Century 117071002, 117-071 Owner’s Manual
PART# 0M-I17071002
Operator's Manual
80 AMP WIRE FEED
WELDER
Made
in
U.S.A.
Form Number 811-597-000
Revision A
August 1999
TABLE OF CONTENTS... 2
SAFETY SUMMARY ....... 3
IM PORTANT SAFETY
INFORMATION .................. 3
SHOCK HAZARDS ............... 3
FLASH HAZARDS ................ 4
FIRE HAZARDS .................... 5
FUME HAZARDS .................. 6
ADDITIONAL SAFETY
INFORMATION ................... 6
ASSEMBLY ...................... 8
UNPACKING THE WELDER 8
PACKING LIST ..................... 8
ASSEMBLE THE FACE
SHIELD .............................. 8
POWER SOURCE
CONNECTION ................... 9
EXTENSION CORDS ........... 9
SELECTING THE
WELDING WIRE ................ 9
INSTALL THE
WELDING WIRE ................ 9
OPERATION .................. 12
DESCRIPTION ................... 12
OPERATING THE
WELDER .......................... 12
DUTY CYCLE ..................... 12
INTERNAL THERMAL
PROTECTION .................. 12
CONTROLS AND
INDICATORS .................... 12
PREPARATIONS FOR
WELDING ......................... 13
SETTING UP THE
WORK PIECE ................... 13
WELDING POSITIONS ....... 13
PREPARING THE JOINT .... 13
GROUND CLAMP
CONNECTION ................. 14
LEARNING TO WELD ... 15
GET TO KNOW
YOUR WELDER ............... 15
HOLDING THE GUN ........... 15
POSITION THE GUN
TO THE WORKPIECE ..... 15
DISTANCE FROM
THE WORKPIECE ........... 16
LAYING A BEAD ................. 16
TYPES OF WELD BEADS.. 16
WELDING
TECHNIQUES ............. 17
TRAVELING THE GUN ....... 17
TYPES OF WELD BEADS • 17
WELDING POSITIONS ...... 18
MULTIPLE PASS
WELDING ......................... 19
SPECIAL WELDING
METHODS ....................... 19
SPOT WELDING ................. 19
SPOT WELDING
INSTRUCTIONS ............... 20
MAINTENANCE ............. 21
GENERAL
MAINTENANCE ............... 21
MAINTENANCE
AND CLEANING ............... 21
TESTING FOR A
SHORTED NOZZLE ......... 21
MAINTAINING
THE WELDER .................. 22
TROUBLESHOOTING ........ 22
SCHEMATIC .................. 24
REPLACEMENT
PARTS LIST ................. 25
LIMITED WARRANTY ... 26
2
Every craftsman respects the tools with
which they work. They know that the
tools represent years of constantly
improved designs and developments.
The true craftsman also knows that tools
are dangerous if misused or abused.
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 specific potential hazards peculiar to
welding.
IMPORTANT SAFETY
This symbol indicates that the
possibility 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 flying debris
in the following step(s).
INFORMATION
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:
• The following safety alert symbols
identify important safety messages in
this manual.
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 fire hazard exists
during the operation of the
step(s) that follow.
This symbol indicates that the
helmet must be worn during
the step(s) that follow to
protect against eye damage
and burns due to flash
hazard.
This symbol indicates that the
possibility of injury or death
exists due to improper
handling and maintenance of
compressed gas cylinders or
regulators
Published standards on safety are
available. They are listed in
ADDITIONAL SAFETY
INFORMATION at the end of this
SAFETY SUMMARY.
The National Electrical Code,
Occupational Safety and Health Act
regulations, local industrial codes and
local inspection requirements also
provide a basis for equipment
installation, use, and service.
SHOCK HAZARDS
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.
3
* IMPORTANT! TO REDUCE THE
RISK OF DEATH, INJURY, OR
PROPERTY DAMAGE, DO NOT
A-I-I-EMPT OPERATION of this
welding equipment until you have read
and understand the following safety
summary.
• Do not, in any manner, come into
physical 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 rod,
d. any metal parts on the electrode
holder.
Do not weld in a damp area or come
in contact with a moist or wet surface.
• Do not attempt to weld if any part of
clothing or body is wet.
• Do not allow the welding equipment to
come in contact with water or
moisture.
cables, welding site, or welder power
cord are exposed to any form of
atmospheric precipitation, or salt
water spray.
Do not carry coiled welding cables
around shoulders, or any other part of
the body, when they are plugged into
the welder.
• Do not modify any wiring, ground
connections, switches, or fuses in this
welding equipment.
• 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.
FLASH HAZARDS
Do not drag welding cables, wire feed
gun, or welder power cord through or
allow them to come into contact with
water or moisture.
Do not touch welder, attempt to turn
welder on or off if any part of the body
or clothing is moist or if you are in
physical contact with water or
moisture.
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.
Do not connect welder ground clamp
to or weld on electrical conduit.
