Klutch MIG 180SG User manual

SAVE THESE INSTRUCTIONS
MIG 180SG Spoolgun Welder with Cart
Owner’s Manual
WARNING: Read carefully and understand all ASSEMBLY AND OPERATION
INSTRUCTIONS before operating. Failure to follow the safety rules and other basic safety
precautions may result in serious personal injury.
Item #55729

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Thank you very much for choosing a Klutch® product!
For future reference, please complete the owner’s record below:
Serial Number/Lot Date Code: ________________________________
Purchase Date: ____________________________________________
Save the receipt, warranty, and this manual. It is important that you read
the entire manual to become familiar with this product before you begin
using it.
This welder is designed for certain applications only. Northern Tool &
Equipment is not responsible for issues arising from modification or
improper use of this product such as an application for which it was not
designed. We strongly recommend that this product not be modified
and/or used for any application other than that for which it was designed.
For technical questions, please call 1-800-222-5381.

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Table of Contents
Intended Use..........................................................................................................................................4
Important Safety Information...............................................................................................................5
General Safety Rules............................................................................................................................6
Specifications of Welder ....................................................................................................................10
Main Parts of Welder...........................................................................................................................11
Setting Up Equipment.........................................................................................................................12
Operating Instructions........................................................................................................................18
Maintenance ........................................................................................................................................24
Troubleshooting..................................................................................................................................25
Parts Diagram Welder.........................................................................................................................27
Parts List Welder.................................................................................................................................28
Parts Diagram Spoolgun ....................................................................................................................29
Parts List Spoolgun ............................................................................................................................29
Parts Diagram of Cart .........................................................................................................................30
Parts List of Cart .................................................................................................................................31
Replacement Parts..............................................................................................................................31
Limited Warranty.................................................................................................................................32

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Intended Use
The Klutch MIG180SG is an inverter-powered, 230V welder with spool gun designed for MIG
welding aluminum and other MIG and flux cored wires. The wire feed system is the spoolgun and
can accommodate a variety of welding wires that are available on 4 inch spools. It comes complete
with a regulator and gas hose for easy connection for MIG welding. Connect this unit to a 230V
NEMA 6-50R receptacle for input power. It is designed to weld materials as thin as 24 gauge all the
way up to 1/4" in a single pass.
Welding with flux core wire gives the operator the flexibility to use this wire feed welder for mobile
applications, including outdoor applications. Flux core wire does not require the use of a separate
shielding gas which can be blown away by the wind in other applications. Since flux core welding
does not use shielding gas, the operator will not have to have shielding gas bottles, or use the
regulator and gas hose.
Welding with an MIG wire does require the use a bottle of shielding gas. See the Setting-Up
Equipment section for recommendations on shielding gas based on the material you are welding.
MIG welding is limited to indoor applications or applications where the influence of wind can be
controlled to prevent shielding gas from blowing away. MIG welding allows you to weld thinner
materials without burn-through. It also creates a much cleaner weld with less spatter and no slag.
The result is little post-weld cleaning of the weld joint.
This unit is intended to be used on a 50 amp 230V AC circuit without the use of an extension cord.
If an extension cord is necessary for your application, use the appropriate size and length of
extension cord that will handle 50 amps the entire length of the extension. We highly recommend
talking with a qualified electrician for cord size recommendations.
High frequency, inverter-based welding is more efficient and provides better control than non-
inverter welding machines.
Accessories Included:
(1) Welding cart
(1) 10.5 ft. Spoolgun
(1) 6.5 ft. Ground cable/clamp
(1) Dual gauge regulator
(1) 10 ft. Gas hose
(2) 0.030 in. Contact tips

