Grizzly G0879, Owner'S Manual

Page 1: ...WARNING NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL INC SS22162 PRINTED IN CHINA V1 12 21 MODEL G0879 FLUX CORE MIG WELDER OWNER S MANUAL For models manufactured since 6 19 4009939 ...

Page 2: ...ng grinding tool integrity and the usage of personal protective equipment The manufacturer will not be held liable for injury or property damage from negligence improper training machine modifications or misuse Some dust created by power sanding sawing grinding drilling and other construction activities contains chemicals known to the State of California to cause cancer birth defects or other repr...

Page 3: ...1 Grounding for Welding Safety 13 SECTION 3 SETUP 14 Unpacking 14 Needed for Setup 14 Inventory 14 Site Considerations 15 Assembly 16 SECTION 4 OPERATIONS 17 Operation Overview 17 Installing Changing Wire 18 Test Run 20 Adjusting Wire Feed Tension 21 Operation Guidelines 22 Welder Duty Cycle 22 Workpiece Inspection 23 Basic Operation 23 Welding Tips 25 SECTION 5 ACCESSORIES 26 SECTION 6 MAINTENANC...

Page 4: ...ade every effort to be exact with the instruc tions specifications drawings and photographs in this manual Sometimes we make mistakes but our policy of continuous improvement also means that sometimes the machine you receive is slightly different than shown in the manual If you find this to be the case and the difference between the manual and machine leaves you confused or unsure about something ...

Page 5: ... names and locations of the controls and features shown below to better understand the instructions in this manual To reduce your risk of serious injury read this entire manual BEFORE using machine Wire Spool Mount Ground Clamp Welding Gun Control Panel Wire Feed Driver ...

Page 6: ...sts wire output speed from welding gun C MIN MAX Power Switch Switches machine between its minimum and maximum output amperage settings MIN setting will yield a 60A output and MAX will yield 70A output D ON OFF Switch Turns machine ON and OFF B C D A Ground Clamp Figure 3 Ground clamp I Ground Clamp Connects workpiece to welding circuit I Welding Gun Figure 2 Welding gun components E Nozzle Protec...

Page 7: ...h gun K Tension Knob Adjusts wire feed tension L Tension Roller Applies tension to wire by pressing against drive roller Amount of ten sion can be adjusted with tension knob J L K Wire Spool Mount Figure 5 Wire spool mount components M Spool Nut Adjusts wire spool tension N Spool Spindle Applies tension to wire spool when spool nut is tightened O Spool Collar Secures wire spool on spindle M O N ...

Page 8: ...A Pamphlet P 1 National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 617 770 3000 Website www nfpa org and www sparky org National Electrical Code NFPA Standard 70 Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B U S Government Printing Office Superintendent of Documents P O Box 371954 Pittsburgh PA 15250 312 353 2220 We...

Page 9: ...cluded Plug Type 5 15 Switch Type ON OFF Rocker Operation Information Minimum Material Thickness 1 16 in Maximum Material Thickness 3 16 in Wire Feed Speed Range Inches per Minute 200 600 IPM Wire Diameter Range 0 030 0 035 in Maximum Wire Spool Diameter 4 in Torch Cable Length 7 ft Ground Cable Length 6 1 2 ft Other Specifications Country of Origin China Warranty 1 Year Approximate Assembly Setup...

Page 10: ...roof DANGEROUS ENVIRONMENTS Do not use machinery in areas that are wet cluttered or have poor lighting Operating machinery in these areas greatly increases the risk of accidents and injury MENTAL ALERTNESS REQUIRED Full mental alertness is required for safe operation of machin ery Never operate under the influence of drugs or alcohol when tired or when distracted For Your Own Safety Read Instructi...

Page 11: ...moving parts or flying debris Make sure they are properly installed undamaged and working correctly BEFORE operating machine FORCING MACHINERY Do not force machine It will do the job safer and better at the rate for which it was designed NEVER STAND ON MACHINE Serious injury may occur if machine is tipped or if the cutting tool is unintentionally contacted STABLE MACHINE Unexpected movement dur in...

Page 12: ...mind that all normal welding hazards are intensified in a confined space ELECTROMAGNETIC FIELDS EMF Welding operations create EMF around welding equipment and workpieces Operators with pacemakers must consult their physician before using this equipment or being within 50 feet of welding operations WELDING FUMES Breathing welding fumes can cause suffocation or poisoning without warning Keep your he...

