Badger Welder M22 User manual

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M22 Cordless Welder
Operations Manual
TM

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Table of Contents
1. Product Features
2. Warranty Information
•Limited Warranty
•Warranty Claims and Repair Services
3. Safety
•Be Aware of Your Surroundings
•Electric Shock Can Cause Death
•Personal Protective Equipment
•Avoid Vehicle Damage
4. Initial Setup
•Unpacking
•Connecting the Battery Fuse
•Battery Fuse Replacement
5. Operation
•Overview
•Startup Instructions Using Internal Batteries
•Startup Instructions Using External Batteries
•Shutdown Instructions
•Changing From Flux-Core to MIG
•Removing the Wire Spool
•Changing Polarity
•Changing the Drive Roll
•Installing a New Wire Spool
•Installing a New Welding Torch Tip
•Connecting Shielding Gas
6. Charging
•Overview
•120 Volt AC Charging
•12 Volt DC Vehicle Charging
•USB and USB-C Charging Ports
7. Troubleshooting
8. Routine Maintenance
•Consumables and Replacement Parts
•Inspecting For Damaged Parts
•Maintenance
•Battery Replacement
Revision History
Revision A –July 4, 2018
Initial release
Revision B –November 25, 2022
Updated images
Revision C –February 3, 2023
Updated Inverter specs

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Section 1.
Product Features
A Complete Welder in a Case
The M22 Badger Welder is a compact, lightweight, self-contained, portable welder designed for quick
setup and welding without the need for any external power source. This self-contained unit includes the
batteries, welding gun, wire feeder, ground clamp and all controls in one easy to carry case making it the
ideal tool for quick welding repairs for off-road, farm, construction, and other off-grid applications.
Long Welding Time
At a typical duty-cycle of about 30%, the M22 Badger Welder can provide up to 18 minutes of trigger
time and as much as 60" of single-pass weld before recharging. The welder also is capable of up to 100%
duty-cycle with no concerns for overheating of any components.
Flux-Core or Mig Welding
The M22 Badger Welder is shipped in a Flux-Core configuration (DCEN) and is ready to weld with no
need for shielding gas. If preferred, the M22 Badger Welder can easily be reconfigured by the user for
MIG welding (DCEP) and includes a shielding gas connection. For MIG welding, it can use standard
Argon/Co2 welding gas or 100% Co2 that some off-road vehicles already have on board.
Key Safety Features
•Cold Tip Design –Prevents unintended arcing before you pull the trigger.
•24vdc Charging –Eliminates the risk of serious damage or personal injury that can happen with
12vdc charging configurations when connected to external power sources.
•Fused Battery –Prevents the risk of a rapid, excessive, battery discharge.
Made in USA
Badger Welders are engineered and built in Wisconsin using an IP67 rated American-made hard case,
with internal components manufactured from powder-coated steel for durability and long life. Our
welders are quality-built and factory-backed.

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Section 2.
Warranty Information
Limited Warranty
The M22 Badger Welder is warranted to be free from defects in materials and workmanship for a period
of one year from the date of the original retail purchase. This warranty does not cover part failure or
damage due to accidents, shipping, normal wear, abuse, improper use, modification, failure to properly
maintain the product, or damage caused by acts of God. Badger Welder, LLC, and its suppliers shall not
be responsible for any incidental or consequential damages resulting from the use or misuse of this
product or arising out of any breach of this warranty. No other express or implied warranties are
covered, including merchantability or fitness for a particular purpose.
Within the one-year warranty period, Badger Welder, LLC will repair or replace any warranted parts or
components that fail due to defects in materials or workmanship, provided that Badger Welder, LLC is
notified by email within 30 days of such defect or failure. This warranty does not cover consumables,
including but not limited to welding wire, contact tips, relays, and batteries. Any attempt to open or
service this welder without prior instructions from Badger Welder, LLC will void this warranty.
Warranty Claims or Repair Services
For warranty claims or any repair services requested, please contact us by email at:
[e-mail]
Please include the following information in your email:
•Your name
•Your phone number
•Product serial number
•Date and location of purchase
•A brief description of any problems or services requested

