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Unplug the Welder. Slightly tighten the Tension Adjusting Knob (10b) on the Wire Feed Assembly, and rewind the Welding Wire slightly before retrying. (See Figure E.) To check the tension on the Wire Feed Assembly, feed the Welding Wire against a piece of scrap wood from 2 to 3 inches away. If the Wire stops instead of bending, turn the Welder OFF. Unplug the unit from its electrical outlet. Then, slightly tighten the Tension Adjusting Knob (10b) on the Wire Feed Assembly. (See Figure E.) FIGURE FCONTACTTIP(15g) NOZZLE(15h) WELDINGWIREHEADTUBE(15f) NOZZLE(15h) CONTACTTIP(15g) HEADTUBE(15f) Turn the Welder OFF, unplug it, and discharge the electrode to ground. Insert the Contact Tip (15g) onto the Welding Wire and screw it firmly into the Head Tube (15f) of the Torch Handle. Replace the Nozzle (15h), and cut off any excess Welding Wire over 1/2 inch. Then, close the Access Panel (12) of the Welder. (See Figure F.) Note: When installing wire of a different size or composition, you will also need to change wire settings, set the gun polarity, and, possibly, install a gas cylinder. See pages 14-16. To Change Wire Settings WARNING! Make sure to turn off the Welder and unplug it from its electrical outlet prior to changing wire settings. Open the Access Panel (12) of the Welder to expose the Wire Feed Assembly. FIGURE GSWING ARM(10a) TENSIONADJUSTINGKNOB(10b) SCREW(10l) FEEDROLLERBRACKET(10k) Loosen, and lower the Tension Adjusting Knob (10b) on the Wire Feed Assembly. Then, raise the Swing Arm (10a). (See Figure G.) Remove the two Screws (10l) that secure the Feed Roller Bracket (10k) in place. Then, remove the Feed Roller Bracket. (See Figure G.) Install a Wire Feed Roller (11) with the proper groove size facing towards the Inner Panel (8) of the welder. Replace the Feed Roller Bracket (10k), and secure in place with the Screws. (See Figure G.) Lower the Swing Arm (10a) on the Wire Feed Assembly. Then, lower and tighten the Tension Adjusting Knob (10b). (See Figure G.) Remove the Gun Nozzle (15h) and Contact Tip (15g). Install a Contact Tip that is one size larger* than the diameter of Welding Wire used. Then, replace the Gun Nozzle. (See Figure F, previous page.) *This accommodates thermal expansion of the wire. Install the Spool of Welding Wire, and route the Wire to the Torch Gun. Then, test and, if necessary, adjust the Wire Feed Assembly as discussed in the previous pages of this manual. Setting The Gun Polarity For Wire Type Set for Electrode Positive (DCEP) for gas welding with solid-core wire. Positive electrode (C), negative ground (D). Shown in illustration, Initial Setup. (See Figure H.) Set for Electrode Negative (DCEN) for gasless flux core wire. Negative electrode (C), positive ground (D). (See Figure H.) When connecting to the weld output terminals, do not place anything between the welding Cable Terminals (A and C) and their copper connections. (See Figure H.) Always read and follow wire manufacturer’s recommended polarity. A. Positive (+) Output Terminal Polarity Changeover Label Negative (–) Output Terminal Red Cable Black Cable C E B D A FIGURE H To Install A Gas Cylinder WARNING: Maximum cylinder height is 1 feet 7 inches (0.5m). Maximum cylinder weight is 22 lb., including gas. NEVER exceed either of these maximums. CAUTION! Do not use an Argon/Mixed pressure regulator/flow meter with CO2 shielding gas. To use CO2 shielding gas, you must install a CO2 gas pressure regulator/ flow meter (neither one included). Thread the provided strap through the slots on the back of the welder. With assistance, set the cylinder onto the shelf at the back of the welder. Secure the cylinder in place with the strap. Remove the protective cap from the cylinder. Stand to the side of the cylinder valve, and open the valve slightly to blow dust and dirt from the valve. Then, close the valve. Make sure the Flow Adjust on the Pressure Regulator/Flow Meter is turned off. Then, screw the Pressure Regulator/Flow Meter (not included) firmly onto the cylinder valve. Attach the Gas Line (41) to the Pressure Regulator/Flow Meter from the Gas Inlet located on the Back Panel (6) of the Welder. Adjust the flow rate of the gas by turning the Flow Adjust. The typical flow rate is 10-30 CFH (cubic feet per hour). Make sure to check the Welding Wire manufacturer’s recommended flow rate. WARNINGRisk of explosion! While the Gas Cylinder is attached, this unit must only be transported using an appropriate welding cart (not included). Transporting this welder any other way could result in the cylinder being damaged or ruptured, causing an explosion and, potentially, severe personal injury. OPERATING INSTRUCTIONS Before You Begin Welding Good welding requires a high degree of skill and experience. You should practice a few sample welds on scrap metal before you begin welding your first project. Additional practice periods are recommended whenever you weld a different thickness of material, wire, or weld a different type of connection....