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Important Safety Information
⚠WARNING
Read and understand all instructions. Failure to follow all instructions may result in serious injury
or property damage.
The warnings, cautions, and instructions in this manual cannot cover all possible conditions or
situations that could occur. Exercise common sense and caution when using this tool. Always be
aware of the environment and ensure that the tool is used in a safe and responsible manner.
Do not allow persons to operate or assemble the product until they have read this manual and
have developed a thorough understanding of how it works.
Do not modify this product in any way. Unauthorized modification may impair the function and/or
safety and could affect the life of the product. There are specific applications for which the product
was designed.
Use the right tool for the job. DO NOT attempt to force small equipment to do the work of larger
industrial equipment. There are certain applications for which this equipment was designed. It will
be a safer experience and do the job better at the capacity for which it was intended. DO NOT use
this equipment for a purpose for which it was not intended.
Industrial or commercial applications must follow OSHA requirements.
⚠WARNING
WORK AREA SAFETY
Inspect the work area before each use. Keep work area clean, dry, free of clutter, and well-lit.
Cluttered, wet, or dark work areas can result in injury. Using the product in confined work areas
may put you dangerously close to other cutting tools and rotating parts.
Do not use the welder where there is a risk of causing a fire or an explosion; e.g., in the presence
of flammable liquids, gases, or dust. The product can create sparks, which may ignite the
flammable liquids, gases, or dust.
Do not allow the product to come into contact with an electrical source. The tool is not insulated
and contact will cause electrical shock.
Keep children and bystanders away from the work area while operating the welder. Do not allow
children to handle the welder.
⚠WARNING
PERSONAL SAFETY
Stay alert, watch what you are doing, and use common sense when operating the tool. Do not use
the tool while you are tired or under the influence of drugs, alcohol, or medication. A moment of
inattention while operating the tool may result in serious personal injury.
Dress properly. Do not wear loose clothing, dangling objects, or jewelry. Keep your hair, clothing
and gloves away from moving parts. Loose clothes, jewelry, or long hair can be caught in moving

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parts. Air vents on the tool often cover moving parts and should be avoided.
Wear the proper personal protective equipment when necessary. Use ANSI Z87.1 compliant safety
goggles (not safety glasses) with side shields, or when needed, a face shield. Use a dust mask in
dusty work conditions. Also use non-skid safety shoes, hardhat, gloves, dust collection systems,
and hearing protection when appropriate. This applies to all persons in the work area.
Do not overreach. Keep proper footing and balance at all times.
⚠CAUTION
WELDER USE AND CARE
Do not force the welder. Products are safer and do a better job when used in the manner for which
they are designed. Plan your work, and use the correct product for the job.
Check for damaged parts before each use. Carefully check that the product will operate properly
and perform its intended function. Replace damaged or worn parts immediately. Never operate the
product with a damaged part.
Store the product when it is not in use. Store it in a dry, secure place out of the reach of children.
Inspect the tool for good working condition prior to storage and before re-use.
Use only accessories that are recommended by the manufacturer for use with your product.
Accessories that may be suitable for one product may create a risk of injury when used with
another tool. Never use an accessory that has a lower operating speed or operating pressure than
the tool itself.
Keep guards in place and in working order. Never operate the product without the guards in place.
General Safety Rules
⚠WARNING
Read and understand all instructions. Failure to follow all instructions listed below may result in
serious injury.
⚠CAUTION
Do not allow persons to operate or assemble this product until they have read this manual and
have developed a thorough understanding of how the unit works.
⚠WARNING
The warnings, cautions, and instructions discussed in this instruction manual cannot
cover all possible conditions or situations that could occur. It must be understood by the
operator that common sense and caution are factors which cannot be built into this product, but
must be supplied by the operator.

