Grizzly Welder H8154 User Manual

MODEL H8154

AC/DC STICK/TIG WELDER

OWNER'S MANUAL

WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE

OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL, INC.

#TS9402 PRINTED IN CHINA

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Table of Contents

INTRODUCTION............................................................................................................................... 2

Foreword .................................................................................................................................... 2

Contact Info................................................................................................................................ 2

Specifications ............................................................................................................................. 3

Identification ............................................................................................................................... 3

SECTION 1: SAFETY....................................................................................................................... 4

Safety Instructions for Stick/TIG Welders .................................................................................. 4

Additional Sources for Welding Codes and Standards.............................................................. 6

SECTION 2: CIRCUIT REQUIREMENTS ........................................................................................ 7

220V Operation.......................................................................................................................... 7

Grounding for Welding Safety.................................................................................................... 8

SECTION 3: INVENTORY................................................................................................................ 9

SECTION 4: OPERATIONS ........................................................................................................... 10

Operation Safety ...................................................................................................................... 10

Welder Duty Cycle ................................................................................................................... 10

Welder Controls ....................................................................................................................... 11

General Welding Operations.................................................................................................... 13

SECTION 5: ACCESSORIES......................................................................................................... 14

SECTION 6: SERVICE ................................................................................................................... 15

Troubleshooting........................................................................................................................ 15

Replacement Parts & Labels ................................................................................................... 17

WARRANTY AND RETURNS........................................................................................................ 21

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INTRODUCTION

Foreword

Contact Info

We are proud to offer the Model H8154 AC/DC

Stick/TIG Welder. This machine is part of a grow-

ing Grizzly family of fine metalworking equipment.

When used according to the guidelines set forth in

this manual, you can expect years of trouble-free,

enjoyable operation and proof of Grizzly’s com-

mitment to customer satisfaction.

If you have any comments regarding this manual,

please write to us at the address below:

Grizzly Industrial, Inc.

Technical Documentation Manager

P.O. Box 2069

Bellingham, WA 98227-2069

Email: [email protected]

The specifications, drawings, and photographs

illustrated in this manual represent the Model

H8154 when the manual was prepared. However,

owing to Grizzly’s policy of continuous improve-

ment, changes may be made at any time with no

obligation on the part of Grizzly.

We stand behind our machines. If you have any

service questions or parts requests, please call or

write us at the location listed below.

Grizzly Industrial, Inc.

1203 Lycoming Mall Circle

Muncy, PA 17756

Phone: (570) 546-9663

Fax: (800) 438-5901

For your convenience, we always keep current

Grizzly manuals available on our website at www.

grizzly.com. Any updates to your machine will be

reflected in these manuals as soon as they are

complete. Visit our site often to check for the lat-

est updates to this manual!

E-Mail: [email protected]

Web Site: http://www.grizzly.com

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Specifications

Stick Welding Current..............................5–130A

Stick Duty Cycle .............................35% @ 130A

AC TIG Welding Current .......................20–160A

AC TIG Duty Cycle.........................35% @ 160A

AC TIG Square Wave Balance ..............30–70%

AC TIG Square Wave Frequency ........20-100Hz

DC TIG Welding Current.........................5–160A

DC TIG Duty Cycle.........................35% @ 160A

DC TIG Current Upslope.........................0.2 sec.

DC TIG Current Downslope ................. 1-10 sec.

TIG Gas Pre-Flow ................................0–10 sec.

TIG Gas Post-Flow...............................1–25 sec.

Power Consumption................23.8A @ 220VAC

Output Power .....................................60–80VDC

Length/Width/Height..................... 21 x 9 x 16 in.

Net Weight.................................................22 lbs.

Figure 2. Model H8154 front connections.

L. Positive Output Socket

M. Negative Output Socket

N. Remote Control Connection

O. Gas Outlet Connection

Identification

Figure 3. Model H8154 features on back of

welder.

P. Power ON/OFF Switch

Q. Gas Inlet Connection

R. Power Cord

Figure 1. Model H8154 control panel.

