May 01, 2013
SPECIFICATIONS
ATD-3130
2
TABLE OF CONTENTS
Safety Summary. .............................................4
Safety Information........................................4
Shock Hazards................................................5
Flash Hazards .................................................5
Fire Hazards.....................................................6
Fume Hazards.................................................7
Compressed Gasses
and Equipment Hazards..........................7
Additional Safety Information..................8
WelderSpecifications. .................................9
Description .....................................................9
Welder Operating Characteristics .........9
Duty Cycle ..................................................9
Internal Thermal Protection .....................9
Know Your Welder......................................10
Welder Installation
Power Source Connection .......................11
Power Requirements ..............................11
Connect to Power Source ....................11
Extension Cords ......................................11
Assembling the Welder ............................11
Unpacking the Welder ..........................11
Packing List.................................................11
Assemble the Face Shield ....................11
Installing the Handle...............................12
Selecting Shielding Gas..........................12
Install the Shielding Gas ........................13
Check the Gas Flow ...................................13
Align and Set the Drive Roller ................13
Install the Welding Wire ..........................14
......................................11
Set the Wire Drive Tension ....................16
Installing Aluminium Wire ......................16
Change Polarity............................................16
Operation.........................................................17
Controls and Indicators ...........................17
Power Switch ..........................................17
Voltage Selector .....................................17
Wire Speed Control ..............................17
Tuning in the Wire Speed ............................17
Learning to Weld ...........................................18
Holding the Gun ........................................18
Welding Techniques..................................19
Moving the Gun .....................................19
Types of Weld Beads ..............................20
Welding Positions ..................................20
Multiple Pass Welding ...........................21
Special Welding Methods ...................22
Spot Welding............................................22
Maintenance..................................................23
General .........................................................23
Consumable Maintenance ......................23
Maintaining the Contact Tip ................23
Maintaining the Nozzle ...........................24
Testing for a Shorted Nozzle .................24
Replace a Gun Liner ..................................24
Preventive Maintenance...........................26
Troubleshooting..........................................26
Wiring Diagram............................................28
Parts List..........................................................29
Suggested Settings...................................33
3
SAFETY SUMMARY
The warnings, cautions and instructions discussed inthis instructionmanual can not cover
all possible conditions or situations that could
occur. It must be understood by the operator
that common sense and caution are factors
which can not be built into this product, but
must be supplied by the operator. Reading this
operator’s manual before using the welder
will enable you to do a better, safer job. Learn
the welder’s applications and limitations as
well as the specic potential hazards peculiar
to welding.
t When you see one of the symbols shown
here, be alert to the possibility of personal injury and carefully read the message
that follows.
This symbol indicates that the possibility of electric shock hazard
exists during the operation of the
step(s) that follow.
This symbol indicates that the possibility of re hazard exists during
the operation of the step(s) that
follow.
IMPORTANT SAFETY INFORMATION
The following safety information is provided
as guidelines 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 the user the
information necessary for safe use and
operation.
A procedure step preceded by a WARNING is
an indication that the next step contains a procedure that might be injurious to a person if
proper safety precautions are not heeded.
A procedure preceded by a CAUTION is an
indication that the next step contains a procedure that might damage the equipment
being used.
A NOTE may be used before or after a procedure step to highlight or explain something in that step.
This symbol indicates that the helmet must be worn during the
step(s) that follow to protect
against eye damage and burns
due to ash hazard.
This symbol indicates that
sibility of toxic gas hazard exists
during operation of the step(s)
that follow.
This symbol indicates that the possibility of being burned by hot slag
exists during operation of the
step(s) that follow.
This symbol indicates that the eye
protection should be worn to protect against ying debris in the following step(s).
This symbol indicates that the possibility of injury or death exists due
to improper handling and maintenance of compresses gas cylinders
or regulators.
the pos-
READ ALL SAFETY INSTRUCTIONS CAREFULLY before attempting to install, operate,
or service this welder. Failure to comply with
these instructions could result in personal
injury and/or property damage.
RETAIN THESE INSTRUCTIONS FOR FUTURE
REFERENCE.
Note:
t The following safety alert symbols identify
important safety messages in this manual.
4
t Published standards on safety are avail-
able. They are listed in ADDITIONAL
SAFETY INFORMATION at the end of this
SAFETY SUMMARY.
The National Electrical Code, Occupation
Safety and Health Act regulations, local
industrial codes and local inspection
requirements also provide a basis for equipment installation, use, and service.
SHOCK HAZARD
WARNING
ELECTRIC SHOCK CAN KILL! To reduce the
risk of death or serious injury from shock,
read, understand, and follow the following
safety instructions. In addition, make certain
that anyone else who uses this welding
equipment, or who is a bystander in the
welding area understands and follows these
safety instructions as well.
t IMPORTANT! TO REDUCE THE RISK OF
DEATH, INJURY, OR PROPERTY DAMAGE, DO NOT ATTEMPT OPERATION of
this welding equipment until you have
read and understand the following safety summary.
t Do not, in any manner, come into physi-
cal contact with any part of the welding
current circuit. The welding current circuit includes:
a) The work piece or any conductive
material in contact with it
b) The ground clamp
c) The electrode or welding wire
d) Any metal parts on the electrode
holder, or wire feed gun
t Do not weld in a damp area or come in
contact with a moist or wet surface.
t Do not attempt to weld if any part of
clothing or body is wet.
t Do not allow the welding equipment to
come in contact with water or moisture.
t Do not drag welding cables, wire feed
gun, or welder
allow them to come into contact with
water or moisture.
t Do not touch welder, attempt to turn
welder on or
or clothing is moist or if you are in physical contact with water or moisture.
t Do not attempt to plug the welder into
the power source if any part of body or
clothing is moist, or if you are in physical
contact with water or moisture.
t Do not connect welder work piece clamp
to or weld on electrical conduit.
t Do not alter power cord or power cord
plug in any way.
t Do not attempt to plug the welder
power cord through or
if any part of the body
into the power source if the ground
prong on power cord plug is bent over,
broken
t Do not allow the welder to be connected
to the power source or attempt to weld if
the welder, welding cables, welding site,
or welder power cord are exposed to any
form of atmospheric precipitation, or salt
water spray.
t Do not carry coiled weldiing cables
around shoulders, or any other part of
the body when they are plugged into the
welder.
t Do not modiify any wiring, ground
connections, switches, or fuses in this
welding equipment.
t Wear welding gloves to help insulate
hands from welding circuit.
t Keep
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.
t Replace any cracked or damaged parts
that are insulated or act as insulators
such as welding cables, power cord, or
electrode holder IMMEDIATELY.
, or missing.
all liquid containers far enough
FLASH HAZARDS
WARNING
ARC RAYS CAN INJURE EYES AND BURN
SKIN! To reduce the risk of injury from arc
rays, read, understand, and follow the following safety instructions. In addition, make
certain that anyone else that uses this welding equipment, or is a bystander in the
welding area understands and follows these
safety instructions as well. Headshields and
should conform to ANSI Z87.1 stan-
dards.
t Do not look at an electric arc without
proper protection. A welding arc is
extremely bright and intense and, with
inadequate or no eye protection, the
retina can be burned, leaving a permanent dark spot in the
shield or helmet with a number 10 shade
lens (minimum) must be used.
t Do not strike a welding arc until all
bystanders and you (the welder) have
of vision. A
5
welding shields and/or helmets in place.
t Do not wear a cracked or broken
helmet and replace any cracked or broken
t Do not allow the uninsulated portion
of the wire feed gun to touch the ground
clamp or grounded work to prevent an
arc
t Provide bystanders with shields or hel-
mets
t Wear protective clothing. The intense light
of the welding arc can burn the skin in
much the same way as the sun, even
through light-weight clothing. Wear dark
clothing of heavy material. The shirt worn
should belong sleevedand thecollar kept
buttoned to protect chest and neck.
t Protect against REFLECTED ARC RAYS. Arc
rays can be
such as a glossy painted surface, aluminum, stainless steel, and glass. It is
possible for your eyes to be injured by
protective helmet or shield. If welding
with
rays can bounce
the lens on the inside of your helmet
or shield, then into your eyes. If a
tive background exists in your welding
area, either remove it or cover it with
something non-
cause skin burn in addition to eye injury.
lenses IMMEDIATELY.
from being created on contact.
with a #10 shade lens.
shiny surfaces
arc rays even when wearing a
a
.R arc rays can also
surface behind you, arc
the surface, then
ammable and non-
-
FIRE HAZARDS
WARNING
FIRE OR EXPLOSION CAN CAUSE DEATH,
INJURY, AND PROPERTY DAMAGE! To
reduce the risk of death, injury, or property
damage from
stand, and follow the following safety
instructions. In addition, make certain that
anyone else that uses this welding equipment, or is a bystander in the welding area,
understands and follows these safety
instructions as well. REMEMBER! Arc welding
by nature produces sparks, hot spatter,
molten metal drops, hot slag, and hot metal
parts that can start
damage eyes.
