PRO-SERIES MMIG140 Use and Care Manual
Contents
1. Mild steel Use 75 Argon and 25 for reduced spatter and reduced penetration for thinner materials Do NOT USE Argon gas concentrations higher than 75 on steel The result will be extremely poor penetration porosity and brittleness of weld Mild Steel Use CO2 for deeper penetration but increased spatter Stainless steel Use a mixed gas consisting of Helium Argon and CO2 Aluminum or bronze Use 100 Argon Operation AWARNING High voltage danger from power source Consult a qualified electrician for proper installation of receptacle at the power source This welder must be grounded while in use to protect the operator from electrical shock If you are not sure if your outlet is properly grounded have it checked by a qualified electrician Do not cut off the grounding prong or alter the plug in any way and do not use any adapters between the welder s power Operating Instructions and Parts Manual SK140i MMIG140 cord and the power source receptacle Make sure the POWER switch is OFF then connect your welder s power cord to a properly grounded 120 VAC 110v 120v 60Hz single phase 20 amp power source 1 Main control component Power switch The power switch supplies electrical current to the welder Whenever the power switch is in the ON position the welding circuit is activated ALWAYS turn the power switch to the OFF position and unplug the welder before performing any maintenance Voltage selector2. 10 fan 2 07 89 400 11 control transformer 1 1 04 02 0102 12 rectifier bracket 1 1 02 01 8162 13 PCB 1 1 05 02 0435 14 PCB support 1 1 01 05 2764 15 rectifier 2 07 37 509 16 handle 2 05 08 015 17 enclosure 1 2 01 01 0060 18 capacitance 2 07 13 051 19 front panel 2 05 05 029 20 wave switch 2 07 80 202 21 potentiometer 2 07 10 663 22 Potentiometer knob 2 07 11 009 23 four core socket 2 07 57 947 24 mig gun 1 2 08 04 0072 25 grounding cable 1 2 08 02 0202 26 main transformer 1 1 04 01 1686 27 torch socket 2 20 02 208 28 wire feeder 2 07 40 110 22 Operating Instructions and Parts Manual SK140i MMIG140 29 middle vertical board 1 1 02 01 0775 30 switch 2 07 80 454 31 hex nut 2 06 14 006 32 welding wire tray baffle 2 05 05 305 33 welding wire tray bolt 2 05 05 308 34 welding ae tray baffle 2 05 05 306 35 welding wire tray spring 2 06 29 037 36 nut 2 05 05 307 23
3. See HOLDING THE TORCH if you are uncertain of the angle at which you will be welding 5 4 With your free hand turn the Wire Speed Dial to maximum and continue to hold onto the knob 5 5 Lower your welding helmet and pull the trigger on the torch to start an arc then begin to drag the torch toward you while simultaneously turning the Wire Speed Dial counter clockwise 5 6 LISTEN As you decrease the wire speed the sound that the arc makes will change from a sputtering to a high pitched buzzing sound and then will begin sputtering again if you decrease the wire speed too much The point on the wire speed adjustment where the high pitched buzzing sound is achieved is the correct setting You can use the wire speed control to slightly increase or 15 decrease the heat and penetration for a given heat setting by selecting higher or lower wire speed settings Repeat this tune in procedure if you select a new heat setting a different diameter wire or a different type of welding wire 6 Welding Techniques AWARNING EXPOSURE TO A WELDING ARC IS EXTREMELY HARMFUL TO THE EYES AND SKIN Prolonged exposure to the welding arc can cause blindness and burns Never strike an arc or begin welding until you are adequately protected Wear flameproof welding gloves a heavy long sleeved shirt trousers with out cuffs high topped shoes and an ANSI approved welding helmet ELECTRIC SHOCK CAN KILL To prevent ELECTRIC SHOCK do not per
4. source 2 Check for proper grounding to the work piece 3 Check output connection 4 Clean surfaces 5 Use correct wire Blown fuse or tripped circuit breaker Inadequate fuse or circuit breaker Check the fuse in power source should be 20amp Arc is hard to start 1 The wrong wire 2 Base metal not grounded reliable 1 Use the correct one 2 Make sure the connection is good Inconsistent arc 1 Not enough drive roller 1 Tighten the drive or wire feed pressure tension adjustor on wire 2 Spool hub tension too feeder tight or loose 2 Adjust the wing nut on 3 Contact tip worn or the spool holder wrong size 3 Replace contact tip 4 Rusty or corroded wire 4 Replace wire Other Call Tech Help Operating Instructions and Parts Manual SK140i MMIG140 Main Circuit chart 120V 20 Operating Instructions and Parts Manual SK140i MMIG140 Repair Parts List Reference n mber Description Part number Qty 1 door latch 2 08 07 803 1 2 left side panel 1 2 01 02 0083 1 3 chain bracket 2 05 17 007 2 4 bottom 1 2 01 04 0400 1 5 gas valve connector 2 07 55 616 1 6 power cord with plug 2 03 05 209 1 7 cable clamp 2 05 05 203 1 8 Circuit breaker 2 07 80 301 1 21 Operating Instructions and Parts Manual SK140i MMIG140 9 potentiometer 2 07 10 663