S. Welder Enclosure Ground Terminal

T. Cooling Fan and Cover

A. Output Current Dial

B. Square Wave Balance Dial

C. Downslope Current Dial

D. Power Light

E. Warning Light

F. Post-Flow Time Dial

G. Welding Current LED Readout

H. Stick/TIG Selector

I. 2-Step/4-Step Selector

J. AC/DC Selector

K. Pre-Flow Time Dial

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��

Safety Instructions for

Stick/TIG Welders

1. READ THIS MANUAL. This manual con-

tains proper operating and safety proce-

dures for this equipment.

3. WELDING IN A CONFINED SPACE CAN

BE HAZARDOUS. Always open all covers,

sustain forced ventilation, remove toxic and

hazardous materials, and provide a power

disconnect to the welder inside the work

space. Always work with someone who

can give you help from outside the space.

Welding can displace oxygen. Always check

for safe breathing atmosphere and provide

air-supplied respirators if necessary. Keep

in mind that all normal welding hazards are

intensified in a confined space.

2. WELDING FUMES. Breathing welding

fumes can cause suffocation or poisoning

without warning. Keep your head out of

welding fumes. Use adequate ventilation

at the arc to safely remove the fumes from

your breathing zone and the general area.

Use ANSI approved respirators for the type

of welding operation. Protect others from

these fumes.

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4. ELECTRIC SHOCK. DO NOT touch live

electrical parts. Connect welder to power

source with approved earth ground. Make

sure all electrical connections are tight,

clean, and dry. Connect workpiece to

approved earth ground. The work lead is

NOT a ground connection and is to be

used only to complete the working welding

circuit.

9. HANDLING GAS CYLINDERS. Regardless

of content, pressurized gas cylinders can

explode. Always secure a protector cap in

place over the outlet valve assembly when

moving the cylinder. A broken off valve

could release the pressurized contents and

cause the cylinder to be hurled about at

dangerously high speeds, causing serious

property damage, personal injury, or death.

Always use safe methods when moving gas

cylinders. Always secure a gas cylinder to a

wall or approved cylinder cart with a chain

before using or storing.

5. PREVENT FIRES. Welding work zones

must be kept clear of flammable liquids,

such as gasoline and solvents; combus-

tible solids, such as paper and wood; and

flammable gases, such as acetylene and

hydrogen. Provide approved fire barriers

and fire extinguishing equipment for the

welding zone. Stay alert for sparks and

spatter thrown into cracks and crevices that

can start a smoldering fire.

10. PROTECT GAS CYLINDERS FROM HEAT

OR DAMAGE. An excess of heat can

cause the pressurized gas to expand and

explode the cylinder. Never weld on the

gas cylinder. Damaging the outside of the

cylinder can cause the cylinder to crack and

explode. Exploding pressurized gas cylin-

ders can cause serious property damage,

personal injury, or death.

6. PERSONAL PROTECTIVE EQUIPMENT.

Wear eye, ear, and body protection

approved for welding operations. Wear

complete body protection, such as clean

and oil-free protective clothing, leather

gloves, protective cap, heavy long-sleeve

shirt, cuffless pants, and high leather boots.

DO NOT wear jewelry or frayed clothing.

Use a welding helmet with correct shade of

filter for the operation. Protect other people

and property in your working zone from

exposure to arc radiation, sparks, and spat-

ter.

11. ELECTRIC AND MAGNETIC FIELDS

(EMF). Welding operations create EMF

around the welding equipment and

workpieces. Workers who have pacemak-

ers must consult with their physician before

using this equipment or being within 50 feet

of welding operations.

12. EQUIPMENT MAINTENANCE. Make sure

equipment inspections and maintenance

are performed by a qualified person as

required. Stop the welding operation and

disconnect the welder from power if the

equipment is damaged or malfunctions.

7. WORKING AREA. Keep working area clear

of any material not involved in the welding

operation. Keep all equipment, workpieces,

and work surfaces clean, dry, and free of

entanglements. Keep lead cables orga-

nized and away from your body.

