Harbor Freight Tools 91146 User's Manual
Contents
1. All maintenance service and repairs not listed in this manual are only to be attempted by a qualified service technician PLEASE READ THE FOLLOWING CAREFULLY THE MANUFACTURER AND OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY NEITHER THE MANUFACTURER OR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT IN FACT THE MANUFACTURER AND OR DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS AND NOT BY THE BUYER THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO SKU 91146 For technical questions please call 1 800 444 3353 PAGE 25 PARTS LIST WELDING MACHINE Part Description Part Description Part Description 2 MIG Gun Outlet 13 Front Panel Bracket 32 Fan Display 4A Voltage Selector Switch 17 8 Pin Relay 36A Inching Button 5A Pause Timer 18 8 Pin Relay Socket 36B Gas Test Button Spot Timer 19 Base 37 Wire Feeder Solenoid Valve Operating LED pHandie oo e E 5B ee ee ee ee Flow Meter i se 9 ASSEMBLY DIAGRAM WELDING MACHINE NOTE Some parts are lis2. TIME Typically the standard welding process used To operate turn the Wire Speed Mode Selector 6 to its 2 Time setting Squeeze the Welding Gun Trigger 18A to start the Pre Gas Then weld accordingly Release the Welding Gun Trigger to stop welding The Post Gas will continue to deliver the protective gas according to the setting of the Post Gas Timer 5D See Figures D F and K 2 4 TIME The benefit of this process is that there is no need to continuously squeeze the Welding Gun Trigger 18A during a long welding job To operate turn the Wire Speed Mode Selector 6 to its 4 Time setting Squeeze and quickly release the Welding Gun Trigger to start and stop welding The Post Gas will continue to deliver the protective gas according to the setting of the Post Gas Timer 5D See Figures D F and K 3 SPOT AND PAUSE This process reduces the number of times the operator must squeeze the Welding Gun Trigger 18A while spot welding This process also allows the operator to lower the welding heat for thin material to avoid burn through To operate turn the Wire Speed Mode Selector 6 to its Spot and Pause setting By squeezing the Welding Gun Trigger 18A the operator can weld and pause in cycle according to the settings of the Pause Timer 5A and Spot Timer 5B See Figures D F and K 4 INTERVAL This process allows the operator to produce the same length and quality of the welding bead more efficiently To operate
3. from the work area When possible move the work to a location well away from combustible materials If relocation is not possible protect the combustibles with a cover made of fire resistant material Remove or make safe all combustible materials for a radius of 35 feet 10 meters around the work area Use a fire resistant material to cover or block all open doorways windows cracks and other openings Enclose the work area with portable fire resistant screens Protect combustible walls ceilings floors etc from sparks and heat with fire resistant covers If working on a metal wall floor ceiling etc prevent ignition of combustibles on the other side by moving the combustibles to a safe location If relocation of the combustibles is not possible designate someone to serve as a fire watch equipped with a fire extinguisher during the welding process and at least one half hour after the welding is completed Do not place the torch on any material other than bare concrete until the torch is completely cooled Do not weld on materials having a combustible coating or combustible internal structure such as walls or ceilings without an approved method for eliminating the hazard Do not dispose of hot slag in containers holding combustible materials Keep a fire extinguisher nearby and know how to use it After welding make a thorough examination for evidence of fire Be aware that easily visible smoke or flame may not be present for some time af
4. may also affect tool performance Always turn off the Welder and unplug the unit from its electrical outlet before performing any inspection maintenance or cleaning procedures Use the right tool or attachment for the right job Do not attempt to force a small tool or attachment to do the work of a larger industrial tool or attachment There are certain applications for which this product was designed It will do the job better and more safely at the rate for which it was intended Do not modify this product and do not use this product for a purpose for which it was not intended Proper cylinder care Secure cylinders to the Base of the Welder a wall or post to prevent them from falling All cylinders should be used and stored in an upright position in a well ventilated area Never drop or strike a cylinder Do not use cylinders that have been dented Cylinder caps should be used when moving or storing cylinders Empty cylinders should be kept in specified areas and clearly marked empty Never use oil or grease on any inlet connector outlet connector or cylinder valve Additional specific instructions for the safe handling of cylinders should be supplied by your cylinder supplier and covered under local state and federal regulations governing pressurized gases A WARNING The brass components of this product contain lead a chemical known to the State of California to cause birth defects or other reproductive harm Californi