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Section 3.
Safety
WARNING: READ AND UNDERSTAND THIS ENTIRE MANUAL BEFORE USE! Keep a printed copy with the
Welder and routinely verify if there are any revisions by checking at www.badgerwelder.com. This
product is a low-voltage, battery-powered welder; however, BE AWARE THAT SERIOUS INJURY OR
DEATH MAY RESULT if welding equipment is not properly installed, used, and maintained.
Be Aware of Your Surroundings
•WELDING CAN CAUSE FIRES AND EXPLOSIONS. Sparks and weld spatter produced by welding
can ignite fuels, gasses, leaves, brush, or other flammable materials. Carefully check the work
area for any flammable materials nearby. Always keep a FIRE EXTINGUISHER nearby.
•Be aware of OTHER PEOPLE around the work area. Make them aware of the dangers of sparks,
weld spatter, fumes, electricity, or looking at the welding arc.
•Mobile working conditions can present other hazards that are not covered in these safety
guidelines. Make yourself aware of the inherent risks of welding and carefully review the work
area to determine if there are any risks of damage, personal injury, or death. You are ultimately
responsible for ensuring a safe work area.
Electric Shock Can Cause Death
•Before replacing any consumables, turn the Power Switch OFF. If servicing the welder or
changing polarity, turn the Power Switch off AND disconnect the Main Battery Fuse located
under the Spool Mounting Plate.
•Never touch the welding tip or ground clamp with bare hands when the power is ON.
•Never perform any service with any external power sources connected to the welder.
•Do not operate the welder if the Spool Mounting Plate is not securely in place.
•Do not use the welder in wet environments. Never immerse any part of the welder or
workpiece in water.
Personal Protective Equipment
•Welding processes produce extreme heat and strong ultraviolet rays. Protect your eyes with a
proper welding helmet. Protect your head and all exposed skin from sparks and UV rays to
prevent burns.
•Always wear dry welding gloves in good condition.
Avoid Vehicle Damage
•If welding on a vehicle, ALWAYS disconnect that vehicle’s POSITIVE and NEGATIVE battery cables
to avoid damage to the vehicle’s electrical systems.
•If using vehicle batteries to power the welder, they MUST BE DISCONNECTED AND REMOVED
from the vehicles.
•ALWAYS place the welder ground clamp on the same metal component that you are welding on
to ensure that the welder’s electrical path is not going through your vehicle’s electrical wires,
brake lines, fuel lines, or other components.
•DO NOT weld on or near a vehicle that is leaking fuel or oil.
•DO NOT attempt to jump start a vehicle with this welder.

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Section 4.
Initial Setup
Unpacking
The M22 Badger Welder is shipped with the batteries fully charged and is set up for Flux-Core welding
with the wire and welding tip already installed and tested. If the welder was shipped to you, we
recommend saving the box and shipping materials in the event that any warranty service or other
repairs are required.
Connecting the Battery Fuse
For safety during shipping, the M22 Badger Welder is shipped with the main Battery Fuse disconnected.
To connect the Battery Fuse:
1. Turn the Power Switch to the OFF/EXTERNAL BATTERY WELD position.
2. Remove the welding torch and ground clamp from the case and place them to the side.
3. Remove the two screws securing the Spool Plate. It is not necessary to remove welding wire
spool. Move the Spool Plate and spool to access the wiring below. Be careful to not kink
the welding wire while moving the spool.
4. On the post labeled “Battery Fuse” Slightly loosen the nut and pull out the shipping isolator.
Retighten the nut on the Battery Fuse Post. Be sure that it is secure, but do not over-tighten.
5. Replace the Spool Plate.
Battery Fuse Replacement
In the event of the Battery Fuse blowing, inspect the welder and if possible, determine the cause.
The replacement Battery Fuse size and type is: 300 Amp MRBF (Marine Rated Battery Fuse).

