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Always
use a contact
tip stamped
with the
same diameter
as the wire it will be used
with.
Note:
Due to inherent
variances
in flux-cored
welding wire, it may be necessary
to use a
contact tip one size larger than your flux core
wire if wire jams occur.
.
If the wire burns back into the tip, remove
the tip from the gun and clean the hole
running
through
it with an oxygen-acety-
lene torch tip cleaner or tip drill.
.
Over time, the hole in the contact
tip will
become
worn by the wire passing
through
it. The more worn this hole
becomes,
the less efficient
is the transfer
of welding
current to the wire and eventu-
ally arc breakage
and difficult arc starting
will result. Replace contact tips when
signs of wear become apparent.
MAINTAINING
THE NOZZLE
The nozzle directs the shielding
gas to the
weld puddle, determines
the size of the
shielding
area, and prevents
the electrically
hot contact
tip from contacting
the work
piece.
CAUTION
\.
KEEP THE NOZZLE
CLEAN!
During the
welding
process,
spatter and slag will build
up inside the nozzle and must be cleaned
out periodically.
Failure to clean and/or
replace the nozzle in a timely fashion
WILL
CAUSE
DAMAGE
TO THE FRONT-END
OF
THE GUN ASSEMBLY.
For best results,
coat the inside of a new, or
freshly
cleaned
nozzle with anti stick spray
or gel.
1.
Stop welding
and clean any accumulated
slag or spatter from the nozzle every 5 to
10 minutes
of welding time.
2.
When welding
overhead,
if any molten
metal drips from the weld puddle and
falls into the nozzle, STOP WELDING
IMMEDIATELY
and clean the nozzle.
3.
If the slag cannot be thoroughly
cleaned
from the nozzle, REPLACE
THE
NOZZLE!
Failure to keep the nozzle adequately
cleaned
can result in the following
problems:
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 gun, which can
DAMAGE
the front-end
of the gun.
A RESTRICTED
nozzle is created when
enough
slag builds up in the nozzle to affect
the direction,
concentration,
and/or rate of
the shielding
gas flow. This problem
can
cause porous,
brittle welds and reduce
penetration.
TESTING
FOR A SHORTED
NOZZLE
Arcing between
the nozzle and the work
piece ALWAYS
means the nozzle is shorted,
but this can be hard to detect through the
lens of a welding
helmet. The following
testing
method
is another way to tell if a
nozzle is shorted.
With the welder
unplugged
from the ac
power source,
touch the probes of an
ohmmeter
or continuity
tester to the end of
the contact
tip and the outside
of the nozzle.
If there is any continuity
at all, the nozzle IS
shorted.
Clean or replace as needed.
REPLACE
A GUN LINER
When installing a new gun liner, care must be
taken not to kink or otherwise damage the gun
liner. See Figure 21 for the drive assembly
and Figure 22 for the gun assembly.
1.
Turn OFF welder
POWER SWITCH
and
unplug welder from power supply.
2.
Open the welder
side panel.
3.
Loosen the tension
arm and lift it up off
the drive roller.
4.
Turn the wire spool counter-clockwise
(be
sure to hold onto the wire itself while
turning the spool or the wire will unspool
itself when it becomes
free of the gun
liner), and remove
wire from gun
assembly.
5.
Lay gun cable and gun handle straight
out in front of unit.
6.
Remove
gun liner holding
clamp by
removing
two self tapping
screws and
Page 22
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