Hot Max 100WFG User manual

WARNING: Do not assemble, install, or operate this equipment without reading ALL of this manual
and the safety precautions and warnings illustrated in this manual.
KDAR Company Tel: [phone]
15009 Manchester Road #283 Fax: [phone]
Ballwin,MO63011 Web Site: www.hotmaxtorches.com
Operator’s Manual
Models 100/135/175WFG
Wire Feed Welders
MIG Welders

SAFETY PRECAUTIONS AND WARNINGS
PLEASE READ BEFORE USING EQUIPMENT
WARNING • Keep children away from this equipment
• Protect your self and others from possible injury
• Pacemaker wearers should consult with their doctor before operating
• Read and follow all instructions in this manual before operating
• All installation, operation, and maintenance procedures are to be per-
formed only by qualified individuals
ELECTRIC SHOCK CAN KILL.
• The input circuits are also live and hot when the power is on
• Do not touch live electrical parts
• Wear dry, hole free insulated work gloves and body protection when operating
• Do not touch torch components if in contact with the work piece or ground
• Always turn off power before cleaning, checking, or changing parts
• Properly ground this piece of equipment per state and federal requirements
• Inspect and replace any worn or damaged torch cables or leads
• Keep all panels and covers securely in place
• Keep away from the torch tip and weld arc when trigger is pressed
• Ground the metal or work piece to the ground cable (Earth Clamp)
• Never dip the tip into water to cool or attempt to use welder in or under water
• This DC equipment holds a lot of power in the off position, before touching, make sure voltage is
near zero on input capacitors before touching any parts.
ARC RAYS CAN BURN SKIN AND EYES
• Arc rays when welding produce intense ultraviolet and infrared rays that can burn skin and eyes
• Where face protection, either helmet or shield when operating with ANSI Z49.1 approved shade #9
recommended for all cutting currents less than 300 amperes. The lens should conform to ANSI
Z87.1 standards for testing.
• Wear approved safety glasses with side shields under the face protection
• Warn others not to stare at the arc as it can cause damage to the eyes. Provide barriers to protect
other workers in the area from the arc while operating
• Wear flame resistant gloves, clothing, and shoes when operating
FUMES AND GASES CAN BE HAZARDOUS
• Arc welding produces fumes and gases and breathing these gases is hazardous to your health
• Keep your head out of the fumes and do not breath the fumes while welding
• Work only in a confined area if it has sufficient ventilation, or while wearing an air supplied respi-
rator. Fumes from welding deplete the oxygen supply and can be harmful. Always be sure there is
ample breathing air
• Read the MSDS sheets and the instructions from manufacturers for metals to be welded, coatings,
and cleaners
• Do not use the welder near hydrocarbon vapors coming from degreasing, cleaning, or spraying
operations. The heat and rays can react with solvent vapors to create the gas phosgene, a very toxic
gas and other irritating gases
• Do not weld coated metals, such as galvanized, lead, or cadmium plated steel. Before welding, all
plating must be removed. The area must be well ventilated or an air supplied hood must be used.
The coatings and chemicals when burned cause highly irritating and toxic fumes.
• Do not weld containers with toxic, flammable, or reactive elements stored in them. They must be
emptied and properly prepared before welding.
KDAR Company 1

