1128762

Flux-cored 125 Amp Welder

Assembly & Operating Instructions

READ ALL INSTRUCTIONS AND WARNINGS BEFORE USING THIS PRODUCT.

This manual provides important information on proper operation & maintenance. Every effort has been

made to ensure the accuracy of this manual. These instructions are not meant to cover every possible

condition and situation that may occur. We reserve the right to change this product at any time

without prior notice.

IF THERE IS ANY QUESTION ABOUT A CONDITION BEING SAFE OR UNSAFE, DO NOT OPERATE THIS PRODUCT!

HAVE QUESTIONS OR PROBLEMS? DO NOT RETURN THIS PRODUCT TO THE RETAILER - CONTACT CUSTOMER SERVICE.

If you experience a problem or need parts for this product, call our customer support at

1-888-376-9601. A copy of the sales receipt is required. FOR CONSUMER USE ONLY – NOT FOR PROFESSIONAL USE. KEEP THIS MANUAL, SALES RECEIPT & APPLICABLE WARRANTY FOR FUTURE

REFERENCE.

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GENERAL PRODUCT SPECIFICATIONS

SPECIFICATIONS • Thermal Overload Protection • Output: 80A (rated current)@18V-20%, 125A (peak current) • Input: 120V, 60Hz, 20A, 1Ph • Duty Cycle 20%@80 AMPS • Wire Size: .030 - .035 Inch • Heat Settings: Two • MAX Metal Thickness: 18 Gauge / 3/16"

FEATURES: • Includes Ground Cable With Clamp, Welding Gun & Brush Hammer

KEEP THIS MANUAL, SALES RECEIPT & APPLICABLE WARRANTY FOR FUTURE

REFERENCE.

READ ALL INSTRUCTIONS AND WARNINGS BEFORE USING THIS PRODUCT.

When unpacking, check to make sure all parts listed are included. If any parts are missing or broken,

please call Customer Support at 1-888-376-9601.

FOR CONSUMER USE ONLY – NOT FOR PROFESSIONAL USE

TABLE OF CONTENTS

The warnings, cautions and instructions dis-cussed in this instruction manual cannotcover all possible conditions or situations thatcould occur. It must be understood by theoperator that common sense and caution arefactors which cannot be built into this prod-uct, but must be supplied by the operator.Reading this operator’s manual before usingthe welder will enable you to do a better,safer job. Learn the welder’s applications andlimitations as well as the specific potentialhazards peculiar to welding.

IMPORTANT SAFETY INFORMATION

The following safety information is providedas guidelines to help you operate your newwelder under the safest possible conditions.Any equipment that uses electrical powercan be potentially dangerous to use whensafety or safe handling instructions are notknown or not followed. The following safetyinformation is provided to give the user theinformation necessary for safe use and oper-ation.

A procedure step preceded by a WARNINGis an indication that the next step contains aprocedure that might be injurious to a personif proper safety precautions are not heeded.

A procedure preceded by a CAUTION is anindication that the next step contains a pro-cedure that might damage the equipmentbeing used.

A NOTE may be used before or after a pro-cedure step to highlight or explain somethingin that step.

READ ALL SAFETY INSTRUCTIONSCAREFULLY before attempting to install,operate, or service this welder. Failure tocomply with these instructions could result inpersonal injury and/or property damage.

RETAIN THESE INSTRUCTIONS FORFUTURE REFERENCE.

Note:• The following safety alert symbols

identify important safety messages in thismanual.

• When you see one of the symbols shownhere, be alert to the possibility of person-al injury and carefully read the messagethat follows.

This symbol indicates that thepossibility of electric shock hazardexists during the operation of thestep(s) that follow.

This symbol indicates that thepossibility of fire hazard existsduring the operation of the step(s)that follow.

This symbol indicates that thehelmet must be worn during thestep(s) that follow to protectagainst eye damage and burnsdue to flash hazard.

This symbol indicates that thepossibility of toxic gas hazardexists during operation of thestep(s) that follow.

This symbol indicates that thepossibility of being burned by hotslag exists during operation of thestep(s) that follow.

This symbol indicates that theeye protection should be worn toprotect against flying debris in thefollowing step(s).

• Published standards on safety areavailable. They are listed in ADDITIONALSAFETY INFORMATION at the end ofthis SAFETY SUMMARY.

The National Electrical Code, OccupationSafety and Health Act regulations, localindustrial codes and local inspection require-ments also provide a basis for equipmentinstallation, use, and service.

SAFETY SUMMARY

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SHOCK HAZARDS

WARNING

ELECTRIC SHOCK CAN KILL! To reducethe risk of death or serious injury from shock,read, understand, and follow the followingsafety instructions. In addition, make certainthat anyone else who uses this weldingequipment, or who is a bystander in thewelding area understands and follows thesesafety instructions as well.

• IMPORTANT! TO REDUCE THE RISKOF DEATH, INJURY, OR PROPERTYDAMAGE, DO NOT ATTEMPT OPERA-TION of this welding equipment until youhave read and understand the followingsafety summary.

• Do not, in any manner, come into physicalcontact with any part of the welding cur-rent circuit. The welding current circuitincludes:

a. the work piece or any conductivematerial in contact with it,

b. the ground clamp,c. the electrode or welding wire,d. any metal parts on the electrode

holder, or wire feed torch.• Do not weld in a damp area or come in

contact with a moist or wet surface.• Do not attempt to weld if any part of cloth-

ing or body is wet.• Do not allow the welding equipment

to come in contact with water or moisture.• Do not drag welding cables, wire feed

torch, or welder power cord through orallow them to come into contact withwater or moisture.

• Do not touch welder, attempt to turnwelder on or off if any part of the body orclothing is moist or if you are in physicalcontact with water or moisture.

• Do not attempt to plug the welder into thepower source if any part of body or cloth-ing is moist, or if you are in physical con-tact with water or moisture.

• Do not connect welder work piece clampto or weld on electrical conduit.

• Do not alter power cord or power cordplug in any way.

• Do not attempt to plug the welder

into the power source if the ground prongon power cord plug is bent over, brokenoff, or missing.

• Do not allow the welder to be connectedto the power source or attempt to weld ifthe welder, welding cables, welding site,or welder power cord are exposed to anyform of atmospheric precipitation, or saltwater spray.

• Do not carry coiled welding cables aroundshoulders, or any other part of the body,when they are plugged into the welder.

• Do not modify any wiring, groundconnections, switches, or fuses in thiswelding equipment.

• Wear welding gloves to help insulatehands from welding circuit.

• Keep all liquid containers far enoughaway from the welder and work area sothat if spilled, the liquid can not possiblycome in contact with any part of thewelder or electrical welding circuit.