5. wire melteo onto contact tip Wire jammed in liner due to dirt accumulation in liner or extreme bending of cable assembly Feed rate too low Contact tip too far away from workpiece Burn back time set too long Drive roll pressure too low or too high Faulty or worn liner Incorrect type or size of liner or liner incorrectly attached 12 Faulty wire feed control 13 Drive rolls worn or incorrectly installed Incorrect Size of drive rolls used 1 NN WARNING Make sure the Power Switch 10 is in its OFF position Unplug the Power Cord Plug from its electrical outlet and allow the Welder to completely cool before performing any inspection maintenance or cleaning procedures Note Always ground the contact tip to insure that there is no residual energy in the Welder 2 Before each use inspect the general condition of the Welder Check for damaged electrical wiring loose connections cracked burnt or broken parts and any other condition that may affect its safe operation If abnormal noise or vibration occurs have the problem corrected before further use Do not use damaged equipment 3 Every six months Blow off or vacuum dirt and dust deposits on the Auxiliary Transformer 23 and other components Dirt or dust deposits on the Welding Transformer and other internal components may reduce the insulating property or cause overheated Transformer During heavy usage clean monthly SKU 91146 For te
6. 3353 PAGE 5 A WARNING Improperly connecting the grounding wire can result in the risk of electric shock Check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded Do not modify the power cord plug provided with the tool Never remove the grounding prong from the plug Do not use the tool if the power cord or plug is damaged If damaged have it repaired by a service facility before use If the plug will not fit the outlet have a proper outlet installed by a qualified electrician GROUNDED EQUIPMENT EQUIPMENT WITH THREE PRONG PLUGS 1 Z WARNING The Power Cord requires the attachment of a 220 volt grounded 3 Prong Plug not included For safety purposes only a qualified certified electrician should attach a Plug to the Power Cord Never modify the Plug in any way To comply with the National Electric Code and to provide additional protection from the risk of electrical shock this product should only be connected to a 220 volt electrical outlet that is protected by a Ground Fault Circuit Interrupter GFCI 2 The grounding prong in the plug is connected to the green wire inside the cord to the grounding system in the welding equipment The green wire in the cord must be the only wire connected to the equipments grounding system and must never be attached to an electrically live terminal See Figure A 3 Your welding equipment must be plugged into an appropriate outlet pro
7. 36A until the welding wire extends about 1 out of the Gun Then reinstall the Gas Nozzle 100A and Contact Tip 90A See Figures F and I Feed the welding wire out of the Gun to check for proper drive roll pressure If necessary tighten the Pressure Adjustment Knob to prevent the wire from slipping See Figure I Cut off the welding wire so that only about 3 8 extends from the Gun Then close the Upper Right Side Panel 21 of the welding machine and turn the Power Switch 10 to its OFF position See Figure I To Install A Gas Cylinder ing in cylinder and equipment damage and personal injury Do not exceed maximum cylinder weight of 100 pounds 43 with CO2 shielding gas To use CO2 shielding gas you must install a CO gas Pressure Regulator Flow Meter not included With assistance set the cylinder upright on the Base 19 of the Welder Make sure to use the accessory Chain to secure the cylinder to the body of the Welder See Figure J next page Remove the Cap from the cylinder Stand to the side of the cylinder Valve and open the Valve slightly to blow dust and dirt from the Valve Then close the Valve See Figure J Make sure the Flow Adjust on the Pressure Regulator Flow Meter 48 is turned off Then screw the Pressure Regulator Flow Meter firmly onto the cylinder Valve See Figure J Attach the Gas Hose 202A from the Pressure Regulator Flow Meter 43 to the Gas Inlet Valve 29 l