WELDING SPARKS CAN CAUSE INJURY, FIRE, OR EXPLOSION
• Remove all flammable materials from the welding area
• Always have a charged fire extinguisher available in the welding area
• When not welding make sure the welding tip is not grounded, this causes a heat build up and possi-
ble fire
• Avoid welding near hydraulic lines, fuel lines, electrical cords, air hoses, or welding guns and ca-
bles
• Sparks and hot metal fly out from the work area when welding, wear approved safety glasses with
side shields under approved helmets, wear proper body and hand protection, and wear flame resis-
tant ear plugs to keep sparks from entering the ears
CYLINDERS CAN EXPLODE IF DAMAGED
• Gas cylinders contain gas under very high pressure. If damaged they can result in that cylinder ex-
ploding. Gas cylinders are a major part of metalworking and must be treated with care.
• Protect gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs
• Always keep cylinders in an upright position securely fastened to a fixed support
• Valve protection caps should always be in place and hand tight except when the cylinder is in use
• Keep all cylinders away from any welding or electrical circuits
• Never allow the arc from a welder to contact a cylinder
• Never cut any type of pressurized cylinder, an explosion could result
• Always turn your face away from the valve when opening the cylinder
• Read and follow all instructions on compressed gas cylinders, associated equipment, and CGA pub-
lication P-1 listed in the Safety Standards before using
ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS
• Electric current used in arc welding can create Electric and Magnetic Fields (EMF)
• Magnetic fields can affect pacemakers and wearers should avoid proximity to EMF. Wearers need to
contact their doctors before operating this type of equipment
• Exposure to EMF during operation of this equipment may have other health effects which are not
yet known
• Route the work and torch cables together and not around your body
• Do not place your body between the torch cable and the work cable. They both need to be on the
same side of your body when operating
• Do not work next to the welding machine
ELECTRICALLY POWERED EQUIPMENT
• Disconnect power source or disconnect the switch at the fuse box before working on any equipment
• Only install equipment using the US National Electrical Code, all local codes, and the manufac-
turer’s recommendations
• Ground the equipment in accordance with the US National Electrical Code
KDAR Company 2
HOT PARTS CAN CAUSE SERIOUS BURNS
• Do not touch hat parts without wearing protection.
• Allow the torch to cool sufficiently before working with parts that could potentially be hot.

NOISE CAN DAMAGE HEARING
• Prolonged noise exposure from welding equipment can cause damage if levels of noise exceed the
OSHA standards
• Wear approved hearing protectors
• Warn other workers nearby of the high noise level and hazard
CALIFORNIA PROPOSITION 65 WARNINGS
• Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause
birth defects, and in some cases, cancer. (California Health and Safety Code Section 25249.5 et seq.)
PRINCIPAL SAFETY STANDARDS
AMERICAN WELDING SOCIETY
• AWS C5.2, Recommended Practices for Plasma Arc Cutting
• AWS F4.1, Recommended Safe Practices for the Preparation for Welding and Cutting
OSHA STANDARDS
• OSHA 29 CFR 1910, Safety and Health Standards
NATIONAL FIRE PROTECTION ASSOCIATION
• NFPA Standard 70, National Electric Code
• NFPA Standard 51B, Cutting and Welding Processes
AMERICAN NATIONAL STANDARDS INSTITUTE
• ANSI Standard Z87.1, Safe practices for Occupation and Educational Eye and Face Protection
• ANSI Standard Z49.1, Safety in Welding and Cutting
KDAR Company 3

KDAR Company 4
Specifications
Description UOM 100WFG 135WFG 175WFG
Power Source V 115 115 230
Frequency HZ 60 60 60
Phase 1 1 1
Rated No-Load Voltage V 29 32 35
Rated Input Current A 12 17 22
Rated Input Capacity KVA 2.8 3.9 5.1
Rated Duty Cycle % 20 20 20
Rated Output Current/Voltage A/V 88/18.4 115/19.8 130/20.5
Output Current Range A 22~100 25~135 30~175
Insulation Grade H H H
Cooling Fan Fan Fan
Case Protection Class IP21S IP21S IP21S
External Dimensions in. 17.3x10.2x14.4 17.3x10.2x14.4 17.3x10.2x14.4
Weight lb. 48.5 52.9 57.3
Features & Benefits
• Light weight, small size all steel case.
• Easy to use.
• MIG/MAG ready, regulator and 5’ hose in-
cluded.
• Output voltage levels—4 selections on the 100
& 135 and 5 selections on the 175
• Infinite wire feed speed control.
• Wire at gun is “cold” when not welding.
• Power on indicator light and overload indicator
light equipped.
• Fan cooled.
• 20% duty cycle minimum.
• Welds 22 gauge up 1/4” with flux cored wire.
• Built in wire feeder with easy to use tension
adjustment lever.
• Dual size grove drive roller to fit sizes .23”
to .35” wire (.6 to .9 mm).
• Easy polarity change for switching to and from
gas.
• Flux covered (FCAW) set up from the factory,
ready to weld.
• Welds steel, aluminum, and stainless (special
gas required for aluminum and stainless).
• 2 year limited warranty on the machine.
• 90 day limited warranty on gun and hose.
• Comes with the following components.
• 5 replacement tips
• Hand held welding shield
• Hex wrench to change wire feed roller.
• Gas nozzle for MIG welding.
• 10# spool adaptor.
• Gas regulator
• 5’ gas hose
Table 1