13. EXPERIENCING DIFFICULTIES. If you

are experiencing difficulties performing the

intended operation, stop using the equip-

ment. Contact our Technical Support

Department at (570) 546-9663.

8. AVOID EXPLOSION HAZARD. Never

weld on closed containers or containers

with fumes inside. Containers should be

prepared per American Welding Society

Publication F4.1, Section 7.

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Additional Sources

Additional Sources for

Welding Codes and Standards

American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126, (305) 443-9353, Website: www.

aws.org.

—Safety in welding, Cutting, and Allied Processes, ANSI Standard Z49.1

—Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping,

AWS F4.1

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

Compressed Gas Association, 1735 Jefferson Davis Highway, Suite 1004, Arlington, VA 22202-4102, (703)

412-0900, Website: www.cganet.com.

—Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1

Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada

M9W 1R3, (800) 463-6727, Website: www.csa-international.org.

—Code for Safety in Welding and Cutting, CSA Standard W117.2

American National Standards Institute (ANSI), 11 West 42nd Street, New York, NY 10036-8002, (212) 642-

4900, Website: www.ansi.org.

—Practice for Occupational and Educational Eye and Face Protection, ANSI Standard Z87.1

U. S. Government Printing Office, Superintendent of Documents, P. O. Box 371954, Pittsburgh, PA 15250

(312) 353-2220, Website: www.osha.gov.

—OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal

Regulations (CFR), Part 1910, Subpart Q, and Part 1929, Subpart J

American Conference of Government Industrial Hygienists (ACGIH), 1330 Kemper Meadow Drive, Suite

600, Cincinnati, OH 45240-1634, (513) 742-2020, Website: www.acgih.org.

—Threshold Limit Values (Booklet)

No list of safety guidelines can be complete.

Every shop environment is different. Always

consider safety first, as it applies to your

individual working conditions. Use this and

other equipment with caution and respect.

Failure to do so could result in serious per-

sonal injury, damage to equipment, or poor

work results.

Like all equipment there is potential danger

when operating this welder. Accidents are

frequently caused by lack of familiarity or

failure to pay attention. Use this welder with

respect and caution to lessen the possibility

of operator injury. If normal safety precau-

tions are overlooked or ignored, serious

personal injury may occur.

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Circuit Requirements

SECTION 2: CIRCUIT REQUIREMENTS

Grounding

220V Operation

In the event of an electrical short, grounding

reduces the risk of electric shock. The grounding

wire in the power cord must be properly connected

to the grounding prong on the plug; likewise, the

outlet must be properly installed and grounded.

All electrical connections must be made in accor-

dance with local codes and ordinances.

Serious personal injury could occur if you

connect the machine to the power source

before you have completed the set up pro-

cess. DO NOT connect the machine to the

power source until instructed to do so.

Electrocution or fire could

Amperage Draw

The Model H8154 welder draws the following

amps under maximum load:

result if this machine is

not grounded correctly

or if your electrical con-

figuration does not com-

ply with local and state

codes. Ensure compliance

by checking with a quali-

fied electrician!

Draw at 220V, Single Phase...............23.8 Amps

Circuit Requirements

Connect your welder to a dedicated and grounded

circuit that is rated for the amperage given below.

Never replace a circuit breaker on an existing cir-

cuit with one of higher amperage without consult-

ing a qualiﬁed electrician to ensure compliance

with wiring codes. If you are unsure about the

wiring codes in your area or you plan to con-

nect your machine to a shared circuit, consult

a qualified electrician.

Extension Cords

We do not recommend the use of extension cords.

Instead, arrange the placement of your equipment

and the installed wiring to eliminate the need for

extension cords.

If you find it absolutely necessary to use an exten-

sion cord at 220V with your machine:

Minimum 220V Circuit Requirement .....30 Amps

•

Use at least a 10 gauge cord that does not

exceed 50 feet in length.