• Replace any cracked or damaged partsthat are insulated or act as insulatorssuch as welding cables, power cord, orelectrode holder IMMEDIATELY.

FLASH HAZARDS

WARNING

ARC RAYS CAN INJURE EYES AND BURNSKIN! To reduce the risk of injury from arcrays, read, understand, and follow the follow-ing safety instructions. In addition, make cer-tain that anyone else that uses this weldingequipment, or is a bystander in the weldingarea understands and follows these safetyinstructions as well. Headshields and filtershould conform to ANSI Z87.1 standards.

• Do not look at an electric arc withoutproper protection. A welding arc isextremely bright and intense and, withinadequate or no eye protection, the reti-na can be burned, leaving a permanentdark spot in the field of vision. A shield orhelmet with a number 10 shade filter lens(minimum) must be used.

• Do not strike a welding arc until allbystanders and you (the welder) havewelding shields and/or helmets in place.

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• Do not wear a cracked or broken helmetand replace any cracked or broken filterlenses IMMEDIATELY.

• Do not allow the uninsulated portion of thewire feed torch to touch the ground clampor grounded work to prevent an arc flashfrom being created on contact.

• Provide bystanders with shields or hel-mets fitted with a #10 shade filter lens.

• Wear protective clothing. The intense lightof the welding arc can burn the skin inmuch the same way as the sun, eventhrough light-weight clothing. Wear darkclothing of heavy material. The shirt wornshould be long sleeved and the collar keptbuttoned to protect chest and neck.

• Protect against REFLECTED ARC RAYS.Arc rays can be reflected off shiny sur-faces such as a glossy painted surface,aluminum, stainless steel, and glass. It ispossible for your eyes to be injured byreflected arc rays even when wearing aprotective helmet or shield. If welding witha reflective surface behind you, arc rayscan bounce off the surface, then off the fil-ter lens on the inside of your helmetor shield, then into your eyes. If a reflec-tive background exists in your weldingarea, either remove it or cover it withsomething non-flammable and non-reflec-tive. Reflective arc rays can also causeskin burn in addition to eye injury.

FIRE HAZARDS

WARNING

FIRE OR EXPLOSION CAN CAUSEDEATH, INJURY, AND PROPERTY DAM-AGE! To reduce the risk of death, injury, orproperty damage from fire or explosion, read,understand, and follow the following safetyinstructions. In addition, make certain thatanyone else that uses this welding equip-ment, or is a bystander in the welding area,understands and follows these safety instruc-tions as well. REMEMBER! Arc welding bynature produces sparks, hot spatter, moltenmetal drops, hot slag, and hot metal partsthat can start fires, burn skin, and damageeyes.

• Do not wear gloves or other clothing thatcontains oil, grease, or other flammablesubstances.

• Do not wear flammable hair preparations.• Do not weld in an area until it is checked

and cleared of combustible and/or flam-mable materials. BE AWARE that sparksand slag can fly 35 feet and can passthrough small cracks and openings. Ifwork and combustibles cannot be sepa-rated by a minimum of 35 feet, protectagainst ignition with suitable, snug-fitting,fire resistant, covers or shields.

• Do not weld on walls until checking forand removing combustibles touching theother side of the walls.

• Do not weld, cut, or perform other suchwork on used barrels, drums, tanks, orother containers that had contained aflammable or toxic substance. The tech-niques for removing flammable substanceand vapors, to make a used containersafe for welding or cutting, are quite com-plex and require special education andtraining.

• Do not strike an arc on a compressedgas or air cylinder or other pressure ves-sel. Doing so will create a brittle area thatcan result in a violent rupture immediatelyor at a later time as a result of roughhandling.

• Do not weld or cut in an area where theair may contain flammable dust (such asgrain dust), gas, or liquid vapors (such asgasoline).

• Do not handle hot metal, such as the workpiece or electrode stubs, with bare hands.

• Wear leather gloves, heavy long sleeveshirt, cuffless trousers, high-toppedshoes, helmet, and cap. As necessary,use additional protective clothing such asleather jacket or sleeves, fire resistantleggings, or apron. Hot sparks or metalcan lodge in rolled up sleeves, trousercuffs, or pockets. Sleeves and collarsshould be kept buttoned and pocketseliminated from the shirt front.

• Have fire extinguisher equipment handyfor immediate use! A portable chemicalfire extinguisher, type ABC, is recom-mended.

• Wear ear plugs when welding overheadto prevent spatter or slag from falling intoear.

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• Make sure welding area has a good,solid, safe floor, preferably concrete ormasonry, not tiled, carpeted, or made ofany other flammable material.

• Protect flammable walls, ceilings, andfloors with heat resistant covers orshields.

• Check welding area to make sure it isfree of sparks, glowing metal or slag, andflames before leaving the welding area.

FUME HAZARDS

WARNING

FUMES, GASSES, AND VAPORS CANCAUSE DISCOMFORT, ILLNESS, ANDDEATH! To reduce the risk of discomfort, ill-ness, or death, read, understand, and followthe following safety instructions. In addition,make certain that anyone else that uses thiswelding equipment or is a bystander in thewelding area, understands and follows thesesafety instructions as well.

• Do not weld in an area until it is checkedfor adequate ventilation as described inANSI standard #Z49.1. If ventilation is notadequate to exchange all fumes andgasses generated during the weldingprocess with fresh air, do not weld unlessyou (the welder) and all bystanders arewearing air-supplied respirators.

• Do not heat metals coated with, or thatcontain, materials that produce toxicfumes (such as galvanized steel), unlessthe coating is removed. Make certain thearea is well ventilated, and the operatorand all bystanders are wearing air-sup-plied respirators.

• Do not weld, cut, or heat lead, zinc, cad-mium, mercury, beryllium, or similar met-als without seeking professional adviceand inspection of the ventilation of thewelding area. These metals produceEXTREMELY TOXIC fumes which cancause discomfort, illness, and death.

• Do not weld or cut in areas that are nearchlorinated solvents. Vapors from chlori-nated hydrocarbons, such as trichloroeth-ylene and perchloroethylene, can bedecomposed by the heat of an electricarc or its ultraviolet radiation. Theseactions can cause PHOSGENE, a HIGH-LY TOXIC gas to form, along with otherlung and eye-irritating gasses. Do notweld or cut where these solvent vaporscan be drawn into the work area or wherethe ultraviolet radiation can penetrate toareas containing even very smallamounts of these vapors.

• Do not weld in a confined area unless itis being ventilated or the operator (andanyone else in the area) is wearing anair-supplied respirator.

• Stop welding if you develop momentaryeye, nose, or throat irritation as this indi-cates inadequate ventilation. Stop workand take necessary steps to improveventilation in the welding area. Do notresume welding if physical discomfortpersists.

