TABLE OF CONTENTS Safety Summary......................................4 Safety Information..................................4 Shock Hazards ......................................5 Flash Hazards ........................................5 Fire Hazards ..........................................6 Fume Hazards........................................7 Compressed Gasses and Equipment Hazards ......................7 Additional Safety Information ................8 Welder Specifications ............................
SAFETY SUMMARY The warnings, cautions and instructions discussed in this instruction manual can not cover all possible conditions or situations that could occur. It must be understood by the operator that common sense and caution are factors which can not be built into this product, but must be supplied by the operator. Reading this operator’s manual before using the welder will enable you to do a better, safer job.
SHOCK HAZARD WARNING ELECTRIC SHOCK CAN KILL! To reduce the risk of death or serious injury from shock, read, understand, and follow the following safety instructions. In addition, make certain that anyone else who uses this welding equipment, or who is a bystander in the welding area understands and follows these safety instructions as well.
• • • • • welding shields and/or helmets in place. Do not wear a cracked or broken helmet and replace any cracked or broken filter lenses IMMEDIATELY. Do not allow the uninsulated portion of the wire feed gun to touch the ground clamp or grounded work to prevent an arc flash from being created on contact. Provide bystanders with shields or helmets fitted with a #10 shade filter lens. Wear protective clothing.
• • • prevent spatter or slag from falling into ear. Make sure welding area has a good, solid, safe floor, preferably concrete or masonry, not tiled, carpeted, or made of any other flammable material. Protect flammable walls, ceilings, and floors with heat resistant covers or shields. Check welding area to make sure it is free of sparks, glowing metal or slag, and flames before leaving the welding area.
• • • • • • • • • • • • • • • • • Do not expose cylinders to electricity of any kind. Do not use a cylinder or its contents for anything other than its intended use. Do not use as a support or roller. Do not locate cylinders in passageways or work area where they may be struck. Do not use a wrench or hammer to open a cylinder valve that cannot be opened by hand. Notify your supplier. Do not modify or exchange gas cylinder fittings. Do not deface or alter name, number or other markings on a cylinder.
WELDER SPECIFICATIONS DESCRIPTION Your new MIG (GMAW) flux core (FCAW) wire feed welder is designed for maintenance and sheet metal fabrication. The welder consists of a single-phase power transformer, stabilizer, rectifier, and a unique built-in control/feeder. Now you can weld sheet metal from 24 gauge up to 1/4 inch thick with a single pass. You can weld thicker steel with beveling and multiple pass techniques. Table 1 lists your MIG welder specifications. Table 1.
KNOW YOUR WELDER Voltage Selector Switch Handle Wire Speed Power Switch Voltage Selector Dial Ground Clamp Ground Cable Power Cable Gun Cable Welding Gun Figure 1. Model Cat. 3175 Handle – Rugged, top mounted handle allows for easy transport of your welder. Wire Speed Control – Use this dial to adjust the speed at which the welder feeds wire to the gun. 1 is the slowest wire feed speed, 10 is the highest.
WELDER INSTALLATION POWER SOURCE CONNECTION POWER REQUIREMENTS This welder is designed to operate on a properly grounded 230 volt, 60Hz, single-phase alternating current (AC) power source fused with a 50 amp time delayed fuse or circuit breaker. It is recommended that a qualified electrician verify the ACTUAL VOLTAGE at the receptacle into which the welder will be plugged and confirm that the receptacle is properly fused and grounded.
3. Once the handle tabs are properly seated in the face shield slots, install the handle cover by firmly pushing it into the recessed area on the face shield. 4. Install the dark glass by sliding it into place behind the glass retaining tabs. Note: if your face shield was supplied with a 3” x 3.8” dark glass you may choose to remove the extra material from the face shield to allow a larger field of vision when welding.
Gas Selection For Aluminium Welding with Aluminium Wire Use only pure Argon when welding Aluminium. INSTALL THE SHIELDING GAS WARNING IMPROPER HANDLING AND MAINTENANCE OF COMPRESSED GAS CYLINDERS AND REGULATORS CAN RESULT IN SERIOUS INJURY OR DEATH! Always secure gas cylinders to the welding cart, a wall, or other fixed support to prevent the cylinder from falling over and rupturing.
Change the drive roller according to the following steps: 1. Open the door to the welder drive compartment. 2. Remove the drive tension by loosening the tension adjusting screw and lifting the Drive Tension Adjustor up, away from the Drive Tension Arm. Pull the drive tension arm away from the drive roller. 3. If there is wire already installed in welder, roll it back onto the wire spool hand-turning the spool counterclockwise.
Figure 7. Wire Installation figure 8A. If you are installing an eightinch spool, install the spindle adapter and drive brake hardware as shown in Figure 8B. The purpose of the drive brake is to cause the spool of wire to stop turning at nearly the same moment that wire feeding stops. Figure 8A. Drive Brake Hardware Installation Figure 8B. Spindle Adapter and Drive Brake Installation 6. Once the drive brake hardware is installed, set the spool tension.
.Set the WIRE SPEED control to the middle of the wire speed range. 16.Straighten the gun cable and pull the trigger on the welding gun to feed the wire through the gun assembly. 17.When at least an inch of wire sticks out past the end of the gun, release the trigger. 18.Select a contact tip stamped with the same diameter as the wire being used. If stamped in metric see DESCRIPTION.