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⚠WARNING
Your Welding Environment
Keep the environment you will be welding in free from flammable materials.
Always keep a fire extinguisher accessible to your welding environment.
Always have a qualified person install and operate this equipment.
Make sure the area is clean, dry, and ventilated. Do not operate the welder in humid, wet, or
poorly ventilated areas.
Always have your welder maintained by a qualified technician in accordance with local, state,
and national codes.
Always be aware of your work environment. Be sure to keep other people, especially children,
away from you while welding.
Keep harmful arc rays shielded from the view of others.
Mount the welder on a secure bench or cart that will keep the welder secure and prevent it
from tipping over or falling.
⚠WARNING
Your Welder’s Condition
Check ground cables, power cords, and welding cables to be sure the insulation is not
damaged. Always replace or repair damaged components before using the welder.
Check all components to ensure they are clean and in good operating condition before use.
⚠CAUTION
Welder Use and Care
Do not operate the welder if the output cable, electrode, torch, wire, or wire feed system is wet.
Do not immerse them in water. These components and the welder must be completely dry before
attempting to use them.
Follow the instructions in this manual.
Keep the welder in the OFF position when not in use.
Connect the ground lead as close to the area being welded as possible to ensure a good
ground.
If you are in contact with the material being welded, ground, or electrode from another welder,
do not allow any body part to come in contact with the welding wire.
Do not weld if you are in an awkward position. Always have a secure stance while welding to
prevent accidents. Wear a safety harness if working above ground.
Do not drape cables over or around your body.
Wear a full coverage helmet with appropriate shade (see ANSI Z87.1 safety standard) and
safety glasses while welding.
Wear proper gloves and protective clothing to prevent your skin from being exposed to hot
metals, UV, and IR rays.
Do not overuse or overheat your welder. Allow proper cooling time between duty cycles.
Keep hands and fingers away from moving parts and stay away from the drive rolls.
Do not point the torch at a body part of yours or anyone else’s.
Always use this welder in the rated duty cycle to prevent excessive heat and failure.

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⚠WARNING
Electrical Shock
Electric arc welders can produce a shock that can cause injury or death. Touching electrically live
parts can cause fatal shocks and severe burns. While welding, all metal components connected to the
wire are electrically hot. Poor ground connections are a hazard, so secure the ground lead before
welding.
Wear dry protective apparel: coat, shirt, gloves, and insulated footwear.
Insulate yourself from the work piece. Avoid contacting the work piece or ground.
Do not attempt to repair or maintain the welder while the power is ON.
Inspect all cables and cords for any exposed wire and replace immediately if found.
Use only recommended replacement cables and cords.
Always attach the ground clamp to the work piece or work table as close to the weld area as
possible.
Do not touch the welding wire and the ground or grounded work piece at the same time.
Do not use a welder to thaw frozen pipes.
⚠WARNING
Fumes and Gases
Do not use plasma cutter in the presence of gasoline, diesel, propane, or other flammable
liquids. Sparks created from the cutter may ignite liquids or fumes, causing an explosion and
serious injury or death.
Fumes emitted from the welding process displace clean air and can result in injury or death.
Do not breathe in fumes emitted by the welding process. Make sure your breathing air is clean
and safe.
Work only in a well-ventilated area or use a ventilation device to remove welding fumes from
the environment where you will be working.
Do not weld on coated materials (galvanized, cadmium plated or containing zinc, mercury, or
barium). They will emit harmful fumes that are dangerous to breathe. If necessary use a
ventilator, respirator with air supply, or remove the coating from the material in the weld area.
The fumes emitted from some metals when heated are extremely toxic. Refer to the material
safety data sheet for the manufacturer’s instructions.
Do not weld near materials that will emit toxic fumes when heated. Vapors from cleaners,
sprays, and degreasers can be highly toxic when heated.
⚠WARNING
UV and IR Arc Rays
The welding arc produces ultraviolet (UV) and infrared (IR) rays that can cause injury to your
eyes and skin. Do not look at the welding arc without proper eye protection.
Always use a helmet that covers your face fully from the neck to the top of your head and to
the back of each ear.
Use a lens that meets ANSI standards and safety glasses. For welders under 160 Amps
output, use a shade 10 lens; for above 160 Amps, use a shade 12. Refer to the ANSI standard
Z87.1 for more information.
Cover all skin areas exposed to the arc with protective clothing and shoes. Flame-retardant
cloth or leather shirts, coats, pants, or coveralls are available for protection.
Use screens or other barriers to protect other people from the arc rays emitted from your
welding.

