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INSTRUCTION MANUAL

MIG/FLUX-CORE WIRE FEED

WELDER KIT

058-8195-2

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Summary of Contents for FLUX-CORE

Page 1: ...INSTRUCTION MANUAL MIG FLUX CORE WIRE FEED WELDER KIT 058 8195 2 ...

Page 2: ... instruction manual thoroughly before using the product It contains important information for your safety as well as operating and maintenance advice Keep this instruction manual for future use Should this product be passed on to a third party then this instruction manual must be included MIG FLUX CORE WIRE FEED WELDER KIT 058 8195 2 ...

Page 3: ...cured on the edge of the wire spool Place the spool on the hub with the wire passing from the bottom of spool into the drive mechanism pages 16 17 steps 1 4 STEP 2 Setting the wire tension Press the trigger on the gun Turn the drive tension adjustment knob 1 clockwise and increase the drive tension until the wire seems to feed smoothly without slipping page 18 steps 1 2 MC 588195 06 1 2 MC 588195 ...

Page 4: ... with the other hand to its maximum position Pull the trigger 1 on the torch to start an arc Drag the torch toward the user while simultaneously turning the wire speed dial counterclockwise page 20 steps 4 5 Please see page 21 for welding techniques if needed MC 588195 25 1 ...

Page 5: ...K START GUIDE TECHNICAL SPECIFICATIONS 3 SAFETY GUIDELINES 4 8 KEY PARTS DIAGRAM 9 IMPORTANT INFORMATION 10 13 ASSEMBLY INSTRUCTIONS 14 18 OPERATING INSTRUCTIONS 19 27 MAINTENANCE 28 TROUBLESHOOTING 29 30 MAIN CIRCUIT CHART 31 EXPLODED VIEW 32 PARTS LIST 33 WARRANTY 34 35 ...

Page 6: ...0 80 A WIRE USED MIG and flux core wire WIRE DIAMETER 0 023 0 030 0 035 DIMENSIONS L x W x H 17 6 x 9 4 x 14 5 WEIGHT 62 lb 10 oz 28 42 kg Welding mode Materials For metal thickness Use wire size Flux core Steel 20 gauge 5 32 0 03 1 32 0 8 mm 0 035 5 128 0 9 mm 5 128 5 32 1 0 4 0 mm MIG Steel Stainless steel 20 gauge 1 8 0 03 1 32 0 8 mm 0 023 3 128 0 6 mm 5 128 1 8 1 0 3 0 mm ...

Page 7: ... indicate this information Note The word Note is used to inform the reader of something he she needs to know about the tool PERSONAL SAFETY These precautions are intended for the personal safety of the user and others working with the user Please take time to read and understand them DANGER Potential hazard that will result in serious injury or loss of life WARNING Potential hazard that could resu...

Page 8: ...ctric shock Do not touch electrical live parts or metal components connected to the welding wire as doing so may cause fatal shock and severe burns Secure the ground lead before welding Wear dry protective apparel like coat shirt gloves and insulated footwear Risk for breathing Never directly inhale the emission of harmful fumes when welding on coated materials like galvanized cadmium plated or co...

Page 9: ... cylinder with MIG gun and do not weld on the cylinder Use proper regulators gas hoses and fittings for the specific application Do not expose the welder to rain Risk of UV and IR arc rays Do not look at the welding arc without proper eye protection as the welding arc produces ultraviolet UV and infrared IR rays Use screens or other barriers to protect other personnel from the rays ...

Page 10: ...repair the damaged components before using the welder Keep hands and fingers away from moving parts and stay away from the drive rolls while the welder is in use Do not allow any body part of the user to come in contact with the welding wire while holding the welding gun Do not allow the user to drape cables over or around the body Do not point MIG gun toward the user or other personnel Do not all...

Page 11: ...r Mount the welder on a secure bench or cart to prevent if from tipping over or falling Connect the ground lead as close to the area being welded to ensure proper ground connection Wear a full covered helmet proper gloves and protective clothing such as leather shirt coat pant and insulated footwear to prevent the skin from being exposed to hot metals while welding Do not overload the welder to pr...

Page 12: ...IRE FEED WELDER KIT 058 8195 2 No Description No Description 1 MIN MAX voltage setting 5 MIG torch 2 1 2 voltage setting 6 Thermal overload indicator 3 Wire feed setting 7 ON OFF switch 4 Ground cable and clamp 1 6 7 2 3 4 MC 588195 01 5 ...

