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811 - 309 - 000 MANUAL . EAR $ OWNERS MANUAL WIRE FEED MODEL No . 934.20105 MIG WELDER Operation Repair Parts CAUTION : Read Rules for Safe Operation and Instructions 811 - 309 - 000 Carefully SEARS ROEBUCK AND CO . , CHICAGO , IL 60684 U . S . A .
Table of Contents IMPORTANT SAFETY INSTRUCTIONS 1 Changing the Drive Roller . . . . . . . . . . . . . . . . . . . 13 INSTALLING ALUMINUM WIRE . . . . . . . . . . . . . . 16 SHOCK HAZARDS . . . . . . . . . . . . . . . . . . . . . . . . . 1 FLASH HAZARDS . . . . . . . . . . . . . . . . . . . . . . . . . 2 PREPARING TO WELD 17 FIRE HAZARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 PREPARING A SAFE WELDING WORK AREA . . 17 FUME HAZARDS . . . . . . . . . . . . . . . . . . . . . . . . . . 3 PREPARING THE WORK PIECE . . . . . . . . . . . . . 17 COMPRESSED GASSES AND EQUIPMENT HAZ - ALUMINUM WELDING PREPARATION . . . . . . . . 18 ARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 CONNECT WELDER GROUND . . . . . . . . . . . . . . 18 ADDITIONAL SAFETY INFORMATION . . . . . . . . . 4 OPERATION 19 PRODUCT DESCRIPTION 5 GETTING TO KNOW YOUR NEW WELDER . . . . 19 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 5 SETTING THE CONTROLS . . . . . . . . . . . . . . . . . 19 WELDER CONTROLS AND THEIR FUNCTIONS . 5 HOLDING THE GUN . . . . . . . . . . . . . . . . . . . . . . . 20 DUTY CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Position of the Gun to the Work Piece . . . . . . . . . 20 INTERNAL THERMAL PROTECTION . . . . . . . . . . 5 Distance from the Work Piece . . . . . . . . . . . . . . . 21 LAYING A BEAD . . . . . . . . . . . . . . . . . . . . . . . . . . 21 ASSEMBLY AND INSTALLATION 6 CLEANING THE WELD BEAD . . . . . . . . . . . . . . . 21 UNPACKING YOUR WELDER . . . . . . . . . . . . . . . . 6 INSTALL THE GROUND CLAMP . . . . . . . . . . . . . . 6 WELDING TECHNIQUES 22 INSTALL WELDING GUN ASSEMBLY . . . . . . . . . . 7 TRAVELING WITH THE GUN . . . . . . . . . . . . . . . . 22 PROVIDE REQUIRED POWER . . . . . . . . . . . . . . . 7 TYPES OF WELD BEADS . . . . . . . . . . . . . . . . . . 22 Power Requirements . . . . . . . . . . . . . . . . . . . . . . . 7 WELDING POSITIONS . . . . . . . . . . . . . . . . . . . . . 23 Connect Welder to Power Source . . . . . . . . . . . . . 8 MULTIPLE PASS WELDING . . . . . . . . . . . . . . . . . 24 Extension Cord Use . . . . . . . . . . . . . . . . . . . . . . . . 8 INSTALL TANK TRAY AND BRACKET . . . . . . . . . . 8 SPECIAL WELDING METHODS 25 SELECT SHIELDING GAS . . . . . . . . . . . . . . . . . . . 9 SPOT WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Gas Selection For Steel Welding With Steel Wire . 9 SPOT WELDING INSTRUCTIONS . . . . . . . . . . . . 25 Gas Selection for Aluminum Welding . . . . . . . . . . 9 Gas Selection for Stainless Steel Welding . . . . . . 9 MAINTENANCE AND TROU - Gas Selection for Steel Welding BLESHOOTING 26 with Silicon - Bronze Wire . . . . . . . . . . . . . . . . . . . . 10 INSTALL THE SHIELDING GAS . . . . . . . . . . . . . . . 10 GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . 26 CHECKING GAS FLOW . . . . . . . . . . . . . . . . . . . . . 11 CONSUMABLE MAINTENANCE AND TROU - SELECT WELDING CURRENT POLARITY . . . . . . 11 BLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . 26 SELECT THE WELDING WIRE . . . . . . . . . . . . . . . 11 TESTING FOR A SHORTED NO72 ' LE . . . . . . . . . 27 Selecting the Type of Wire . . . . . . . . . . . . . . . . . . . 11 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . 27 SELECT THE SPOOL SIZE . . . . . . . . . . . . . . . . . . 12 REPLACEMENT PARTS LIST 33 Wire Spool Storage . . . . . . . . . . . . . . . . . . . . . . . . 13 Select the Wire Diameter . . . . . . . . . . . . . . . . . . . . 13 WARRANTY 34 INSTALL THE WELDING WIRE . . . . . . . . . . . . . . . 13
IMPORTANT SAFETY INSTRUCTIONS Page 1 IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS ! DO NOT OPERATE YOUR WELDER UNTIL YOU HAVE READ AND UNDERSTAND THESE INSTRUCTIONS ( welding rod or welding wire ) . Any metal parts on the electrode holder or MIG gun . ELECTRIC SHOCK CAN KILL ! NEVER weld in a damp area or come in contact with a moist or wet surface when welding . NEVER attempt to weld if any part of clothing or I _ : _ l ARC RAYS CAN INJURE EYES AND body is wet . BURN SKIN ! NEVER allow the welding equipment to come in contact with water or moisture . NEVER drag welding cables ( or MIG gun assem - FIRE OR EXPLOSION CAN CAUSE bly ) or weld powercord through or allow them to DEATH , INJURY , AND PROPERTY DAMAGE ! come into contact with water or moisture . NEVER touch welder , attempt to turn welder on or off , or attempt to plug welder into powersource if FUMES , GASSES , AND VAPORS CAN any part of body or clothing is wet or damp , or if CAUSE DISCOMFORT , ILLNESS , AND DEATH ! standing in or in physical contact of any kind with water or moisture . NEVER connect welder ground clamp to or weld on electrical conduit . IMPROPER HANDLING AND MAIN - TENANCE OF COMPRESSED GAS CYLIN - NEVER alter powercord or powercord plug in any DERS AND REGULATORS CAN RESULT IN SERIOUS INJURY OR DEATH ! way . IMPORTANT ! DO NOT ATTEMPT OPERATION NEVER attempt to plug welder into powersource if of this welding equipment until reading and under - ground prong on powercord plug is bent over , standing the following safety instructions to reduce broken off , or missing . risk of DEATH , INJURY , AND PROPERTY DAM - AGE . NEVER allow welder to be connected to power - source or attempt to weld if welder , welding cables SHOCK HAZARDS ( or MIG gun assembly ) , welding site , or welder powercord are exposed to rain , snow , sleet , mist , ELECTRIC SHOCK CAN KILL ! To reduce risk of fog or other forms of atmospheric precipitation or death from electric shock , read , understand , and mist or spray off an ocean or other body of water . follow the following safety insructions . In Addition , make certain that anyone who uses this welding NEVER carry coiled welding cables around shoul - equipment or is a bystander in the welding area ders , or any other part of the body , when they are understands and follows these safety instructions plugged into the welder . as well . NEVER modify any wiring , ground connections , NEVER Stand , Sit , Lie , Lean On , Touch , or come switches , or fuses in this welding equipment . into physical contact in any way with any part of the welding current circuit including : ALWAYS wear welding gloves to help insulate the work piece or any conductive material in con - hands from welding circuit . tact with it . The ground clamp . The electrode
IMPORTANSTAFETYINSTRUCTIONPSage2 ALWAYSkeep containers of water or other liquids the inside of your helmet or shield , then into your far enough away from welder and work area so that eyes . If a reflective background exists in your weld - if spilled , the liquid could not possibly come in contact ing area , either remove it or cover it with something with the welder , welding cables ( or MIG gun assem - nonflammable and non - reflective . Reflective arc bly ) , welder powercord , the workpiece being welded , rays can also cause skin burn in addition to eye or any other part of the electrical welding circuit . injury . ALWAYS replace any cracked or damaged parts FIRE HAZARDS that are insulated or act as insulators such as welding cables ( or MIG gun assembly ) , or power - cord IMMEDIATELY . FIRE OR EXPLOSION CAN CAUSE DEATH , IN - JURY , AND PROPERTY DAMAGE ! To reduce FLASH HAZARDS risk of death , injury , or property damage from fire or explosion , read , understand , and follow the fol - lowing safety insrtuctions . In addition , make cer - ARC RAYS CAN INJURE EYES AND BURN tain that anyone else that uses this welding SKIN ! To reduce risk of injury from arc rays , read equipment , or is a bystander in the welding area , understand and follow the following safety insrtuc - understands and follows theses safety instructions tions . In addition , make certain that anyone else as well . REMEMBERI Arc welding by nature pro - that uses this welding equipment , or is a bystander duces sparks , hot spatter , molten metal drops , hot in the welding area , understands and follows these slag , and hot metal parts which can start fires , burn safety instructions as well skin and damage eyes . NEVER look at an electric arc without proper pro - tection . A welding arc is extremely bright and in - tense and , with inadequate or no eye protection , NEVER wear gloves or other clothingthat contain the retina can be burned , leaving a permanent oil , grease , or other flammable substances . dark spot in the field of vision . A shield or helmet with a number 10 shade filter lens ( minimum ) must NEVER wear flammable hair preparations . be used . NEVER weld in an area until it has been checked NEVER strike a welding arc until all bystanders and cleared of combustable and / or flammable ma - and you ( the welder ) have welding shields and / or terials . BE AWARE that sparks and slag can fly 35 helmets in place . feet and can pass through small cracks and open - NEVER wear a cracked or broken helmet and ings . If work and combustibles cannot be sepa - rated by a minimum of 35 feet , protect against replace any cracked or broken filter lenses IMME - DIATELY . ignition with suitable , snug - fitting , fire resistant covers or shields . ALWAYS provide bystanders with shields or hel - mets fitted with a number 10 shade filter lens . NEVER weld on walls until checking for and remov - ing combustibles touching the wall on the other side . ALWAYS wear protective clothing . The intense light of the welding arc can bum the skin in much NEVER weld , cut , or perform other hot work on the same way as the sun , even through light - used barrels , drums , tanks , or other containers weight clothing . Wear dark clothing of heavy mate - that contained a flammable or toxic substance . rial . The shirt worn should be long sleeved and the The techniques for removing flammable sub - collar kept buttoned to protect chest and neck . stances and vapors , to make a used container safe for welding or cutting , are quite complex and re - ALWAYS protect against REFLECTED ARC quire special education and training . RAYS . Arc rays can be reflected off shiny surfaces such as a glossy painted surface , aluminum , stain - NEVER strike an arc on a compressed gas or air less steel , and glass . It is possible for your eyes to be injured by reflected arc rays even when wearing cylinder or other pressure vessel . Doing so will create a brittle area that can result in a violent a protective helmet or shield . If welding with a reflective surface behind you , arc rays can rupture immediately or at a later time as a result of " bounce off " the surface , then off the filter tens on rough handling .
IMPORTANT SAFETY INSTRUCTIONS Page ) 3 NEVER weld or cut in an area where the air may nized steel , unless the coating is removed , the contain flammable dust ( such as grain dust ) , gas , area is well ventilated , or the operator and _ all ' or liquid vapors ( such as gasoline ) . bystanders wear air - supplied respirators . NEVER handle hot metal , such as the workpiece NEVER weld , cut , or heat lead , zinc , cadmium , or welding wire , with bare hands . mercury , beryllium , or similar metals without seek - ing professional advise and inspection of the ven - ALWAYS wear leather gloves , heavy long sleeve tilation of the welding area . These metals produce EXTREMELY TOXIC fumes which can cause dis - shirt , cuffless trousers , high - topped shoes , helmet , comfort , illness , and death . and cap . As necessary , use additional protective clothing such as leather jacket or sleeves , fire resistant leggings , or apron . Hot sparks or metal NEVER weld or cut in areas that are near chlorin - can lodge in rolled up sleeves , trouser cuffs , or ated solvents . Vapors from chlorinated hydrocar - pockets . Sleeves and collars should be kept but - bons , such as trichlorbethylene and toned and pockets eliminated from the front . perchloroethylene , can be decomposed by the heat of an electric arc or its ultraviolet radiation to form PHOSGENE , a HIGHLY TOXIC gas , along ALWAYS have fire extinguishing equipment handy for instant use ! A portable chemical fire extin - with other lung and eye - irritating gasses . Do not weld or cut where these solvent vapors can be quisher , type ABC , is recommended . drawn into the work area or where the ultraviolet radiation can penetrate to areas containing even ALWAYS wear ear plugs when welding overhead very small amounts of these vapors . to prevent spatter or stag from falling into ear . NEVER weld in a confined area unless it is being ALWAYS make sure welding area has a good , ventilated or the operator ( and anyone else in the solid , safe floor , preferably concrete or masonry , area ) is wearing an air - supplied respirator . not tiled , carpeted , or made of any other flammable material . NEVER bring gas cylinders into or allow gas leaks in a confined space . Leaked gas can rapidly re - ALWAYS protect flammable walls , ceilings , and duce oxygen concentration levels in a confined floors with heat resistant covers or shields . space . ALWAYS check welding area to make sure it is ALWAYS shut off shielding gas supply at its source free of sparks , glowing metal or slag , and flames before leaving a confined area and check to make before leaving the welding area . sure that the area is safe before reentering it . FUME HAZARDS ALWAYS stop welding if you develop momentary eye , nose , or throat irritation as this indicates in - FUMES , GASSES , AND VAPORS CAN CAUSE adequate ventilation . Stop work and take neces - DISCOMFORT , ILLNESS , AND DEATH ! To re - sary steps to improve ventilation in the welding duce risk of discomfort , illness , or death , read , area . Do not resume welding if physical discomfort understand , and follow the following safety instruc - persists . tions . In addition , make certain that anyone else that uses this welding equipment or is a bystander COMPRESSED GASSES AND in the welding area , understands and follows these EQUIPMENT HAZARDS safety instructions as well . NEVER weld in an area until it has been checked IMPROPER HANDLING AND MAINTENANCE OF COMPRESSED GAS CYLINDERS AND for adequate ventilation as described in ANSI REGULATORS CAN RESULT IN SERIOUS IN - standard # Z49 . 1 . If ventilation is not adequate to JURY OR DEATH ! To reduce risk or injury or death exchange all fumes and gasses generated during the welding process with fresh air , do not weld from compressed gasses and equipment hazards , unless you ( the welder ) and all bystanders are read , understand , and follow the following safety wearing air - supplied respirators . instructions . In addition , make certain that anyone else who uses this welding equipment or is a bystander in the welding area understands and NEVER heat metals coated with or containing ma - terials that produce toxic fumes , such as galva - follows these safety instructions as well .
IMPORTANT SAFETY INSTRUCTIONS Page 4 NEVER use flammable gasses with MIG welders . ALWAYS protect cylinder , especially valve , from Only inert or non - flammable gasses are suitable bumps , falls , falling objects , and weather . for MIG welding . Examples are Carbon Dioxide , Argon , Helium , etc . or mixtures of more than one ALWAYS make sure cylinder cap is securely in of these gasses . place , on the cylinder , whenever cylinder is moved . NEVER attempt to mix gasses or refill a cylinder yourself . ALWAYS remove faulty regulator from service im - mediately for repair ( first close cylinder valve ) if NEVER expose cylinders to excessive heat , any of the following occur : Gas leaks extemally , delivery pressure continues to rise with down sparks , slag , and flame , etc . Cylinders exposed to stream valve closed , and / or gauge pointer does temperatures above 130 degrees F . will require not move off the stop pin when pressurized or fails water spray cooling . to return to the stop pin after pressure is released . NEVER expose cylinders to electricity of any kind . ADDITIONAL SAFETY NEVER use cylinder or its contents for anything INFORMATION other than its intended use . Do not use as a sup - port or roller . For additional information concerning welding NEVER locate cylinders in passageways or work safety , refer to the following standards and comply areas where they may be struck . with as applicable . NEVER lift cylinders off the ground by their valves 1 . ANSI Standard Z49 . 1 - - SAFETY IN WELDING or caps or with chains , slings , or magnets . AND CUTTING - - - obtainable from the American Welding Society , 2051 N . W . 7th St . , Miami , FL NEVER use a wrench or hammer to open a cylin - 33125 Telephone ( 305 ) 443 - 9353 der valve that cannot be opened by hand . Notify your supplier . 2 . ANSI Standard Z87 . 1 - - SAFE PRACTICE NEVER modify or exchange gas cylinder fittings . FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION - - obtainable from NEVER deface or altar name , number , or other the American National Standards Institute , 1430 markings on a cylinder . It is illegal and hazardous . Broadway , New York , NY 10018 NEVER use cylinders without the name of the gas 3 . NFPA Standard 51B - - CUTTING AND WELD - marked on the cylinder . Do not rely on cylinder ING PROCESSES - - obtainable from the Na - color to identify the content . tional Fire Protection Association , 470 Atlantic Ave . , Boston , MA 02210 NEVER connect a regulator to a cylinder contain - ing gas other than that for which the regulator was designed . 4 . CGA Pamphlet P - 1 - - SAFE HANDLING OF COMPRESSED GASSES IN CYLINDERS NEVER attempt to make regulator repairs . Send obtainable from the Compressed Gas Associa - faulty regulators for repair to manufacturer's des - tion , 500 5th Ave . , New York , NY 10036 ignated repair center . 5 . OSHA Standard 29 CFR , Part 1910 , Subpart Q , NEVER attempt to lubricate regulator . WELDING , CU'I - I'ING AND BRAZING - - ob - tainable from your state OSHA office . ALWAYS handle cylinders carefully to prevent leaks and damage to their wails , valves , or safety devices . 6 . CSA Standard W177 . 2 - - Code for SAFETY IN WELDING AND CUTTING - - obtainable from Canadian Standards Association , 178 Rexdale ALWAYS secure cylinders with a steel chain so Blvd . , Rexdate , Ontario , Canada M9W 1R3 that they cannot be knocked over .
PRODUCT DESCRIPTION Page . 5 PRODUCT DESCRIPTION WIRE SPEED - This control adjusts the speed at Your new Metal Inert Gas ( MIG ) wire feed welder which the wire is fed out of the gun . The wire speed is designed for maintenance , and sheetmetal fab - needs to be closely matched ( " tuned - in " ) to the rication . The welder consists of a single - phase rate at which it is being melted off . Some things power transformer , stabilizer , rectifier , and a that affect wire speed selection are the type and unique built - in control / feeder . This MIG welder is diameter of the wire being used , the heat setting capable of welding with . 024 " and . 030 " solid steel , selected , and the welding position to be used . or stainless steel wires and . 030 " aluminum ( spec # 5356 alloy ) wire on DC positive polarity and with . 030 " , self - shielding flux - core wire on DC negative polarity . DUTY CYCLE NOTE ; When using . 035 Flux Core wire your duty cycle may be shorter than 20 % . The duty cycle rating of a welder tells the operator how long he or she can weld and how long the welder must rest - to cool . tt is expressed as a Now you can weld 20 gauge sheet metal up to percentage of 10 minutes ( the industry recognized 3 / 16 " with a single pass . Welds 114 " steel with cycle time ) and represents the maximum welding beveling and multiple pass . time allowed , with the balance of the 10 - minute cycle required for cooling ( see chart below ) . SPECIFICATIONS Primary ( input ) volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 VAC Your new welder has a duty cycle rating of 20 % . Primary ( input ) Amps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 You can weld for 2 minutes out of 10 , with the Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single remaining 8 minutes required for cooling . Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Hz Kilovolt Amps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 Secendary ( output ) volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Duty Cycle Maximum Required Secondary ( output ) amps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Rating Welding Time Resting Time Duty Cycle Rating : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 % Open Circuit Volts ( Max . ) . . . . . . . . . . . . . . . . . . . . . . 31 VDC 20 % 2 Minutes 8 Minutes WELDER CONTROLS AND THEIR 40 % 4 Minutes 6 Minutes FUNCTIONS 60 % 6 Minutes 4 Minutes 80 % 8 Minutes 2 Minutes 100 % 10 Minutes 0 Minutes POWER SWITCH - Has three settings : LOW , OFF , and HIGH . Setting the switch to OFF shuts the welder off . When set to LOW , the welder can produce up to 45 amps of welding current . When set on HIGH , up to 75 amps of welding current will INTERNAL THERMAL PROTECTION be available . NOTE : The actual amperage will vary depending on wire speed , length of the arc held when welding , the type of wire being used , If you exceed the duty cycle of your welder , and and the ACTUAL voltage available at the wall internal thermal protector will open and shut off ai ! receptacle . welder functions . After cooling , the thermal protec - tor will automatically reset and the welder wilt func - ELECTRIC SHOCK CAN KILL ! To reduce risk of tion normally again . electric shock , be aware that having the POWER SWITCH in the OFF position does not remove power from all intemal circuitry of the welder . DO NOT CONSTANTLY EXCEED THE DUTY CYCLE OR DAMAGE TO THIS WELDER CAN RESULT !