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Warn people in your welding area when you are going to strike an arc so they can protect
themselves.
⚠WARNING
Fire Hazards
Do not weld on containers or pipes that contain or have had flammable, gaseous, or liquid
combustibles in them. Welding creates sparks and heat that can ignite flammable and
explosive materials.
Do not operate any electric arc welder in areas where flammable or explosive materials are
present.
Remove all flammable materials within 35 feet of the welding arc. If removal is not possible,
tightly cover them with fireproof covers.
Take precautions to ensure that flying sparks do not cause fires or explosions in hidden areas,
cracks, or areas you cannot see.
Keep a fire extinguisher close in the case of fire.
Wear garments that are oil-free without pockets or cuffs that will collect sparks.
Do not have on your person any items that are combustible, like lighters or matches.
Keep the work lead connected as close to the weld area as possible to prevent any unknown,
unintended paths of electrical current from causing electrical shock and fire hazards.
To prevent any unintended arcs, cut the wire back to ¼" stick out after welding.
⚠CAUTION
Hot Materials - Welded materials are hot and can cause severe burns if handled improperly.
Do not touch welded materials with bare hands.
Do not touch the torch nozzle after welding until it has had time to cool down.
⚠CAUTION
Electromagnetic Field
Electromagnetic fields can interfere with various electrical and electronic devices such as
pacemakers.
Consult your doctor before using any electric arc welder or cutting device
Keep people with pacemakers away from your welding area when welding.
Do not wrap cables around your body while welding.
Wrap the MIG gun and ground cables together whenever possible.
Keep the MIG gun and ground cables on the same side of your body.
⚠WARNING
Shielding Gas Cylinders Can Explode
High pressure cylinders can explode if damaged, so treat them carefully.

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Never expose cylinders to high heat, sparks, open flames, mechanical shocks, or arcs.
Do not touch the cylinder with the MIG gun.
Do not weld on the cylinder
Always secure the cylinder upright to a cart or stationary object.
Keep cylinders away from welding or electrical circuits.
Use the proper regulators, gas hose, and fittings for the specific application.
Do not look into the valve when opening it.
Use a protective cylinder cap whenever possible.
⚠CAUTION
Proper Care, Maintenance, and Repair
Always have power disconnected when working on internal components.
Do not touch or handle the PC board without being properly grounded with a wrist strap. Place
the PC board in a static-proof bag to move or ship.
Do not put hands or fingers near moving parts, like the drive rolls of a fan.
Specifications of Welder
Item
Specification
Power Supply
230V, 28.5A, 50/60 Hz, Single Phase
No-Load Voltage
54V DC
Output Range
30 to 160A DC
Duty Cycle
30% @ 160A
Suggested Wire
.030 - .035 wire, steel, stainless steel, and aluminum
Dimensions
28-3/4” x 13” x 19-7/8”
Weight
35-1/4 lb.

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Main Parts of Welder
Figure 1.
2
3
4
5
3
11
9
2
6
FOR PROOF
ONLY
12
10
7
1
8
4
5

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Reference
Subassembly
1
Spool Gun
2
Positive (+) Weld Output Connection
3
Output Voltage Control
4
Power On Indicator Light
5
Alarm Indicator Light
6
Securement Strap
7
MIG Cart
8
Wire Feed Speed Control
9
Negative (-) Weld Output Connection
10
Inert Gas Regulator and Gas Hose
11
Ground Cable and Clamp
12
Contact Tips
Setting Up Equipment
⚠WARNING
ELECTRIC SHOCK CAN KILL!
High voltage danger from power source! Consult a qualified electrician for proper installation
of receptacle. This welder must be grounded while in use to protect the operator from
electrical shock.
Do not remove grounding prong or alter the plug in any way. Use only the supplied adapter
between the welder's power cord and the power source receptacle. Make sure the POWER
switch is OFF when connecting your welder's power cord directly to a properly grounded 230
VAC, 60 HZ, Single Phase, 50 Amp input power supply.
1. POWER REQUIREMENT 230V - AC single phase 230V (200-240V) 50/60 HZ fused with a 50
amp time delayed fuse or circuit breaker is required. DO NOT OPERATE THIS UNIT if the
ACTUAL power source voltage is less than 215 volts AC or greater than 240 volts AC.
2. EXTENSION CORD - We do not recommend extension cords because of the voltage drop
they produce. This drop in voltage can affect the performance of the welder. If you need to
use an extension cord, check with a qualified electrician and your local electrical codes for
your specific area.
3. INSTALLING SPOOL GUN - The Quick Draw Spool Gun has three connection points at the
back of the spool gun. See Figure 2. (1) The gas connection is a slide on quick connector. (2)
The weld power connection has a twist lock connector. (3) The trigger connection is the 5-Pin
snap on connector.

