Professional Documents
Culture Documents
SAFETY
Safety ......................................................... 2
Specifications ............................................. 6
Setup .......................................................... 7
Basic Welding ............................................ 12
SETUP
BASIC WELDING
MAINTENANCE
Page 2
5. Do not overreach.
Keep proper footing and balance at all times.
6. Avoid unintentional starting. Make sure you are
prepared to begin work before turning on the Welder.
7. Never leave the Welder unattended while
energized. Turn power off if you have to leave.
8. The warnings, precautions, and instructions
discussed in this instruction manual cannot
cover all possible conditions and situations
that may 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.
Item 61849
SETUP
SAFETY
BASIC WELDING
MAINTENANCE
WELDING TIPS
Item 61849
Page 3
SAFETY
SETUP
BASIC WELDING
WELDING TIPS
MAINTENANCE
Page 4
Item 61849
SETUP
SAFETY
MAINTENANCE
WELDING TIPS
BASIC WELDING
Item 61849
Page 5
Grounding
SAFETY
Grounded Welders
SETUP
Extension Cords
BASIC WELDING
WELDING TIPS
Specifications
Electrical Rating
120V~ / 20A
Welding Output
60 ~ 120A, AC
18 gauge (0.048") to 3/16" (0.19") mild steel only
Not for welding aluminum or stainless steel
20% @ 90A
(See explanation on page 14)
Capacity
MAINTENANCE
Duty Cycle
Page 6
27
KVA
2.38
Item 61849
Symbology
Gun Cable
Overheat Shutdown Indicator
Cooling Fan
Housing Ground Point
Alternating Current
SAFETY
~
A
OCV
KVA
IPM
AWG
Amperes
Open Circuit Voltage
Kilovolt Amperes
(Volts / 1000 * Amperes)
Inches Per Minute
American Wire Gauge
SETUP
Volts
BASIC WELDING
Setup
Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this
manual including all text under subheadings therein before set up or use of this product.
TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION:
Turn the Power Switch off and unplug the Welder before assembly.
Notch drops
into slot on
Cover here
Handle
Screw
WELDING TIPS
Cover Assembly
Cover
MAINTENANCE
Item 61849
Page 7
GUN
SAFETY
ON
MIN
OFF
MAX
Specifications
Wire
0.030"0.035"Flux-Core
Capacity 18Ga.3/16"SteelPlate
Weldable Mild,LowAlloySteel
Materials (NotforAluminumorStainlessSteel)
GROUND
120V~
60Hz
20A
Cover
SETUP
Wire
Spool
BASIC WELDING
Knob
3. Remove the Knob, Spring and the Top Plate.
If replacing a Spool, remove the old Spool
and all remaining wire from the liners.
Spring
Top Plate
WELDING TIPS
Wire Spool
Spindle
.03
0
MAINTENANCE
wire must
unwind in this
direction
Page 8
Item 61849
.03
.03
Feed
Tensioner
Feed
Knob
Feed
Roller
.03
SETUP
Feed Swing
Arm
SAFETY
HOLD WIRE
SECURELY
0
leader
wire liner
.03
.03
13. Lay the Gun Cable out in a straight line so that the
wire moves through it easily. Leave the cover open,
so that the feed mechanism can be observed.
Item 61849
Wire
Spool
Feed
Tensioner
Feed Swing
Arm
Gun
BASIC WELDING
.03
welding
wire
WELDING TIPS
Wire
Liner
Nozzle
MAINTENANCE
IMPORTANT:
Contact
Tip
Page 9
SAFETY
WARNING
SETUP
BASIC WELDING
ON
MIN
OFF
MAX
Specifications
Wire
0.030"0.035"Flux-Core
Capacity 18Ga.3/16"SteelPlate
Weldable Mild,LowAlloySteel
Materials (NotforAluminumorStainlessSteel)
GROUND
120V~
60Hz
20A
WELDING TIPS
15. Point the Gun away from all objects and press
the Trigger until the wire feeds out of the Gun
two inches.
The Wire Liner may come out with the welding
wire, this is normal, just push the Wire Liner
back into the Gun.