Plug/Receptacle Type

Recommended Plug/Receptacle....NEMA L6-30

The extension cord must also contain a

ground wire and plug pin.

A qualified electrician MUST size cords over

50 feet long to prevent damage to the weld-

er.

Figure 4. NEMA L6-30 plug and receptacle.

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Workpiece Ground

Grounding for

Welding Safety

The incoming power circuit to the welder and the

working welding circuit are two separate circuits

that must have separate grounds. The weld-

ing circuit consists of the internal components

of the welder, the welding cables, the electrode

holder/torch assembly, the work clamp, and the

workpiece.

There are two or more electrical circuits involved

in any welding operation. The practice of safely

grounding these circuits is documented in vari-

ous codes and standards (refer to Additional

Sources for Welding Codes and Standards on

Page 6).

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."

Welding Machine Ground

When properly connected to a power source, the

Model H8154 welder is grounded through the

power cord and local power grid. The internal

welding circuit of the welder is insulated from the

external enclosure. However, to avoid shocking

hazards if this internal insulation fails, you must

establish a separate earth ground for the welder's

external enclosure. This ground will ensure that

if a short does occur and the metal enclosure

becomes integrated with the welding current, the

current will safely dissipate directly through the

ground instead of through you.

Always ensure that the ground for the incom-

ing power circuit to the welder and the

ground for the working welding circuit are

never connected. Failure to comply with this

warning could result in death, serious per-

sonal injury, or property damage.

You must also avoid "double grounding" the

workpiece. ANSI Z49.1 states that "Care shall be

taken to avoid the flow of welding current through

a connection intended only for safety grounding

since the welding current may be of a higher mag-

nitude than the grounding conductor can safely

carry."

Note: Refer to the publication NFPA 70, National

Electric Code, Article 250, Grounding, and your

local electrical codes for the correct method of

establishing this ground.

The grounding terminal for the H8154 external

enclosure is located on the left rear of the welder

(see Figure 5).

Note: The work lead from the welder is some-

times incorrectly referred to as the "ground lead."

The work lead from the welder is NOT a ground.

The work lead and the ground connection to the

workpiece are separate and must NOT be con-

nected in any way.

TIG welders use a high frequency current

that creates a high electro-magnetic field

(EMF) around the welder. EMF disrupts elec-

tronic devices. To avoid damage, keep elec-

tronic devices at least 50 feet from the

welder when it is powered on. Workers who

have pacemakers must consult with their

physician before using this equipment or

being within 50 feet of welding operations.

Figure 5. Location of external enclosure

grounding terminal on the rear of the Model

H8154.

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SECTION 3: INVENTORY

The Model H8154 was carefully packed when it left our warehouse. If you discover the machine is damaged

or a part is missing after you have signed for delivery, please immediately call Customer Service at (570)

546-9663 for advice.

Save the containers and all packing materials for possible inspection by the carrier or its agent. Otherwise,

filing a freight claim can be difficult.

When you are completely satisfied with the condition of your shipment, inventory the contents.

Figure 6. Model H8154 inventory.

A. Model H8154 AC/DC Stick/TIG Welder

B. Gas Nozzles (#4, #5, and #6)

C. Collets (1.6, 1.8, and 2.0mm)

D. Collet Body

G. Work Clamp and Cable

H. Stick Electrode Clamp and Cable

I. Gas Tubing (Inlet)

J. TIG Torch Assembly, Cable, Gas Tubing,

and Torch Remote Control

E. Small Collet Backcap

F. Long Collet Backcap

K. Foot Remote Control

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SECTION 4: OPERATIONS

A duty cycle is the number of minutes out of 10

Operation Safety

minutes that the welder can safely operate at the

current amperage output without over-heating.

For instance, the Model H8154 has a stick duty

cycle of 35% at 130A output. This means that the

welder can operate continuously for 3.5 minutes

at 130A output, then the arc must be stopped for

at least 6.5 minutes to allow the welder to cool

off before starting the arc again. It is important to

leave the main power to the welder ON so that the

cooling fan can speed the cooling process.