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Figure 2.
Figure 3.
4. CONNECT THE SPOOL GUN
a. Connect the Gas Connector on the Spool Gun to the Gas Connection Receptacle on
the lower front panel of the welding unit. See Figure 3.
1
3
2
Gas Connection
Receptacle
Positive (+)
Weld Receptacle
Negative (-)
Weld Receptacle
Trigger Control
Receptacle

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b. Connect the weld cable twist lock connector on the Spool Gun to the positive (+)
Weld Receptacle on the lower front panel of the welding unit. See Figure 3.
NOTE: When welding with flux cored wire on steel, the weld cable twist lock connector on the
spool gun should be connected to the negative (-) Weld Receptacle on the lower front panel
of the welding unit to run DCEN (DC Electrode Negative).
c. Connect the 5-Pin Trigger Connection on the Spool Gun to the Trigger Control
Receptacle on the lower front panel of the welding unit. See Figure 3.
d. Connect the weld cable twist lock connector on the Ground Cable and Clamp to the
negative (-) Weld Receptacle on the lower front panel of the welding unit. See Figure
3.
NOTE: When welding with flux cored wire on steel, the weld cable twist lock connector on the
Ground Cable and Clamp should be connected to the positive (+) Weld Receptacle on the
lower front panel of the welding unit to run DCEN (DC Electrode Negative).
5. DRIVE ROLL INSTALLATION - Before installing any welding wire into the unit, the groove must
be placed into position on the wire drive mechanism. Adjust the drive roller according to the
following steps. See the following picture regarding the wire feeder structure:
1. Drive Roll
2. Drive Roll Pressure Arm
3. Wire Inlet Guide Tube
4. Pressure Roll
5. L shaped Hex wrench
Figure 4.
a. Open the spool cover to the spool gun drive compartment.
b. Remove the drive roller.
c. Use an “L” shaped hex wrench in the accessory package. Insert the tool into the set
screw in the drive roller and turn counter-clockwise to loosen the set screw and
remove the drive roller from the drive roller shaft.
d. The drive roller has two grooves in it. The grooves are the same size and the drive
roll can be reversed if the groove wears. Push the drive roll onto the drive roller shaft,
align the groove with the wire, and use the “L” shaped hex wrench to tighten the drive
roller to the shaft. To tighten, turn set screw clockwise.
e. Close the spool cover.

