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17

WARNING

Electric shock can kill!

Always turn the

power OFF and unplug the power cord from

the ac power source before changing polarity.

CAUTION

Do not use a ratchet, crescent or other lever

type wrench to tighten knobs on the polarity

block. The nuts must be hand tightened only.

Too much torque applied to one of the knobs

could cause the knob to break off.

1. Remove the retaining knobs from the +

and - mounting posts on the Gas/No Gas

Board on the inside of your welder.

A. For Gasless welding, mount the

Ground Clamp ring terminal to the “+”

mounting post and the Torch ring ter-

minal to the “-” mounting post.

B. For Gas (MIG) welding, mount the

Ground Clamp ring terminal to the “-”

mounting post and the Torch ring

terminal to the “+” mounting post.

See configuration shown in Figure 14.

2. Attach the ground clamp to the work

piece, making sure that it is cleaned of

dirt, oil, rust, scale, oxidation, and paint at

the point of connection.

Note:

It is best to connect the ground clamp

directly to the work piece and as close to the

weld as possible. If it is impractical to con-

nect the ground clamp directly to the work

piece, connect it to metal that is securely

attached to the work piece, but not electrical-

ly insulated from it. Make certain this other

metal is of equal or greater thickness than

that of the workpiece.

CAUTION

Risk of electric component damage! 

If the

ground clamp is being connected to an auto-

mobile or other equipment with on-board

computer systems, solid state electronic 

controls, solid state sound systems, etc., do

not weld until disconnecting the battery that

is attached to the chassis ground. Failure to

do so may result in electronic component

damage.

Figure 14. 

Changing Polarity

ADJUSTING THE SPOOL POSITION

Before you begin welding, you may want to

adjust the position of the spool so it is most

comfortable for you. There are three posi-

tions to chose from.

To change the position of the spool:

1. With a flat tipped screwdriver, loosen

the screw which connects the spool cas-

ing to the gun.

2. Pull the casing far enough away from

the gun to allow for rotation of the cas-

ing.

3. Rotate the casing to one of the three

available positions, making sure that the

grooves on the gun are aligned with the

grooves on the casing.

4. Push the casing and the gun back

together.

5. With a flat tipped screwdriver, tighten

the screw which connects the spool cas-

ing to the gun.

Figure 15

. Spool Adjustment

Summary of Contents for WE6442

Page 1: ...duct read this manual and follow all its Safety Rules and Operating Instructions Model WE6442 UPC 052249 065388 Clarke Power Products Inc 28740 Glenwood Rd Perrysburg OH 43551 Tel 800 227 9603 or 419...

Page 2: ...ress where product was purchased 3 Your full name street address and telephone number 4 Your Return Authorization Number clearly marked on outside of package Clarke Power Products will not be responsi...

Page 3: ...to install operate or service this welder Failure to comply with these instructions could result in personal injury and or property damage RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE Note The follo...

Page 4: ...Do not attempt to plug the welder into the power source if the ground prong on power cord plug is bent over broken off or missing Do not allow the welder to be connected to the power source or attemp...

Page 5: ...an start fires burn skin and damage eyes Do not wear gloves or other clothing that contains oil grease or other flammable substances Do not wear flammable hair preparations Do not touch the hot weld b...

Page 6: ...hich can cause discomfort illness and death Do not weld or cut in areas that are near chlorinated solvents Vapors from chlorinated hydrocarbons such as trichloroethylene and perchloroethylene can be d...

Page 7: ...epair if any of the following conditions exist Gas leaks externally Delivery pressure continues to rise with down stream valve closed The gauge pointer does not move off the stop pin when pressurized...

Page 8: ...elding time allowed The balance of the 10 minute cycle is required for cooling This welder has a duty cycle rating of 25 at the rated output This means that you can weld for 2 5 minutes out of 10 with...

Page 9: ...t and you will be unable to weld A poor connection at the ground clamp will waste power and heat Scrape away dirt rust scale oil or paint before attaching the ground clamp Ground Cable The ground cabl...

Page 10: ...rs between the welder s power cord and the power source receptacle Make sure the POWER switch is OFF then connect your welder s power cord to a properly grounded 220 Vac 60 Hz single phase 20 amp powe...

Page 11: ...the front screw holes on the bottom of the welder The curved face of the front foot should face the front of the welder 3 Insert the two Phillips head screws includ ed in the accessories bag into the...

Page 12: ...rities in the air from infecting the weld Inadequate shielding will result in porous brittle welds Although there are many gasses and gas mixtures available for MIG welding the following recommendatio...

Page 13: ...ween you and the regulator Never aim the open cylinder valve port at yourself or bystanders Failure to comply with this warning could result in serious personal injury Note If the cylinder you have is...

