2 Welding method

2.2.1 Submerged Arc Welding (SAW)
Use A2TF J1 / A2TF J1 Twin automatic welding equipment for Submerged Arc Welding.
• Submerged Arc Light duty
Submerged Arc Light duty with a Ø20 mm connector permits a load up to 800 A
(100%).
This version can be equipped with feed rollers for single or twin wire welding (twin-arc). A
special knurled feed roller is available for flux-cored wire, which guarantees even wire feed
without the risk of deformation due to high feed pressure.
2.2.2 MIG/MAG welding
For MIG/MAG welding use either automatic welding equipment A2TG J1 or A2TG J1 4WD.
A2TG J1 4WD consists of a four wheel drive wire feed unit.
The welding head is water-cooled. The cooling water is supplied by hoses from connections
intended for the purpose.
2.3 Definitions
SAW The weld bead is protected by a cover of flux during the welding.
SAW Light duty Permits welding with lower current load and thin wire.
MIG/MAG welding The weld bead is protected by shielding gas during welding.
Twin-arc welding Welding with two wires in one welding head.
2.4 Horizontal welding

The products described in this manual are designed for horizontal welding.
NOTE!
Do not use A2 Multitrac when welding on inclined planes.
0449 165 160 -9- © ESAB AB 2023

3 INSTALLATION
3 INSTALLATION
3.1 General
The installation must be carried out by a professional.
WARNING!
Rotating parts can cause injury, take great care.
3.2 Main components A2TF J1 / A2TF J1 Twin (SAW)
1. Carriage 6. Wire feed motor

2. Carrier 7. Wire guide
3. Wire feed unit 8. Flux hopper
4. Slide kit, manual 9. Flux tube
5. Contact tube 10. Guide pin
0449 165 160 - 10 - © ESAB AB 2023

3 INSTALLATION
3.3 Main components A2TG J1 / A2TG J1 4WD (MIG/MAG)
1. Carriage 5. Connector
2. Carrier 6. Wire feed motor
3. Wire feed unit 7. Wire guide
4. Slide kit, manual
3.4 Description of main components

3.4.1 Carriage
The carriage is provided with 4-wheel drive. Secured the carriage with the locking lever (1).
3.4.2 Carrier
Fit the control unit, wire feed unit and flux hopper, among other things, on the carrier.
3.4.3 Wire feed unit
The wire feed unit guides and feeds the welding wire into the connector / contact tube.
3.4.4 Manual slides
The horizontal and vertical position of the welding head is adjusted by way of linear slides.
The angular motion can be freely adjusted using the rotary slide.
3.4.5 Contact tube / Connector
Transfers welding current to the wire during welding.
0449 165 160 - 11 - © ESAB AB 2023

3 INSTALLATION
3.4.6 Wire feed motor

The motor feeds the welding wire.
3.4.7 Guide pin
The guide pin is used to help positioning the welding head in the joint.
3.4.8 Flux hopper / Flux tube
The flux is filled into the flux hopper. It is then transferred to the workpiece through the flux
tube.
The amount of flux to be dropped down is controlled by way of the flux valve fitted to the flux
hopper.
For more information, see section "Refilling with flux powder".
3.5 Mounting
3.5.1 Wire drum (Accessories)
Mount the wire drum (1) on the brake hub (2).
WARNING!
To prevent the reel from 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.
3.6 Adjusting the brake hub

The brake hub is adjusted at delivery. If readjustment is required, follow the instructions
below. Adjust the brake hub so the wire is slightly slack when wire feed stops.
0449 165 160 - 12 - © ESAB AB 2023

3 INSTALLATION
Adjusting the braking torque:

1. Turn the red handle to the locked
position.
2. Insert a screwdriver into the springs
in the hub.
○ Turn the springs clockwise to
reduce the braking torque.
○ Turn the springs
counter-clockwise to increase
the braking torque.
NOTE!
Turn both springs the same amount.
3.7 Connections
3.7.1 General
• The PEK must be connected by a qualified person. See separate instruction manual.
• For connection of welding power source, see separate instruction manual.
0449 165 160 - 13 - © ESAB AB 2023

3 INSTALLATION
3.7.2 Automatic welding equipment A2TF J1 / A2TF J1 Twin (Submerged Arc

Welding, SAW)
1. Connect the control cable (7) between the power source (8) and the PEK (2).
2. Connect the return cable (11) between the power source (8) and work piece (9).
3. Connect the welding cable (10) between the power source (8) and the automatic
welding equipment (1).
4. Connect the measurement cable (12) between the power source (8) and workpiece
(9).
1. Automatic welding equipment 5. Control cable

