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1.
While welding aluminum with the Spool gun or MIG gun you must use 100% argon. You
cannot use a mix as you would with steel or stainless.
2.
While welding aluminum with the Spool gun or MIG gun you must use the next size up tip
or a special oversize tip for the wire because the heat will cause the aluminum wire to
swell and it will either drag or seize in the tip.
3.
While welding aluminum with the MIG process, best results are achieved by using a dedi-
cated stainless steel brush to remove the oxide layer and using acetone or aluminum
cleaner before welding to remove any residues. Even though aluminum may appear shiny
and clean, it still has an oxide layer and a thin layer of oil left over from the manufacturing
process. Some soot will appear in most Aluminum MIG welds but if a lot is noticed, you
have either contaminated metal, or insufficient gas flow. You can also induce turbulence
by having too much of a torch angle. Start with a 90 degree angle and then lean the gun
slightly (about 15 degrees) to the
“
push
”
position.
4.
Welding aluminum is not a short circuit process. It is a spray transfer process. Spray trans-
fer is a process that is can be used to weld many metals, but in Aluminum it must be used
to weld correctly. In spray transfer, the wire does not short out against the weld material.
Instead a steady
“
spray
”
of droplets of molten metal pinches off before the wire can con-
tact the material. It is a much quieter process. If you are not familiar with the spray trans-
fer process, please research it before you try it. If you incorrectly adjust the welder while
welding aluminum in the MIG process, you will burn up contact tips almost instantly.
5.
When using the optional spool gun, the amp/wire speed control is controlled at the panel.
Contact Everlast directly to purchase the correct spool gun for this welder.
6.
Flux Core requires the use of serrated drive rollers. These grip the wire and feed it correct-
ly at a steady speed. Flux Core drive rolls are available for purchase as an optional item.
7.
2 lb rolls of wire can be used in the main unit. However the wire spool holder must be dis-
assembled and the cap screw reused as the carrier and the two shouldered spacers can be
fitted on either side to center the roll. Alternately two small pieces of PVC and a small
spring with a couple washers can be purchased locally to create spacers to provide enough
wire tension. There are also wire spool adapters available online from a variety of sources
which allow the spool carrier to remain in place without disassembly. Everlast does not
currently offer these direct for this machine.
8.
When running this unit on a generator, the manufacturer of the generator must certify it
as a having
“
Clean Power
”
output. This means the unit produces a truer sine wave and is
not a modified sine wave generator and is largely free from harmonic distortion. A clean
power generator is usually listed as such, but the manufacturer of the generator should be
able to clarify the clean power status of the generator through the technical department of
the generator manufacturer. Everlast does not keep a list of approved generators nor
does it make endorsements of generators that are listed as clean power output. The gen-
erator power requirement for this unit is unit is 6500 continuous watts for best results.
General Notes Concerning Operation:
