Page 3 - TABLE OF CONTENTS
3 TABLE OF CONTENTS Safety Summary ......................................4 Safety Information ..................................4Shock Hazards ......................................5Flash Hazards ........................................5Fire Hazards ..........................................6Fume Ha...
Page 4 - IMPORTANT SAFETY INFORMATION; WARNING; SAFETY SUMMARY
4 The warnings, cautions and instructions dis-cussed in this instruction manual can not coverall possible conditions or situations that couldoccur. It must be understood by the operatorthat common sense and caution are factorswhich can not be built into this product, butmust be supplied by the opera...
Page 5 - SHOCK HAZARD; ELECTRIC SHOCK CAN KILL!; FLASH HAZARDS
5 SHOCK HAZARD WARNING ELECTRIC SHOCK CAN KILL! To reduce the risk of death or serious injury from shock,read, understand, and follow the followingsafety instructions. In addition, make certainthat anyone else who uses this weldingequipment, or who is a bystander in thewelding area understands and f...
Page 6 - FIRE HAZARDS; To
6 welding shields and/or helmets in place. • Do not wear a cracked or broken helmet and replace any cracked or bro-ken filter lenses IMMEDIATELY. • Do not allow the uninsulated portion of the wire feed gun to touch the groundclamp or grounded work to prevent anarc flash from being created on contact...
Page 7 - prevent spatter or slag from falling into ear.; FUME HAZARDS; COMPRESSED GASSES AND
7 prevent spatter or slag from falling into ear. • Make sure welding area has a good,solid, safe floor, preferably concrete ormasonry, not tiled, carpeted, or made ofany other flammable material. • Protect flammable walls, ceilings, andfloors with heat resistant covers orshields. • Check welding are...
Page 8 - Wash hands after Handling.; ADDITIONAL SAFETY INFORMATION
8 • Do not expose cylinders to electricity ofany kind. • Do not use a cylinder or its contents foranything other than its intended use. Donot use as a support or roller. • Do not locate cylinders in passagewaysor work area where they may be struck. • Do not use a wrench or hammer to opena cylinder v...
Page 9 - WELDER SPECIFICATIONS; DESCRIPTION; DUTY CYCLE; INTERNAL THERMAL PROTECTION; CAUTION
9 WELDER SPECIFICATIONS DESCRIPTION Your new MIG (GMAW) flux core (FCAW)wire feed welder is designed for mainte-nance and sheet metal fabrication. Thewelder consists of a single-phase powertransformer, stabilizer, rectifier, and aunique built-in control/feeder. Now you can weld sheet metal from 24ga...
Page 10 - KNOW YOUR WELDER
10 KNOW YOUR WELDER Handle – Rugged, top mounted handle allows for easy transport of your welder. Wire Speed Control – Use this dial to adjust the speed at which the welder feeds wire to thegun. 1 is the slowest wire feed speed, 10 is thehighest. You will need to adjust or “tune-in”your wire speed f...
Page 11 - POWER SOURCE CONNECTION; ACTUAL VOLTAGE; ASSEMBLING THE WELDER; WELDER INSTALLATION
11 POWER SOURCE CONNECTION POWER REQUIREMENTS This welder is designed to operate on a proper-ly grounded 230 volt, 60Hz, single-phase alter-nating current (AC) power source fused with a50 amp time delayed fuse or circuit breaker. Itis recommended that a qualified electrician ver-ify the ACTUAL VOLTA...
Page 12 - Face Shield Assembly
12 3. Once the handle tabs are properly seat- ed in the face shield slots, install thehandle cover by firmly pushing it into therecessed area on the face shield. 4. Install the dark glass by sliding it into place behind the glass retaining tabs. Note: if your face shield was supplied with a3” x 3.8”...
Page 13 - INSTALL THE SHIELDING GAS; CHECK THE GAS FLOW; ALIGN AND SET THE DRIVE ROLLER; Feed Motor
13 Gas Selection For Aluminium Weldingwith Aluminium Wire Use only pure Argon when weldingAluminium. INSTALL THE SHIELDING GAS WARNING IMPROPER HANDLING AND MAINTE-NANCE OF COMPRESSED GAS CYLIN-DERS AND REGULATORS CAN RESULT INSERIOUS INJURY OR DEATH! Always secure gas cylinders to the welding cart,...
Page 14 - Wire Diameter; Drive Roller Sizing; INSTALL THE WELDING WIRE; Electric shock can kill!; Drive Roller
14 Change the drive roller according to the follow-ing steps: 1. Open the door to the welder drive com- partment. 2. Remove the drive tension by loosening the tension adjusting screw and lifting the DriveTension Adjustor up, away from the DriveTension Arm. Pull the drive tension armaway from the dri...
Page 16 - SET THE WIRE DRIVE TENSION; INSTALLING ALUMINIUM WIRE
16 16. Set the WIRE SPEED control to the middle of the wire speed range. 16. Straighten the gun cable and pull the trigger on the welding gun to feed thewire through the gun assembly. 17. When at least an inch of wire sticks out past the end of the gun, release the trigger. 18. Select a contact tip ...
