Craftsman 93420105 User Manual WELDER Manuals And Guides L0803454

CRAFTSMAN Welder Manual L0803454 CRAFTSMAN Welder Owner's Manual, CRAFTSMAN Welder installation guides

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. EAR$

OWNERS

MANUAL

MODEL No.

934.20105

CAUTION:

Read Rules for

Safe Operation

and Instructions

Carefully

811-309-000

MANUAL

WIRE FEED

MIG WELDER

Operation

Repair Parts

811-309-000

SEARS ROEBUCK AND CO., CHICAGO, IL 60684 U.S.A.

Table of Contents

IMPORTANT SAFETY INSTRUCTIONS 1

SHOCK HAZARDS ......................... 1

FLASH HAZARDS ......................... 2

FIRE HAZARDS ........................... 2

FUME HAZARDS .................... ...... 3

COMPRESSED GASSES AND EQUIPMENT HAZ-

ARDS ................................... 3

ADDITIONAL SAFETY INFORMATION ......... 4

PRODUCT DESCRIPTION 5

SPECIFICATIONS ......................... 5

WELDER CONTROLS AND THEIR FUNCTIONS. 5

DUTY CYCLE ............................. 5

INTERNAL THERMAL PROTECTION .......... 5

ASSEMBLY AND INSTALLATION 6

UNPACKING YOUR WELDER ................ 6

INSTALL THE GROUND CLAMP .............. 6

INSTALL WELDING GUN ASSEMBLY .......... 7

PROVIDE REQUIRED POWER ............... 7

Power Requirements ....................... 7

Connect Welder to Power Source ............. 8

Extension Cord Use ........................ 8

INSTALL TANK TRAY AND BRACKET .......... 8

SELECT SHIELDING GAS ................... 9

Gas Selection For Steel Welding With Steel Wire. 9

Gas Selection for Aluminum Welding .......... 9

Gas Selection for Stainless Steel Welding ...... 9

Gas Selection for Steel Welding

with Silicon-Bronze Wire .................... 10

INSTALL THE SHIELDING GAS ............... 10

CHECKING GAS FLOW ..................... 11

SELECT WELDING CURRENT POLARITY ...... 11

SELECT THE WELDING WIRE ............... 11

Selecting the Type of Wire ................... 11

SELECT THE SPOOL SIZE .................. 12

Wire Spool Storage ........................ 13

Select the Wire Diameter .................... 13

INSTALL THE WELDING WIRE ............... 13

Changing the Drive Roller ................... 13

INSTALLING ALUMINUM WIRE .............. 16

PREPARING TO WELD 17

PREPARING A SAFE WELDING WORK AREA.. 17

PREPARING THE WORK PIECE ............. 17

ALUMINUM WELDING PREPARATION ........ 18

CONNECT WELDER GROUND .............. 18

OPERATION 19

GETTING TO KNOW YOUR NEW WELDER .... 19

SETTING THE CONTROLS ................. 19

HOLDING THE GUN ....................... 20

Position of the Gun to the Work Piece ......... 20

Distance from the Work Piece ............... 21

LAYING A BEAD .......................... 21

CLEANING THE WELD BEAD ............... 21

WELDING TECHNIQUES 22

TRAVELING WITH THE GUN ................ 22

TYPES OF WELD BEADS .................. 22

WELDING POSITIONS ..................... 23

MULTIPLE PASS WELDING ................. 24

SPECIAL WELDING METHODS 25

SPOT WELDING .......................... 25

SPOT WELDING INSTRUCTIONS ............ 25

MAINTENANCE AND TROU-

BLESHOOTING 26

GENERAL MAINTENANCE ....... .......... 26

CONSUMABLE MAINTENANCE AND TROU-

BLESHOOTING .......................... 26

TESTING FOR A SHORTED NO72'LE ......... 27

TROUBLESHOOTING ...................... 27

REPLACEMENT PARTS LIST 33

WARRANTY 34

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!

I_:_l ARC RAYS CAN INJURE EYES AND

BURN SKIN!

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

body is wet.

NEVER allow the welding equipment to come in

contact with water or moisture.

FIRE OR EXPLOSION CAN CAUSE

DEATH, INJURY, AND PROPERTY DAMAGE!

FUMES, GASSES, AND VAPORS CAN

CAUSE DISCOMFORT, ILLNESS, AND DEATH!

IMPROPER HANDLING AND MAIN-

TENANCE OF COMPRESSED GAS CYLIN-

DERS AND REGULATORS CAN RESULT IN

SERIOUS INJURY OR DEATH!

IMPORTANT! DO NOT ATTEMPT OPERATION

of this welding equipment until reading and under-

standing the following safety instructions to reduce

risk of DEATH, INJURY, AND PROPERTY DAM-

AGE.

SHOCK HAZARDS

ELECTRIC SHOCK CAN KILL! To reduce risk of

death from electric shock, read, understand, and

follow the following safety insructions. In Addition,

make certain that anyone who uses this welding

equipment or is a bystander in the welding area

understands and follows these safety instructions

as well.

NEVER Stand, Sit, Lie, Lean On, Touch, or come

into physical contact in any way with any part of the

welding current circuit including:

the work piece or any conductive material in con-

tact with it. The ground clamp. The electrode

NEVER drag welding cables (or MIG gun assem-

bly) or weld powercord through or allow them to

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

any part of body or clothing is wet or damp, or if

standing in or in physical contact of any kind with

water or moisture.

NEVER connect welder ground clamp to or weld

on electrical conduit.

NEVER alter powercord or powercord plug in any

way.

NEVER attempt to plug welder into powersource if

ground prong on powercord plug is bent over,

broken off, or missing.

NEVER allow welder to be connected to power-

source or attempt to weld if welder, welding cables

(or MIG gun assembly), welding site, or welder

powercord are exposed to rain, snow, sleet, mist,

fog or other forms of atmospheric precipitation or

mist or spray off an ocean or other body of water.

NEVER carry coiled welding cables around shoul-

ders, or any other part of the body, when they are

plugged into the welder.

NEVER modify any wiring, ground connections,

switches, or fuses in this welding equipment.

ALWAYS wear welding gloves to help insulate

hands from welding circuit.

IMPORTANTSAFETYINSTRUCTIONSPage2

ALWAYSkeep containers of water or other liquids

far enough away from welder and work area so that

if spilled, the liquid could not possibly come in contact

with the welder, welding cables (or MIG gun assem-

bly), welder powercord, the workpiece being welded,

or any other part of the electrical welding circuit.

ALWAYS replace any cracked or damaged parts

that are insulated or act as insulators such as

welding cables (or MIG gun assembly), or power-

cord IMMEDIATELY.

FLASH HAZARDS

ARC RAYS CAN INJURE EYES AND BURN

SKIN! To reduce risk of injury from arc rays, read

understand and follow the following safety insrtuc-

tions. 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

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,

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.

NEVER strike awelding arc until all bystanders

and you (the welder) have welding shields and/or

helmets in place.

NEVER wear acracked or broken helmet and

replace any cracked or broken filter lenses IMME-

DIATELY.

ALWAYS provide bystanders with shields or hel-

mets fitted with a number 10 shade filter lens.

ALWAYS wear protective clothing. The intense

light of the welding arc can bum the skin in much

the same way as the sun, even through light-

weight clothing. Wear dark clothing of heavy mate-

rial. The shirt worn should be long sleeved and the

collar kept buttoned to protect chest and neck.

ALWAYS protect against REFLECTED ARC

RAYS. Arc rays can be reflected off shiny surfaces

such as a glossy painted surface, aluminum, stain-

less steel, and glass. It is possible for your eyes to

be injured by reflected arc rays even when wearing

aprotective helmet or shield. If welding with a

reflective surface behind you, arc rays can

"bounce off" the surface, then off the filter tens on

the inside of your helmet or shield, then into your

eyes. If a reflective background exists in your weld-

ing area, either remove it or cover it with something

nonflammable and non-reflective. Reflective arc

rays can also cause skin burn in addition to eye

injury.

FIRE HAZARDS

FIRE OR EXPLOSION CAN CAUSE DEATH, IN-

JURY, AND PROPERTY DAMAGE! To reduce

risk of death, injury, or property damage from fire

or explosion, read, understand, and follow the fol-

lowing safety insrtuctions. In addition, make cer-

tain that anyone else that uses this welding

equipment, or is a bystander in the welding area,

understands and follows theses safety instructions

as well. REMEMBERI Arc welding by nature pro-

duces sparks, hot spatter, molten metal drops, hot

slag, and hot metal parts which can start fires, burn

skin and damage eyes.

NEVER wear gloves or other clothingthat contain

oil,grease, or other flammable substances.

NEVER wear flammable hair preparations.

NEVER weld in an area until it has been checked

and cleared of combustable and/or flammable ma-

terials. BE AWARE that sparks and slag can fly 35

feet and can pass through small cracks and open-

ings. If work and combustibles cannot be sepa-

rated by a minimum of 35 feet, protect against

ignition with suitable, snug-fitting, fire resistant

covers or shields.

NEVER weld on walls until checking for and remov-

ing combustibles touching the wall on the other side.

NEVER weld, cut, or perform other hot work on

used barrels, drums, tanks, or other containers

that contained a flammable or toxic substance.