8. CHICAGO d Yes fie Power Tools INDUSTRIAL MIG WELDER 250 AMP Model 91146 ASSEMBLY AND OPERATING INSTRUCTIONS TOO 3491 Mission Oaks Blvd Camarillo CA 93011 Visit our Web site at http www harborfreight com Copyright 2005 by Harbor Freight Tools All rights reserved No portion of this manual or any artwork contained herein may be reproduced in any shape or form without the express written consent of Harbor Freight Tools For technical questions please call 1 800 444 3353 PRODUCT SPECIFICATIONS Description tem 3 Description Input Voltage 220V 60 Hz 45 Input Amperage Power Cord 10 AWG 6 Long Power Plug 220V not included Requires 50 Amp Circuit 60 250 Amps 100 195 Amps Thickness Capacit Wheels Front Swivel Castors 3 1 4 Diameter x 1 Thick Rear Rigid 8 Diameter x 1 1 2 Thick on 7 8 Diameter Axle Accessories Gas Pressure Regulator w Flow Meter ae Gloves Face Mask 1 Torch Liner 5 Spare Tips 187 Pownds o SAVE THIS MANUAL You will need this manual for the safety warnings and precautions assembly operating inspection maintenance and cleaning procedures parts list and assembly diagram Keep your invoice with this manual Write the invoice number on the inside of the front cover Keep this manual and invoice in a safe and dry place for future reference UNPACKING When unpacking check to make sure all the parts shown on the Parts Lists on pag
9. Wire Tension Open the Upper Right Side Panel 21 and remove the Lock Knob on the Wire Spool Hub 33 See Figure I next page Insert a Wire Spool not included onto the Wire Spool Hub 33 and secure the Wire Spool in place with the Lock Knob See Figure l Lower the Pressure Adjustment Knob on the Wire Feeder 37 See Figure l Hold the welding wire tightly to keep it from unraveling Then pull out about 6 of welding wire from the Wire Spool and make a clean cut at the end of the wire See Figure l Push the welding wire through the guides in the Wire Feeder 37 and about 4 into the Gun Power Cable 40A Continue to hold the wire See Figure l SKU 91146 For technical questions please call 1 800 444 3353 PAGE 15 WIRE SPOOL NOT INCLUDED IN bY LOCK KNOB GUN POWER CABLE 5 ON S PRESSURE ADJUSTMENT KNOB PRESSURE INDICATOR SCALE 7 8 CONTACT TIP 90A GAS NOZZLE 100A POWER SWITCH 10 TO ON TIGHTEN PRESSURE INDICATOR WIRE GUN TRIGGER SKU 91146 For technical questions please call 1 800 444 3353 PAGE 16 Turn the Pressure Adjustment Knob clockwise to tighten the tension of the welding wire NOTE Use the Pressure Indicator Scale to set the desired drive roll pressure See Figure I Remove the Gas Nozzle 100A and Contact Tip 90A See Figure I Turn the Power Switch 10 to its ON position See Figure I Depress the Inching Button
10. a Health amp Safety code 25249 5 et seq A WARNING This product when used for welding cutting and similar applications produces chemicals known to the State of California to cause cancer and birth defects or other reproductive harm California Health amp Safety code 25249 5 et seq A WARNING People with pacemakers should consult with their physician s before using this product Operation of electrical equipment in close proximity to a heart pacemaker could cause interference or failure of the pacemaker A WARNING The warnings precautions and instructions discussed in this instruction manual cannot cover all possible conditions and situations that may 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 SKU 91146 For technical questions please call 1 800 444 3353 PAGE 11 PRODUCT OVERVIEW 1 This Welder is designed for MIG MAG welding on mild steel stainless steel and nonferrous materials up to 3 8 thickness Additional features of this unit are as follows See Figure D A Constant voltage transformer with step up adjustment B Digital step less electronic speed control C 2 4 Times interval and spot pause welding D Pre gas and post gas flow E Soft start burnback F Real time digital volt amp meter G Two inductance outlets High amp Low H Easy connect twist lock