or explosion, read, under-
burn skin, and
t Do not wear gloves or other clothing that
contains oil,
substances.
t Do not wear
tions.
t Do not weld in an area until it is checked
and cleared of combustible and/or
mable materials. BE AWARE that sparks
and slag can
through small cracks and openings. If
work and combustibles cannot be separated by a minimum of 35 feet, protect
against ignition with suitable, snug
ting, resistant, covers or shields.
t Do not weld on walls until checking for
and removing combustibles touching the
other side of the walls.
t Do not weld, cut, or perform other such
work on used barrels, drums, tanks, or
other containers that had contained a
niques for removing
stance and vapors, to make a used container safe for welding or cutting, are
quite complex and require special education and training.
t Do not strike an arc on a compressed
gas or air cylinder or other pressure vessel. Doing so will create a brittle area
that can result in a violent rupture immediately or at a later time as a result of
rough handling.
t Do not weld or cut in an area where the
air may contain
grain dust), gas, or liquid vapors (such as
gasoline).
t Do not handle hot metal, such as the
work piece or electrode stubs, with bare
hands.
t Wear leather gloves, heavy long sleeve
shirt, cu
shoes, helmet, and cap. As necessary,
use additional protective clothing such as
leather jacket or sleeves,
leggings, or apron. Hot sparks or metal
can lodge in rolled up sleeves, trouser
or pockets. Sleeves and collars
should be kept buttoned and pockets
eliminated from the shirt front.
t Have
for immediate use! A portable chemical
extinguisher, type ABC, is recom-
mended.
t Wear ear plugs when welding overhead to
grease, or other
hair prepara-
35 feet and can pass
or toxic substance. The tech-
sub-
dust
(such as
ss trousers, high-topped
resistant
extinguisher equipment handy
6
prevent spatter or slag from falling into ear.
t Make sure welding area has a good,
solid, safe
masonry, not tiled, carpeted, or made of
any other
t Protect ammable walls, ceilings, and
with heat resistant covers or
shields.
t Check welding area to make sure it is free
of sparks, glowing metal or slag, and
s before leaving the welding area.
r, preferably concrete or
material.
FUME HAZARDS
WARNING
FUMES, GASSES, AND VAPORS CAN
CAUSE DISCOMFORT, ILLNESS, AND
DEATH! To reduce the risk of discomfort, ill-
ness, or death, read, understand, and follow
the following safety instructions. In addition,
make certain that anyone else that uses this
welding equipment or is a bystander in the
welding area, understands and follows
these safety instructions as well.
can be decomposed by the heat of an
electric arc or its ultraviolet radiation.
These actions can cause PHOSGENE, a
HIGHLY TOXIC gas to form, along with
other lung and eye-irritating gasses. Do
not weld or cut where these solvent
vapors can be drawn into the work area
or where the ultraviolet radiation can
penetrate to areas containing even very
small amounts of these vapors.
t Do not weld in a
is being ventilated or the operator (and
anyone else
air-supplied respirator.
t Stop welding if you develop momentary
eye, nose, or throat irritation as this indicates inadequate ventilation. Stop work
and take necessary steps to improve ventilation in the welding area. Do not
resume welding if physical discomfort
persists.
in the area) is wearing an
area unless it
COMPRESSED GASSES AND
EQUIPMENT HAZARDS
WARNING
t 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.
t Do not heat metals coated with, or
contain, materials that produce toxic
fumes (such as galvanized steel), unless
the coating is removed. Make certain the
area is well ventilated, and the operator
and all bystanders are wearing airplied respirators.
t Do not weld, cut, or heat lead, zinc, cad-
mium, mercury, beryllium, or similar
metals without seeking professional
advice and inspection of the ventilation
of the welding area. These metals produce EXTREMELY TOXIC fumes which can
cause discomfort, illness, and death.
t Do not weld or cut in areas that are near
chlorinated solvents. Vapors from chlorinated hydrocarbons, such as
trichloroethylene and perchloroethylene,
that
sup-
IMPROPER HANDLING AND
MAINTENANCE OF COMPRESSED GAS
CYLINDERS AND REGULATORS CAN
RESULT IN SERIOUS INJURY OR DEATH!
To reduce the risk of injury or death from
compressed gasses and equipment hazards,
read, understand, and follow the following
safety instructions. In addition, make certain
that anyone else who uses this welding
equipment or a bystander in the welding
area understands and follows these safety
instructions as well.
t
Do not use ammable gasses with MIG
welders. Only inert or nonammable
gasses are suitable for MIG welding.
Examples are Carbon Dioxide, Argon,
Helium, etc. or mixtures of more than
one of these gasses.
t Do not attempt to mix gasses or
cylinder yourself. Do not expose cylinders to excessive heat, sparks, slag and
etc. Cylinders exposed to temperatures above 130°F will require water
spray cooling.
a
7
t Do not expose cylinders to electricity of
any kind.
t Do not use a cylinder or its contents for
anything other than its intended use. Do
not use as a support or roller.
t Do not locate cylinders in passageways
or work area where they may be struck.
t Do not use a wrench or hammer to open
a cylinder valve that cannot be opened
by hand. Notify your supplier.
t Do not modify or exchange gas cylinder
ttings.
t Do not deface or alter name, number or
other markings on a cylinder. Do not rely
on cylinder color to identify the contents.
t Do not connect a regulator to a cylinder
containing gas other than that for which
the regulator was designed.
t Do not attempt to make regulator repairs.
Send faulty regulators to manufacturer’s
designated repair center for repair.
t Do not attempt to lubricate a regulator.
t Always change cylinders carefully to pre-
vent leaks and damage to their walls,
valves, or safety devices.
t Always secure cylinders with a steel chain
so that they cannot be knocked over.
t Always protect a cylinder, especially the
valve, from bumps, falls, falling objects
and weather. Remember that gasses in
the cylinders are
damage to a regulator can cause the
regulator or portion of the regulator to
be explosively ejected from the cylinder.
t Always make certain the cylinder cap is
securely in place on the cylinder, whenever the cylinder is moved.
t Always close the cylinder valve and
immediately remove a faulty regulator
from service, for repair, if any of the following conditions exist.
t Gas leaks externally.
t Delivery pressure continues to rise with
down stream valve closed.
t The gauge pointer does not move o the
stop pin when pressurized or fails to
return to the stop pin after pressure is
released.
under pressure and
WARNING
This product contains chemicals, including
lead, or otherwise produces chemicals
known to the State of California to cause
cancer, birth defects and other reproductive
harm. Wash hands after Handling.
(California Health & Safety Code Sec.
25249.5 et seq.)
ADDITIONAL SAFETY INFORMATION
For additional information concerning welding safety, refer to the following standards
and comply with them as applicable.
t ANSI Standard Z49.1 – SAFETY
WELDING AND CUTTING – obtainable
from the American Welding Society, 550
NW Le Jeune Road, Miami, FL 33126
Telephone (800) 443-9353, Fax (305)
443-7559 – www.amweld.org or
www.aws.org
t ANSI Standard Z87.1 – SAFE PRACTICE
FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION –
obtainable from the American National
Standards Institute, 11 West 42nd St.,
New York, NY 10036 Telephone (212)
642-4900,
Fax (212) 398-0023 – www.ansi.org
t NFPA Standard 51B – CUTTING AND
WELDING PROCESS – obtainable from
the National Fire Protection Association,
1 Batterymarch Park, P.O. Box 9101,
Quincy, MA 02269-9101 Telephone
(617) 770-3000
Fax (617) 770-0700 – www.nfpa.org
t OSHA Standard 29 CFR, Part 1910,
Subpart Q., WELDING, CUTTING AND
BRAZING – obtainable from your state
OSHA oce or U.S. Dept. of Labor
OSHA, Oce of Public Aairs, Room
N3647, 200 Constitution Ave.,
Washington, DC 20210 –
www.osha.gov
t CSA Standard W117.2 – Code for
SAFETY IN WELDING AND CUTTING. –
obtainable from Canadian Standards
Association, 178 Rexdale Blvd.,
Etobicoke, Ontario M9W 1R3 –
www.csa.ca
t American Welding Society Standard
A6.0. WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES. – obtainable from the
American Welding Society
Jeune Road, Miami, FL 33126
Telephone (800) 443-9353, Fax (305)
443-7559 – www.amweld.org or
www.aws.org
IN
, 550 NW Le
8
WELDER SPECIFICATIONS
Table 2. Duty Cycle Ratings
DESCRIPTION
Your new MIG (GMAW) core (FCAW)
wire feed welder is designed for maintenance and sheet metal fabrication. The
welder consists of a single-phase power
transformer, stabilizer,
unique built-in control/feeder.