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Section 5.
Operation
Overview
The M22 Badger Welder was designed primarily for quick off-road repairs and remote welding tasks
where no power grid is available. While it is a very powerful tool, it does have its limitations and
differences compared to traditional welding equipment. It is recommended that you practice welding
with your Badger Welder prior to needing it in an off-grid application.
Startup Instructions Using INTERNAL BATTERIES
STEP 1: Start with the Welder Power Switch in the OFF/EXTERNAL BATTERY position.
STEP 2: Uncoil the Welding Torch and Ground Clamp Cables and attach Ground Clamp to bare
metal on the workpiece.
STEP 3: Loosen Wire Spool Tension Nut as needed.
STEP 4: Switch Welder Power Switch to INTERNAL BATTERY WELD position.
STEP 5: Adjust wire speed and spool tension as needed during welding.
Startup Instructions Using EXTERNAL BATTERIES
STEP 1: Start with the Welder Power Switch in the OFF/EXTERNAL BATTERY position.
STEP 2: Uncoil the Welding Torch and Ground Clamp Cables and attach Ground Clamp to bare
metal on the workpiece.
STEP 3: Loosen Wire Spool Tension Nut as needed.
STEP 4: If using external automotive batteries, use the optional cables to connect the batteries
in SERIES as shown below to provide 24 Volts DC. When using EXTERNAL BATTERIES,
they MUST BE DISCONNECTED AND REMOVED from vehicles. (Note: If using the MIG
DCEP configuration with external batteries, DO NOT reverse the polarity of the external
batteries. Polarity is determined inside the welder.)
STEP 5: Connect the optional cables from the series-wired 24 Volt DC batteries to the 24 VDC
port on the welder.
STEP 6: Adjust wire speed and spool tension as needed during welding.
Shutdown Instructions
STEP 1: Turn Welder Power Switch to OFF/EXTERNAL BATTERY position.
STEP 2: Disconnect External Battery connections, if used.
STEP 3: Allow welding equipment to cool, then recoil cables.
STEP 4: Tighten Spool Tension Nut before closing cover.

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Section 5.
Operation (Continued)
Changing Between Flux-Core and MIG
The M22 Badger Welder is shipped in the Flux-Core configuration. Switching between Flux-Core and
MIG requires changing the wire spool, changing the wire-feeder drive roll, changing the welding torch
tip, reversing the polarity, and connecting your shielding gas source if using MIG.
Removing the Wire Spool
Cut the wire near the wire feeder while holding the wire, then tuck the cut wire on the spool through a
hole in the spool to prevent unraveling. With the power on, advance the wire until the cut end passes
the drive roll, then turn off the power. Using some pliers, grab the wire near the torch tip and pull out
the remaining wire. Remove the wire spool and unscrew the torch tip. Clean the end of the welding
torch if needed to remove excess buildup of weld spatter.
Changing Polarity
Remove the two screws securing the Spool Plate and move the Spool Plate to the side. Locate the two
wires labeled ELECTRODE and GROUND, which should be attached to posts labeled POSITIVE and
NEGATIVE. Relocate the wires as needed:
•For Flux-Core (DCEN) the ELECTRODE should be attached to the NEGATIVE post and the
GROUND should be attached to the POSITIVE post.
•For MIG (DCEP) the ELECTRODE should be attached to the POSITIVE post and the GROUND
should be attached to the NEGATIVE post.
Changing the Drive Roll
Open the feeder tension knob to access the drive roll. Remove the drive roll and flip it over or replace it
with the appropriate drive roll if you are changing wire size. Do not discard the removed drive roll.
Installing a New Wire Spool
Install the new welding wire spool on the spool plate with the wire coming off the spool in a
counterclockwise direction. Adjust the spool tension enough that the spool can still rotate. Route the
wire around the vertical roller and into the feeder tube. Open the drive roll tension lock and route the
wire into the torch tube and verify that it aligns with the appropriately sized notch in the drive roll.
Close the drive roll tension knob and adjust tension if needed. Turn the power on and advance the wire
until it extends out of the end of the torch by a few inches. Turn off the power switch.
Installing a New Welding Torch Tip
With the wire extending out of the end of the welding torch, install the appropriately sized tip over the
wire, then screw it into the end of the welding torch.
Connecting Shielding Gas
For MIG welding, your inert shielding gas can be connected to the welder using the 4mm O.D. push-to-
connect fitting located on the control panel just above the external battery connector. You can use
standard Argon/Co2 welding gas, or 100% Co2 if desired.