ASSEMBLYANDINSTALLATIONPage6 ASSEMBLY AND INSTALLATION 4 . Lay out the parts and compare to following illus - trations to familiarize yourself with the parts and what they are called . This will help you when ELECTRIC SHOCK CAN KILL ! To re - reading the manual . duce risk of electric shock , DO NOT PLUG WELDER IN TO AC POWER SOURCE UNTIL 5 . Grasp the top handle of the welder and lift the TOLD TO DO SO later in this manual . welder out of the carton . INSTALL THE GROUND CLAMP UNPACKING YOUR WELDER Connect the ground clamp to the ground cable ( coming out of the front of the welder ) according to 1 . Open the top of the shipping carton . the instructions packaged with the ground clamp . 2 . Remove any cartons or bags containing acces - sories . 3 . Open the cartons or bags packed with your welder and inspecttheir contents for damage . Report any missing or damaged items immedi - ately !
ASSEMBLY AND INSTALLATION Page 7 Knob O O O 000 0 0 DRIVE ASSEMBLY INSTALL WELDING GUN ASSEMBLY On Gun On Welder 1 . Insert the brass tail piece of the welding gun through hole in the front of the welder . 2 . Align the gun's tail - piece with the hole in the brass conductor block on the front of the drive Female nPlugs assembly . w / Male Pi 3 , Push the gun's tail - piece into the drive assembly NOTE : The connectors will plug together only one ALL THE WAY until it stops against the brass way , due to their shape ( see illustration ) . The conductor block . ( NOTE : The gun's tail piece connectors will lock together when properly con - should be about 1 / 16 " from the drive roller ) nected . 4 . Rotate the gun so the brass fitting ( on the gun's PROVIDE REQUIRED POWER tail - piece ) is pointing up , then plug the gas hose ( coming up through the welder's drive deck ) onto the barbed fitting . Power Requirements NOTE : Ahose clamp is not needed on this fitting . This welder is designed to operate on a properly grounded 120 volt , 60 hertz , single phase , alternat - 5 . Make sure gun is still pushed all the way into the ing current ( AC ) power source on a 20 amp branch brass conductor block , then tighten the gun circuit . It is recommended that a qualified electri - clamping knob ( on top of the brass gun conduc - cian verify the ACTUAL VOLTAGE at the recepta - tor block ) until the gun is held securely in place . cle into which the welder will be plugged and confirm that the receptacle is properly fused and grounded . IMPORTANT : Hand tighten only . do not over - tighten . DO NOT OPERATE THIS WELDER if the AC - TUAL power source voltage is less that 105 volts 6 . Plug the trigger lead connector ( hanging from the gun's tail - piece ) into the mating connector AC greater than 132 volts AC . Contact a qualified that's mounted in the deck of the welder . electrician if this problem exists . Improper perform -
ASSEMBLY AND INSTALLATION Page 8 ance and / or damage to the welder will result if tabs of the tank tray with the two holes in the operated on inadequate or excessive power . welder . Reinstall the two sheetmetal screws that were removed and TIGHTEN ONLY . ELECRIC SHOCK CAN KILL ! FIRE CAN KILL , INJURE , AND CAUSE PROPERTY DAMAGE ! To . Attach the two tank support straps to the tank reduce the risk of electric shock and fire , connect support tray using 1 each # 10 Phillips head only to properly grounded and fused outlets . screw , 1 each # 10 Iockwasher , and 1 each # 10 NEVER ALTER the AC powercord or powercord Hex nut on each side . The straps should be plug provided on the welder . NEVER ALTER and mounted to the outside surface of the tank tray . extension cord or extension cord plugs . TIGHTEN LIGHTLY . Connect Welder to Power Source 1 , DO NOT ALTER the AC power cord or power - cord plug on the welder . Doing so may VOID THE WARRANTY . If the welder's AC powercord plug does not mate with your existing recepta - cle , have an appropriate receptacle installed by a qualified electrician in accordance with the National Electrical Code and local codes and ordinances . Do not use any adapters between the welder's AC powercord plug and AC power source receptacle . 2 . Make sure the POWER SWITCH on the front of 3 , Remove the two sheetmetal screws ( one from the welder is turned to its " OFF " position . Then each side ) that are located directly above the plug the welder's powercord plug into the AC screws removed in step # 1 above . Position the power source receptacle . ends of the tank support straps over the holes in the welder and reinstall the screws . Extension Cord Use 4 . Tighten all hardware securely . For optimum welder performance , and extension cord should not be used unless absolutely neces - san / . If necessary , care must be taken in selecting . Position the upper tank bracket ( flanges pointing an extension cord appropriate for use with your downward ) over the two empty holes on the specific welder . back of the welder and push two # 10 Phillips head bolts through the holes . Select a property grounded extension cord that the AC powercord of the welder and AC power source receptacle will mate with directly without the use of 6 . Raise the wire drive compartment lid of the adaptors . Make sure the extension cord is properly welder , place a Iockwasher on each of the bolts , wired and in good electrical condition . then thread a # 10 hex nut onto each bolt and tighten securely . For an extension cord length not exceeding 25 feet , choose one with the same AWG wire size as 7 , Place each end of the tank restraining chain into that stamped on the welder's powercord , Exten - each of the key - hole slots in the upper tank sion cord lengths longer than 25 feet will require bracket . This chain will restrain a tank from fall - heavier wire gauges to compensate for voltage ing over and should always be used . losses that will cause decreased perfomance . INSTALL TANK TRAY AND IMPORTANT - GAS CYUNDER SIZE RESTRIC - BRACKET TION ! The tank tray you have installed on the back of this welder will handle gas cylinders no longer 1 . Remove the screw from the bottom - rear comer than 20 cubic feet . If you select a cylinder larger than 20 cubic feet , it must be chained to a wall or of each side of the welder . Slide the tank tray other fixed support . into position , lining up the slotted holes in the
ASSEMBLYANDINSTALLATIONPage9 SELECT SHIELDING GAS Gas Selection For Aluminum Gas Welding The shielding gas plays an extremely important role in the MIG welding process . As with most welding processes , it is critical that the molten weld puddle be " shielded " from the atmosphere . Inade - quate shielding will result in porous , brittle welds . Notonly is shieldingthe weld important , but select - ing the proper gas to shield with is of equal impor - 100 % ARGON tance . Generally , the shielding gas selected is dependent upon the type and thickness of metal being welded . Selecting the wrong gas for the metal to be welded can result in porosity , brittle - ness , and / or undesirable penetration of the weld . Although there are many gasses and mixtures Our only recommendation for shielding an alumP available for MIG welding , the following recom - num weld is pure Argon . Do not attempt to use the mendations are based on the electrical output Argon / Carbon Dioxide mixture ( recommended for characteristics and metal - thickness welding capa - steel ) when welding aluminum . bilitiesof this specific MIG welder . Gas Selection For Stainless Steel Welding GAS SELECTION FOR STEEL WELDING WITH STEEL WIRE _ o / o BEST _ o / , Â° ACCEPTABLE HELIUM 75 % ARGON ARGON F " _ " _ ' ' % ARGON r - - 2 _ % co 2 _ % c ( : f 25 % CO = _ J The best shielding gas for stainless steel welding is a mixture of 90 % helium , 7.5 % Argon , and 2.5 % For either mild or low carbon ( High Strength Struc - Carbon Dioxide . However , the 75 % argon 25 % tural ) steel , in the thicknesses that can be welded Carbon Dioxide mixture ( recommended for steel ) with this welder , our primary recommendation is a can also be used , but an increase in the area being gas mixture of 75 % Argon and 25 % Carbon Diox - heated by the arc will be experienced causing ide . This gas mixture helps to prevent burn slightly greater distortion of the base metal . Also through and distortion on very thin steel , yet pro - this mixture can cause a decrease in the ability of vides food penetration on thicker steel . Its ability the stainless steel weld to resist corrosion . Either to minimize spatter results in clean , smooth weld mixture can be obtained in a single cylinder from appearances . In addition , it provides food puddle your local gas distributor . control when welding vertically or overhead . This gas mixture is available pre - mixed in a single cyl - inder from your local gas distributor . Note : Potential Shielding Gas Problems
ASSEMBLYANDINSTALLATIONPage 10 PRESSED GASSES AND EQUIPMENT HAZ - Gas Selection For Steel Welding With Silicon - bronze Wire ARDS in the SAFETY INSTRUCTION section of this manual . 1 . Secure gas cylinder to the tank bracket kit , a wall or other fixed support . 2 . Remove the protective cap from the cylinder 100 % ARGON and inspect the regulator connecting threads for dust , dirt , oil , and grease . Remove any dust or dirt with a clean cloth . DO NOT ATTACH THE REGULATOR IF OIL , GREASE , OR DAMAGE ARE PRESENT . . Open the cylinder valve FOR JUST AN IN - Use only pure Argon when welding steel with Sili - STANT to blow out any foreign matter inside the con - Bronze wire . valve port to reduce the risk of plugging or dam - aging the regulator . NEVER AIM THE CYLIN - DER VALVE PORT AT YOURSELF OR ANY 1 . DEFECTIVE GAS - - Just like any other prod - BYSTANDERS WHEN OPENING CYLINDER uct , a cylinder of gas can be defective . Moisture TO REDUCE THE RISK OF PERSONAL IN - or other impurities in the gas can create dirty JURY . porous , brittle welds with greatly reduced pene - tration . The only remedy is to replace the cylin - der . 4 . Screw the regulator into the cylinder valve and tighten with a wrench while keeping gauges 2 . MIXTURE COMPOSITION CHANGE - - This upright for easy and accurate reading . problem concerns only cylinders that contain a mixture of two or more gasses . The mixture NOTE : If the cylinder you have is equipped with composition in a cylinder can be changed if the male regulator connecting threads instead of fe - cylinder is stored in cold temperatures . For the male , you wilt need to obtain a special compressed gas cylinder adapter from your gas supplier to 75 % Argon 25 % Carbon Dioxide mixture , the cylinder should not be stored below 40 degrees install between your gas cylinder and regulator . R This information is normally found on the label on the cylinder that indicates the contents 5 . Locate the brass barbed fitting and brass retain - of the cylinder . ing nut in the parts bag and place the fitting through the nut as pictured on next page . Then thread the nut onto the male - threaded outlet This problem can create a variety of unfavorable weld characteristics including porosity , brittles , and port on the regulator and wrench tighten . improper penetration . Brass 3 . INSUFFICIENT SHIELDING GAS COVER - Brass barbed retaining nut fitting AGE - - This problem can be created by several causes as listed in the TROUBLESHOOTING section of this manual . The symptoms are the same for al ! of them ; dirty , porous , brittle , and / or non - penetrating welds . INSTALL THE SHIELDING GAS IMPROPER HANDLING AND MAINTENANCE Outlet port fitting OF COMPRESSED GAS CYLINDERS AND on regulator REGULATORS CAN RESULT IN SERIOUS IN - 6 . Slide the spring clamp ( in parts bag ) down one JURY OR DEATHI Always secure gas cylinders to end of the gas hose about three inches . Push the tank bracket kit , a wall , or other fixed support the same end of the gas hose onto the barbed to prevent the cylinder from falling over and ruptur - fitting . Then compress the ears of the spring ing . Read , understand , and follow alt the COM -