2. PEK 6. Return cable
3. Power source 7. Welding cable
4. Work piece 8. Measurement cable
0449 165 160 - 14 - © ESAB AB 2023

3 INSTALLATION
3.7.3 Automatic welding equipment A2TG J1 (Gas metal arc welding,

MIG/MAG)
1. Connect the control cable (7) between the power source (8) and the PEK (2).
2. Connect the return cable (11) between the power source (8) and work piece (9).
3. Connect the welding cable (10) between the power source (8) and the automatic
4. Connect the gas hose (5) between the reducer valve (6) and the gas connection (13)
on the welding equipment.
5. Connect the cooling water hoses (3) between the cooling unit (4) and the automatic
6. Connect the measurement cable (12) between the power source (8) and workpiece
(9).

0449 165 160 - 15 - © ESAB AB 2023

3 INSTALLATION
3.7.4 Automatic welding equipment 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).
3. Connect the welding cable (10) between the welding power source (8) and the
automatic welding equipment (1).
4. Connect the gas hose (5) between the reduction valve (6) and the gas valve on the
5. Connect the hoses for cooling water (3) between the cooling unit (4) and the
6. Connect the measuring cable (12) between the welding power source (8) and the
work piece (9).

0449 165 160 - 16 - © ESAB AB 2023

4 OPERATION
4 OPERATION
4.1 General
CAUTION!
Read and understand the instruction manual before
installing or operating.
General safety regulations for handling the equipment can be found in the "SAFETY"
chapter of this manual. Read it through before you start using the equipment!
Return cable
Before starting the welding, check that the return cable is connected. See section
"Connections".
4.2 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 in the "Installation" chapter.
2. Check that feed roller (1) and contact jaw or contact tip (3) has the correct dimension
for the selected wire size.
3. For A2TF J1 Twin and A2TG J1:
○ Feed the wire through the wire guide (8).
4. When welding with fine wire:
○ Feed the wire through the fine wire feed unit (6).
Ensure that the straightener is correctly adjusted so that the wire emerges
straight out through the contact jaws or contact tip (3).
5. Pull the end of the wire through the straightener (2).
○ For a wire diameter greater than 2 mm, straighten out 0.5 m of wire and feed it
by hand down through the straightener.
6. Locate the end of the wire in the feed roller (1) groove.
7. Set the wire tension on the feed roller with the knob (4).
NOTE!
Do not tension more than is required to achieve an even feed.
0449 165 160 - 17 - © ESAB AB 2023

4 OPERATION
8.
Feed the wire forward 30 mm below the contact tip by pressing on the PEK.
9. Direct the wire by adjusting the knob (5).
NOTE!
Always use a guide tube (7) to ensure even feed of fine wire (1.6–2.5 mm).
For MIG/MAG welding with wire sizes < 1.6 mm, use a guide spiral, which is
inserted in the guide tube (7).
4.3 Loading the welding wire (A2TG J1 4WD)
1. Check that the feed rollers (1, 4) and the contact nozzle (7) has the correct dimension
for the selected wire size.
NOTE!
The feed rollers are marked with their respective groove diameter (D) on the
opposite side of the roller.
2. Undo the pressure devices (10).
3. Put up the pressure arms (11).
4. Put the end of the wire through the wire guide nipple (12).
5. Locate the end of the wire in the feed roller (1) groove. Feed the wire through the
intermediate nozzle (3).
6. Locate the end of the wire in the other feed roller (4) groove. Feed the wire through
the outlet nozzle (9).
0449 165 160 - 18 - © ESAB AB 2023

4 OPERATION
7. Put down the pressure arms (11) and adjust the wire tension on the feed rollers (1, 4)
by way of the pressure devices (10).
NOTE!
Do not tighten down too hard.
8.
Feed the wire forward 30 mm below the contact nozzle by pressing on the PEK.
4.4 Changing the feed roller (A2TF J1 / A2TF J1 Twin, A2TG J1)
4.4.1 Single wire
• Release the knobs (3) and (4).

• Release the hand wheel (2).
• Change the feed roller (1).
The feed rollers are marked with their respective
wire sizes.
4.4.1.1 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. A special curved pressure roller for
twin wire replaces the standard pressure roller for single wire.
• Assemble the pressure roller with special stub shaft (order no. 0146 253 001).
4.4.1.2 Flux-cored wire for knurled rollers (Accessories)
• Change the feed roller (1) and pressure roller (5) as a pair for the wire size to be used.
NOTE!
A special stub shaft is required for the pressure roller (order no. 0212 901 101).
• Tighten the pressure screw (4) with moderate pressure to ensure that the flux-cored
wire does not deform.
0449 165 160 - 19 - © ESAB AB 2023