Page 14: ...e roller for the wire size you are using should be fac ing you Use only the proper size drive roller when using your welder Table 4 indicates which drive roller groove should be used with each wire di...

Page 15: ...ert the leading end of the wire into the inlet guide tube located in the Wire Spool Casing Then push it across the drive roller and into the gun assembly about six inches 11 Line the wire up in the to...

Page 16: ...AGE switch and dial to the desired setting The VOLTAGE selectors control the weld heat There are six volt age heat selections available on this welder Placing the voltage switch in MIN position and th...

Page 17: ...k piece connect it to metal that is securely attached to the work piece but not electrical ly insulated from it Make certain this other metal is of equal or greater thickness than that of the workpiec...

Page 18: ...UNING IN THE WIRE SPEED This is one of the most important parts of MIG welder operation and must be done before starting each welding job or whenever any of the following variables are changed heat se...

Page 19: ...intervals All prac tice welds should be done on scrap metal that can be discarded Do not attempt to make any repairs on valuable equipment until you have satisfied yourself that your practice welds a...

Page 20: ...d 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 sl...

Page 21: ...vel It is performed very much the same as the flat weld except that angle B see HOLDING THE GUN p 19 is such that the wire and therefore the arc force is directed more toward the metal above the weld...

Page 22: ...you will need to prepare the edges of the material to be joined by grinding a bevel on the edge of one or both pieces of the metal being joined When this is done a V is created between the two pieces...

Page 23: ...eld 2 The PUNCH AND FILL METHOD produces a weld with the most finished appearance of the three spot weld methods In this method the arc is direct ed through a hole punched or drilled into the top piec...

Page 24: ...ed with the same diameter as the wire it will be used with Note Due to inherent variances in flux cored welding wire it may be necessary to use a contact tip one size larger than your flux core wire i...

Page 25: ...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 unplug...

Page 26: ...26 TABLE 5 TROUBLESHOOTING...

Page 27: ...27 SPOOL GUN WELDER MODEL WE6442 WIRING DIAGRAM...

Page 28: ...28 SPOOL GUN WELDER MODEL WE6442 PARTS LIST...

Page 29: ...29 SPOOL GUN WELDER MODEL WE6442 PARTS DIAGRAM THIS PARTS LIST AND LINE DRAWING ARE FOR REFERENCE ONLY THIS TOOL CAN ONLY BE SERVICED AT AN AUTHORIZED CLARKE REPAIR FACILITY...

Page 30: ...30 SPOOL GUN WELDER MODEL WE6442 GUN PARTS LIST...

Page 31: ...31 SPOOL GUN WELDER MODEL WE6442 GUN PARTS DIAGRAM THIS PARTS LIST AND LINE DRAWING ARE FOR REFERENCE ONLY THIS TOOL CAN ONLY BE SERVICED AT AN AUTHORIZED CLARKE REPAIR FACILITY...

Page 32: ...riginal 2 Le nom complet et l adresse du magasin o le produit a t achet 3 Vos nom adresse et num ro de t l phone 4 Votre num ro d autorisation de retour clairement indiqu l ext rieur de l emballage Cl...

Page 33: ...ervice de cette soudeuse Le d faut de se conformer ces directives pour rait r sulter en des blessures corporelles et ou des dommages la propri t CONSERVER CES DIRECTIVES POUR LA R F RENCE FUTURE Remar...

Page 34: ...ource d alimentation de courant si la broche de la mise la terre de la fiche du cordon d alimen tation est repli e bris e ou manquante Ne pas permettre le branchement de la soudeuse sur la source d al...

Page 35: ...mages aux yeux Ne pas porter de gants ou autres v tements qui sont souill s d huile de graisse ou d autres sub stances inflammables Ne pas utiliser de produits pour les cheveux qui sont inflammables N...

Page 36: ...euvent causer des malaises la maladie et la mort Ne pas souder ou couper dans des endroits rap proch s de solvants chlor s Les vapeurs mis es par les hydrocarbures chlor s telles que le trichlor thyl...

Page 37: ...r imm diatement un r gulateur d fectueux de la bonbonne pour la r paration si une ou l autres des conditions suivantes existe Des fuites de gaz externes La pression du d bit continue de monter avec la...

Page 38: ...uda ge Le restant du cycle de 10 minutes est n ces saire au refroidissement Cette soudeuse est dot e d un coefficient de cycle de service de 25 la sortie du coefficient Ceci signifie que vous pouvez s...

Page 39: ...souder Un mauvais branche ment de la pince de mise la terre entra ne une perte de puissance et de chaleur liminez toute poussi re rouille tartre huile ou peinture avant d attacher la pince de mise la...

Page 40: ...ntation de la soudeuse et la prise d alimenta tion Assurez vous que le bouton d alimentation est la position OFF lorsque vous brancher le cor don d alimentation de votre soudeuse la source d alimentat...