Damage to your eyes and lungs could result

from using this machine without proper

protective gear. Always wear safety glasses,

welder's helmet, and a respirator when oper-

ating this welder.

The Model H8154 operates with an efficient cool-

ing fan (at the rear of the welder) and has an

internal thermostat that will shut the welder down

if the maximum duty cycle has been reached.

Shutdown will be evident by the loss of welding

circuit and the illumination of the yellow warning

light on the face of the welder. When the welder

has cooled sufficiently, the internal thermostat

will re-establish the welding circuit and the yellow

warning light will go out.

NOTICE

If you have never used this type of machine

or equipment before, WE STRONGLY REC-

OMMEND that you read books, trade maga-

zines, or get formal training before begin-

ning any projects. Regardless of the con-

tent in this section, Grizzly Industrial will

not be held liable for accidents caused by

lack of training.

Note: Most electrodes used with stick welding are

consumed within a few minutes, so the welder

has a chance to cool down when the welding cir-

cuit is stopped to install a new electrode.

However, with TIG welding, the operator needs to

plan his work within the duty cycle constraints of

the welder.

Welder Duty Cycle

Always treat the welding components as if

they carry live welding current, even when

the welder reaches the duty cycle limit and

shuts down. When the welder re-establishes

the welding current, the electrode and work

leads will immediately carry live welding cur-

rent. Ignoring this warning could result in

death or serious personal injury.

As the welder produces the desired power output

for the welding operation, some of the power is

converted to heat. In order to protect the welder

components from over-heating, each welder has

an established duty cycle. The duty cycle is vari-

able depending upon the amperage output being

used.

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Welder Controls

NOTICE

After completing the welding operation,

keep the power to the welder ON for a

period of time to let the welder fan cool

the welder down. To avoid damage to your

welder, never shut the power OFF before

the welder enclosure is completely cool to

the touch.

E. Warning Light:

—Not Lit: The welder is ready for use.

—Yellow: When the duty cycle has been

exceeded, the internal thermostat will dis-

able the welding circuit until the fan has

sufficiently cooled the welder.

Figure 7. Model H8154 controls.

—Green: Output current is too high or the

A. Output Current Dial: Adjust this control for

welder has failed.

the correct welding output current.

—Red: Input current is incorrect.

—AC/DC Stick Welding....................5–130A

—AC TIG Welding..........................20–160A

—DC TIG Welding ...........................5–160A

F. Post-Flow Time Dial: This knob will control

the amount of time (0–25 seconds) gas will

flow through the TIG torch after the welding

arc is shut off.

B. Square Wave Percentage: Use this dial to

adjust the deposition and penetration of the

AC TIG arc. The dial is incremented in per-

centage of the positive square wave cycle.

For example, when the dial is set at 60%,

40% of each current cycle is negative and

60% is positive.

G. Welding Current: This LED readout shows

the welding output current in amperes.

H. Stick/TIG Selector: Use this switch to select

stick or TIG welding.

C. Downslope Current Dial: Use this dial to

control the amount of time (0–10 seconds) the

welding current decreases from the selected

output current to OFF.

D. Power Light: This will light when the power

is turned ON.

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I. 2-Step/4-Step Selector (TIG only): Select

either the 2-step or 4-step sequence for TIG

welding.

4. Release the torch thumb switch at any

time to raise the welding current to the

selected output current over the preset

upslope time of 0.2 seconds.

Note: The foot remote control can be sub-

stituted for the torch thumb switch in these

steps.

5. Press the thumb switch again to end the

welding operation.

—2-Step

6. The welding current decreases to the pre-

set finish current, and stays at the level

while the thumb switch is depressed.

1. To start the sequence, press and hold

the torch thumb switch.

7. Release the thumb switch at any time to

2. Gas flows for 0.5 seconds to purge the

shut off the welding current.

torch line of air.