SERVICETool service must be performed only by qualified repair personnel. Service or maintenance by unqualifiedpersonnel could result in a risk of injury.

When servicing a tool, use only identical replacement parts and follow instructions in the manual. Useof unauthorized parts or failure to follow Maintenance Instructions may create a risk of shock or injury.

SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE.This manual contains important information regarding safety, operation, maintenance and storage of this product.Before use, read carefully and understand all warnings, cautions, instructions and labels. Failure to do so could resultin serious personal injury, property damage or even death.

IMPORTANT SAFETY INSTRUCTIONS

Before using this tool, you need to become familiar with its operation. If you are unsure about theoperation of the tool, or have any questions about its proper use, call the Customer Service Department at1-888-376-9601. Follow these instructions for safe handling of the tool:� Be sure your work area is clean and secure. Be sure the area is free from all foreign material, nails,

staples, or any other material.� Always use the appropriate safety gear when operating. Including but not limited to, goggles, dust

mask or respirator.

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The welder consistsof a single-phase power transformer, and aunique built-in control/feeder. This welder iscapable of welding with 0.030 inch self-shielding flux-core wire. Now you can weld18 gauge sheet metal up to 3/16 inch with asingle pass. You can weld 1/4 inch steel withbeveling and multiple pass techniques. Table1 lists your wire feed welder specifications.

Table 1. Welder Specifications

Primary (input) volts 120 VacPrimary (inputs) Amps 20Phase SingleFrequency 60 HzSecondary (output) volts 19Secondary (output) amps 80Duty Cycle Rating at 80 amps 20%Open Circuit Volts (Max.) 27 VAC

DUTY CYCLEThe duty cycle rating of a welder defines howlong the operator can weld and how long thewelder must be rested and cooled. Duty cycleis expressed as a percentage of 10 minutesand represents the maximum welding timeallowed. The balance of the 10 minute cycle isrequired for cooling.

Your new welder has a duty cycle rating of20% at the CSA rated output of 80 amps.This means that you can weld for two (2)minutes out of 10 with the remaining eight (8)minutes required for cooling. (See Table 2.)

Table 2. Duty Cycle RatingsDuty Maximum RequiredCycle Welding RestingRating Time Time20% 2 minutes 8 minutes40% 4 minutes 6 minutes60% 6 minutes 4 minutes80% 8 minutes 2 minutes

100% 10 minutes 0 minutes

INTERNAL THERMAL PROTECTION

CAUTIONDo not constantly exceed the duty cycle ordamage to the welder can result. If youexceed the duty cycle of the welder, an inter-nal thermal protector will open, shutting off allwelder functions except the cooling fan. Ifthis happens, DO NOT SHUT OFF THEWELDER. Leave the welder turned on withthe fan running. After cooling, the thermalprotector will automatically reset and thewelder will function normally again. Howeveryou should wait at least ten minutes after thethermal protector opens before resumingwelding. You must do this even if the thermalprotector resets itself before the ten minutesis up or you may experience less than speci-fied duty cycle performance.

If you find that the welder will not weld fortwo minutes without stopping, reduce thewire speed slightly and tune in the welder atthe lowest wire speed setting that still pro-duces a smooth arc. Welding with the wirespeed set too high causes excessive currentdraw and shortens the duty cycle.

WELDER SPECIFICATIONS

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Handle – Rugged, top mounted handleallows for easy transport of your welder.

Wire Speed Control – Use this dial to adjustthe speed at which the welder feeds wire tothe torch. 1 is the slowest wire feed speed, 10is the highest. You will need to adjust or “tune-in” your wire speed for different welding condi-tions (thickness of metals, metal type, wiresize, etc.). When the wire speed is properly“tuned-in” the welding wire will melt into thematerial you are welding as quickly as it is fedthrough the welding torch.

Voltage Selector – This two position switchadjusts the voltage or “heat” of your welder.Select MIN setting for lower voltage andMAX setting for higher voltage. Differentmaterials and material thickness will requiredifferent voltage settings. You will need toadjust your voltage accordingly for differentwelding conditions. By properly adjustingyour voltage settings and wire feed speed,you will enable clean, precision welds.

Power Switch – This switch turns the welderON and OFF. (Make sure the power switch isin the OFF position before performing anymaintenance on the welder.)

Power Cord – This is a standard, grounded120 volt power cord. (Make sure you areusing a properly grounded 120 Vac, 60Hz,single phase, 20 amp power source.)

Ground Clamp – Attaching the groundclamp to your work piece “completes” thewelding current circuit. You must attach theground clamp to the metal you are welding. Ifthe ground clamp is not connected to themetal work piece you intend to weld, thewelder will not have a completed circuit andyou will be unable to weld. A poor connectionat the ground clamp will waste power andheat. Scrape away dirt, rust, scale, oil orpaint before attaching the ground clamp.

Ground Cable – The ground cable connectsthe ground clamp to the internal workings ofthe welder.

Welding Torch and Cable – The weldingtorch controls the delivery of the welding wireto the material to be welded. The weldingwire is fed through the welding cable andwelding torch when the welding torch triggeris pulled. You will need to install a contact tipand welding nozzle to the end of the weldingtorch, as described later in this manual, priorto welding.

Circuit Breaker – This unit is equipped witha circuit breaker switch which protects thewelder’s power supply from line voltagesurges. If circuit breaker is tripped, reset bypressing the button located inside the accesspanel on the dividing wall of the welder.

Welding Terms -Now that you are familiarwith the main parts of the welder, make noteof the following terms. You will see themused throughout this manual.weld puddle: The localized volumeof molten metal in a weld prior to itssolidification.weld angle: The angle of the welding wire,as it extends from the welding torch, in rela-tion to the item being welded.slag: The protective coating that forms onthe surface of molten metal.arc: A sustained luminous discharge of elec-tricity across a gap in a circuit.welding bead: The extended build up of aweld, made by pushing or pulling the weldpuddle.

KNOW YOUR WELDER

Figure 1. Model WE6482 Welder

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POWER SOURCE CONNECTION

POWER REQUIREMENTSThis welder is designed to operate on aproperly grounded 120 volt, 60Hz, single-phase alternating current (ac) power sourcefused with a 20 amp time delayed fuse or cir-cuit breaker. It is recommended that a quali-fied electrician verify the ACTUAL VOLTAGEat the receptacle into which the welder willbe plugged and confirm that the receptacle isproperly fused and grounded. The use of theproper circuit size can eliminate nuisance cir-cuit breaker tripping when welding.

DO NOT OPERATE THIS WELDER if theACTUAL power source voltage is less than105 volts ac or greater than 132 volts ac.Contact a qualified electrician if this problemexists. Improper performance and/or damageto the welder will result if operated on inade-quate or excessive power.