ASSEMBLY AND INSTALLATION Page 11 clamp witha pliers , slide it up the gas hose , and 3 . Pull the trigger on the gun to allow the gas to release clamp when it is positioned on a portion flow . KEEP PULLED . Listen for gas to flow from of the hose that is over the brass fitting . ' the end of the welding gun . If no gas is heard or felt , check all previous steps in connecting the gas . 4 . Release the trigger . Your gas regulator has been factory set for delivery of 20 Cubic Feet Per Hour of shielding gas . If welding outside or in a draft , it may become nec - SPRING CLAMP essary to set up a windbreak to keep the shielding HOSE gas from being blown from the weld area . MAKE SURE TO TURN OFF THE GAS CYUN - 7 . Locate the remaining brass barbed fitting ( male DER VALVE WHEN DONE WELDING . threaded ) in the parts bag and thread the fitting into the gas solenoid port located in the rear of SELECT WELDING CURRENT the welder ( see illustration below ) BEING CAREFUL TO PREVENT CROSS THREAD - POLARITY ING . Turn the fitting into the solenoid port WITH YOUR FINGERS ONLY until you can't turn any This welder comes factory set for DC Positive more . Then , use a wrench to tighten it securely Polarity operation . This polarity is required when - do not overtighten . using gas - shielded steel welding wires . If you wish to use self - shielding flux - core wire , it will be necessary to set the welder for DC Negative Polarity operation . To do this , refer to on sticker on the inside of hood . SELECT THE WELDING WIRE Selecting the Type of Wire It is very important to select a type of wire that is compatible with the metal to be welded ( base met - 8 . Slide the remaining hose clamp about 3 " up the al ) . If the wire is incompatible with the base metal , end of the gas hose opposite the regulator . Then the quality of important characteristics such as push the hose onto the barbed fitting installed in penetration and strength may be sacrificed . step # 7 above and clamp into place . The welding wires recommended for most of the CHECKING GAS FLOW mild and low carbon steel applications you will have are AWS classification numbers E70S - 3 and IMPROPER HANDLING AND MAINTENANCE E70S - 6 . These two wires are very similar , but the OF COMPRESSED GAS CYLINDERS AND E70S - 6 tends to work a little better on moderately REGULATORS CAN RESULT IN SERIOUS IN - dirty steel and on sheet metal where smooth weld JURY AND DEATH ! To reduce risk of injury or beads are required . These differences are very death , always stand to the side of the cylinder subtle , so in most applications , either wire is ac - ceptable . opposite the regulator when opening the cylinder valve , keeping the cylinder valve between you and the regulator . Self - shielding , flux - core , steel wire is used primar - ily for welding mild steel without the use of a shield - 1 . Slowly crack open the cylinder valve , then turn ing gas . It is especially good to use when welding open ALL THE WAY ! needs to take place in windy environment . How - ever , it produces more spatter than solid wire gas - 2 . Turn POWER SWITCH on the front of the shielded welding and leaves a slag on top of the welder to either the LOW or HIGH position . weld that needs to be chipped off . Our recommen -
ASSEMBLY AND INSTALLATION Page 12 dation for self - shielding , flux - core , steel wire is that on an 8 " spool . However , welding wire oxi - AWS classification number E71T - GS . dizes over time , so it is important to select a spool size that will be used up within the times recom - NOTE : With flux core wire you will bum through mended below . metats thinner than 18 gauge . STEEL WIRE is usually coated with copper to WARNING : When welding aluminum with a wire prevent the wire from rusting and to enhance the feed welder rated at 90 amps or less , we highly transmission of welding current from the contact recommend that : tip to the wire . It is recommended that copper - coated steel welding wire be bought in spool a . The aluminum to be welded is between sizes that will be consumed in six months or t / 16 " ( t . 59mm ) and 1 / 8 " ( 3.17mm ) thick . tess . In the early stages of aging , the copper coating b . A . 030 diameter , 5356 aluminum alloy weld - will begin oxidizing . The more time passes , the ing wire is used . heavier the oxidization will get . To check the wire for copper oxidization , unspool about two feet of c . The teflon gun liner ( part # 4325 ) is installed wire , pinch wire between thumb and forefinger , in the mig gun . then pull thumb and forefinger down the length of wire . Look at thumb and forefinger ; there will d . The composite rubber drive roller ( part # be a line created by the copper oxidization . A 4324 ) is installed inthe wire feed welder . fairly fresh spool will leave a light gray line , whereas a well - oxidized spool will leave a darker line . Heavy copper oxidization will cause e . 100 % pure argon shielding gas is used . arc flutter and possibly wire drive slippage . If steel wire continues to oxidize , the steel wire NOTE : Failure to utilize these set - up recommen - under the copper coating will rust causing even dations will result in wire feeding problems and worse arc flutter and drive problems . poor quality welds . 1 . Stainless Steel Wire Selection 2 . SELF - SHIELDING , FLUX - CORE , STEEL When welding stainless steel , the alloy of the WIRE spools should be selected based on the welding wire must be the same as the alloy of same guidelines as for steel wire . the base metal . As with aluminum , the alloy number can most often be determined by con - . ALUMINUM WIRE is even more of a potential suiting the owner / operator manual , service manual , dealer , distributor , or manufacturer of storage problem than steel . It tends to oxidize much faster and the oxidation is much heavier . the item to be welded . Otherwise , seek the ad - vise of someone who may have had previous The early stages of oxidation are virtually invis - ible , but as time passes , a white powder will experience with the same or similar welding application . Stainless steel wire is quite expen - develop that will cause extreme arc flutter , wire drive problems , contamination build - up in the sive , the trial - and - error method of alloy determi - liner , wire burn - back into the contact tip , and a nation should be avoided if at all possible . poor weld . ideally it would be best to use up a 2 . Silicon'Bronze Wire Selection spool of aluminum wire within three months . The most popular application for silicon - bronze MIG welding is non - structure sheetmetal weld - 1 STAINLESS STEEL WIRE oxidizes at a rela - ing , especially auto body work . A weld with sili - tively slow rate and its oxidation is very light , so con - bronze wire is very similar to that produced the care for handling and storing stainless steel by oxygen - acetylene brazing . It is fairly flat and wire is much less cdtical than for aluminum and easy to grind smooth . Our recommended wire steel wires . However , because stainless steel for this application is AWS classification number wire is quite expensive , it is still a good practice ERCuSi - A . to fotlow the storage recommendations . SELECT THE SPOOL SIZE 5 . SILICON - BRONZE WIRE spools should be se - lected based on the same guidelines as for This welder will accept either 4 " or 8 " spools . Wire copper - coated steel wire . on a 4 " spool wilt usually cost more per pound than
ASSEMBLYANDINSTALLATIONPage19 INSTALL THE WELDING WIRE WireSpool Storage ELECTRIC SHOCK CAN KILL ! Always turn the The above recommended spool storage times are POWER SWITCH to its OFF position and unplug rules - of - thumb and can be impacted by many fac - tors such as length of time in distribution prior to the welder's powercord from the AC power source retail sale , warehouse conditions , time of year ( ie : before installing wire . Humid months or dry months ) , and how packaged 1 . Remove the nozzle and contact tip from the end by the manufacturer . of the gun assembly . Although these factors are out of your control , 2 . Unscrew ( turn counter - clockwise ) the tension there are some things that you can do to slow adjusting screw ALL THE WAY . down the oxidization process : store in a dry place when not in use ; store in sealed plastic bag when 3 . Make sure that the wire diameter stamped on not in use and leave unopened in the manufac - the outside of the drive roller is the same as the turer's package until ready to use . diameter of the wire being installed . If it is not the same , change the drive roller as follows : NOTE : If spool has developed heavy oxidation , the only solution to the problem is to discard the spool of wire . However , if you have an oxidized spool of CHANGING THE DRIVE ROLLER wire , do not discard it until trying the following : unspool a few turns of wire to see if the wire further ELECTRIC SHOCK CAN KILL ! Always turn the down on the spool is in usable condition , if not - - POWER SWITCH to its OFF position and unplug discard the spool . the welder's powercord from the AC power source before changing a drive roller . SELECT THE WIRE DIAMETER a . Remove drive tension ( see step # 2 above ) . t . Steel and Stainless Steel Welding b . If there is wire already installed in the welder , Base Metal Wire roll it back onto the wire spool by hand - turn - Thickness Diameter ing the spool clockwise ( to the right ) , but be careful not to allow the wire to come out of . 024 " ( . 6mm ) 20 Gauge to 1 / 8 " Gauge the rear end of the gun without holding onto . 030 " ( . 8mm ) 18 Gauge to 1 / 8 " it or it will unspool itself . Put the end of the wire into the hole on the outside edge of the 2 . Aluminum Welding spool and bend it over to hold the wire in place , then remove the spool of wire from Base Metal Wire the welder . Thickness Diameter i i c , Remove the retaining screw and washer 1 / 16 " to 1 / 8 " . 030 " ( . 8ram ) from the drive roller . 3 . Silicon - Bronze Wire Welding of Steel To be used for welding non - structural sheet - KE'f _ NAY metal to sheetmetal or non - structural sheet - metal to heavier steel . Use . 030 " ( . 8mm ) diameter wire for these applications . 4 . Steel welding with Self - Shielding Flux - Core Wire Your welder can use only . 30 Flux - Core wire AWS # E71T - GS , KEY _ Base Metal Wire Thickness Diameter i i 18 Gauge to 3 / t6 " . 030 " ( . 8 mm )
ASSEMBLY AND INSTALLATION Page 14 d . Remove the drive roller by pulling it straight 8 . Place the spool on the spindle in such a manner out and off the drive motor shaft . that when the wire comes off the spool it will look like this : e . Find the side of the drive roller that is stamped with the same wire diameter as that of the wire being installed . Push the drive roller onto the drive motor shaft . Make sure the side stamped with the desired wire diameter is facing out . IMPORTANT ! Make sure the key remains properly installed in its slot in the drive motor shaft . f . Replace the drive roller retaining screw and washer , then tighten securely . 4 . Remove the wire spool holder from the deck of not like this : the welder by pulling up lightly on the spindle while pulling firmly outward on the tab of the wire spool holder until it clears the hold - down tabs on the deck of the welder . o 9 . If you are installing a 4 - inch spool of wire , install the drive brake hardware on top of the spool of wire according to the following illustration . How - ever , if you are installing an 8 - inch spool , install the spindle adaptor INSTEAD of the drive brake hardware and move on to step # 11 . 5 . Turn wire spool holder over and insert the 1 / 4 - 21 x 2 3 / 4 " hex head bolt through the hole that goes up through the spindle . Make sure that you push the hex head of the bolt all the way into the hex hole in the bottom of the wire spool holder . 6 . Reinstall the wire spool holder onto the welder making sure to push it all the way into the hold - down tabs . 7 . Unwrap the spool of wire then find the leading end of the wire ( it goes through a hole in the 10 . Adjust the drive brake tension . The purpose of outer edge of the spool , and is bent over the the drive brake is to cause the spool of wire to spool edge to prevent the wire from unspooling ) , stop turning at nearly the same moment that BUT DO NOT UNHOOK IT YET ! wire feeding stops .
