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OPERA

TING INSTR

UCTIONS

21

FLUX-CORE WIRE FEED WELDER KIT 058-8194-4

Types of welding beads:

Stringer 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-588194-13

fig M

MC-588194-14

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Содержание 058-8194-4

Страница 1: ...INSTRUCTION MANUAL FLUX CORE WIRE FEED WELDER KIT 058 8194 4 ...

Страница 2: ...is 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 FLUX CORE WIRE FEED WELDER KIT 058 8194 4 ...

Страница 3: ...er is in place for the wire to be installed Remove the packaging from the wire spool and identify the leading end of the wire secured on the edge of the spool page 15 STEP 2 Setting 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 17 MC 588194 06 1 2 MC 588194 08 1...

Страница 4: ... Turn the wire speed dial with the other hand to its maximum position and continue to hold onto the knob 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 19 Please see page 21 for welding techniques if needed MC 588194 25 1 ...

Страница 5: ...START GUIDE TECHNICAL SPECIFICATIONS 3 SAFETY GUIDELINES 4 8 KEY PARTS DIAGRAM 9 IMPORTANT INFORMATION 10 12 ASSEMBLY INSTRUCTIONS 13 17 OPERATING INSTRUCTIONS 18 26 MAINTENANCE 27 TROUBLESHOOTING 28 29 MAIN CIRCUIT CHART 30 EXPLODED VIEW 31 PARTS LIST 32 WARRANTY 33 34 ...

Страница 6: ...LDER KIT 058 8194 4 POWER SUPPLY single phase 120 V 60 Hz NO LOAD VOLTAGE 34V OUTPUT CURRENT 30 65 A Peak 125 A DUTY CYCLE 20 65 A WIRE USED 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 46 lb 5 oz 21 kg ...

Страница 7: ...ndicate 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 result...

Страница 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 harmful fume emission when welding on coated materials like galvanized cadmium plated or contac...

Страница 9: ...ylinder 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 ...

Страница 10: ...pair 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 allow...

Страница 11: ...he welder 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 coat and insulated footwear to prevent the skin from being exposed to hot metals while welding Do not overload the welder to prevent it fr...

Страница 12: ...E FEED WELDER KIT 058 8194 4 No Description No Description 1 MIN MAX voltage setting 5 MIG gun 2 1 2 voltage setting 6 Thermal overload indicator 3 Wire speed setting 7 ON OFF switch 4 Ground cable and clamp 1 5 6 7 2 3 4 MC 588194 04 ...

Страница 13: ...eck the contents 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 Tw...

Страница 14: ...e drive motor Thermal Indicator If the duty cycle of the welder kit exceeds the maximum level the internal temperature of the welder kit will exceed the allowable operating range 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 temperatur...

Страница 15: ...ORMATION 12 FLUX CORE WIRE FEED WELDER KIT 058 8194 4 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 588194 23 1 2 ...

Страница 16: ...e wire drive compartment 2 Remove the drive tension by loosening the 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 installed i...

Страница 17: ...of the drive roller can be selected based on the wire diameter 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 588194 04 1 2 fig D MC 588194 05 Wire ...

Страница 18: ...azard 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 line...

Страница 19: ...e spool tension using the wing nut if the tension is high or low 6 Disconnect 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...

Страница 20: ... thread the contact tip into the end of the gun and tighten securely 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...

Страница 21: ...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 welding...

Страница 22: ...t setting 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 is ...

Страница 23: ...e 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 fini...

Страница 24: ...ger 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 588194 13 fig M MC 588194 14 ...

Страница 25: ... 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 positi...

Страница 26: ...tion 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 588194 18 ...

Страница 27: ... 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 j...

Страница 28: ... 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 surfa...

Страница 29: ...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 actual ...

Страница 30: ...erature 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 acces...

Страница 31: ...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 connect...

Страница 32: ...nsistent 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 ...

Страница 33: ...MAIN CIRCUIT CHART 30 FLUX CORE WIRE FEED WELDER KIT 058 8194 4 Welding gun switch Earth champ 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 MC 588194 22 ...

Страница 34: ...MAIN CIRCUIT CHART 31 FLUX CORE WIRE FEED WELDER KIT 058 8194 4 ...

Страница 35: ...EXPLODED VIEW 31 FLUX CORE WIRE FEED WELDER KIT 058 8194 4 27 1 4 8 9 6 7 12 31 34 26 25 28 24 21 20 19 23 22 10 29 30 32 33 2 3 5 11 13 14 18 15 16 17 MC 588194 23 ...

Страница 36: ...20 Cable holder 1 4 Cable holder 1 21 Back panel 1 5 Front panel 1 22 Rectifier 1 6 PCB support 1 23 Rectifier bracket 1 7 PCB 1 24 Vertical middle panel 1 8 Bottom 1 25 Spool holder 1 9 Feet 1 26 Plastic hinge 2 10 Control transformer 4 27 Left panel 1 11 Thermal relay 1 28 Fuse 1 12 Circuit breaker 1 29 Door bolt 1 13 Main transformer 1 30 Wire feeder 1 14 Fan bracket 1 31 MIN MAX 1 2 voltage sw...

Страница 37: ...uel 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 w...

Страница 38: ...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 rights...

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