CONNECT TO POWER SOURCE

WARNING

High voltage danger from power source!Consult a qualified electrician for properinstallation of receptacle at the power source.This welder must be grounded while in use toprotect the operator from electrical shock. Ifyou are not sure if your outlet is properlygrounded, have it checked by a qualified elec-trician. Do not cut off the grounding prong oralter the plug in any way and do not use anyadapters between the welder’s power cordand the power source receptacle. Make surethe POWER switch is OFF then connect yourwelder’s power cord to a properly grounded120 Vac, 60 Hz, single phase, 20 amp powersource.

EXTENSION CORDSFor optimum welder performance, an exten-sion cord should not be used unlessabsolutely necessary. If necessary, care mustbe taken in selecting an extension cordappropriate for use with your specific welder.

Select a properly grounded extension cordthat will mate directly with the power sourcereceptacle and the welder power cord with-out the use of adapters. Make certain thatthe extension cord is properly wired and ingood electrical condition. Extension cordsmust be a #12 gauge cord at the smallest.Do not use an extension cord over 25 ft. inlength.

ASSEMBLING THE WELDERThe following procedures describe theprocess required to assemble, install, main-tain, and prepare to weld with your new wirefeed welder.UNPACKING THE WELDER1. Remove any cartons or bags containing

parts/accessories. (Most parts areshipped inside the welder door.)

2. Open the cartons or bags packed withyour welder and inspect their contents fordamage.

3. Layout the parts and compare them tothe the packing list in Table 1 to familiar-ize yourself with the parts and what theyare called. This will help you when read-ing the manual.

PACKING LISTTable 3 contains a list of the items you willfind packed in the carton.

Table 3. Packing List

ITEM QTY.

Welder 1Handle Screws 2Shaded Lens 1Welder Handle 1Wire Brush/Hammer 1Parts Bag 1Contact Tip 0.030 1Contact Tip 0.035 1Nozzle 1Manual 1

WELDER INSTALLATION

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INSTALLING THE HANDLE1. Line up the holes in the handles with the

holes on the top of the welder.2. Place a lock washer then a washer onto

the welder handle screws.3. Insert the screws with the washers

through the holes on the welder handleand into the top of the welder and tighten.(see Figure 3)

ALIGN AND SET THE DRIVE ROLLERBefore installing any welding wire into theunit, the proper sized groove must be placedinto position on the wire drive mechanism.

Adjust the drive roller according to thefollowing steps:1. Open the door to the welder drive com-

partment.2. Remove the drive tension by loosening

the tension adjusting knob and lifting theDrive Tension Adjustor away from theDrive Tension Arm. Pull the drive tensionarm away from the drive roller.

3. If there is wire already installed in thewelder, roll it back onto the wire spool byhand-turning the spool counterclockwise.Be careful not to allow the wire to comeout of the rear end of the inlet guide tubewithout holding onto it or it will unspoolitself. Put the end of the wire into the holeon the outside edge of the wire spool andbend it over to hold the wire in place.Remove the spool of wire from the drivecompartment of the welder.

4. Rotate the Drive Roller Cap counterclock-wise and remove it from the Drive Roller.

5. Pull the Drive Roller off of the DriveRoller Shaft.

Figure 3. Handle Installation

Figure 4. Feed Motor

Figure 5. Drive Roller Adjustments

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Note: The drive roller has two wire sizegrooves built into it. When installing the driveroller, the number stamped on the drive rollerfor the wire size you are using should be fac-ing you. Use only the proper size drive rollerwhen using your welder.

Table 4 indicates which drive roller grooveshould be used with each wire diameter size.

4. Find the side of the drive roller that isstamped with the same wire diameter asthat of the wire being installed (seeFigure 6). Push the drive roller onto thedrive roller shaft, with the side stampedwith the desired wire diameter facing you.

5. Reinstall the Drive Roller Cap and lock inplace by turning it clockwise.

6. Close the door to the welder drive com-partment.

SELECTING THE WELDING WIREThis welder uses both four inch or eight inchspools of 0.030 inch (0.6mm) or 0.035 inch(0.9mm) self shielding flux-core wire. Steelfrom 18 gauge up to 3/16 inch thick can bewelded with this wire.

NOTE:• Metal thinner than 18 gauge cannot be

welded with this machine. Attempting to do

so will cause burn through (blowing holes)in the metal you are intending to weld.

• If a spool has developed heavy oxidation,the only solution to the problem is to dis-card the spool of wire.

If you have an oxidized spool of wire, do notdiscard it until you have unspooled a fewturns of wire to see if the wire further downon the spool is in usable condition, if not, –discard the spool.

INSTALL THE WELDING WIRE

WARNING

Electric shock can kill! Always turn thePOWER switch OFF and unplug the powercord from the ac power source beforeinstalling wire.

Tech Tip: Before installing welding wire,make sure that you have removed any oldwire from the Torch Assembly. This will helpto prevent the possibility of the wire jamminginside the Torch Liner.

Be very careful when removing the weldingnozzle. The contact tip on this welder is elec-trically hot whenever the torch trigger ispulled. Make certain POWER is turned OFF.

1. Remove the nozzle and contact tip fromthe end of the torch assembly.

2. Make sure the proper groove on the driveroller is in place for the wire beinginstalled. If the proper groove is not inplace, change the drive roller asdescribed above.

3. Unwrap the spool of wire and then findthe leading end of the wire (it goesthrough a hole in the outer edge of thespool and is bent over the spool edge toprevent the wire from unspooling), BUTDO NOT UNHOOK IT YET.

4. Place the spool on the spindle in such amanner that when the wire comes off thespool, it will look like the top illustration inFigure 7. The welding wire should alwayscome off the top of the spool into thedrive mechanism.

Wire Diameter Drive Roller Groove:

.030 inch 0.8

.035 inch 0.9

Table 4. Drive Roller Sizing

Figure 6. Drive Roller

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5. If you are installing a four-inch spool ofwire, install the drive brake hardware onthe top of the spool of wire according tofigure 8A. If you are installing an eight-inchspool, install the spindle adapter and drivebrake hardware as shown in Figure 8B.The purpose of the drive brake is to causethe spool of wire to stop turning at nearlythe same moment that wire feeding stops.

6. Once the drive brake hardware is installed,set the spool tension.a) With one hand, turn the wire spool and

continue turning it while adjusting thetension on the spool.

b) With your free hand, tighten (turn clock-wise) the drive tension adjustment knob.

c) Stop tightening when drag is felt on thewire spool that you are turning, then stophand-turning the wire spool.

