GENERAL PRODUCT SPECIFICATIONS SPECIFICATIONS • Thermal Overload Protection • Output: 80A (rated current)@18V-20%, 125A (peak current) • Input: 120V, 60Hz, 20A, 1Ph • Duty Cycle 20%@80 AMPS • Wire Size: .030 - .035 Inch • Heat Settings: Two • MAX Metal Thickness: 18 Gauge / 3/16" FEATURES: • Includes Ground Cable With Clamp, Welding Gun, Face Shield & Brush Hammer KEEP THIS MANUAL, SALES RECEIPT & APPLICABLE WARRANTY FOR FUTURE REFERENCE. READ ALL INSTRUCTIONS AND WARNINGS BEFORE USING THIS PRODUCT.
SAFETY SUMMARY TABLE OF CONTENTS The warnings, cautions and instructions discussed in this instruction manual cannot cover all possible conditions or situations that could occur. It must be understood by the operator that common sense and caution are factors which cannot 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 HAZARDS 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.
• • • • • 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 torch 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. The intense light of the welding arc can burn the skin in much the same way as the sun, even through light-weight clothing.
• • • 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.
DESCRIPTION WELDER SPECIFICATIONS Your new MIG (Metal Inert Gas) 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 selfshielding 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.
KNOW YOUR WELDER Power Cord – This is a standard, grounded 120 volt power cord. (Make sure you are using a properly grounded 120 Vac, 60Hz, single phase, 20 amp power source.) Ground Clamp – Attaching the ground clamp to your work piece “completes” the welding current circuit. You must attach the ground clamp to the metal you are welding. If the ground clamp is not connected to the metal work piece you intend to weld, the welder will not have a completed circuit and you will be unable to weld.
WELDER INSTALLATION POWER SOURCE CONNECTION POWER REQUIREMENTS This welder is designed to operate on a properly grounded 120 volt, 60Hz, singlephase alternating current (ac) power source fused with a 20 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.
towards the face mask (4), while at the same time pushing upwards (5). (Alignment of the second tab is made easier by applying pressure to the point (3) shown below.) Figure 2. Face Shield Assembly 3. Install the dark glass (D) by sliding it into place behind the glass retaining tabs (E). 4. Once protective dark glass has been installed into face shield, secure it in place with the retaining clips (F).
Note: The drive roller has two wire size grooves built into it. When installing the drive roller, the number stamped on the drive roller for the wire size you are using should be facing you. Use only the proper size drive roller when using your welder. Table 4 indicates which drive roller groove should be used with each wire diameter size. Wire Diameter Drive Roller Groove: .030 inch .035 inch 0.8 0.9 Table 4. Drive Roller Sizing 4.
Figure 7. Wire Installation 5. If you are installing a four-inch spool of wire, install the drive brake hardware on the top of the spool of wire according to figure 8A. If you are installing an eight-inch 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.
heat. There are two voltage heat selections (labeled MIN and MAX) available on this welder. Position MIN provides the lowest voltage (heat) and position MAX the highest voltage (heat). 16. Set the WIRE SPEED control to the middle of the wire speed range. 17. Straighten the torch cable and pull the trigger on the welding torch to feed the wire through the torch assembly. 18. When at least an inch of wire sticks out past the end of the torch, release the trigger. 19. Turn the Power Switch to the OFF position.
OPERATION Operation of this welder consists of selecting and adjusting operating controls for optimum voltage (welding heat) and wire speed settings. CONTROLS AND INDICATORS WARNING Electric shock can kill! Whenever the Torch Trigger switch is in the ON position, the welding circuit is activated. Under this condition, an arc will occur if the welding wire or any part of the welding circuit comes in contact with welding ground. POWER SWITCH - The power switch supplies electrical current to the welder.
You can use the wire speed control to slightly increase or decrease the heat and penetration for a given heat setting by selecting higher or lower wire speed settings. Repeat this tune-in procedure if you select a new heat setting, a different diameter wire, or a different type of welding wire. LEARNING TO WELD MIG (Metal Inert Gas) welding is the process of uniting metallic parts by heating and allowing the metals to flow together through the use of an electrical arc.
On a fillet weld joint, the nozzle is generally positioned in such a manner so as to split the angle between the horizontal and vertical members of the weld joint. In most cases, a fillet weld will be 45 degrees. Distance from the Work Piece The end of the welding torch is designed with the contact tip recessed from the end of the nozzle and the nozzle electrically insulated from the rest of the torch. This permits the operator to actually rest the nozzle on the work piece and drag it along while welding.
There are two basic types of weld beads, the stringer bead and the weave bead. 1. The STRINGER BEAD (Figure 12) is formed by traveling with the torch in a straight line while keeping the wire and nozzle centered over the weld joint. This is the easiest type of bead to make. 2. The HORIZONTAL POSITION (Figure 15) is next in difficulty level. It is performed very much the same as the flat weld except that angle B (see HOLDING THE TORCH - p.
WARNING Hot slag can cause fires and serious injury from burns! Be sure to wear protective clothing, eye, and ear gear when using the Overhead Position. 4. The OVERHEAD POSITION (Figure 17) is the most difficult welding position because gravity is pulling at the weld puddle trying to make it drip off the work piece. Angle A (see HOLDING THE TORCH - p.15) should be maintained at 60 degrees, the same as in the flat position.
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. There are three methods of spot welding: Burn-Through, Punch and Fill, and Lap (see Figure 20). Each has advantages and disadvantages depending on the specific application as well as personal preference. allowed to fill up the hole leaving a spot weld that is smooth and flush with the surface of the top piece.
MAINTENANCE GENERAL 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. Keep the wire drive compartment lid closed at all times unless the wire needs to be changed or the drive tension needs adjusting. 2. Keep all consumables (contact tips, nozzles, and torch liner) clean and replace when necessary. See CONSUMABLE MAINTENANCE and TROUBLESHOOTING later in this section for detailed information. 3.
A SHORTED nozzle results when spatter buildup bridges the insulation in the nozzle, allowing welding current to flow through it as well as the contact tip. When shorted, a nozzle will steal welding current from the wire whenever it contacts the grounded work piece. This causes erratic welds and reduced penetration. In addition, a shorted nozzle overheats the end of the torch, which can DAMAGE the front-end of the torch.
Figure 21. Drive Assembly Figure 22.
TABLE 5 – TROUBLESHOOTING 24
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Part Number: RG46x11T Reduction Gear 46Tx11T Part Number: RG31x12T Reduction Gear 31Tx12T Motor Gear Part Number: G24T Gear 24T Part Number: RG32x12T Reduction Gear 32Tx12T Diagram of Gear Box for 125 Amp MIG/Fluxcore Welder HIT125 Part Number: G20T Gear 20T 201604