If the wire does not feed properly and the
Spool is stationary, turn the Welder to OFF,
unplug it, and slightly tighten the Feed
Tensioner clockwise before retrying.
Gun
Welding
Wire
MAINTENANCE
Page 10
Item 61849
SAFETY
.03
Incrementally
increase tension
until
wire bends.
2-3
SETUP
GUN
ON
MIN
OFF
MAX
BASIC WELDING
Wire
0.030"0.035"Flux-Core
Capacity 18Ga.3/16"SteelPlate
Weldable Mild,LowAlloySteel
Materials (NotforAluminumorStainlessSteel)
GROUND
120V~
60Hz
20A
Nozzle
Contact
Tip
MAINTENANCE
Gun
WELDING TIPS
Item 61849
Page 11
Basic Welding
SAFETY
SETUP
BASIC WELDING
GUN
ON
MIN
OFF
MAX
Specifications
Wire
0.030"0.035"Flux-Core
Capacity 18Ga.3/16"SteelPlate
Weldable Mild,LowAlloySteel
Materials (NotforAluminumorStainlessSteel)
GROUND
WELDING TIPS
120V~
60Hz
20A
MAINTENANCE
Page 12
Item 61849
GUN
Overload
Indicator
ITEM 61207
ON
Wire
Speed
Dial
MIN
SETUP
Gun
Cable
SAFETY
Current
Switch
OFF
MAX
Specifications
BASIC WELDING
Power
Switch
GROUND
120V~
60Hz
20A
Ground
Cable
Gun Cable:
The welding Gun connects here. The wire and welding
current feeds to the weld through here.
The welding Gun is energized whenever
the Power Switch is on.
Wire Speed Dial:
This controls the speed that the welding wire feeds out
of the welding Gun.
Adjust this according to the weld settings chart
to achieve a good weld. (See next page.)
Ground Cable:
This connects to the base metal to provide a good
connection for the current to travel back to the Welder.
Power
Cord
Overload Indicator:
This lights up if duty cycle work period is exceeded
and the Welder is overheated. Rest the Gun
on an electrically non-conductive, heat-resistant
surface, such as a concrete slab, well clear of the
ground clamp while allowing the Welder to cool
with the Power Switch on, so the Fan can help
cool the Welder. Once the Welder cools enough
to be used again, use shorter welding periods and
longer rest periods to prevent needless wear.
Current Switch:
This controls the output amperage of the Welder.
Adjust this according to the weld settings
chart to achieve a good weld.
Power Switch:
This turns on power to the Welding Gun
and internal cooling fan.
Power Cord:
Plug the Power Cord into a properly grounded
120V~ outlet, on at least a 20 amp dedicated circuit
with delayed action type circuit breaker or fuses.
Item 61849
Page 13
WELDING TIPS
Wire
0.030"0.035"Flux-Core
Capacity 18Ga.3/16"SteelPlate
Weldable Mild,LowAlloySteel
Materials (NotforAluminumorStainlessSteel)
MAINTENANCE
SAFETY
16 Gauge
14 Gauge
MIN current
1.5
2
4
speed
speed
speed
1.5
2
3
speed
speed
speed
1/ "
8
3/ "
16
MAX current
8
9
speed
speed
8
9.5
speed
speed
SETUP
* This chart is only intended to show general guidelines for different wire sizes and for different
thicknesses of material. The settings should only be used at the beginning of a weld and must be
adjusted after stopping and carefully inspecting the weld. Proper welding takes experience.
WELDING TIPS
ITEM 61207
Gun
MIN
MAX
Wire
0.030"0.035"Flux-Core
Capacity 18Ga.3/16"SteelPlate
Weldable Mild,LowAlloySteel
Materials (NotforAluminumorStainlessSteel)
concrete slab
MAINTENANCE
120V~
60Hz
20A
Page 14
Item 61849
SAFETY
Clamps
Workpieces
Clean
surfaces to
bare metal.
GUN
Workpiece
ITEM 61207
MIN
OFF
MAX
Wire
0.030"0.035"Flux-Core
Capacity 18Ga.3/16"SteelPlate
Weldable Mild,LowAlloySteel
Materials (NotforAluminumorStainlessSteel)
Clean
surface to
bare metal.