11. chnical questions please call 1 800 444 3353 PAGE 22 4 To replace the 3 AMP Buss Fuse Failure of the Welder to operate may be caused by a blown 3 AMP Fuse 7 as indicated by its melted wire strand within the Fuse To replace the Fuse unscrew and remove the Fuse Cap Remove the old Fuse and install a new 3 AMP Fuse Then replace the Fuse Cap 5 When storing make sure to store the Welder in a safe clean dry location out of reach of children and unauthorized users 6 A CAUTION All maintenance service and repairs not listed in this manual are only to be attempted by a qualified service technician INSPECTION MAINTENANCE AND CLEANING WELDING GUN 1 Make sure the Power Switch 10 on the Welding Machine is in its OFF position Unplug the Power from its electrical outlet and allow the Welder to completely cool before performing any inspection maintenance or cleaning procedures Note Always ground the contact tip to insure that there is no residual energy in the Welder 2 Before each use Inspect the general condition of the Welding Gun Check for damaged electrical wiring gas hose loose connections cracked burnt or broken parts and any other condition that may affect its safe operation If abnormal noise or vibration occurs have the problem corrected before further use Do not use damaged equipment 3 Before each use Clean welding spatter from the inside of the Gas Nozzle 100A and spray with an anti spat
12. eparate cable of appropriate size IMPORTANT Only a qualified certified electrician should perform this procedure Do not touch the welding wire if you are in contact with the workpiece ground or another welding wire from a different machine Do not allow the welding wire to touch earth ground Accidental earth discharges may cause overheating and fire hazards Do not pass equipment cables through or near lifting chains crane cables or any electrical lines Never use the Welder near water Ensure that the surrounding area and cutting objects are dry Do not spray water or other liquids on or near the Welder Avoid all direct contact between the skin and wet garments and metal parts under electrical power Check that gloves and protective clothing are dry Never leave the Welder unattended when it is plugged into an electrical outlet Make sure to unplug it from its electrical outlet before leaving the area Do not unplug the Welder by pulling on the Power Cord Keep the Power Cord away from heated surfaces Always turn off the Welder in the event of a power failure Significant DC electrical voltage exists after turning off and unplugging the Welder Discharge the electrode to ground before handling SKU 91146 For technical questions please call 1 800 444 3353 PAGE 10 25 26 27 28 29 30 31 32 Performance of this Welder may vary depending on variations in local line voltage Extension cord usage
13. es 26 and 27 are included If any parts are missing or broken please call Harbor Freight Tools at the number shown on the cover of this manual as soon as possible GENERAL SAFETY RULES ZN WARNING READ AND UNDERSTAND ALL INSTRUCTIONS Failure to follow all instructions listed below may result in electric shock fire and or serious injury SAVE THESE INSTRUCTIONS WORK AREA Is Keep your work area clean and well lit Cluttered benches and dark areas invite accidents 2 Do not operate welding equipment in explosive atmospheres such as in the presence of flammable liquids gases or dust Welding equipment creates sparks which may ignite the dust or fumes SKU 91146 For technical questions please call 1 800 444 3353 PAGE 2 3 Keep bystanders children and visitors away while operating welding equipment Distractions can cause you to lose control Protect others in the work area from arc rays sparks and slag Provide barriers or shields as needed ELECTRICAL SAFETY 1 Grounded welding equipment must be plugged into an outlet properly installed and grounded in accordance with all codes and ordinances Never remove the grounding prong or modify the plug in any way Do not use any adapter plugs Check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded If the welding equipment should electrically malfunction or break down grounding provides a low resistance path to carry electrici
14. he Axle located at the rear of the Base 19 Secure both Wheels to the Axle by inserting one Cotter Pin through each end of the Axle Once inserted make sure to spread each Cotter Pin to keep them in place See Figure G 3 To attach the two Front Castor Wheels 48 to the Welder align the four holes in each top plate of a Castor Wheel with the four threaded mounting holes located in each corner at the bottom front of the Welder Use four Bolts 45 and four Washers 46 to secure each Castor Wheel to the Base See Figure G IIT rrr bul COTTER PIN 44 4 FRONT AXLE PAE A CASTOR WHEEL 48 BASE 19 FIGURE G REAR WHEEL 47 SKU 91146 For technical questions please call 1 800 444 3353 PAGE 14 To Attach The Gun Power Cable And Ground Clamp Cable 1 Insert the plug of the Gun Power Cable 40A firmly into the MIG Gun Outlet 2 See Figure H Insert the plug of the Ground Clamp Cable 201 firmly into the High Inductance Outlet 3A or the Low Inductance Outlet 3B NOTE The High Inductance Outlet allows for a higher welding heat resulting in a deeper penetration of the welding wire into thicker workpieces The Low Inductance Outlet allows for a lower welding heat and is typically used for thinner workpieces See Figure H GUN GROUND POWER CLAMP CABLE 40A CABLE 201A HIGH INDUCTANCE OUTLET 3A LOW INDUCTANCE OUTLET 3B FIGURE H To Install Welding Wire Spool And Adjust