Now you can weld sheet metal from 24
gauge up to 3/16 inch thick with a single
pass. You can weld thicker steel with beveling and multiple pass techniques. Table 1
lists your MIG welder
Table 1. Welder
Primary (input) Volts 120V A C
Primary (input) Amps 13
Frequency 60 Hz
Secondary (output) volts 21
CSA rated output amps 60
Open Circuit Volts (Max.) 30V DC
Duty Cycle Rating 40%
This MIG welder, equipped with gas, is capable
of welding with .023” (0.6mm) and .030” (0.8mm)
solid steel wire using DC reverse polarity, and with
.030” (0.8mm)and .035” (0.9mm) self shielded
diameter solid steel wire .035” (0.9mm) using DC
reverse polarity may also be used. Welding with
larger than .035” (0.9mm) is not recommended.
r, an d a
elgniSesahP
WELDER OPERATING
CHARACTERISTICS
DUTY CYCLE
The duty cycle rating of a welder
how long the operator can weld and how
long the welder must be rested and cooled.
Duty cycle is expressed as a percentage of
10 minutes and represents the maximum
welding time allowed. The balance of the
10-minute cycle is required for cooling. Your
new welder has a duty cycle rating of 40% at
the rated output. This means that you can
weld for four (4) minutes out of 10 with the
remaining six (6) minutes required for cooling. (See Table 2).
Duty Maximum Required
Cycle Welding Resting
Rating Time Time
20% 2 minutes 8 minutes
40% 4 minutes 6 minutes
60% 6 minutes 4 minutes
80% 8 minutes 2 minutes
100% 10 minutes 0 minutes
INTERNAL THERMAL PROTECTION
CAUTION
Do not constantly exceed the duty cycle or
damage to the welder can result. If you
exceed the duty cycle of the welder, an internal thermal protector will open, shutting
all welder functions except the cooling fan. If
this happens, DO NOT SHUT OFF THE
WELDER. Leave the welder turned on with
the fan running. After cooling, the thermal
protector will automatically reset and the
welder will function normally again.
However you should wait at least ten minutes after the thermal protector opens
before resuming welding. You must do this
even if the thermal protector resets itself
before the ten minutes is up or you may
experience less than
performance.
If you
two minutes without stopping, reduce the
wire speed slightly and tune in the welder at
the lowest wire speed setting that still produces a smooth arc. Welding with the wire
speed set too high causes excessive current
draw and shortens the duty cycle.
that the welder will not weld for
duty cycle
9
KNOW YOUR WELDER
Handle
Power Switch– This switch turns the welder
ON and OFF.
in the OFF position before performing any
maintenance on the welder.)
(Make sure the power switch is
Wire
Speed
Power
Switch
Voltage
Selector
Ground
Clamp
Ground
Cable
Power
Cable
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 the gun. 1 is the slowest wire feed
speed, 10 is the highest. You will need to
adjust or “tune-in” your wire speed for different welding conditions (thickness of metals, gas -vs- gasless welding, metal type,
wire size, etc.). When the wire speed is properly “tuned-in” the welding wire will melt
into the material you are welding as quickly
as it is fed through the welding gun.
VoltageSelector– This four position dial
adjusts the voltage or “heat” of your welder.
1 is the lowest and 4 is the highest.
materials and material thickness will require
adjust your voltage accordingly for
welding conditions. By properly adjusting
your voltage settings and wire feed speed,
you will enable clean, precision welds. (Refer
to the Suggested Settings Chart on p.33 of
this manual OR on the inside of the door of
the welder.)
Gun
Cable
Figure 1.
Figure 1. Model 3130
voltage settings. You will need to
Welding Gun
PowerCord –This is a standard, grounded
120 volt power cord. (Make sure you are
using a properly grounded 120V AC, 60 Hz,
single phase, 20 Amp power source.)
Ground Clamp – Attaching the ground
clamp to your work piece “completes” the
welding current circuit. You must attach the
ground clamp to the metal you are welding.
If the ground clamp is not connected to the
metal work piece you intend to weld, the
welder will not have a completed circuit and
you will be unable to weld. A poor connection at the ground clamp will waste power
and heat. Scrape away dirt, rust, scale, oil or
paint before attaching the ground clamp.
GroundCable – The ground cable connects
the ground clamp to the internal workings of
the welder.
Welding Gunand Cable– The welding
gun controls the delivery of
to the material to be welded. The welding
wire is fed through the welding cable and
welding gun when the welding gun trigger is
pulled. You will need to install a contact tip
and welding nozzle to the end of the welding gun, as described later in
prior to welding.
Welding Terms
Now that you are familiar with the main
parts of the welder, make note of the following terms. You will see them used throughout this manual.
Weldpuddle: The localized volume
of molten metal in a weld prior to its
Weldangle: The angle of the welding wire,
as it extends from the welding gun, in relation to the item being welded.
Slag: The protective coating that forms on
the surface of molten metal.
Arc: A sustained luminous discharge of elec-
tricity across a gap in a circuit.
Weldingbead: The extended build up of a
weld, made by pushing or pulling the weld
puddle.
the welding wire
this manual,
10
WELDER INSTALLATION
POWER SOURCE CONNECTION
POWER REQUIREMENTS
This welder is designed to operate ona properly grounded 120 volt, 60 Hz , single-phase alternating current (AC) power source fused with a
20 Amp time delayed fuse or circuit breaker. It
is recommendedthat a
ify the ACTUAL VOLT AGE atthe receptacleinto
which the welder will be plugged and
that the receptacle is properly fused and
grounded. The useof the proper circuit size can
eliminate nuisance circuit breaker tripping
when welding.
DO NOT OPERATE THIS WELDER if the
ACTUAL power source voltage is less than 105
volts AC or greater than 132 volts AC. Contact
a
electrician if this problem exists.
Improper performance and/or damage to the
welder will result if operated on inadequate or
excessive power.
CONNECT TO POWER SOURCE
electrician ver-
m
tacle and the welder power cord without the
use of adapters. Make certain that the extension is properly wired and in good electrical
condition. Extension cords must be a #12
gauge cord at the smallest. Do not use an
extension cord
over 25 ft. in length.
ASSEMBLING THE WELDER
The following procedures describe the process
required to assemble, install, maintain, and
prepare to weld with your new wire feed
welder.
UNPACKING THE WELDER
1. Remove any cartons or bags containing
parts/accessories. (Most parts are shipped
INSIDE the welder door.)
2. Open the cartons or bags packed with your
welder and inspect their contents for damage.
3. Layout the parts and compare them to the
the packing list in Table 3 to familiarize yourself with the parts and what they are called.
This will help you when reading the manual.
PACKIN G LI ST
Table 3 contains a list of the items you will d
packed in the carton.
WARNING
High voltage danger from power source!
Consult a
lation of receptacle at the power source.
This welder must be grounded while in use to
protect the operator from electrical shock. If you
are not sure if your outlet is properly grounded,
have itchecked by a
cut
the grounding prong or alter the plug in
any way and do not use any adapters between
the welder’s power cord and the power source
receptacle. Make sure the POWER switch is OFF
then connect your welder’s power cord to a
properly grounded 120 V AC, 60 Hz, single
phase, 20 Amp power source.
EXTENSION CORDS
For optimum welder performance, an extension cord should not be used unless absolutely
necessary. If necessary, care must be taken in
selecting an extension cord appropriate for use
with your s
Select a properly grounded extension cord that
will mate directly with the power source recep-
electrician for proper instal-
electrician. Donot
welder.
Table 3. Packing List
.YTQMETI
Welder 1
Face Shield 1
Face Shield Handle 1
Face Shield Handle Cover 1
Face Shield Retaining Clips 2
Shaded Lens 1
Welder Handle 1
Wire Brush/Hammer 1
Parts Bag 1
Handle Screws 2
Contact Tip .023” 1
Contact Tip .030” 1
Contact Tip .035” 1 *
Nozzle 1 *
Wire .035 Flux Core 1/2 lb. **
Wire .023 Solid Core 1/2 lb.
Instruction Manual 1
* - Installed On Torch
** - Installed On Welder
ASSEMBLE THE FACE SHIELD
1. Insert the upper tongue of the handle
into the upper slot on the face shield.
2. Align the second tab on the handle with
the second slot in the face shield by pushing the bottom of the handle in towards
the face mask, while at the same time
11
pushing upwards. (Alignment of the second tab is made easier by applying pressure to the point shown below.)