Page 13: ...with the packaging list below After unpacking the welder unit inspect for any damage that may have occurred during transit Check for loose missing or damaged parts A shipping damage claim must be filled with carrier ON OFF switch This switch is used to turn the power supply of the welder kit ON and OFF through the main transformer and control circuit MIN MAX 1 2 voltage setting Two adjustment swit...

Page 14: ...ange which in turn makes the thermal overload light glow and the welder kit to be shut down automatically Allow the welder kit to cool down for 20 minutes until the thermal overload light turns OFF automatically The temperature of the welder kit is then within the allowable operating range Power cord The power cord connects the welder to the 120 V power supply Connect the 15 A plug into a 120 V 20...

Page 15: ...h arc with excessive spatter will be found and a smooth weld bead will not be obtained Gas selection Different materials require different shielding gas when MIG welding Refer to the set up chart inside the wire drive compartment Mild steel Use 75 Argon and 25 for reduced spatter and reduced penetration for thinner materials Use CO2 for deeper penetration and increased spatter Note Do not use argo...

Page 16: ...MATION 13 MIG FLUX CORE WIRE FEED WELDER KIT 058 8195 2 Wire drive compartment The wire drive compartment has wire feed components 1 such as wire feeder and spool hub and a set up chart 2 1 2 3 4 5 6 MC 588195 25 1 2 ...

Page 17: ...e wire drive compartment 2 Remove the drive tension by loosening the drive tension adjusting knob 1 and lifting the drive tension adjustor and drive tension arm 2 away from the drive roller fig B 3 Put an end of the wire into the hole on outside edges of the wire spool and bend it over to hold the wire in place Remove the wire spool from the wire drive compartment Note If the wire is already insta...

Page 18: ...he wire diameter select the correct groove using the following table Note When installing the drive roller the number stamped on the drive roller should face the user Push the drive roller onto the drive roller shaft 6 Reinstall the drive roller cap and lock in place by turning it clockwise Close the wire drive compartment 0 6 fig C 1 2 MC 588195 04 1 2 fig D MC 588195 05 Wire Diameter Roller Groo...

Page 19: ...ial hazard that could result in serious injury or loss of life Always switch off the power and unplug the power cord from the AC power source before installing the wire Remove any wire or wire spool that is rusty Do not weld metal thinner than 18 gauge as doing so may burn the metal Before installing remove any old wire from the MIG gun assembly to prevent the wire from being jammed inside the gun...

Page 20: ...sconnect the welder from the power source and remove the leading end of the wire from the spool 7 Cut off any bent portion of the wire using a wire cutter 8 Loosen the tension adjusting knob holding the drive tension arm in place and lift the tension arm up off the drive roller 9 Insert the wire into the inlet guide tube and feed it of about six inches across the drive roller and into the torch as...

Page 21: ...17 Install the nozzle on the gun assembly and cut off excess wire that extends past the end of the nozzle Setting the wire tension 1 Press the trigger on the gun 2 Turn the drive tension adjustment knob 1 clockwise and increase the drive tension until the wire seems to feed smoothly without slipping fig G WARNING Potential hazard that could result in serious injury or loss of life Ensure that wire...

Page 22: ...o a scrap piece of the same type of the material to be welded Note The thickness of the scrap piece should be equal to or greater than the thickness of the actual workpiece and free of oil paint and rust 2 Select the heat setting 3 Hold the torch in one hand and allow the nozzle to rest on the edge of the workpiece farther from the user and at an angle similar to that which will be used when weldi...

Page 23: ...is achieved Use the wire feed control to slightly increase or decrease the heat and penetration by selecting higher or lower wire feed settings Repeat this tune in procedure if a new heat setting a different diameter wire or a different type of welding wire is selected Angle A Angle B Angle A can be varied but in most cases the optimum angle will be 60 degrees the point at which the torch handle i...

Page 24: ...dle For most welding jobs pull the torch along the weld joint for greater weld puddle visibility fig K Travel speed The rate at which the torch is being pushed or pulled along the weld joint For a fixed heat setting if the travel speed is faster the penetration will be low and the finished weld bead will be low and narrow Likewise if the travel speed is slow the penetration will be deep and the fi...

Page 25: ...inger bead Weave bead The stringer bead is formed by travelling with the torch in a straight line while keeping the wire and nozzle centered over the weld joint fig L The weave bead is made by weaving the wire from side to side while moving with the torch fig M fig L MC 588195 13 fig M MC 588195 14 ...

Page 26: ...on angle B should be about 30 degrees downward from being perpendicular to the workpiece fig O 3 Vertical position The torch can be easily pulled from top to bottom in this position though it is difficult to prevent the puddle from running downward Pushing the torch from bottom to top provides better puddle control and allows slower rates of travel speed to achieve deeper penetration For this posi...

