Sears MIG Wire Feed Welder User manual

S£ S
CRRFTSMRN°
MIG Wire Feed Welder
WELDING INSTRUCTION GUIDE
•INTRODUCTION
. SAFETY
•PREPARE TO WELD
•KNOW YOUR WELDER
•ESPANOL
CAUTION:
Read and follow all Safety Rules
and Operating Instructions before
First Use of this Product.
Sears, Roebuck and Co., Hoffman Estates, IL 60179 USA
811-600-000 (June 1998)

TABLE OF CONTENTS .... 2
INTRODUCTION ................ 3
SAFETY SUMMARY .......... 4
SAFETY INFORMATION .......... 4
SHOCK HAZARDS .............. 5
FLASH HAZARDS ................ 6
FIRE HAZARDS ................... 6
FUME HAZARDS ................. 7
COMPRESSED GASSES
AND EQUIPMENT
HAZARDS ........................ 8
ADDITIONAL SAFETY
INFORMATION ................. 9
PREPARING TO WELD ... 10
WIRE FEED WELDING
VARIABLES ....................... 10
SELECT THE WIRE ........... 10
Solid Steel Wire
Selection ..................... 10
Self-Shielding Flux-Core
Steel Wire .................. 10
Aluminum Wire Selection10
Stainless Steel Wire
Selection .................... 12
Silicon Bronze Wire
Selection .................... 12
SELECTING THE WIRE
SPOOL SIZE .................. 12
SELECTING THE WIRE
DIAMETER ..................... 13
SELECTING SHIELDING
GAS ................................ 13
Gas Selection For Steel
Welding With Steel
Wire ............................ 13
Gas Selection For
Aluminum Gas
Welding ...................... 14
Gas Selection For
Stainless Steel
Welding ...................... 14
Gas Selection For Steel
Welding With Silicon
Bronze Wire ............... 14
SELECT WELDING
CURRENT POLARITY ... 14
PREPARING THE WORK
AREA .................................. 14
SETTING UP THE WORK
PIECE ................................. 15
PREPARING THE JOINT ... 15
WORKPIECE CLAMP
CONNECTION ............... 17
Tuning In the Wire
Speed ......................... 17
GET TO KNOW YOUR
WELDER ....................... 19
LEARNING TO WELD ............ 19
HOLDING THE GUN .......... 19
Position the Gun to the
Work Piece ................. 19
Distance from the Work
Piece .......................... 20
LAYING A BEAD .................... 20
WELDING TECHNIQUES ...... 20
MOVING THE GUN ............ 20
TYPES OF WELD BEADS .21
WELDING POSITIONS ...... 22
MULTIPLE PASS
WELDING ........................ 23
SPECIAL WELDING
METHODS .......................... 24
SPOT WELDING ................ 24
SPOT WELDING
INSTRUCTIONS ............. 25

This Welding Instruction Guide provides
basic information about wire feed
welding. It is to be used together with
the User's Guide to provide all of the
information needed to safely and
effectively use your wire feed welder.
The information in this book applies to
almost all wire feed welders and gives
the methods and techniques needed to
make satisfactory welds and do it safely.
Where information is shown that does
not necessarily apply to all models or
brands of welders, it will be marked as
either optional on some welder models,
or does not apply to all models.

Every craftsman respects the tools with
which they work. They know that the
tools represent years of constantly
improved designs and developments.
The true craftsman also knows that tools
are dangerous if misused or abused.
Reading this operator's manual before
using the welder will enable you to do a
better, safer job. Learn the welder's
applications and limitations as well as
the specific potential hazards peculiar to
welding.
SAFETY INFORMATION
The following safety information is
provided as guidelines to help you
operate your new welder under the
safest possible conditions.Any
equipment that uses electrical power can
be potentially dangerous to use when
safety or safe handling instructions are
not known or not followed. The following
safety information isprovided to give the
user the information necessary for safe
use and operation.
When a procedure step is preceded by a
WARNING, it is an indication that the
step contains a procedure that might be
injurious to a person if proper safety
precautions are not heeded.
When a procedure step is preceded by a
CAUTION, it is an indication that the
step contains a procedure that might
damage the equipment being used.
ANOTE may be used before or after a
procedure step to highlight or explain
something in that step.
READ ALL SAFETY INSTRUCTIONS
CAREFULLY before attempting to
install, operate, or service this welder.
Failure to comply with these instructions
could result In personal injury and/or
property damage.
RETAIN THESE INSTRUCTIONS FOR
FUTURE REFERENCE.
NOTE:
The following safety alert symbols
identify important safety messages in
this manual.
When you see one of the symbols shown
here, be alert to the possibility of
personal injury and carefully read the
message that follows.
This symbol indicates that the
possibility of electric shock
hazard exists during the
operation of the step(s) that
follow.
This symbol indicates that the
possibility of fire hazard exists
during the operation of the
step(s) that follow.
This symbol indicates that the
helmet must be worn during the
step(s) that follow to protect
against eye damage and burns
due to flash hazard.
This symbol indicates that the
possibility of toxic gas hazard
exists during operation of the
step(s) that follow.
This symbol indicates that the
possibility of being burned by
hot slag exists during operation
of the step(s) that follow.
This symbol indicates that the
eye protection should be worn
to protect against flying debris in
the following step(s).
Published standards on safety are
available. They are listed in ADDITIONAL
SAFETY INFORMATION at the end of
this SAFETY SUMMARY.