ASSEMBLY AND INSTALLATION Page , _ 15 _ a . With one hand , turn the wire spool and con - rying welding current whenever the welder , is , turned on - - WHETHER THE TRIGGER i _ tinue turning it while adjusting the tension . PULLED OR NOT ! b . With your free hand , tighten ( turn clockwise ) the wing - nut . 18 . When at least and inch of wire sticks out past the end of the gun , release the trigger . c . Stop tightening when drag is felt on the wire spool that you are tuming , then stop hand 19 . Select a contact tip stamped withthe same wire turning the wire spool . diameter as the diameter of the wire being used . If stamped in metric , use the cross - refer - ence chart below . NOTE : If TOO MUCH tension is applied , the wire will slip on the drive roller or will not be able to be fed at all . If TOO LITTLE tension is applied , the spool of wire will want to unspool itself . Readjust U . S : Tip Size Metric Tip Size . . . . . the drive brake tenion as necessary to correct for either of these problems . . 6mm . 024 " . 030 " . 8mm 11 . After checking to make sure that your welder is . 035 " . gmm disconnected from the AC power source , free the leading - end of the wire from the spool , but 20 . Slide the contact tip over the wire ( protruding do not let go of it until told to do so , or the wire from the end of the gun ) , thread it into the end will unspool itself . of the gun , and hand tighten securely . t2 . Using a wire cutter , cut the bent end off the 21 . leading - end of the wire so that only a straight Install the nozzle on the end of the gun assem - leading - end remains . bly , then coat the inside of the nozzle with anti - stick spray or gel ( not supplied ) . 13 . Hold the tension arm up off the drive roller and insert the leading - end of the wire into the inlet 22 . Cut off excess wire that extends past the end guide tube . Then push it across the drive roller of the nozzle . and into the gun assembly about six inches . 23 . Set the wire drive tension . 14 . Line the wire up in the outside groove of the drive roller , then allow the drive tension arm to ARC FLASH CAN INJURE EYES ! To reduce risk drop onto the drive roller . of arc flash , make certain that the wire coming out of the end of the gun does not come in contact with 15 . Tighten ( turn clockwise ) the tension adjusting the ground clamp or any grounded material during screw until the tension roller is applying enough the drive tension setting process or arcing will force on the wire to prevent it from slipping out occu r . of the drive assembly . NOW YOU CAN LET GO OF THE WIRE . a . Pull the trigger on the gun . 16 . Plug the welder's powercord into the AC power b . Turn the drive tension adjustment knob source , turn the POWER SWITCH on the front clockwise ( to the right ) , increasing the drive of the welder to either HIGH or LOW , and set tension until the wire seems to feed the WIRE SPEED control to the middle of the smoothly without slipping . wire speed range . 17 . Pull the trigger on the welding gun to feed the c . Block the end of the nozzle by holding it up wire through the gun assembly . against something that doesn't conduct electricity , such as a block of wood or a ARC FLASH CAN INJURE EYES ! To reduce the concreate floor , then trigger the gun again . risk of arc flash , make certain that the welding wire , The wire should slip at the drive roller . How - ever , if the bird - nests at the drive roller , re - when it finally comes out of the endof the gun , does thread the drive system using less drive not touch the ground calmp or any grounded piece of metal . IMPORATANT ! The welding wire is car - tension and try again .
ASSEMBLY AND INSTALLATION Page 16 LL When set correctly , there should be no slippage between the wire and the drive teller under normal conditions , but if an obstruction occurs along the wire feed path , the wire should then slip on the drive roller . INSTALLING ALUMINUM WIRE Install aluminum wire the same as steel wire , but with the following exceptions . a . Select only . 030 " diameter wire of the 5356 aluminum alloy . Use a . 035 " contact tip , the composite rubber drive roller ( Part # 4324 ) , and teflon line ( Part # 4325 ) . b . Be sure to adjust the drive tension properly . Aluminum wire is very sensitive to slight changes in drive tension .
PREPARING TO WELD Page . 17 PREPARING TO WELD PREPARING A SAFE WELDING bystanders in the welding area . It is a must that the welding work area be cleared of all flammables WORK AREA and that a type ABC chemical fire extinguisher is always close at hand . READ The SAFETY INSTRUCTIONS ! They wilt ELECTRIC SHOCK CAN KILL ! tell you how to properly prepare for welding by : 1 . Preparing a safe welding work area . _ ] _ JD ] ARC RAYS CAN INJURE EYES AND 2 . Providing the necessary personal eye and skin BURN SKIN ! protection for you and all bystanders in the weld - ing area . 3 . Providing adequate ventilation , or respiration equipment if necessary , to protect you and any FIRE OR EXPLOSION CAN CAUSE bystanders in the welding area . DEATH , INJURY , AND PROPERTY DAMAGEI PREPARING THE WORK PIECE FUMES , GASSES , AND VAPORS CAN Much of the success in producing a quality weld CAUSE DISCOMFORT , ILLNESS , AND DEATH ! can be attributed to the preparation of the weld - joint area of the work piece . 1 . Clean the weld - joint area of dirt , rust , scale , oil , IMPROPER HANDLING AND MAIN - and / or paint . Failure to do so may result in a TENANCE OF COMPRESSED GAS CYLIN - porous , brittle weld . DERS AND REGULATORS CAN RESULT IN SERIOUS INJURY OR DEATHI , Select a type of joint appropriate for your appli - cation . The more popular types of welding joints DO NOT PROCEED TO PREPARE TO WELD are illustrated inthe TYPES OF JOINTS chart at until you read and understand each of the five the end of this section . parts of the SAFETY INSTRUCTIONS section in this manual . The SAFETY INSTRUCTIONS will NOTE : If you select a BUTT WELD JOINT , you tell you how to REDUCE THE RISKS OF DEATH , may have to prepare the edges of the metal to be INJURY , ILLNESS , DISCOMFORT , AND PROP - joined by grinding a bevel on the edges . ERTY DAMAGE to you , the bystanders in the welding area , and property in the vicinity of the welding area from SHOCK HAZARDS , FLASH GRINDING METAL CAN INJURE EYES ! To re - HAZARDS , FIRE HAZARDS , FUME HAZARDS , duce the risk of eye injury , ALWAYS wear goggles AND COMPRESSED GASSES AND EQUIP - and inspect the grinder to verify that it is in good MENT HAZARDS . condition before using . An important factor in making a satisfactory weld is During the welding process , the work pieces will preparation . This includes the study of the welding become hot and tend to expand causing the pieces process and equipment by the operator and then to shift from their initial position . If possible , it is practicing on scrap material before actual welding best if the work pieces can be securely clamped jobs are attempted . An organized , well - lighted work area should be available to provide comfort , ( before welding ) into the position desired after convenience , and safety to the operator and all welding is completed .