Note: If TOO MUCH tension is applied to thewire spool, the wire will slip on the drive rolleror will not be able to feed at all. If TOO LIT-TLE tension is applied, the spool of wire willwant to unspool itself. Readjust the drivebrake tension as necessary to correct foreither problem.7. After checking to make sure that your

welder is disconnected from the ac powersource, free the leading end of the wirefrom the spool, but do not let go of it untiltold to do so, or the wire will unspool itself.

8. Using a wire cutter, cut the bent end offthe leading end of the wire so that only astraight leading end remains.

9. Loosen the tension adjusting knob holdingthe drive tension arm in place and lift thetension arm up off the drive roller.

10. Insert the leading end of the wire into theinlet guide tube. Then push it across thedrive roller and into the torch assemblyabout six inches.

CAUTIONMake certain that the welding wire is actuallygoing into the torch liner. Be very sure it hasnot somehow been accidentally been routedalongside the liner or even in some otherdirection. If this should happen, the wirecould feed inside the cable casing or take aright angle and follow the wires and gas hoseinside the welder. It could also feed back onitself jamming up the mechanism.

11. Line the wire up in groove of the driveroller, then allow the drive tension arm todrop onto the drive roller.

12. Flip the quick release drive tensioner backup into position on the drive tensioner arm.

13. Tighten (turn clockwise) the drive tensionadjusting knob until the tension roller isapplying enough force on the wire to pre-vent it from slipping out of the driveassembly.

14. Let go of the wire.15. Connect the welder power cord to the ac

power source. Turn the welder ON. Setthe VOLTAGE switch to the voltage (heat)setting recommended for the gauge metalthat is to be welded. Refer to the labelmounted on the cover, inside the drivecompartment, for recommended voltage(heat) settings for your welding job. TheVOLTAGE selector controls the weld

Figure 7. Wire Installation

Figure 8A. DriveBrake Hardware

Installation

Figure 8B. SpindleAdapter and DriveBrake Installation

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heat. There are two voltage heat selec-tions (labeled MIN and MAX) available onthis welder. Position MIN provides thelowest voltage (heat) and position MAXthe highest voltage (heat).

16. Set the WIRE SPEED control to the mid-dle of the wire speed range.

17. Straighten the torch cable and pull thetrigger on the welding torch to feed thewire through the torch assembly.

18. When at least an inch of wire sticks outpast the end of the torch, release thetrigger.

19. Turn the Power Switch to the OFF position.20. Select a contact tip stamped with the

same diameter as the wire being used. Ifstamped in metric see Table 4 on p. 12 ofthis manual.

Note: Due to inherent variances in flux-coredwelding wire, it may be necessary to use acontact tip one size larger than your flux corewire if wire jams occur.

21. Slide the contact tip over the wire (pro-truding from the end of the torch). Threadthe contact tip into the end of the torchand hand-tighten securely.

22. Install the nozzle on the torch assembly.For best results, coat the inside of thenozzle with anti-stick spray or gel.

23. Cut off the excess wire that extends pastthe end of the nozzle.

24. Turn the welder ON.

SET THE WIRE DRIVE TENSION

WARNING

Arc flash can injure eyes! To reduce therisk of arc flash, make certain that the wirecoming out of the end of the torch does notcome in contact with work piece, groundclamp or any grounded material during thedrive tension setting process or arcing willoccur.1. Pull the trigger on the torch.2. Turn the drive tension adjustment knob

clockwise, increasing the drive tensionuntil the wire seems to feed smoothlywithout slipping.

When set correctly, there should be no slip-page between the wire and the drive rollerunder normal conditions. If an obstructionoccurs along the wire feed path, the wireshould then slip on the drive roller.

After the tension is properly adjusted, thequick release drive tensioner may unlockedand relocked and no readjustment of thedrive tension adjustment knob will be neces-sary (unless the diameter or type of wire ischanged).

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Operation of this welder consists of selectingand adjusting operating controls for optimumvoltage (welding heat) and wire speedsettings.

CONTROLS AND INDICATORS

WARNING

Electric shock can kill! Whenever the TorchTrigger switch is in the ON position, the weld-ing circuit is activated. Under this condition,an arc will occur if the welding wire or anypart of the welding circuit comes in contactwith welding ground.

POWER SWITCH - The power switch sup-plies electrical current to the welder.Whenever the power switch is in the ONposition, the welding circuit is activated.ALWAYS turn the power switch to the OFFposition and unplug the welder before per-forming any maintenance.

VOLTAGE SELECTOR - The voltage selec-tor controls the welding heat. The voltageselector is labeled "MIN" and "MAX". MIN isthe lowest heat and MAX is the highest.Refer to the label inside the welder side door(or on page 27 of this manual) for recom-mended voltage selector settings for yourwelding job. Switch position “MAX” producesthe rated output of 80 amps.

WIRE SPEED CONTROL - The wire speedcontrol adjusts the speed at which the wire isfed out of the welding torch. The wire speedneeds to be closely matched (tuned-in) to therate at which it is being melted off. Somethings that affect wire speed selection are thetype and diameter of the wire being used, theheat setting selected, and the welding positionto be used.

Note: The wire will feed faster without anarc. When an arc is being drawn, the wirespeed will slow down.

TUNING IN THE WIRE SPEEDThis is one of the most important parts ofMIG welder operation and must be donebefore starting each welding job or wheneverany of the following variables are changed:heat setting, wire diameter, or wire type.

1. Connect the Ground Clamp to a scrappiece of the same type of material whichyou will be welding. It should be equal toor greater than the thickness of the actualwork piece, and free of oil, paint, rust,etc.

2. Select a heat setting.3. Hold the torch in one hand, allowing the

nozzle to rest on the edge of the work-piece farthest away from you, and at anangle similar to that which will be usedwhen welding. (See HOLDING THETORCH on page 16 if you are uncertainof the angle at which you will be welding)

4. With your free hand, turn the Wire SpeedDial to maximum and continue to holdonto the knob.

WARNING

EXPOSURE TO A WELDING ARC ISEXTREMELY HARMFUL TO THE EYESAND SKIN! Prolonged exposure to thewelding arc can cause blindness and burns.Never strike an arc or begin welding until youare adequately protected. Wear flameproofwelding gloves, a heavy long sleeved shirt,cuffless trousers, high topped shoes, and awelding helmet.

5. Lower your welding helmet and pull thetrigger on the torch to start an arc, thenbegin to drag the torch toward you whilesimultaneously turning the Wire SpeedDial counter-clockwise.

6. LISTEN! As you decrease the wire speed,the sound that the arc makes will changefrom a sputtering to a high-pitchedbuzzing sound and then will begin sput-tering again if you decrease the wirespeed too much. The point on the wirespeed adjustment where the high-pitchedbuzzing sound is achieved is the correctsetting.