TheNationalElectricalCode,
OccupationalSafetyandHealthAct
regulations,localindustrialcodesand
localinspectionrequirementsalso
provideabasisforequipment
installation,use,andservice.
SHOCK HAZARDS
WARNING
Electric shock can kill! To
reduce therisk of death or
seriousinjuryfrom shock,
read,understand,andfollow the
following safety instructions.Inaddition,
make certainthatanyoneelsewho uses
thisweldingequipment,or who isa
bystanderintheweldingarea
understandsandfollows thesesafety
instructionsas well.
• IMPORTANT!TO REDUCE THE RISK
OF DEATH, INJURY,OR PROPERTY
DAMAGE,DO NOTAI-FEMPT
OPERATIONofthisweldingequipment
untilyouhavereadandunderstandthe
following safetysummary.
• Do not,inanymanner,comeinto
physicalcontactwithanypartofthe
weldingcurrentcircuit.The welding
currentcircuitincludes:
a. theworkpieceor anyconductive
materialincontactwithit,
b. theworkpiececlamp,
c. theelectrodeorweldingwire,
d. anymetal partsontheelectrode
holder,orwirefeed gun.
• Do notweldina dampareaorcomein
contactwitha moistorwetsurface.
• Do notattempttoweldifanypart of
clothingor bodyis wet.
• Do notallowtheweldingequipmentto
comein contactwithwaterormoisture.
• Do notdragweldingcables,wirefeed
gun,orwelderpowercordthroughor
allowthemtocomeintocontactwith
wateror moisture.
• Do not touch welder, attempt to turn
welder on or off if any part of the body
or clothing is moist or if you are in
physical contact with water or moisture.
• Do not attempt to plug the welder into
the power source if any part of body or
clothing is moist, or if you are in
physical contact with water or moisture.
• Do not connect welder workpiece
clamp to or weld on electrical conduit.
• Do not alter power cord or power cord
plug in any way.
•Do not attempt to plug the welder into
the power source if the ground prong
on power cord plug is bent over, broken
off, or missing.
• Do not allow the welder to be
connected to the power source or
attempt to weld if the welder, welding
cables, welding site, or welder power
cord are exposed to any form of
atmospheric precipitation, or salt water
spray.
• Do not carry coiled welding cables
around shoulders, or any other part of
the body, when they are plugged into
the welder.
• Do not modify any wiring, ground
connections, switches, or fuses in this
welding equipment.
•Wear welding gloves to help insulate
hands from welding circuit.
•Keep all liquidcontainers far enough
away from the welder and work area so
that if spilled, the liquid can not possibly
come in contact with any part ofthe
welder or electrical welding circuit.
•Replace any cracked or damaged parts
that are insulated or act as insulators
such as welding cables, power cord, or
electrode holder IMMEDIATELY.

FLASH HAZARDS
WARNING
ARC RAYS CAN INJURE
EYES AND BURN SKIN! To
reduceriskof injuryfrom arc
rays,read, understand,andfollow the
following safetyinstructions.Inaddition,
makecertainthatanyoneelsewhouses
thisweldingequipment,or isa bystander
intheweldingarea, understandsand
followsthesesafetyinstructionsaswell.
• Do not look at an electric arc without
proper protection. A welding arc is
extremely bright and intense and, with
inadequate or no eye protection, the
retina can be burned, leaving a
permanent dark spot in the field of
vision. A shield or helmet with a
number 10 shade filter lens (minimum)
must be used.
•Do not strike a welding arc until all
bystanders and you (the welder) have
welding shields and/or helmets in
place.
• Do not wear a cracked or broken
helmet and replace any cracked or
broken filter lenses IMMEDIATELY.
•Do not allow the uninsulated portion of
the wire feed gun to touch the
workpiece clamp or grounded work to
prevent an arc flash from being created
on contact.
•Provide bystanders with shields or
helmets fitted with a #10 shade filter
lens.
• Wear protective clothing. The intense
light of the welding arc can burn the
skin in much the same way as the sun,
even through light-weight clothing.
Wear dark clothing of heavy material.
The shirt worn should be long sleeved
and the collar kept buttoned to protect
chest and neck.
• Protect against REFLECTED ARC
RAYS. Arc rays can be reflected off
shiny surfaces such as a glossy
painted surface, aluminum, stainless
steel, and glass. It is possible for your
eyes to be injured by reflected arc rays
even when wearing a protective helmet
or shield. If welding with a reflective
surface behind you, arc rays can
bounce off the surface, then off the filter
lens on the inside of your helmet or
shield, then into your eyes. If a
reflective background exists in your
welding area, either remove it or cover
it with something non-flammable and
non-reflective. Reflected arc rays can
also cause skin burn in addition to eye
injury.
FIRE HAZARDS
WARNING
FIRE OR EXPLOSION CAN
CAUSE DEATH, INJURY,
AND PROPERTY DAMAGE!
To reduce risk of death, injury, or
property damage from fire or explosion,
read, understand, and follow the
following safety instructions. In addition,
make certain that anyone else that uses
this welding equipment, or is a bystander
in the welding area, understands and
follows these safety instructions as well.
REMEMBER! Arc welding by nature
produces sparks, hot spatter, molten
metal drops, hot slag, and hot metal
parts that can start fires, burn skin, and
damage eyes.
• Do not wear gloves or other clothing
that contain oil, grease, or other
flammable substances.
•Do not wear flammable hair
preparations.
•Do not weld in an area until it is
checked and cleared of combustible
and/or flammable materials. BE
AWARE that sparks and slag can fly
35 feet and can pass through small
cracks and openings. Ifwork and
combustibles cannot be separated by a
minimum of 35 feet, protect against
ignition with suitable, snug-fitting, fire
resistant, covers or shields.
•Do not weld on walls until checking for
and removing combustibles touching
the other side of the walls.