The techniques for removing flammable sub-

stances and vapors, to make a used container safe

for welding or cutting, are quite complex and re-

quire special education and training.

NEVER 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.

NEVER weld or cut in an area where the air may

contain flammable dust (such as grain dust), gas,

or liquid vapors (such as gasoline).

NEVER handle hot metal, such as the workpiece

or welding wire, with bare hands.

ALWAYS 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 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 but-

toned and pockets eliminated from the front.

ALWAYS have fire extinguishing equipment handy

for instant use! A portable chemical fire extin-

quisher, type ABC, is recommended.

ALWAYS wear ear plugs when welding overhead

to prevent spatter or stag from falling into ear.

ALWAYS make sure welding area has agood,

solid, safe floor, preferably concrete or masonry,

not tiled, carpeted, or made of anyother flammable

material.

ALWAYS protect flammable walls, ceilings, and

floors with heat resistant covers or shields.

ALWAYS check welding area to make sure it is

free of sparks, glowing metal or slag, and flames

before leaving the welding area.

FUME HAZARDS

FUMES, GASSES, AND VAPORS CAN CAUSE

DISCOMFORT, ILLNESS, AND DEATH! To re-

duce risk of discomfort, illness, or death, read,

understand, and follow the following safety instruc-

tions. 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.

NEVER weld in an area until it has been 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.

NEVER heat metals coated with or containing ma-

terials that produce toxic fumes, such as galva-

IMPORTANT SAFETY INSTRUCTIONS Page)3

nized steel, unless the coating is removed, the

area is well ventilated, or the operator and _all'

bystanders wear air-supplied respirators.

NEVER weld, cut, or heat lead, zinc, cadmium,

mercury, beryllium, or similar metals without seek-

ing professional advise and inspection of the ven-

tilation of the welding area. These metals produce

EXTREMELY TOXIC fumes which can cause dis-

comfort, illness, and death.

NEVER weld or cut in areas that are near chlorin-

ated solvents. Vapors from chlorinated hydrocar-

bons, such as trichlorbethylene and

perchloroethylene, can be decomposed by the

heat of an electric arc or its ultraviolet radiation to

form PHOSGENE, a HIGHLY TOXIC gas, 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.

NEVER weld in aconfined area unless it is being

ventilated or the operator (and anyone else in the

area) is wearing an air-supplied respirator.

NEVER bring gas cylinders into or allow gas leaks

in a confined space. Leaked gas can rapidly re-

duce oxygen concentration levels in a confined

space.

ALWAYS shut off shielding gas supply at its source

before leaving a confined area and check to make

sure that the area is safe before reentering it.

ALWAYS stop welding if you develop momentary

eye, nose, or throat irritation as this indicates in-

adequate ventilation. Stop work and take neces-

sary steps to improve ventilation in the welding

area. Do not resume welding if physical discomfort

persists.

COMPRESSED GASSES AND

EQUIPMENT HAZARDS

IMPROPER HANDLING AND MAINTENANCE

OF COMPRESSED GAS CYLINDERS AND

REGULATORS CAN RESULT IN SERIOUS IN-

JURY OR DEATH! To reduce risk or injury or death

from compressed gasses and equipment hazards,

read, understand, and follow the following safety

instructions. In addition, make certain that anyone

else who uses this welding equipment or is a

bystander in the welding area understands and

follows these safety instructions as well.

IMPORTANT SAFETY INSTRUCTIONS Page 4

NEVER use flammable gasses with MIG welders.

Only inert or non-flammable gasses are suitable

for MIG welding. Examples are Carbon Dioxide,

Argon, Helium, etc. or mixtures of more than one

of these gasses.

NEVER attempt to mix gasses or refill a cylinder

yourself.

NEVER expose cylinders to excessive heat,

sparks, slag, and flame, etc. Cylinders exposed to

temperatures above 130 degrees F. will require

water spray cooling.

NEVER expose cylinders to electricity of any kind.

NEVER use cylinder or its contents for anything

other than its intended use. Do not use as a sup-

port or roller.

NEVER locate cylinders in passageways or work

areas where they may be struck.

NEVER lift cylinders off the ground by their valves

or caps or with chains, slings, or magnets.

NEVER use a wrench or hammer to open a cylin-

der valve that cannot be opened by hand. Notify

your supplier.

NEVER modify or exchange gas cylinder fittings.

NEVER deface or altar name, number, or other

markings on a cylinder. It is illegal and hazardous.

NEVER use cylinders without the name of the gas

marked on the cylinder. Do not rely on cylinder

color to identify the content.

NEVER connect a regulator to a cylinder contain-

ing gas other than that for which the regulator was

designed.

NEVER attempt to make regulator repairs. Send

faulty regulators for repair to manufacturer's des-

ignated repair center.

NEVER attempt to lubricate regulator.

ALWAYS handle cylinders carefully to prevent

leaks and damage to their wails, valves, or safety

devices.

ALWAYS secure cylinders with a steel chain so

that they cannot be knocked over.

ALWAYS protect cylinder, especially valve, from

bumps, falls, falling objects, and weather.

ALWAYS make sure cylinder cap is securely in

place, on the cylinder, whenever cylinder is moved.

ALWAYS remove faulty regulator from service im-

mediately for repair (first close cylinder valve) if

any of the following occur: Gas leaks extemally,

delivery pressure continues to rise with down

stream valve closed, and/or gauge pointer does

not move off the stop pin when pressurized or fails

to return to the stop pin after pressure is released.

ADDITIONAL SAFETY

INFORMATION

For additional information concerning welding

safety, refer to the following standards and comply

with as applicable.

1. ANSI Standard Z49.1 -- SAFETY IN WELDING

AND CUTTING ---obtainable from the American

Welding Society, 2051 N.W. 7th St., Miami, FL

33125 Telephone (305) 443-9353

2. ANSI Standard Z87.1 -- SAFE PRACTICE

FOR OCCUPATION AND EDUCATIONAL EYE

AND FACE PROTECTION -- obtainable from

the American National Standards Institute, 1430

Broadway, New York, NY 10018

3. NFPA Standard 51B -- CUTTING AND WELD-

ING PROCESSES -- obtainable from the Na-

tional Fire Protection Association, 470 Atlantic

Ave., Boston, MA 02210

4. CGA Pamphlet P-1 --SAFE HANDLING OF

COMPRESSED GASSES IN CYLINDERS

obtainable from the Compressed Gas Associa-

tion, 500 5th Ave., New York, NY 10036

5. OSHA Standard 29 CFR, Part 1910, Subpart Q,

WELDING, CU'I-I'ING AND BRAZING -- ob-

tainable from your state OSHA office.

6. CSA Standard W177.2 -- Code for SAFETY IN

WELDING AND CUTTING -- obtainable from

Canadian Standards Association, 178 Rexdale

Blvd., Rexdate, Ontario, Canada M9W 1R3

PRODUCT DESCRIPTION Page. 5

PRODUCT DESCRIPTION

Your new Metal Inert Gas (MIG) wire feed welder

is designed for maintenance, and sheetmetal fab-

rication. The welder consists of asingle-phase

power transformer, stabilizer, rectifier, and a

unique built-in control/feeder. This MIG welder is

capable of welding with .024" and .030" solid steel,

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.

WIRE SPEED - This control adjusts the speed at

which the wire is fed out of the gun. The wire speed

needs to be closely matched ("tuned-in") to the

rate at which it is being melted off. Some things

that affect wire speed selection are the type and

diameter of the wire being used, the heat setting

selected, and the welding position to be used.

DUTY CYCLE

NOTE; When using .035 Flux Core wire your duty

cycle may be shorter than 20%.

Now you can weld 20 gauge sheet metal up to

3/16" with a single pass. Welds 114" steel with

beveling and multiple pass.

SPECIFICATIONS

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

percentage of 10 minutes (the industry recognized

cycle time) and represents the maximum welding

time allowed, with the balance of the 10-minute

cycle required for cooling (see chart below).

Primary (input) volts .............................. 120 VAC

Primary (input) Amps ....................................... 18

Phase ....................................................... Single

Frequency ................................................ 60 Hz

Kilovolt Amps ................................................ 2.2

Secendary (output) volts ............................... 18

Secondary (output) amps ............................. 75

Duty Cycle Rating: ..................................... 20%

Open Circuit Volts (Max.) ...................... 31 VDC

WELDER CONTROLS AND THEIR

FUNCTIONS

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

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,

and the ACTUAL voltage available at the wall

receptacle.

ELECTRIC SHOCK CAN KILL! To reduce risk of

electric shock, be aware that having the POWER

SWITCH in the OFF position does not remove

power from all intemal circuitry of the welder.

Your new welder has a duty cycle rating of 20%.

You can weld for 2 minutes out of 10, with the

remaining 8 minutes required for cooling.

Duty Cycle

Rating

Maximum Required

Welding Time Resting Time

20% 2Minutes 8 Minutes

40% 4 Minutes 6 Minutes

60% 6 Minutes 4 Minutes

80% 8 Minutes 2 Minutes

100% 10 Minutes 0 Minutes

INTERNAL THERMAL PROTECTION

If you exceed the duty cycle of your welder, and

internal thermal protector will open and shut off ai!

welder functions. After cooling, the thermal protec-

tor will automatically reset and the welder wilt func-

tion normally again.

