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117-035 160 - 225 Amp Wire Feed Welder Owners Manual

117-035 160 - 225 Amp Wire Feed Welder Owners Manual
 
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Description Prop65
 
This Operators manual provides specific information for your welder model. This manual contains information such as the Important Safety Instructions, Usage and Maintenance of your welder. Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product described. Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or property damage! Retain instructions for future reference.
Model Coverage: 117-035, 117-037, 117-042, 2225, 83160, 83225
Product Features
Safety Summary
Safety Information . . . . . . . . . . . . . . . . . . . . .1
Shock Hazards . . . . . . . . . . . . . . . . . . . . . . . .1
Flash Hazards . . . . . . . . . . . . . . . . . . . . . . . .2
Fire Hazards . . . . . . . . . . . . . . . . . . . . . . . . . .3
Fume Hazards . . . . . . . . . . . . . . . . . . . . . . . .3
Compressed Gasses and
Equipment Hazards . . . . . . . . . . . . . . . . . . . .4
Additional Safety Information . . . . . . . . . . . . .4
Introduction
Description . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Welder Performance . . . . . . . . . . . . . . . . . . .6
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . .6
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Specifications . . . . . . . . . . . . . . . . . . . . . . . . .6
Installation
Unpacking Your Welder . . . . . . . . . . . . . . . . .7
Power Requirements . . . . . . . . . . . . . . . . . . .7
Preparation For Use . . . . . . . . . . . . . . . . . . . .7
230 Volt to 208 Volt Conversion . . . . . . . . . .7
Power Source Connection . . . . . . . . . . . . . .8
Extension Cord Use . . . . . . . . . . . . . . . . . . .8
Select Shielding Gas . . . . . . . . . . . . . . . . . .8
Gas Selection For Steel Welding . . . . . . . .8
Gas Selection for Aluminum Welding . . . .8
Gas Selection For Stainless Steel
Welding . . . . . . . . . . . . . . . . . . . . .8
Gas Selection For Steel Welding With Silicon
Bronze Wire . . . . . . . . . . . . . . . .9
Select Type Of Wire . . . . . . . . . . . . . . . . . . . .9
Solid Steel Wire Selection . . . . . . . . . . . . .9
Aluminum Wire Selection . . . . . . . . . . . . . .9
Stainless Steel Wire Selection . . . . . . . . . .9
Silicon-Bronze Wire Selection . . . . . . . . . .9
Self-Shielding, Flux-Core, Steel Wire
Selection . . . . . . . . . . . . . . . . . . . . . . . . .9
Select The Spool Size . . . . . . . . . . . . . . . .9
Steel Wire . . . . . . . . . . . . . . . . . . . . . . . . .9
Aluminum Wire . . . . . . . . . . . . . . . . . . . .10
Stainless Steel Wire . . . . . . . . . . . . . . . . .10
Self-shielding, Flux Core, and Steel Wire 10
Silicon-Bronze Wire . . . . . . . . . . . . . . . . .11
Wire Spool Storage . . . . . . . . . . . . . . . . .11
Select The Wire Diameter . . . . . . . . . . . .11
Silicon-Bronze Wire Welding of Steel . . .11
Self-Shielding, Flux Core, Steel
Wire Weldingof Steel . . . . . . . . . . . . . .11
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Assemble The Cart . . . . . . . . . . . . . . . . .11
Install Gun/Powercord Storage Brackets .11
Install Hood Handle . . . . . . . . . . . . . . . . .11
Assemble Welding Gun . . . . . . . . . . . . . .12
Install the Shielding Gas . . . . . . . . . . . . .12
Regulate Gas Flow . . . . . . . . . . . . . . . . .13
Install the Welding Wire . . . . . . . . . . . . . .13
Install Aluminum Wire . . . . . . . . . . . . . . .16
Operation
Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . .17
Getting To Know Your New Welder . . . . . . . .17
Setting the Controls . . . . . . . . . . . . . . . . . . .17
Select Welding Current Polarity and 
Connect Welder Ground . . . . . . . . . . .18
Cleaning The Weld Bead . . . . . . . . . . . . . . .18
Learning to Weld
Preparing to Weld . . . . . . . . . . . . . . . . . . . . .19
Preparing A Safe Work Area . . . . . . . . . .19
Preparing the Work Piece . . . . . . . . . . . .19
Aluminum Welding Preparation . . . . . . . .19
Holding the Gun . . . . . . . . . . . . . . . . . . . .20
Position Of The Gun To The Work Piece .20
Distance From The Work Piece . . . . . . . .20
Laying a Bead . . . . . . . . . . . . . . . . . . . . .20
Welding Techniques . . . . . . . . . . . . . . . . . . .21
Moving the Gun . . . . . . . . . . . . . . . . . . . .21
Types of Weld Beads . . . . . . . . . . . . . . . .21
Welding Positions . . . . . . . . . . . . . . . . . .22
Special Welding Methods . . . . . . . . . . . . . . .23
Spot Welding . . . . . . . . . . . . . . . . . . . . . .23
Stitch Welding . . . . . . . . . . . . . . . . . . . . .24
Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Maintenance and Troubleshooting
General Maintenance . . . . . . . . . . . . . . . . . .25
Maintaining The Welder . . . . . . . . . . . . . .25
Testing for a Shorted Nozzle . . . . . . . . . .26
Troubleshooting . . . . . . . . . . . . . . . . . . . .26
Defective Gas . . . . . . . . . . . . . . . . . . . .26
Insufficient Shielding Gas Coverage . . .26
Basic Troubleshooting Guide . . . . . . . . . .27
Manufacturer’s Limited Warranty . . . . . . . . .29


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