B. For MIG (GMAW) welding, mount the Ground Clamp ring terminal to the “” mounting post and the Torch ring terminal to the “+” mounting post. See configuration shown in Figure 9. OPERATION Operation of this welder consists of selecting and adjusting operating controls for optimum voltage (welding heat) and wire speed settings. CONTROLS AND INDICATORS Figure 9. Changing Polarity 2.
piece farthest away from you, and at an angle similar to that which will be used when welding. (SEE HOLDING THE GUN on page 18 if you are uncertain of the angle at which you will be welding) 4. With your free hand, turn the Wire Speed Dial to maximum and continue to hold onto the knob. WARNING EXPOSURE TO A WELDING ARC IS EXTREMELY HARMFUL TO THE EYES AND SKIN! Prolonged exposure to the welding arc can cause blindness and burns. Never strike an arc or being welding until you are adequately protected.
Angle A Figure 10. Gun Position, Angle A 2. Angle B (Figure 11) can be varied for two reasons: to improve the ability to see the arc in relation to the weld puddle and to direct the force of the arc. Angle B 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.
Figure 12. Travel Direction For most welding jobs you will pull the gun along the weld joint to take advantage of the greater weld puddle visibility. 2. TRAVEL SPEED is the rate at which the gun is being pushed or pulled along the weld joint. For a fixed heat setting, the faster the travel speed, the lower the penetration and the lower and narrower the finished weld bead. Likewise, the slower the travel speed, the deeper the penetration and the higher and wider the finished weld bead. Figure 13.
force, is directed more toward the metal above the weld joint. This is to help prevent the weld puddle from running downward while still allowing slow enough travel speed to achieve good penetration. A good starting point for angle B is about 30 degrees DOWN from being perpendicular to the work piece. Figure 16. Horizontal Position 3. The VERTICAL POSITION (Figure 17) is the next most difficult position.
The illustrations in Figure 19 show the sequence for laying multiple pass beads into a single V butt joint. NOTE: WHEN USING SELF-SHIELDING FLUX-CORE WIRE it is very important to thoroughly chip and brush the slag off each completed weld bead before making another pass or the next pass will be of poor quality. SPECIAL WELDING METHODS SPOT WELDING The purpose of a spot weld is to join pieces of metal together with a spot of weld instead of a continuous weld bead.
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 surface of the top piece. Select the wire diameter, heat setting, and tune in the wire speed as if you were welding the same thickness material with a continuous bead. 3.
Note: Due to inherent variances in fluxcored welding wire, it may be necessary to use a contact tip one size larger than your flux core wire if wire jams occur. 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. 2. Over time, the hole in the contact tip will become worn by the wire passing through it.
Figure 22. Drive Assembly of the gun liner with a wrench and rotate Gas Valve counterclockwise to unscrew fitting. Note: Rotate Gas Valve – Do not rotate brass fitting or gun liner twist inside gun cable and may cause damage to gun cable. 11.The Live Wire Terminal is held in place on the Gas Valve by the brass fitting on the end of the gun liner. When the brass fitting is removed , slide the Live Wire Terminal off of the brass fitting. 12.Firmly grip the gun cable and pull the gun liner all the way out. 13.
PREVENTIVE MAINTENANCE Except for internal and external cleaning, cleaning the nozzle, and occasionally retightening screws, there is no periodic maintenance recommended for your welder. TROUBLESHOOTING The following TROUBLESHOOTING information is provided as a guide to help resolve some of the more common problems that could be encountered. Table 5 is a troubleshooting table provided to help you determine a possible remedy when you are having a problem with your welder.
TABLE 5 – TROUBLESHOOTING TROUBLE POSSIBLE CAUSE POSSIBLE REMEDY Dirty, porous, brittle weld 1. Plugged welding nozzle 2. No shielding gas 1. Clean or replace nozzle. 2. Tank empty, flow restricted or regulator set too low. 3. See SELECTING SHIELDING gas section of manual. 4. Replace spool of wire. 3. Wrong type of gas 4. Dirty or rusty welding wire Wire feed works but no arc 1. Bad ground or loose connection 1. Check ground and connections. Tighten as necessary. 2. Bad connection to gun or faulty 2.
WIRE FEED WELDER WIRING DIAGRAM 28
WIRE FEED WELDER PARTS LIST 01 02 03 04 05 06 07 08 09 10 11 12 13 13 14 15 16 17 18 19 20 21 22 23 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 PRT 22710076 E1292 P.C.BOARD "CSA" PRT 04600146 JOHNSON MOTOR ø37 + PINION PRT 21600035 HANDLE PRT 22210014 THERMOSTAT 100° 10A PRT 04600286 FAN&FAN MOTOR ASSY.
WIRE FEED WELDER GUN PARTS LIST 01 02 03 04 05 06 07 07 07 08 09 10 11 12 12A 13 13A 14 15 16 17 PRT 04600163 PRT 23005332 PRT 23005145 PRT 23005091 PRT 23005285 PRT 23005146 PRT 23005018 PRT 23005019 PRT 23005020 PRT 23005147 PRT 21200010 PRT 33800032 PRT 30900021 PRT 23005254 PRT 30900002 PRT 22910001 PRT 22910001 PRT 30900020 PRT 04600063 PRT 23005148 PRT 23005318 HANDLE ASSY., BLUE GAS VALVE SWAN NECK WITH INSULATING COVER SWAN NECK LINER ISOLATING COVER FOR NECK TW1 TORCH DIFFUSER 0.
SUGGESTED SETTINGS 33
NOTES 34
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