PART# 0M-I17071002 Operator's Manual 80 AMP WIRE FEED WELDER Made in U.S.A.
TABLE OF CONTENTS... 2 SAFETY SUMMARY ....... 3 IM PORTANT SAFETY INFORMATION .................. SHOCK HAZARDS ............... FLASH HAZARDS ................ FIRE HAZARDS .................... FUME HAZARDS .................. ADDITIONAL SAFETY INFORMATION ................... ASSEMBLY ...................... UNPACKING THE WELDER PACKING LIST ..................... ASSEMBLE THE FACE SHIELD .............................. POWER SOURCE CONNECTION ................... EXTENSION CORDS ...........
Every craftsman respects the tools with which they work. They know that the tools represent years of constantly improved designs and developments. The true craftsman also knows that tools are dangerous if misused or abused. This symbol indicates that the possibility of toxic gas hazard exists during operation of the step(s) that follow. This symbol indicates that the possibility of being burned by hot slag exists during operation of the step(s) that follow.
* • IMPORTANT! TO REDUCE THE RISK OF DEATH, INJURY, OR PROPERTY DAMAGE, DO NOT A-I-I-EMPT OPERATION of this welding equipment until you have read and understand the following safety summary. Do not, in any manner, come into physical contact with any part of the welding current circuit. The welding current circuit includes: a. the work piece or any conductive material in contact with it, b. the ground clamp, c. the electrode or welding rod, d. any metal parts on the electrode holder.
Do not wear a crackedor broken helmetand replaceany cracked or brokenfilter lenses IMMEDIATELY. Do not allow the uninsulatedportion of the wire feed gun to touch the ground clamp or groundedwork to preventan arc flash from being createdon contact. instructions as well. REMEMBER! Arc welding by nature produces sparks, hot spatter, molten metal drops, hot slag, and hot metal parts that can start fires, burn skin, and damage eyes. • Provide bystanderswith shieldsor helmetsfitted with a #10 shade filter lens.
sleeves, fire resistant leggings, or apron. Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves and collars should be kept buttoned and pockets eliminated from the shirt front. steel), unless the coating is removed. Make certain the area is well ventilated, and the operator and all bystanders are wearing air-supplied respirators.
• ANSI StandardZ87.1 -- SAFE PRACTICEFOR OCCUPATIONAND EDUCATIONALEYE AND FACE PROTECTION-- obtainablefrom the American NationalStandards Institute, 11 West 42ndSt., New York, NY 10036 Telephone (212) 642-4900, Fax (212) 398-0023 - www.ansi.org • NFPA Standard 51B -- CUTTING AND WELDING PROCESS -obtainable from the National Fire Protection Association, 1 Batterymarch Park, P.O. Box 9101, Quincy, MA 02269-9101 Telephone (617) 770-3000, Fax (617) 770-0700 - www.nfpa.
The following procedures describe the process required to assemble, install, maintain, and prepare to weld with your new wire feed 80 amp ac welder• PACKING LIST Table 1 contains a list of the items you will find packed in the carton• Table 1. Packing List UNPACKING THE WELDER 1. Remove any cartons or bags containing parts/accessories. 2. Open the cartons or bags packed with your welder and inspect their contents for damage• Report any missing or damaged items immediately• 3. 4.
. Place the face shield handle over the mating holes in the face shield and use the provided handle screws to mount the face shield handle to the face shield. POWER SOURCE CONNECTION WARNING High voltage danger from power source! Consult a qualified electrician for proper installation of receptacle at the power source. • This welder must be grounded while in use to protect the operator from electrical shock.
spool edge to prevent the wire from unspooling) BUT DO NOT UNHOOK IT YET. Place the spool on the spindle in such a manner that when the wire . comes off the spool, it will look like the top illustration in Figure 2. ( Right Way ii o Figure . Wrong Way . Figure . 2. Proper wire Installation Adjust the drive brake hardware on the top of the spool of wire (see Figure 3). a. With one hand, turn the wire spool and continue turning it while adjusting the tension. b.
12. Let go of the wire. 13. Plug the welder's power cord into the ac power source. Adjust the HEAT selection switches, on the front of the welder, to any of the four heat settings. WARNING ARC RAYS CAN INJURE EYES! To reduce the risk of arc flash, make certain that the welding wire, when it finally comes out of the end of the gun, does not touch the ground clamp or any grounded piece of metal.
DESCRIPTION Table 3. Duty Cycle Ratings Your new Wire Feed welder is designed for maintenance and sheet metal fabrication. The welder consists of a single-phase power transformer, and a unique built-in control/feeder. This welder is capable of welding with 0.030 inch self-shielding flux-core wire. Now you can weld 18 gauge sheet metal up to 3/16 inch with a single pass. You can weld 1/4 inch steel with beveling and multiple pass techniques. Table 2 lists your wire feed welder specifications.
The MINIMAX SELECTOR allows you to select minimum and maximum heat settings within the high and low ranges. Refer to the instruction label inside the welder's hood for suggestions on which heat setting to use for your welding job. PREPARATIONS ,I 1 I \ FOR WELDING An important factor in making a satisfactory weld is preparation. This includes studying the process and equipment and then practice welding before attempting to weld finished product.