15. identally Store idle welding equipment out of reach of children and other untrained persons Welding equipment is dangerous in the hands of untrained users Maintain welding equipment with care Keep equipment clean and dry Properly maintained equipment is less likely to malfunction and is easier to control Do not use damaged welding equipment Tag damaged equipment Do not use until repaired Check for misalignment or binding of moving parts breakage of parts and any other condition that may affect the equipment s operation If damaged have the equipment serviced before using Many accidents are caused by poorly maintained equipment SKU 91146 For technical questions please call 1 800 444 3353 PAGE 4 8 Use only accessories that are recommended by the manufacturer for your model Accessories that may be suitable for one type of welding equipment may become hazardous when used on another type of equipment Al Equipment service must be performed only by qualified repair personnel Service or maintenance performed by unqualified personnel could result in a risk of injury 2 When servicing welding equipment use only identical replacement parts Follow instructions in the Inspection Maintenance And Cleaning section of this manual Use of unauthorized parts or failure to follow maintenance instructions may create a risk of electric shock burns or other injury SKU 91146 For technical questions please call 1 800 444
16. leggings rubber soled fire resistant shoes or boots should be worn when using this Welder Do not wear pants with cuffs shirts with open pockets or any clothing that can catch and hold molten metal or sparks Keep clothing free of grease oil solvents or any other flammable substances Wear dry insulating gloves and protective clothing Wear an approved head covering to protect head and neck Use aprons cape sleeves and shoulder covers and bibs designed and approved for welding procedures When welding overhead or in confined spaces wear flame resistant ear plugs or ear muffs to keep sparks out of ears 4 Avoid overexposure to fumes and gases Always keep your head out of the fumes Do not breathe the fumes Use enough ventilation or exhaust or both to keep fumes and gases from your breathing zone and general area Where ventilation is questionable have a qualified technician take an air sampling to determine the need for corrective measures Use mechanical ventilation to improve air quality If engineering controls are not feasible use an approved respirator Work in a confined area only if it is well ventilated or while wearing an air supplied respirator Follow OSHA guidelines for Permissible Exposure Limits PELs for various fumes and gases Follow the American Conference of Governmental Industrial Hygienists recommendations for Threshold Limit Values TLV s for fumes and gases Have a recognized specialist in Industrial Hygiene
17. male and female welding cables l Forced air cooling system J Thermal overload protection FRONT PANEL 14 CONTROLS 1 ront Pane Wire Speed Potentiometer 10 2 1 Power Switc Pause Timer 1 gital Volt AMP Disp D Digital Wire Feed Speed Displa 4 4A U gt g gt SKU 91146 For technical questions please call 1 800 444 3353 PAGE 12 BACK PANEL CONTROLS o Parts Description Gas Inlet Valve Back Panel FIGURE E SIDE PANEL PRE SOFT BURN POST CONTROLS GAS START BACK GAS TIMER 5F TIMER TIMER 5G 5E 5D INCHING GAS TEST BUTTON O BUTTON 36A 36B Post Gas Timer Pre Gas Timer Burn Back Timer oft Start Potentiometer SKU 91146 For technical questions please call 1 800 444 3353 PAGE 13 ASSEMBLY INSTRUCTIONS NOTE For additional references to the parts listed in the following pages refer to the Assembly Diagrams on pages 26 and 28 To Attach A Power Cord Plug L Only a qualified certified electrician should attach a 220 volt Power Plug not included to the Power Cord of the Welder 2 For further instructions refer to page 5 and page 6 of this manual To Attach The Rear Wheels And Front Castor Wheels 1 WARNING Prior to performing any further assembly procedures make sure the Power Cord Plug of the Welder is unplugged from its electrical outlet 2 To attach the two Rear Wheels 47 to the Welder slide a Wheel onto each end of t
