MANUFACTURED
BY
WELDING INDUSTRIES:
OF
AUSTRALIA
PT'Y
LTtj
EUUI
PMENT
MANUFACTURING
DIU1
SI
ON
i
12
Dawz.
Road, Edwards
t
own
,
Sou
t
h
SALES
BRANCHES
MelGuurnE
83
429
4766
AA324P3
Sydney
02
647
2655
AA24155
biewc;kstl
e
845'
61
1668
Wol
1
ongong
642
29
3447
Brisbane
07
344
135'1
clic.
3074
pi-I
83
465
Facsimile
U3
4.55
Aust.
5837
ph
88
276
Facsimile
08
276
Mac
kay
079
51
Adel
ai
de
88
352
Per
t
h
89
361
Laurrcestorr
003 44
WELD-t.1-C:HARGE
251i
AA32493
861
2
64P4
AA82856
8303
3532
3022
AA82856
76
88
AA92936
9322
THE
I
NFCIRPlATI
01.1
CONTAINED
IN
THE FOLDER
I
S
SET
OUT
TO
ENABLE
YOU
TO
PROPERLY
MAINTAIN YOUR
NEW
EQUIPMENT
AND
ENSURE THAT YOU OBTAIN
MAXIMUM
OPERATING'
EFFICIENCY,
PLEASE ENSURE THAT THIS
FOLDER
I
S
KEPT
IN
A
SAFE
PLACE
FOR
READY
REFERENCE
WHEN
REQUIRED
RETURN FlACHINE
TO
PLACE
OF
PURCHASE
OR
YOUR
NEAREST
WIA
SALES
AND
SERVICE
BRANCH
FOR
REPAIR
IF
FAULTY.
SAFETY
Before
this
equiprrter1t
is
put
into
operation,
the
SAFETY
PRACTICES
section
at:
the
back
of
the
Manual
MUST
BE
READ COPlPLETELY. This
will
help
avoid possible
injury
due
to
misuse
or
improper
welding
applications.
I
WELD-1.1-CHARGE
PlANUAL
PAGE
1
CONTENTS
General
Description
1
Prepara
t
i
or1
for.
Me1
di
nq
Opera
t
i
or1
1
Preparation
for
Battery
Charging Operation
2
War
rl
i
n
CJS
3
Servicing
3
Safe
Practices in Using Electric
Arc
Processes
and
Equiptment
3
Opera.tor's Personal Protection
3
Operating Precautions
4
Uerl
t
i
l
a.
t
i
on
5
Fire and Explosion Prevention
5
Page
Mu
I
GENERAL
DESCRI
PT1
ON
The
Model
MC81
Hobby
Welder
is
a
smal
1
,
lightweight portable
k.C.
arc
welding machine
of
the fixed tapped transformer
design, suitable
for
marrual
arc
welding Iwith
2.5mm
and
3.25mm
coated electrodes,plus
a
12
volt medium duty battery charger
suitable
for
car,
boat
and other
medium
duty
batteries.
The
rrlachine
has
been
manufactured
to
operate
from
the
normal
household
240
v01
t
10
arrrp
58
Hz
single
phase
power
supply,
and
ful
lr
rsompl
ies
~i
th
Austral
ian
Standards specification
ASlP66
for
limited input class
machine^,
tested
tu
Australian
Test
Specification
AS31P5,Approual
Number
S/221/MC81.
Cooling
is
by
cc~nuection with
entry
located underneath
the
rrtachine,
so
a5
tu
remove
heat
from
the
transformer
in
an
updraught manner,
always
ensure
the
welder
is
located in
a
dry
place
and do not obstruct
the
bottom
of
the
unit.
PREPARATI01.4
FOR
WELDING
OPERATION
1
Careful
ly
read
the
enclosed
Safety
In~ttuctiorns.
3.
Irlsert
the
three-pin
plug into
a
18
amp
power point.
r
&l.
Place
the
proper elec
trctde
in
the
el
ec trode holder
at
the
desired angle.
(For
best
results,
use
the
qual
itr
Austat-c
electrode
nominated
from
the
electrode guide..)
6.
To
strike
the
arc,
move
the
electrode along
the
piece to be
welded,
as
if
c,triking
a
rrlatch.
As
the
puddle
of
molten
metal
forms,
move
the
electrude
in
the
direction to
be
welded.
(It
i
5
rlormal
to
drag
an
el
ec
trode
when
we1
ding.
>
7.
To
stop welding, simply lift
the
electrode and
break
the
arc,
8.
The
rrlachirle is
of
rugged cunstruction
with
a
1
iberal
rating
far-
its c1a.s~.
It
must,
however,
be
remembered it
has
been
desigr~ed
tu
run
2.51~1m
and
3.25mm
electrodes
CIFI
a
10
amp
power
point,
A
sensible a.pproach to
work
capacity
will
avoid
an
over1
clad condi tion on both machine
and
houc,ehcll
d
supply.