DO NOT CONSTANTLY EXCEED THE DUTY

CYCLE OR DAMAGE TO THIS WELDER CAN

RESULT!

ASSEMBLYANDINSTALLATIONPage6

ASSEMBLY AND INSTALLATION

ELECTRIC SHOCK CAN KILL! To re-

duce risk of electric shock, DO NOT PLUG

WELDER IN TO AC POWER SOURCE UNTIL

TOLD TO DO SO later in this manual.

UNPACKING YOUR WELDER

1. Open the top of the shipping carton.

2. Remove any cartons or bags containing acces-

sories.

4. Lay out the parts and compare tofollowing illus-

trations to familiarize yourself with the parts and

what they are called. This will help you when

reading the manual.

5. Grasp the top handle of the welder and lift the

welder out of the carton.

INSTALL THE GROUND CLAMP

Connect the ground clamp to the ground cable

(coming out of the front of the welder) according to

the instructions packaged with the ground clamp.

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

000

0 0

DRIVE ASSEMBLY

Knob

INSTALL WELDING GUN

ASSEMBLY

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

assembly.

3, Push the gun's tail-piece into the drive assembly

ALL THE WAY until it stops against the brass

conductor block. (NOTE: The gun's tail piece

should be about 1/16" from the drive roller)

4. Rotate the gun so the brass fitting (on the gun's

tail-piece) is pointing up, then plug the gas hose

(coming up through the welder's drive deck)

onto the barbed fitting.

NOTE: Ahose clamp is not needed on this fitting.

5. Make sure gun is still pushed all the way into the

brass conductor block, then tighten the gun

clamping knob (on top of the brass gun conduc-

tor block) until the gun is held securely in place.

IMPORTANT: Hand tighten only. do not over-

tighten.

6. Plug the trigger lead connector (hanging from

the gun's tail-piece) into the mating connector

that's mounted in the deck of the welder.

On Gun

Female Plug

w/Male Pins

On Welder

NOTE: The connectors will plug together only one

way, due to their shape (see illustration). The

connectors will lock together when properly con-

nected.

PROVIDE REQUIRED POWER

Power Requirements

This welder is designed to operate on a properly

grounded 120 volt, 60 hertz, single phase, alternat-

ing current (AC) power source on a 20 amp branch

circuit. It is recommended that a qualified electri-

cian verify the ACTUAL VOLTAGE at the recepta-

cle into which the welder will be plugged and

confirm that the receptacle is properly fused and

grounded.

DO NOT OPERATE THIS WELDER if the AC-

TUAL power source voltage is less that 105 volts

AC greater than 132 volts AC. Contact a qualified

electrician if this problem exists. Improper perform-

ASSEMBLY AND INSTALLATION Page 8

ance and/or damage to the welder will result if

operated on inadequate or excessive power.

ELECRIC SHOCK CAN KILL! FIRE CAN KILL,

INJURE, AND CAUSE PROPERTY DAMAGE! To

reduce the risk of electric shock and fire, connect

only to properly grounded and fused outlets.

NEVER ALTER the AC powercord or powercord

plug provided on the welder. NEVER ALTER and

extension cord or extension cord plugs.

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

the welder is turned to its "OFF" position. Then

plug the welder's powercord plug into the AC

power source receptacle.

Extension Cord Use

For optimum welder performance, and extension

cord should not be used unless absolutely neces-

san/. If necessary, care must be taken in selecting

an extension cord appropriate for use with your

specific welder.

Select aproperty grounded extension cord that the

AC powercord of the welder and AC power source

receptacle will mate with directly without the use of

adaptors. Make sure the extension cord is properly

wired and in good electrical condition.

For an extension cord length not exceeding 25

feet, choose one with the same AWG wire size as

that stamped on the welder's powercord, Exten-

sion cord lengths longer than 25 feet will require

heavier wire gauges to compensate for voltage

losses that will cause decreased perfomance.

INSTALL TANK TRAY AND

BRACKET

1. Remove the screw from the bottom-rear comer

of each side of the welder. Slide the tank tray

into position, lining up the slotted holes in the

tabs of the tank tray with the two holes in the

welder. Reinstall the two sheetmetal screws that

were removed and TIGHTEN ONLY.

.Attach the two tank support straps to the tank

support tray using 1each #10 Phillips head

screw, 1 each #10 Iockwasher, and 1 each #10

Hex nut on each side. The straps should be

mounted to the outside surface of the tank tray.

TIGHTEN LIGHTLY.

3, Remove the two sheetmetal screws (one from

each side) that are located directly above the

screws removed in step #1 above. Position the

ends of the tank support straps over the holes in

the welder and reinstall the screws.

4. Tighten all hardware securely.

.Position the upper tank bracket (flanges pointing

downward) over the two empty holes on the

back of the welder and push two #10 Phillips

head bolts through the holes.

6. Raise the wire drive compartment lid of the

welder, place a Iockwasher on each of the bolts,

then thread a #10 hex nut onto each bolt and

tighten securely.

7, Place each end of the tank restraining chain into

each of the key-hole slots in the upper tank

bracket. This chain will restrain a tank from fall-

ing over and should always be used.

IMPORTANT-GAS CYUNDER SIZE RESTRIC-

TION! The tank tray you have installed on the back

of this welder will handle gas cylinders no longer

than 20 cubic feet. If you select acylinder larger

than 20 cubic feet, it must be chained to a wall or

other fixed support.

ASSEMBLYANDINSTALLATIONPage9

SELECT SHIELDING GAS

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 isof equal impor-

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

available for MIG welding, the following recom-

mendations are based on the electrical output

characteristicsand metal-thickness welding capa-

bilitiesof this specific MIG welder.

GAS SELECTION FOR STEEL WELDING WITH

STEEL WIRE

Gas Selection For Aluminum Gas Welding

100% ARGON

Our only recommendation for shielding an alumP

num weld is pure Argon. Do not attempt to use the

Argon/Carbon Dioxide mixture (recommended for

steel) when welding aluminum.

Gas Selection For Stainless Steel Welding

75% ARGON

25% CO=

For either mild or low carbon (High Strength Struc-

tural) steel, in the thicknesses that can be welded

with this welder, our primary recommendation is a

gas mixture of 75% Argon and 25% Carbon Diox-

ide. This gas mixture helps to prevent burn

through and distortion on very thin steel, yet pro-

vides food penetration on thicker steel. Its ability

to minimize spatter results in clean, smooth weld

appearances. In addition, it provides food puddle

control when welding vertically or overhead. This

gas mixture is available pre-mixed in asingle cyl-

inder from your local gas distributor.

_o/o BEST

HELIUM

F"_"_''%ARGON

_% c(:f

_o/, ° ACCEPTABLE

ARGON

r- -2_% co 2

The best shielding gas for stainless steel welding

is a mixture of 90% helium, 7.5% Argon, and 2.5%

Carbon Dioxide. However, the 75% argon 25%

Carbon Dioxide mixture (recommended for steel)

can also be used, but an increase in the area being

heated by the arc will be experienced causing

slightly greater distortion of the base metal. Also

this mixture can cause a decrease in the ability of

the stainless steel weld to resist corrosion. Either

mixture can be obtained in a single cylinder from

your local gas distributor.

Note: Potential Shielding Gas Problems

ASSEMBLYANDINSTALLATIONPage 10

Gas Selection For Steel Welding With Silicon-

bronze Wire

100% ARGON

Use only pure Argon when welding steel with Sili-

con-Bronze wire.

1. DEFECTIVE GAS -- Just like any other prod-

uct, a cylinder of gas can be defective. Moisture

or other impurities in the gas can create dirty

porous, brittle welds with greatly reduced pene-

tration. The only remedy is to replace the cylin-

der.

2. MIXTURE COMPOSITION CHANGE -- This

problem concerns only cylinders that contain a

mixture of two or more gasses. The mixture

composition in acylinder can be changed if the

cylinder is stored in cold temperatures. For the

75% Argon 25% Carbon Dioxide mixture, the

cylinder should not be stored below 40 degrees

R This information is normally found on the

label on the cylinder that indicates the contents

of the cylinder.

This problem can create a variety of unfavorable

weld characteristicsincluding porosity,brittles, and

improper penetration.

3. INSUFFICIENT SHIELDING GAS COVER-

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

OF COMPRESSED GAS CYLINDERS AND

REGULATORS CAN RESULT IN SERIOUS IN-

JURY OR DEATHI Always secure gas cylinders to

the tank bracket kit, a wall, or other fixed support

to prevent the cylinder from falling over and ruptur-

ing. Read, understand, and follow alt the COM-

PRESSED GASSES AND EQUIPMENT HAZ-

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

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-

STANT to blow out any foreign matter inside the

valve port to reduce the risk of plugging or dam-

aging the regulator. NEVER AIM THE CYLIN-

DER VALVE PORT AT YOURSELF OR ANY

BYSTANDERS WHEN OPENING CYLINDER

TO REDUCE THE RISK OF PERSONAL IN-

JURY.

4. Screw the regulator into the cylinder valve and

tighten with a wrench while keeping gauges

upright for easy and accurate reading.