•Do not weld, cut, or perform other such
work on used barrels, drums, tanks, or
other containers that had contained a
flammable or toxic substance. The
techniques for removing flammable
substances and vapors, to make a
used container safe for welding or
cutting, are quite complex and require
special education and training.
• Do not strike an arc on a compressed
gas or air cylinder or other pressure
vessel. Doing so will create a brittle
area that can result in a violent rupture
immediately or at a later time as a
result of rough handling.
•Do not weld or cut in an area where the
air may contain flammable dust (such
as grain dust), gas, or liquid vapors
(such as gasoline).
• Do not handle hot metal, such as the
workpiece or electrode stubs, with bare
hands.
• Wear leather gloves, heavy long sleeve
shirt, cuffless trousers, high-topped
shoes, helmet, and cap. As necessary,
use additional protective clothing such
as leather jacket or sleeves, fire
resistant leggings, or apron. Hot sparks
or metal can lodge in rolled up sleeves,
trouser cuffs, or pockets. Sleeves and
collars should be kept buttoned and
pockets eliminated from the shirt front.
•Have fire extinguishing equipment
handy for immediate use! A portable
chemical fire extinguisher, type ABC, is
recommended.
• Wear ear plugs when welding
overhead to prevent spatter or slag
from falling into ear.
• Make sure welding area has a good,
solid, safe floor, preferably concrete or
masonry, not tiled, carpeted, or made
of any other flammable material.
• Protect flammable walls, ceilings, and
floors with heat resistant covers or
shields.
• Check welding area to make sure it is
free of sparks, glowing metal or slag,
and flames before leaving the welding
area.
FUME HAZARDS
WARNING
FUMES, GASSES, AND
VAPORS CAN CAUSE
DISCOMFORT, ILLNESS,
AND DEATH!
To reduce risk of discomfort, illness, or
death, read, understand, and follow the
following safety instructions. In addition,
make certain that anyone else that uses
this welding equipment or is a bystander
in the welding area, understands and
follows these safety instructions as well.
•Do not weld in an area until it is
checked for adequate ventilation as
described in ANSI standard #Z49.1. If
ventilation is not adequate to exchange
all fumes and gasses generated during
the welding process with fresh air, do
not weld unless you (the welder) and
all bystanders are wearing air-supplied
respirators.
• Do not heat metals coated with, or that
contain, materials that produce toxic
fumes (such as galvanized steel),
unless the coating is removed. Make
certain the area is well ventilated, and
the operator and all bystanders are
wearing air-supplied respirators.
• Do not weld, cut, or heat lead, zinc,
cadmium, mercury, beryllium, or
similar metals without seeking
professional advice and inspection of
the ventilation of the welding area.
These metals produce EXTREMELY
TOXIC fumes which can cause
discomfort, illness, and death.
•Do not weld or cut in areas that are
near chlorinated solvents. Vapors from
chlorinated hydrocarbons, such as
trichloroethylene and
perchloroethylene, can be decomposed
bythe heat of an electric arc or its
ultraviolet radiation. These actions can
cause PHOSGENE, a HIGHLY TOXIC
gas to form, along with other lung and

eye-irritatinggasses.Donotweldorcut
wherethesesolventvaporscanbe
drawnintotheworkareaorwherethe
ultravioletradiationcanpenetrateto
areascontainingevenverysmall
amountsofthesevapors.
•Do not weld in a confined area unless it
is being ventilated or the operator (and
anyone else in the area) is wearing an
air-supplied respirator.
•Stop welding if you develop momentary
eye, nose, or throat irritation as this
indicates inadequate ventilation. Stop
work and take necessary steps to
improve ventilation in the welding area.
Do not resume welding if physical
discomfort persists.
COMPRESSED GASSES AND
EQUIPMENT HAZARDS
WARNING
IMPROPER HANDLING AND
MAINTENANCE OF
COMPRESSED GAS
CYLINDERS
AND REGULATORS CAN RESULT IN
SERIOUS INJURY OR DEATH!
To reduce risk of injury or death from
compressed gasses and equipment
hazards, read understand and follow the
following safety instructions. In addition,
make certain that anyone else who uses
this welding equipment or a bystander in
the welding area understands and
follows these safety instructions as well.
• Do not use flammable gasses with MIG
welders. Only inert or nonflammable
gasses are suitable for MIG welding.
Examples are Carbon Dioxide, Argon,
Helium, etc. or mixtures of more than
one of these gasses.
• Do not attempt to mix gasses or refill a
cylinder yourself Do not expose
cylinders to excessive heat, sparks,
slag and flame, etc. Cylinders exposed
to temperatures above 130°F will
require water spray cooling.
•Do not expose cylinders to electricity of
any kind.
•Do not use a cylinder or its contents for
anything other than its intended use.
Do not use as a support or roller.
• Do not locate cylinders in passageways
or work areas where they may be
struck.
•Do not use a wrench or hammer to
open a cylinder valve that cannot be
opened by hand. Notify your supplier.
• Do not modify or exchange gas
cylinder fittings.
• Do not deface or alter name, number or
other markings on a cylinder. Do not
rely on cylinder color to identify the
contents.
• Do not connect a regulator to a cylinder
containing gas other than that for which
the regulator was designed.
• Do not attempt to make regulator
repairs. Send faulty regulators to
manufacturer's designated repair
center for repair.
• Do not attempt to lubricate a regulator.
• Always change cylinders carefully to
prevent leaks and damage to their
walls, valves, or safety devices.
• Always secure cylinders with a steel
chain so that they cannot be knocked
over.
• Always protect a cylinder, especially
the valve, from bumps, falls, falling
objects and weather. Remember that
gasses in the cylinders are under
pressure and damage to a regulator
can cause the regulator or portion of
the regulator to be explosively ejected
from the cylinder.
• Always make certain the cylinder cap is
securely in place on the cylinder,
whenever the cylinder is moved.
• Always close the cylinder valve and
immediately remove a faulty regulator
from service, for repair, if any of the
following conditions exist.
• Gas leaks externally.
• Delivery pressure continues to rise with
down stream valve closed.
• The gauge pointer does not move off
the stop pin when pressurized or fails
to return to the stop pin after pressure
is released.