.-
~
LJELD-N-CHARGE
IIHNUAL
PAGE
2
9.
When
welding
on
motor
vehicles1
ensure
battery leads
are
removed
f
rum
the
terrrri
nal
S.
WIA
manufacture
a
wide range
of
mild
steel
and special
purpose
electrodes
which
cater
for
industry needs. The
table
5et
out
below lists
those
kustasrc electpudes
that
are
cornmun1y
used
for
the
welding
you
are
1
ikely
to
per+urrr~.
The
correct
selected electrode
will
influence
Goth
the
quality
of
we1
d
and
stabi
1
i
ty
of
arc
Therefore,
shoul
d
you
want
the
best
resul
t,
ask
for
f4uc.tar.c
now
available in
the
ccrtvenient
E41
13
*EHUSTHHC
135
2.5mm
3
,
25mm
F1
ux:
B1
ue
and
Wh
i
t
e
Stripe
Tip: Plain
E481
6
%LISTARC
16TC
2,
~KIKI
3.25mm
F1
ux:
Grey
Tip:
Bronze
HPPII
CATION
Popular general
purpose
(G.P.)
electrode used
with
ease
in
a1
1
posi t ions, vertical
up
or
down.
The
smc~oth
Qurceful
arc
makes
it
an
ideal
rad
fur
all
general
mild
steel
appl
ications.
Smooth
running
wi
th
a
ssf
t
arc
I
qen
era
1
purpose
electrode
particularly
suited tu
1
igh
t
stlee
tme
tal
and
smcm
t
h
mi
tre
f
i
11
et
we1
ds.
A
low hydrogen
el
ectrade
with
good
arc
5.ta.tril
i
tr
and out-af-
position welding characteristics.
This electrode is ideal
for
medium
carburl
steel
or
steel
with
doubtful
anal
rsi
5.
1.
Discunnect battery
from
car,
boat,
etc.
2.
Connect
the
work
clamp
to
the negative
(->
battery
terminal,
4.
Insert
the
3
pin
plug
into
a
10
amp
power.
point,
5.
Turn
the
current switch to
"L~w
Current"
for
norma
or
to
"High
Current"
for
faster
charging.
6.
Leave
battery in
well
ventilated
area
for
charging
1
charging
I/JELD-1.\l-CHAf?OE
PlAblUAL
PAGE
3
WARNINGS
1
,
Corlnec
t
and disconrtec t battery
charger
1
eads
m1
y
when
supply
cable is disconnected
from
supply
rr1air15,
as
any
resu
l
tan
t
spark
may
cause
an
expl
osiclrl,
2.
Whilst
the
charger is disconnected
from
the
supply
mains,
csnnect
only
the
positive
lead
of
the
charger
to
the
positive
lead
of.
the
battery and
only
the
negative
(work>
lead of
the
charger
to the negative
terminal
of
the battery.
3.
Do
not
over
charge
the
battery.
An
over
charged battery
KI~Y
develop excessive
heat
which
may
cause
an
explosion,
4.
Do
not
STTIUkF?
strike
a
rrlatch, cause
spark,
weld
or
alluw
conductive
materials
in
the
vicinity
of
the
battery during
cha.rging.
5,
Use
in
a
we1
1
ventilated
area
and
do
not
operate
in
a
conf
i
ned
space.
SERU
I
C1
NC3
The
battery charger
is.
protected
from
short
circuit uuerlclad
by
a
6
amp
3AG
standard action
type
+use,
The fuse will blow if
the
uutpu
t
1
eads
are
shorted
togettier
or
if
the
charger is
cannected
to
a
battery with
a
short
circuit fault,
Replace tilobJr1 fuse
only
with
a
6
amp
3AG
standard acticlrl
type
fuse.
SAFE
PRACTICES
IN
USING
ELECTRIC
ARC
PROCESSES
AND
EQUIPrlEbJT
Welding
equipment
and
prcrces5e5
are
nett
particularly
hazardous:
however,
ther
are
certain safe practises
the
user
should
fol
low
tu protect himC.el
f
and
others
from
injury.
The
following
notes
prepared
by
Welding Industries
of
Australia
Pty,
1
td.
tu
assist with
operator
safety
are
only
a
basic guide
to
E.afe
working habits.
k
detailed list
of
standards
for
use
thruughuut industry is available
from
the
Standards Association
of
Austral
ia.
Individual State Authorities
such
as
Electricity,
Department
of
Labour, Industry
or
Mines
Department
and
other
local
health
OP
safety Inspection Authorities
may
also
have
additional
requirements.
I
NSTALLAT
I
Ut4
OF
EQU
I
PblENT
Instal
1
and rrlaintain equipment in accordance with
the
local
electrical a.1~thor.i
ty
codes.