NOTE: If the cylinder you have is equipped with

male regulator connecting threads instead of fe-

male, you wilt need to obtain a special compressed

gas cylinder adapter from your gas supplier to

install between your gas cylinder and regulator.

5. Locate the brass barbed fitting and brass retain-

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

port on the regulator and wrench tighten.

Brass

Brass barbed retaining nut

fitting

Outlet port fitting

on regulator

6. Slide the spring clamp (in parts bag) down one

end of the gas hose about three inches. Push

the same end of the gas hose onto the barbed

fitting. Then compress the ears of the spring

clamp witha pliers, slide it up the gas hose, and

release clamp when it is positioned on aportion

of the hose that is over the brass fitting. '

SPRING CLAMP

HOSE

7. Locate the remaining brass barbed fitting (male

threaded) in the parts bag and thread the fitting

into the gas solenoid port located in the rear of

the welder (see illustration below) BEING

CAREFUL TO PREVENT CROSS THREAD-

ING. Turn the fitting into the solenoid port WITH

YOUR FINGERS ONLY until you can't turn any

more. Then, use a wrench to tighten it securely

-do not overtighten.

8. Slide the remaining hose clamp about 3" up the

end of the gas hose opposite the regulator. Then

push the hose onto the barbed fitting installed in

step #7 above and clamp into place.

CHECKING GAS FLOW

IMPROPER HANDLING AND MAINTENANCE

OF COMPRESSED GAS CYLINDERS AND

REGULATORS CAN RESULT IN SERIOUS IN-

JURY AND DEATH! To reduce risk of injury or

death, always stand to the side of the cylinder

opposite the regulator when opening the cylinder

valve, keeping the cylinder valve between you and

the regulator.

1. Slowly crack open the cylinder valve, then turn

open ALL THE WAY!

2. Turn POWER SWITCH on the front of the

welder to either the LOW or HIGH position.

ASSEMBLY AND INSTALLATION Page 11

3. Pull the trigger on the gun to allow the gas to

flow. KEEP PULLED. Listen for gas to flow from

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-

essary to set up a windbreak to keep the shielding

gas from being blown from the weld area.

MAKE SURE TO TURN OFF THE GAS CYUN-

DER VALVE WHEN DONE WELDING.

SELECT WELDING CURRENT

POLARITY

This welder comes factory set for DC Positive

Polarity operation. This polarity is required when

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-

al). If the wire is incompatible with the base metal,

the quality of important characteristics such as

penetration and strength may be sacrificed.

The welding wires recommended for most of the

mild and low carbon steel applications you will

have are AWS classification numbers E70S-3 and

E70S-6. These two wires are very similar, but the

E70S-6 tends to work a little better on moderately

dirty steel and on sheet metal where smooth weld

beads are required. These differences are very

subtle, so in most applications, either wire is ac-

ceptable.

Self-shielding, flux-core, steel wire is used primar-

ily for welding mild steel without the use of a shield-

ing gas. It is especially good to use when welding

needs to take place in windy environment. How-

ever, it produces more spatter than solid wire gas-

shielded welding and leaves a slag on top of the

weld that needs to be chipped off. Our recommen-

ASSEMBLY AND INSTALLATION Page 12

dation for self-shielding, flux-core, steel wire is

AWS classification number E71T-GS.

NOTE: With flux core wire you will bum through

metats thinner than 18 gauge

WARNING: When welding aluminum with a wire

feed welder rated at 90 amps or less, we highly

recommend that:

a. The aluminum to be welded is between

t/16" (t .59mm) and 1/8" (3.17mm) thick.

b. A .030 diameter, 5356 aluminum alloy weld-

ing wire is used.

c. The teflon gun liner (part # 4325) is installed

in the mig gun.

d. The composite rubber drive roller (part #

4324) is installed inthe wire feed welder.

e. 100% pure argon shielding gas is used.

NOTE: Failure to utilize these set-up recommen-

dations will result in wire feeding problems and

poor quality welds.

1. Stainless Steel Wire Selection

When welding stainless steel, the alloy of the

welding wire must be the same as the alloy of

the base metal. As with aluminum, the alloy

number can most often be determined by con-

suiting the owner/operator manual, service

manual, dealer, distributor, or manufacturer of

the item to be welded. Otherwise, seek the ad-

vise of someone who may have had previous

experience with the same or similar welding

application. Stainless steel wire is quite expen-

sive, the trial-and-error method of alloy determi-

nation should be avoided if at all possible.

2. Silicon'Bronze Wire Selection

The most popular application for silicon-bronze

MIG welding is non-structure sheetmetal weld-

ing, especially auto body work. A weld with sili-

con-bronze wire is very similar to that produced

by oxygen-acetylene brazing. It is fairly flat and

easy to grind smooth. Our recommended wire

for this application is AWS classification number

ERCuSi-A.

SELECT THE SPOOL SIZE

This welder will accept either 4" or 8" spools. Wire

on a 4" spool wilt usually cost more per pound than

that on an 8" spool. However, welding wire oxi-

dizes over time, so it is important to select aspool

size that will be used up within the times recom-

mended below.

.STEEL WIRE is usually coated with copper to

prevent the wire from rusting and to enhance the

transmission of welding current from the contact

tip to the wire. It is recommended that copper-

coated steel welding wire be bought in spool

sizes that will be consumed in six months or

tess.

In the early stages of aging, the copper coating

will begin oxidizing. The more time passes, the

heavier the oxidization will get. To check the wire

for copper oxidization, unspool about two feet of

wire, pinch wire between thumb and forefinger,

then pull thumb and forefinger down the length

of wire. Look at thumb and forefinger; there will

be a line created by the copper oxidization. A

fairly fresh spool will leave a light gray line,

whereas a well-oxidized spool will leave a

darker line. Heavy copper oxidization will cause

arc flutter and possibly wire drive slippage. If

steel wire continues to oxidize, the steel wire

under the copper coating will rust causing even

worse arc flutter and drive problems.

2. SELF-SHIELDING, FLUX-CORE, STEEL

WIRE spools should be selected based on the

same guidelines as for steel wire.

.ALUMINUM WIRE is even more of a potential

storage problem than steel. It tends to oxidize

much faster and the oxidation is much heavier.

The early stages of oxidation are virtually invis-

ible, but as time passes, a white powder will

develop that will cause extreme arc flutter, wire

drive problems, contamination build-up in the

liner, wire burn-back into the contact tip, and a

poor weld. ideally it would be best to use up a

spool of aluminum wire within three months.

1STAINLESS STEEL WIRE oxidizes at arela-

tively slow rate and its oxidation is very light, so

the care for handling and storing stainless steel

wire is much less cdtical than for aluminum and

steel wires. However, because stainless steel

wire is quite expensive, it is still agood practice

to fotlow the storage recommendations.

5. SILICON-BRONZE WIRE spools should be se-

lected based on the same guidelines as for

copper-coated steel wire.

ASSEMBLYANDINSTALLATIONPage19

WireSpool Storage

The above recommended spool storage times are

rules-of-thumb and can be impacted by many fac-

tors such as length of time in distribution prior to

retail sale, warehouse conditions, time of year (ie:

Humid months or dry months), and how packaged

by the manufacturer.

Although these factors are out of your control,

there are some things that you can do to slow

down the oxidization process: store in a dry place

when not in use; store in sealed plastic bag when

not in use and leave unopened in the manufac-

turer's package until ready to use.

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

wire, do not discard it until trying the following:

unspool a few turns of wire to see if the wire further

down on the spool is in usable condition, if not --

discard the spool.

SELECT THE WIRE DIAMETER

t. Steel and Stainless Steel Welding

Base Metal Wire

Thickness Diameter

20 Gauge to 1/8" Gauge

18 Gauge to 1/8"

.024" (.6mm)

.030" (.8mm)

2. Aluminum Welding

Base Metal Wire

Thickness Diameter

i i

1/16"to 1/8" .030" (.8ram)

3. Silicon-Bronze Wire Welding of Steel

To be used for welding non-structural sheet-

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,

Base Metal Wire

Thickness Diameter

i i

INSTALL THE WELDING WIRE

ELECTRIC SHOCK CAN KILL! Always turn the

POWER SWITCH to its OFF position and unplug

the welder's powercord from the AC power source

before installing wire.

1. Remove the nozzle and contact tip from the end

of the gun assembly.

2. Unscrew (turn counter-clockwise) the tension

adjusting screw ALL THE WAY.

3. Make sure that the wire diameter stamped on

the outside of the drive roller is the same as the

diameter of the wire being installed. If it is not the

same, change the drive roller as follows:

CHANGING THE DRIVE ROLLER

ELECTRIC SHOCK CAN KILL! Always turn the

POWER SWITCH to its OFF position and unplug

the welder's powercord from the AC power source

before changing a drive roller.

a. Remove drive tension (see step #2 above).

b. If there is wire already installed in the welder,

roll it back onto the wire spool by hand-turn-

ing the spool clockwise (to the right), but be

careful not to allow the wire to come out of

the rear end of the gun without holding onto

it or it will unspool itself. Put the end of the

wire into the hole on the outside edge of the

spool and bend it over to hold the wire in

place, then remove the spool of wire from

the welder.

c, Remove the retaining screw and washer

from the drive roller.

