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Metal Man MIG/Stick 200 Operating Instructions And Parts Manual

Metal man mig/stick 200 welder operating instructions and parts manual
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  • Page 2: General Safety Information

    METAL MAN MIG/Stick 200 WORK GEAR Operating Instructions and Parts Manual using product. Protect yourself and others by observing all safety information, warnings, and cautions. Failure to comply with instructions could result in personal injury and/or damage to product or property. Please retain instructions for future reference 1.
  • Page 3 MIG/Stick 200 Operating Instructions and Parts Manual -Wear proper gloves and protective clothing to prevent your skin from being exposed to hot metals, UV and IR rays. -Do not overuse or overheat your welder. Allow proper cooling time between duty cycles.
  • Page 4 MIG/Stick 200 Operating Instructions and Parts Manual UV and IR Arc Rays The welding arc produces ultraviolet (UV) and infrared (IR) rays that can cause injury to your eyes and skin. Do not look at the welding arc without proper eye protection.
  • Page 5 MIG/Stick 200 Operating Instructions and Parts Manual Sparks/Flying Debris Welding creates hot sparks that can cause injury. Chipping slag off welds creates flying debris. -Wear protective apparel at all times: ANSI-approved safety glasses Electromagnetic Field -Electromagnetic fields can interfere with various electrical and electronic devices such as pacemakers.
  • Page 6 140 amps DC using electrodes from 1/16" to 1/8" for a single pass capacity of 3/16" on mild steel. The MIG/Stick 200 is well equipped for the home shop or for those on-the-go welders that need a portable multi-process machine.

  • Page 7: Package Contents

    MIG/Stick 200 Operating Instructions and Parts Manual 4. Package Contents Please check the contents of your package. 1 MIG/Stick 1 Operator's 200 Power Manual Source 1 Regulator 1 MIG Gun with Gas Hose 1 Ground 1 Electrode Cable with Holder with...
  • Page 8 MIG/Stick 200 Operating Instructions and Parts Manual 5. Know your Welder - Upper Front Panel 1. Power On Indicator - Lights up when primary power is connected and the power switch is in the "On" position. 2. Thermal Overload Indicator - Lights up when the thermal overload circuit is activated and protecting the unit.
  • Page 9 MIG/Stick 200 Operating Instructions and Parts Manual 6. Know your Welder - Lower Front Panel 1. Ground Cable Connection - Connects the ground cable and clamp to the welding machine. 2. MIG Gun Trigger Connection - 4-Pin Twist Connect trigger connection for the MIG Gun.
  • Page 10 MIG/Stick 200 Operating Instructions and Parts Manual 7. Know your Welder - Back Panel 1. Specifications Label - This label communicates the specifications and the serial number of this unit. 2. Primary Power Switch - This switch applies power to the unit in the "On"...
  • Page 11 MIG/Stick 200 Operating Instructions and Parts Manual 9. Assembly & Set-Up For Stick Welding Choose a location for your welding unit. This location should in an area free of debris and away from flammable materials. A welding cart or cabinet may be desired for easy moving of your welder to the area it will be operating.
  • Page 12 MIG/Stick 200 Operating Instructions and Parts Manual 9. Assembly & Set-Up For Stick Welding (Continued) Flip the Mode Selector Switch on the front panel to the Stick Mode. Turn on the Primary Power Switch on the back panel. See Section 16 for detailed information on operating a stick welder.
  • Page 13 MIG/Stick 200 Operating Instructions and Parts Manual 10. Assembly & Set-Up For MIG Welding (Continued) Connect the supplied gas hose to the regulator Install the other end of the gas hose to the inert gas fitting on the back of the unit.
  • Page 14 MIG/Stick 200 Operating Instructions and Parts Manual 10. Assembly & Set-Up For MIG Welding (Continued) Flip the mode selector switch on the front panel to MIG Open the wire compartment door and remove the hardware from the wire spool support Slide on a 4"...
  • Page 15 MIG/Stick 200 Operating Instructions and Parts Manual 10. Assembly & Set-Up For MIG Welding (Continued) Plug the Primary Power Cord into a 230V, 50A receptacle. The plug and receptacle design is a NEMA 6-50 design. See Section 11 for detailed information on power requirements.