OPERATION

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You can use the wire speed control to slightlyincrease or decrease the heat and penetra-tion for a given heat setting by selectinghigher or lower wire speed settings. Repeatthis tune-in procedure if you select a newheat setting, a different diameter wire, or adifferent type of welding wire.

LEARNING TO WELDMIG (Metal Inert Gas) welding is the processof uniting metallic parts by heating and allow-ing the metals to flow together through theuse of an electrical arc. The electrical arc iscreated between a continuous consumablewire electrode (the welding wire) and thework piece. An inert shielding gas is used toprotect the weld puddle from contaminationand enhance the welding capabilities of theelectrical arc.

Whether you have welded before or not, it isimportant that you become familiar with yournew welder, its controls, and the resultsachieved at different settings. We strongly rec-ommend that you practice with your newwelder on scrap metal trying different heatsettings, base metal thicknesses, and weldingpositions for each type and size of wire youwill be using. By doing this you will gain a feelfor how changes in these welding variablesaffect the weld.

Of course, if you have not welded before,you will need to develop welding skills andtechniques as well.

The self-taught welder learns through aprocess of trial and error. The best way toteach yourself how to weld is with short peri-ods of practice at regular intervals. All prac-tice welds should be done on scrap metalthat can be discarded. Do not attempt tomake any repairs on valuable equipmentuntil you have satisfied yourself that yourpractice welds are of good appearance andfree of slag or gas inclusions. What you failto learn through practice will be learnedthrough mistakes and re-welds later on.

HOLDING THE TORCHThe best way to hold the welding torch is theway that feels most comfortable to you.While practicing to use your new welder,experiment holding the torch in different posi-

tions until you find the one that seems towork best for you. Refer to WELDINGPOSITIONS - p.18

Position the Torch to the Work PieceThere are two angles of the torch nozzle inrelation to the work piece that must be con-sidered when welding.1. Angle A (Figure 9) can be varied, but in

most cases the optimum angle will be 60degrees, the point at which the torch han-dle is parallel to the work piece. If angle Ais increased, penetration will increase. Ifangle A is decreased, penetration willdecrease also.

2. Angle B (Figure 10) can be varied for tworeasons: to improve the ability to see thearc in relation to the weld puddle and todirect the force of the arc.

The force of the welding arc follows astraight line out of the end of the nozzle.If angle B is changed, so will the direction ofarc force and the point at which penetrationwill be concentrated.

On a butt weld joint, the only reason to varyangle B from perpendicular (straight up) tothe work piece would be to improve visibilityof the weld puddle. In this case, angle B canbe varied anywhere from zero to 45 degreeswith 30 degrees working about the best.

Angle BFigure 10. Torch Position, Angle B

Angle A

Figure 9. Torch Position, Angle A

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On a fillet weld joint, the nozzle is generallypositioned in such a manner so as to split theangle between the horizontal and verticalmembers of the weld joint. In most cases, afillet weld will be 45 degrees.

Distance from the Work PieceThe end of the welding torch is designed withthe contact tip recessed from the end of thenozzle and the nozzle electrically insulatedfrom the rest of the torch. This permits theoperator to actually rest the nozzle on thework piece and drag it along while welding.This can be very helpful to beginning weldersto steady the torch, allowing the welder toconcentrate on welding technique. If the noz-zle is held off the work piece, the distancebetween the nozzle and the work pieceshould be kept constant and should notexceed 1/4 inch or the arc may beginsputtering, signaling a loss in weldingperformance.

WELDING TECHNIQUES

WARNING

EXPOSURE TO A WELDING ARC ISEXTREMELY HARMFUL TO THE EYESAND SKIN! Prolonged exposure to the weld-ing arc can cause blindness and burns.Never strike an arc or begin welding until youare adequately protected. Wear flameproofwelding gloves, a heavy long sleeved shirt,cuffless trousers, high topped shoes and awelding helmet.

WARNING

ELECTRIC SHOCK CAN KILL! To preventELECTRIC SHOCK, do not perform anywelding while standing, kneeling, or lyingdirectly on the grounded work.

MOVING THE TORCHTorch travel refers to the movement of thetorch along the weld joint and is broken intotwo elements: Direction and Speed. A solidweld bead requires that the welding torch bemoved steadily and at the right speed along

the weld joint. Moving the torch too fast, tooslow, or erratically will prevent proper fusionor create a lumpy, uneven bead.

1. TRAVEL DIRECTION is the direction thetorch is moved along the weld joint inrelation to the weld puddle. The torch iseither PUSHED (see Figure 11) into theweld puddle or PULLED away from theweld puddle.

For most welding jobs you will pull thetorch along the weld joint to take advan-tage of the greater weld puddle visibility.

2. TRAVEL SPEED is the rate at which thetorch is being pushed or pulled along theweld joint. For a fixed heat setting, thefaster the travel speed, the lower the pen-etration and the lower and narrower thefinished weld bead. Likewise, the slowerthe travel speed, the deeper the penetra-tion and the higher and wider the finishedweld bead.

TYPES OF WELD BEADSThe following paragraphs discuss the mostcommonly used welding beads.

Once you have the torch in position with thewire lined up on the weld joint, lower yourhelmet, pull the trigger and the arc will start.In a second or two you will notice a weldpuddle form and the base of the bead begin-ning to build. It is now time to begin to movewith the torch. If you are just learning toweld, simply move the torch in a straight lineand at a steady speed along the weld joint.Try to achieve a weld with the desired pene-tration and a bead that is fairly flat and con-sistent in width.

As you become more familiar with your newwelder and better at laying some simple weldbeads, you can begin to try some differentweld bead types.

Figure 11. Travel Direction

Figure 14. Flat Position

Figure 13. Weave Bead

Figure 12. Stringer Bead

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There are two basic types of weld beads, thestringer bead and the weave bead.

1. The STRINGER BEAD (Figure 12) isformed by traveling with the torch in astraight line while keeping the wire and noz-zle centered over the weld joint. This is theeasiest type of bead to make.

2. The WEAVE BEAD (Figure 13) is usedwhen you want to deposit metal over a widerspace than would be possible with a stringerbead. It is made by weaving from side to sidewhile moving with the torch. It is best to hesi-tate momentarily at each side before weav-ing back the other way.

WELDING POSITIONSThere are four basic welding positions: flat,horizontal, vertical, and overhead.1. The FLAT POSITION (Figure 14) is theeasiest of the welding positions and is mostcommonly used. It is best if you can weld inthe flat position if at all possible asgood results are easierto achieve.