KE'f_NAY

KEY _

18 Gauge to 3/t6" .030" (.8 mm)

ASSEMBLY AND INSTALLATION Page 14

d. Remove the drive roller by pulling it straight

out and off the drive motor shaft.

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

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.

8. Place the spool on the spindle in such a manner

that when the wire comes off the spool it will look

like this:

not like this:

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

outer edge of the spool, and is bent over the

spool edge to prevent the wire from unspooling),

BUT DO NOT UNHOOK IT YET!

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.

10. Adjust the drive brake tension. The purpose of

the drive brake is to cause the spool of wire to

stop turning at nearly the same moment that

wire feeding stops.

a. With one hand, turn the wire spool and con-

tinue turning it while adjusting the tension.

b. With your free hand, tighten (turn clockwise)

the wing-nut.

c. Stop tightening when drag is felt on the wire

spool that you are tuming, then stop hand

turning the wire spool.

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

the drive brake tenion as necessary to correct for

either of these problems.

11. After checking to make sure that your welder is

disconnected from the AC power source, free

the leading-end of the wire from the spool, but

do not let go of it until told to do so, or the wire

will unspool itself.

t2. Using awire cutter, cut the bent end off the

leading-end of the wire so that only astraight

leading-end remains.

13. Hold the tension arm up off the drive roller and

insert the leading-end of the wire into the inlet

guide tube. Then push it across the drive roller

and into the gun assembly about six inches.

14. Line the wire up in the outside groove of the

drive roller, then allow the drive tension arm to

drop onto the drive roller.

15. Tighten (turn clockwise) the tension adjusting

screw until the tension roller is applying enough

force on the wire to prevent it from slipping out

of the drive assembly. NOW YOU CAN LET

GO OF THE WIRE.

16. Plug the welder's powercord into the AC power

source, turn the POWER SWITCH on the front

of the welder to either HIGH or LOW, and set

the WIRE SPEED control to the middle of the

wire speed range.

17. Pull the trigger on the welding gun to feed the

wire through the gun assembly.

ARC FLASH CAN INJURE EYES! To reduce the

risk of arc flash, make certain that the welding wire,

when it finally comes out of the endof the gun, does

not touch the ground calmp or any grounded piece

of metal. IMPORATANT! The welding wire is car-

ASSEMBLY AND INSTALLATION Page,_15_

rying welding current whenever the welder, is,

turned on -- WHETHER THE TRIGGER i_

PULLED OR NOT!

18. When at least and inch of wire sticks out past

the end of the gun, release the trigger.

19. Select a contact tip stamped withthe same wire

diameter as the diameter of the wire being

used. If stamped in metric, use the cross-refer-

ence chart below.

U.S:Tip Size Metric Tip Size .....

.024"

.030"

.035"

.6mm

.8mm

.gmm

20.

21.

22.

Slide the contact tip over the wire (protruding

from the end of the gun), thread it into the end

of the gun, and hand tighten securely.

Install the nozzle on the end of the gun assem-

bly, then coat the inside of the nozzle with

anti-stick spray or gel (not supplied).

Cut off excess wire that extends past the end

of the nozzle.

23. Set the wire drive tension.

ARC FLASH CAN INJURE EYES! To reduce risk

of arc flash, make certain that the wire coming out

of the end ofthe gun does not come in contact with

the ground clamp or any grounded material during

the drive tension setting process or arcing will

occu r.

a. Pull the trigger on the gun.

b. Turn the drive tension adjustment knob

clockwise (to the right), increasing the drive

tension until the wire seems to feed

smoothly without slipping.

c. Block the end of the nozzle by holding it up

against something that doesn't conduct

electricity, such as a block of wood or a

concreate floor, then trigger the gun again.

The wire should slip at the drive roller. How-

ever, if the bird-nests at the drive roller, re-

thread the drive system using less drive

tension and try again.

ASSEMBLY AND INSTALLATION Page 16

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

WORK AREA bystanders in the welding area. It is amust that the

welding work area be cleared of all flammables

and that a type ABC chemical fire extinguisher is

always close at hand.

ELECTRIC SHOCK CAN KILL!

_]_JD] ARC RAYS CAN INJURE EYES AND

BURN SKIN!

READ The SAFETY INSTRUCTIONS! They wilt

tell you how to properly prepare for welding by:

1. Preparing a safe welding work area.

2. Providing the necessary personal eye and skin

protection for you and all bystanders in the weld-

ing area.

FIRE OR EXPLOSION CAN CAUSE

DEATH, INJURY, AND PROPERTY DAMAGEI

3. Providing adequate ventilation, or respiration

equipment if necessary, to protect you and any

bystanders in the welding area.

FUMES, GASSES, AND VAPORS CAN

CAUSE DISCOMFORT, ILLNESS, AND DEATH!

IMPROPER HANDLING AND MAIN-

TENANCE OF COMPRESSED GAS CYLIN-

DERS AND REGULATORS CAN RESULT IN

SERIOUS INJURY OR DEATHI

DO NOT PROCEED TO PREPARE TO WELD

until you read and understand each of the five

parts of the SAFETY INSTRUCTIONS section in

this manual. The SAFETY INSTRUCTIONS will

tell you how to REDUCE THE RISKS OF DEATH,

INJURY, ILLNESS, DISCOMFORT, AND PROP-

ERTY DAMAGE to you, the bystanders in the

welding area, and property in the vicinity of the

welding area from SHOCK HAZARDS, FLASH

HAZARDS, FIRE HAZARDS, FUME HAZARDS,

AND COMPRESSED GASSES AND EQUIP-

MENT HAZARDS.

An important factor in making a satisfactory weld is

preparation. This includes the study of the welding

process and equipment by the operator and then

practicing on scrap material before actual welding

jobs are attempted. An organized, well-lighted

work area should be available to provide comfort,

convenience, and safety to the operator and all

PREPARING THE WORK PIECE

Much of the success in producing a quality weld

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,

and/or paint. Failure to do so may result in a

porous, brittle weld.

,Select atype of joint appropriate for your appli-

cation. The more popular types ofwelding joints

are illustrated inthe TYPES OF JOINTS chart at

the end of this section.

NOTE: If you select a BUTT WELD JOINT, you

may have to prepare the edges of the metal to be

joined by grinding a bevel on the edges.

GRINDING METAL CAN INJURE EYES! To re-

duce the risk of eye injury, ALWAYS wear goggles

and inspect the grinder to verify that it is in good

condition before using.

During the welding process, the work pieces will

become hot and tend to expand causing the pieces

to shift from their initial position. If possible, it is

best if the work pieces can be securely clamped

(before welding) into the position desired after

welding is completed.

PREPARING TO WELD Page 18

450 PLATE

37.5 °

SINGLE BEVELJOINT

DOUBLE BEVEL JOINT

BUTT WELD JOINTS

BUTT JOINT

600PLATE

SINGLEV JOINT

6O0

DOUBLEVJOINT

CLOSED JOINT

DOUBLE VEE JOINT

3/32" TO 1/8" 60--

"-_N '_''r 1/16" TO 1/8" _

OPEN JOINT SHOUI.._ER EDGE

1/4" OR MORE

VEE JOINT

--\/

FEATHER EDGE

1/8" OR MORE

SINGLE FILLET

LAP JOINT

LET WELD JOINTS

DOUBLE FILLET __

SINGLE FILLET T-JOINT

SINGLE STRAP JOINT DOUBLE STRAP JOINT

DOUBLE FILLET T-JOINT

ALUMINUM WELDING

PREPARATION

1. A clean weld-joint area is a must in obtaining a

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-

num cleaner.

2. Aluminum is often anodized to prevent it from

oxidizing. However, and anodized surface will

NOT conduct electricity. Therefore, to weld ano-

dized aluminum, you must sand or grind the

anodized coating from the weld joint area and

from the site where the ground clamp will be

connected.

To determine if the aluminum you intend to weld is

anodized, simply touch the two probes of an elec-

trical continuity test light or ohmmeter to the alumi-

num in question. The probes should be an inch or

two apart. If there is no indication of electrical

continuity, the aluminum IS anodized.

CONNECT WELDER GROUND

Attach the ground clamp to the work piece making

sure that the work piece is cleaned of dirt, oil, rust,

scale, oxidation, and paint at the point of connec-

tion.

It is best to connect the ground clamp directly to the

work piece and as close to the weld as possible. If

it is impractical to connect the ground clamp di-

rectly to the work piece, connect it to metal that is

securely attached to the work piece, but not elec-

tricallyinsulated from it. Also, make sure thisother

metal is of about the same or greater thickness

than that of the work piece.

RISK OF ELECTRONIC COMPONENT DAM-

AGE! If the ground clamp is being connected to

an automobile or other equipment with on-board

computer systems, solid state electronic controls,

solid state sound systems, etc., DO NOT WELD

until disconnecting the cable from the battery that

is attached to chassis ground. Failure to do so

may result in ELECTRONIC COMPONENT DAM-

AGE!