3. Once the handle tabs are properly seated in the face shield slots, install the
handle cover by
pushing it into the
recessed 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 a
3” x 3.8” dark glass you may choose to
remove the extra material from the face
shield to allow a larger
of vision when
welding. To remove the extra material,
remove the glass from the face shield and
carefully cut the material out of the face
shield with a utility knife.
5. Once protective dark glass has been
installed into face shield, secure it in
place with the retaining clips. Align the
holes on each of the retaining clips with
the pins on the retaining tabs and
press into place.
Figure 3. Handle Installation
SELECTING SHIELDING GAS
The shielding gas plays an extremely important role in the MIG welding process. It is critical that the molten weld puddle be shielded
from the atmosphere. The shielding gas creates a protective pocket around the weld puddle which keeps impurities in the air from contaminating the weld. Inadequate shielding will
result in porous, brittle welds.
Although there are many gasses and gas mixtures available for MIG welding, the following
recommendations are based on the electrical
output characteristics and metal thickness
capabilities of this s
MIG welder.
Face Shield
Handle
Cover
Dark
Glass
Retaining
Clip
Retaining
Clip
Handle
Extra
Material
Retaining
Tabs
Figure 2. Face Shield Assembly
INSTALLING THE HANDLE
1. Insert the tabs of the welder handle into
the slots providedon the top of the welder.
2. Insert a large
in the accessories bag) into
head screw (included
each hole on
the top of the welder handle.
3. With a
tip screwdriver, securely tight-
en both screws. (see Figure 3)
Gas Selection For Steel Welding With
Steel Wire
For either mild or low carbon (High Strength
Structural) steel, use a gas mixture of 75%
Argon and 25% Carbon Dioxide. DO NOT
USE Argon gas concentrations higher than
75% onsteel. Theresult will be extremely poor
penetration, porosity, and brittleness
of weld.
This gas mixture helps to prevent burn
through and distortion on very thin steel yet
provides good penetration on thicker steel. Its
ability to minimize spatter results in clean,
smooth weld appearances. In addition, it provides good puddle control when welding vertically or overhead.
Gas Selection For Stainless Steel Welding
The best shielding gas forstainless steel welding is
a mixture of 90% Helium, 7.5% Argon, and 2.5%
Carbon Dioxide. However, the 100% Argon, can
also be used, but an increase in the area being
heated by the arc will be experienced causing
slightly greater distortion of the base metal.
Gas Selection For Steel Welding With
Silicon Bronze Wire
Use only pure Argon when welding steel with
Silicon-Bronze wire.
12
Gas Selection For Aluminium Welding
with Aluminium W ire
Use only pure Argon when welding Aluminium.
INSTALL THE SHIELDING GAS
WARNING
IMPROPER HANDLING AND MAINTENANCE OF COMPRESSED GAS CYLINDERS AND REGULATORS CAN RESULT IN
SERIOUS INJURY OR DEATH! Always
secure gas cylinders to the welding cart, a
wall, or other
cylinder from falling over and rupturing.
Read, understand, and follow all the COMPRESSED GASSES AND EQUIPMENT HAZARDS in the SAFETY SUMMARY at the front
of this manual. Secure your gas cylinder to
the welding cart, or other
1. Remove theprotective cap from thecylinder
and inspect the regulator connecting
threads for dust, dirt, oil, and grease.
Remove any dust or dirt with a clean cloth.
DO NOT ATTACH YOUR REGULATOR IF
OIL, GREASE, OR DAMAGE ARE PRESENT.
2. Open the cylinder valve FOR JUST AN
INSTANT to blow out any foreign matter
inside the valve port. Never aim the open
valve cylinderport at yourself or bystanders.
3. Screw the regulator into
and tighten with a wrench.
4. Firmly push the gas hose over barbed
tings on back of welder and regulator.
5. Secure both ends of hose onto barbed
tings with hose clamps.
support to prevent the
support.
the cylinder valve
-
-
CHECKTHEGASFLOW
WARNING
bystanders. Failure to comply with this warning
could result in serious personal injury.
Note: If the cylinder you have is equipped with
male regulator connecting threads instead of
female, you will need to obtain a special compressed gas cylinder adaptor from your gas
supplier to install between your gas cylinder
and regulator.
-The gas control function does not
the welder to be turned on or plugged in.
-To avoid damage to your regulator, make
sure you have the regulator valve closed
before opening the cylinder valve.
1. Slowly crack open the cylinder valve, then
turn open ALL THE WAY.
2. Pull the trigger on the gun to allow the gas
to
w. KEEP THE TRIGGER PULLED. Listen
and feel for gas
welding gun. If your regulator has no
adjustment, it has been preset at the factory for a
your gas regulator has an adjustment to
control the gas
ment key clockwise to increase gas
counterclockwise to reduce
welding, the gas
20 cubic feet per hour. If no gas is heard or
felt, verify all steps involved in connecting
the gas.
3. Release the trigger.
Note: If welding outside or in a draft, it
become necessary to set up a wind break to
keep the shielding gas from being blown from
the weld area.
-MAKE SURE TO TURN OFF THE GAS
CYLINDER VALVE WHEN DONE WELDING.
of 20 cubic feet per hour. If
from the end of the
rate, turn the adjust-
should be set at 15-
require
w. For most
may
ALIGN AND SET THE DRIVE ROLLER
Before installing any welding wire into the
unit, the proper sized groove must be placed
into position on the wire drive mechanism.
;
IMPROPER HANDLING AND MAINTENANCE OF COMPRESSED GAS CYLINDERS
AND REGULATORS CAN RESULT IN SERIOUS INJURY OR DEATH. To reduce the risk of
injury or death, always stand to the side of the
cylinder opposite the regulator when opening
the cylinder valve, keeping the cylinder valve
between you and the regulator. Never aim the
open cylinder valve port at yourself or
Figure 4. Feed Motor
13
Change the drive roller accordingto the following steps:
1. Open the door to the welder drive compartment.
2. Remove the drive tension by loosening the
tension adjusting screw and liftingthe Drive
Tension Adjustor up, away from the Drive
Tension Arm. Pull the drive tension arm
away from the drive roller.
3. If there is wire already installed in welder,
roll itback onto thewire spoolhand-turning
the spool counterclockwise. Be careful not
to allow the wire to come out of the rear
end of the inlet guide tube without holding
onto it or it will unspool itself. Put the end of
the wire into the hole on the outside edge
of the wire spool and bend it over to hold
the wire in place. Remove the spool of wire
from the drive compartment of the welder.
4. Rotate the Drive Roller Cap counterclockwise and remove it from the Drive Roller.
that of the wire being installed (see Figure
6). Push the drive roller onto the drive roller
haft, with the side stamped with the
s
desired wire diameter facing you.
Figure 6. Drive Roller
7. Reinstall the Drive Roller Cap and lock in
place by turning it clockwise.
8. Close thedoor to thewelder drive compartment.
Figure 5. Drive Roller Adjustments
5. Pull the Drive Roller o of the Drive Roller
Shaft.
Note: The
built into it. When installing the drive roller, the
number stamped on the dr
size you are using should be facing you. Use
only the proper size drive roller when using
your welder.
Table 4 indicates which drive roller groove
should be used with each wire diameter size.
Wire Diameter Drive Roller Groove:
.023 inch 0.6
.030 inch 0.8
.035 inch 0.8
6. Find the side of the drive roller that is
stamped with the same wire diameter as
drive roller has two wire size grooves
ive roller for the wire
Table 4. Drive Roller Sizing
INSTALL THE WELDING WIRE
WARNING
Electric shock can kill! Always turn the
POWER switch OFF and unplug the power cord
from theac power sourcebefore installingwire.
1. Remove the nozzle and contact tip from
the end of the gun assembly.
2. Make sure the proper groove on the
drive roller is in place for the wire being
installed. If the proper groove is not in
place, change the drive roller as
described above.
3
. Unwrap the spool of wire and then
the leading end of the wire (it goes
through a hole in the outer edge of the
spool and is bent over the spool edge to
prevent the wire from unspooling), BUT
DO NOT UNHOOK IT YET.
4. Place the spool on the spindle in such a
manner that when the wire comes
spool, it will look like the top illustration
in Figure 7. The welding wire should
always come
the drive mechanism.
5. If you are installing a four-inch spool of
wire, install the drive brake hardware on
the top ofthe spool ofwire according to
the top of the spool into
the
-
14
Figure 7. Wire Installation
ure 8A. If you are installing an eight-inch
spool, install the spindle adapter and drive
brake hardware as shown in Figure 8B. The
purpose of the drive brake is to cause the
spool of wire to stop turning at nearly the
same moment that wire feeding stops.