Ground
Clamp
GROUND
120V~
60Hz
20A
GUN
ITEM 61207
ITEM 61207
MIN
OFF
MAX
Specifications
GUN
ON
Wire
0.030"0.035"Flux-Core WIRE
Capacity 18Ga.3/16"SteelPlate
Weldable Mild,LowAlloySteel
Materials (NotforAluminumorStainlessSteel)
ON
MIN
OFF
MAX
Specifications
FEED SPEED
Wire
0.030"0.035"Flux-Core
Capacity 18Ga.3/16"SteelPlate
Weldable Mild,LowAlloySteel
Materials (NotforAluminumorStainlessSteel)
GROUND
GROUND
120V~
60Hz
20A
WELDING TIPS
120V~
60Hz
20A
ON
MIN
OFF
MAX
Specifications
Wire
0.030"0.035"Flux-Core
Capacity 18Ga.3/16"SteelPlate
Weldable Mild,LowAlloySteel
Materials (NotforAluminumorStainlessSteel)
GROUND
GUN
120V~
60Hz
20A
ITEM 61207
HOLD
GUN
CLEAR
ON
MIN
OFF
MAX
Specifications
Wire
0.030"0.035"Flux-Core
Capacity 18Ga.3/16"SteelPlate
Weldable Mild,LowAlloySteel
Materials (NotforAluminumorStainlessSteel)
GROUND
120V~
60Hz
20A
Page 15
MAINTENANCE
GUN
BASIC WELDING
ON
Specifications
Item 61849
SETUP
SAFETY
stringer bead
weave bead
SETUP
BASIC WELDING
90
45
fillet weld joint
WELDING TIPS
MAINTENANCE
Page 16
Drag Angle
0-15
Weld
Direction
Stickout
(up to 1/2")
Item 61849
GUN
ITEM 61207
Gun
MIN
concrete slab
MAX
SAFETY
Wire
0.030"0.035"Flux-Core
Capacity 18Ga.3/16"SteelPlate
Weldable Mild,LowAlloySteel
Materials (NotforAluminumorStainlessSteel)
GROUND
BASIC WELDING
up to 2 minutes welding
at rated output
GUN
HOLD
GUN
CLEAR
ON
MIN
OFF
MAX
Specifications
Wire
0.030"0.035"Flux-Core
Capacity 18Ga.3/16"SteelPlate
Weldable Mild,LowAlloySteel
Materials (NotforAluminumorStainlessSteel)
GROUND
120V~
60Hz
20A
Gun
MAINTENANCE
concrete slab
Item 61849
WELDING TIPS
SETUP
120V~
60Hz
20A
Page 17
Welding Tips
SAFETY
slag
BASIC WELDING
spatter
base metal
Strike Test
clamp
dead-blow hammer
SCRAP
workpiece
WELDING TIPS
GOOD WELD
bends and is not brittle
MAINTENANCE
dead-blow hammer
clamp
SCRAP
workpiece
POOR WELD
snaps or cracks
Page 18
Item 61849
Weld Diagnosis
PROPER PENETRATION
EXCESS PENETRATION OR
BURN-THROUGH
Ideal heat
Too hot
Current
Too High or
Wire Feed
Too Fast
GUN
GUN
TO CORRECT:
ITEM 61207
TO CORRECT:
ON
ITEM 61207
GUN
ON
MIN
OFF
Weld Speed
Too Fast
Weld Speed
Too Slow
Stickout
Too Long
TO CORRECT:
TO CORRECT:
TO CORRECT:
MIN
MAX
Specifications
MAX
GROUND
Specifications
Wire
0.030"0.035"Flux-Core
Capacity 18Ga.3/16"SteelPlate
Weldable Mild,LowAlloySteel
Materials (NotforAluminumorStainlessSteel)
Wire
0.030"0.035"Flux-Core
Capacity 18Ga.3/16"SteelPlate
Weldable Mild,LowAlloySteel
Materials (NotforAluminumorStainlessSteel)
or
ON
MIN
OFF
MAX
weld
slower
weld
faster
120V~
60Hz
20A
GROUND
120V~
60Hz
20A
ITEM 68887
maintain
less
than 1/2"
stickout
Wire
.030-.035 Flux-core
Capacity XX Ga. X/X Steel Plate
Electrode X
Cables
Ground Clamp X
GROUND
Item 61849
120V~
60Hz
Page 19
MAINTENANCE
Current
Too Low
Good
Weld
WELDING TIPS
BASIC WELDING
SETUP
INADEQUATE PENETRATION
SAFETY
Weld Problems
EXCESS PENETRATION OR
BURN-THROUGH
Weld droops on top and
underneath or falls through
entirely, making a hole.