2. The HORIZONTAL POSITION (Figure 15)is next in difficulty level. It is performed verymuch the same as the flat weld except thatangle B (see HOLDING THE TORCH - p.16)is such that the wire, and therefore the arcforce, is directed more toward the metalabove the weld joint. This is to help preventthe weld puddle from running downwardwhile still allowing slow enough travel speedto achieve good penetration. A good startingpoint for angle B is about 30 degrees DOWNfrom being perpendicular to the work piece.

3. The VERTICAL POSITION (Figure 16) isthe next most difficult position. Pulling thetorch from top to bottom may be easier formany people, but in some instances it can bedifficult to prevent the puddle from runningdownward. Pushing the torch from bottom totop may provide better puddle control andallow slower rates of travel speed to achievedeeper penetration. When vertical welding,angle B (see HOLDING THE TORCH - p.16)is usually always kept at zero, but angle Awill generally range from 45 to 60 degrees toprovide better puddle control.

Figure 16. Vertical Position

Figure 15. Horizontal Position

Figure 17. Overhead Position

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WARNING

Hot slag can cause fires and serious injuryfrom burns! Be sure to wear protective cloth-ing, eye, and ear gear when using theOverhead Position.

4. The OVERHEAD POSITION (Figure 17) isthe most difficult welding position becausegravity is pulling at the weld puddle trying tomake it drip off the work piece. Angle A (seeHOLDING THE TORCH - p.16) should bemaintained at 60 degrees, the same as in theflat position. Maintaining this angle willreduce the chances of molten metal fallinginto the nozzle should it drip from the weldpuddle. Angle B should be held at zerodegrees so that the wire is aiming directlyinto the weld joint. If you experience exces-sive dripping of the weld puddle, select alower heat setting. Also, the weave beadtends to work better than the stringer beadwhen welding overhead.

MULTIPLE PASS WELDING

Butt Weld Joints. When butt welding thickermaterials, you will need to prepare the edgesof the material to be joined by grinding abevel on the edge of one or both pieces ofthe metal being joined. When this is done, aV is created between the two pieces ofmetal, that will have to be welded closed. Inmost cases more than one pass or bead willneed to be laid into the joint to close the V.Laying more than one bead into the sameweld joint is known as a multiple-pass weld.

The illustrations in Figure 18 show thesequence for laying multiple pass beads intoa single V butt joint.

NOTE: WHEN USING SELF-SHIELDINGFLUX-CORE WIRE it is very important tothoroughly chip and brush the slag off eachcompleted weld bead before making anotherpass or the next pass will be of poor quality.

Fillet Weld Joints. Most fillet weld joints, onmetals of moderate to heavy thickness, willrequire multiple pass welds to produce astrong joint. The illustrations in Figure 19show the sequence of laying multiple passbeads into a T fillet joint and a lap fillet joint.

Figure 18. Butt Joints

Figure 19. Fillet Weld Joints

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SPECIAL WELDING METHODS

SPOT WELDINGThe purpose of a spot weld is to join piecesof metal together with a spot of weld insteadof a continuous weld bead. There are threemethods of spot welding: Burn-Through,Punch and Fill, and Lap (see Figure 20).Each has advantages and disadvantagesdepending on the specific application as wellas personal preference.

1. The BURN-THROUGH METHOD weldstwo overlapped pieces of metal togetherby burning through the top piece and intothe bottom piece.

With the burn-through method, larger wirediameters tend to work better than small-er diameters because they have greatercurrent carrying capabilities allowing thearc to burn through very quickly whileleaving a minimal amount of filler metalbuild up. Wire diameters that tend to workbest, with the burn-through method are0.035 inch self-shielding flux-core wire.

Do not use 0.030 inch self-shielding flux-core wires when using the burn-throughmethod unless the metal is VERY thin orexcessive filler metal build-up and mini-mal penetration is acceptable.

Always select the HIGH heat setting withthe burn-through method and tune in thewire speed prior to making a spot weld.

2. The PUNCH AND FILL METHOD pro-duces a weld with the most finishedappearance of the three spot weld meth-ods. In this method, a hole is punched ordrilled into the top piece of metal and thearc is directed through the hole to pene-trate into the bottom piece. The puddle is

allowed to fill up the hole leaving a spotweld that is smooth and flush with thesurface of the top piece.

Select the wire diameter, heat setting,and tune in the wire speed as if you werewelding the same thickness material witha continuous bead.

3. The LAP SPOT METHOD directs thewelding arc to penetrate the bottom andtop pieces, at the same time, right alongeach side of the lap joint seam.

Select the wire diameter, heat setting,and tune in the wire speed as if you werewelding the same thickness material witha continuous bead.

SPOT WELDING INSTRUCTIONS

1. Select the wire diameter and heat settingrecommended above for the method ofspot welding you intend to use.

2. Tune in the wire speed as if you weregoing to make a continuous weld.

3. Hold the nozzle piece completely perpen-dicular to and about 1/4 inch off the workpiece.

4. Pull the trigger on the torch and release itwhen it appears that the desired penetra-tion has been achieved.

5. Make practice spot welds on scrap metal,varying the length of time you hold thetrigger, until a desired spot weld is made.

6. Make spot welds on the actual workpiece at desired locations.

Figure 20. Spot Welding

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GENERALThis welder has been engineered to givemany years of trouble-free service providingthat a few very simple steps are taken toproperly maintain it.1. Keep the wire drive compartment lid

closed at all times unless the wire needsto be changed or the drive tension needsadjusting.

2. Keep all consumables (contact tips, noz-zles, and torch liner) clean and replacewhen necessary. See CONSUMABLEMAINTENANCE and TROUBLESHOOT-ING later in this section for detailedinformation.

3. Replace power cord, ground cable,ground clamp, or torch assembly whendamaged or worn.

4. Periodically clean dust, dirt, grease, etc.from your welder. Every six months, or asnecessary, remove the side panels fromthe welder and air-blow any dust and dirtthat may have accumulated inside thewelder.

WARNING

Electric shock can kill! To reduce the risk ofelectric shock, always unplug the welderfrom its ac power source before removingside panels.

CONSUMABLE MAINTENANCEIT IS VERY IMPORTANT TO MAINTAIN THECONSUMABLES TO AVOID THE NEEDFOR PREMATURE REPLACEMENT OFTHE TORCH ASSEMBLY.

The TORCH LINER is intended to provide anunrestricted path for the welding wire to flowthrough the torch assembly. Over time theliner will accumulate dust, dirt, and otherdebris. Replacement is necessary whenthese accumulations begin to restrict the freeflow of wire through the torch assembly.

MAINTAINING THE CONTACT TIPThe purpose of the CONTACT TIP is totransfer welding current to the welding wirewhile allowing the wire to pass through itsmoothly.

Always use a contact tip stamped with thesame diameter as the wire it will be used with.