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Installation/Setup
Package Contents
1. WFG Welder
2. Ground Clamp Cable Assembly
3. Gun Cable Assemblies
4. 10# Spool Adapter
5. 5’ Gas Hose
6. Gas regulator
7. Gas Shield Nozzle
8. 5 Contact Tips
9. Hex Wrench
10. Face shield with welding lens
Safety Considerations
Warning
Electric Shock Can Kill
• Only qualified personnel should attempt to install this equipment.
• Turn off the input power at the fuse box or disconnect switch and discharge capacitors
before working inside the equipment.
• Take care not to touch electrically hot parts
• Make sure the unit is switched off before plugging it into a the power outlet.
Figure 1

Installation/Setup
6KDAR Company
Selecting A Location
The WFG Welder should be placed where clean cool air can easily flow through the vents in the front of the
unit. Dirt and dust can be drawn into the unit resulting in excessive operating temperatures and shutdowns,
therefore, dirt and dust around the unit should be kept to a minimum.
The WFG Welder should be placed on a stable, level surface suitable to hold the unit’s weight.
These units are not made to be stacked and therefore should never be set on top of one another.
Output Connections
1. Ground Clamp 1/4 turn Connection Port
2. Gun Cable Connection Port
3. Gun Lead Connections
4. Connector Block
5. Positive (+) & Negative (-) Output Terminals
6. Wire Feed Gearbox
7. Thumbscrew
Figure 2
1
2
3 4
5
6
7

Installation/Setup
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Ground Clamp & Lead Connection
1. Ground Cable Attachment: The Hot Max Mig
Welders use a convenient 1/4 turn connection for
attaching the ground cable to the unit. Insert the
male end of the ground cable into the female con-
nection port and turn 1/4 turn clockwise.
2. For FCAW (Flux Cored Arc Welding) Only:
The WFG series of welders are delivered set up for
FCAW welding with negative electrode polarity.
The short yellow cable coming out of the connec-
tor block is attached to the negative (-) output ter-
minal and the ground lead is connected to the posi-
tive (+) terminal.
3. GMAW (Gas Metal Arc Welding) Only: To set
up for GMAW welding with positive electrode po-
larity, connect the short yellow cable coming from
the connector block to the positive (+) output ter-
minal and the ground lead to the negative (-) out-
put terminal. Make sure all connections are tight.
Warning Always unplug the welder before connecting or disconnecting the Ground Clamp cable
and/or the Gun Cable.
Gun Installation
1. Insert the male connector on the gun cable into the
gun cable connection port. With the connector all
the way in the connector block tighten the thumb-
screw in the connector box.
2. Insert the gun cable terminals to the two gun lead
connectors. It does not matter which terminal goes
in which connector.
Figure 3