OPERATION Page 19

OPERATION

GETTING TO KNOW YOUR NEW

WELDER

Whether you have welded before or not, it is impor-

tant that you become familiar with your new

welder, its controls, and the results achieved at

different settings. We strongly recommend that

you practice with your new welder on scrap metal

trying different heat settings, base metal thick-

nesses, and welding positions for each type and

size of wire that you will be using. By doing this

you will gain a feel for how changes in these

welding variables affect the weld.

Of course, if you have not MIG welded before, you

will need to develop welding skills and techniques

as well. The self-taught welder learns through a

process of trial and error. The best way to teach

yourself how to weld is with short periods of prac-

tice at regular intervals.

DO NOT ATTEMPT TO WELD on any valuable

equipment until you have made practice welds on

scrap metal that can be discarded. The scrap

metal should be of the same type and thickness as

that of the item to be welded. Only after you are

satisfied that your practice welds are of good

strength and appearance, should you attempt your

actual welding job.

SETTING THE CONTROLS

1. The POWER SWITCH has three settings: LOW,

OFF, and HIGH. When in the OFF position,

power is disconnected from all welder functions.

The LOW position is selected for welding steel

thicknesses of 16 gauge or thinner. The HIGH

position is selected for steel thicker than 16

gauge. The variables that affect the heat selec-

tor setting are wire type and size, base metal

type and thickness, and desired penetration.

2. The WIRE SPEED CONTROL is variable from

SLOW to FAST. To achieve successful welding

results, it is important that the wire be fed at the

same rate it is being melted off into the weld

puddle; if too fast the wire will tend to push the

gun away from the work piece and if too slow,

the wire will bum back into, and may damage

the contact tip. In either case, an extremely

poor weld will result.

"TUNING IN" THE WIRE SPEED is one of the

most important parts of MIG welder operation and

must be done before starting each welding job or

whenever any of the following variables are

changed: heat setting, wire diameter, or wire type.

a. Set up and ground ascrap piece of the same

type of metal that you will be welding, it

should be equal to or greater than the thick-

ness of the actual work piece and free of

paint, oil, rust, etc.

b. Select a heat setting.

c. Hold the gun in one hand atlowing the nozzle

to rest on the edge of the work piece farthest

away from you and at an angle similar to that

which will be used when actually welding.

d. With your free hand, turn the WIRE SPEED

control to maximum and continue to hold

onto the knob.

ARC RAYS CAN INJURE EYES AND BURN

SKINI To reduce risk of injury from arc rays, never

strike awelding arc until you and all bystanders in

the welding area have welding helmets or shields

in place and are wearing the recommended pro-

tective clothing. DO NOT CONTINUE unless you

have read, understand, and intend to follow the

entire SAFETY INSTRUCTIONS section of this

manual.

e, Lower your welding helmet and pull the trig-

ger on the gun to start an arc, then begin to

drag the gun toward you while turning down

on the WIRE SPEED control knob at the

same time.

LISTEN! As you decrease the wire speed,

the sound that the arc makes will change

from a sputtering to a smooth, high-pitched

buzzing sound and then will begin sputtering

again if you decrease the wire speed too far.

Selecting the best wire speed setting is much the

same as "tuning in" a radio: continue decreasing

the wire speed until the arc noise passes the best-

sounding, high-pitched buzz and begins to sputter

again, then turn the WIRE SPEED control the

opposite direction until you come back to the best

sounding arc noise. The welder is now "tuned in"

and welding can begin.

OPERATION Page 20

REPEAT THIS TUNE-IN PROCEDURE if you se-

lect a new heat setting, a different diameter _vire,

or a different type wire.

NOTE: When "tuning-in" the wire speed for self-

shielding flux-core wire, you will find a very wide

"best-sounding range", spanning as much as 60

degrees on the WIRE SPEED contro!. It is impor-

tant to know that the heat of the arc and penetra-

tion into the base metal increases as the wire

speed is increased within the "best-sounding

range" for a given heat setting.

Therefore, you can use the wire speed control to

slightlyincrease or decrease heat and penetration

for a given heat settingby selecting higheror lower

wire speed settings WITHIN the _est-sounding

range".

HOLDING THE GUN

The best way to hold the welding gun is the way

that feels most comfortable to you. While practic-

ing touse your new welder, experiment holding the

gun in different positions untilyou find the one that

seems to work best for you.

Position of the Gun to the Work Piece

There are two angles of the gun nozzle in relation

to the work piece that must be considered when

welding.

1. Angle "A" can be varied, but in most cases the

optimum angle will be 60 degrees; the point at

which the gun handle is parallel to the work

piece. If angle "A" is increased, penetration will

increase. If it is decreased, so will penetration.

i J,

8oii

==lllliHi .................. ==lHi

,lllllll

2. Angle "B" can be varied for two reasons: to

improve the ability to see the arc in relation to

the weld puddle and to directthe force of the arc.

The force of the welding arc follows a straight tine

out the end of the no>>te. If angle "B" is changed,

so will the direction of the arc force and the point at

which penetration will be concentrated.

On a butt weld joint, the only reason to vary angle

"B" from being perpendicular (straight up) to the

work piece would be to improve visibility of the

weld puddle. In this case, angle "13'can be varied

anywhere from zero to 45 degrees with30 degrees

working about the best.

30 °,,,,_P II

,_ _v,'*" !

•!

Angle A

On a fillet weld joint the nozzle is generally posi-

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

90 degree angle so angle "13"will most often be 45

degrees.

45"..---_

.f/

%%%

1lI

Angle B

Distance from the Work Piece

The end of the welding gun is designed with the

contact tip recessed from the end of the nozzle and

the nozzle electrically insulated from the rest of the

gun. This permits the operator to actually rest the

nozzle on and drag it along the work piece while

welding. This can be very helpful to beginning

welders to steady the gun, allowing the welder to

concentrate on welding technique. If the nozzle is

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

sputtering, signaling a toss in welding perform-

ance.

LAYING A BEAD

ARC RAYS CAN INJURE EYES AND BURN

SKIN! To reduce the risk of injury from arc rays,

never start awelding arc until you and all bystand-

ers in the welding area have welding helmets or

shields in place and are wearing the recom-

mended protective clothing. DO NOT CONTINUE

unless you have read, understand, and intend to

follow the entire SAFETY iNSTRUCTIONS sec-

tion of this manual.

IMPORTANT! The wire in this welder is always

electrically energized whenever the switch is not in

the OFF position, and will arc whenever brought

into contact with any electrically conductive mate-

rials that the ground clamp of the welder is con-

nected to or in contact with.

Therefore, it is best to clip the wire back to the

contact tip so that you don't create an arc when

lining up on the seam to be welded.

OPERATION Page 21

Once you have the gun in position with the wire

lined up on the weld joint, lower your helmet, pull

the trigger and the arc will start. In a second or

two, you will notice aweld puddle form and the

base ofa bead beginning to build. It is now time to

begin to travel with the gun. If you are just learning

to weld, travel by simply dragging the gun in a

straight line and at a steady speed along the weld

joint. Try to achieve a weld with the desired pene-

tration and abead that is faidy fiat and consistant

inwidth.

CLEANING THE WELD BEAD

When using solid wire and shielding gas, cleaning

of the weld bead is not normally necessary. How-

ever, when welding with self-shielding flux-core

wire, slag is deposited on the top of the weld bead.

This slag consists of the flux from the welding wire

as well as any impurities the flux was able to

remove from the molten weld puddle.

This slag must be cleaned from the weld bead both

for cosmetic reasons and to visually inspect the

finished weld bead. Cleaning the weld bead is

done best with a chipping hammer followed by a

wire brush.

Slag must also be cleaned from a weld bead that

was stopped in the middle and now will be restart-

ed from the point at which it was stopped. A poor

weld will result when a weld bead is started or laid

on a weld bead that has not been cleaned of slag.

CHIPPING AND BRUSHING SLAG CAN INJURE

EYES! To reduce the risk of eye injury from flying

slag, always have eye protection such as goggles,

in place prior to chipping slag.

WELDING TECHNIQUES Page 22

WELDING TECHNIQUES

As you become more familiar with your new welder

and better at laying some simple weld beads, you

can begin to try some different welding techniques

to improve and add versatility to your welding

skills.

TRAVELING WITH THE GUN

Gun travel refers to the movement of the gun along

the weld joint and is broken into two elements:

Direction and Speed. A solid weld bead requires

that the welding gun be moved steadily and at the

right speed along the weld joint. Moving the gun

too fast, too slow, or irratically will prevent proper

fusion or create a lumpy, uneven bead.

1. TRAVEL DIREC-

TION is the direction

the gun is moved

along the weld joint in

relation to the weld

puddle. The gun is

either PUSHED into

the weld puddle or

PULLED away from

the weld puddle.

PULLING

PUSHING

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:

VERTICAL WELDING can be done by starting at

the top of aweld joint and "pulling" the gun down

toward the bottom. However, in the event that

puddle control becomes difficult (such as the pud-

dle wanting to "run" downward), starting avertical

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.

.TRAVEL SPEED is the rate at which the gun is

being "pushed" or "pulled" along the weld joint.

For a fixed heat setting, the faster the travel

speed, the lower the penetration and the lower

and narrower the finished weld bead. Likewise,

the slower the travel speed, the deeper the

penetration and the higher and wider the fin-

ished weld bead.