Page 13: ...ndersized circuit To reduce the risk of these hazards avoid over loading the machine during operation and make sure it is connected to a power supply circuit that meets the specified circuit requirements For your own safety and protection of property consult an electrician if you are unsure about wiring practices or electrical codes in your area Note Circuit requirements in this manual apply to a ...

Page 14: ...ord size gets longer and the gauge size gets smaller higher gauge numbers indicate smaller sizes Any extension cord used with this machine must be in good condition and contain a ground wire and matching plug receptacle Additionally it must meet the following size requirements Minimum Gauge Size 12 AWG Maximum Length Shorter is Better 25 ft Grounding Plug Requirements Figure 6 Typical 5 15 plug an...

Page 15: ...lding cables the electrode holder gun assembly the work clamp and the workpiece ANSI Welding Standards Z49 1 11 3 2 1 specify that Grounding of the workpiece shall be done by locating the work on a grounded metal floor or platen or by connection to a grounded building frame or other satisfactory ground Always ensure that the ground for the incoming power circuit to the welder and the ground for th...

Page 16: ...e call us immediately at 570 546 9663 IMPORTANT Save all packaging materials until you are completely satisfied with the machine and have resolved any issues between Grizzly or the shipping agent You MUST have the original pack aging to file a freight claim It is also extremely helpful if you need to return your machine later Unpacking Loose Parts Figure 7 Qty A Face Shield 1 B Face Shield Handle ...

Page 17: ...chine Data Sheet for the weight and footprint specifications of your machine Some workbenches may require additional rein forcement to support the weight of the machine and workpiece materials Consider anticipated workpiece sizes and addi tional space needed for auxiliary stands work tables or other machinery when establishing a location for this machine in the shop Below is the minimum amount of ...

Page 18: ...to lift top cover and expose wire spool spindle and feed mechanism see Figure 10 Figure 11 Wire spool installed Wire Spool Spool Nut Compression Spring Spool Collar 3 Install wire roll on spool spindle so spool will feed counterclockwise 4 Secure wire spool using spool collar com pression spring and spool nut see Figure 11 Wire spool should have some resistance but rotate freely Figure 10 Handle i...

Page 19: ...per protective gear Always wear safety glasses welder s helmet and a respirator when oper ating this welder Test Run Once assembly is complete test run the machine to ensure it is properly connected to power and safety components are functioning correctly If you find an unusual problem during the test run immediately stop the machine disconnect it from power and fix the problem BEFORE operating th...

Page 20: ...nects machine to power and turns machine ON 5 Properly connects ground clamp as close as possible to workpiece or to metal workbench where workpiece is mounted and electrically connected 6 Adjusts machine to desired settings 7 Welds workpiece 8 Disconnects ground clamp from workpiece and places ground clamp and welding gun away from conductive materials 9 Allows welder fan to cool machine 10 Turns...

Page 21: ...depending on what thickness of metal is being welded on Use 0 030 wire for thinner met als and 0 035 for thicker metals Wire thickness primarily affects the depositional rate of the con sumable metal amperage so machine settings may also need to be adjusted if the wire size has been changed To install change wire 5 Remove wire drive roller by twisting cap counterclockwise Lift up to remove cap wit...

Page 22: ...feeding wire through machine Once wire appears at gun tip release trigger see Figure 16 Figure 15 Nozzle and contact tip removed from welding gun Gun Trigger Figure 16 Wire extending from gun Welding Wire 12 Turn machine OFF and disconnect from power source 13 Slide contact tip for appropriate wire gauge over wire and screw in place Snug with needle nose pliers DO NOT overtighten 14 Slidegunnozzle...

Page 23: ...t Wire Spool Nut Note Wire tension should be tight enough to prevent wire from slipping in driver wheel but not so tight that it cannot feed through assem bly smoothly If wire tension is too low it can cause wire spool to unravel 5 Once desired wire tension is achieved close top cover of machine 3 Use wire tension knob to adjust wire tension Turn knob clockwise to increase tension and counterclock...

Page 24: ...s own distinct sound when it is progressing correctly Operation Guidelines Welder Duty Cycle As the welder produces the desired power output for the welding operation power is converted to heat In order to protect the welder components from over heating each welder has an estab lished duty cycle which varies depending on the amperage output being used A duty cycle is the number of minutes out of 1...