Installation/Setup
KDAR Company 8
Gas Connection
• Cylinder can explode if damaged. Keep cylinder chained upright to a secure support.
• Keep cylinder away from areas where it could be damaged.
• Never lift or move the welder with the cylinder attached.
• Do not let the welding electrode touch the cylinder.
• Keep the cylinder away from welding or other live circuits.
• Shielding Gas may be harmful to health or cause death.
• Turn off gas supply when not in use.
• Refer to American National Standard Z-49.1, “Safety in Welding and Cutting” from the Ameri-
can Welding Society for more information.
Warning
Gas Hook Up
When using the GMAW process, a cylinder of shielding gas
must be used. Shielding gas cylinders and gas can be obtained
at a local gas supply or some farm supply stores. The recom-
mended gases for the Hot Max WFG welders is either Welding
grade CO2 or a Argon/CO2 blend with 75-80% Argon and 20-
25% CO2 (see Suggested Settings chart on the welder com-
partment door).
1. Insure the cylinder is properly secured to a wall or other
stationary support to prevent it from falling over during
setup or operation. Be sure the cylinder is insulated from
the work circuit and ground.
2. Once the cylinder is properly secured, remove the cylinder
cap. Standing to one side slowly open the cylinder valve
for an instant to blow away any debris that may have accu-
mulated in the valve outlet.
3. Attach the flow regulator (Figure 5) to the cylinder valve
and tighten with a wrench.
4. Attach one end of the gas hose to the output fitting of the
regulator (1) and tighten securely with a wrench.
5. Test to insure the flow regulator is closed by opening cylin-
der valve slightly. If the regulator is not closed turn the
black knob counter clockwise until the flow of gas has
stopped.
Figure 4
Figure 5
1
2
Open

Installation/Setup
KDAR Company 9
Input Connections
The WFG series welders have power input cables located on the rear of the unit. (figure 4)
Requirements For Rated Output
The WFG100 and WFG135 has a 15 amp, 125 volt, three prong plug (NEMA Type 5-15P) installed at the fac-
tory. This plug must be connected to a mating grounded outlet that is connected to a 15 amp circuit with a
nominal voltage rating of 115 to 125 volts, 60 Hertz, AC only.
The WFG 175 has a 30 amp, 230 volt three prong crow foot plug (NEMA Type 6-50R) installed at the factory.
This plug must be connected to a mating grounded outlet that is connected to a minimum 30 amp circuit with
nominal voltage rating of 210 to 240 volts, 60 Hertz, AC only.
Gas Hook Up (cont.)
6. Reopen the regulator valve until the flow indicator shows
15 PSI (initial flow setting). The setting may need to be
adjusted by the operator to compensate for welding condi-
tions.
7. Connect the other end of the hose to the WFG series
welder (2) making sure that the hose is not kinked or
twisted.
8. Always close the cylinder valve and open the regulator
valve when not in use.

Operation
KDAR Company 10
Electric Shock Can Kill
• Do not touch live electrical parts of the electrode with skin or wet clothing.
• Insulate yourself from work and ground.
• Always wear insulated gloves and keep them dry.
Safety Considerations
Warning
Fumes & Gases Can Be Hazardous
• Plasma cutter should only be used in a well ventilated area or with an exhaust
system.
• Keep your head away from the fumes.
Arc Rays Can Burn Skin and Eyes
• Always were eye, ear and body protection.
Cutting Sparks Can Cause Injury, Fire , or Explosion
• Do not use near flammable material.
• Do not cut or gouge on containers that have held combustibles.

Operation
KDAR Company 11
Controls
1. Power On/Off Switch—The fan will run when
the power is on and air will be exhausted form the
front of the unit. The welding output and wire
feeder will remain off until the gun trigger is
pressed.
2. Power On Indicator—This LED is on and re-
mains on when the power switch is in the on posi-
tion.
3. Speed Control—Controls the wire feed speed .
The control can be preset on the dial to the setting
specified on the application chart located inside the
wire feed section door.
4. Voltage Control—A 4 position selector switch
gives full range adjustment of voltage. Do not
change selections while welding; this could cause
damage to the switch.
5. Overload Indicator—This LED comes on to indi-
cate the duty cycle had been exceeded. Output will
be shut off until the unit has cooled to an accept-
able operating temperature. The fan will continue
to run.
6. Overload Breaker—This breaker protects the unit
from damage due to exceeding the maximum out-
put. The breaker pops out when tripped and must
be pushed in to be reset.
7. Gun Trigger—Pressing the trigger activates the
welding output, wire feed and gas operation. Re-
leasing the trigger stops the welding output, wire
feed and gas operation. Releasing the trigger also
starts the burn back function to prevent the weld-
ing wire from sticking to the working weld.
1
2 3
4
5
6
7
Figure 8
Figure 6
Figure 7