5. the arc in relation to the weld puddle and to direct the force of the arc z MINN Angle B 4 Distance from the work piece If the nozzle is held off the work piece the distance between the nozzle and the work piece should be kept constant and should not exceed 1 4 inch or the arc may begin sputtering signaling a loss in welding performance 5 Tuning in the wire speed This is one of the most important parts of MIG welder operation and must be done before starting each welding job or whenever any of the following variables are changed heat setting wire diameter or wire type Operating Instructions and Parts Manual SK140i MMIG140 AWARNING EXPOSURE TO A WELDING ARC IS EXTREMELY HARMFUL TO THE EYES AND SKIN Prolonged exposure to the welding arc can cause blindness and burns Never strike an arc or begin welding until you are adequately protected Wear flameproof welding gloves a heavy long sleeved shirt trousers with out cuffs high topped shoes and an ANSI approved welding helmet 5 1 Connect the Ground Clamp to a scrap piece of the same type of material which you will be welding It should be equal to or greater than the thickness of the actual work piece and free of oil paint rust etc 5 2 Select a heat setting 5 3 Hold the torch in one hand allowing the nozzle to rest on the edge of the work piece farthest away from you and at an angle similar to that which will be used when welding
6. The voltage selector controls the welding voltage heat This unit has a five step voltage control Refer to the label inside the welder side door for recommended voltage selector settings for your welding job Wire speed control The wire speed control adjusts the speed at which the wire is fed out of the MIG gun The wire speed needs to be closely matched tuned in to the rate at which it is being melted off Some things that affect wire speed selection are the type and diameter of the wire being used the heat setting selected and the welding position to be used Note The wire will feed faster without an arc When an arc is being drawn the wire speed will slow down 2 Hold the MIG gun The best way to hold the MIG gun is the way that feels most comfortable to you While practicing to use your new welder experiment holding the torch in different positions until you find the one that seems to work best for you 3 Position the MIG gun to the work piece There are two angles of the MIG gun nozzle in relation to the work piece 14 that must be considered when welding 3 1 Angle A can be varied but in most cases the optimum angle will be 60 degrees the point at which the MIG gun handle is parallel to the work piece If angle A is increased penetration will increase If angle A is decreased penetration will decrease also A ANN Angle A 3 2 Angle B can be varied for two reasons to improve the ability to see
7. clockwise the drive tension adjusting knob until the tension roller is applying enough force on the wire to prevent it from Operating Instructions and Parts Manual SK140i MMIG140 slipping out of the drive assembly Do not over tighten 4 2 14 NOW YOU CAN LET GO OF THE WIRE 4 2 15 Plug in and turn the welder ON Set the VOLTAGE switch to the voltage heat setting recommended for the gauge metal that is to be welded Refer to the set up chart on the inside of the wire feed compartment door 4 2 16 Set the WIRE SPEED control in the middle of the wire speed range 8 17 Straighten the MIG gun cable pull the trigger on the welding torch to feed the wire through the torch assembly When at least one inch of the wire sticks out past the end of the torch release the trigger 4 2 18 Turn the Power Switch to the OFF position 4 2 19 Select a contact tip stamped with the same diameter as the wire being used 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 4 2 20 Slide the contact tip over the wire protruding from the end of the gun Thread the contact tip into the end of the gun adaptor and tighten securely 4 2 21 Install the nozzle on the gun assembly To keep spatter from sticking to inside of the nozzle use anti spatter spray or gel 4 2 22 Cut off the excess wire that extends more than past
8. most difficult welding position Angle A see HOLDING THE TORCH should be 6 3 Welding position 60 Operating Instructions and Parts Manual SK140i MMIG140 Maintaining this angle will reduce the chances of molten metal falling into the nozzle Angle B should be held at zero degrees so that the wire is aiming directly into the weld joint If you experience excessive dripping of the weld puddle select a lower heat setting Also the weave bead tends to work DEET ar the stringer 6 4 Multiple pass welding Butt Weld Joints When butt welding thicker materials you will need to prepare the edges of the material to be joined by grinding a bevel on the edge of one or both pieces of the metal being joined When this is done a V is created between the 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 Y Laying more than one bead into the same weld joint is known as a multiple pass weld The illustrations in following figure show the sequence for laying multiple pass beads into a single V butt joint First_or Root Paso ar Pas s WZ Ue A NOTE WHEN USING SELF SHIELDING important to thoroughly chip and brush the slag off each completed weld bead before making another pass or the next pass will be of poor quality Fillet Weld Joints Most fillet weld joints on metals of moderate to heav