8. The shielding gas continues to flow for

3. The welding current starts with a preset

upslope time of 0.2 seconds from the pre-

set starting current of 15A to the selected

output current

the post-flow time selected.

J. AC/DC Selector: Use this switch to select

AC or DC current output.

4. Release the thumb switch to end the

K. Pre-Flow Time Dial: This knob will control

the amount of time (0–10 seconds) gas will

flow through the TIG torch before the welding

current in turned on.

welding sequence.

5. The welding current decreases from the

selected output current to the preset fin-

ish current over the preset downslope

time, then the welding current shuts off.

6. The shielding gas continues to flow for

the post-flow time selected.

—4-Step

1. To start the sequence, press the torch

thumb switch.

2. The welding current starts at the preset

starting current of 15 amps, and stays at

that level while the torch thumb switch is

depressed.

3. Gas flows for 0.5 seconds to purge the

torch line of air.

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6. Decide which type of weld is correct for your

General Welding

Operations

project and properly prepare the metal.

7. Select the correct settings on the front control

panel for your welding operation.

Becoming a good welder takes a lot of practice

and experience. If you are a novice, read books

and get help from an experienced welder before

beginning a welding operation.

8. Make sure all connections, hoses, gas cylin-

der, and grounds are correct and secure.

Note: Insert the welding cable connectors

into the welder output sockets and twist

clockwise until fully secure. For TIG weld-

ing, connect the additional remote connector

(torch or foot) and gas hose to the appropri-

ate connections.

Practice on scrap metal and expect to spend con-

siderable time learning the many aspects of good

welding.

Although it is beyond the scope of this manual to

instruct how to weld, here are some general steps

for successful welding:

9. Stay aware of the work environment around

you as you weld, and ensure that flying

sparks do not start a fire.

1. Read and understand this manual and ensure

that all safety instructions are followed.

10. Look slightly ahead of the arc. Even with

the protection of the welder's hood, looking

directly at the arc can damage your eyes.

2. Establish a safe and efficient welding envi-

ronment and ensure that you are properly

protected for the welding operation. Ensure

that there is a working fire extinguisher read-

ily available.

11 . Listen to the sound of the weld. Each type

of weld has its own distinct sound when it is

progressing correctly.

3. Have an experienced welder stand by to

12. During at least one hour after the welding

operation is complete, check for smoldering

material or fire.

assist if needed.

4. Select the correct electrode, tungsten rod,

and filler metal type and size for your welding

project.

5. Choose the correct amperage output and be

aware of the duty cycle for this amperage.

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ACCESSORIES

SECTION 5: ACCESSORIES

H7786—Auto Darkening Welding Helmet

H9745—Leather Shoe Covers

H9746—Leather Knee Pads

Automatic UV and IR filters protect eyes from

harmful visible and invisible light during welding.

Switching time is less than or equal to 2 millisec-

onds, so there's no need to flip the helmet up to

see your work under normal light conditions. Full

face protection features adjustable head suspen-

sion and adjustable delay time, sensitivity and

H9748—Leather Jacket Medium (40–42)

H9887—Leather Jacket Large (44–46)

H9888—Leather Jacket X-Large (48–52)

These leather jackets, knee pads, and shoe cov-

ers provide full protection from welding sparks

and spatter. Gloves not included.

dark shade protection. Viewing area is 3¹⁄2" x 1 ⁄2".

Includes 2 AAA batteries.

Figure 8. Model H7786 welding helmet.

Figure 10. Models H9748/H9746/H9745 leather

welding protection.

G7868—Welding Respirators

Flame retardant outer shell is recommended for

welding applications. Special depth filter pro-

vides high loading capacity for metal fumes with-

out increasing breathing resistance. Heavy-duty

adjustable headstrap and soft, closed cell foam

face seal offers maximum comfort, protection and

fit. 5 pack.

H3157—Deluxe Welding Gloves

Top grain, leather gloves protect against welding

hazards. Extra long to protect wrists and fore-

arms. One size fits all.

Figure 9. Model G7868 welding respirators.