ADDITIONAL SAFETY
INFORMATION
For additional information concerning
welding safety, refer to the following
standards and comply with them as
applicable.
• ANSI Standard Z49.1 -- SAFETY IN
WELDING AND CUTTING --
obtainable from the American Welding
Society, 2051 N.W. 7th St., Miami, FL
33125 Telephone [phone]
• ANSI Standard Z87.1 -- SAFE
PRACTICE FOR OCCUPATION AND
EDUCATIONAL EYE AND FACE
PROTECTION -- obtainable from the
American National Standards Institute,
1430 Broadway, NewYork, NY 10018.
• NFPA Standard 51B -- CUTTING
AND WELDING PROCESSES --
obtainable from the National Fire
Protection Association, 470 Atlantic
Ave., Boston, MA 02210
•CGA Pamphlet P-I - SAFE HANDLING
OF COMPRESSED GASSES IN
CYLINDERS - obtainable from the
Compressed Gas Association, 500, 5th
Ave. New York, NY 10038
• OSHA Standard 29 CFR, Part 1910,
Subpart Q, WELDING, CUTTING AND
BRAZING -- obtainable from your
state OSHA office.
• CSA Standard W117.2 -- Code for
SAFETY IN WELDING AND
CUTTING.- obtainable from
Canadian Standards Association, 178
Rexdale Blvd. Etobicoke, Ontario M9W
1R3
• American Welding Society Standard
A6.0 - WELDING AND CUTTING
CONTAINERS WHICH HAVE HELD
COMBUSTIBLES - obtainable from the
American Welding Society, 2051 N.W.
7th St., Miami, FL 33125 Telephone
[phone]
9

WIRE FEED WELDING
VARIABLES
SELECT THE WIRE
It isvery importantto selecta typeof
wirethatiscompatiblewiththemetalto
bewelded(basemetal). Ifthewireis
incompatiblewiththe basemetal,the
qualityof importantcharacteristicssuch
as penetrationand strengthmay be
sacrificed.
Solid Steel Wire Selection
The welding wires recommended for
most of the mild and low carbon steel
applications you will have are AWS
classification numbers E70S-3 and
E70S-6. These two wires are very
similar, but the E70S-6 tends to work a
little better on moderately dirty steel and
on sheet metal where smooth weld
beads are required. These differences
are very subtle, so in most applications,
either wire is acceptable.
Self-Shielding Flux-Core Steel Wire
Self-shielding,flux-core steel wire is
usedprimarilyfor weldingmild steel
withoutthe useofa shieldinggas. Itis
especiallygoodtousewhenwelding
needstotake placeina windy
environment.However,itproducesmore
spatter than solidwire gas-shielded
weldingand leavesa slagontopofthe
weld that needs to be chipped off. Our
recommendation for self-shielding, flux-
core steel wire is AWS classification
number E71T-GS.
NOTE: WITH FLUX-CORE WIRE YOU
WILL BURN THROUGH
METALS THINNER THAN 18
GAUGE.
Aluminum Wire Selection
Selecting the proper wire for welding
aluminum is much more complicated
than steel wire selection, primarily due to
the large number of aluminum alloys
available. Also the recommended wire
alloy is not necessarily the same as the
base metal to be welded.
Because of the large number of alloys in
use, a major problem is identifying the
alloy number of the base metal to be
welded. The alloy number is usually a
four digit number and most often can be
determined by referring to the owner/
operation manual, dealer, distributor, or
manufacturer of the item to be welded. If
the alloy number cannot be determined,
wire selection becomes a matter of trial-
and-error. The only other
recommendation is to seek the advice of
someone who may have had previous
experience with the same or similar
aluminum welding application.
After determining the alloy of the base
metal, refer to the chart in Table 1to find
the recommended wire.
10