7. After checking to make sure that your
welder is disconnected from the AC
power source,
the wire from the spool, but do not let go
of it until instructed to do so, or the wire
will unspool itself.
8. Use a wire cutter, cut the bent end
leading end of the wire so that only a
straight leading end remains.
9. Flip down the screw holding the drive tension armin place and liftthe tension armup
the drive roller.
10. Insert the leading end of the wire into the
inlet guide tube. Then push it across the
drive roller and into the gun assembly
about six inches.
CAUTION
Make certain that the welding wire is actually going into the gun liner. Be very sure it
has not somehow been accidentally routed
alongside the liner or even in some other
direction. If this should happen, the wire
could feed inside the cable casing or take a
right angle and follow the wires and gas
hose inside
back on itself jamming up the mechanism.
the welder. It could also feed
free the leading end of
the
Figure 8A. Drive
Brake Hardware
Installation
6. Once the drive brake hardware is installed,
set the spool tension. With one hand, turn
the wire spool and continue turning it while
adjusting the tension on the spool. With
your free hand, tighten (turn clockwise) the
knob that holds the spool in place. Stop
tightening when drag is felt on the wire
spool that you are turning, then stop handturning the wire spool.
Note: If TOO MUCH tension is applied to the
wire spool, the wire will slip on the drive roller
or will not be able to feed at all. If TOO LITTLE
tension is applied, the spool of wire will wantto
unspool itself. Readjust the drive brake ten
as necessary to correct for either problem.
Figure 8B. Spindle
Adapter and Drive
Brake Installation
sion
11. Line the wire up in the inside groove of the
drive roller, then allow thedrive tensionarm
to drop onto the drive roller
12. Flip the quick release drive tensioner back
up into position on the drive tensioner arm.
13. Tighten (turn clockwise) the drive tension
adjusting screw until the tension roller is
applying enough force on the wire to prevent it from slipping out of the drive assembly.
14. Let go of the wire.
15. Connect the welder power cord to the ac
power source. Turn the welder ON by setting the VOLTAGE switch to the voltage
(heat) setting recommended for the gauge
metal thatis to be welded. Referto the label
mounted onthe cover, insidethe drivecompartment, for recommended voltage (heat)
settings for your welding job. The VOLTAGE
selector controls the weld heat. There are
four voltage heat selections (numbered 1
through 4) available on this welder. Position
1
provides the lowest voltage (heat) and
position 4 the highest voltage (heat).
16. Set the WIRE SPEEDcontrol to the middle of
the wire speed range.
.
15
17. Straighten the gun cable and pull the trigger on the welding gun to feed the wire
through the gun assembly.
18. When at least aninch of wire sticks outpast
the end of the gun, release the trigger.
19. Select a contact tip stamped with the same
diameter asthe wirebeing used.If stamped
in metric see DESCRIPTION.
Note: Due to inherent variances in
welding wire, it may be necessary to use a contact tip one size larger than your
if wire jams occur.
20. Slide the contact tip over the wire (protruding from the end of the gun). Thread the
contact tip into the end of the gun and
hand-tighten securely.
21. Install the nozzle on the gun assembly. For
best results, coat the inside of the nozzle
with anti-stick spray or gel.
22. Cut
end of the nozzle.
the excess wire that extends past the
x-cored
core wire
SET THE WIRE DRIVE TENSION
WARNING
INSTALLING ALUMINIUM WIRE
Install aluminium wire the same as steel
wire, but with the following exceptions:
1. Install a plastic liner (PN PRT30900002) in
the welding gun.
2. Adjust the drive tens
Aluminium wire is very sensitive to slight
changes in drive tension.
Note: For welding aluminium with this unit,
5356 alloy wire is recommended because of
its superior feedability. A plastic liner is needed. When welding with softer aluminium
alloys, you may experience feed problems.
ion VERY carefully.
CHANGE POLARITY
This welder allows you to change the welding
current polarity. Select straight polarity for
welding with
reverse polarity for MIG welding(GMAW) when
using mild steel, stainless steel or silicon bronze
wire. Reverse polarity is also suggested with
some
Change the polarity of your welder according
to the following procedure steps. Figure 8
shows what the polarity block should look like
core wire used in hard facing.
for each polarity setting.
core wire (FCAW). Select
To reducethe risk ofarc sh, makecertain that
the wire coming out of the end of the gun does
not come in contact with work piece, ground
clamp or any grounded material during the
drive tension setting process or arcing will
occur.
1. Pull the trigger on the gun.
2. Turn the drive tension adjustment knob
clockwise, increasing the drive tension until
the wire seems to feed smoothly without
slipping.
When set correctly, there should be no slippage between the wire and the drive roller
under normal conditions. If an obstruction
occurs along the wire feed path, the wire
should then slip on the drive roller.
After the tension is properly adjusted, the
quick release drive tensioner may unlocked
and relocked and no readjustment of the
drive tension adjustment knob will be necessary (unless the diameter or type of wire is
changed).
WARNI NG
Electric shock can kill! Always turn the power
OFF and unplug the power cord from the AC
power source before changing polarity.
CAUTION
Do not use a ratchet, crescent or other lever
type wrench to tighten knobs on the polarity
block. The nuts must be hand tightened only.
Too much torque
could cause the knob to break
1. Remove the retaining knobs from the (+)
and (-) mounting posts on the Gas/No
Gas Board, located just below the drive
motor on the inside of your welder.
A. For Gasless (FCAW) welding, mount
the Ground Clamp ring terminal to
the (+) mounting post and the Torch
ring terminal to the (-) mounting post.
applied to one of the knobs
.
16
B. For MIG (GMAW) welding, mount the
Ground Clamp ring terminal to the “” mounting post and the Torch ring
terminal to the “+” mounting post.
See
Figure 9. Changing Polarity
2. Attach the ground clamp to the work
piece, making sure that it is cleaned of
dirt, oil, rust, scale, oxidation, and paint
at the point of connection.
Note: It is best to connect the ground clamp
directly to the work piece and as close to the
weld as possible. If it is impractical to connect the ground clamp directly to the work
piece, connect it to the metal that is securely attached to the work piece, but not electrically insulated from it. Make certain this
other metal is of equal or greater thickness
than that of the workpiece.
shown in Figure 9.
CAUTION
OPERATION
Operation of this welder consists of selecting
and adjusting operating controls for optimum voltage (welding heat) and
settings.
CONTROLS AND INDICATORS
POWER SWITCH - The power switch supplies electrical current to the welder.
ALWAYS turn the power switch to the OFF
position and unplug the welder before performing any maintenance.
VOLTAGE SELECTOR - The voltage selector
controls the welding heat. The voltage selector is numbered 1-4. Number 1 is the lowest
heat and number 4 is the highest. Refer to
the label under the welder hood (or on page
32 of this manual) for recommended heat
settings for your welding job.
WIRE SPEED CONTROL - The wire speed
control adjusts the speed at which the wire is
fed out of the welding gun. The wire speed
needs to be closely matched (tuned-in) to
the rate at which it is being melted
things that
the type and diameter of the wire being
used, the heat setting selected, and the
welding position to be used.
wire speed selection are
wire speed
. Some
Risk of electric component damage! If
the ground clamp is being connected to an
automobile or other equipment with onboard computer systems, solid state electronic controls, solid state sound systems,
etc., do not weld until disconnecting the
battery that is attached to the chassis
ground. Failure to do so may result in electronic component damage.
Note: The wire will feed faster without an
arc. When an arc is being drawn, the wire
speed will slow down.
TUNING IN THE WIRE SPEED
This is one of the most important parts of MIG
welder operation and must be done before
starting each welding job or whenever any o f
the following variables are changed: heat
setting wire diameter, or wire type.
1. Set up and ground a scrap piece of the
same type of material which you will be
welding. It should be equal to or greater
than the thickne ss of the actual work piece,
and free of oil, paint, rust, etc.
2. Select a heat setting.
3. Hold the gun in one hand, allowing the
nozzle to rest on the edge of the work-
17
piece farthest away from you, and at an
angle similar to that which will be used
when welding. (SEE HOLDING THE GUN
on page 18 if you are uncertain of the
angle at which you will be welding)
4. With your free hand, turn the Wire Speed
Dial to maximum and continue to hold
onto the knob.
WARNING
EXPOSURE TO A WELDING ARC IS
EXTREMELY HARMFUL TO THE EYES AND
SKIN! Prolonged exposure to the welding
arc can cause blindness and burns. Never
strike an arc or being welding until you are
adequately protected. Wear ameproof
welding gloves, a heavy long sleeved shirt,
cuess trousers, high topped shoes and a
welding helmet.
5. Lower your welding helmet and pull the
trigger on the gun to start an arc, then
begin to drag the gun towards you while
simultaneously turning the Wire Speed
Dial counter-clockwise.