Figure 11. Model H3157 deluxe welding gloves.

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Troubleshooting

SECTION 6: SERVICE

Review the troubleshooting and procedures in this section to fix or adjust your machine if a problem devel-

ops. If you need replacement parts or you are unsure of your repair skills, then feel free to call our Technical

Support at (570) 546-9663.

Troubleshooting

Symptom

Possible Cause

Possible Solution

Welder does not 1. Plug/receptacle is at fault or wired incor- 1. Test for good contacts; correct the wiring.

power up or the

breaker trips.

rectly.

2. Wiring is open/has high resistance.

2. Check for broken wires or disconnected/corroded

connections, and repair/replace as necessary.

3. Replace faulty ON/OFF switch.

3. ON/OFF switch is at fault.

4. Duty cycle has been exceeded.

4. Let the fan cool the welder.

Porosity (small cavi- 1. Arc length is too long.

1. Reduce length of arc.

ties or holes caused

from gas pockets

in weld); poor weld

bead color.

2. Workpiece is dirty or damp.

2. Remove all grease, oil, moisture, coatings, rust, and

dirt from workpiece before welding; blow out all air

and moisture from gas lines.

3. Damp electrodes.

3. Use dry electrodes.

4. Inadequate gas flow (TIG).

5. Incorrect electrode/filler metal used.

6. Loose fittings in torch/gas hoses (TIG).

4. Adjust gas flow rate as necessary.

5. Use correct type and size of electrode/filler metal.

6. Tighten torch/gas hose fittings; check gas hoses and

connections for leaks; replace if necessary.

Excessive spatter.

1. Amperage too high for electrode.

2. Voltage too high; arc length too long.

3. Incorrect electrode/tungsten rod used.

4. Incorrect gas or gas settings (TIG).

1. Select large electrode or decrease amperage.

2. Reduce voltage or arc length.

3. Use correct type and size of electrode/tungsten rod.

4. Use the correct gas for the welding operation; adjust

the gas flow as necessary.

Distortion of base 1. Excessive heat applied to base metal.

metal.

1. Make tack welds along joint before starting opera-

tion; select lower amperage for electrode; increase

travel speed; weld in small segments and allow cool-

ing between welds.

Burn through or 1. Excessive heat applied to base metal.

excessive penetra-

tion of base metal.

1. Select lower amperage; use smaller electrode;

increase and/or maintain steady travel speed.

Lack of penetration. 1. Improper joint preparation.

2. Improper weld technique.

1. Material too thick; joint preparation must provide

access to bottom of groove.

2. Keep arc on leading edge of weld puddle; reduce

travel speed.

3. Insufficient heat applied to weld.

4. Incorrect gas or gas settings (TIG).

3. Increase amperage; select larger electrode.

4. Use the correct gas for the welding operation; adjust

the gas flow as necessary.

-15-

H8154 AC/DC Stick/TIG Welder

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Symptom

Possible Cause

Possible Solution

Failure of weld to 1. Insufficient heat applied to weld.

1. Increase amperage; select larger electrode.

2. Widen groove to access bottom during welding;

keep arc on leading edge of weld puddle; place

stringer bead in proper location at joint during weld-

ing.

fuse completely with

base metal or prior

weld bead.

2. Improper welding technique.

3. Workpiece dirty.

3. Remove all grease, oil, moisture, coatings, rust, and

dirt from workpiece before welding.

4. Duty cycle exceeded.

4. Shut down welder and allow it to cool.

Unstable arc.

1. Weld circuit polarity is incorrect.

1. Switch cable polarity at welder.

2. Remove ¹⁄2" of contaminated tungsten rod and prop-

2. Tungsten rod is contaminated (TIG).

erly repoint rod.

3. Arc too long.

3. Shorten arc; lower torch/electrode closer to

workpiece.

4. Workpiece is dirty or damp.

5. Incorrect gas or gas settings (TIG).

4. Remove all grease, oil, moisture, coatings, rust, and

dirt from workpiece before welding.