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⚠WARNING
ELECTRIC SHOCK CAN KILL!
High voltage danger from power source! Consult a qualified electrician for proper installation
of receptacle. This welder must be grounded while in use to protect the operator from
electrical shock.
Do not remove grounding prong or alter the plug in any way. Use only the supplied adapter
between the welder's power cord and the power source receptacle. Make sure the POWER
switch is OFF when connecting your welder's power cord directly to a properly grounded 230
VAC, 60 HZ, Single Phase, 50 Amp input power supply.
6. INSTALLING WIRE
a. The MIG wire can be mild steel, stainless steel, or aluminum solid wire. Flux core wire
may also be used for mild steel for use with 4” spools of wire.
NOTE: Metal thinner than 22 gauge should not be welded with this spool gun. Attempting to
do so will cause burn-through in the metal you are intending to weld. Remove any wire that is
rusty. If the whole spool is rusty, discard it.
b. Install the wire
NOTE: Before installing, make sure that you have removed any wire from the spool gun
assembly. This will help to prevent the possibility of the wire jamming inside the spool gun
liner. Be careful when removing the welding nozzle. The contact tip on this welder is
electrically live when the torch trigger is pulled. Make certain POWER is turned OFF.
c. Remove the nozzle and contact tip from the end of the spool gun assembly.
d. Remove any wrapping from the outside of the spool of wire. DO NOT UNHOOK THE
WIRE AT THIS TIME.
e. Remove the Spool Securement Screw by turning it clockwise.
f. Place the spool on the spool hub so that the wire comes off the top of the spool. The
welding wire should always come off the top of the spool into the drive mechanism.
g. This spool gun can use 4 inch spools. The thumb screw on the center post is
designed to adjust the pressure tension on the spool. Turn it clockwise to increase the
spool tension.
h. Turn the spool while tightening the tension adjustment until the spool slows down and
operator feels a slight drag. The operator may need to repeat these steps until proper
spool tension is achieved.
NOTE: If TOO MUCH tension is applied to the wire spool, the wire will slip on the drive roller
or will not be able to feed at all. If TOO LITTLE tension is applied, the spool of wire will try to
unspool itself when the gun trigger is released. Readjust the spool hub tension as necessary
to correct for either problem.
i. After checking to make sure that your welder is disconnected from the AC power
source, remove the leading end of the wire from the spool. DO NOT LET GO OF THE
WIRE until instructed to do so, or the wire will unspool itself.
j. Using a wire cutter, cut the bent end off the leading end of the wire so that only a
straight leading end remains.
k. Squeeze the tension arm toward the front of the gun to open up a gap between the
drive roll and the pressure roll.
l. Insert the leading end of the wire into the inlet guide tube, then push it across the
drive roller and into the liner (about 2 inches).

Page 16 of 33
⚠CAUTION
CHECK WIRE PATH
Make certain that the welding wire is actually going into the torch liner. If not, the wire can jam
or keep the wire from feeding correctly.
m. Check to see if the wire is in the drive roller groove, then release the tension arm into
place on the drive roller.
n. Tighten (turn clockwise) the pressure arm adjustment knob (if needed) until the
tension roller is applying enough force on the wire to prevent it from slipping out of the
drive assembly. DO NOT OVERTIGHTEN. See Figure 5.
Figure 5.
o. NOW YOU CAN RELEASE THE WIRE.
p. Plug in the welder and turn the power switch to the ON position. Set the VOLTAGE
and wire speed on the front of the welder.
NOTE: Due to wire swelling that may occur when aluminum wire gets hot, it may be
necessary to use a contact tip one size larger than your wire if wire jams occur.
q. Slide the contact tip over the wire (protruding from the end of the torch). Thread the
contact tip into the end of the torch and hand-tighten securely with a pliers
r. Install the nozzle on the gun assembly.
s. Cut off the excess wire that extends past the end of the nozzle. Leave ¼” sticking out.
7. GAS INSTALLATION
⚠WARNING
Shielding gas cylinders and high pressure cylinders can explode if damaged, so treat them
carefully.
Never expose cylinders to high heat, sparks, open flames, mechanical shocks, or arcs.
Do not weld on the cylinder.

Page 17 of 33
Always secure the cylinder upright to a cart or stationary object.
Keep cylinders away from welding or electrical circuits.
Use the proper regulators, gas hose, and fittings for the specific application.
a. Polarity Changing - When MIG wire is used, shielding gas is required and the polarity
on this unit needs to be electrode positive.
i. Electrode Positive for MIG Welding - The Weld Power Cable should be
connected to the positive (+) weld output connection on the front of the
machine. The ground cable would then be connected to the negative (-) weld
output connection.
ii. Electrode Negative for Flux Core Welding - The Weld Power Cable should be
connected to the negative (-) weld output connection on the front of the
machine. The ground cable will then be connected to the positive (+) weld
output connection. Refer to the polarity Setting Label inside the wire
compartment.
iii. Connect one end of the gas hose to the gas hose connection on the back of
the welder. Use a wrench to snug up the connection.
Reference
Subassembly
1
Gas Bottle Valve
2
Gas Flow Gauge (Set at 20 CFM)
3
Gas Pressure Gauge
4
Regulator
5
Gas Flow Adjuster
6
Gas Hose
7
Gas Cylinder
iv. Connect the other end of the gas hose to the gas hose connection on the
supplied regulator/flow gauge. Use a wrench to snug up the connection.
v. Before installing the regulator, it is good practice to make certain there isn’t
any debris is in the gas bottle connection. Rotate the bottle so the gas
connection is not pointing toward you or anyone else. Turn the valve on the
gas bottle clockwise and quickly close it. This quick thrust of gas will clear
7
3
2
1

