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GASLESS
WIRE FEED WELDER
USER’S GUIDE
GUIDE DE L’UTILISATEUR
Form 00-99-000378/1003
98026053
© 2003
800034584 Rev.00
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SAFETY INFORMATION The following safety information is provided as a guideline to help you operate your new welder under the safest possible conditions. Any equipment that uses electrical power can be potentially dangerous to use when safety or safe handling instructions are not known or not followed. The following safety information is provided to give you the information necessary for safe use and operation. When a WARNING precedes a procedure step, it is an indication that the step conta
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• Wear welding gloves to help insulate hands from welding circuit. • Keep all liquid containers far enough away from the welder and work area so that if spilled, the liquid can not possibly come in contact with any part of the welder or electrical welding circuit. • Replace any cracked or damaged parts that are insulated or act as insulators such as welding cables, power cord, or electrode holder IMMEDIATELY. EMF INFORMATION WARNING Welding current will cause electromagnetic fields as it
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exists in your welding area, either remove it or cover it with something nonflammable and non-reflective. Reflected arc rays can also cause skin burn in addition to eye injury. FIRE HAZARDS WARNING FIRE OR EXPLOSION CAN CAUSE DEATH, INJURY, AND PROPERTY DAMAGE! To reduce risk of death, injury, or property damage from fire or explosion, read, understand, and follow the following safety instructions. In addition, make certain that anyone else that uses this welding equipment, or is a bystan
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• Do not weld in an area until it is checked for adequate ventilation as described in ANSI standard #Z49.1. If ventilation is not adequate to exchange all fumes and gasses generated during the welding process with fresh air, do not weld unless you (the welder) and all bystanders are wearing air-supplied respirators. • Do not heat metals coated with, or that contain, materials that produce toxic fumes (such as galvanized steel), unless the coating is removed. Make certain the area is well ve
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INTRODUCTION DESCRIPTION Your new welder is designed for repair, maintenance, and sheet metal fabrication. The welder consists of a single-phase power transformer, and a unique built-in control/feeder. Now you can weld 18-gauge steel sheet metal up to 3/16 inch with a single pass. Welds thicker metal with beveling and multiple pass. Your new wirefeed welder is equipped with infinite wire speed control to accurately select the proper wire feed rate needed for various welding conditions.
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DO NOT OPERATE THIS WELDER if the actual power source voltage is less than 100 volts AC or greater than 125 volts AC. Contact a qualified electrician if this problem exists. Improper performance and/or damage to the welder will result if operated on inadequate or excessive power. WARNING ELECTRIC SHOCK CAN KILL! FIRE CAN KILL, INJURE, AND CAUSE PROPERTY DAMAGE! • To reduce the risk of electric shock and fire, connect only to properly grounded and fused outlets. • Never alter the AC power
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• Always turn the power switch to the OFF position and unplug the welder’s power cord from the AC power source before installing wire. 1. Remove the nozzle and contact tip from the end of the gun assembly. 2. Release the wire tension arm by flipping the drive tension knob out. Move the wire tension arm up and away from the drive roller. 3. Make sure that the wire diameter stamped on the drive roller is the same as the diameter of the wire being installed. If it is not the same,
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13. Pull the trigger on the welding gun to feed the wire through the gun assembly. WARNING ARC FLASH CAN INJURE EYES! To reduce the risk of arc flash, make certain that the welding wire, when it finally comes out of the end of the gun, does not touch the ground clamp or any grounded piece of metal. 14. When at least an inch of wire sticks out past the end of the gun, release the trigger. 15. Select a contact tip stamped with the same wire diameter as the diameter of the wire being u
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to be welded. Only after you are satisfied that your practice welds are of good strength and appearance, should you attempt your actual welding job. CONTROLS & THEIR FUNCTIONS ON-OFF – THERMAL INDICATOR To turn the power on to the welder, push the main switch to ON. Your welder has a lighted main switch. This light will come on if the welder has overheated. The light indicates that a thermostat has shut off the power within the welder. Once the welder has cooled, the thermostat will turn