• Do not alter power cord or power cord
plug in any way.
• Do not attempt to plug the welder into
the power source if the ground prong
on power cord plug is bent over,
broken off, or missing.
• Do not allow the welder to be
connected to the power source or
attempt to weld if the welder, welding
WARNING
ARC RAYS CAN INJURE EYES AND
BURN SKIN! To reduce 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.
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 field of
vision. A shield or helmet with a
number 10 shade filter lens (minimum)
must be used.
Do not strike a welding arc until all
bystanders and you (the welder) have
welding shields and/or helmets in
place.
4
Do notweara crackedor broken
helmetand replaceanycracked or
brokenfilter lensesIMMEDIATELY.
Do not allowtheuninsulatedportionof
thewire feedgun totouchthe ground
clampor groundedworkto preventan
arcflash frombeingcreatedon
contact.
Providebystanderswithshieldsor
helmetsfittedwitha #10 shadefilter
lens.
Wear protectiveclothing.The intense
lightof theweldingarccanburnthe
skin in muchthesamewayas the
sun, eventhroughlight-weight
clothing.Wear dark clothingof heavy
material.Theshirtworn shouldbe
longsleevedandthecollarkept
buttonedto protectchestand neck.
ProtectagainstREFLECTEDARC
RAYS.Arc rayscan be reflectedoff
shinysurfacessuch as a glossy
paintedsurface,aluminum,stainless
steel,andglass.It is possibleforyour
eyes to be injuredby reflectedarc
raysevenwhen wearinga protective
helmetorshield. If weldingwith a
reflectivesurfacebehindyou, arc rays
can bounceoff the surface,then off
thefilterlenson the insideof your
helmetorshield,then intoyour eyes.
Ifa reflectivebackgroundexistsin
your weldingarea,eitherremoveit or
cover it withsomethingnon-flammable
and non-reflective.Reflectedarc rays
can alsocauseskin burninadditionto
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
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 fires,
burn skin, and damage eyes.
• Do not wear gloves or other clothing
that contain oil, grease, or other
flammable substances.
Do not wear flammable hair
preparations.
Do not weld in an area until it is
checked and cleared of combustible
and/or flammable materials. BE
AWARE that sparks and slag can fly
35 feet and can pass through small
cracks and openings. If work and
combustibles cannot be separated by
a minimum of 35 feet, protect against
ignition with suitable, snug-fitting, fire
resistant, covers or shields.
• Do not weld on walls until checking for
and removing combustibles touching
the other side of the walls.
• Do not weld, cut, or perform other
such work on used barrels, drums,
tanks, or other containers that had
contained a flammable or toxic
substance. The techniques for
removing flammable substances and
vapors, to make a used container safe
for welding or cutting, are quite
complex and require special education
and training.
• 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.
• Do not weld or cut in an area where
the air may contain flammable dust
(such as grain dust), gas, or liquid
vapors (such as gasoline).
• Do not handle hot metal, such as the
workpiece or electrode stubs, with
bare hands.
Wear leather gloves, heavy long
sleeve shirt, cuffless trousers, high-
topped shoes, helmet, and cap. As
necessary, use additional protective
clothing such as leather jacket or
5
sleeves, fire resistant leggings, or
apron. Hot sparks or metal can lodge
in rolled up sleeves, trouser cuffs, or
pockets. Sleeves and collars should
be kept buttoned and pockets
eliminated from the shirt front.
Have fire extinguishing equipment
handy for immediate use! A portable
chemical fire extinguisher, type ABC,
is recommended.
• Wear ear plugs when welding
overhead to prevent spatter or slag
from falling into ear.
• Make sure welding area has a good,
solid, safe floor, preferably concrete or
masonry, not tiled, carpeted, or made
of any other flammable material.
• Protect flammable walls, ceilings, and
floors with heat resistant covers or
shields.
Check welding area to make sure it is
free of sparks, glowing metal or slag,
and flames before leaving the welding
area.
FUME HAZARDS
WARNING
FUMES, GASSES, AND VAPORS CAN
CAUSE DISCOMFORT, ILLNESS, AND
DEATH! To reduce risk of discomfort,
illness, 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.
• 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
6
steel), unless the coating is removed.
Make certain the area is well
ventilated, and the operator and all
bystanders are wearing air-supplied
respirators.
Do not weld, cut, or heat lead, zinc,
cadmium, 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.
• Do not weld or cut in areas that are
near chlorinated solvents. Vapors from
chlorinated hydrocarbons, such as
trichloroethylene and
perchloroethylene, 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.
• Do not weld in a confined area unless
it is being ventilated or the operator
(and anyone else in the area) is
wearing an air-supplied respirator.
• 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.
ADDITIONAL SAFETY
INFORMATION
For additional information concerning
welding safety, refer to the following
standards and comply with them as
applicable.
