Northern Industrial MIG 135 User Manual

Item# 164611
OPERATOR’S MANUAL
Read carefully and understand RULES FOR SAFE OPERATION and instructions before
operating. Failure to follow the safety rules and other basic safety precautions may
result in serious personal injury.
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Northern Industrial MIG 135 Specifications

General

Welding Process	MIG (GMAW)
Input Voltage	120V
Amperage Range	30-135A
Duty Cycle	20% @ 90A
Wire Feed Speed	Variable
Wire Size	0.023 in. - 0.035 in.

Summary

Safety First: Rules for Safe Operation

General Safety Precautions

Initial safety advice emphasizes understanding rules for safe operation and basic safety precautions.

Introduction and Manual Guidance

Save This Manual

Instruction to save the manual for future reference, including safety warnings and operating procedures.

MIG Welder Overview

Description

Details the MIG 135 as a portable DC MIG welder capable of welding with solid or flux core wire.

Specifications and Dimensions

Lists technical specifications such as power supply, voltage, output range, duty cycle, and dimensions.

Removing from Carton

Instructions for unpacking the welder and checking contents against the packing list.

Know Your Welder: Components and Controls

ON/OFF Switch and Wire Feed

Identifies the ON/OFF switch for power supply and the wire speed control for wire feed adjustment.

Wire Compartment

Describes the contents of the wire compartment: wire feeder, spool hub, set up chart, and polarity terminals.

General Safety Information

Welding Environment Safety

Guidelines for maintaining a safe welding environment, including fire prevention and ventilation.

Welder Condition and Safe Use

Ensures the welder's components are in good condition and instructs on proper usage.

Specific Hazards and Warnings

Electrical Shock Hazards

Warns about the danger of electric shock from arc welders and precautions to prevent it.

Fumes and Gases

Highlights the danger of welding fumes and the need for ventilation and safe breathing air.

Additional Safety Hazards

UV and IR Arc Rays

Details the harm from UV and IR arc rays and required eye and skin protection.

Fire Hazards

Covers fire risks associated with welding, including flammable materials and sparks.

Further Precautions and Procedures

Hot Materials, Sparks, and EMF

Covers handling hot materials, flying debris, and electromagnetic field precautions.

Shielding Gas Cylinder Safety

Safety guidelines for handling and using high-pressure shielding gas cylinders.

Proper Care, Maintenance, and Repair

Assembly Instructions

MIG Gun/Torch Assembly

Step-by-step guide for attaching the MIG gun/torch, including setting screws and identifying openings.

Connections and Polarity Setup

Instructions for connecting trigger leads, ground cable, and setting polarity for different welding types.

Installation and Setup

Power Requirement and Extension Cords

Details power source requirements and recommendations for using extension cords.

Install Wire Roller

Drive Roller and Wire Selection

Guide to removing drive rollers, selecting wire diameter, and matching it to the correct groove.

Wire Installation Steps

Wire Spool Installation and Tensioning

Instructions for installing wire spools and adjusting tension for smooth wire feeding.

Wire Installation Steps

Wire Feeding and Initial Setup

Steps for feeding wire, setting voltage/speed, installing contact tips, and nozzle.

Wire Tension and Gas Setup

Setting Wire Tension

Procedure for adjusting drive tension knob for smooth wire feeding without slipping.

Shielding Gas Installation

Connecting Gas Hose and Regulator

Steps for connecting the gas hose, regulator, and ensuring proper gas flow.

Shielding Gas Installation

Shielding Gas Selection

Guidance on selecting appropriate shielding gases for different metal types.

Operating the Welder

Main Control Components Overview

Explanation of the power switch, voltage selector, and wire speed control functions.

Operating the Welder

MIG Gun Handling and Positioning

Best practices for holding and positioning the MIG gun relative to the workpiece.

Work Piece Distance and Wire Speed Tuning

Adjusting nozzle distance and tuning wire speed for optimal arc performance.

Welding Techniques

Torch Movement and Travel Speed

Details torch travel direction and speed for achieving quality weld beads.

Types of Welding Beads

Explains different weld bead types like stringer and weave beads.

Welding Techniques

Welding Positions Explained

Describes flat, horizontal, vertical, and overhead welding positions and techniques.

Multiple Pass Welding

Butt and Fillet Weld Joint Preparation

Guidelines for preparing butt and fillet joints for multi-pass welding.

Spot Welding Methods

Introduces burn-through, punch and fill, and lap spot welding methods.

Multiple Pass Welding

Spot Welding Techniques

Instructions for performing spot welds using different methods.

Maintenance Procedures

Minor and Routine Maintenance

Regular maintenance tasks including cleaning and component checks.

Troubleshooting Guide

Main Circuit Diagram

Repair Parts List

Key Component Identification (Parts 1-4)

Lists reference numbers, descriptions, part numbers, and quantities for initial welder components.

Repair Parts List

Key Component Identification (Parts 5-23)

Lists reference numbers, descriptions, part numbers, and quantities for welder internal components.

Repair Parts List

Key Component Identification (Parts 24-34)

Lists reference numbers, descriptions, part numbers, and quantities for welder external components.

Safety Standards and References

Welding Safety Standards

References ANSI, NFPA, and OSHA standards for welding safety and practices.

Safety Standards and References

Combustible Container Standards

Information on AWS Standard A6.0 for welding containers that have held combustibles.

Warranty Information

Limited Warranty Details

Covers the terms and conditions of the limited warranty for new equipment.

Warranty Periods and Coverage

Outlines warranty periods for different parts and categories of the welder.