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Summary of Contents for Metal Man M190
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Page 3: Safety Summary
Note: SAFETY SUMMARY • The following safety alert symbols identify important safety messages in The warnings, cautions and instructions dis- this manual. cussed in this instruction manual cannot • When you see one of the symbols shown cover all possible conditions or situations that here, be alert to the possibility of person- could occur. -
Page 4: Shock Hazards
SHOCK HAZARDS into the power source if the ground prong on power cord plug is bent over, broken off, or missing. • Do not allow the welder to be connected WARNING to the power source or attempt to weld if the welder, welding cables, welding site, or welder power cord are exposed to any ELECTRIC SHOCK CAN KILL! To reduce... -
Page 5: Fire Hazards
helmet and replace any cracked or bro- • Do not wear flammable hair preparations. ken filter lenses IMMEDIATELY. • Do not weld in an area until it is checked • Do not allow the uninsulated portion and cleared of combustible and/or flam- of the wire feed torch to touch the ground mable materials. -
Page 6: Fume Hazards
masonry, not tiled, carpeted, or made of LY TOXIC gas to form, along with other any other flammable material. lung and eye-irritating gasses. Do not • Protect flammable walls, ceilings, and weld or cut where these solvent vapors floors with heat resistant covers or can be drawn into the work area or where shields. -
Page 7: Additional Safety Information
anything other than its intended use. Do ADDITIONAL SAFETY INFORMATION not use as a support or roller. For additional information concerning welding • Do not locate cylinders in passageways safety, refer to the following standards and or work area where they may be struck. comply with them as applicable. -
Page 8: Welder Operating Characteristics
WELDER SPECIFICATIONS DESCRIPTION Your new welder has a duty cycle rating of 15% at the rated output. This means that you Your new MIG (Metal Inert Gas) wire feed can weld for one-and-a-half (1.5) minutes of welder is designed for maintenance and 10 with the remaining eight-and-a-half (8.5) sheet metal fabrication. -
Page 10: Welder Installation
Select a properly grounded extension cord WELDER INSTALLATION that will mate directly with the power source receptacle and the welder power cord without POWER SOURCE CONNECTION the use of adapters. Make certain that the extension cord is properly wired and in good POWER REQUIREMENTS electrical condition. -
Page 11: Selecting Shielding Gas
2. Align the second tab on the handle with SELECTING SHIELDING GAS the second slot in the face shield by The shielding gas plays an extremely impor- pushing the bottom of the handle in tant role in the MIG welding process. It is crit- towards the face mask (4), while at the ical that the molten weld puddle be shielded same time pushing upwards (5). -
Page 12: Install The Shielding Gas
INSTALL THE SHIELDING GAS Note: If the cylinder you have is equipped with male regulator connecting threads instead of female, you will need to obtain a WARNING special compressed gas cylinder adapter from your gas supplier to install between your gas cylinder and regulator. IMPROPER HANDLING AND MAINTE- -The gas control function does not require NANCE OF COMPRESSED GAS CYLIN-... -
Page 13: Selecting The Welding Wire
Adjust the drive roller according to the Wire Diameter Drive Roller Groove: following steps: .023 inch 1. Open the door to the welder drive com- .030 inch partment. .035 inch 2. Remove the drive tension by loosening the tension adjusting knob and lifting the Drive Tension Adjustor away from the Table 4. -
Page 14: Install The Welding Wire
INSTALL THE WELDING WIRE 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 WARNING figure 8A. If you are installing an eight-inch spool, install the spindle adapter and drive brake hardware as shown in Figure 8B. -
Page 15: Set The Wire Drive Tension
straight leading end remains. 19. Turn the Power Switch to the OFF 9. Loosen the tension adjusting knob holding position. the drive tension arm in place and lift the 20. Select a contact tip stamped with the tension arm up off the drive roller. same diameter as the wire being used. -
Page 16: Change Polarity
CHANGE POLARITY This welder allows you the capability to change the welding current polarity. You may select either dc Straight (dc - Flux Cored) or dc Reverse Polarity (dc + MIG). For welding steel with solid wire, stainless steel, flux cored hardfacing of steel, and silicon bronze welding of steel, select dc Reverse Polarity (dc + MIG). -
Page 17: Operation
TUNING IN THE WIRE SPEED OPERATION This is one of the most important parts of Operation of this welder consists of selecting MIG welder operation and must be done and adjusting operating controls for optimum before starting each welding job or whenever voltage (welding heat) and wire speed set- any of the following variables are changed: tings. -
Page 18: Learning To Weld
You can use the wire speed control to slightly tions until you find the one that seems to increase or decrease the heat and penetra- work best for you. Refer to WELDING tion for a given heat setting by selecting POSITIONS - p.20) higher or lower wire speed settings. -
Page 19: Welding Techniques
with 30 degrees working about the best. moved steadily and at the right speed along On a fillet weld joint, the nozzle is generally the weld joint. Moving the torch too fast, too positioned in such a manner so as to split the slow, or erratically will prevent proper fusion angle between the horizontal and vertical or create a lumpy, uneven bead. -
Page 20: Welding Positions
There are two basic types of weld beads, the 2. The HORIZONTAL POSITION (Figure 16) stringer bead and the weave bead. is next in difficulty level. It is performed very much the same as the flat weld except that 1. The STRINGER BEAD (Figure 13) is angle B (see HOLDING THE TORCH - p.18) formed by traveling with the torch in a is such that the wire, and therefore the arc... -
Page 21: Multiple Pass Welding
The illustrations in Figure 19 show the sequence for laying multiple pass beads into WARNING a single V butt joint. NOTE: WHEN USING SELF-SHIELDING Hot slag can cause fires and serious injury FLUX-CORE WIRE it is very important to from burns! Be sure to wear protective cloth- thoroughly chip and brush the slag off each ing, eye, and ear gear when using the completed weld bead before making another... -
Page 22: Special Welding Methods
SPECIAL WELDING METHODS arc is directed through the hole to pene- trate into the bottom piece. The puddle is allowed to fill up the hole leaving a spot SPOT WELDING weld that is smooth and flush with the The purpose of a spot weld is to join pieces surface of the top piece. -
Page 23: Maintenance
Always use a contact tip stamped with the MAINTENANCE same diameter as the wire it will be used GENERAL with. Note: Due to inherent variances in flux-cored This welder has been engineered to give welding wire, it may be necessary to use a many years of trouble-free service providing contact tip one size larger than your flux core that a few very simple steps are taken to... -
Page 24: Testing For A Shorted Nozzle
A SHORTED nozzle results when spatter 7. Take torch handle halves apart by remov- buildup bridges the insulation in the nozzle, ing four phillips head screws. allowing welding current to flow through it as 8. Remove the hanging hook from the two well as the contact tip. -
Page 25: Preventive Maintenance
PREVENTIVE MAINTENANCE Except for internal and external cleaning, cleaning the nozzle, and occasionally retight- ening screws, there is no periodic mainte- nance recommended for your welder. TROUBLESHOOTING The following TROUBLESHOOTING informa- tion is provided as a guide to help resolve some of the more common problems that could be encountered. - Page 26 TABLE 5 – TROUBLESHOOTING...
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