9. the end of the nozzle 4 2 23 Turn the welder ON 5 Setting the wire tension AWARNING 12 Arc flash can injure eyes To reduce the risk of arc flash make certain that the wire coming out of the end of the torch does not come in contact with work piece ground clamp or any grounded material during the drive tension setting process or arcing will occur 5 1 Press the trigger on the torch 5 2 Turn the drive tension adjustment knob clockwise increasing the drive tension until the wire seems to feed smoothly without slipping 6 Gas installation AWARNING Shielding gas cylinders and high pressure cylinders can explode if damaged so treat them carefully Never expose cylinders to high heat sparks open flames mechanical shocks or arcs Do not touch cylinder with MIG gun Do not weld on the cylinder Always secure cylinder upright to a cart or stationary object Keep cylinders away from welding or electrical circuits Use the proper regulators gas hose and fittings for the specific application When MIG wire is used shielding gas is required 1 Polarity changing Factory polarity setting electrode positive is for MIG solid wire using a shielding gas The RED lead is connected to positive and the ground lead is connected to the negative For Flux Core welding no shielding gas is required The RED lead is connected to the negative polarity terminal and the ground c
10. to repeat these steps until proper spool tension is achieved 11 NOTE If TOO MUCH tension is applied to the wire spool the wire will slip on the drive roller or will not be able to feed at all If TOO LITTLE tension is applied the spool of wire will want to unspool itself when the trigger is released Readjust the spool tension using the wing nut as necessary to correct for either problem 4 2 7 After checking to make sure that your welder is disconnected from the AC power source free the leading end of the wire from the spool but DO NOT LET GO OF IT until it is secure in the drive system or the wire will unspool itself 4 2 8 Using a wire cutter cut the bent end off the leading end of the wire so that only a straight leading end remains 4 2 9 Loosen the tension adjusting knob holding the drive tension arm in place and lift the tension arm up off the drive roller 4 2 10 Insert the leading end of the wire into the inlet guide tube Then push it across the drive roller and into the MIG gun torch assembly about six inches A CAUTION e Make certain that the welding wire is actually going into the torch liner If not the wire will jam in the mechanism 4 2 11 Be sure the wire lines up in the groove of the drive roller then place the drive tension arm back in place above the drive roller 4 2 12 Position the quick release drive tension back up into position into the drive tension arm 4 2 13 Tighten turn
11. 40 1 2 Your Welder s Condition Check ground cable power cord and welding cable to be sure the insulation is not damaged Always replace or repair damaged components before using the welder Check all components to ensure they are clean and in good operating condition before use 1 3 Use of Your Welder 4 CAUTION Do not operate the welder if the output cable electrode MIG gun wire or wire feed system is wet Do not immerse them in water These components and the welder must be completely dry before attempting to use them Follow the instructions in this manual Keep welder in the off position when not in use Connect ground lead as close to the area being welded as possible to ensure a good ground Do not allow any body part to come in contact with the welding wire if you are in contact with the material being welded ground or electrode from another welder Do not weld if you are in an awkward position Always have a secure stance while welding to prevent accidents Wear a safety harness if working above ground Do not drape cables over or around your body Wear a full coverage helmet with appropriate shade see ANSI Z87 1 safety standard and safety glasses while welding 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 Keep hands and finge
