| Safety Summary |
| Safety Information . . . . . . . . . . . . . . . . . . . . .1 |
| Shock Hazards . . . . . . . . . . . . . . . . . . . . . . . .1 |
| Flash Hazards . . . . . . . . . . . . . . . . . . . . . . . .2 |
| Fire Hazards . . . . . . . . . . . . . . . . . . . . . . . . . .3 |
| Fume Hazards . . . . . . . . . . . . . . . . . . . . . . . .3 |
| Compressed Gasses and |
| Equipment Hazards . . . . . . . . . . . . . . . . . . . .4 |
| Additional Safety Information . . . . . . . . . . . . .4 |
| Introduction |
| Description . . . . . . . . . . . . . . . . . . . . . . . . . . .6 |
| Welder Performance . . . . . . . . . . . . . . . . . . .6 |
| Accessories . . . . . . . . . . . . . . . . . . . . . . . . . .6 |
| Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 |
| Specifications . . . . . . . . . . . . . . . . . . . . . . . . .6 |
| Installation |
| Unpacking Your Welder . . . . . . . . . . . . . . . . .7 |
| Power Requirements . . . . . . . . . . . . . . . . . . .7 |
| Preparation For Use . . . . . . . . . . . . . . . . . . . .7 |
| 230 Volt to 208 Volt Conversion . . . . . . . . . .7 |
| Power Source Connection . . . . . . . . . . . . . .8 |
| Extension Cord Use . . . . . . . . . . . . . . . . . . .8 |
| Select Shielding Gas . . . . . . . . . . . . . . . . . .8 |
| Gas Selection For Steel Welding . . . . . . . .8 |
| Gas Selection for Aluminum Welding . . . .8 |
| Gas Selection For Stainless Steel |
| Welding . . . . . . . . . . . . . . . . . . . . .8 |
| Gas Selection For Steel Welding With Silicon |
| Bronze Wire . . . . . . . . . . . . . . . .9 |
| Select Type Of Wire . . . . . . . . . . . . . . . . . . . .9 |
| Solid Steel Wire Selection . . . . . . . . . . . . .9 |
| Aluminum Wire Selection . . . . . . . . . . . . . .9 |
| Stainless Steel Wire Selection . . . . . . . . . .9 |
| Silicon-Bronze Wire Selection . . . . . . . . . .9 |
| Self-Shielding, Flux-Core, Steel Wire |
| Selection . . . . . . . . . . . . . . . . . . . . . . . . .9 |
| Select The Spool Size . . . . . . . . . . . . . . . .9 |
| Steel Wire . . . . . . . . . . . . . . . . . . . . . . . . .9 |
| Aluminum Wire . . . . . . . . . . . . . . . . . . . .10 |
| Stainless Steel Wire . . . . . . . . . . . . . . . . .10 |
| Self-shielding, Flux Core, and Steel Wire 10 |
| Silicon-Bronze Wire . . . . . . . . . . . . . . . . .11 |
| Wire Spool Storage . . . . . . . . . . . . . . . . .11 |
| Select The Wire Diameter . . . . . . . . . . . .11 |
| Silicon-Bronze Wire Welding of Steel . . .11 |
| Self-Shielding, Flux Core, Steel |
| Wire Weldingof Steel . . . . . . . . . . . . . .11 |
| Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .11 |
| Assemble The Cart . . . . . . . . . . . . . . . . .11 |
| Install Gun/Powercord Storage Brackets .11 |
| Install Hood Handle . . . . . . . . . . . . . . . . .11 |
| Assemble Welding Gun . . . . . . . . . . . . . .12 |
| Install the Shielding Gas . . . . . . . . . . . . .12 |
| Regulate Gas Flow . . . . . . . . . . . . . . . . .13 |
| Install the Welding Wire . . . . . . . . . . . . . .13 |
| Install Aluminum Wire . . . . . . . . . . . . . . .16 |
| Operation |
| Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . .17 |
| Getting To Know Your New Welder . . . . . . . .17 |
| Setting the Controls . . . . . . . . . . . . . . . . . . .17 |
| Select Welding Current Polarity and |
| Connect Welder Ground . . . . . . . . . . .18 |
| Cleaning The Weld Bead . . . . . . . . . . . . . . .18 |
| Learning to Weld |
| Preparing to Weld . . . . . . . . . . . . . . . . . . . . .19 |
| Preparing A Safe Work Area . . . . . . . . . .19 |
| Preparing the Work Piece . . . . . . . . . . . .19 |
| Aluminum Welding Preparation . . . . . . . .19 |
| Holding the Gun . . . . . . . . . . . . . . . . . . . .20 |
| Position Of The Gun To The Work Piece .20 |
| Distance From The Work Piece . . . . . . . .20 |
| Laying a Bead . . . . . . . . . . . . . . . . . . . . .20 |
| Welding Techniques . . . . . . . . . . . . . . . . . . .21 |
| Moving the Gun . . . . . . . . . . . . . . . . . . . .21 |
| Types of Weld Beads . . . . . . . . . . . . . . . .21 |
| Welding Positions . . . . . . . . . . . . . . . . . .22 |
| Special Welding Methods . . . . . . . . . . . . . . .23 |
| Spot Welding . . . . . . . . . . . . . . . . . . . . . .23 |
| Stitch Welding . . . . . . . . . . . . . . . . . . . . .24 |
| Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 |
| Maintenance and Troubleshooting |
| General Maintenance . . . . . . . . . . . . . . . . . .25 |
| Maintaining The Welder . . . . . . . . . . . . . .25 |
| Testing for a Shorted Nozzle . . . . . . . . . .26 |
| Troubleshooting . . . . . . . . . . . . . . . . . . . .26 |
| Defective Gas . . . . . . . . . . . . . . . . . . . .26 |
| Insufficient Shielding Gas Coverage . . .26 |
| Basic Troubleshooting Guide . . . . . . . . . .27 |
| Manufacturer’s Limited Warranty . . . . . . . . .29 |