PREPARING TO WELD Page 18 450 PLATE 600PLATE BUTT WELD JOINTS 37.5 Â° SINGLE V JOINT SINGLE BEVELJOINT 6O0 BUTT JOINT DOUBLEV JOINT DOUBLE BEVEL JOINT 3 / 32 " TO 1 / 8 " 60 - - V I " - _ N ' _ ' ' r 1 / 16 " TO 1 / 8 " _ VEE JOINT CLOSED JOINT OPEN JOINT SHOUI . . _ ER EDGE 1 / 4 " OR MORE - - \ / FEATHER EDGE DOUBLE VEE JOINT 1 / 8 " OR MORE LET WELD JOINTS DOUBLE FILLET _ _ SINGLE FILLET LAP JOINT SINGLE FILLET T - JOINT DOUBLE FILLET T - JOINT SINGLE STRAP JOINT DOUBLE STRAP JOINT CONNECT WELDER GROUND ALUMINUM WELDING PREPARATION Attach the ground clamp to the work piece making sure that the work piece is cleaned of dirt , oil , rust , 1 . A clean weld - joint area is a must in obtaining a scale , oxidation , and paint at the point of connec - tion . quality aluminum weld . Remove dirt and oxida - tion with a stainless steel bristled wire brush and any oil or grease with a good chemical alumi - It is best to connect the ground clamp directly to the num cleaner . work piece and as close to the weld as possible . If it is impractical to connect the ground clamp di - rectly to the work piece , connect it to metal that is 2 . Aluminum is often anodized to prevent it from securely attached to the work piece , but not elec - oxidizing . However , and anodized surface will tricallyinsulated from it . Also , make sure thisother NOT conduct electricity . Therefore , to weld ano - metal is of about the same or greater thickness dized aluminum , you must sand or grind the than that of the work piece . anodized coating from the weld joint area and from the site where the ground clamp will be connected . RISK OF ELECTRONIC COMPONENT DAM - AGE ! If the ground clamp is being connected to an automobile or other equipment with on - board To determine if the aluminum you intend to weld is computer systems , solid state electronic controls , anodized , simply touch the two probes of an elec - solid state sound systems , etc . , DO NOT WELD trical continuity test light or ohmmeter to the alumi - until disconnecting the cable from the battery that num in question . The probes should be an inch or is attached to chassis ground . Failure to do so two apart . If there is no indication of electrical may result in ELECTRONIC COMPONENT DAM - AGE ! continuity , the aluminum IS anodized .
OPERATION Page 19 OPERATION " TUNING IN " THE WIRE SPEED is one of the GETTING TO KNOW YOUR NEW most important parts of MIG welder operation and WELDER must be done before starting each welding job or whenever any of the following variables are Whether you have welded before or not , it is impor - changed : heat setting , wire diameter , or wire type . tant that you become familiar with your new welder , its controls , and the results achieved at a . Set up and ground a scrap piece of the same different settings . We strongly recommend that type of metal that you will be welding , it you practice with your new welder on scrap metal should be equal to or greater than the thick - trying different heat settings , base metal thick - ness of the actual work piece and free of nesses , and welding positions for each type and paint , oil , rust , etc . size of wire that you will be using . By doing this you will gain a feel for how changes in these b . Select a heat setting . welding variables affect the weld . c . Hold the gun in one hand atlowing the nozzle Of course , if you have not MIG welded before , you to rest on the edge of the work piece farthest will need to develop welding skills and techniques away from you and at an angle similar to that as well . The self - taught welder learns through a which will be used when actually welding . process of trial and error . The best way to teach yourself how to weld is with short periods of prac - d . With your free hand , turn the WIRE SPEEDold tice at regular intervals . control to maximum and continue to h onto the knob . DO NOT ATTEMPT TO WELD on any valuable ARC RAYS CAN INJURE EYES AND BURN equipment until you have made practice welds on scrap metal that can be discarded . The scrap SKINI To reduce risk of injury from arc rays , never metal should be of the same type and thickness as strike a welding arc until you and all bystanders in that of the item to be welded . Only after you are the welding area have welding helmets or shields satisfied that your practice welds are of good in place and are wearing the recommended pro - strength and appearance , should you attempt your tective clothing . DO NOT CONTINUE unless you actual welding job . have read , understand , and intend to follow the entire SAFETY INSTRUCTIONS section of this manual . SETTING THE CONTROLS e , Lower your welding helmet and pull the trig - 1 . The POWER SWITCH has three settings : LOW , ger on the gun to start an arc , then begin to OFF , and HIGH . When in the OFF position , drag the gun toward you while turning down on the WIRE SPEED control knob at the power is disconnected from all welder functions . same time . The LOW position is selected for welding steel thicknesses of 16 gauge or thinner . The HIGH position is selected for steel thicker than 16 LISTEN ! As you decrease the wire speed , gauge . The variables that affect the heat selec - the sound that the arc makes will change tor setting are wire type and size , base metal from a sputtering to a smooth , high - pitched type and thickness , and desired penetration . buzzing sound and then will begin sputtering again if you decrease the wire speed too far . 2 . The WIRE SPEED CONTROL is variable from SLOW to FAST . To achieve successful welding Selecting the best wire speed setting is much the same as " tuning in " a radio : continue decreasing results , it is important that the wire be fed at the the wire speed until the arc noise passes the best - same rate it is being melted off into the weld sounding , high - pitched buzz and begins to sputter puddle ; if too fast the wire will tend to push the again , then turn the WIRE SPEED control the gun away from the work piece and if too slow , opposite direction until you come back to the best the wire will bum back into , and may damage sounding arc noise . The welder is now " tuned in " the contact tip . In either case , an extremely and welding can begin . poor weld will result .
OPERATION Page 20 REPEAT THIS TUNE - IN PROCEDURE if you se - 2 . Angle " B " can be varied for two reasons : to lect a new heat setting , a different diameter _ vire , improve the ability to see the arc in relation to the weld puddle and to directthe force of the arc . or a different type wire . The force of the welding arc follows a straight tine NOTE : When " tuning - in " the wire speed for self - out the end of the no > > te . If angle " B " is changed , shielding flux - core wire , you will find a very wide so will the direction of the arc force and the point at " best - sounding range " , spanning as much as 60 which penetration will be concentrated . degrees on the WIRE SPEED contro ! . It is impor - tant to know that the heat of the arc and penetra - On a butt weld joint , the only reason to vary angle tion into the base metal increases as the wire " B " from being perpendicular ( straight up ) to the speed is increased within the " best - sounding work piece would be to improve visibility of the range " for a given heat setting . weld puddle . In this case , angle " 13 ' can be varied anywhere from zero to 45 degrees with30 degrees Therefore , you can use the wire speed control to working about the best . slightlyincrease or decrease heat and penetration for a given heat settingby selecting higher or lower wire speed settings WITHIN the _ est - sounding range " . 30 Â° , , , , _ P I I , _ _ v , ' * " ! \ I HOLDING THE GUN ! I The best way to hold the welding gun is the way ! t that feels most comfortable to you . While practic - ! ing to use your new welder , experiment holding the ! gun in different positions untilyou find the one that â¢ ! seems to work best for you . Position of the Gun to the Work Piece Angle A There are two angles of the gun nozzle in relation to the work piece that must be considered when On a fillet weld joint the nozzle is generally posi - welding . tioned in such a manner so as to " split " the angle between the horizontal and vertical members of the weld joint . In most cases , a fillet weld joint is a 1 . Angle " A " can be varied , but in most cases the optimum angle will be 60 degrees ; the point at 90 degree angle so angle " 13 " will most often be 45 which the gun handle is parallel to the work degrees . piece . If angle " A " is increased , penetration will increase . If it is decreased , so will penetration . 45 " . . - - - _ . f / % % % l 8oii I 1 = = lllliHi . . . . . . . . . . . . . . . . . . = = lHi , lllllll Angle B i J ,
OPERATION Page 21 Distance from the Work Piece Once you have the gun in position with the wire lined up on the weld joint , lower your helmet , pull The end of the welding gun is designed with the the trigger and the arc will start . In a second or contact tip recessed from the end of the nozzle and two , you will notice a weld puddle form and the the nozzle electrically insulated from the rest of the base of a bead beginning to build . It is now time to gun . This permits the operator to actually rest the begin to travel with the gun . If you are just learning nozzle on and drag it along the work piece while to weld , travel by simply dragging the gun in a welding . This can be very helpful to beginning straight line and at a steady speed along the weld welders to steady the gun , allowing the welder to joint . Try to achieve a weld with the desired pene - concentrate on welding technique . If the nozzle is tration and a bead that is faidy fiat and consistant inwidth . held off the work piece , the distance between the nozzle and the work piece should be kept constant and should not exceed 1 / 4 " or the arc may begin CLEANING THE WELD BEAD sputtering , signaling a toss in welding perform - ance . When using solid wire and shielding gas , cleaning of the weld bead is not normally necessary . How - LAYING A BEAD ever , when welding with self - shielding flux - core wire , slag is deposited on the top of the weld bead . ARC RAYS CAN INJURE EYES AND BURN This slag consists of the flux from the welding wire SKIN ! To reduce the risk of injury from arc rays , as well as any impurities the flux was able to never start a welding arc until you and all bystand - remove from the molten weld puddle . ers in the welding area have welding helmets or shields in place and are wearing the recom - This slag must be cleaned from the weld bead both mended protective clothing . DO NOT CONTINUE for cosmetic reasons and to visually inspect the unless you have read , understand , and intend to finished weld bead . Cleaning the weld bead is follow the entire SAFETY iNSTRUCTIONS sec - done best with a chipping hammer followed by a tion of this manual . wire brush . Slag must also be cleaned from a weld bead that IMPORTANT ! The wire in this welder is always electrically energized whenever the switch is not in was stopped in the middle and now will be restart - the OFF position , and will arc whenever brought ed from the point at which it was stopped . A poor weld will result when a weld bead is started or laid into contact with any electrically conductive mate - rials that the ground clamp of the welder is con - on a weld bead that has not been cleaned of slag . nected to or in contact with . CHIPPING AND BRUSHING SLAG CAN INJURE Therefore , it is best to clip the wire back to the EYES ! To reduce the risk of eye injury from flying contact tip so that you don't create an arc when slag , always have eye protection such as goggles , lining up on the seam to be welded . in place prior to chipping slag .