WARNING WARNING ARC RAYS CAN INJURE EYES AND BURN SKIN! To reduce the risk of injury from arc rays, never strike a welding arc until you, and all bystanders in the welding area, have welding helmet or shield in place and are wearing the recommended protective clothing. DO NOT CONTINUE unless you have read, understand and intend to follow the entire SAFETY SUMMARY provided at the front of this manual. To help prevent eye injuries when grinding, always wear goggles.
GET TO KNOW YOUR WELDER Whether you have welded before or not, it is important that you become familiar with your new welder, its controls, and the results achieved at different settings. We strongly recommend that you practice your new welder on scrap metal trying different heat settings, base metal thicknesses, and welding positions for each type. By doing this you will gain a feel for how changes in these welding variables affect the weld.
Distance From The Workpiece The end of the welding gun is designed with the contact tip recessed from the end of the nozzle and the nozzle electrically insulated from the rest of the gun. This permits the operator to actually rest the nozzle on the work piece and drag it along while welding. This can be very helpful to beginning welders to steady the gun, allowing the welder to concentrate on welding technique.
As you become more familiar with your new welder and better at laying some simple weld beads, you can begin to try some different welding techniques to improve, and add versatility to your welding skills. TRAVELING THE GUN Gun travel refers to the movement of the gun along the weld 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.
WELDING POSITIONS There are three basic welding positions: flat, horizontal, and vertical. . The FLAT POSITION (Figure 12) is the easiest of the welding positions and is probably the one you have been using thus far. It is best if you can weld in the flat position if at all possible as good results are easier to achieve. Figure 13. Horizontal Position Weld . Figure 12. Flat Position Weld . The HORIZONTAL POSITION (Figure 13) is next in difficulty level.
MULTIPLE PASS WELDING Butt Weld Joints. In PREPARING THE WORK PIECE, we discussed the need for edge preparation on thicker materials 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 of metal, that will have to be welded closed. In most cases more than one pass or bead will need to be rayed into the joint to close the V. Laying more than one bead into the same weld joint is known as a multiple-pass weld.
VERY thin or excessive filler metal build-up and minimal penetration is acceptable• Always select the HIGH heat setting with the burn-through method prior to making a spot weld. 2• The PUNCH AND FILL METHOD produces a weld with the most finished appearance of the three spot weld methods. In this method, a hole is punched or drilled into the top piece of metal and the arc is directed through this hole to penetrate into the bottom piece.
GENERAL MAINTENANCE periodically. replace fashion This welder has been engineered to give many years of trouble-free service providing that a few very simple steps are taken to properly maintain it. 1. 2. . Keep the wire drive compartment lid closed at all times unless the wire needs to be changed or the drive tension needs adjusting. Keep all consumables (contact tips, nozzles, and gun liner) clean and replace when necessary.
nozzle. If there is any continuity at all, the nozzle IS shorted. Clean or replace as needed. The following paragraphs describe the procedures required to maintain and troubleshoot your welder. MAINTAINING WELDER THE Except for internal and external cleaning, cleaning the nozzle, and occasionally retightening screws, there is no periodic maintenance recommended for your welder.
Table 4. Troubleshooting TROUBLE Dirty, porous brittle weld Wire feed works but no arc POSSIBLE CAUSE Nothing works Clean or replace nozzle 1. Bad ground or loose connection 1. Check ground and connections tighten as necessary 2. Check connection to gun or replace gun to gun or 1. Faulty wire speed circuit board 2. No tension on the drive roller 1. Replace wire speed circuit board 3. Faulty drive motor (very rare) 3. Replace drive motor 1. Faulty trigger on gun 2. Faulty transformer (rare) 3.
Wire Feed Drive Gun Leads Wire Feed Motor Welding Gun Black Ground Calmp White Wire Speed Control Black Power Cord Blacl_ White Yellow Red White Low Off (Back View Of Switch) High Min 1 Max 2 Switch Transformer 24
1117-o711
Manufacturer warrants that it will repair, at no charge for parts or labor, the Welder or Welding Gun or Cables, proven defective in material or workmanship, during the following time period(s) after date of original retail purchase: For 5 Years: The Welders Transformer and Rectifier For 2 Years: The Entire Welder (excluding For 1 Year: The Welder's accessories packed with the welder) Welding Gun If after reasonable efforts by the manufacturer, the Welder or Welding Gun or Cables is/are deemed unrepa
117-071 (2171, 83071, 20101) Item 1 2 3 4 5 6 7 8 Lincoln Stock # 131-419-000 880-406-001 238-542-000 334-221-000 $27119 9 10 KP11-30, KH711 11 KP21T-50 12 13 14 15 16 Not Shown $24355-3 880-459-666 312-076-666 KP45-40-15 334-228-000 Customer# 880-392-888 880-397-000 410-832-*** 410-833-010 131-350-002 412-375-666 410-385-*** 880-382-000 238-490-010 334-221-000 246258 246-405-000 43100,334-160-300, KP2039-2B1, M15523 43480, 334-203-300, KP1942-1, M15578 248-311-000 246-404-000 880-395-000 880-391