  • Page 16: Power Requirements

    MIG/Stick 200 Operating Instructions and Parts Manual 11. Power Requirements This unit uses a single phase 230VAC(220-240V), 60HZ circuit with 50 amp time delayed fuse or circuit breaker is required. DO NOT OPERATE THIS UNIT if the ACTUAL power source voltage is less than 215volts ac or greater than 240 volts High voltage danger from power source! Consult a qualified electrician for proper installation of receptacle.
  • Page 17 MIG/Stick 200 Operating Instructions and Parts Manual Remove the drive tension by loosening the tension adjusting knob and lifting the Drive Tension Adjustor away from the Drive Tension Arm. Pull the drive tension arm away from the driver roller. If there is wire already installed in the welder, roll it back onto the wire spool by hand-turning the spool counterclockwise.
  • Page 18 MIG/Stick 200 Operating Instructions and Parts Manual 13. Installing Wire 13.1 Select the wire. The following wires can be used in this machine: .023 - .035 MIG Wire .030 - .035 Flux Core Wire MIG wire can be either mild steel, stainless steel or aluminum solid wire. For use NOTE: 24 gauge cannot be welded with this machine.
  • Page 19 MIG/Stick 200 Operating Instructions and Parts Manual 13.6 The welder can use both 4in and 8in spools, see the following figure for installation: The wing nut is designed to adjust the pressure tension of the wire spool. 13.7 Setting the wire spool tension: a) Turn the spool of wire with one hand.
  • Page 20 MIG/Stick 200 Operating Instructions and Parts Manual 13.11. Insert the leading end of the wire into the inlet guide tube. Then push it across the drive roller and into the torch assembly about six inches. Make certain that the welding wire is actually going into the torch liner. If not, the wire can jam or keep the wire from feeding correctly.

  • Page 21: Gas Installation

    MIG/Stick 200 Operating Instructions and Parts Manual 13.23 Cut off the excess wire that extends past the end of the nozzle. stick out. 13.24. Turn the welder ON 14. Setting the wire tension Arc flash can injure eyes! To reduce the risk of arc flash, make certain that...
  • Page 22 MIG/Stick 200 Operating Instructions and Parts Manual 15.2 The gas hose, regulator and gas cylinder connection Attach one end of the gas hose to the gas solenoid valve (gas inlet) located on the back panel of the welder. Attach the other end to the gas regulator which is attached to the shielding gas cylinder.
  • Page 23 MIG/Stick 200 Operating Instructions and Parts Manual 15.3 Gas selection. Different materials require different shielding gas when MIG welding, refer to the set up chart inside the wire feed compartment. Mild steel: Use 75% Argon and 25% for reduced spatter and reduced penetration for thinner materials.

  • Page 24: Operation

    MIG/Stick 200 Operating Instructions and Parts Manual being used, the heat setting selected, 16. Operation and the welding position to be used. Note: The wire will feed faster without an arc. When an arc is being drawn, High voltage danger from power the wire speed will slow down.