PROPER PENETRATION
Weld is visible underneath and
bulges slightly on top.
INADEQUATE PENETRATION
Weld does not contact the joint
fully, just on the surface.
SETUP
PROFILE VIEWS
BASIC WELDING
PROFILE
VIEW
1.
MAINTENANCE
2.
3.
4.
Page 20
Bend at Joint
PROFILE
VIEW
POSSIBLE CAUSES AND SOLUTIONS
1. Improper clamping:
Clamp workpieces securely.
Make tack welds to hold workpieces.
2. Excessive heat:
Weld a small portion and allow to cool before
proceeding.
Increase weld speed.
Reduce wire feed speed.
Item 61849
Excessive Spatter
Porosity
TOP
VIEW
SETUP
TOP
VIEW
SAFETY
TOP
VIEW
TOP
VIEW
Item 61849
WELDING TIPS
Crooked/Wavy Bead
Burn-Through
MAINTENANCE
BASIC WELDING
TOP
VIEW
Page 21
Maintenance
SAFETY
SETUP
Gun
concrete slab
BASIC WELDING
Nozzle
Contact
Tip
MAINTENANCE
Page 22
Nozzle
Contact
Tip
Item 61849
Troubleshooting
Be CERTAIN to shut off the Welder, disconnect it from power, and discharge the Gun to ground
before adjusting, cleaning, or repairing the unit.
Wire Feed Motor Runs But Wire Does Not Feed Properly
SAFETY
IMPORTANT!
SETUP
BASIC WELDING
MAINTENANCE
Page 23
Troubleshooting (continued)
IMPORTANT!
SAFETY
Be CERTAIN to shut off the Welder, disconnect it from power, and discharge the Gun to ground
before adjusting, cleaning, or repairing the unit.
SETUP
BASIC WELDING
WELDING TIPS
MAINTENANCE
Page 24
Item 61849
FM
MAINTENANCE
PE
S1-2
AC120V 60Hz
S1-1
Overheat
Indicator
MIN
TH
CN2
CN3
CN4
TR1
CR1
TR2
630V104K
C1
WELDING TIPS
t+
MAX
S2
0.5A
TS
D1
1N4007
CR1
CR2-1
22F 50V
C2
R5
CR2-2
CN1
G5LC-14 12DC
CR2
1 2 3 4 5 6 7
D2
W08
BASIC WELDING
R3
1K
R4
620
FUSE2
JQX-29F-A 12VDC
3.13A
FUSE1
Item 61849
0.510W
TIP35C
Q1
WR1
2.2K
SETUP
C3
470F
R1
30
R2
47
RT1
14D181
RP1
1K
SAFETY
OUTPUT
Wiring Schematic
Page 25
Parts List
SAFETY
Part
SETUP
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Description
Qty
1
2
1
1
1
1
1
1
1
1
1
4
1
1
1
2
4
1
Part
19
20
21
22
23
23a
23b
23c
23d
23e
23f
24
25
26
27
28
29
30
Description
Conducting Strip
Heat Relay
Middle Panel
Right Panel
Wire Feeder
Feed Tensioner
Swing Arm
Tension Roller
Liner
Feed Knob
Feed Roller
Wire Spool
Left Panel
Cover Latch
Cover Latch Bracket
Cover
Handle
Handle Screw
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
23d
23e
WELDING TIPS
.
0
3
0
BASIC WELDING
Part 23 Detail
MAINTENANCE
23c
23b
23a
Page 26
Item 61849
MAINTENANCE
WELDING TIPS
BASIC WELDING
SETUP
SAFETY
Assembly Diagram
Item 61849
Page 27