WELDING TECHNIQUES Page 22 WELDING TECHNIQUES . As you become more familiar with your new welder TRAVEL SPEED is the rate at which the gun is and better at laying some simple weld beads , you being " pushed " or " pulled " along the weld joint . can begin to try some different welding techniques For a fixed heat setting , the faster the travel to improve and add versatility to your welding speed , the lower the penetration and the lower skills . and narrower the finished weld bead . Likewise , the slower the travel speed , the deeper the penetration and the higher and wider the fin - TRAVELING WITH THE GUN ished weld bead . Gun travel refers to the movement of the gun along TYPES OF WELD BEADS - 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 1 . The STRINGER BEAD is formed by traveling right speed along the weld joint . Moving the gun with the gun in a straight line while keeping the too fast , too slow , or irratically will prevent proper wire and nozzle centered over the weld joint . fusion or create a lumpy , uneven bead . This is the easiest type of bead to make and is the type you have been using up to this point . 1 . TRAVEL DIREC - TION is the direction PULLING the gun is moved along the weld joint in relation to the weld puddle . The gun is either PUSHED into PUSHING the weld puddle or PULLED away from the weld puddle . For most welding jobs you will " pull " the gun along the weld joint to take advantage of the greater weld puddle visability . However , there are a few applications where " pushing " the gun may provide some advantages : 2 . The WEAVE BEAD is used when you want to deposit metal over a wider space than would be VERTICAL WELDING can be done by starting at possible with a stringer bead . ' It is made by the top of a weld joint and " pulling " the gun down weaving from side to side while traveling with toward the bottom . However , in the event that the gun . It is best to hesitate momentarily at puddle control becomes difficult ( such as the pud - each side before weaving back the other way . dle wanting to " run " downward ) , starting a vertical weld at the bottom of a weld joint and " pushing " the gun up toward the top will help to overcome this problem . ALUMINUM WELDING can be done using either direction of gun travel , but " pushing " will leave a weld that is cleaner in appearance . " Pulling " the gun will leave a sooty weld since the finished weld is always being blasted by the arc and the impuri - ties coming out of the weld puddle . This problem affects the weld appearance only and the weld can be cleaned up with a stainless steel bristled wire brush .
WELDING TECHNIQUES Page 23 = WELDING POSITIONS The VERTICAL POSITION is the next most difficult position . " Pulling " the gun from top to bottom may be easier for many people , but in There are four basic welding positions : fiat , hori - some instances it can be difficult to prevent the zontal , vertical , and overhead . puddle from " running " downward . " Pushing " the gun from bottom to top may provide better pud - dle control and allow slower rates of travel 1 . The FLAT POSITION is the easiest of the weld - speed to achieve deeper penetration . When ing positions and is probably the one you have vertical welding , angle " B " ( see POSITION OF been using thus far . It is best if you can weld in GUN TO THE WORK PIECE above ) is usually the fiat position if at all possible as good results always kept at zero , but angle " A " wil ! generally are easier to achieve . range from 45 to 60 degrees to provide better puddle control . 2 . The HORIZONTAL PosmoN is next in diffi - , The OVERHEAD POSITION is the most difficult culty level . It is performed very much the same welding position because gravity is pulling at the as the flat weld except that angle " B " ( see PO - weld puddle trying to make it drip off the work SITION OF THE GUN TO THE WORK PIECE piece . Angle = A " ( see POSITION OF THE GUN above ) is such that the wire , and therefore the TO THE WORK PIECE above ) should be main - arc force , is directed more toward the metal tained at 60 degrees , the same as in the flat above the weld joint . This is to help prevent the position . Maintaining this angle will reduce the weld puddle from " running " downward while still chances of molten metal falling into the nozzle allowing slow enough travel speed to achieve should it drip from the weld puddle . Angle " B " good penetration . A good starting point for an - should be held at zero degrees so that the wire gle " B " is about 30 degrees DOWN from being is aiming directly into the weld joint . If you expe - perpendicular to the work piece . rience 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 .
WELDING TECHNIQUES Page 24 MULTIPLE PASS WELDING , , , , , , , , , , , , , , , , , 1 . Butt Weld Joints In PREPARING THE WORK PIECE , we discussed First or Root Pass the need for edge preparation on thicker materials by grinding a bevel on the edge of one or both pieces of the metal being joined . When this is done , a ' _ / " 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 layed into the joint to close the " V " . Laying more than one bead into the same weld joint is known as a " multiple - pass " weld . Second Pass The illustrations , on this page , 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 off each completed weld bead Third Pass before making another pass or the next pass will be of poor quality . 2 . Fillet Weld Joints Most fillet weld joints , on metals of moderate to heavy thickness , will require multiple pass welds to produce a strong joint . The illustrations below Finished Weld show the sequence of laying multiple pass beads into a " T " fillet joint and a lap fillet joint . I I i1 _ III I iiii ii i ill iii ii iiii I i iiiii Lap - Joint eweldeds T - Joint in three Passes in three Pass
SPECIAL WELDING METHODS Page 25 SPECIAL WELDING METHODS SPOT WELDING and the arc is directed through this hole to pene - trate into the bottom piece . The puddle is al - lowed to fill up the hole leaving a spot weld that is smooth and flush with the 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 . BURN THROUGH PUNCH AND FILL 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 . LAP SPOT Select the wire diameter , heat setting , and = tune - in " the wire speed as if you were welding the same The purpose of a spot weld is to join pieces of thickness material with a continuous bead . metal together with a " spot " of weld instead of a continuous weld bead . There are three methods of spot welding : Bum - Through , Punch and Fill , and Lap . Each has advantages and disadvantages SPOT WELDING INSTRUCTIONS depending on the specific application as well as personal preferance . 1 . Select the wire diameter and heat setting rec - 1 . The BURN - THROUGH METHOD welds two ommended above for the method of spot weld - overlapped pieces of metal together by burning ing you intend to use . through the top piece and into the bottom piece . With the burn - through method , larger wire diame - ters tend to work better than smaller diameters 2 . Tune in the wire speed as if you were going to make a continuous weld . because they have greater current carrying ca - pacities allowing the arc to burn through very quickly while leaving a minimal amount of filler metal build up . . 030 " diameter solid wire or . 035 " 3 . Hold the nozzle piece completely perpendicular self - shielding flux - core wire tend to work the best . to and about 1 / 4 " off the work piece , . 024 " diameter solid and . 030 " self - shielding flux - core wires should not be used with the bum - 4 . Pull the trigger on the gun and release it when it through method unless the metal is VERY thin or appears that the desired penetration has been excessive filler metal build - up and minimal pene - achieved . tration is acceptable . Always select the HIGH heat setting with the burn - 5 . Make practice spot welds on scrap metal , vary - through method and " tune - in " the wire speed prior ing the length of time you hold the trigger , until a to making a spot weld . desired spot weld is made . 2 . The PUNCH AND FILL METHOD produces a weld with the most " finished " appearance of the 6 . Make spot welds on the actual work piece at three spot weld methods , tn this method , a hole desired locations . is punched or drilled into the top piece of metal
MAINTENANCE AND TROUBLESHOOTING Page 26 MAINTENANCE AND TROUBLESHOOTING GENERAL MAINTENANCE b . Remove wire from gun assembly and gun assembly from welder . This welder has been engineered to give many years of trouble - free service providing that a few c . Remove nozzle and contact tip from gun very simple steps are taken to properly maintain it . d . Loosen set screw holding liner collet in place 1 . Keep the wire drive compartment lid closed at all at rear of gun . times unless the wire needs to be changed or the drive tension needs adjusting . e . Lay gun assembly out in a straight line . 2 . Keep all consumables ( contact tips , nozzles , and gun liner ) clean and replace when neces - sary . See CONSUMABLE MAINTENANCE AND TROUBLESHOOTING later in this section for detailed information . 3 . Replace powercord , 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 , f , Holding rear of gun assembly , grasp liner remove the side panels from the welder and collet and pull liner out of gun assembly . air - blow any dust and dirt that may have accu - mulated inside the welder . Insert new liner into gun assembly and push g Â° ELECTRIC SHOCK CAN KILL ? To reduce risk of all the way through being careful not to kink the liner . The excess liner wilt protrude from electric shock , always unplug the welder from its the end of the gun . AC power source before removing side panels . CONSUMABLE MAINTENANCE h , With the gun assembly lying in a straight AND TROUBLESHOOTING line , mark the liner at the end of the gun's gas diffuser . IT IS VERY IMPORTANT TO MAINTAIN THE CONSUMABLES TO AVOID THE NEED FOR Hold the gun handle firmly in place , then PREMATURE REPLACEMENT OF THE GUN gently pull outward on the excess liner so ASSEMBLY . that the mark you made is about 118 " out past the end of the gas diffuser . 1 . The GUN LINER is intended to provide an unre - stricted path for the welding wire to flow through Using a wire cutter , cut the liner at the end of the gun assembly . Over time it will accumulate the gas diffuser so that the liner ends up dust , dirt , and other debds . Replacement is recessed into the gas diffuser about 1 / 8 " , then necessary when these accumulations begin to use a file to remove any burrs on the liner restrict the free flow of wire through the gun where the cut was made . assembly . k . Tighten the set screw , but DO NOT OVER TO REPLACE A GUN LINER : TIGHTEN or damage to the collet may re - sult . When removing or installing a gun liner , care must be taken not to kink or otherwise damage it or 1 . Reinstall gun assembly into welder ( see IN - replacement will be necessary . STALL WELDING GUN ASSEMBLY in the ASSEMBLY AND INSTALLATION section ) . a . Turn POWER SWITCH to the OFF position .
MAINTENANCE AND TROUBLESHOOTING Page 27 2 . The CONTACT TIP's purpose is to transfer TESTING FOR A SHORTED NOZZLE welding current to the welding wire while allow - ing the wire to pass through it smoothly . Arcing between the nozzle and the work piece ALWAYS means the nozzle is shorted , but this can a . Always use a contact tip stamped with the be hard to detect through the lens of a welding same diameter as the wire it will be used helmet . The following testing method is another with . way to tell if a nozzle is shorted . b _ If the wire burns back into the tip , remove the With the welder unplugged from the AC power tip from the gun and clean the hole running source , touch the probes of an ohmmeter or conti - through itwith an oxygen - acetylene torch tip nuity tester to the end of the contact tip and the cleaner . This is especially important to do after an aluminum wire burn - back . outside of the nozzle . If there is any continuityat all , the nozzle IS shorted . Clean or replace as needed . C , 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 TROUBLESHOOTING efficient is the transfer of welding current to the wire and eventually arc breakage and difficult arc starting will result . Replace con - The following TROUBLESHOOTING section is tact tips when signs of wear become appar - provided as a guide to help resolve some of the ent . more common problems that could be encoun - tered . Should you or qualified repair personnel be 3 . The NOZZLE prevents the electrically " hot " con - unable to resolve a problem or determine which of tact tip from contacting the work piece . the possible solutions will remedy a specific prob - lem , contact MIG WELDER SERVICE for over - the - phone diagnostic assistance at : KEEP THE NOZZLE CLEAN ! During the welding ( 800 ) - 328 - 2921 . In Minnesota call : ( 612 ) 884 - process , spatter and slag will build up inside the 3211 . nozzle and must be cleaned out periodically . a . Always coat the inside of a new or freshly BEFORE CALLING MIG WELDER SERVICE , cleaned nozzle with anti - stick spray or gel . have the welder unplugged from the AC power source , the side panels removed , and the tele - b . Stop welding and clean any accumulated phone as near to the welder as possible . slag or spatter from the nozzle every 5 to 10 minutes of welding time . C * When welding overhead , if any molten metal ELECTRIC SHOCK CAN KILL ! drips from the weld puddle and falls into the nozzle , STOP WELDING IMMEDIATELY and clean the nozzle . _ ARC RAYS CAN INJURE EYES AND d . If the slag cannot be thoroughly cleaned from the nozzle , REPLACE THE NOZZLE ! BURN SKIN ! Failure to keep the nozzle adequately cleaned can result in a SHORTED NOZZLE which results when spatter build - up bridges the insulation in the nozzle FIRE OR EXPLOSION CAN CAUSE allowing welding current to flow through it as well as the contact tip . When shorted , a nozzle will DEATH , INJURY , AND PROPERTY DAMAGE ! steal welding current from the wire whenever it contacts the grounded work piece . This causes erratic welds and reduced penetration . In addition , a shorted nozzle overheats the end of the gun FUMES , GASSES , AND VAPORS CAN which can DAMAGE the gas diffuser and / or con - ductor tube . CAUSE DISCOMFORT , ILLNESS , AND DEATH !