Page 41: ...nez les ouvertures du pied avant avec les orifices des vis avant sur le dessous de la soudeuse La face courb e du pied avant doit faire face au devant de la soudeuse 3 Ins rez les deux vis Phillips co...

Page 42: ...quate entra ne des soudures poreuses et fragiles Bien qu il existe plusieurs gaz et compos s de gaz disponibles pour le soudage MIG les recomman dations suivantes sont bas es sur les caract ris tique...

Page 43: ...z la valve de la bouteille en gardant la valve entre vous et le r gulateur Ne dirigez jamais le port de valve de la bouteille ouverte vers vous ou d autres personnes Le non respect de cet avertissemen...

Page 44: ...deuse Le tableau 4 indique quelle rainure doit tre utili s e avec chaque diam tre de fil 4 Trouvez la taille de d vidoir appos e corres pondant au diam tre du fil installer voir figu re 10 Enfoncez le...

Page 45: ...ier de la bobine Poussez le ensuite travers le d vidoir et dans le pistolet sur environ six pouces 11 Alignez le fil sur la rainure sup rieure du d vidoir et poussez le bras de tension contre le d vid...

Page 46: ...lecteurs de TENSION contr lent la chaleur de la soudure Il existe 6 s lections temp rature de tension pour cette soudeuse La tension chaleur minimale est atteinte en pla ant le bouton de tension la p...

Page 47: ...a pince de mise la terre directement sur la pi ce travailler branchez la au m tal bien fix sur la pi ce sans en tre isol au niveau lectrique Assurez vous que ce m tal ou les autres m taux sont d paiss...

Page 48: ...la vitesse d avancement du fil ralentit MISE AU POINT DE LA VITESSE DE D ROULEMENT DU FIL Il s agit d une des parties les plus importantes du fonctionnement de la soudeuse MIG qui doit tre effectu e a...

Page 49: ...intervalles r guliers Toutes les soudures de pratique devraient tre faites sur des pi ces de m tal pou vant tre mises aux rebuts N essayez pas d utili ser des quipements de valeur tant que vous n tes...

Page 50: ...e long du joint de soudure Il se divise en deux l ments Sens et vitesse Un cordon de soudure solide exige un d placement stable et la bonne vitesse du pistolet le long du joint de sou dure D placer le...

Page 51: ...voir COMMENT TENIR LE PISTOLET la page 19 est tel que le fil et donc la force de l arc est dirig plus avant sur le m tal au dessus du joint de soudure Ceci aide emp cher le bain de fusion de couler ve...

Page 52: ...le rebord d une des morceaux de m tal joindre Une fois ceci effectu un V est cr entre les deux morceaux de m tal qui sera referm par le soudage Dans la plupart des cas plus d une passe ou cordon doive...

Page 53: ...fectuer une soudure par points 2 La M THODE DE POINTE ET REMPLIS SAGE est la soudure offrant le meilleur fini parmi les trois m thodes de soudage par points Avec cette m thode l arc est dirig vers un...

Page 54: ...r sans heurt Utilisez toujours un tube contact du m me diam tre que le fil utilis Remarque tant donn les variations inh rentes au fil de soudage fourr il peut tre n cessaire d utiliser un tube contact...

Page 55: ...ntre la buse et la pi ce de m tal signifie TOUJOURS que la buse est court circuit e mais ceci peut tre difficile d tecter travers la lentille d un casque de soudeur La m thode de test sui vante est un...

Page 56: ...26 TABLEAU 5 D PANNAGE...

Page 57: ...27 DIAGRAMME DE C BLAGE DE LA SOUDEUSE PISTOLET BOBINE WE6442...

Page 58: ...28 LISTE DES PI CES DE LA SOUDEUSE PISTOLET BOBINE WE6442...

Page 59: ...S PI CES DE LA SOUDEUSE PISTOLET BOBINE WE6442 CETTE LISTE DES PI CES AINSI QUE LE SCH MA SONT TITRE DE R F RENCE SEULEMENT CET APPA REIL NE PEUT TRE R PAR QUE PAR LE PERSONNEL D UN CENTRE DE SER VICE...

Page 60: ...30 LISTE DES PI CES DU PISTOLET DE LA SOUDEUSE PISTOLET BOBINE WE6442...

Page 61: ...CES DU PISTOLET DE LA SOUDEUSE PISTOLET BOBINE WE6442 CETTE LISTE DES PI CES AINSI QUE LE SCH MA SONT TITRE DE R F RENCE SEULEMENT CET APPAREIL NE PEUT TRE R PAR QUE PAR LE PERSONNEL D UN CENTRE DE SE...

Page 62: ...220v SPOOL GUN WELDER OPERATING MANUAL Model WE6442 UPC 052249 065388 WE6442 M001 0904...

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