4 OPERATION
4.5 Changing the feed rollers (A2TG J1 4WD)
• Undo the pressure devices (10).

• Put up the pressure arms (11).
• Undo the mounting screws (2) of the
feed rollers.
• Replace the feed rollers (1, 4).
• Adjust the wire tension on the new feed
rollers.
4.6 Contact equipment for Submerged Arc Welding

4.6.1 For single wire 1.6–4.0 mm – Light duty (D20)
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.
4.6.2 For twin wires 2×1.2–2.0 mm – Light Twin (D35)
Use automatic welding equipment A2TF J1 Twin (SAW) where the

following are included:
• Connector Twin D35 (2)
• Fine-wire feed unit (5)
• Guide tubes (4, 6)
Tighten the contact tip (3) with a key in order to ensure that a good contact is achieved.
0449 165 160 - 20 - © ESAB AB 2023

4 OPERATION
4.6.2.1 Accessories
• Fine-wire straightener (5) to be fitted on top of the clamp of the

wire feed unit (1).
NOTE!
When mounting the fine-wire straightener, remove the
plate (7) if it exists.
NOTE!
Do not remove the protection plate (8).
4.6.2.2 Adjustment of the wires for twin-arc welding

Position the wires in the joint so as to achieve optimal weld quality by rotating the connector.
The two wires can be rotated so that they are positioned one after the other along the line of
the joint, or in any position up to 90° across the joint, i.e. one wire on each side of the joint.
4.7 Contact equipment for MIG/MAG welding

4.7.1 For single wire 1.6–2.5 mm (D35)
Use automatic welding equipment A2TG J1

(MIG/MAG) where the following are included:
Tighten the contact tip (3) with a key in order to ensure
that a good contact is achieved.
0449 165 160 - 21 - © ESAB AB 2023

4 OPERATION
4.7.2 For single wire < 1.6 mm (D35)
Use automatic welding equipment A2TG J1

• Guide tubes (4)
Tighten the contact tip (3) with a key in order to ensure
that a good contact is achieved.
4.7.2.1 Accessories
• Fine-wire straightener (5) to be fitted on top of the clamp of the

wire feed unit (1).
NOTE!
When mounting the fine-wire straightener, remove the
plate (7) if it exists.
NOTE!
Do not remove the protection plate (8).
4.7.3 For single wire 1.0–2.4 mm (wire feed unit with four-wheel drive)
Use automatic welding equipment A2TG J1 4WD

• Contact device D35 (6)
Tighten the contact device (6) using the Allen
screw (8).
• Contact nozzle (7)
Tighten the contact nozzle in order to ensure that
a good contact is achieved.
Select a wire guide insert of the correct dimension for
the type of wire to be used. See the instruction manual
for contact device MTW 600 (0449 006 xxx).
0449 165 160 - 22 - © ESAB AB 2023

4 OPERATION
4.8 Refilling with flux powder
1. Close the flux valve (1) on the flux hopper.

2. Remove the optional cyclone on the flux recovery
unit, if fitted.
3. Fill with flux powder.
NOTE!
The flux powder must be dry. Use
preheated flux powder only when the
flux hopper is designed for that.
4. Position the flux tube without twisting it.
5. Adjust the height of the flux nozzle above the weld
so that the correct amount of flux is delivered.
Flux coverage should be sufficient so that
penetration of the arc does not occur.
4.9 Transportation
• Disengage the wheels by turning the locking lever (1).
• Make sure the safety chain (2) is properly fastened. This prevents accidents, for
example if the carrier is not adequately locked to the foot clamp of the carriage.
NOTE!
Use the lifting eye bolt (3) when lifting the equipment.
0449 165 160 - 23 - © ESAB AB 2023

4 OPERATION
4.10 Conversion of A2TF J1 / A2TF J1 Twin (Submerged Arc

Welding) to MIG/MAG welding
Assemble in accordance with the instructions accompanying the conversion kit.
4.11 Conversion of A2TF J1 (Submerged Arc Welding) to Twin-arc

Assemble in accordance with the instructions accompanying the conversion kit.
0449 165 160 - 24 - © ESAB AB 2023