Operation
KDAR Company 12
Loading Wire
Note: Always turn power off when working inside the
welder enclosure.
4” Diameter Spool
1. Remove wing nut and washer (1) and the plastic
tension spacer (2).
2. Place the spool (label out) on the shaft with the
wire feeding from under the spool.
3. Replace the spacer, washer and wing nut
8” Diameter Spool
1. Remove the wing nut, washer and plastic tension
spacer.
2. Place the spool adaptor (3) over the shaft as shown
in Figure 10.
3. Replace spacer, washer and wing nut. Make sure
the wing nut is positioned so that it does not inter-
fere with the locking tab (4).
4. Place spool on the spool adaptor making sure the
hole in the spool engages the stud (5) on the spool
adaptor.
Adjusting Friction Break
While turning the spool with one hand begin tighten-
ing the wing nut with the other. Once you start to feel
tension; then turn the wing nut an additional 1/4 to 1/2
turn.
The intent is for the friction break to produce just
enough friction to prevent the spool from continuing
to turn after the drive motor has stopped.
1 2
Figure 9
3
4
5
Figure 10

KDAR Company 13
Operation
Wire Feeding
1. Release the spring loaded tension arm (1) by flip-
ping it to the right and down.
2. Lift the idle arm (2).
3. Make sure the grove size on the drive roll (3) is in
the feeding position that matches the wire size be-
ing used. Refer to the Suggested Settings for
Welding chart at the back of this manual or on the
inside of the welder compartment door.
4. Detach the end of the wire from the spool.
Note: In order to prevent the spool from unwind-
ing; it is important to keep tension on the wire un-
til after the idle arm and tension arm are back in
place.
5. Thread the wire through the inlet tube (4), over the
drive roll (3) and into the outlet guide tube (5).
6. Close the idle arm (2).
7. Move the spring loaded tension arm (1) into posi-
tion.
8. If required, rotate the wire spool counter clockwise
to take up any slack in the wire.
9. If feeding problem occur because the wire is ex-
cessively flattened, turn the wing nut on the spring
loaded tension arm (1) counter clockwise to reduce
the pressure. If the drive roll (3) is slipping while
feeding the wire; turn the wing nut clockwise to
create more tension on the wire.
1
2
Figure 11
3 4
5
When feeding the wire, the drive roll, the connector
block and gun contact tip are electrically charged
relative to work and ground and remain charged
for several seconds after the gun trigger is released.
Warning
10. Remove nozzle (6) and contact tip (7) from end of
gun.
Figure 12
67
Figure 13
11. Turn on the Hot Max WFG.
12. With the gun cable assembly straight; press the
trigger switch. The welding wire will feed
through the cable and gun. Release the trigger
when the wire has fed approximately 2 inches
past the end of the gun.
13. Turn off the Hot Max WFG.
14. Replace the contact tip (7) and nozzle (6)
15. Cut wire off approximately 3/8” form the end
of the contact tip. The Hot Max WFG is ready
for welding.

