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KDAR Company 

13 

Operation 

Wire Feeding

 

 
1.  Release the spring loaded tension arm (1) by flip-

ping it to the right and down. 

 
2.  Lift the idle arm (2). 
 
3.  Make sure the grove size on the drive roll (5) is in 

the feeding position that matches the wire size be-
ing used. Refer to the Suggested Settings for 
Welding chart at the back of this manual or on the 
inside of the welder compartment door. 

 
4.  Detach the end of the wire from the spool and clip 

a small amount of wire to get a good straight start. 

 

Note:

 In order to prevent the spool from un-

winding; it is important to keep tension on the wire 
until after the idle arm and tension arm are back in 
place. 

 
5.  Thread the wire through the inlet tube (4), over the 

drive roll (5) and into the outlet guide tube (6). 

 
6.  Close the idle arm (2). 
 
7.  Move the spring loaded tension arm (1) into posi-

tion. 

 
8.  If required, rotate the wire spool counter clockwise 

to take up any slack in the wire. 

 
9.  If feeding problem occur because the wire is ex-

cessively flattened, turn the wing nut on the spring 
loaded tension arm (1) counter clockwise to reduce 
the pressure. If the drive roll (5) is slipping while 
feeding the wire; turn the wing nut clockwise to 
create more tension on the wire. 

When feeding the wire, the drive roll, the connector 
block and gun contact tip are electrically charged 
relative to work and ground and remain charged 
for several seconds after the gun trigger is released. 

Warning 

Figure 13 

10. Remove nozzle (7) and contact tip (8) from 

end of gun. 

 
11. Turn on the Hot Max 175WFG. 
 
12. With the gun cable assembly straight; press the 

trigger switch. The welding wire will feed 
through the cable and gun. Release the trigger 
when the wire has fed approximately 2 inches 
past the end of the gun. 

 
13. Turn off the Hot Max 175WFG. 
 
14. Replace the contact tip (8) and nozzle (7) 
 
15. Cut wire off approximately 3/8” from the end 

of the contact tip. The Hot Max 175WFG is 
ready for welding. 

 

Summary of Contents for 125WFG

Page 1: ...t reading ALL of this manual and the safety precautions and warnings illustrated in this manual KDAR Company Tel 314 692 8555 1 Mulch Lane Fax 314 692 8578 St Louis MO 63044 Web Site www hotmaxtorches...

Page 2: ...r helmet or shield when operating ANSI Z49 1 approved shade 9 recommended for all cutting currents less than 300 amperes The lens should conform to ANSI Z87 1 standards for testing Wear approved safet...

Page 3: ...from a welder to contact a cylinder Never cut any type of pressurized cylinder an explosion could result Always turn your face away from the valve when opening the cylinder Read and follow all instruc...

Page 4: ...California Health and Safety Code Section 25249 5 et seq PRINCIPAL SAFETY STANDARDS AMERICAN WELDING SOCIETY AWS C5 2 Recommended Practices for Plasma Arc Cutting AWS F4 1 Recommended Safe Practices...

Page 5: ...d FCAW set up from the factory ready to weld Welds steel aluminum and stainless special gas required for aluminum and stainless 2 year limited warranty on the machine 90 day limited warranty on gun an...

Page 6: ...qualified personnel should attempt to install this equipment Turn off the input power at the power panel or disconnect switch and discharge capacitors before working inside the equipment Take care not...

Page 7: ...ht Components and Controls 1 Output voltage adjust knob 2 Power switch 3 Wire feed rate adjust knob 4 Thermal overload indicator 5 Ground clamp connection port 6 Gun trigger lead connectors 7 Door lat...

Page 8: ...the positive terminal 3 GMAW Gas Metal Arc Welding Only To set up for GMAW welding with positive electrode po larity connect the cable coming from the wing nut 6 on the connector block to the positiv...

Page 9: ...r a Argon CO2 blend with 75 80 Argon and 20 25 CO2 see Suggested Settings chart on the welder compartment door 1 Insure the cylinder is properly secured to a wall or other stationary support to preven...

Page 10: ...h the plug for terminating the power cable located on the back of the machine Make sure the plug you purchase is rated for 250 Volts and 50 Amps minimum Gas Hook Up cont 7 Reopen the regulator valve u...

Page 11: ...hem dry Safety Considerations Warning Fumes Gases Can Be Hazardous Plasma cutter should only be used in a well ventilated area or with an exhaust system Keep your head away from the fumes Arc Rays Can...

Page 12: ...wire feed section door 4 Overload Indicator This LED comes on to indi cate the duty cycle had been exceeded Output will be shut off until the unit has cooled to an accepta ble operating temperature T...

Page 13: ...the locking tab 4 Diameter Spool 1 Remove wing nut 5 and the plastic tension spacer 6 2 Place the spool label out on the shaft with the wire feeding from under the spool 3 Replace the spacer washer an...

Page 14: ...wire spool counter clockwise to take up any slack in the wire 9 If feeding problem occur because the wire is ex cessively flattened turn the wing nut on the spring loaded tension arm 1 counter clockwi...

Page 15: ...d The wire can touch the metal lightly 9 Lower the welding helmet pull the trigger on the gun and start welding The contact tip should be about 3 8 from the work surface 10 Release the trigger to stop...

Page 16: ...Warning 5 Turn the power off 6 Loosen the drive roll set screw 3 with the hex wrench provided with the Hot Max 175WFG 7 Remove the drive roll 4 turn it around and put it back on the shaft 8 Cut and s...

Page 17: ...ox needs no lubrication or maintenance Wire Spool Shaft Requires no maintenance Do Not Lubricate Warning Electrical Shock Can Kill Disconnect from the input power source prior to working inside the Ho...

Page 18: ...Possible Cause 1 Check to insure the power switch is turned on 2 Insure correct voltage is applied to the welder and the plug is correctly wired 3 Check to insure the circuit breaker is not tripped 1...

Page 19: ...Insure proper gas flow for the process 5 Make sure the connections for the ground cable are correct 6 Make sure the drive roll is installed and aligned properly 7 Make sure the wire size is correct a...

Page 20: ...care and operation of your welder 3 If warranty work is required DO NOT RE TURN THIS WELDER TO THE RETAIL ER Contact KDAR Company for instruc tions Visit www hotmaxtorches com or call KDAR Company M F...

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