5 MAINTENANCE
5 MAINTENANCE
5.1 General
CAUTION!
All warranty undertakings from the supplier cease to apply if the customer attempts
any work to rectify any faults in the product during the warranty period.
NOTE!
Before doing any kind of maintenance work, make sure the mains cable is
disconnected.
5.2 Daily
• Clean flux and dirt off moving parts.
• Check that the contact tip and all electrical cables are connected.
• Make sure all screwed joints are tightened.
• Check that guides and drive rollers are not worn or damaged.
• Check the brake hub braking torque. Tighten if the wire reel continues to rotate when
the wire feed is stopped. Loosen if the feed rollers slip. As a guide, the braking torque
for a 30 kg wire reel should be 1.5 Nm.
To adjust the braking torque, see section "Adjusting the brake hub".
5.3 Periodic
• Inspect the wire guides, drive rollers and contact tip on the wire feed unit.
• Replace any worn or damaged components, see section "WEAR PARTS".
• Inspect the slides, lubricate them if they are binding.
• Lubricate the chain.
• Tensioning the chain between the trolley's front and back axles.
○ Dismantle the trolley wheels and blanks. Remove the Y flange bearing bolts.
○ Tension the chain by moving the trolley's rear axle parallel in relation to the front
axle.
○ Reassemble in the reverse order.
• Tensioning the chain from the trolley's front axle to the drive motor and gearbox.
○ Tension the chain by moving the drive motor and gearbox.
0449 165 160 - 25 - © ESAB AB 2023

6 TROUBLESHOOTING
6 TROUBLESHOOTING
6.1 General
Equipment
• Instruction manual for included parts.
Check
• That the power supply is connected for the correct mains supply.
• That all three phases are supplying the correct voltage (phase sequence is not
important).
• That welding cables and connections are not damaged.
• That the controls are correctly set.
• That the mains supply is disconnected before starting repairs.
6.2 Possible errors

1. Symptom Current and voltage readings show large fluctuations
Cause 1.1 Contact jaws or nozzle are worn or wrong size.
Action Replace contact jaws or nozzle.
Cause 1.2 Wire feed roller pressure is inadequate.
Action Increase pressure on wire feed rollers.
2. Symptom Wire feed is uneven
Cause 2.1 Pressure on wire feed rollers is incorrectly set.
Action Adjust pressure on wire feed rollers.
Cause 2.2 Wire feed rollers are of the wrong size.
Action Replace wire feed rollers.
Cause 2.3 Grooves in wire feed rollers are worn.
Action Replace wire feed rollers.
3. Symptom Welding cables are overheating
Cause 3.1 Poor electrical connection.
Action Clean and tighten all electrical connections.
Cause 3.2 Cross-sectional area of welding cables is too small.
Action Use cables with a larger cross-section or use parallel cables.
0449 165 160 - 26 - © ESAB AB 2023

7 ORDERING SPARE PARTS
7 ORDERING SPARE PARTS

CAUTION!
Repair and electrical work should be performed by an authorised ESAB service
technician. Use only ESAB original spare and wear parts.
A2TF J1 / A2TF J1 Twin and A2TG J1 / A2TG J1 Twin are designed and tested in
accordance with the international and European standards EN 60974-5, EN 12100-2 and
EN 60974-10. On completion of service or repair work, it is the responsibility of the
person(s) performing the work to ensure that the product still complies with the requirements
of the above standards.
Spare parts and wear parts can be ordered through your nearest ESAB dealer, see
esab.com. When ordering, please state product type, serial number, designation and spare
part number in accordance with the spare parts list. This facilitates dispatch and ensures
correct delivery.
0449 165 160 - 27 - © ESAB AB 2023

DIMENSION DRAWING
DIMENSION DRAWING
A2TF J1 / A2TF J1 Twin
Recommended adjusting
Measure Butt joint Fillet joint
A 165 mm 165 mm
B 668 mm 668 mm
C 455 mm 455 mm
0449 165 160 - 28 - © ESAB AB 2023

DIMENSION DRAWING
A2TG J1 / A2TG J1 4WD
Recommended adjusting
Measure Butt joint Fillet joint
A 165 mm 165 mm
B 668 mm 668 mm
C 455 mm 455 mm
0449 165 160 - 29 - © ESAB AB 2023

SPARE PARTS LIST
SPARE PARTS LIST

A2TF J1/ A2TF J1 Twin/ A2TG J1/ A2TG J1 4WD
Ordering no. Denomination Notes

0461 233 880 A2 Multitrac SAW A2TF J1 SAW
0461 233 881 A2 Multitrac SAW Twin A2TF J1 Twin SAW
0461 234 880 A2 Multitrac MIG/ MAG A2TG J1 MIG/ MAG
0461 234 881 A2 Multitrac MIG/ MAG A2TG J1 4WD MIG/ MAG
0449 165 160 - 30 - © ESAB AB 2023