12. IG140 3 5 Based on the wire diameter select the correct groove using the following table Wire Diameter Roller Groove 024 inch 0 6 030 035 inch 0 8 The drive roller has two wire size grooves When installing the drive roller the number stamped on the drive roller for the wire size you are using should face in This identifies the inside groove the wire will line up with Assemble the drive roller onto the drive roller shaft T E a a a A A _ Drive Roller Shaft 4 Install the wire 4 1 Selecting the wire Available wire for this machine Wire Type Available MIG wire Yes 023 inch MIG wire Yes 10 030 inch Flux core wire Yes 030 inch Flux core wire Yes 035 inch MIG wires available are mild steel stainless steel or aluminum solid wire and must be used with shielding gas Four or eight inch spools are available NOTE e Burn through will occur if you attempt to weld mild or stainless steel thinner than 24 gauge Remove all rusted wire if the whole spool is rusty discard it 4 2 Install the wire AWARNING Electric shock can kill Always turn the POWER switch OFF and unplug the power cord from the AC power source before installing wire NOTE e Before installing make sure that you have removed any old wire from the torch and cable assembly This will help to prevent the possibility of the wire jamming insi
13. Operating Instructions and Parts Manual SK 140i mmic140 Please read and save these instructions Read through this owner s manual carefully before 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 READ ALL INSTRUCTIONS AND WARNINGS BEFORE USING THIS PRODUCT This manual provides important information on proper operation amp maintenance Every effort has been made to ensure the accuracy of this manual These instructions are not meant to cover every possible condition and situation that may occur We reserve the right to change this product at any time without prior notice IF THERE IS ANY QUESTION ABOUT A CONDITION BEING SAFE OR UNSAFE DO NOT OPERATE THIS PRODUCT DO NOT RETURN THIS PRODUCT TO THE RETAILER If you experience a problem have questions or need parts for this product call Customer Service at 1 866 460 9436 Monday Friday 8 AM 4 PM Central Time A copy of the sales receipt is required FOR CONSUMER USE ONLY NOT FOR PROFESSIONAL USE KEEP THIS MANUAL SALES RECEIPT amp APPLICABLE WARRANTY FOR FUTURE REFERENCE CALIFORNIA PROPOSITION 65 WARNING This product may contain chemicals including lead known to the State of California to cause cancer and birth defects or other reproductive harm Was
14. able is connected to the positive terminal Operating Instructions and Parts Manual SK140i MMIG140 OCEN DCEP Seed Davee La ed rahe napi m ued med pecrsds poene SELF SHIELDING FLUX WIRE MKVFLUX CORE WIRE PIAR SATIO SLT iS PILAR SATOI SLT MGS 2 The gas hose regulator and gas cylinder connections Connect the gas hose to the gas solenoid valve on the back panel of the welder Connect the other end to the regulator connected to the shielding gas cylinder See the following illustration CHINE Cylinder valve Controls GAS CYLINDER flow 1 Cylinder pressure gauge 2 Gas flow gauge set at 20 CFM 3 Regulator 4 Adjustment knob Controls gas flow to the welder a Gas hose 6 Gas cylinder NOTE Slowly open the cylinder valve by turning it counterclockwise until the cylinder pressure gauge registers the cylinder pressure Turn the adjustment knob clockwise slowly to increase gas flow to 20 cfm To reduce the gas flow turn the adjustment counterclockwise The gas solenoid valve is on the back panel of the welder Gas flow can be heard at the end of the gun when the trigger is activated No gas flow will result in a harsh arc with excessive spatter a smooth weld bead will not be obtained 3 Gas selection Different materials require different shielding gas when MIG welding refer to the set up chart inside the wire feed compartment also
15. acles on the front panel of the machine 1 6 The terminals next to the positive and negative marks are for MIG gun lead or ground cable depending on polarity requirements The MIG gun lead is Red and the ground cable is black When flux core welding the ground cable lead is connected to and the red MIG gun torch lead is connected to When MIG solid wire welding reverse the connection Tighten connections line securely F Operating Instructions and Parts Manual SK140i MMIG140 Installation 1 Power requirement AC single phase 120v 110 120V 60HZ with a 20 amp time delayed fuse or circuit breaker is required DO NOT OPERATE THIS UNIT if the ACTUAL power source voltage is less than 105 volts ac or greater than 132 volts AC AWARNING High voltage danger from power source Consult a qualified electrician for proper installation of receptacle This welder must be grounded while in use to protect the operator from electrical shock e Do not remove grounding prong or alter the plug in any way Do not use any adapters between the welder s power cord and the power source receptacle Make sure the POWER switch is OFF when connecting your welder s power cord to a properly grounded 120Vac 60Hz single phase 20 amp power source 2 Extension cord It is strongly recommended that an extension cord should not be used because of the voltage drop it produces This drop in vol