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5. Lower your welding helmet and pull the trigger on the gun to start an arc, then begin to drag the gun toward you while turning down on the WIRE SPEED control knob at the same time. 6. Listen! As you decrease the wire speed, the sound that the arc makes will change from a sputtering to a smooth, high-pitched buzzing sound and then will begin sputtering again if you decrease the wire speed too far — very similar to tuning in a radio. The points on the WIRE SPEED control where this high-pit
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GENERAL WELDING INFORMATION PREPARATIONS FOR WELDING An important factor in making a satisfactory weld is preparation. This includes studying the process and equipment and then practice welding before attempting to weld finished product. An organized, safe, convenient, comfortable, well lighted work area should be available to the operator. The work area should specifically be free of all flammables with both a fire extinguisher and bucket of sand available. To properly prepare for weldin
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HOLDING THE GUN The best way to hold the welding gun is the way that feels most comfortable to you. While practicing to use your new welder, experiment holding the gun in different positions until you find the one that seems to work best for you. Position the Gun to the Work Piece There are two angles of the gun nozzle in relation to the work piece that must be considered when welding. 1. Angle A can be varied, but in most cases the optimum angle will be 60 degrees - the point at whic
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2. Angle B can be varied for two reasons: to improve the ability to see the arc in relation to the weld puddle and to direct the force of the arc. The force of the welding arc follows a straight line out of the end of the nozzle. If angle B is changed, so will the direction of arc force and the point at which penetration will be concentrated. On a butt weld joint, the only reason to vary angle B from perpendicular (straight up) to the work piece would be to improve visibility of th
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GENERAL MAINTENANCE This welder has been engineered to give many years of trouble-free service providing that a few very simple steps are taken to properly maintain it. Before performing any maintenance or service on your welder, read and understand all warnings in this manual. Unless instructed otherwise, always unplug the welder prior to maintaining or servicing it. 1. Keep the hood closed at all times unless the wire needs to be changed or the drive tension needs adjusting. 2. Keep a
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4. The more worn this hole becomes, the less efficient is the transfer of welding current to the wire, and eventually arc breakage and difficult arc starting will result. Replace contact tips when signs of wear become apparent. Welding Nozzle Maintenance and Replacement The nozzle directs the shielding gas to the weld puddle, determines the size of the shielding area, and prevents the electrically hot contact tip from contacting the work piece. Keep the nozzle clean! During the welding p
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SYMPTOM POSSIBLE CAUSE REMEDY to clamp connection Wrong size contact tip Use proper tip Low primary voltage Have primary voltage checked by electrician Too long or improper extension See instruction under extension cord cord use Wrong type or size of wire Check manual for proper wire size or type Wall receptacle improperly wired Consult electrician Wrong welding polarity Change to proper polarity Faulty gun assembly Replace gun No wire feed but arc works Faulty wire speed swit
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REPLACEMENT PARTS LIST Reference Part Number Description Number 08 9807600561 POWER CORD 09 9807600400 STRAIN RELIEF 11 9807600402 ON/OFF SWITCH 13 9807600513 KNOB 23 9807600460 SWITCH 24 9807600566 POWER TRANSFORMER 25 9807600434 THERMAL CUT OUT 30 9807600563 COMPLETE TORCH ASSY 34 9807600571 CIRCUIT BOARD MP 325 35 9807600464 COMPLETE WIRE FEED ASSEMBLY (W/O MOTOR) 57 9807600600 WIRE SPINDLE 9807600564 GROUND CLAMP 9807600603 WIRE SPOOL BRAKE SPRING 9807600577 DRIVE MO
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Reference Part Number Description Number 01 9807600575 THRUST RING NUT 02 9807600474 WIRE TENSION ARM 03 9807600576 DRIVE ROLLER BRACKET 04 9807600475 GUN CLAMP 05 9807600578 DRIVE TENSION SHAFT 06 9807600476 DRIVE ROLLER .024/.030-IN. 07 9807600477 DRIVE BEARING ROLLER 10 9807600579 DRIVE TENSIONER KNOB 11 9807600580 DRIVE TENSION SPRING 20