KDAR Company 14
Operation
Welding
1. See Suggested Settings at the back of this manual
or on the inside of the wire feed compartment door
for welding wire and shielding gas recommenda-
tions.
2 See Suggested Settings for information on setting
the controls on the Hot Max WFG for specific
welding wire and metal thickness.
3. Set the voltage and wire speed.
4. Insure the unit is set up for the correct polarity for
the welding wire and process being used. The Hot
Max WFG is shipped set up for FCAW (Flux
Cored Arc Welding)
5. Insure the proper nozzle and tip are installed on the
gun for the welding wire and process being used.
6. If required, turn on gas supply.
7. Connect the ground clamp to the metal being
welded. The clamp must make a good connection.
8. Position the gun of the joint to be welded. The
wire can touch the metal lightly.
9. Lower the welding helmet, pull the trigger on the
gun and start welding. The contact tip should be
about 3/8” from the work surface.
10. Release the trigger to stop welding and pull the
gun away from the work after the arc has stopped.
11. If there is no more welding top be done, close the
valve on the gas cylinder (if gas was used) and pull
the trigger on the gum to release the gas pressure
and then turn of the Hot Max WFG.
Changing the Welder for Feeding
Different Wire Sizes
The Hot Max WFG is shipped ready to run .035
gasless flux cored wire. To run other sizes of wire
the contact tip must be changed and the drive feed
roll may need to be changed.
Changing the Contact Tip
1. To change the contact tip (1) you must first
remove the nozzle (2). This is done by un-
screwing it counter clockwise.
2. Unscrew the contact tip counter clockwise.
3. Screw in selected contact tip clockwise. Hand
tighten only.
4. Replace nozzle by screwing on clockwise.
21
Figure 14

KDAR Company 15
Operation
Changing Drive Roll
The drive roll has two groves; the smaller grove is
for .023” - .025” welding wire and the larger grove is
for .030” - .035” welding wire. The welder is shipped
set up for the larger welding wire sizes.
To change the drive roll position:
1. Connect the unit to the appropriate power source.
2. Open the wire drive compartment door, release the
spring loaded tension arm (1) by flipping it to the
right and down and lift the idle arm (2).
3. Turn the power on.
4. Turn the feed control speed to the minimum set-
ting and momentarily pull the trigger to turn the
drive roll. Stop when the set screw is facing up.
When feeding the wire, the drive roll, the connector
block and gun contact tip are electrically charged
relative to work and ground and remain charged
for several seconds after the gun trigger is released.
Warning
5. Turn the power off.
6. Loosen the drive roll (3) set screw with the hex
wrench provided with the Hot Max WFG.
7. Remove the drive roll turn it around and put it
back on the shaft.
8. Cut and straighten about 5” of the desired wire and
feed it through the wire inlet tube (4) and into the out-
let tube (5). Line up the drive roll grove with the weld-
ing wire and tighten with the hex wrench. Make sure
the set screw is on the flat part of the shaft.
1
2
3
4
5
Shielding
Process Welding Wire Gas 16 ga 14 ga 12 ga 10 ga
MIG DC+ .035 Dia 4043
Aluminum Wire
100% Argon B-5.5 C-7 C-9 C-9
MIG DC+ .035 Dia 5356
Aluminum Wire
100% Argon B-5.5 C-8 C-9 C-10
MIG DC+ .030 Dia 308L
Stainless Steel
Wire
98% Argon/
2% Oxygen
A-3 C-7 C-7 C-7
Voltage/Wire Speed
Aluminum & Stainless Steel Wire
The Hot Max WFG is capable of welding with
both .035” aluminum and .030” stainless steel
welding wire. See the table below for welder set-
tings for these wires.
Table 2
Figure 15
Figure 16