Note: Due to inherent variances in flux-coredwelding wire, it may be necessary to use acontact tip one size larger than your flux corewire if wire jams occur.

1. If the wire burns back into the tip, removethe tip from the torch and clean the holerunning through it with an oxygen-acety-lene torch tip cleaner or tip drill.

2. Over time, the hole in the contact tip willbecome worn by the wire passing throughit. The more worn this hole becomes, theless efficient is the transfer of weldingcurrent to the wire and eventually arcbreakage and difficult arc starting willresult. Replace contact tips when signs ofwear become apparent.

MAINTAINING THE NOZZLEThe nozzle directs the shielding gas to theweld puddle, determines the size of theshielding area, and prevents the electricallyhot contact tip from contacting the workpiece.

CAUTIONKEEP THE NOZZLE CLEAN! During thewelding process, spatter and slag will buildup inside the nozzle and must be cleanedout periodically. Failure to clean and/orreplace the nozzle in a timely fashion WILLCAUSE DAMAGE TO THE FRONT-END OFTHE TORCH ASSEMBLY.

For best results, coat the inside of a new, orfreshly cleaned nozzle with anti stick sprayor gel.1. Stop welding and clean any accumulated

slag or spatter from the nozzle every 5 to10 minutes of welding time.

2. When welding overhead, if any moltenmetal drips from the weld puddle andfalls into the nozzle, STOP WELDINGIMMEDIATELY and clean the nozzle.

3. If the slag cannot be thoroughlycleaned from the nozzle, REPLACE THENOZZLE!

Failure to keep the nozzle adequatelycleaned can result in the following problems:

MAINTENANCE

A SHORTED nozzle results when spatterbuildup bridges the insulation in the nozzle,allowing welding current to flow through it aswell as the contact tip. When shorted, a noz-zle will steal welding current from the wirewhenever it contacts the grounded workpiece. This causes erratic welds and reducedpenetration. In addition, a shorted nozzleoverheats the end of the torch, which canDAMAGE the front-end of the torch.

A RESTRICTED nozzle is created whenenough slag builds up in the nozzle to affectthe direction, concentration, and/or rate ofthe shielding gas flow. This problem cancause porous, brittle welds and reducepenetration.

TESTING FOR A SHORTED NOZZLEArcing between the nozzle and the workpiece ALWAYS means the nozzle is shorted,but this can be hard to detect through thelens of a welding helmet. The following test-ing method is another way to tell if a nozzleis shorted.

With the welder unplugged from the acpower source, touch the probes of an ohm-meter or continuity tester to the end of thecontact tip and the outside of the nozzle. Ifthere is any continuity at all, the nozzle ISshorted. Clean or replace as needed.

REPLACE A TORCH LINERWhen installing a new torch liner, care mustbe taken not to kink or otherwise damage thetorch liner. See Figure 21 for the driveassembly and Figure 22 for the torchassembly.1. Turn OFF welder POWER SWITCH and

unplug welder from power supply.2. Open the welder side panel.3. Loosen the tension arm and lift it up off

the drive roller.4. Turn the wire spool counter-clockwise (be

sure to hold onto the wire itself while turn-ing the spool or the wire will unspool itselfwhen it becomes free of the torch liner),and remove wire from the welder.

5. Lay torch cable and torch handle straightout in front of unit.

6. Remove torch Strain Relief Clamp byremoving the four screws.

7. Take torch handle halves apart by

removing four phillips head screws.8. Remove the hanging hook from the two

case halves by carefully pulling it apartuntil it is free from the torch.

9. Remove liner from gas block by pulling itfrom the bottom of the gas block, beingcareful not to separate gas block halves.

10. Remove liner from outer torch sleeve bypulling from torch end.

11. Install new liner, starting from torch endand feeding towards unit.

12. Push the new liner back through gasblock and into the neck of the torch until itis fully seated then push into the grooveat the rear or base of the block.

13. Return all components to the handlecasing and realign them as they wereoriginally.

Tech Tip: Be sure all o-ring’s have beenreturned to their original positions.14. Fit liner for length at feeder end by cutting

liner with wire cutters.15. Reinstall liner holding clamp at feeder.16. With both halves of the handle case in

place, tighten the four phillips headscrews.

17. Replace hanging hook.18. Reinstall the welding wire according to

specifications in INSTALL THE WELDINGWIRE section.

19. Close side panel.20. Plug welder into power supply and turn

POWER SWITCH to ON position.

PREVENTIVE MAINTENANCEExcept for internal and external cleaning,cleaning the nozzle, and occasionally retight-ening screws, there is no periodic mainte-nance recommended for your welder.

TROUBLESHOOTINGThe following TROUBLESHOOTING informa-tion is provided as a guide to help resolvesome of the more common problems thatcould be encountered. Table 5 is a trou-bleshooting table provided to help you deter-mine a possible remedy when you are havinga problem with your welder. This table doesnot provide all possible solutions, only thosepossibilities considered to likely be commonfaults. The table consists of a TROUBLE orsymptom, a POSSIBLE CAUSE for thesymptom, and a POSSIBLE REMEDY forthat symptom.

22

23

Figure 21. Drive Assembly

Figure 22. Torch Assembly

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TABLE 5 – TROUBLESHOOTING

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MMIG125 WIRING DIAGRAM

26

MMIG125 PARTS LIST

No. Part # Description Qty1 1.1.01.02.0070 Left Board 12 2.07.40.357 Wire Feeder 13 1.2.01.01.0538 Spool Holder 14 1.1.02.01.0604 Middle Vertical Board 15 1.1.01.04.0112 Underpan 16 1.1.01.03.0207 Back Panel 17 2.05.05.043 Plastic Frame 28 2.05.05.045 Handle 19 1.1.01.02.0069 Right Board 110 2.07.89.707 Fan Blade 111 1.2.07.02.0027 Fan Motor 112 1.1.02.01.0609 Fan Bracket 113 1.1.04.01.0456 Main Transformer 114 2.05.05.016 Feet 415 2.07.36.527 Heat Relay 1

No. Part # Description Qty16 1.1.05.02.0168 Control PCB 117 2.05.05.106 PCB Holder 118 2.07.11.009 Potentiometer Knob 119 1.1.01.03.0209 Front Panel 120 2.05.05.201 Cable Holder 221 2.07.80.031 Main Switch 122 1.2.07.01.0050 Power Cord 123 1.2.08.02.0072 Grounding Cable 124 1.2.08.04.0009 MIG Torch 125 2.07.80.221 Switch 126 2.20.05.401 Torch Holder 127 1.2.07.02.0057 Indicator 128 1.2.07.02.0036 Control Transformer 129 2.07.80.301 Circuit Breaker 130 2.08.07.803 Door Latch 1

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