BASE
METAL
ALLOY
7005
7021
7039
7046
7146
Table 1. Aluminum Wire Alloy Selection Chart
WIRE WELDING EASE WELD DUCTILITY USE IN TEMPS COLOR MATCH LOW CORROSION
ALLOY & CRACK STRENGTH OVER 150 AFTER WHEN IMMERSED
RESISTANCE DEGREES F ANODIZING IN WATER
5356 GOOD GOOD GOOD GOOD GOOD GOOD
6061 4043 GOOD FAIR GOOD GOOD POOR GOOD
6070 5356 GOOD GOOD GOOD POOR GOOD FAIR
4043 GOOD FAIR GOOD GOOD POOR GOOD
5356 GOOD GOOD GOOD POOR GOOD FAIR
6005
6063
6101
6151
6201
6351
6951
5052 5356 GOOD GOOD GOOD POOR GOOD GOOD
5454
5652 5554 FAIR FAIR GOOD GOOD GOOD GOOD
5086 5356 GOOD GOOD GOOD POOR GOOD GOOD
5154 5183 GOOD GOOD GOOD POOR GOOD GOOD
5254 5556 GOOD GOOD GOOD POOR GOOD GOOD
5356
5005 4043 GOOD GOOD FAIR GOOD POOR GOOD
5050 5356 GOOD GOOD GOOD GOOD GOOD GOOD
4043 GOOD GOOD FAIR GOOD POOR GOOD
3004 5356 GOOD GOOD GOOD GOOD POOR GOOD
1100 GOOD GOOD GOOD GOOD GOOD GOOD
3003 4043 GOOD GOOD GOOD GOOD POOR GOOD
2219 2319 GOOD GOOD GOOD GOOD GOOD GOOD
2014 2319 FAIR GOOD GOOD GOOD GOOD GOOD
2036
1100 4043 GOOD GOOD GOOD GOOD POOR GOOD
1060
1070 4043 GOOD GOOD GOOD GOOD POOR GOOD
1080 1100 GOOD GOOD GOOD GOOD GOOD GOOD
1350
NOTE: This chart assumes that the base metal being welded is all the same alloy.
However, it is possible to weld two different alloys together. If this is an
application that you become interested in, contact your local welding supply
distributor or the American Welding Society (AWS) for assistance in selecting
the proper wire.
11

Stainless SteelWire Selection
When weldingstainlesssteel,thealloyof
the weldingwiremustbethe same as
the alloyofthe basemetal. Aswith
aluminum, the alloy number can most
often be determined by consulting the
owner/operator manual, service manual,
dealer, distributor, or manufacturer of the
item to be welded. Otherwise, seek the
advice of someone who may have had
previous experience with the same or
similar welding application. Stainless
steel wire is quite expensive. The trial-
and-error method of alloy determination
should be avoided whenever possible.
Silicon Bronze Wire Selection
The most popular application for silicon-
bronze MIG welding is non-structural
sheet metal welding, especially auto
body work. A weld with silicon bronze
wire is very similar to that produced by
oxygen-acetylene brazing. It is fairly flat
and easy to grind smooth. Our
recommended wire for this application is
AWS classification number ERCuSi-A.
SELECTING THE WIRE SPOOL
SIZE
This welder will accept either four inchor
eightinchspools.Wire ona four inch
spoolwillusuallycostmore perpound
thanon an eightinchspool. However,
weldingwireoxidizesovertime,soitis
importantto selecta spoolsizethatwill
be usedupwithinthetimes
recommendedbelow.
1= STEEL WIRE -is usually coated
with copper to prevent the wire from
rusting and to enhance the
transmission of welding current
from the contact tip to the wire. It is
recommended that copper-coated
2.
3.
=
steel welding wire be bought in
spool sizes that will be consumed
in six months or less. In the early
stages of aging, the copper coating
will begin oxidizing. The more time
that passes, the heavier the
oxidization will get. To check the
wire for copper oxidation, unspool
about two feet of wire, pinch the
wire between thumb and forefinger,
then pull the thumb and forefinger
down the length of wire. Look at the
thumb and fore finger; there will be
a line created by the copper
oxidation. A fairly fresh spool will
leave a light gray line, whereas a
well oxidized spool will leave a
darker line. Heavy copper oxidation
will cause arc flutter and possibly
wire drive slippage. If steel wire
continues to oxidize, the steel wire
under the copper coating will rust
causing even worse arc flutter and
drive problems.
SELF-SHIELDING, FLUX-CORE,
STEELWIRE - spoolsshouldbe
selectedbasedonthesame
guidelinesas for copper-coated
steelwire.
ALUMINUMWIRE -haseven
moreofa potentialstorageproblem
thansteel. Ittendsto oxidizemuch
fasterandtheoxidationismuch
heavier.Theearlystagesof
oxidationarevirtuallyinvisible,but
astimepasses,a whitepowderwill
developthatwillcauseextremearc
flutter, wiredriveproblems,
contaminationbuild-upintheliner,
wireburn-backintothecontacttip
anda poorweld. Ideally,itwould
bebesttouseupa spoolof
aluminumwirewithinthreemonths.
STAINLESS STEEL WIRE -
oxidizes at a relatively slow rate
and its oxidationis very light,so the
care for handling and storing
stainless steel wire is much less
criticalthan for aluminum and steel
wires. However, because stainless
12