Page 27: ...sition For this position angle A should be maintained at 60 degrees Maintaining this angle will reduce falling of molten metal into the nozzle fig Q Angle B should be zero degrees so that the wire is aiming directly into the weld joint If excessive dripping of the weld puddle occurs select a lower heat setting fig Q MC 588195 18 ...

Page 28: ...nt to close the V fig R Note When using self shielding flux core wire it is necessary to thoroughly chip and brush the slag off each completed weld bead before making another pass Fillet weld joint Most fillet weld joints on metals of moderate to heavy thickness will require multiple pass welds to produce strong joint The sequence of lying multiple pass beads into a T fillet joint and a lap fillet...

Page 29: ...in or excessive filler metal and minimal penetration is acceptable 2 Punch and fill method This method produces a weld with the most finished appearance In this method a hole is punched or drilled into the top piece of metal and the arc is directed through the hole to penetrate into the bottom piece The puddle is allowed to fill up the hole leaving a spot weld that is smooth and flush with the sur...

Page 30: ...2 Tune in the wire speed as if a continuous weld is to be performed 3 Hold the nozzle piece completely perpendicular to and about inch off the workpiece 4 Pull the trigger on the torch and release it when the desired penetration is achieved 5 Make practice spot welds on scrap metal and vary the duration of time of holding the trigger until a desired spot weld is made 6 Make spot welds on the actua...

Page 31: ...mperature of 10 F 120 F and relative humidity of less than 90 It is recommended to repack the welder when transporting or storing the welder after use Cleaning is required before storage WARNING Potential hazard that could result in serious injury or loss of life Unplug the welder before performing any maintenance or service Only use the welder after replacing or repairing any damaged parts or acc...

Page 32: ...4 Transformer is broken 1 Check the circuit or fuse of the power supply 2 Replace the power cord 3 Replace the main switch 4 Replace the transformer The welder does not weld 1 Incorrect power input 2 Inadequate current at the output 3 Poor connection of output cable 4 Dirty surfaces 5 Wrong welding wire 1 Check the power source 2 Check for proper grounding to the workpiece 3 Check the output conne...

Page 33: ...consistent arc or wire feed 1 Not enough drive roller pressure 2 Spool hub tension too tight or loose 3 Contact tip worn or wrong size 4 Rusty or corroded wire 1 Tighten the drive tension adjustor on wire feeder 2 Adjust the wing nut on the spool holder 3 Replace the contact tip 4 Replace the wire PROBLEM POSSIBLE CAUSES SOLUTIONS ...

Page 34: ...RCUIT CHART 31 MIG FLUX CORE WIRE FEED WELDER KIT 058 8195 2 Welding gun switch Welding gun 2 3 4 5 2 1 2 1 _ _ _ _ 2 2 3 3 4 1 1 S1 T1 J G L S2 S3 PCB MAX fan TR1 24V MIN _ NO GAS GAS Earth champ MC 588195 24 ...

Page 35: ...EXPLODED VIEW 32 MIG FLUX CORE WIRE FEED WELDER KIT 058 8195 2 28 1 4 8 9 6 7 31 12 34 37 27 26 25 22 21 20 19 24 23 10 29 32 33 35 36 2 3 5 11 13 14 18 15 16 17 30 MC 588195 25 ...

Page 36: ...le holder 1 23 Rectifier 1 5 Front panel 1 24 Rectifier bracket 1 6 PCB support 1 25 Vertical middle panel 1 7 PCB 1 26 Spool holder 1 8 Bottom 1 27 Plastic hinge 2 9 Feet 1 28 Left panel 1 10 Control transformer 4 29 Fuse 1 11 Thermal relay 1 30 Red terminal 1 12 Circuit breaker 1 31 Black terminal 1 13 Main transformer 1 32 Door bolt 1 14 Fan bracket 1 33 Wire feeder 1 15 Fan 2 34 MIN MAX 1 2 vo...

Page 37: ... fuel lubricants vacuum bags blades belts sandpaper bits fluids tune ups or adjustments e This warranty will not apply where damage is caused by repairs made or attempted by others i e persons not authorized by the manufacturer f This warranty will not apply to any product that was sold to the original purchaser as a reconditioned or refurbished product unless otherwise specified in writing g This...

Page 38: ...s This warranty applies only to the original purchaser and may not be transferred Neither the retailer nor the manufacturer shall be liable for any other expense loss or damage including without limitation any indirect incidental consequential or exemplary damages arising in connection with the sale use or inability to use this product Notice to consumer This warranty gives you specific legal righ...

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