• ANSI Standard Z49.1 -- SAFETY IN
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
• ANSI StandardZ87.1-- SAFE
PRACTICEFOROCCUPATIONAND
EDUCATIONALEYEAND FACE
PROTECTION-- obtainablefromthe
AmericanNationalStandardsInstitute,
11West42ndSt., New York, NY
10036 Telephone (212) 642-4900,
Fax (212) 398-0023 - www.ansi.org
• 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
• OSHA Standard 29 CFR, Part 1910,
Subpart Q., WELDING, CUTTING
AND BRAZING -- obtainable from
your state OSHA office or U. S. Dept.
of Labor OSHA, Office of Public
Affairs, Room N3647, 200 Constitution
Ave. NW Washhington, DC 20210 -
www.osha.gov
• CSA Standard W117.2 -- Code for
SAFETY IN WELDING AND
CUI-rlNG.- obtainable from
Canadian Standards Association, 178
Rexdale Blvd. Etobicoke, Ontario
M9W 1R3 - www.csa.ca
American Welding Society Standard
A6.0. WELDING AND CUI-FING
CONTAINERS WHICH HAVE HELD
COMBUSTIBLES. -- 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
7
The following procedures describe the
process required to assemble, install,
maintain, and prepare to weld with your
new wire feed 80 amp ac welder•
UNPACKING THE WELDER
PACKING LIST
Table 1 contains a list of the items you
will find packed in the carton•
Table 1. Packing List
1. Remove any cartons or bags
containing parts/accessories.
2. Open the cartons or bags packed
with your welder and inspect their
contents for damage• Report any
missing or damaged items
immediately•
3. Layout the parts and compare them
to the illustrations in Figure 1 and
the packing list in Table 1 to
familiarize yourself with the parts
and what they are called• This will
help you when reading the manual•
4. Grasp the top handle of the welder
and lift the welder out of the carton•
PART NO. ITEM QTY.
Welder 1
332-239-000 Face Shield 1
Face Shield Handle 1
Handle Screws 3
Shaded Lens 1
Clear Lens 1
930-405-000 Parts Bag 1
334-160-000 Contact Tip, 0.030 2
334-203-000 Nozzle 1
331-469-001 Wire .030 Fluxcore (1/2#)
804-502-000 Card, Registration 1
811-597-000 Manual, Instruction 1
ASSEMBLE THE FACE
SHIELD
Face Shield
Welding Wire
Weld Gun Nozzle
Contact Tip
Figure 1. Welder Parts/Accessories
•
Press one of the lens retainer tabs
(located in the rectangular lens
cavity inside the face shield) toward
the center of the lens cavity and lift
the retainer out of the cavity (may
require the use of a straight blade
screw driver to pry the tab).
.
Insert the clear plastic lens then the
shaded lens into the rectangular
lens cavity in the face shield• The
lenses are put in from the inside
and the clear lens goes in first to
protect the shaded lens. Insert the
lens retainer in place behind the
shaded lens and snap the tabs into
the holding slots at the ends of the
lens cavity to secure the lenses in
place•
8
. Place the face shield handle over
the mating holes in the face shield
and use the provided handle screws
to mount the face shield handle to
the face shield.
POWER SOURCE
CONNECTION
WARNING
High voltage danger from power
source! Consult a qualified
electrician for proper installation 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
it checked by a qualified electrician.
Do not cut off 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 Vac, 60 Hz,
single phase, 15 amp power source. Do
not operate this welder if the source
voltage is less than 105 Vac or greater
than 132 Vac. 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.
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 specific welder.
Select a properly grounded extension
cord that will mate directly with the ac
power source receptacle and the welder
power cord without the use of adapters.
Make certain that the extension cord is
properly wired and in good electrical
condition.
Extension cords must fit the following
wire size guidelines:
• 0-25 ft. requires #12 gauge
• Do not use an extension cord over 25
ft. in length
SELECTING THE WELDING
WIRE
This welder uses only four inch spools of
0.030 inch (0.8mm) self shielding flux-
core wire, AWS classification number
E71T-GS. Steel from 18 gauge up to
3/16 inch thick can be welded with this
wire.
NOTE:
• Metal thinner than 18 gauge cannot
be welded with this machine.
Attempting to do so will cause burn
through (blowing holes) in the metal
you are intending to weld.
• If a spool has developed heavy
oxidation, the only solution to the
problem is to discard the spool of wire.
If you have an oxidized spool of wire, do
not discard it until you have unspooled a
few turns of wire to see if the wire further
down on the spool is in usable condition,
if not, - discard the spool.
INSTALL THE WELDING
WIRE
WARNING
Electric shock can kill! Always turn the
POWER switch OFF 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.
.
Remove the drive tension by
unscrewing (ALL THE WAY in a
counter-clockwise direction) the
tension adjusting screw.
.
Unwrap the spool of wire then find
the leading end of the wire (it goes
through a hole in the outer edge of
the spool and is bent over the
9
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