6. LISTEN! As you decrease the wire speed,
the sound that the arc makes will change
from a sputtering to a high-pitc
buzzing sound and then will beginsputtering again if you decrease the wire speed
too much. The wire speed that creates a
smooth high-pitched buzzing sound will
achieve the best quality weld.
You can use the wire speed control to slightly
increase or decrease the heat and penetration
for a given heat setting by selecting hugher or
lower wire speed settings. Repeat this tune-in
procedure if you select a new heat setting, a
dierent diameter wire, or a dierent type of
welding wire.
LEARNING TO WELD
MIG (Metal Inert Gas) welding is the process
of uniting metallic parts by heating and
allowing the metals to ow together through
the use of an electrical arc. The electrical arc
is created between a continuous consumable wire electrode (the welding wire) and
the work piece. An inert shielding gas is
used to protect the weld puddle from con-
hed
tamination and enhance the welding capabilities of the electrical arc.
Whether you have welded before or not, it is
important that you become familiar with
your new welder, its controls, and the results
achieved at dierent settings. We strongly
recommend that you practice
welder on scrap metal trying dierent heat
settings, base metal thicknesses, and welding positions for each type and size of wire
you will be using. By doing this you will gain
a feel for how changes in these welding
variables aect the weld.
Of course, if you have not welded before,
you will need to develop welding skills and
techniques as well.
The self-taught welder learns through a
process of trial and error. The best way to
teach yourself how to weld is with short periods of practice at regular intervals. All practice welds should be done on scrap metal
that can be discarded. Do not attempt to
make any repairs on valuable equipment
until you have satised yourself that your
practice welds are of good appearance and
free of slag or gas inclusions. What you fail
to learn through practice will be learned
through mistakes and re-welds later on.
with your new
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 dierent
positions until you nd the one that seems to
work best for you. Refer to WELDING POSITIONS - p.20.
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 (Figure 10) can be varied, but in
most cases the optimum angle will be 60
degrees. The point at which the gun
handle is parallel to the work piece. If
angle A is increased, penetration will
increase. If angle A is decreased, penetration will decrease also.
18
Angle A
Figure 10. Gun Position, Angle A
2. Angle B (Figure 11) 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.
Angle B
work piece and drag it along while welding.
This can
welders to steady the gun, allowing the
welder to concentrate on welding technique.
If the nozzle is held
distance between the nozzle and the work
piece should be kept constant and should
not exceed 1/4 inch or the arc may begin
sputtering, signaling a loss in welding performance.
be very helpful to beginning
the work piece, the
WELDING TECHNIQUES
WARNING
EXPOSURE TO A WELDING ARC IS
EXTREMELY HARMFUL TO THE EYES AND
SKIN! Prolonged exposure to the welding
arc can cause blindness and burns. Never
strike an arc or begin welding until you are
adequately protected. Wear
welding gloves, a heavy long sleeved shirt,
trousers, high topped shoes and a
welding helmet.
ameproof
Figure 11. Gun Position, Angle B
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 the weld puddle. In this case, angle B
can be varied anywhere from zero to 45
degrees with 30 degrees working about the
best.
On a
positioned in such a manner so as to split
the angle between the horizontal and vertical members of the weld joint. In most
cases, a
DISTANCE FROM THE WORK PIECE
The end of the welding gun is designed with
the contact tip recessed from the end of the
nozzle and the nozzle electrically insulated
from the rest of the gun. This permits the
operator to actually rest the nozzle on the
weld joint, the nozzle is generally
weld will be 45 degrees.
WARNING
ELECTRIC SHOCK CAN KILL! To prevent
ELECTRIC SHOCK, do not perform any welding while standing, kneeling, or lying directly on the grounded work.
MOVING THE GUN
Gun travel refers to the movement of the
gun along the weld joint and is broken into
two elements: direction and speed. A solid
weld bead requires that the welding gun be
moved steadily and at the right speed
the weld joint. Moving the gun too fast, too
slow, or erratically will prevent proper fusion
or create a lumpy, uneven bead.
1. TRAVEL DIRECTION is the direction the
gun is moved along the weld joint in relation to the weld puddle. The gun is either
PUSHED (see Figure 12) into the weld
puddle or PULLED away from the weld
puddle.
along
19
Figure 12. Travel Direction
For most welding jobs you will pull the gun
along the weld joint to take advantage of
the greater weld puddle visibility.
2. TRAVEL SPEED is the rate at which the
gun is being pushed or pulled along the
weld joint. For a
faster the travel speed, the lower the penetration and the lower and narrower the
weld bead. Likewise, the slower
the travel speed, the deeper the penetration and the higher and wider the
ished weld bead.
heat setting, the
TYPES OF WELD BEADS
The following paragraphs discuss the most
commonly used welding beads.
Once you have the gun in position with the
wire lined up on the weld joint, lower your
helmet, pull the trigger and the arc will start.
In a second or two you will notice a weld
puddle form and the base of the bead
beginning to build. It is now time to begin to
move with the gun. If you are just learning
to weld, simply move the gun in a straight
line and at a steady speed along the weld
joint. Try to achieve a weld with the desired
penetration and a bead that is fairly
consistent in width.
and
Figure 13. Stringer Bead
2. The WEAVE BEAD (Figure 14) is used
when you want to deposit metal over a
wider space than would be possible with a
stringer bead. It is made by weaving from
side to side while moving with the gun. It is
best to hesitate momentarily at each side
before weaving back the other way.
Figure 14. Weave Bead
WELDING POSITIONS
There are four basic welding positions:
horizontal, vertical, and overhead.
1. The FLAT POSITION (Figure 15) is the
easiest of the welding positions and is most
commonly used. It is best if you can weld in
the
results are easier to achieve.
position if at all possible as good
As you become more familiar with your
welder and better at laying some simple
weld beads, you can begin to try some different weld bead types.
There are two basic types of weld beads, the
stringer bead and the weave bead.
1. The STRINGER BEAD (Figure 13) is formed
by traveling with the gun in a straight line
while keeping the wire and nozzle centered
over the weld joint. This is the easiest type of
bead to make.
new
20
Figure 15. Flat Position
2. The HORIZONTAL POSITION (Figure 16)
is next in
much the same as the
angle B (see HOLDING THE GUN
such that the wire, and therefore the arc
level. It is performed very
weld except that
- p.18) is
force, is directed more toward the metal
above the weld joint. This is to help prevent
the weld puddle from running downward
while still allowing slow enough travel speed
to achieve good penetration. A good starting point for angle B is about 30 degrees
DOWN from being perpendicular to the
work piece.
Figure 16. Horizontal Position
3. The VERTICAL POSITION (Figure 17) is
the next most
gun from top to bottom may be easier for
many people, but in some instances it can
be
ning downward. Pushing the gun from bottom to top may provide better puddle control and allow slower rates of travel speed to
achieve deeper penetration. When vertical
welding, angle B (see HOLDING THE GUN p.18) is usually always kept at zero, but
angle A will generally range from 45 to 60
degrees to provide better puddle control.
to prevent the puddle from run-
position. Pulling the
WARNING
Hot slag can cause and serious injury
from burns! Be sure to wear protective clothing and eye gear when using the Overhead
Position.
4. The OVERHEAD POSITION (Figure 18) is
the most
gravity is pulling at the weld puddle trying to
make it drip
HOLDING THE GUN - p.18) should be
maintained at 60 degrees, the same as in
the
reduce the chances of molten metal falling
into the nozzle should it drip from the weld
puddle. Angle B should be held at zero
degrees so that the wire is aiming directly
into the weld joint. If you experience excessive dripping of the weld puddle, select a
lower heat setting. Also, the weave bead
tends to work better than the stringer bead
when welding overhead.
position. Maintaining this angle will
Figure 18. Overhead Position
welding position because
the work piece. Angle A
(see
Figure 17. Vertical Position
MULTIPLE PASS WELDING
Butt Weld Joints. When butt welding thick-
er materials, you will need to prepare the
edges of the material to be joined by grinding a bevel on the edge of one or both
pieces of the metal being joined. When this
is done, a V is created between the two
pieces of metal, that will have to be welded
closed. In most cases more than one pass or
bead will need to be laid into the joint to
close the V . Laying more than one bead into
the same weld joint is known as a multiplepass weld.
21
The illustrations in Figure 19 show the
sequence for laying multiple pass beads into
a single V butt joint.
NOTE: WHEN USING SELF-SHIELDING
FLUX-CORE WIRE it is very important to thoroughly chip and brush the slag o each
completed weld bead before making another pass or the next pass will be of poor quality.