Page 18 of 33
any debris in the connection. Connect the regulator to the gas bottle
connection. Use a wrench to snug up the connection.
vi. Open the Gas Bottle Valve on the cylinder of gas.
vii. Turn the Gas Flow Adjuster on the regulator so that the gas flow rate is set at
approximately 20 CFM. Make certain you are reading the correct scale on the
gauge.
NOTE: Slowly open the cylinder valve by turning it counterclockwise until the cylinder
pressure gauge registers on the first gauge of the regulator. Turn the adjustment knob
clockwise (right) slowly to increase gas flow to 20 CFM. To reduce the gas flow, turn the
adjustment counter-clockwise (left). The gas valve is located on the back panel of the welder
and activated by the trigger. Gas flow should be heard when the trigger is activated. No gas
flow will result in a harsh arc with excessive spatter; a smooth weld bead will be difficult to
obtain. Avoid unnecessary gas loss by closing the tank valve when finished welding.
viii. Gas selection
Different materials require different shielding gas when MIG welding. Refer to
the set up chart inside the wire feed compartment.
Mild steel: Use 75% Argon and 25% CO2 for reduced spatter and
reduced penetration for thinner materials. Do NOT USE Argon gas
concentrations higher than 75% on steel. The result will be extremely
poor penetration, porosity, and brittleness of weld.
Mild steel: Use CO2 for deeper penetration but increased spatter. (A
CO2 regulator adapter will be needed.)
Stainless steel: Use a mixed gas consisting of Helium, Argon, and CO2.
Aluminum or bronze: Use 100% Argon.
Operating Instructions
⚠WARNING
High voltage danger from power source!
Consult a qualified electrician for proper installation of receptacle at the power source. This
welder must be grounded while in use to protect the operator from electrical shock. If you are
not sure if your outlet is properly grounded, have it checked by a qualified electrician. Do not
cut off the grounding prong or alter the plug in any way and do not use any adapter, other than
the supplied adapter, between the welder's power cord and the power source receptacle.
Make sure the POWER switch is OFF then connect your welder's power cord to a properly
grounded 230 VAC (220V - 240V), 60 HZ, single phase, 50 amp power source.
MIG OPERATION
1. POWER SWITCH - The power switch supplies electrical current to the welder. Whenever the
power switch is in the ON position, the welding circuit is activated. ALWAYS turn the power
switch to the OFF position and unplug the welder before performing any maintenance.
2. VOLTAGE CONTROL – Adjust the voltage control to adjust the welding voltage/heat. This unit
has an infinite voltage control. Refer to the Setting Label (inside the wire compartment) for
recommended voltage selector settings for your welding job.
3. WIRE SPEED CONTROL - The wire speed control adjusts the speed at which the wire is fed
out of the welding torch. The wire speed needs to be closely matched (tuned-in) to the rate at
which it is being melted off. Some things that affect wire speed selection are the type and
diameter of the wire being used, the heat setting selected, and the welding position to be
used. Refer to the Setting Label for recommended wire speed settings for your welding job.