Page 25: ...quality and safety of welds Ensure work area is free of flammable materials Make sure the workpiece is clean before welding for both the location of the weld and the ground clamp Sealed containers DO NOT weld burn or heat sealed or pressurized containers Observe specific guidelines when welding a workpiece to ensure safe practice has not been overlooked Becoming familiar with welding techniques an...

Page 26: ...r to weld However it is generally recommended that the operator utilize the dragging tech nique to avoid slag inclusions in welds 9 Squeeze trigger so wire begins to feed into weld Once wire makes contact with workpiece arc will start and weld pool will begin to form Maintain consistent dis tance between contact tip and workpiece of 3 16 1 4 see Figure 23 Note Keep welding gun cable as straight as...

Page 27: ...w of gun travel speed can cause built up and convex welds with bad slag coverage Too fast of gun travel speed can cause narrow globby welds with minimal penetration Wire Speed Wire speed is strongly related to amperage but it has more to do with weld heat Too high of wire speed can cause stub bing and poor slag coverage Too low of wire speed can cause globby welds with lots of spatter Amperage Out...

Page 28: ... Kevlar heat resistant thread for durability adjustable wrists and waist fit Figure 24 H7439 Welding Bib H7439 Kinco 20 Welding Bib This welding bib measures 22 wide by 20 long and features an adjustable waist strap Installing unapproved accessories may cause machine to malfunction resulting in serious personal injury or machine damage To reduce this risk only install accessories recommended for t...

Page 29: ...5 Capacity 75 lbs Figure 29 T32085 Welding Respirator Kit T32085 Welding Respirator Kit Medium The T32085 Welding Respirator Kit is a size medium respirator providing protection for certain particulates found in welding at concentrations up to 10 times the Permissible Exposure Level PEL NIOSH approved for P100 The P100 pancake filters provide at least 99 97 filtration efficiency against solid and ...

Page 30: ...cking Welding Clamp Milwaukee Torque Lock locking tools provide faster setup and more locking force for the pro fessional tradesmen The patent pending thumb screw provides the user with a more convenient geometry for hand force while providing clear ance to generate more torque with the unique screwdriver through hole design Figure 33 T30368 Diffuser for G0879 T30368 MIG Gas Diffuser MIG Gas Diffu...

Page 31: ...30371 Nozzle for G0879 T30371 MIG Nozzle MIG Nozzle for use with the G0879 Welder Figure 36 T30367 Torch Neck for G0879 T30367 Torch Neck for G0879 Torch Neck for use with the G0879 Welder order online at www grizzly com or call 1 800 523 4777 ...

Page 32: ...n Weekly Maintenance Dust and dirt build up in machine and cooling fan Schedule If the machine stops functioning it is possible that the machine may have blown a fuse To replace fuse on welder 1 DISCONNECT MACHINE FROM POWER 2 Raise top cover of machine as shown in Assembly on Page 16 Replacing Fuse Figure 37 Removing left side panel 4 Remove clear fuse cover on circuit board labeled FUSE see Figu...

Page 33: ...ck and welded to contact tip 8 Duty cycle exceeded 9 Drive roller groove does not match wire gauge 1 Replace welding wire spool Page 16 2 Match contact tip to wire gauge 3 Tighten tension knob Page 21 4 Clean wire sheath replace contact tip replace welding torch assembly 5 Adjust nut so spool moves freely Page 16 6 Replace welding wire spool Page 16 7 Replace contact tip DO NOT run trigger This wi...

Page 34: ...e speed 4 Increase welding torch travel speed 5 Maintain contact tip to workpiece distance of 3 16 1 4 Page 24 Lack of weld penetration 1 Improperly cleaned workpiece wrong type of material material too thick for welding operation 2 Welding output amperage too low 3 Wire speed too slow 4 Welding torch moved too quick 5 Contact tip to workpiece distance to short 1 Clean workpiece use correct type o...

Page 35: ...erty or for incidental contingent special or consequential damages arising from the use of our products The manufacturers reserve the right to change specifications at any time because they constantly strive to achieve better quality equipment We make every effort to ensure that our products meet high quality and durability standards and we hope you never need to use this warranty In the event you...

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