TYPES OF WELD BEADS -

1. The STRINGER BEAD is formed by traveling

with the gun in astraight line while keeping the

wire and nozzle centered over the weld joint.

This is the easiest type of bead to make and is

the type you have been using up to this point.

2. The WEAVE BEAD is used when you want to

deposit metal over a wider space than would be

possible with a stringer bead.' It is made by

weaving from side to side while traveling with

the gun. It is best to hesitate momentarily at

each side before weaving back the other way.

WELDING TECHNIQUES Page 23

WELDING POSITIONS

There are four basic welding positions: fiat, hori-

zontal, vertical, and overhead.

1. The FLAT POSITION is the easiest of the weld-

ing positions and is probably the one you have

been using thus far. It is best if you can weld in

the fiat position if at all possible as good results

are easier to achieve.

=The VERTICAL POSITION is the next most

difficult position. "Pulling" the gun from top to

bottom may be easier for many people, but in

some instances it can be difficult to prevent the

puddle from "running" downward. "Pushing" the

gun from bottom to top may provide better pud-

dle control and allow slower rates of travel

speed to achieve deeper penetration. When

vertical welding, angle"B" (see POSITION OF

GUN TO THE WORK PIECE above) is usually

always kept at zero, but angle "A" wil! generally

range from 45 to 60 degrees to provide better

puddle control.

2. The HORIZONTAL PosmoN is next in diffi-

culty level. It is performed very much the same

as the flat weld except that angle "B" (see PO-

SITION OF THE GUN TO THE WORK PIECE

above) is such that the wire, and therefore the

arc force, is directed more toward the metal

above the weld joint. This is to help prevent the

weld puddle from "running" downward while still

allowing slow enough travel speed to achieve

good penetration. A good starting point for an-

gle "B" is about 30 degrees DOWN from being

perpendicular to the work piece.

,The OVERHEAD POSITION is the most difficult

welding position because gravity is pulling at the

weld puddle trying to make it drip off the work

piece. Angle =A" (see POSITION OF THE GUN

TO THE WORK PIECE above) should be main-

tained at 60 degrees, the same as in the flat

position. Maintaining this angle will reduce the

chances of molten metal falling into the nozzle

should it drip from the weld puddle. Angle "B"

should be held at zero degrees so that the wire

is aiming directly into the weld joint. If you expe-

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

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.

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

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

show the sequence of laying multiple pass beads

into a "T" fillet joint and a lap fillet joint.

,,,,,,,,,,,,,,,,,

First or Root Pass

Second Pass

Third Pass

Finished Weld

III

ill iii ii iiii I

T-Joint in three Passes

I I i1_

Iiiiiii

Lap-Joint welded

in three Passes

iiii ii i

SPECIAL WELDING METHODS Page 25

SPECIAL WELDING METHODS

SPOT WELDING

BURN THROUGH PUNCH AND FILL

LAP SPOT

The purpose of aspot weld is to join pieces of

metal together with a "spot" of weld instead of a

continuous weld bead. There are three methods

of spot welding: Bum-Through, Punch and Fill, and

Lap. Each has advantages and disadvantages

depending on the specific application as well as

personal preferance.

1. The BURN-THROUGH METHOD welds two

overlapped pieces of metal together by burning

through the top piece and into the bottom piece.

With the burn-through method, larger wire diame-

ters tend to work better than smaller diameters

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"

self-shielding flux-core wire tend to work the best.

.024" diameter solid and .030" self-shielding flux-

core wires should not be used with the bum-

through method unless the metal is VERY thin or

excessive filler metal build-up and minimal pene-

tration is acceptable.

Always select the HIGH heat setting with the burn-

through method and "tune-in" the wire speed prior

to making a spot weld.

2. The PUNCH AND FILL METHOD produces a

weld with the most "finished" appearance of the

three spot weld methods, tn this method, a hole

is punched or drilled into the top piece of metal

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 acontinuous bead.

3. The LAP SPOT METHOD directs the welding

arc to penetrate the bottom and top pieces, at

the same time, right along each side of the lap

joint seam.

Select the wire diameter, heat setting, and =tune-

in"the wire speed as if you were welding the same

thickness material with a continuous bead.

SPOT WELDING INSTRUCTIONS

1. Select the wire diameter and heat setting rec-

ommended above for the method of spot weld-

ing you intend to use.

2. Tune in the wire speed as if you were going to

make a continuous weld.

3. Hold the nozzle piece completely perpendicular

to and about 1/4" off the work piece,

4. Pull the trigger on the gun and release it when it

appears that the desired penetration has been

achieved.

5. Make practice spot welds on scrap metal, vary-

ing the length of time you hold the trigger, until a

desired spot weld is made.

6. Make spot welds on the actual work piece at

desired locations.

MAINTENANCE AND TROUBLESHOOTING Page 26

MAINTENANCE AND TROUBLESHOOTING

GENERAL MAINTENANCE

This welder has been engineered to give many

years of trouble-free service providing that afew

very simple steps are taken to properly maintain it.

1. Keep the wire drive compartment lid closed at all

times unless the wire needs to be changed or

the drive tension needs adjusting.

2. Keep all consumables (contact tips, nozzles,

and gun liner) clean and replace when 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,

remove the side panels from the welder and

air-blow any dust and dirt that may have accu-

mulated inside the welder.

ELECTRIC SHOCK CAN KILL? To reduce risk of

electric shock, always unplug the welder from its

AC power source before removing side panels.

CONSUMABLE MAINTENANCE

AND TROUBLESHOOTING

IT IS VERY IMPORTANT TO MAINTAIN THE

CONSUMABLES TO AVOID THE NEED FOR

PREMATURE REPLACEMENT OF THE GUN

ASSEMBLY.

1. The GUN LINER is intended to provide an unre-

stricted path for the welding wire to flow through

the gun assembly. Over time it will accumulate

dust, dirt, and other debds. Replacement is

necessary when these accumulations begin to

restrict the free flow of wire through the gun

assembly.

TO REPLACE A GUN LINER:

When removing or installing a gun liner, care must

be taken not to kink or otherwise damage it or

replacement will be necessary.

a. Turn POWER SWITCH to the OFF position.

b. Remove wire from gun assembly and gun

assembly from welder.

c. Remove nozzle and contact tip from gun

d. Loosen set screw holding liner collet in place

at rear of gun.

e. Lay gun assembly out in a straight line.

g°

Holding rear of gun assembly, grasp liner

collet and pull liner out of gun assembly.

Insert new liner into gun assembly and push

all the way through being careful not to kink

the liner. The excess liner wilt protrude from

the end of the gun.

With the gun assembly lying in astraight

line, mark the liner at the end of the gun's

gas diffuser.

Hold the gun handle firmly in place, then

gently pull outward on the excess liner so

that the mark you made is about 118" out

past the end of the gas diffuser.

Using awire cutter, cut the liner at the end of

the gas diffuser so that the liner ends up

recessed into the gas diffuser about 1/8", then

use a file to remove any burrs on the liner

where the cut was made.

k. Tighten the set screw, but DO NOT OVER

TIGHTEN or damage to the collet may re-

sult.

1. Reinstall gun assembly into welder (see IN-

STALL WELDING GUN ASSEMBLY in the

ASSEMBLY AND INSTALLATION section).

MAINTENANCE AND TROUBLESHOOTING Page 27

2. The CONTACT TIP's purpose is to transfer

welding current to the welding wire while allow-

ing the wire to pass through it smoothly.

a. Always use a contact tip stamped with the

same diameter as the wire it will be used

with.

b_ Ifthe wire burns back into the tip, remove the

tip from the gun and clean the hole running

through itwith an oxygen-acetylene torch tip

cleaner. This is especially important to do

after an aluminum wire burn-back.

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

efficient is the transfer of welding current to

the wire and eventually arc breakage and

difficult arc starting will result. Replace con-

tact tips when signs of wear become appar-

ent.

3. The NOZZLE prevents the electrically"hot" con-

tact tip from contacting the work piece.

KEEP THE NOZZLE CLEAN! During the welding

process, spatter and slag will build up inside the

nozzle and must be cleaned out periodically.

a. Always coat the inside of a new or freshly

cleaned nozzle with anti-stick spray or gel.

b. Stop welding and clean any accumulated

slag or spatter from the nozzle every 5 to 10

minutes of welding time.

C* When welding overhead, if any molten metal

drips from the weld puddle and falls into the

nozzle, STOP WELDING IMMEDIATELY

and clean the nozzle.

d. If the slag cannot be thoroughly cleaned

from the nozzle, REPLACE THE NOZZLE!

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

allowing welding current to flow through it as well

as the contact tip. When shorted, anozzle will

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

which can DAMAGE the gas diffuser and/or con-

ductor tube.

TESTING FOR A SHORTED NOZZLE

Arcing between the nozzle and the work piece

ALWAYS means the nozzle is shorted, but this can

be hard to detect through the lens of a welding

helmet. The following testing method is another

way to tell if a nozzle is shorted.

With the welder unplugged from the AC power

source, touch the probes of an ohmmeter or conti-

nuity tester to the end of the contact tip and the

outside of the nozzle. If there is any continuityat

all, the nozzle IS shorted. Clean or replace as

needed.