Always
use
cc1rrec1;
rated
pri~~2r.y
cable and
~.uppl~
outlets,
and
have
only
qualified electrical
personnel
carry nut
instal
lat
ion
and main tenat-lce
work,
Make
sure
you
always
USE
the
provided
work
cab1
E
fur. grclurld
returt-1
from
wsrk
to
we1
der,
Never
use
p
ipes
carrying
gas
or
flammabl
e
l
iquidc. for ground return circui tc.,
OPERATOR'
E;
PERSONAL
PROTECT
101.4
The
radiation
from
the
arc
welding
process
is
intense
and
visibly bright and
can
damage
eyes.,
penetrate
1
ightweight
clothing and burn
the
skin.
Therefore, adequate protection
for.
both operator and
persur~c,
working within
the
we\ding
area
must
be
VJOT'~
at
a1
1
times.
Caution:
Do
not
use
ordinary
ga.s
WEI
ding
goggles
as,
these
yoygl
e5
do nut
provide suff icier1
t
face and
eye
protect i una
In
the
case
o-f
eye-burn, otltain professional medical attention
irrmediate1;v.
For
temporary
treatment,
apply
a
drop
of
2%
Butrn
sclluticln to
eyes
at
twe-hour.
intervals
or
CMurirle'
at
hourly
intervals,
fur
as
lung
as
acute burning sensation persists.
Avoid contact with electrode and ground circuits.
Use
a.
rubber
mat
or
uJouden
platform
to
stand
on
when
welding
in
damp
lucatisrls
or
on
metal
floors,
Do
not
loup
an
energised cable
around your body
or
tuck
an
electrode holder under your
arm.
E>:pased
corlductorc,
ur
ather
bare
metal
in
the
welding circuit,
or
an
electrical
lr
alive piece of equiptment which
is,
not
correctly eapthed, can
cause
a
fatal
s.hock
tu
a
person
whose
body
becorr~es
a
cclnductor.
USE
only
fully insulated, appr~ued electrode hulders
and
luck
type
cable connectors. Plaintain holder,
work
clamp,
welding
cable=.,
and
other
exposed
parts
uf
the
rnachine
in
good
cundi
t
iun
.
LJELD-1.4-CHHRGE
PlAt4UCiL PAGE
S
VENT
I
LAT
I
ON
Adequate ventilation rr~ust
be
provided for operator safety
.as
severe
dis.corrlfort, il
lrIec,s
or
even
death
can
result
f.r.om
toxic
fumes,
Good
veri
ti
lation
is
particular1
y
needed
when
we1
ding
or
gas-cutting alloys which
a.re
likely to contain lead,
zinc,
cadmium, beryl ium,
and
other rmterialf;
that
may
produce toxic
vapours and gases.
Do
not
Mork
in
a
conf ined space
url1
ess
i
t
is correc
t
1
y
ventila.ted by air, and if
neceSsa.ry,
wear
air supplied
respirators.
Never
ventilate
with
oxygen,
and
always
make
sure
any
person within
the
suspect
area
has
adequate protection.
Do
not
we1
d
or
gas-cut containers or
ve5,sel
E.
which have
he1
d
toxic materials b~ithout exercising
all
proper precautions.
The
heat
of
the
arc
or
flame
wi
11
decCllTlpoc,e vapours
fr~m
cl
urinated
solvent5
and
form
phosgene,
a.
highly toxic
gas
which irritates
both
eye
and
1
ung,
Trichlorethyl
ene
and perchlorethylene
VapuUrfj
can
be
decomposed by
the
ultra-violet iradient>
pr1er.y
of
an
arc to
a1
SCI
furm
ptlc~c,gena,
F
I
RE
AND
EXPLUS
I
UN
PREVENT
I
ON
Safety conscious clperatclrs
always
take
the
proper precautions
in preparing
a
location to prevent
fires
be-fore
setting
up
their
equip
tmen
t
,
Combuc,tabl
@E.,
suet-I
az.
wood,
paper,
c~i
1
,
grease,
paint
,
containers which
have
held gasoline
or
volatile liquid, can
cause fires or
rxy
I
usion and
shw1
d
be
removed
at
1
east
18
metres
(preferably
more)
frcrm
the
work location. Sparks
c+'.rt
travel
18
metres
or
mure
and lodge in
floor
cracks
to
stay
hot
er1wgi-l and srr~oulder
1
any after the
job
is
finished.
Empty
containers,
or
v,es;selc,
that
have
held cc~mbustable
or
can
produce f lamrrlable vapours
when
heated,
rr~clst
never
be
welded
or
-Flame-cut
without completing
the
precautions
set
aut
and
described
in
A51674-1388
"Fire
Precautions in Cutting, Heating
and
LJeldirrq Operatiens". Extracts
frorrl
this code, c.uch
as
thorough steam
or
cauc,tic cleaning, solvent
or
water
washing
dcpendir1g
clrl
the combustable's ~.olubil i
ty,
fcl1
lowed by purging
and inerting with ni trogen
or
carbon diuxide, should
be
stictly
adhered to.
Water-f
i
11
ing
just
below
working
level
may
substitute
fur
inerting.
/