SPARE PARTS LIST
Item Qty Ordering no. Denomination Notes

no.
0461 233 880 Automatic welding equipment A2TF J1, SAW
1 1 0449 100 883 Carriage
2 1 0449 154 880 Carrier
3 1 0449 152 880 Slide travel kit, manual 90 mm
4 1 0449 150 900 Wire feed unit complete
5 1 0460 504 880 Control box PEK
6 1 0449 153 900 Cable kit L= 1.6 m
6:1 1 0460 909 881 Pulse transducer cable
6:2 1 0461 249 881 Motor cable
6:3 1 0461 239 880 Arc welding cable
0449 165 160 - 31 - © ESAB AB 2023

SPARE PARTS LIST

no.
0461 233 881 Automatic welding equipment A2TF J1 Twin, SAW
1 1 0449 100 883 Carriage
2 1 0449 154 880 Support
4 1 0449 150 901 Wire feed unit complete Twin
6 1 0449 153 900 Cable kit L= 1.6 m
6:2 1 0461 249 881 Motor cable
0449 165 160 - 32 - © ESAB AB 2023

SPARE PARTS LIST

no.
0461 233 880 Automatic welding equipment A2TG J1, MIG/ MAG
1 1 0449 100 883 Carriage
2 1 0449 154 880 Carrier
4 1 0449 150 902 Wire feed unit complete
6 1 0449 153 900 Cable kit L= 1.6 m
6:2 1 0461 249 881 Motor cable
0449 165 160 - 33 - © ESAB AB 2023

SPARE PARTS LIST

no.
0461 234 881 Automatic welding equipment A2TG J1 4 WD, MIG/ MAG
1 1 0449 100 883 Carriage
2 1 0449 154 880 Carrier
4 1 0449 150 903 Wire feed unit complete 4 WD
6 1 0449 153 900 Cable kit L= 1.6 m
6:2 1 0461 249 881 Motor cable
0449 165 160 - 34 - © ESAB AB 2023

SPARE PARTS LIST

no.
0449 100 883 Carriage
1 1 0449 087 001 Cover
9 3 0333 087 005 Y-Flange unit
12 4 0415 857 001 Rubber wheel
13 4 0211 102 962 Roll pin
14 1 0461 241 880 Motor cable L = 1.9 m
15 1 0461 242 880 Pulse transducer cable L = 2,1 m
23 2 0449 205 880 Guide arm complete
27 1 0413 366 320 Clamp
29 1 0413 366 105 Clamp
30 1 0413 366 112 Clamp
31 1 0449 101 001 Plate
40 1 0800 185 001 Bearing bushing
43 1 0449 089 881 Drive unit
44 1 049 098 001 Shaft with eccentric
45 1 0449 099 001 Shaft support
47 1 0449 096 001 Shaft
50 1 0333 630 001 Adjustable locking lever
53 1 0449 097 001 Plate
54 1 0449 103 001 Pressure screw
55 8 0449 206 001 Clamp
56 4 0191 498 003 Cover plate
59 2 0333 086 003 Sprocket for carriage
60 2 0211 102 952 Roll pin
61 1 0218 201 501 Chain 3/8” x 5.7
62 1 0218 201 601 Chain lock 3/8” x 5.7
71 3 0449 108 001 Plate
72 9 0219 504 302 Spring washer
74 1 0413 539 002 Clamp
75 1 0193 570 131 Locking lever
84 4 0163 139 002 Bushing
85 4 0162 414 002 Insulating pipe
87 1 0413 527 001 Plate
0449 165 160 - 35 - © ESAB AB 2023

SPARE PARTS LIST
0449 165 160 - 36 - © ESAB AB 2023

SPARE PARTS LIST

no.
0449 154 880 Carrier
4 1 0413 671 001 Chain attachment
5 1 0413 597 001 Safety chain
11 6 0163 139 002 Bushing
12 6 0162 414 002 Insulating tube
14 1 0413 528 001 Column
15 1 0413 540 001 Clamp
16 1 0413 530 880 Arm
17 1 0146 967 880 Brake hub
18 1 0413 532 001 Attachment
20 1 0413 317 002 Handle
22 2 0156 442 002 Clamp screw R21 M8
24 1 0334 185 886 Box girder beam complete
27 1 0413 317 001 Handle
30 2 0218 301 113 Lifting eye bolt
0449 165 160 - 37 - © ESAB AB 2023

SPARE PARTS LIST
0449 165 160 - 38 - © ESAB AB 2023

SPARE PARTS LIST

no.
0449 152 880 Slide travel kit Manual
1 2 0413 518 880 Slide 90 mm
2 1 0413 506 880 Circular slide
0449 165 160 - 39 - © ESAB AB 2023

SPARE PARTS LIST

no.
0413 518 880 Slide
1 1 0413 519 001 Slide profile
3 1 0413 521 001 Runner
5 1 0413 522 001 Lead screw
7 1 0334 537 002 Crank
9 2 0413 523 001 Axis
17 4 0190 240 107 Bearing
0449 165 160 - 40 - © ESAB AB 2023

