Century 93420559, 117-078, 117-076 Owner’s 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.
A NOTE 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
Electric shock can kill! To
WARNING
reduce the risk of death or
read,understand,andfollow the
following safety instructions.Inaddition,
make certainthat anyoneelsewho uses
thisweldingequipment,or who is a
bystanderinthe weldingarea
understandsandfollows these safety
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:
• Do not weldina damparea orcomein
contactwitha moistorwetsurface.
• Do not attempttoweldifany part of
clothingor bodyis wet.
• Do notallowtheweldingequipmentto
comein contactwithwater ormoisture.
• Do notdragweldingcables,wirefeed
gun,orwelderpowercordthroughor
allowthemtocome intocontactwith
wateror moisture.
seriousinjuryfrom shock,
a. theworkpieceor anyconductive
materialincontactwithit,
b. theworkpiececlamp,
c. the electrodeorweldingwire,
d. anymetal partsonthe electrode
holder,orwirefeed gun.
• 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 of the
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,
makecertainthat anyoneelsewhouses
thisweldingequipment,or is a bystander
intheweldingarea, understandsand
followsthese safetyinstructionsaswell.
• 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.
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