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This spool gun has been engineered to need minimal service providing that a few very simple steps are taken to properly
maintain it.
1.
Keep the spool cover and tension mechanism cover closed at all times unless the wire needs to be changed or the drive
pressure needs adjusting.
2.
Keep all consumables (contact tips, nozzles, and liner) clean and replace when necessary. See “Consumable
Maintenance” (below) and “Troubleshooting” for detailed information.
3.
Avoid directing grinding particles towards the spool gun. These conductive particles can build up inside the spool gun
and cause severe damage.
4.
Periodically clean dust, dirt, grease, etc. from your equipment.
WARNING: DISCONNECT FROM POWER SOURCE WHEN CARRYING OUT THIS OPERATION.
5.
The wire feed drive roller will eventually wear during normal use. With the correct pressure, the idler roller must feed the
wire without slipping. If the grooves in the wire feed drive roller are worn deep enough that the idler roller and the wire
feed drive roller make contact when the wire is in place between them, the wire feed drive roller must be replaced.
6.
Check all cables periodically. They must be in good condition and not cracked.
WARNING: ELECTRIC SHOCK CAN KILL!
Be aware that the ON/OFF SWITCH, when OFF, does not remove
power from all internal circuitry in the welder. To reduce the risk of electric shock, always unplug the welder from its AC
power source and wait several minutes for electrical energy to discharge before removing side panels
IT IS VERY IMPORTANT TO MAINTAIN THE CONSUMABLES TO AVOID THE NEED FOR
PREMATURE REPLACEMENT OF THE GUN ASSEMBLY.
MAINTAINING THE CONTACT TIP:
The purpose of the CONTACT TIP is to transfer welding current to the welding wire while allowing the wire to pass through it
smoothly.
Always use a contact tip that is stamped one size larger in diameter than the welding wire it will be used with.
1.
If the wire burns back into the tip, remove the tip from the gun and clean the hole running through it with an oxygen-
acetylene torch tip cleaner or tip drill. If the burned-back wire cannot be removed, the tip will have to be replaced.
2.
With extended use over time, this hole will become worn. Increased wear on the hole causes increased resistance in the
transfer of welding current from the contact tip to the wire. This will result in less stable arc characteristics and difficult
arc starting.
CAUTION: KEEP THE NOZZLE CLEAN!
During the welding process, spatter and slag will build up inside the nozzle and must be cleaned out periodically. Failure
to clean and/or replace the nozzle in a timely fashion will cause damage to the front end of the gun assembly, which is not
replaceable. The results of the inaction may require the replacement of the entire gun assembly.
Failure to keep the nozzle adequately cleaned can result in the following problems:
A shorted nozzle results when spatter buildup bridges across the insulation in the nozzle allowing welding current to flow
through it as well as the contact tip. When shorted, a nozzle will steal welding current from the wire whenever it contacts the
grounded workpiece. This causes erratic welds and reduced penetration. In addition, a shorted nozzle overheats the end of
the gun which can damage the front-end of the gun.
TESTING FOR A SHORTED NOZZLE
Arcing between the nozzle and the workpiece 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 continuity tester to the end of the
contact tip and the outside of the nozzle. If there is any continuity at all, the nozzle is shorted. Clean or replace as needed.
Maintenance & Servicing
General Maintenance