5=
steel wire is quite expensive, it is
still a good practice to follow the
storage recommendations.
SILICON-BRONZE WIRE -spools
should be selected based on the
same guidelines as for copper-
coated steel wire
The above recommended spool storage
times are rules-of-thumb and can be
impacted by many factors such as length
of time in distribution prior to retail sale,
warehouse conditions, time of year (i.e.
humid months or dry months), and how
the spool was packaged by the
manufacturer.
Although these factors are out of your
control, there are some things that you
can do to slow down the oxidation
process: store in a dry place when not in
use, store in sealed plastic bag when not
in use, and leave unopened in the
manufacturer's package until ready to
use.
NOTE: if a spool has developed heavy
oxidation, the only solution to
the problem is to discard the
spool of wire.
• if you have an oxidized spool of
wire, do not discard it until you
have unspooled a few turns of
wire to see if the wire further
down on the spool is in usable
condition, if not, - discard the
spool.
SELECTING THE WIRE DIAMETER
Using a wire that is too small in diameter
can cause excessive weld spatter and
weld heat. A wire that is too large can
cause wire stubbing (stubbing is caused
when the molten metal bridge between
the electrode and weld pool cannot be
broken and the electrode stubs into the
pool and the pool freezes) and, at low
amperages, cause an uneven arc. In
either case, the weld is ruined. Use
Table 2 below to identify the
recommended wire diameter to use for
the metal being welded. The
recommendations supplied in Table 2 are
for typical applications only.
Table 2. Wire Diameter Amperage
Ranges (Typical)
METAL
WIRE AMP THICKNESS
DIAMETER RANGE
26-18
0.024 inch 30-90 Gauge
0.030 inch 60-200 18 Gauge -
3/16 inch
0.035 inch 90-230 14 Gauge -
5/16 inch
SELECTING SHIELDING GAS
The shielding gas plays an extremely
importantrole in theMIG welding
process.As withmost welding
processes,itiscriticalthatthe molten
weldpuddlebe shieldedfrom the
atmosphere.Inadequateshieldingwill
resultin porous,brittlewelds.
Not only is shielding the weld important;
selecting the proper gas to shield with is
of equal importance. Generally, the
shielding gas selected is dependent
upon the type and thickness of metal
being welded. Selecting the wrong gas
for the metal to be welded can result in
porosity, brittleness, and/or undesirable
penetration of the weld.
Although there are many gasses and gas
mixtures available for MIG welding, the
following recommendations are based on
the electrical output characteristics and
metal thickness welding capabilities of
this specific MIG welder.
Gas Selection For Steel Welding With
SteelWire
Foreithermild or lowcarbon(High
StrengthStructural)steel, in thicknesses
thatcanbeweldedwiththiswelder,our
primaryrecommendationisa gas
13

mixtureof75%Argonand25%Carbon
Dioxide,though100%CarbonDioxideis
alsoacceptable.DONOTUSEArgon
gasconcentrationshigherthan75%on
steel.Theresultwillbeextremelypoor
penetration,porosity,andbrittlenessof
weld.
Thisgasmixturehelpstopreventburn
throughanddistortiononverythinsteel
yetprovidesgoodpenetrationonthicker
steel.Itsabilitytominimizespatter
resultsinclean,smoothweld
appearances.Inaddition,itprovides
goodpuddlecontrolwhenwelding
verticallyoroverhead.Thisgasmixture
isavailablepre-mixedinasinglecylinder
fromyourlocalgasdistributor.
Gas Selection ForAluminum Gas
Welding
Our onlyrecommendation for shielding
analuminumweldispureArgon. Do not
attemptto usetheArgon/Carbon Dioxide
(recommended for steel)whenwelding
aluminum.
Gas Selection For Stainless Steel
Welding
The best shielding gas for stainless steel
weldingisa mixtureof90% Helium,
7.5% Argon, and2.5% CarbonDioxide.
However,the 75% Argon, 25% Carbon
Dioxidemixture(recommended for steel)
canalsobe used,butanincreaseinthe
area beingheatedbythe arcwillbe
experiencedcausingslightlygreater
distortionofthebasemetal. Also this
mixturecancausea decreaseinthe
abilityofthestainlesssteelweld toresist
corrosion.Eithermixturecan be
obtainedin a singlecylinderfrom your
localgasdistributor.
NOTE: Potential shielding gas
problems.
1. DEFECTIVE GAS -Just like any
other product, a cylinder of gas can
be defective. Moisture or other
impurities in the gas can create
dirty, porous, brittle welds with
.
greatly reduced penetration. The
only remedy is to replace the
cylinder.
INSUFFICIENT SHIELDING GAS
COVERAGE - This problem can be
created by several causes. The
symptoms are a dirty, porous,
brittle, and/or non-penetrating weld.
Refer to your WELDER USER'S
GUIDE for corrective action.
Gas Selection For SteelWelding With
Silicon BronzeWire
Use onlypureArgon whenweldingsteel
withSilicon-Bronzewire.
SELECT WELDING CURRENT
POLARITY
Direct current (dc) reversepolarity is
required when usinggas-shieldedsteel
weldingwires. Direct currentstraight
polarity is usedwithself-shieldingflux
coredwires. Depending onthe
configurationofyour welderas itwas
manufactured,youmay needto convert
thepolarityfor thetypeofwireyouwill
be using. (Note:someweldersdo not
havethecapabilityofchangingthe
polarity.)
Direct current reverse polarity is
sometimes referred to as DCEP (Direct
Current Electrode Positive) and dc
straight polarity is sometimes referred to
as DCEN (Direct Current Electrode
Negative).
PREPARING THE WORK
AREA
An important factor in making a
satisfactory weld is preparation. This
includes studying the process and
equipment and then practice welding
before attempting to weld finished
product. An organized, safe, convenient,
comfortable, well-lighted work area
should be available to the operator. The
work area should specifically be free of
all flammables with both a fire
14