SPECIAL WELDING METHODS
SPOT WELDING
The purpose of a spot weld is to join pieces
of metal together with a spot of weld instead
of a continuous weld bead. There are three
methods of spot welding: Burn-Through,
Punch and Fill, and Lap (see Figure 21).
Each has advantages and disadvantages
depending on the specic application as
well as personal preference.
Figure 21. Spot Welding
Figure 19. Butt Joints
Fillet Weld Joints. Most llet weld joints, on
metals of moderate to heavy thickness, will
require multiple pass welds to produce a
strong joint. The illustrations in Figure 20
show the sequence of laying multiple pass
beads into a T llet joint and a lap llet joint.
1. The BURN-THROUGH METHOD welds
two overlapped pieces of metal together
by burning through the top piece and into
the bottom piece.
With the burn-through method, larger wire
diameters tend to
diameters because they have greater current
carrying capabilities allowing the arc to burn
through very quickly while leaving a minimal
amount of ller metal build up. Wire diameters that tend to work best, with the burnthrough method, are 0.030 inch diameter
solid wire or 0.035 inch self-shielding uxcorewire.
Do not use 0.023 inch diameter solid or
0.030 inch self-shielding ux-core wires
when using the burn-through method
unless the metal is VERY thin or excessive
ller metal build-up and minimal penetration is acceptable.
work better than smaller
22
Figure 20. Fillet Weld Joints
Always select the HIGH heat setting with the
burn-through method and tune in the wire
speed prior to making a spot weld.
2. The PUNCH AND FILL METHOD produces
a weld with the most nished appearance
of the three spot weld methods. In this
method, a hole is punched or drilled into
the top piece of metal and the arc is
directed through the hole to penetrate
into the bottom piece. The puddle is
allowed to
weld that is smooth and
surface of the top piece.
Select the wire diameter, heat setting, and
tune in the wire speed as if you were welding the same thickness material with a continuous bead.
3. The LAP SPOT METHOD directs the welding arc to penetrate the bottom and top
pieces, at the same time, right along each
side of the lap joint seam.
Select the wire diameter, heat setting, and
tune in the wire speed as if you were welding the same thickness material with a continuous bead.
up the hole leaving a spot
with the
SPOT WELDING INSTRUCTIONS
1. Select the wire diameter and heat setting
recommended above for the method of
spot welding you intend to use.
2. Tune in the wire speed as if you were
going to make a continuous weld.
3. Hold the nozzle piece completely perpendicular to and about 1/4 inch
piece.
4. Pull the trigger on the gun and release it
when it appears that the desired penetration has been achieved.
5. Make practice
varying the length of time you hold the
trigger, until a desired spot weld is made.
6. Make spot welds on the actual work piece
at desired locations.
spot welds on scrap metal,
the work
MAINTENANCE
GENERAL
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.
1. Keep the wire drive compartment lid
closed at all times unless the wire needs
to be changed or the drive tension needs
adjusting.
2. Keep all consumables (contact tips, nozzles,
and gun liner) clean and replace when necessary. See CONSUMABLE MAINTENANCE
and TROUBLESHOOTING later in this section for detailed information.
3. Replace power cord, ground cable,
ground clamp, or gun assembly when
damaged or worn.
4. Periodically clean dust, dirt, grease, etc.
from your welder. Every six months, or as
necessary, remove the side panels from
the welder and air-blow any dust and
dirt that may have accumulated inside
the welder.
WARNING
Electric shock can kill! To reduce the risk of
electric shock, always unplug the welder
from its ac power source before removing
side panels.
CONSUMABLE MAINTENANCE
IT IS VERY IMPORTANT TO MAINTAIN THE
CONSUMABLES TO AVOID THE NEED FOR
PREMATURE REPLACEMENT OF THE GUN
ASSEMBLY.
The GUN LINER is intended to provide an
unrestricted path for the welding wire to
through the gun assembly. Over time the
liner will accumulate dust, dirt, and other
debris. Replacement is necessary when these
accumulations begin to restrict the free
of wire through the gun assembly.
w
w
MAINTAINING THE CONTACT TIP
The purpose of the CONTACT TIP is to transfer welding current to the welding wire while
allowing the wire to pass through it smoothly.
Always use a contact tip stamped with the
same diameter as the wire it will be used with.
23
Note: Due to inherent variances in x-
cored welding wire, it may be necessary to
use a contact tip one size larger than your
core wire if wire jams occur.
1. If the wire burns back into the tip, remove
the tip from the gun and clean the hole
running through it with an oxygen-acetylene torch tip cleaner or tip drill.
2. Over time, the hole in the contact tip will
become worn by the wire passing
through it. The more worn this hole
becomes, the less
of welding current to the wire and eventually arc breakage and arc
starting will result. Replace contact tips
when signs of wear become apparent.
is the transfer
MAINTAINING THE NOZZLE
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.
CAUTION
KEEP THE NOZZLE CLEAN! During the
welding process, spatter and slag will build
up inside the nozzle and must be cleaned
out periodically. Failure to clean and/or
replace the nozzle in a timely
CAUSE DAMAGE TO THE FRONT-END OF
THE GUN ASSEMBLY.
fashion WILL
reduced penetration. In addition, a shorted
nozzle overheats the end of the gun, which
can DAMAGE the front-end of the gun.
A RESTRICTED nozzle is created when
enough slag builds up in the nozzle to
the direction, concentration, and/or rate of
the shielding gas
porous, brittle welds and reduce penetration.
w. This problem can cause
t
TESTING FOR A SHORTED NOZZLE
Arcing between the nozzle and the work
piece ALWAYS means the nozzle is shorted,
but this can be hard to detect through the
lens of a welding helmet. The following testing method is another way to tell if a nozzle
is shorted.
With the welder unplugged from the AC
power source, touch the probes of an ohmmeter or continuity tester to the end of the
contact tip and the outside of the nozzle. If
there is any continuity at all, the nozzle IS
shorted. Clean or replace as needed.
REPLACE A GUN LINER
When installing a new gun liner, care must be
taken not to kink or otherwise damage the
gun liner. See Figure 22 for the drive assembly and Figure 23 for the gun assembly.
For best results, coat the inside of a new, or
freshly cleaned nozzle with anti stick spray
or gel.
1. Stop welding and clean any accumulated
slag or spatter from the nozzle every 5 to
10 minutes of welding time.
2. When welding overhead, if any molten
metal drips from the weld puddle and
falls into the nozzle, STOP WELDING
IMMEDIATELY and clean the nozzle.
3. If the slag cannot be thoroughly cleaned
from the nozzle, REPLACE THE NOZZLE!
Failure to keep the nozzle adequately
cleaned can result in the following problems:
A SHORTED nozzle results when spatter
buildup bridges the insulation in the nozzle,
allowing welding current to
as well as the contact tip. When shorted, a
nozzle will steal welding current from the
wire whenever it contacts the grounded
work piece. This causes erratic welds and
through it
1. Turn OFF welder POWER SWITCH and
unplug welder from power supply.
2. Open the welder side panel.
3. Loosen the tension arm and lift it up
the drive roller.
4. Turn the wire spool counter-clockwise (be
sure to hold onto the wire itself while turning the spool or the wire will unspool itself
when it becomes free of the gun liner),
and remove wire from gun assembly.
5. Lay gun cable and gun handle straight
out in front of unit.
6. Remove gun liner holding clamp by
removing the three screws.
7. Take gun handle halves apart by removing
8. Remove gas hose from fast coupler
ting on Gas Valve. Depress lip on fast
coupler
pull gas hose out.
9. Remove Fast Coupler Fitting from Gas
Valve using a 9 millimeter wrench.
10. Firmly hold the brass
phillips head screws.
back towards and
on the end
24
Figure 22. Drive Assembly
of the gun liner with a wrench and rotate
Gas Valve counterclockwise to unscrew
tting.
Note: Rotate Gas Valve – Do not rotate
brass tting or gun liner twist inside gun
cable and may cause damage to gun
cable.
11.The Live Wire Terminal is held in place
on the Gas Valve by the brass tting on
the end of the gun liner. When the brass
tting is removed , slide the Live Wire
Terminal o of the brass tting.
12.Firmly grip the gun cable and pull the
gun liner all the way out.
13.Install the new gun liner into gun cable,
starting from the end where the welding
gun will be mounted, and feeding the
liner all the way through the gun cable to
the wire feed roller.
Note: It may be helpful to apply a small
amount of liquid soap to the end of the
gun liner to decrease resistance during
installation process.
14.Slide the eyelet of the Live Wire Terminal
onto the threaded end of the gun liner
brass tting.
15. Firmly hold the brass tting on the end
of the gun liner with a wrench and rotate
Gas Valve clockwise to screw it onto tting.
Note: R
brass tting or gun liner will twist inside
gun cable and may cause damage to
gun cable.