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Section 6.
Charging
Overview
The M22 Badger Welder uses AGM batteries that are rated at 24 Volts DC. A full charge may show over
26 volts, and the normal operating range for welding is between 24 and 27 volts. For optimal welding,
you may need to recharge the batteries when they reach 24 volts or connect the welder to external
batteries for additional welding time.
120 Volt AC Charger
The M22 Badger Welder includes a 120 Volt AC charger that is designed for 24 Volt DC batteries. If your
charger is lost or damaged, a replacement can be found at www.badgerwelder.com or at most battery
supply stores or even pharmacies and retailers that sell electric wheelchairs and scooters. Make sure
the charger is a Fully Automatic Smart Charger designed for 24 Volt AGM batteries and utilizes a 3-pin
XLR connector.
The XLR Charging Port is located on the outside front of the welder, to the right of handle. To charge,
turn the Power Switch to the CHARGE position, then plug in the 24 Volt DC Smart Charger. Follow the
Charger manufacturer’s instructions included with the Charger. When charging is complete, unplug the
Charger from the welder and turn the Power Switch to the OFF/EXTERNAL BATTERY position. Charging
time will vary based on battery level, but typically takes between 3 and 4 hours. The charging circuit is
protected by a pop-up circuit breaker located on the control panel below the wire-feeder.
12 Volt DC In-Vehicle Charging
The M22 Badger Welder can also be recharged from a 12 Volt DC vehicle. To do this, plug the supplied
120 Volt AC Smart Charger into the vehicle’s 300W+ 120 Volt AC outlet if available, or simply use a
portable 300W to 400w DC to AC inverter available at www.badgerwelder.com or at most auto supply
stores, or other stores that sell vehicle accessories.
Be sure that the vehicle is running to prevent draining of the vehicle battery. Plug the inverter into the
vehicle’s cigarette plug, then plug the supplied AC charger into the inverter and follow the instructions
above for the 120 Volt AC charger. In-vehicle charging times will be similar to using the 120 AC charger
alone.
USB and USB-C Charging Ports
The M22 Badger Welder includes a dual Charging Port with one USB and one USB-C port. A fully
charged welder can deliver over 100,000mAh of charge to your portable devices. To use these ports,
turn the Power Switch to the CHARGE position. The USB ports will light up to indicate they are on.
When you are done charging your devices, turn the Power Switch back to the OFF/EXTERNAL BATTERY
position to avoid a very slow drain of the batteries. Be aware that use of the USB ports can drain the
batteries below the voltage needed for welding and could extend the recharging time.