Page 17 - Risk of electric component damage!; CONTROLS AND INDICATORS; POWER SWITCH; TUNING IN THE WIRE SPEED; OPERATION; Changing Polarity
17 B. For MIG (GMAW) welding, mount the Ground Clamp ring terminal to the “-” mounting post and the Torch ringterminal to the “+” mounting post. See configuration shown in Figure 9. 2. Attach the ground clamp to the work piece, making sure that it is cleaned ofdirt, oil, rust, scale, oxidation, and ...
Page 18 - With your free hand, turn the Wire Speed; Prolonged exposure to the welding; LEARNING TO WELD; Position the Gun to the Work Piece
18 piece farthest away from you, and at anangle similar to that which will be usedwhen welding. (SEE HOLDING THE GUNon page 18 if you are uncertain of theangle at which you will be welding) 4. With your free hand, turn the Wire Speed Dial to maximum and continue to holdonto the knob. WARNING EXPOSUR...
Page 19 - Distance from the Work Piece; WELDING TECHNIQUES; To prevent; MOVING THE GUN; is the direction the; Gun Position, Angle A
19 2. Angle B (Figure 11) can be varied for two reasons: to improve the ability to see thearc in relation to the weld puddle and todirect the force of the arc. The force of the welding arc follows astraight line out of the end of the nozzle. If angle B is changed, so will the direction ofarc force a...
Page 20 - is the rate at which the; TYPES OF WELD BEADS; Stringer Bead
20 For most welding jobs you will pull the gunalong the weld joint to take advantage ofthe greater weld puddle visibility. 2. TRAVEL SPEED is the rate at which the gun is being pushed or pulled along theweld joint. For a fixed heat setting, thefaster the travel speed, the lower the pen-etration and ...
Page 21 - MULTIPLE PASS WELDING; When butt welding thick-
21 force, is directed more toward the metalabove the weld joint. This is to help preventthe weld puddle from running downwardwhile still allowing slow enough travel speedto achieve good penetration. A good start-ing point for angle B is about 30 degreesDOWN from being perpendicular to thework piece....
Page 22 - SPECIAL WELDING METHODS; The PUNCH AND FILL METHOD produces
22 The illustrations in Figure 19 show thesequence for laying multiple pass beads intoa single V butt joint. NOTE: WHEN USING SELF-SHIELDING FLUX-CORE WIRE it is very important to thor-oughly chip and brush the slag off each com-pleted weld bead before making anotherpass or the next pass will be of ...
Page 23 - CONSUMABLE MAINTENANCE; GUN LINER; MAINTAINING THE CONTACT TIP; MAINTENANCE
23 the top piece of metal and the arc isdirected through the hole to penetrateinto the bottom piece. The puddle isallowed to fill up the hole leaving a spotweld that is smooth and flush with thesurface of the top piece. Select the wire diameter, heat setting, andtune in the wire speed as if you were...
Page 24 - MAINTAINING THE NOZZLE; SHORTED; TESTING FOR A SHORTED NOZZLE
24 Note: Due to inherent variances in flux- cored welding wire, it may be necessary touse a contact tip one size larger than yourflux core wire if wire jams occur. 1. If the wire burns back into the tip, remove the tip from the gun and clean the holerunning through it with an oxygen-acety-lene torch...
Page 27 - TABLE 5 – TROUBLESHOOTING
27 TABLE 5 – TROUBLESHOOTING TROUBLE Dirty, porous, brittle weld Wire feed works but no arc Arc works but no feeding wire Nothing works except fan Low output or nonpenetrating weld Wire is jamming or “birdnesting” atthe drive roller Wire burns back to contact tip Ground clamp and/or ground cablegets...
Page 28 - WIRE FEED WELDER WIRING DIAGRAM
Page 29 - WIRE FEED WELDER PARTS LIST
29 WIRE FEED WELDER PARTS LIST 01 PRT 22710076 E1292 P.C.BOARD "CSA" 1 02 PRT 04600146 JOHNSON MOTOR ø37 + PINION 1 03 PRT 21600035 HANDLE 1 04 PRT 22210014 THERMOSTAT 100° 10A 1 05 PRT 04600286 FAN&FAN MOTOR ASSY. 220V 1 06 PRT 21605036 CABLE CLAMP W/NUT 1 07 PRT 21690425 PLASTIC TRIM 1...
Page 31 - WIRE FEED WELDER GUN PARTS LIST
31 WIRE FEED WELDER GUN PARTS LIST 01 PRT 04600163 HANDLE ASSY., BLUE 1 02 PRT 23005332 GAS VALVE 1 03 PRT 23005145 SWAN NECK WITH INSULATING COVER 1 04 PRT 23005091 SWAN NECK LINER 1 05 PRT 23005285 ISOLATING COVER FOR NECK 2 06 PRT 23005146 TW1 TORCH DIFFUSER 1 07 PRT 23005018 0.023 CONTACT TIP 1 ...
Page 33 - SUGGESTED SETTINGS
Page 34 - NOTES