16. arefully for any damage that may have occurred during transit Check for loose or damaged parts Know your Welder Wire speed amperage setting On off switch Voltage setting Trigger connection for MIG torch and spool gun Wire compartment Ground cable clamp Regulator and gas hose MIG gun and spool gun 1Flux core nozzle a connection and 2 pcs Contact tips P MIG gun L shaped hex wrench Operating Instructions and Parts Manual SK140i MMIG140 ON OFF Switch In the off position no power is being supplied to the MIG gun In the ON position power is supplied to the main transformer and control circuit Wire speed setting For adjustment of the wire feed speed Wire compartment Inside the wire compartment are the wire feeder spool hub holder set up chart and polarity terminals Heat Settings To adjust output voltage heat settings Refer to the set up chart inside the wire feed compartment Spot timer adjustment Set the spot times with this adjust 0 5S 4 20S Welding Cable and MIG gun The welding wire is driven through the welding cable and MIG gun to the work piece It is attached to the drive system the gun trigger activates the drive motor MIG gun and spool gun connection This machine could use for spool gun and MIG gun by using this connection and directly connect the spool gun could use for aluminum welding wire Ground Cable and Clamp The ground cable clamp are attached to th
17. cap whenever possible 1 5 Proper Care Maintenance and Repair A DANGER Always have power disconnected when working on internal components Do not touch or handle PC board without being properly grounded with a wrist strap Put PC board in static proof bag to move or ship Do not put hands or fingers near moving parts such as drive rolls of fan Assembly 1 1 MIG gun torch attachment Locate the set screw inside the front panel on the front of the drive system on the terminal block where the MIG gun will be inserted Loosen set screw Insert MIG gun all the way into the receptacle and tighten set screw into the retaining groove on the end of the MIG gun Operating Instructions and Parts Manual SK140i MMIG140 Retaining groove Ground cable lead MIG gun connection id Trigger leads 1 2 Identify openings for the trigger leads and ground cable on the lower right side of the front panel Receptacle for MIG gun and spool Opening for ground cable lead Trigger connection for MIG gun and spool gun 1 3 Open the welding wire feeding door is arranged on the ground cable A welding torch from nua hes gws inserted into the socket and then after the wrench to tighten the screws 1 4 for MIG torch operation in flip the torch selector switch left For spool gun operation flip the torch selector switch right 1 5 Connect the trigger leads into the recept
18. ce power cord ground cable ground clamp or electrode assembly when damaged or worn MINOR AND ROUTINE MAINTENANCE Store in a clean dry location free from corrosive gas dust and high humidity Temperatures should range from 10 F 120 F and a relative humidity less than 90 When transporting or storing the welder after use it is recommended to repack the product as it was received for protection Cleaning is required before storage and you must seal the plastic bag in the box for storage Operating Instructions and Parts Manual SK 140i MMIG140 Please read and save these instructions Read through this owner s manual carefully before 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 Trouble shooting Chart Symptom s Welder does not work when the main switch is Possible Causes s 1 No power input 2 Power cord or power plug is broken Corrective Action s 1 Check circuit or fuse of power source 2 Replace power cord 2 Inadequate current at output 3 Poor connection of output cable 4 Dirty surfaces 5 Wrong welding wire turned on 3 Main switch is broken 3 Replace switch 4 Transformer is broken 4 Replace the transformer Will not weld 1 Incorrect power input 1 Check the power
19. de the gun Liner e Be careful when removing the welding nozzle The contact tip on this welder is live when the gun trigger is pulled Make certain POWER is turned OFF 4 2 1 Remove the nozzle and contact tip from the end of the gun assembly See following images for reference cantact tip nozzle Operating Instructions and Parts Manual SK140i MMIG140 4 2 2 Make sure the proper groove on the drive roller is in place for the wire installed If not change the drive roller as described above 4 2 3 Remove the packaging from the spool of wire and then identify the leading end of the wire secured in a hole on the edge of the spool DO NOT UNHOOK IT AT THIS TIME 4 2 4 Place the spool on the spool hub with the wire coming off the bottom of the spool The bottom of the spool aligns with inlet to the drive system for smooth flow of the wire See following figure He A 0 ee a gt lt a TaN Right Way o h NE rr 9 J i Wrang Way Wire Installation 4 2 5 The welder can use both 4 in and 8 in spools See the illustration below The wing nut controls the tension on the spool 4 2 6 Setting the wire spool tension a Turn the spool of wire with one hand b Increase the spool tension by tightening turn clockwise the wing nut while turning the spool Turn the spool while tightening the wing nut until the spool slows down and operator feels a slight drag Stop tightening the wing nut operator may need