SPARE PARTS LIST

no.
0413 506 880 Rotary slide
1 1 0413 507 001 Flange
2 1 0413 508 001 Tensioning ring
3 1 0413 509 001 Flange
7 2 0219 504 405 Bellleville spring T = 0.6
8 1 0193 571 105 Locking piece
10 1 0193 570 123 Locking lever
0449 165 160 - 41 - © ESAB AB 2023

SPARE PARTS LIST

no.
0449 150 900 Wire feed unit complete (Right) SAW
1 1 0147 639 882 Wire feed unit
2 1 0413 072 881 Bearing housing
3 1 0215 701 210 Wedge, flat
4 1 0413 517 001 Bracket for motor
5 1 0812 312 001 Motor with pulse transducer
8 1 0218 810 183 Insulated Hand wheel
12 1 0413 510 001 Contact tube D20, L = 260 mm
13 1 0416 984 880 Guide pin complete
14 1 0333 094 880 Clamp for Flux tube
15 1 0332 948 001 Flux tube
16 1 0332 994 883 Flux container
17 1 0413 318 001 Holder
55 1 0449 475 001 Bar
61 1 0462 132 880 Protecting cover
62 1 0449 528 001 Protection plate
0449 165 160 - 42 - © ESAB AB 2023

SPARE PARTS LIST

no.
0449 150 901 Wire feed unit complete (Right) UP, Twin
1 1 0147 639 886 Wire feed unit Twin
3 1 0215 701 210 Wedge, flat
12 1 0333 852 881 Contact device Twin, L = 275
15 1 0153 299 880 Flux nozzle
16 1 0332 994 883 Flux container
17 1 0413 318 001 Holder
22 0156 800 002 Wire liner
23 1 0145 787 880 Fine wire straightener
50 1 0146 967 880 Brake hub
51 1 0413 532 002 Attachment
52 2 0154 734 001 Clamp
55 1 0457 713 001 Bar
61 1 0462 132 880 Protecting cover
0449 165 160 - 43 - © ESAB AB 2023

SPARE PARTS LIST

no.
0449 150 902 Wire feed unit complete (Right) MIG/ MAG
1 1 0147 639 882 Wire feed unit
3 1 0215 701 210 Wedge, flat
11 2 0417 699 001 Rubber clamp
12 1 0030 465 389 Contact device
18 1 0461 238 881 Solenoid valve and cable
20 1 0155 300 001 Plate
22 1 0156 800 002 Wire liner
25 1 0333 754 001 Hose L = 2,25 m, D 14/ 6.3
26 6 0193 761 002 Hose clamp
27 2 0147 336 880 Hose coupling
55 1 0449 475 001 Bar
61 1 0462 132 880 Protection cover
0449 165 160 - 44 - © ESAB AB 2023

SPARE PARTS LIST

no.
0449 150 903 Wire feed unit complete (Right) 4WD, MIG/ MAG
1 1 0456 424 902 Wire feed unit
12 1 0457 460 881 Contact device MTW 600, L = 250
18 1 0461 238 881 Solenoid valve and cable
22 0156 800 002 Wire liner
25 0333 754 001 Hose D 14/ 6.3
27 2 0147 336 880 Hose coupling
30 1 0449 011 001 Support
35 1 0449 009 002 Motor bracket
36 1 0449 009 001 Motor bracket
43 2 0163 139 002 Bushing
0449 165 160 - 45 - © ESAB AB 2023

SPARE PARTS LIST

no.
0147 639 882 Straightener (right mounted)
1 1 0156 449 001 Clamp
6 2 0212 900 001 Spacer screw
7 4 0215 201 209 O-ring D11.3 x 2.4
8 2 0218 400 801 Pressure roller arm
9 1 0218 810 181 Hand wheel
10 1 0218 810 182 Hand wheel
11 3 0332 408 001 Stub shaft
13 3 0153 148 880 Roller
14 1 0415 498 001 Thrust roller carrier
15 2 0212 902 601 Spacer screw
23 1 0334 571 880 Contact clamp
30 1 0212 601 110 Nut M10
0449 165 160 - 46 - © ESAB AB 2023

SPARE PARTS LIST

no.
0147 639 886 Straightener (right mounted)
1 1 0156 449 001 Clamp
5 1 0156 530 001 Clamp half
6 1 0212 900 001 Spacer screw
7 2 0215 201 209 O-ring D11.3 x 2.4
8 1 0218 400 801 Pressure roller arm
9 1 0218 810 181 Hand wheel
11 1 0332 408 001 Stub shaft
12 1 0218 524 580 Pressure roller Twin
13 1 0153 148 880 Roller
15 1 0212 902 601 Spacer screw
19 2 0219 501 013 Spring washer D18.1/10.2
28 1 0156 531 001 Clamp half
30 1 0212 601 110 Nut M10
0449 165 160 - 47 - © ESAB AB 2023