16.Return all components to the handle casing and realign them as they were origi-
nally.
otate Gas Valve – Do not rotate
17. With both halves of the handle case in
place, tighten the ve phillips head screws.
18.Using wire cutters, trim the new gun liner
to approximately 3/16 inch beyond the
edge of the Cable Holding Clamp. ( The
goal is to make sure that the end of the
gun liner will be as close to the drive
roller as possible after the Cable Holding
Clamp is assembled. This will make
installing the welding wire much easier. )
19.Reinstall liner holding clamp at feeder.
20.Reinstall the welding wire according to
specications in INSTALL THE WELDING
WIRE section.
21.Close side panel.
22.Plug welder into power supply and turn
POWER SWITCH to ON position.
Figure 23. Gun Assembly
25
PREVENTIVE MAINTENANCE
Except for internal and external cleaning,
cleaning the nozzle, and occasionally
retightening screws, there is no periodic
maintenance recommended for your welder.
TROUBLESHOOTING
The following TROUBLESHOOTING information is provided as a guide to help
resolve some of the more common problems
that could be encountered.
Table 5 is a troubleshooting table provided
to help you determine a possible remedy
when you are having a problem with your
welder. This table does not provide all possible solutions, only those possibilities considered to likely be common faults. The table
consists of a TROUBLE or symptom, a POSSIBLE CAUSE for the symptom, and a POSSIBLE REMEDY for that symptom.
26
TABLE 5 – TROUBLESHOOTING
TROUBLE
Dirty, porous, brittle weld
Wire feed works but no arc
Arc works but no feeding wire
Nothing works except fan
POSSIBLE CAUSE
1. Plugged welding nozzle
2. No shielding gas
3. Wrong type of gas
4. Dirty or rusty welding wire
1. Bad ground or loose connection
2. Bad connection to gun or faulty
gun
1. Faulty wire speed control
assembly
2. No tension on drive roller
3. Faulty drive motor (RARE!)
1. Faulty trigger on gun
2. Exceeded duty cycle; thermal
protector opened
3. Faulty transformer (RARE!)
POSSIBLE REMEDY
1. Clean or replace nozzle.
2. Tank empty, flow restricted or
regulator set too low.
3. See SELECTING SHIELDING
gas section of manual.
4. Replace spool of wire.
1. Check ground and connections.
Tighten as necessary .
2. Check connection to gun or
replace gun.
1. Replace wire speed control
assembly.
2. Adjust the drive tension.
3. Replace drive motor .
1. Replace gun trigger.
2. Let welder cool at least 10 min-
utes (observe and maintain proper
duty cycle.)
3. Replace transformer.
Low output or nonpenetrating weld
Wire is jamming or “birdnesting” at
the drive roller
Wire burns back to contact tip
1. Loose connection inside
machine
2. Too long improper extension
cord
3. Wrong type or size wire
4. Poor ground connection
5. Wrong size contact tip
6. Loose gun connection or faulty
gun assembly
7. Wrong welding polarity set
8. Dirty or rusty welding wire
1. Too much tension on drive roller
2. Gun liner worn damaged
3. Contact tip is clogged or dam-
aged
4. Liner stretched or is too long
1. Gun liner worn or damaged
2. Liner stretched or is too long
3. Wrong size contact tip
4. Contact tip is clogged or dam-
aged
5. Wire feed speed is too slow
1. Blow inside of machine out with
compressed air. Clean and tighten
all connections.
2. See EXTENSION CORDS section of manual.
3. Use correct size wire.
4. Reposition clamp and check
cable to clamp connection.
5. Use correct size contact tip.
6. Tighten gun or replace gun.
7. Change to proper polarity.
8. Replace spool of wire.
1. Adjust drive tension. (See
INSTALL THE WELDING WIRE)
2. Replace gun liner.
3. Replace contact tip.
4. Trim liner to proper length.
1. Replace gun liner.
2. Trim liner to proper length.
3. Use correct size contact tip.
4. Replace contact tip.
5. Increase wire feed speed.
Ground clamp and/or ground
cable gets hot
Gun nozzle arcs to work surface
Bad connection from cable to clamp
Slag building inside nozzle or nozzle is shorted
Tighten connection or replace cable.
Clean or replace nozzle as needed.
27
WIRE FEED WELDER WIRING DIAGRAM
28
WIRE FEED WELDER PARTS LIST
13 PRT21910048 .023 (0.6MM) 1/2LB (0,225KG) SOLID CORE WIRE SPOOL 1
13 PRT21910046 .035 (0.9MM) 1/2LB (0,225KG) FLUX CORE WIRE SPOOL 1
18 PRT20220018 POWER CORD 3XAWG14 7'5' (2,25M) W/15A PLUG 1
26 PRT44120087 TRANSFORMER 1PH MIG 115V 40X60 AL 1
33 PRT43210161 EARTH CABLE 10MM² 6-1/2' (2M) CL.200/0.8 1
43 PRT04600361 SCREWS SET FOR HANDLE AND CABINET 1
1"ASC"V011DRAOB.C.PR1.2950E44001722TRP10
1NOINIP+52øROTOMNOSNHOJ34100640TRP20
1ELDNAH53000612TRP30
1A01°001TATSOMREHT41001222TRP40
1V011.YSSAROTOMNAF&NAF45000640TRP50
1WERCS+01øPMALCELBAC43200640TRP60
1MIRTCITSALP52409612TRP70
1TEMMORGHCROT22409612TRP80
183øBONKRETEMOITNETOPKCALB73300640TRP01
1V052-A61HCTIWSREWOPWOLLEY53000222TRP11
1REDLOHLOOPSETELPMOC20000640TRP21
1SLEBAL/WLENAPGNIDIVID28100050TRP41
182øREDEEFERIWCITSALP71000444TRP51
18,0-6,052X7øLLORDEEF47050833TRP61
2SNIP+STROPPUSLENAPSSECCA42409612TRP71
1LENAPTNORF67100050TRP91
1SLEBAL/WLENAPREPPU18100050TRP02
183øBONKHCTIWSKCALB07200640TRP12
1A71HCTIWS56150222TRP22
1LA52X04EKOHC79053144TRP32
111-NCAN4A01V011ROTCATNOC61052222TRP42
1FB03SMPREIFITCER12000422TRP52
1TATSOMREHT054=L°05174001222TRP72
1SLEBAL/WLENAPRAER87100050TRP82
1GN-G)M2,2('3'7²MM01HCROT8/042100032TRP92
1WERCS+01øPMALCELBAC43200640TRP03
1REVUOLHTIWMIRTTNORF24409612TRP13
163øPAT34409612TRP23
1A002PMALCHTRAE70001122TRP43
1EMARFKCAB62409612TRP53
1LENAPREWOL500924200733TRP63
1HCTALROOD62209612TRP73
1LEBAL/WROODEDIS97100050TRP83
1DRAOBEGNAHCSAGON/SAGTIK41100640TRP93
189X57-501X05DLEIHSECAF14050912TRP04
111NID89X57SSALGKRAD70050912TRP14
1REMMAH/HSURBERIW93050912TRP24
29
30
WIRE FEED WELDER GUN PARTS LIST
03 PRT 23005145 SWAN NECK WITH INSULATING COVER 1
I58250032TRP50
PITTCATNOC5”30.28150032TRP70
NOCHCROT23000833TRP01
11 PRT 30900021 RUBBER OUTER SLEEVE ø17,5 + HOSES 1
12 PRT 23005254 STEEL LINER 1.4X4BLUE 2,2M W/END FITTING 1
13 PRT 22910001 FAST CONNECTION FOR HOSE ø4 M6X0,75 1
13A PRT 22910001 PLASTIC LINER END FITTING ø4 M6X0,75 1
15 PRT 04600063 KIT 2 PINS MALE CONNECTOR + 2 CONTACTS 1
16 PRT 23005148 NECK+OUTER INSULATION+DIFFUSER 1
17 PRT 23005318 ALUMINIUM GAS VALVE + NECK + DIFFUSER 1
1CKALB,.YSSAELDNAH89100640TRP10
1EVLAVSAG23350032TRP20
1RENILKCENNAWS19050032TRP40
2KCENROFREVOCGNITALOS
1RESUFFIDHCROT1WT64150032TRP60
1PITTCATNOC3”20.81050032TRP70
1PITTCATNOC0”30.91050032TRP70
1
1ELZZONSAGHCROT74150032TRP80
18,0X3,6TCATNOCNO-TSAF01000212TRP90
1GNIRPSTCAT
1M5,24X5,1RENILCITSALP20000903TRPA21
1M6,44X2øESOHSAGHCROT02000903TRP41
31
32
SUGGESTED SETTINGS
33
NOTES
34
35
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