20. e work piece to complete the circuit allowing the flow of current needed to weld Thermal Indicator If the duty cycle of the welder is exceeded the internal temperature will exceed safe temperatures and the machine will shut down The Thermal overload light will come on indicating this allow about 15 minutes for cool down before the light will go off and the temperature to fall into an allowable operating range Power Cord The power cord connects the welder to the 120 volt power supply Plug the 15 amp plug into a 120 volt 20 amp receptacle to supply power to the welder General Safety Information 1 1 Your Welding Environment Keep the environment you will be welding in free from flammable materials Always keep a fire extinguisher accessible to your welding environment Always have a qualified person install and operate this equipment Make sure the area is clean dry and ventilated Do not operate the welder in humid wet or poorly ventilated areas Always have your welder maintained by a qualified technician in accordance with local state and national codes Always be aware of your work environment Be sure to keep other people especially children away from you while welding Keep harmful arc rays shielded from the view of others Mount the welder on a secure bench or cart that will keep the welder secure and prevent it from tipping over or falling Operating Instructions and Parts Manual SK140i MMIG1
21. form any welding while standing kneeling or lying directly on the grounded work 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 Moving the torch too fast too slow or erratically will prevent proper fusion or create a lumpy uneven bead Travel direction is the direction the torch is moved along the weld joint in relation to the weld puddle The torch is either PUSHED into the weld puddle or PULLED away from the weld puddle Weld Puddle PUSH PULL Operating Instructions and Parts Manual SK140i MMIG140 For most welding jobs you will pull the torch along the weld joint to take advantage of the greater weld puddle visibility Travel speed is the rate at which the torch is being pushed or pulled along the weld joint For a fixed heat setting the faster the travel speed the lower the penetration and the lower and narrower the finished weld bead Likewise the slower the travel speed the deeper the penetration and the higher and wider the finished weld bead 6 2 Types of welding beads As you become more familiar with your new welder and better at laying some simple weld beads you can begin to try some different weld bead types The STRINGER BEAD is formed by traveling with the torch in a straight line w
22. h hands after handling Operating Instructions and Parts Manual SK140i MMIG140 Description SK140i is a Portable DC MIG capable of welding with solid with shielding gas or flux core wire Power requirements are 120VAC 60HZ 20 amp with time delayed fuse or circuit breaker Features infinite heat voltage settings and wire speed spot timer overload and thermal protection For use with or with out shielding gas designed for mild steel and stainless steel welding in construction automotive repair and light industrial Welds mild steel between 24 gauge to 3 16 in a single pass Will accept spool gun sold separately Specifications and Dimension DESCRIPTION SPECIFICATIONS Power supply 1 phase 120V 60HZ No load voltage 27V Output Range 20 90A Peak140A Duty cycle 20 Suggested wire MIG and Flux core wire Wire Diameter 023 030 035 Dimension L x W x H 17 3 x 10 2 x 14 4 Weight 26 5lbs Operating Instructions and Parts Manual SK140i MMIG140 Removing from carton 1 1 Remove cartons bags or Styrofoam containing the welder and accessories 1 2 Check the contents with the packing list below ITEM QTY Portable MIG Welder 1 unit MIG torch 1 piece Ground cable clamp 1 piece Gas hose 1 piece Contact tips 2 pieces Gas regulator 1 piece MIG nozzle 1 piece L shaped hex wrench 1 piece 1 3 After unpacking the unit inspect c
23. hile keeping the wire and nozzle centered over the weld joint see following figure The WEAVE BEAD Used when you want to deposit metal over a wider space than would be possible with a stringer bead It is made by weaving from side to side while moving with the torch It is best to hesitate momentarily at each side before weaving back the other way FLAT POSITION Is easiest of the welding positions and is most commonly used It is best if you can weld in the flat position if at all possible as good results are easier to achieve HORIZONTAL POSITION Is performed very much the same as the flat weld except that angle B see HOLDING THE TORCH is such that the wire directed more toward the metal above the weld joint is to help prevent the weld puddle from running downward while still allowing slow enough travel speed A good starting point for angle B is about 30 degrees DOWN from being perpendicular to the work piece a aad a VERTICAL POSITION Is easier for many people to Pull the torch from top to bottom It can be difficult to prevent the puddle from running downward Pushing the torch from bottom to top may provide better puddle control and allow slower rates of travel speed to achieve deeper penetration When vertical welding angle B see HOLDING THE TORCH is usually always kept at zero but angle A will generally range from 45 to 60 degrees to provide better puddle control OVERHEAD POSITION Is the