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NOTE: The wire will feed faster without an arc. When an arc is being drawn, the wire speed
will slow down.
4. HOLDING THE TORCH - The best way to hold the welding torch is the way it feels most
comfortable to you. While practicing using your welder, experiment with holding the torch in
different positions until you find the one that seems to work best for you.
5. POSITIONING THE TORCH TO THE WORK PIECE - There are two angles of the torch
nozzle in relation to the work piece that must be considered when welding:
a. Angle A can be varied but in most cases the optimum angle will be 60 degrees, the
point at which the torch angle is parallel to the work piece. If angle A is increased,
penetration will increase. If angle A is decreased, penetration will decrease also.
b. Angle B can be varied for two reasons: to improve the availability to see the arc in
relation to the weld puddle and to direct the force of the arc. See the following
illustration.
c. DISTANCE FROM THE WORK PIECE - If the nozzle is held off the work piece, the
distance between the nozzle and the work piece should be kept constant and should
not exceed 1/4 inch or the arc may begin sputtering, signaling a loss in welding
performance.
d. TUNING IN THE WIRE SPEED - This is one of the most important parts of wire
welder operation and must be done before starting each welding job or whenever the
voltage setting or wire diameter is changed.
⚠WARNING
EXPOSURE TO A WELDING ARC IS EXTREMELY HARMFUL TO THE EYES AND SKIN!
Prolonged exposure to the welding arc can cause blindness and burns. Never strike an arc or
begin welding until you are adequately protected. Wear flame-proof welding gloves, a heavy
long sleeved shirt, trousers without cuffs, high topped shoes, and an ANSI approved welding
helmet.
e. Connect the Ground Clamp to a scrap piece of the same type of material which you
will be welding. It should be equal to or greater than the thickness of the actual work
piece, and free of oil, paint, rust, etc.
f. Select a heat setting.
g. Hold the torch in one hand. Hold the wire just off the work piece. (See the HOLDING
THE TORCH section on the previous page if you are uncertain of the angle at which
you will be welding.)
h. Set the wire feed speed based on the thickness of material and the set-up chart on
the back side of the wire feeder door.
i. Lower your welding helmet and pull the trigger on the torch and let the wire feed into
the work piece to start an arc, then begin to drag the torch toward you.
j. LISTEN! If the arc is sputtering, increase the wire speed slightly and try again.
Continue increasing the wire speed until you achieve a smooth buzzing sound. If the
wire seems to "pound" into the work piece, decrease the wire speed slightly and try
again. Use the wire speed control to slightly increase or decrease the heat and
penetration for a given voltage setting by increasing or decreasing the wire speed
slightly. Repeat this tune-in procedure if you select a new voltage setting, a different
wire diameter, or a different roll of wire.

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6. WELDING TECHNIQUES
⚠WARNING
EXPOSURE TO A WELDING ARC IS EXTREMELY HARMFUL TO THE EYES AND SKIN!
Prolonged exposure to the welding arc can cause blindness and burns. Never strike an arc or
begin welding until you are adequately protected. Wear flame-proof welding gloves, a heavy
long sleeved shirt, trousers without cuffs, high topped shoes, and an ANSI approved welding
helmet.
⚠WARNING
ELECTRIC SHOCK CAN KILL!
To prevent ELECTRIC SHOCK, do not perform any welding while standing, kneeling, or lying
directly on the grounded workpiece.
a. Moving the torch - Torch travel refers to the movement of the torch along the weld
joint and is broken into two elements: Direction and Speed. A solid weld bead
requires that the welding torch be moved steadily and at the right speed along the
weld joint. Moving the torch too fast, too slow, or erratically will prevent proper fusion
or create a lumpy, uneven bead.
Travel direction is the direction the torch is moving along the weld joint in relation to
the weld puddle. The torch is either PUSHED into the weld puddle or PULLED away
from the weld puddle.
For most welding jobs you will pull the torch along the weld joint to take advantage of
the greater weld puddle visibility.
IMPORTANT: When MIG welding aluminum materials, a PUSH technique is
required to provide proper gas coverage and weld penetration.
Travel speed is the rate at which the torch is being pushed or pulled along the weld
joint. For a fixed heat setting, the faster the travel speed, the lower the penetration
and the lower and narrower the finished weld bead. Likewise, the slower the travel
speed, the deeper the penetration and the higher and wider the finished weld bead.
b. Types of welding beads - As you become more familiar with the welder and better at
laying some simple weld beads, you can begin to try different weld bead types.
The STRINGER BEAD is formed by traveling with the torch in a straight line while