extinguisherandbucketofsand
available.
Toproperlyprepareforwelding,itis
necessaryto:
1. prepareanorganized,welllighted
workarea(seeFigure1).
2. provideprotectionfortheeyesand
skinoftheoperatorandby-
bystanders,
3. andsetuptheworkpieceand
maketheworkpiececlamp
connection.
I I
ip
I\
i/_'q \ Metal j@
.J Surface _
Figure 1. Work Surface Preparation
SETTING UP THE WORK
PIECE
PREPARING THE JOINT
For effective welding, the surfaces to be
joined must be free of dirt, rust, scale, oil
or paint. Welding on metals not properly
cleaned will cause a brittle and porous
weld.
Aluminum welding requires more
detailed preparation than steel welding.
1. A clean weld joint area is a must in
obtaining a quality aluminum weld.
Remove dirt and oxidation with a
stainless steel bristled wire brush.
Remove any oil or grease with a
good chemical aluminum cleaner.
2. Aluminum is often anodized to
prevent it from oxidizing. However,
an anodized surface will NOT
conduct electricity. Therefore, to
weld anodized aluminum, you must
sand or grind the anodized coating
from the weld joint area and from
the site where the workpiece clamp
will be connected.
To determine if the aluminum you intend
to weld is anodized, simply touch the two
probes of an electrical continuity tester
or ohmmeter to the aluminum in
question. The probes should be an inch
or two apart. If there is no indication of
electrical continuity, the aluminum is
anodized.
If the base metal pieces to be joined are
thick or heavy, it may be necessary to
bevel the edges, with a metal grinder, at
the point of contact, as in Figure 2. The
angle of the bevel should be
approximately 60 degrees.
INCORRECT
I
CORRECT
Figure 2. Workpiece Preparation
WARNING
ARC RAYS CAN INJURE
EYES AND BURN SKIN! To
help prevent eye injuries when
grinding, always wear goggles. The
grinder must also be inspected to verify
that it is in good condition.
See the chart, TYPES OF WELD
JOINTS, in Figure 3, for detailed
instructions for preparing the weld joint.
During welding, the work pieces will
become hot and will tend to expand. The
expansion may cause the pieces to shift
from the regular position. If possible, the
work pieces should be clamped into the
position they are to occupy when the
welding is completed.
15

45" PLATE BUTT WELD JOINTS . 60 PLATE
37.5" _ _P_
_P_ SINGLE V JOINT
SINGLE BEVEL JOINT _ _ _ 60"
DOUBLE BEVEL JOINT DOUBLE V JOINT
3/32" TO 1/8"
I _11_
CLOSEDJOINT I1
_/80",.._/ OPEN JOINT
DOUBLE VEE JOINT
18% -_/_
.10,.TO1/8"\ /VEEJO,NT
SHOULDEREDaE _80"
1/4" OR MORE "_
FEATHER EDGE
1/8" OR MORE
SINGLE FILLET
LAP JOINT
SINGLE STRAP JOINT
FILLET WELD JOINTS
DOUBLE FILLET
DOUBLE STRAP JOINT
SINGLE FILLET T-JOINT DOUBLE FILLET T-JOINT
Figure 3. Types of Weld Joints
16

WORKPIECECLAMP
CONNECTION
Itis best to connect theworkpiece clamp
directlyto thework pieceand as closeto
theweld as possible.If itisimpractical
to connecttheworkpiececlampdirectly
tothework piece,connectittothe metal
thatissecurelyattachedtothework
piece,but notelectricallyinsulatedfrom
it. Also, make suretheattachedmetal
piece isofaboutthesame orgreater
thicknessas theworkpiece.
CAUTION
There is risk of electronic component
damage if the workpiece clamp is
being connected to an automobile or
other equipment with on-board
computer systems, solid state
electronic controls, solid state sound
systems, etc., DO NOT WELD until
disconnecting the cable from the
battery that is attached to chassis
ground. Failure to do so may result in
ELECTRONIC COMPONENT
DAMAGE.
Tuning In the Wire Speed
Tuning the wire speed is one of the most
important parts of MIG welder operation.
Selecting the best wire speed setting is
much the same as tuning in a station on
the radio. It must be done before starting
each welding job or whenever the heat
setting, wire diameter, or wire type are
changed. Tune the wire speed according
to the following steps.
1,
2,
3.
Set up and ground a scrap piece of
the same type of metal that you will
be welding. It should be equal to or
greater than the thickness of the
actual work piece and free of paint,
oil, rust, etc.
Select a heat or voltage setting.
Hold the gun in one hand allowing
the nozzle to rest on the edge of the
work piece farthest away from you
and at an angle similar to that
which will be used when actually
welding.
WARNING
ARC RAYS CAN INJURE
EYES AND BURN SKIN! To
reduce the risk of injury from
arc rays, never strike a welding arc until
you, and all bystanders in the welding
area, have welding helmet or shield in
place and are wearing the recommended
protective clothing. DO NOT CONTINUE
unless you have read, understand and
intend to follow the entire SAFETY
SUMMARY provided at the front of this
manual.
.With your free hand, turn the WIRE
SPEED control to maximum and
continue to hold onto the adjust-
ment knob.
5. Lower your welding helmet and pull
the trigger on the gun to start an
arc.
6. Begin to drag the gun toward you
while turning down the WIRE
SPEED control at the same time.
7. LISTEN! As you decrease the wire
speed, the sound that the arc
makes will change from a sputter-
ing sound to a smooth, high-pitched
buzzing sound and then will begin
sputtering again, if you decrease
the wire speed too far.
8. Continue to decrease the wire
speed until the arc noise passes
the high-pitched buzzing (preferred
sound) and begins to sputter again.
g, Turn the WIRE SPEED control
back, in the opposite direction until
you come back to the preferred
sounding arc noise.
The WIRE SPEED is now tuned in.
REMEMBER! Repeat this tune in
procedure whenever you select a new
heat setting, a different wire diameter, or
a different type of wire.
NOTE: When tuning in the WIRE
SPEED for self-shielding flux-
core wire, you will find a very
17