KDAR Company 16
Maintenance
General Maintenance
Power Supply Compartment
The Hot Max WFG does not have any serviceable
parts inside the power supply compartment. Do not
attempt to service parts in the power supply compart-
ment. Contact KDAR Company for instructions if
you have problems that can not be corrected by fol-
lowing the trouble shooting instructions.
If you are working in dusty areas, dirt may get into
the air vents and cause the welder to run hot and trip
the thermal overload protection. If this happens, blow
the dirt out with low pressure air regularly.
Wire Feed Compartment
1. Occasionally dirt will accumulate in the wire feed
compartment. When this happens, simply vacuum
the dirt out of the compartment.
2. Each time the wire spool is changed, inspect the
inside diameter of the wire feed inlet tube. If nec-
essary, clean the inside of the tube.
3. The motor and gearbox needs no lubrication or
maintenance.
Wire Spool Shaft
Requires no maintenance. Do Not Lubricate.
Warning
Electrical Shock Can Kill
Disconnect from the input power source
prior to working inside the Hot Max WFG.
Allow only qualified personnel to do mainte-
nance and trouble shooting.
Gun Cable
1. To clean the cable liner, remove the gun cable
assembly from the welder and lay it out
straight on the floor.
2. Take the contact tip off of the gun. Blow low
pressure air through the liner from the gun end
of the liner.
3. Flex the cable over its entire length and blow
air through again. Repeat flexing the cable and
blowing air through until no dirt comes out .
Contact Tip & Nozzle
1. When dirt builds up in the contact tip hole,
wire feeding can be restricted. To clean the tip,
run the appropriate sized tip cleaner through
the tip repeatedly. This should remove any dirt
that has built up on the walls of the contact tip.
KDAR Company tip cleaner number TC-1 is
available for selected distributors or hotmax-
torches.com.
2. Remove splatter from the inside gas nozzle and
the tip frequently

KDAR Company 17
Troubleshooting
Warning
Most components of the WFG series welders are not serviceable by the operator and should only be ser-
viced by a qualified repair technician. Unauthorized repairs to these units may result in danger to the
operator and will void the factory warranty. For your safety, please follow all safety precautions found
throughout this manual.
Problem
Nothing happens when the trigger is pulled; no wire
feed, weld output or gas flow. Fan is not operating.
When trigger is pulled there is no wire feed, weld
output or gas flow but the fan operates.
Little or no gas flow is evident when the trigger is
pulled. Wire feed, weld output and fan operate as
normal.
No wire feed when the trigger is pulled but the fan
runs, gas flows and there is weld output.
Possible Cause
1. Check to insure the power switch is turned on.
2. Insure correct voltage is applied to the welder.
3. Check to insure the circuit breaker is not
tripped.
1. The welder may have overheated and tripped
the thermostat. Let the welder cool down and
weld at a lower amperage setting.
2. Check for obstructions in the air flow and to
insure the gun cable assembly connections are
correct.
3. Gun trigger may not operate properly.
1. Check to insure the gas supply is adequate.
2. Check the regulator and gas hoses to insure
there are no problems.
3. Check to insure there are no obstructions or
leaky seals in the gun cable assembly connec-
tion.
1. Check to see if the wire drive motor is turning.
If it is, make sure the drive roll is the correct
size and is installed properly.
2. Check to insure the cable liner and/or tip are not
clogged.
3. Check to insure the correct sized cable liner and
tip are installed.

KDAR Company 18
Troubleshooting
Problem
Arc is unstable—Poor starting
Possible Cause
1. Check to insure proper input voltage to the
welder.
2. Check electrode polarity to make sure it is cor-
rect for the process being used.
3. Check tip for proper size and damage; replace if
necessary.
4. Insure proper gas flow for the process.
5. Make sure the connections for the work cable are
correct.
6. Make sure the drive roll is installed and aligned
properly.
7. Make sure the line size is correct and there is no
damage to the gun cable assembly.
Note: For problems that can not be corrected by following the troubleshooting proce-
dures listed above; please contact KDAR Company. NEVER attempt to work on any part
of the welder not listed above. Unauthorized repairs to the unit may result in danger to
the operator and will void the factory warranty.

KDAR Company 19
Additional Hot Max Products
Hot Max Stick Welders
300 Amp AC
300/200 Amp ACDC
Hot Max Plasma Cutter
25 Amp
Big Max
Propane Torch
Mobil Max
Portable Torch Kit
Hot Max
Cutting Torch Kit
Little Max
Propane Torch Kit