SPARE PARTS LIST

no.
0413 072 881 Bearing housing with stub shaft
1 1 0413 073 002 Searing housing
2 2 0190 726 003 Ball bearing
3 1 0334 575 001 Stub shaft
4 1 0215 701 014 Retaining ring D17
5 3 0334 576 001 Spacer
0449 165 160 - 48 - © ESAB AB 2023

SPARE PARTS LIST

no.
0332 994 883 Flux hopper complete
1 1 0332 837 001 Hopper for flux
6 1 0153 347 881 Flux valve
7 1 00203 017 80 Flux strainer
16 1 0443 383 002 Flux hose L = 500
0449 165 160 - 49 - © ESAB AB 2023

SPARE PARTS LIST

no.
0153 347 880 Flux valve
1 1 0153 348 001 Outlet
2 1 0153 349 001 Shaft
3 1 0211 102 938 Roll pin d 3 x 20
0449 165 160 - 50 - © ESAB AB 2023

SPARE PARTS LIST

no.
0333 852 881 Connector Twin L=275 A6 UP
2 1 0333 772 001 Nozzle holder
7 1 0417 959 881 Contact equipment L = 275, Heavy Duty
8 2 0415 032 001 Guide pipe
9 2 0334 279 001 Spiral to connector L = 366
0449 165 160 - 51 - © ESAB AB 2023

SPARE PARTS LIST

no.
0417 959 881 Contact equipment L = 275 mm
4 1 0443 372 001 Screw
5 4 0219 504 307 Beleville spring T = 1.1
8 1 0443 344 881 Pipe L = 275
0449 165 160 - 52 - © ESAB AB 2023

SPARE PARTS LIST

no.
0153 299 880 Flux nozzle
1 1 0153 290 002 Pipe holder
2 1 0153 296 001 Pipe bend
3 1 0153 425 001 Wheel
0449 165 160 - 53 - © ESAB AB 2023

SPARE PARTS LIST

no.
0145 787 880 Fine wire straightener for twin
wire
1 1 0145 788 001 Case
2 2 0145 789 001 Roller
3 2 0145 790 001 Roller
5 2 0190 240 103 Bearing bushing D12/10
6 2 0145 792 001 Screw
9 2 0145 793 001 Runner
10 2 0145 796 002 Screw
11 2 0145 794 001 Knob
13 1 0145 795 001 Link
15 1 0151 287 001 Hose L = 600
0449 165 160 - 54 - © ESAB AB 2023

SPARE PARTS LIST

no.
0030 465 389 Connector
2 1 0145 226 001 Insulating sleeve
3 1 0190 680 313 O-ring OR 15.3 x 2.4
4 1 0190 680 303 O-ring OR 5.3 x 2.4
5 1 0190 680 405 O-ring OR 22.2 x 3
8 1 0334 278 880 Insert tube
9 1 0334 279 001 Spiral
22 1 0146 099 001 Plug
23 1 0145 534 882 Contact tube
24 1 0145 227 882 Gas nozzle
25 1 0144 998 882 Water hose
39 1 0040 979 804 Extension L = 108, D20
0449 165 160 - 55 - © ESAB AB 2023

SPARE PARTS LIST

no.
0456 424 902 Feed unit
1 1 0455 046 003 Gear housing
2 2 0368 749 881 Pressure device
3 1 0458 997 001 Shaft
4 1 0459 001 880 Pressure arm
5 2 0458 999 001 Shaft
6 1 0458 993 001 Spring
8 4 0215 702 706 Locking washer
9 2 0458 722 001 Shaft
10 1 0380 351 001 Wire guide nipple
11 1 0455 072 001 Intermediate nozzle D13 (W)
12 1 0469 837 880 Outlet nozzle (W)
13 1 0457 365 001 Current connection
19 1 0455077003 Drive unit with pulse transducer
21 4 0459 441 880 Gear wheel
22 1 0459 440 001 Motor gear (W)
28 2 0458 721 001 Locking nut M6
0449 165 160 - 56 - © ESAB AB 2023