MAINTENANCE AND TROUBLESHOOTING Page 28 In the following TROUBLESHOOTING table , a POSSIBLE CAUSE , listed for certain problems , is INSUFFICIENT SHIELDING GAS COVERAGE . IMPROPER HANDLING AND MAINTE - This " cause " itself can be the result of many differ - NANCE OF COMPRESSED GAS CYLINDERS ent causes . Below , and preceeding the TROU - AND REGULATORS CAN RESULT IN SERIOUS BLESHOOTING table , is a table listing the causes INJURY OR DEATH ! and solutions for insufficient shielding gas cover - age . All of these causes have one or more of the DO NOT ATTEMPT TO TROUBLESHOOT THIS following symptoms : a weed that is dirty , porous , WELDER unless you have read , understand , and brittle , and / or non - penetrating . intend to follow all five parts of the SAFETY IN - STRUCTIONS section of this welder . DISCONNECT THE WELDER FROM THE AC POWER SOURCE BEFORE A'I'rEMPTING ANY INSPECTION OR WORK ON THE INSIDE OF THE WELDER . BASIC TROUBLESHOOTING GUIDE REMEDY POSSIBLE CAUSE SYMPTOM Open gas valve Gas cylinder valve turned off DIRTY , POROUS , BRITTLE WELD Replace gas cylinder Gas cylinder empty or near empty Tighten fitting Loose gas supply - line fittings Replace hose Gas supply hose leaking Clean or replace nozzle or Plugged welding nozzle clean gas diffuser or gas diffuser Thaw regulator / flowmeter and Frozen regulator / flowmeter change gas from CO2 to a mix ( see selecting shielding gas ) Broken or defective Have repaired or replace regulator / flowmeter Change polarity Wrong polarity
MAINTENANCE AND TROUBLESHOOTING Page 29 ii Gas flow rate too low DIRTY , POROUS , BRITTLE Increase flow rate from WELD regutator / flowmeter Wind or draft blowing gas Try Increasing flow rate or set away from weld puddle up wind break Wrong type of gas See select shielding gas WIRE FEED AND GAS Bad ground or Check ground or tighten all WORKS , BUT NO ARC loose connection connections Bad connection to gun Check connection to gun or or faulty gun replace gun GAS AND ARC WORK BUT Faulty wire speed circuit Replace wire speed circuit NOT WIRE FEED board / potentiometer board / potentiometer No tension on driver roller Adjust drive tension Faulty drive motor Replace drive motor ( extremely rare ) WIRE FEED AND ARC Faulty solenoid switch Replace solenoid switch BUT NO GAS Faulty regulator / fiowmeter Have repaired or replace regulator / flowmeter Gas bottle empty Replace gas bottle Clogged nozzle or gas diffuser Clean or replace as needed NOTHING WORKS BUT Faulty trigger on gun Replace trigger FAN IS ON
MAINTENANCE AND TROUBLESHOOTING Page 30 i ii ir Allow welder to cool at least 10 NOTHING WORKS BUT Exceeded duty cycle ; thermal FAN IS ON minutes with fan running protector opened circuit ( observe duty cycle ) Replace rectifier Faulty rectifier Replace transformer Faulty transformer ( extremely rare ) Blow inside of machine out LOW OUTPUT OR Loose connection inside the machine NON - PENETRATING WELD with compressed air clean and tighten all connections See manual under Too long or improper extension cord extension cord use Check manual for proper Wrong type or size of wire wire size or type Check manual and change gas Wrong type of gas or no gas Reposition clamp and check Poor ground connection cable to clamp connection Change polarity Wrong polarity Use proper size tip Wrong size contact tip Tighten gun connection Loose gun connection or replace gun or faulty gun assembly WtRE " BIRDNESTING " AT Too much tension Adjust drive tension DRIVE ROLLER on drive roller ( see manual ) See gun assemblyual Gun assembly not completely instruction in man seated into drive assembly
MAINTENANCE AND TROUBLESHOOTING Page 31 . . . . . i lllllll iii . . . . . . . i i WIRE " BIRDNESTING " AT Gun liner worn or damaged Replace liner DRIVE ROLLER Replace contact tip Contact tip is clogged or damaged Trim liner to proper length Liner stretched or too long Using aluminum wire with a Replace liner with teflon liner steel liner ( Part # 4325 ) Using aluminum wire with a Replace drive roller with a steel drive roller rubber drive roller ( Part # 4324 ) WIRE BURNS BACK TO Gun liner worn or damaged Replace liner CONTACT TIP Liner stretched or too long Trim liner to proper length Wrong size contact tip Use correct size contact tip Contact tip clogged Replace contact tip or damaged Using aluminum wire with a Replace liner with teflon liner steel liner ( Part # 4325 ) Using aluminum wire with a Replace ddve roller with a steel drive roller rubber drive roller ( Part # 4324 ) Problems feeding See installing aluminum wire aluminum wire in manual CONSTANT GAS FLOW Replace solenoid Faulty solenoid or debris in solenoid
MAINTENANCE AND TROUBLESHOOTING Page 32 = = = = llll , Check connections and FAN MOTOR DOES NOT RUN Loose connection or replace fan motor if needed faulty motor Bad connection from GROUND CLAMP AND / OR Tighten connection or CABLE GETS HOT cable to clamp replace cable GUN NOZZLE ARCS TO Slag buildup inside nozzle Clean nozzle or replace nozzle WORK SURFACE or nozzle shorted
REPLACEMENT PARTS LIST Page 33 REPLACEMENT PARTS LIST ii i iin i 10 PART No . ITEM DESCRIPTION ITEM DESCR | ! _ TION PART No . 1 Rectifier 410 - 694 - 020 860 - 905 - 666 21 Faceplate 2 Fan Motor Kit 216 - 087 - 666 22 880 - 094 - 666 Wire Speed Control 3 Fan Blade 316 - 009 - 666 23 Knob 246 - 041 - 666 312 - 076 - 666 ! 24 Power Switch 4 Sjoindle 246 - 177 - 6 _ 312 - 077 - 666 25 433t Steel Uner , 5 Spindle Adaptor Teflon Uner 4325 6 Power Cord w / Strain Relief 248 - 197 - 666 26 860 - 744 - 000 Gun Wiring Harness 253 - 018 - 666 27 238 - 224 - 100 7 Fitting _ , Complete Gun Assembly 8 Solenoid 246 - 212 - 666 28 334 - 221 - 000 TriQaer Assembly 253 - 038 - 000 29 334 - 219 - 000 . . . . . . 9 . . . . Fitting . . . . . . Handle Cap Conductor Tube Insulation 334 - 269 - 000 10 Drive Roller , Q24 / 03,0 / . 035 4323 30 880 - 089 - 666 31 334 - 228 - 000 11 Tension Arm iGas Diffuser 12 Inlet Guide Tube 239 - 123 - 666 32 4309 . 024 Contact liDS ( Bag of 6 ) 13 Drive Base 312 - 103 - 666 33 4328 Steel Nozzle ( Tapered ) , 4329 Spot Nozzle ( . Notched . ) 14 Drive Motor 216 - 089 - 666 34 Base 410 - 643 - 010 412 - 465 - 666 35 238 - 216 - 666 15 Mig Gun Connector Ground Cable Less Clamp 16 Knob 246 - 326 - 000 36 Transformer 880 - 011 - 888 Reactor Coil 880 - 010 - 888 17 Mig Connector Jumper 412 - 464 - 666 37 18 Handle 880 - 012 - 010 38 ( Not Shown ) Left Side Panel 410 - 557 - 030 412 - 278 - 010 39 19 Hood Hinge ( Not Shown ) Hood 410 - 575 - 010 410 - 568 - 030 40 20 Right Side & Cover ( Not Shown ) Regulator 332 - 226 - 000
WARRANTY Page 34 WARRANTY FULL 1 - YEAR WARRANTY If , within 1 - year from the date of purchase , this Welder fails due to a defect in material or work - manship , simply return it to the nearest Sears store throughout the United States , and Sears wilt repair or replace it , free of charge . This warranty gives you specific legal rights , and you may also have other rights which vary from state to state . Sears , Roebuck and Co . , Dept . 817WA Hoffman Estates , IL 60179 . SERVICING SHOULD BE PERFORMED BY QUALIFIED SERVICE PERSONNEL 1 . PART NUMBER The Model Number will be found on the welder 2 . PART DESCRIPTION nameplate . Always mention the Model Number 3 . MODEL NUMBER when requesting service or repair parts for your 4 . NAME OF ITEM Sears Welder . If the parts you need are not stocked locally , your All parts listed herein may be ordered from any order will be electronically transmitted to a Sears Sears Service Center and most Sears stores . Repair Parts Distribution Center for expedited handling . WHEN ORDERING REPAIR PARTS , ALWAYS GIVE THE FOLLOWING INFORMATION : SEARS ROEBUCK AND CO . , Chicago , IL . 60684 U . S . A . FORM NO . 811 - 449 - 000 PRINTED IN USA