TROUBLESHOOTING

The following TROUBLESHOOTING section is

provided as a guide to help resolve some of the

more common problems that could be encoun-

tered. Should you or qualified repair personnel be

unable to resolve a problem or determine which of

the possible solutions will remedy a specific prob-

lem, contact MIG WELDER SERVICE for over-

the-phone diagnostic assistance at:

(800)-328-2921. In Minnesota call: (612) 884-

3211.

BEFORE CALLING MIG WELDER SERVICE,

have the welder unplugged from the AC power

source, the side panels removed, and the tele-

phone as near to the welder as possible.

ELECTRIC SHOCK CAN KILL!

_ARC RAYS CAN INJURE EYES AND

BURN SKIN!

FIRE OR EXPLOSION CAN CAUSE

DEATH, INJURY, AND PROPERTY DAMAGE!

FUMES, GASSES, AND VAPORS CAN

CAUSE DISCOMFORT, ILLNESS, AND DEATH!

MAINTENANCE AND TROUBLESHOOTING Page 28

IMPROPER HANDLING AND MAINTE-

NANCE OF COMPRESSED GAS CYLINDERS

AND REGULATORS CAN RESULT IN SERIOUS

INJURY OR DEATH!

DO NOT ATTEMPT TO TROUBLESHOOT THIS

WELDER unless you have read, understand, and

intend to follow all five parts of the SAFETY IN-

STRUCTIONS section of this welder.

In the following TROUBLESHOOTING table, a

POSSIBLE CAUSE, listed for certain problems, is

INSUFFICIENT SHIELDING GAS COVERAGE.

This "cause" itself can be the result of many differ-

ent causes. Below, and preceeding the TROU-

BLESHOOTING table, is a table listing the causes

and solutions for insufficient shielding gas cover-

age. All of these causes have one or more of the

following symptoms: a weed that is dirty, porous,

brittle, and/or non-penetrating.

DISCONNECT THE WELDER FROM THE AC

POWER SOURCE BEFORE A'I'rEMPTING ANY

INSPECTION OR WORK ON THE INSIDE OF

THE WELDER.

SYMPTOM

BASIC TROUBLESHOOTING GUIDE

POSSIBLE CAUSE

Gas cylinder valve turned off

Gas cylinder empty or near

empty

Loose gas supply-line fittings

Gas supply hose leaking

Plugged welding nozzle

or gas diffuser

Frozen regulator/flowmeter

Broken or defective

regulator/flowmeter

Wrong polarity

DIRTY, POROUS, BRITTLE

WELD

REMEDY

Open gas valve

Replace gas cylinder

Tighten fitting

Replace hose

Clean or replace nozzle or

clean gas diffuser

Thaw regulator/flowmeter and

change gas from CO2 to a mix

(see selecting shielding gas)

Have repaired or replace

Change polarity

MAINTENANCE AND TROUBLESHOOTING Page 29

DIRTY, POROUS, BRITTLE

WELD Gas flow rate too low

WIRE FEED AND GAS

WORKS, BUT NO ARC

GAS AND ARC WORK BUT

NOT WIRE FEED

WIRE FEED AND ARC

BUT NO GAS

NOTHING WORKS BUT

FAN IS ON

Wind or draft blowing gas

away from weld puddle

Wrong type of gas

Bad ground or

loose connection

Bad connection to gun

or faulty gun

Faulty wire speed circuit

board/potentiometer

No tension on driver roller

Faulty drive motor

(extremely rare)

Faulty solenoid switch

Faulty regulator/fiowmeter

Gas bottle empty

Clogged nozzle or gas diffuser

Faulty trigger on gun

Increase flow rate from

regutator/flowmeter

Try Increasing flow rate or set

up wind break

See select shielding gas

Check ground or tighten all

connections

Check connection to gun or

replace gun

Replace wire speed circuit

board/potentiometer

Adjust drive tension

Replace drive motor

Replace solenoid switch

Have repaired or replace

regulator/flowmeter

Replace gas bottle

Clean or replace as needed

Replace trigger

MAINTENANCE AND TROUBLESHOOTING Page 30

NOTHING WORKS BUT

FAN IS ON

LOW OUTPUT OR

NON-PENETRATING WELD

WtRE "BIRDNESTING" AT

DRIVE ROLLER

Exceeded duty cycle; thermal

protector opened circuit

Faulty rectifier

Faulty transformer

(extremely rare)

Loose connection inside

the machine

Too long or improper

extension cord

Wrong type or size of wire

Wrong type of gas or no gas

Poor ground connection

Wrong polarity

Wrong size contact tip

Loose gun connection

or faulty gun assembly

Too much tension

on drive roller

Gun assembly not completely

seated into drive assembly

i ii ir

Allow welder to cool at least 10

minutes with fan running

(observe duty cycle)

Replace rectifier

Replace transformer

Blow inside of machine out

with compressed air clean and

tighten all connections

See manual under

extension cord use

Check manual for proper

wire size or type

Check manual and change gas

Reposition clamp and check

cable to clamp connection

Change polarity

Use proper size tip

Tighten gun connection

or replace gun

Adjust drive tension

(see manual)

See gun assembly

instruction in manual

WIRE "BIRDNESTING" AT

DRIVE ROLLER

WIRE BURNS BACK TO

CONTACT TIP

CONSTANT GAS FLOW

MAINTENANCE AND TROUBLESHOOTING Page 31

..... illlllll iii ....... i i

Contact tip is clogged

or damaged

Liner stretched or too long

Using aluminum wire with a

steel liner

Using aluminum wire with a

steel drive roller

Gun liner worn or damaged

Liner stretched or too long

Wrong size contact tip

Contact tip clogged

or damaged

Using aluminum wire with a

steel liner

Using aluminum wire with a

steel drive roller

Problems feeding

aluminum wire

Faulty solenoid or

debris in solenoid

Replace contact tip

Trim liner to proper length

Replace liner with teflon liner

(Part # 4325)

Replace drive roller with a

rubber drive roller (Part #4324)

Trim liner to proper length

Use correct size contact tip

Replace contact tip

Replace liner with teflon liner

(Part # 4325)

Replace ddve roller with a

rubber drive roller (Part # 4324)

See installing aluminum wire

in manual

Replace solenoid

Replace liner

Gun liner worn or damaged

MAINTENANCE AND TROUBLESHOOTING Page 32

FAN MOTOR DOES NOT RUN Loose connection or

faulty motor

Bad connection from

cable to clamp

= = = =llll,

Check connections and

replace fan motor if needed

Tighten connection or

replace cable

GROUND CLAMP AND/OR

CABLE GETS HOT

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

ITEM DESCR|!_TION

1 Rectifier

2 Fan Motor Kit

3 Fan Blade

4 Sjoindle

5 Spindle Adaptor

6 Power Cord w/Strain Relief

7Fitting _,

8 Solenoid

..........9 Fitting ......

10 Drive Roller ,Q24/03,0/.035

11 Tension Arm

12 Inlet Guide Tube

13 Drive Base

14 Drive Motor

15 Mig Gun Connector

16 Knob

17 Mig Connector Jumper

18 Handle

19 Hood Hinge

20 Right Side & Cover

PART No. ITEM

860-905-666 21

216-087-666 22

316-009-666 23

312-076-666 !24

312-077-666 25

248-197-666 26

253-018-666 27

246-212-666 28

253-038-000 29

4323 30

880-089-666 31

239-123-666 32

312-103-666 33

216-089-666 34

412-465-666 35

246-326-000 36

412-464-666 37

880-012-010 38

412-278-010 39

410-568-030 40

DESCRIPTION

Faceplate

Wire Speed Control

Knob

Power Switch

Steel Uner,

Teflon Uner

Gun Wiring Harness

Complete Gun Assembly

TriQaer Assembly

Handle Cap

Conductor Tube Insulation

iGas Diffuser

.024 Contact liDS (Bag of 6)

Steel Nozzle(Tapered),

Spot Nozzle (.Notched.)

Base

Ground Cable Less Clamp

Transformer

Reactor Coil

PART No.

410-694-020

880-094-666

246-041-666

246-177-6_

433t

4325

860-744-000

238-224-100

334-221-000

334-219-000

334-269-000

334-228-000

4309

4328

4329

410-643-010

238-216-666

880-011-888

880-010-888

(Not Shown) Left Side Panel 410-557-030

(Not Shown) Hood 410-575-010

(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

The Model Number will be found on the welder

nameplate. Always mention the Model Number

when requesting service or repair parts for your

Sears Welder.

All parts listed herein may be ordered from any

Sears Service Center and most Sears stores.

WHEN ORDERING REPAIR PARTS, ALWAYS

GIVE THE FOLLOWING INFORMATION:

1. PART NUMBER

2. PART DESCRIPTION

3. MODEL NUMBER

4. NAME OF ITEM

If the parts you need are not stocked locally, your

order will be electronically transmitted to aSears

Repair Parts Distribution Center for expedited

handling.

SEARS ROEBUCK AND CO., Chicago, IL. 60684 U.S.A.

FORM NO. 811-449-000 PRINTED IN USA

Craftsman 93420105 User Manual WELDER Manuals And Guides L0803454

CRAFTSMAN Welder Manual L0803454 CRAFTSMAN Welder Owner's Manual, CRAFTSMAN Welder installation guides

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