widepreferredsoundingrange.
The range could span as much
as 60° on the WIRE SPEED
control. It is important to know
that the heat of the arc and
penetration into the base metal
increases as the wire speed
increases within the preferred
sounding range for a given heat
setting. It is possible, therefore,
to use the wire speed control to
slightly increase or decrease
heat and penetration by
selecting higher or lower wire
speed settings WITHIN the
preferred sounding range for a
given heat setting.
18

LEARNING TO WELD
Whether you have welded before or not,
it is important that you become familiar
with your new welder, its controls, and
the results achieved at different settings.
We strongly recommend that you
practice with your new welder on scrap
metal trying different heat settings, base
metal thicknesses, and welding positions
for each type and size of wire that you
will be using. By doing this you will gain
a feel for how changes in these welding
variables affect the weld.
Of course, if you have not MIG welded
before, you will need to develop welding
skills and techniques as well.
The self-taught welder learns through a
process of trial and error. The best way
to teach yourself how to weld is with
short periods of practice at regular
intervals. All practice welds should be
done on scrap metal that can be
discarded. Do not attempt to make any
repairs on valuable equipment until you
have satisfied yourself that your practice
welds are of good appearance and free
of slag or gas inclusions. What you fail to
learn through practice will be learned
through mistakes and re-welds later on.
HOLDING THE GUN
The best way to hold the welding gun is
the way that feels most comfortable to
you. While practicing to use your new
welder, experiment holding the gun in
different positions until you find the one
that seems to work best for you.
Position the Gun to the Work Piece
There are two angles of the gun nozzle
in relation to the work piece that must be
considered when welding.
1. Angle A (Figure 4) can be varied,
but in most cases the optimum
angle will be 60 degrees. The point
at which the gun handle is parallel
to the work piece. Ifangle A is
increased, penetration will increase.
If angle A is decreased, penetration
will decrease also.
_\
Angle A
Figure 4. Gun Position, Angle A
2, Angle B (Figure 5) can be varied for
two reasons: to improve the ability
to see the arc in relation to the weld
puddle and to direct the force of the
arc.
\1
Angle B
Figure 5. Gun Position, Angle B
The force of the welding arc follows a
straight line out of the end of the nozzle.
If angle B is changed, so will the
direction of arc force and the point at
which penetration will be concentrated.
On a butt weld joint, the only reason to
vary angle B from perpendicular (straight
up) to the work piece would be to
improve visibility of the weld puddle. In
this case, angle B can be varied
anywhere from zero to 45 degrees with
30 degrees working about the best.
19

On a fillet weld joint, the nozzle is
generally positioned in such a manner so
as to split the angle between the
horizontal and vertical members of the
weld joint. In most cases, a fillet weld
will be 45 degrees.
Distance from the Work Piece
The end of the welding gun is designed
with the contact tip recessed from the
end of the nozzle and the nozzle
electrically insulated from the rest of the
gun. This permits the operator to
actually rest the nozzle on the work
piece and drag it along while welding.
This can be very helpful to beginning
welders to steady the gun, allowing the
welder to concentrate on welding
technique. 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.
LAYING A BEAD
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 untilyou are adequately
protected. Wear flameproof welding
gloves, A heavy long sleeved shirt,
cuffiess trousers, high topped shoes and
a 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 work.
WELDING TECHNIQUES
MOVING THE GUN
Gun travel refers to the movement of the
gun along the weld joint and is broken
into two elements: Direction and Speed.
A solid weld bead requires that the
welding gun be moved steadily and at
the right speed along the weld joint.
Moving the gun too fast, too slow, or
erratically will prevent proper fusion or
create a lumpy, uneven bead.
1, TRAVEL DIRECTION is the
direction the gun is moved along
the weld joint in relation to the weld
puddle. The gun is either PUSHED
(see Figure 6) into the weld puddle
or PULLED away from the weld
puddle.
Figure 6. Gun Travel Direction
For most welding jobs you will pull
the gun along the weld joint to take
advantage of the greater weld
puddle visibility. However, there are
a few applications where pushing
the gun may provide some
advantages:
a, VERTICAL WELDING can
be done by starting at the
top of aweld joint and
pulling the gun down toward
the bottom. However, in the
event that puddle control
becomes difficult (such as
the puddle wanting to run
downward), starting a
vertical weld at the bottom
of a weld joint and pushing
the gun up toward the top
2O