  • Page 25: Welding Techniques

    MIG/Stick 200 Operating Instructions and Parts Manual 4. Distance from the work piece 5.4. With your free hand, turn the If the nozzle is held off the work Wire Speed Dial to maximum and piece, the distance between the continue to hold onto the knob.
  • Page 26 MIG/Stick 200 Operating Instructions and Parts Manual 6.1 Moving the torch Torch travel refers to the movement of the torch along the weld joint and is broken into two elements: Direction and Speed. A solid weld bead requires that the welding torch be moved steadily and at the right speed along the weld joint.
  • Page 27 MIG/Stick 200 Operating Instructions and Parts Manual two pieces of metal that will have to be welded closed. In most cases more than one pass or bead will need to be laid into the joint to close the Laying more than one bead into the same weld joint is known as a multiple-pass weld.
  • Page 28 MIG/Stick 200 Operating Instructions and Parts Manual 6.5 Spot welding bottom and top pieces, at the same There are three methods of spot time, right along each side of the lap welding: Burn-Through, Punch and joint seam. Select the wire diameter, Fill, and Lap.
  • Page 29 MIG/Stick 200 Operating Instructions and Parts Manual -E7018AC 70,000 PSI tensile Note: Rate of travel over the work strength, Used for out of position and also affects the weld. To ensure tacking. proper penetration and enough rod 2. Selecting the proper electrode...
  • Page 30 MIG/Stick 200 Operating Instructions and Parts Manual 4.2 Striking the arc EXPOSURE TO A WELDING ARC IS EXTREMELY HARMFUL TO THE EYES AND SKIN. welding until you have adequate protection. 4.3 Types of weld bead The following paragraphs discuss the...
  • Page 31 MIG/Stick 200 Operating Instructions and Parts Manual prevent proper fusion or create a lumpy, uneven bead. To prevent ELECTRIC SHOCK, do not perform any welding while standing, kneeling, or lying directly on the grounded work. The horizontal position it is 4.6 Finish the bead...

  • Page 32: Maintenance

    MIG/Stick 200 Operating Instructions and Parts Manual MINOR AND ROUTINE Maintenance MAINTENANCE The welder needs regular Store in a clean dry location free from maintenance. corrosive gas, dust and high humidity. Periodically clean dust, dirt, grease, Temperature should range from 10 etc.
  • Page 33 MIG/Stick 200 Operating Instructions and Parts Manual 18. Main Circuit chart...

  • Page 34: Repair Parts List

    MIG/Stick 200 Operating Instructions and Parts Manual 19. Repair Parts List Reference Description Part number number Hinge 2.05.17.012 Case cover, enclosure 1.1.01.01.0324 Wire retainer 2.05.17.020 Control transformer 1.2.07.02.0882 Main PC Board 1.1.05.02.0231 Door 1.1.02.01.7990 Door lock 2.08.07.803...
  • Page 35 MIG/Stick 200 Operating Instructions and Parts Manual Spool holder 2.05.17.008 Rear bushing 2.06.29.301 Spool baffle 5.02.01.502 4 spool holder 5.02.01.503 8 spool adaptor 2.05.17.008 Washer 5.02.01.504 Front Bushing 2.05.17.010 Mat Washer 2.06.17.005 Wing nut 2.06.05.002 Vertical center sheet metal 1.1.02.01.1119 Copper pillar connection 1.1.02.02.0517...
  • Page 36 MIG/Stick 200 Operating Instructions and Parts Manual MIG Torch 2.20.08.502 American Connector 2.05.05.050 MIG torch receptacle 1.1.02.02.0293 Wire feeder assembly 1.2.01.01.1089 25.1 Tension adjustment nut 2.07.40.110-1 25.2 Tension nut washer 2.07.40.110-2 25.3 Tension spring 2.07.40.110-3 25.4 Drive roller 2.07.40.110-4 Welding mode (MIG/Stick) 1.2.07.02.1806...
  • Page 37 MIG/Stick 200 Operating Instructions and Parts Manual Circuit Breaker 2.07.80.769 Main Switch 2.07.80.213 Copper Nut 1.1.02.02.0425 Gas Valve connector 1.1.02.02.0297 Gas solenoid valve 1.2.07.02.1778 Handle 2.05.08.028 Gas regulator 2.07.46.710 Gas hose 1.2.08.03.0050...
  • Page 38 MIG/Stick 200 Operating Instructions and Parts Manual Other Safety and Standards Information This manual is designed to inform the operator of safety and general use of this model only. For further information about welding safety refer to the following standards and comply with them where applicable.

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