24. lowed to fill up the hole leaving a spot weld that is smooth and flush with the surface of the top piece Select the wire diameter heat setting and tune in the wire speed as if you were welding the same thickness material with a continuous bead 3 The LAP SPOT METHOD directs the welding arc to penetrate the bottom and top pieces at the same time right along each side of the lap joint seam Select the wire diameter heat setting and tune in the wire speed as if you were welding the same thickness material with a continuous bead 6 6 SPOT WELDING INSTRUCTIONS 1 Select the wire diameter and heat setting recommended above for the method of spot welding you intend to use 2 Tune in the wire speed as if you were going to make a continuous weld 3 Hold the nozzle piece completely perpendicular to and about 1 4 inch off the work piece 4 Pull the trigger on the torch and release it when it appears that the desired penetration has been achieved 5 Make practice spot welds on scrap metal varying the length of time you hold the trigger until a desired spot weld is made 6 Make spot welds on the actual work piece at desired locations Maintenance The welder needs the regular maintenance as following Periodically clean dust dirt grease etc from your welder Every six months or as necessary remove the cover panel from the welder and air blow any dust and dirt that may have accumulated inside the welder Repla
25. r protection Use screens or other barriers to protect other people from the arc rays emitted from your welding Warn people in your welding area when you are going to strike an arc so they can protect themselves Fire Hazards EN em AWARNING Do not weld on containers or pipes that contain or have had flammable gaseous or liquid combustibles in them Welding creates sparks and heat that can ignite flammable and explosive materials Do not operate any electric arc welder in areas where flammable or explosive materials are present Remove all flammable materials within 35 feet of the welding arc If removal is not possible tightly cover them with fireproof covers Take precautions to ensure that flying sparks do not cause fires or explosions in hidden areas cracks or areas you cannot see Keep a fire extinguisher close in the case of fire Wear garments that are oil free with no pockets or cuffs that will collect sparks Do not have on your person any items that are combustible such as lighters or matches Keep work lead connected as close to the weld area as possible to prevent any unknown unintended paths of electrical current from causing electrical shock and fire hazards To prevent any unintended arcs cut wire back to stick out after welding Operating Instructions and Parts Manual SK140i MMIG140 Hot Materials A CAUTION Welded materials are hot and can cause severe burn
26. rs away from moving parts and stay away from the drive rolls Do not point MIG gun at any body part of yourself or anyone else Always use this welder in the rated duty cycle to prevent excessive heat and failure 1 4 Specific Areas of Danger Caution or Warning Electrical Shock AWARNING Electric arc welders can produce a shock that can cause injury or death Touching electrically live parts can cause fatal shocks and severe burns While welding all metal components connected to the wire are electrically hot Poor ground connections are a hazard so secure the ground lead before welding Wear dry protective apparel coat shirt gloves and insulated footwear Insulate yourself from the work piece Avoid contacting the work piece or ground Do not attempt to repair or maintain the welder while the power is on Inspect all cables and cords for any exposed wire and replace immediately if found Use only recommended replacement cables and cords Always attach ground clamp to the work piece or work table as close to the weld area as possible Do not touch the welding wire and the ground or grounded work piece at the same time Do not use a welder to thaw frozen pipes Fumes and Gases AWARNING Fumes emitted from the welding process displace clean air and can result in injury or death Operating Instructions and Parts Manual SK140i MMIG140 Do not breathe in fumes emitted by the