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Section 7.
Troubleshooting
Trouble
Possible Issue
Possible Solution
No power to
welder.
Batteries are discharged.
Verify batteries are fully charged and the
welder Power Switch is in the INTERNAL
BATTERY WELD position.
Battery Fuse is Blown.
Check Battery Fuse under Spool Plate.
Welder will not
charge.
Welder Power Switch is not in the
CHARGE position.
Turn Welder Power Switch to CHARGE
position.
Charging Breaker is tripped.
Check pop-up charging breaker located on
the control panel below the wire feeder.
AC Charger is not powered.
Verify charger is plugged into a live power
source and the charger power switch is on.
Power is on,
but wire does
not feed when
trigger is
pressed.
Welding tip is clogged.
Check the welding tip for a clogged end or
burned back wire; clean or replace tip if
needed.
Wire speed control is set too low.
Verify wire speed control is not set too low
and that the drive wheel is turning with the
trigger pull.
Wire is not seated in drive roll
groove, or drive wheel is wrong size.
Check wire feeder to be sure wire is seated
in the appropriately sized roll groove.
Feeder tension is too tight or too
loose.
Adjust the feeder tension if needed to keep
the wire in the drive roll groove and keep
both wheels turning.
Spool Brake is too tight.
Check that spool tension is not set too tight.
Poor weld
quality.
Power is too low.
Verify that batteries are fully charged, or
external power source is wired properly.
Ground clamp is not on bare metal.
Use a grinder or wire brush to remove paint
or rust for a bare metal grounding surface.
Wrong wire size or type.
Verify wire size and type for desired welding
configuration.
Wrong polarity for desired welding
configuration.
Verify polarity wiring is correctly configured:
Flux-Core DCEN, or MIG DCEP.
Wire speed is too fast or too slow.
Adjust wire speed as required.
Shielding gas configuration is wrong.
No gas should be used for flux core. Verify
gas source is working for MIG welding.
Cannot create
welding arc.
Work piece is painted or rusty.
Use a grinder or wire brush to remove paint
or rust.
Ground clamp is not on bare metal.
Use a grinder or wire brush to remove paint
or rust for a bare metal grounding surface.
Ground clamp is not electrically
connected to workpiece.
Verify that ground clamp is on the same
steel component that you are welding.

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Section 8.
Routine Maintenance
Recommended Consumables and Replacement Parts
•Welding Wire
oFor Flux-Core welding, the recommended wire is 1lb or 2lb spools of E71T-11, or E71T-
GS, 0.030 diameter Flux Core wire. You can also use 0.035 diameter if preferred.
oFor MIG welding, the recommended wire is 1lb or 2lb spools of ER70S-6 Mild Steel Wire,
0.023 diameter.
•Welding Torch Tips
oBadger Welders use standard Tweco screw-in tips in 0.023, 0.030, or 0.035 to match
your desired wire diameter.
•Welding Torch Nozzle
oBadger Welders use standard Tweco style ½” screw-on shielding nozzle.
•Wire Drive Rolls
oBadger Welders include a reversible drive roll for 0.030” or 0.035” wire. Other sizes are
available to match other wire sizes. Do not use knurled drive rolls with Flux-Core wire.
•Battery Fuse
oThe replacement Battery Fuse size and type is: 300 Amp MRBF (Marine Rated Battery
Fuse). Refer to Section 4. Initial Setup for instruction on replacing the fuse.
Inspecting for Damage or Wear
Before each use, inspect the welder and consumables for damage or excessive wear. Repair or replace
worn or damaged components. DO NOT turn on or use the welder if there are any exposed or broken
wires or any missing components or parts. DO NOT turn on or use the welder if it is wet or there are any
signs of moisture inside of the case.
Maintenance
To extend the life of the welder, vacuum out any dirt or dust and wipe down surfaces with a dry cloth.
Keep the cover closed when not in use to minimize contamination of the welding wire path and the
internal electrical components. Recharge the batteries after any use and keep the batteries fully
charged as much as possible.
Battery Replacement
With proper use and charging, the batteries should last several years. If you notice the welding trigger
time is beginning to get significantly shorter, it may be time for a replacement. Batteries can be replaced
by the user, by Badger Welder, LLC, or by one of our service centers. Please contact Badger Welder LLC
for battery replacement instructions or a list of service centers. To avoid damage to welder and possible
personal injury, do not attempt to open the case without instructions. Opening the case without
instructions from Badger Welder, LLC will void the warranty.