SPARE PARTS LIST

no.
0457 460 881 Contact device MTW 600, 250 mm
1 1 0457 457 002 Cooling jacket
2 1 0457 455 002 Contact tube
3 1 0457 456 001 Insulation sleeve
4 1 0457 451 001 Gas nozzle
5 1 0457 452 001 Spatter protection
6 1 0457 453 001 Centering sleeve
7 1 0457 617 001 Allen screw
8 1 0457 459 001 Insulation sleeve
9 1 0457 458 001 O-ring
10 1 0457 616 880 Water hose set
11 1 0457 625 005 Contact tip Ø1.2 (W)
1 0457 625 007 Contact tip Ø1.5 (W)
1 0457 625 008 Contact tip Ø1.6 (W)
1 0457 625 009 Contact tip Ø1.8 (W)
12 0457 458 002 O-ring
13 1 0457 454 002 Wear insert (Steel spiral) L = 260, wire Ø 1.0-1.6 mm
(W)
1 0457 620 002 Wear insert (Brass tube) L = 258, wire Ø 2.0-2.4 mm
(W)
0449 165 160 - 57 - © ESAB AB 2023

SPARE PARTS LIST

no.
0461 238 881 Solenoid valve with cable
2 1 0157 259 001 Contact
3 0262 612 802 Cable
7 3 0262 613 329 Cable
11 1 0193 054 002 Solenoid valve 42 V
12 1 0194 269 002 Bushing
0449 165 160 - 58 - © ESAB AB 2023

SPARE PARTS LIST
0449 165 160 - 59 - © ESAB AB 2023

For contact information visit esab.com
ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone +46 (0) 31 50 90 00
manuals.esab.com

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A2 Multitrac

A2TF J1/ A2TF J1 Twin/

0449 165 160 GB 20230626 Valid for: serial no. 940-xxx-xxxx

0449 165 160 © ESAB AB 2023

4.6 Contact equipment for Submerged Arc Welding ................................ 20

7 ORDERING SPARE PARTS ........................................................................ 27

Rights reserved to alter specifications without notice.

0449 165 160 © ESAB AB 2023

1.2 Safety precautions

0449 165 160 -5- © ESAB AB 2023

4. Personal safety equipment:

ELECTRIC SHOCK - Can kill

0449 165 160 -6- © ESAB AB 2023

MOVING PARTS - Can cause injuries

0449 165 160 -7- © ESAB AB 2023

ESAB has an assortment of welding accessories and personal protection equipment

0449 165 160 -8- © ESAB AB 2023

2.2 Welding method

2.4 Horizontal welding

0449 165 160 -9- © ESAB AB 2023

3.2 Main components A2TF J1 / A2TF J1 Twin (SAW)

1. Carriage 6. Wire feed motor

0449 165 160 - 10 - © ESAB AB 2023

3.3 Main components A2TG J1 / A2TG J1 4WD (MIG/MAG)

3.4 Description of main components

0449 165 160 - 11 - © ESAB AB 2023

3.4.6 Wire feed motor

Mount the wire drum (1) on the brake hub (2).

3.6 Adjusting the brake hub

0449 165 160 - 12 - © ESAB AB 2023

Adjusting the braking torque:

0449 165 160 - 13 - © ESAB AB 2023

3.7.2 Automatic welding equipment A2TF J1 / A2TF J1 Twin (Submerged Arc

1. Automatic welding equipment 5. Control cable

0449 165 160 - 14 - © ESAB AB 2023

3.7.3 Automatic welding equipment A2TG J1 (Gas metal arc welding,

1. Automatic welding equipment 5. Control cable

0449 165 160 - 15 - © ESAB AB 2023

1. Automatic welding equipment 5. Control cable

0449 165 160 - 16 - © ESAB AB 2023

A2TF J1 (SAW) A2TF J1 Twin (SAW) A2TG J1 (MIG/MAG)

0449 165 160 - 17 - © ESAB AB 2023

4.3 Loading the welding wire (A2TG J1 4WD)

0449 165 160 - 18 - © ESAB AB 2023

• Release the knobs (3) and (4).

4.4.1.1 Twin wire (Twin-arc)

0449 165 160 - 19 - © ESAB AB 2023

4.5 Changing the feed rollers (A2TG J1 4WD)

• Undo the pressure devices (10).

4.6 Contact equipment for Submerged Arc Welding

The following are included:

4.6.2 For twin wires 2×1.2–2.0 mm – Light Twin (D35)

Use automatic welding equipment A2TF J1 Twin (SAW) where the

0449 165 160 - 20 - © ESAB AB 2023

• Fine-wire straightener (5) to be fitted on top of the clamp of the

4.6.2.2 Adjustment of the wires for twin-arc welding

4.7 Contact equipment for MIG/MAG welding

Use automatic welding equipment A2TG J1

0449 165 160 - 21 - © ESAB AB 2023

4.7.2 For single wire < 1.6 mm (D35)