27. s if handled improperly Do not touch welded materials with bare hands Do not touch MIG gun nozzle after welding until it has had time to cool down Sparks Flying Debris A CAUTION 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 or shield welder s hat and ear plugs to keep sparks out of ears and hair Electromagnetic Field A CAUTION Electromagnetic fields can interfere with various electrical and electronic devices such as pacemakers Consult your doctor before using any electric arc welder or cutting device Keep people with pacemakers away from your welding area when welding Do not wrap cable around your body while welding Wrap MIG gun and ground cable together whenever possible Keep MIG gun and ground cables on the same side of your body Shielding Gas Cylinders Can Explode AWARNING High pressure cylinders can explode if damaged so treat them carefully Never expose cylinders to high heat sparks open flames mechanical shocks or arcs Do not touch cylinder with MIG gun Do not weld on the cylinder Always secure cylinder upright to a cart or stationary object Keep cylinders away from welding or electrical circuits Use the proper regulators gas hose and fittings for the specific application Do not look into the valve when opening it Use protective cylinder
28. tage can affect the performance of the welder If you need to use an extension cord it must be a 12 gauge cord or larger Do not use an extension cord over 25 ft in length 3 Install the wire roller Before installing any welding wire into the unit the proper sized groove must be placed into position on the wire drive mechanism Adjust the drive roller according to the following steps see following picture of the Drive Tension Drive tension Arm adjustor Wire Roller 3 1 Open the door to the welder drive compartment 3 2 see 1 Loosen the tension adjusting wing nut and lifting the Drive Tension Adjustor away from the Drive Tension Arm see 2 Pull the drive tension arm away from the wire roller 2 3 3 If there is wire already installed in the welder roll it back onto the wire spool by hand turning the spool counterclockwise Be careful not to allow the wire to come out of the rear end of the inlet guide tube without holding onto it or it will unspool itself Put the end of the wire into the hole on the outside edge of the wire spool and bend it over to hold the wire in place Remove the spool of wire from the spool hub by removing the drive tensioning wing nut and hardware 3 4 open the machine door using the L type six angle wrench counterclockwise unscrewing the screw drive roller on the wire and wire feed mechanism remove the drive roller Operating Instructions and Parts Manual SK140i MM
29. welding process Make sure your breathing air is clean and safe Work only in a well ventilated area or use a ventilation device to remove welding fumes from the environment where you will be working Do not weld on coated materials galvanized cadmium plated or containing zinc mercury or barium They will emit harmful fumes that are dangerous to breathe If necessary use a ventilator respirator with air supply or remove the coating from the material in the weld area The fumes emitted from some metals when heated are extremely toxic Refer to the material safety data sheet for the manufacturer s instructions Do not weld near materials that will emit toxic fumes when heated Vapors from cleaners sprays and degreasers can be highly toxic when heated UV and IR Arc Rays A DANGER 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 Always use a helmet that covers your full face from the neck to top of head and to the back of each ear Use a lens that meets ANSI standards and safety glasses For welders under 160 Amps output use a shade 10 lens for above 160 Amps use a shade 12 Refer to the ANSI standard Z87 1 for more information Cover all bare skin areas exposed to the arc with protective clothing and shoes Flame retardant cloth or leather shirts coats pants or coveralls are available fo
30. y thickness will require multiple pass welds to produce strong joint The illustrations in Figure 19 show the sequence of laying multiple pass beads into a T fillet joint and a lap fillet joint J Lap Joint Weided IRA in Three Passes t T Jom in k Three Passes Maal 6 5 Spot welding There are three methods of spot welding Burn Through Punch and Fill and Lap Each has advantages and disadvantages depending on the specific application as well as personal preference 1 The BURN THROUGH METHOD welds two overlapped pieces of metal together by burning through the top piece and into the bottom piece With the burn through method larger wire diameters tend to work better than smaller diameters Wire diameters that tend to work best with the burn through method are 035 inch self shielding flux core wire Do not use Operating Instructions and Parts Manual SK140i MMIG140 wires when using the burn through method unless the metal is VERY thin or excessive filler metal build up and minimal penetration is acceptable Always select the HIGH heat setting with the burn through method and tune in the wire speed prior to making a spot weld 2 The PUNCH AND FILL METHOD produces a weld with the most finished appearance of the three spot weld methods In this method a hole is punched or drilled into the top piece of metal and the arc is directed through the hole to penetrate into the bottom piece The puddle is al
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