5. Use the correct gas for the welding operation; adjust

the gas flow as necessary.

Arc wanders.

1. Improper gas flow (TIG).

2. Arc too long.

1. Adjust gas flow as necessary.

2. Shorten arc; lower torch/electrode closer to

workpiece.

3. Contaminated electrode/tungsten rod.

4. Workpiece is dirty or damp.

3. Replace electrode; (TIG) Remove ⁄2" of contami-

nated tungsten rod and properly repoint rod.

4. Remove all grease, oil, moisture, coatings, rust, and

dirt from workpiece before welding.

5. Incorrect gas or gas settings (TIG).

5. Use the correct gas for the welding operation; adjust

the gas flow as necessary.

Arc is difficult to 1. Weld circuit not complete.

1. Check clamps and cables; tighten all connections.

2. Check all gas hoses and connections for leaks and

tighten/replace as necessary; adjust gas flow as

necessary.

start.

2. No or inadequate gas flow (TIG).

3. Incorrect electrode/tungsten rod used.

4. Workpiece is dirty or damp.

3. Use correct type and size of electrode/tungsten rod.

4. Remove all grease, oil, moisture, coatings, rust, and

dirt from workpiece before welding.

5. Incorrect gas or gas settings (TIG).

5. Use the correct gas for the welding operation; adjust

the gas flow as necessary.

-16-

H8154 AC/DC Stick/TIG Welder

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Replacement Parts & Labels

REF PART #

DESCRIPTION

REF PART #

DESCRIPTION

PH8154001

GAS INLET TUBE

COLLET BODY

GAS NOZZLE #4

GAS NOZZLE #5

GAS NOZZLE #6

PH8154010

PH8154011

PH8154012

PH8154013

PH8154014

PLABEL-14

PLABEL-12

PH8154017

PH8154018

COLLET 2MM

PH8154002

PH8154003

PH8154004

PH8154005

PH8154006

PH8154007

PH8154008

PH8154009

TIG TORCH & CABLE ASSEMBLY

WORK CLAMP & CABLE

ELECTRODE CLAMP & CABLE

FOOT REMOTE CONTROL

ELECTRICITY LABEL

LONG COLLET BACKCAP

SMALL COLLET BACKCAP

COLLET 1.6MM

READ MANUAL LABEL

WELDER ID LABEL

COLLET 1.8MM

SHOCK WARNING LABEL

Safety labels warn about machine hazards and ways to prevent injury. The owner of this welder

MUST maintain the original location and readability of the labels on the welder. If any label is

removed or becomes unreadable, REPLACE that label before using the welder again. Contact

Grizzly at (800) 523-4777 or www.grizzly.com to order new labels.

-17-

H8154 AC/DC Stick/TIG Welder

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WARRANTY AND RETURNS

Grizzly Industrial, Inc. warrants every product it sells for a period of 1 year to the original purchaser from

the date of purchase. This warranty does not apply to defects due directly or indirectly to misuse, abuse,

negligence, accidents, repairs or alterations or lack of maintenance. This is Grizzly’s sole written warranty

and any and all warranties that may be implied by law, including any merchantability or fitness, for any par-

ticular purpose, are hereby limited to the duration of this written warranty. We do not warrant or represent

that the merchandise complies with the provisions of any law or acts unless the manufacturer so warrants.

In no event shall Grizzly’s liability under this warranty exceed the purchase price paid for the product and

any legal actions brought against Grizzly shall be tried in the State of Washington, County of Whatcom.

We shall in no event be liable for death, injuries to persons or property or for incidental, contingent, special,

or consequential damages arising from the use of our products.

To take advantage of this warranty, contact us by mail or phone and give us all the details. We will then

issue you a “Return Number,’’ which must be clearly posted on the outside as well as the inside of the

carton. We will not accept any item back without this number. Proof of purchase must accompany the

merchandise.

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.

Please feel free to write or call us if you have any questions about the machine or the manual.

Thank you again for your business and continued support. We hope to serve you again soon.

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