18. ne the required minimum cord size 6 If you are using an extension cord outdoors make sure it is marked with the suffix W A W in Canada to indicate it is acceptable for outdoor use 7 Make sure your extension cord is properly wired and in good electrical condition Always replace a damaged extension cord or have it repaired by a qualified electrician before using it 8 Protect your extension cords from sharp objects excessive heat and damp or wet areas SYMBOLOGY Double Insulated 6 Canadian Standards R Association Underwriters Laboratories Inc olts Alternating Current CA ee mo No Load Revolutions FIGURE C xxxx min per Minute RPM SKU 91146 For technical questions please call 1 800 444 3353 PAGE 7 SPECIFIC SAFETY RULES 1 Maintain a safe working environment Keep the work area well lit Make sure there is adequate surrounding workspace Always keep the work area free of obstructions grease oil trash and other debris Do not use the Welder in areas near flammable chemicals dusts and vapors 2 Maintain labels and nameplates on the Welder These carry important information If unreadable or missing contact Harbor Freight Tools for a replacement 3 Prevent eye injury and burns Wearing and using personal safety clothing and safety devices reduce the risk of injury Wear ANSI approved safety impact eyeglasses with a welding helmet featuring at least a number 10 shade lens rating Leather
19. ne voltage Broken Power lead Repair Wrong voltage Check voltage against rating plate Torch or work lead loose or broken Tighten and repair connections Welder welds but soon stops welding Variable or sluggish welding Proper ventilation hindered Make sure all case openings are free for proper circulation of air Welder loaded beyond rating Operate at normal current and duty cycle consistent with rating Fan motor inoperative Check leads and motor bearings Fan motor can be tested on 220V line with welder on voltage across fan motor should be approximately 220V Poor internal connections Check for loose or hot connections and tighten Excessive dust accumulation in welder Blow out welder with low pressure Poor terminal connection Check and clean all connections Current too low Check recommended currents wire type and size Low line voltage Check the input line to be as specified on the nameplate Check with power company Welding leads too small Use larger welding leads Old and badly frayed welding cables Replace Too many spatters Insufficient gas Increase gas flow Loose gas fittings on regulator or gas line Check and secure gas fittings Voltage is too high Decrease the welding voltage Torch is too inclined Correct the torch angle Nozzle is dirty Clean the
20. nozzle Inductance is not sufficient Correct the inductance Poor penetration Current too low Increase welding current Wire feed is not constant Correct the wire feeding Edges are too far apart Correct the distance between the edges Chamfer is too small Correct the chamfer Projection is too far out Correct the projection Porosity Dirt on welding metal or work piece Clean the work piece and welding metal Protection gas impure or high humidity in gas Change the gas Current intensity is too low Increase the current Hot cracks Dirt on welding metal or work piece Clean the work piece and welding metal Impure weld material Consult the wire supplier High heat supply Decrease the current Type of wire is inappropriate Change the appropriate wire Welder won t shut off Line switch has failed mechanically Clean on Replace switch For technical questions please call 1 800 444 3353 PAGE 21 TROUBLESHOOTING GUIDE WELDING GUN amp WIRE DRIVE Problem____ Possible Cause _ _ _ No arc Interruption of welding power circuit to we gun or workpiece 2 Power source or control defective 3 Trigger wire broken cut or disconnected 4 Power source contractor not activated ding current too high Contact tip not correctly tightened Ground clamp making poor contact ding
21. ocated on the Back Panel 30 of the Welding machine See Figure J SKU 91146 For technical questions please call 1 800 444 3353 PAGE 17 ts Adjust the flow rate of the gas by turning the Flow Adjust The typical flow rate is 20 CFH cubic feet per hour Check the welding wire manufacturer s recommended flow rate See Figure J PRESSURE REGULATOR FLOW METER CYLINDER CAP CYLINDER VALVE ARGON GAS OR MIXED GAS GAS INLET VALVE 29 FIGURE J di BACK PANEL 30 Welding Gun Duty Cycle And Overheating A IMPORTANT Welding longer than the rated duty cycle for this Welding equipment can damage the Gun and void its warranty 2 Duty cycle is a percentage of 10 minutes that the unit can weld at its rated load without overheating See Figure L page 20 3 If the unit should overheat the thermostat opens output stops and the cooling fans continue to run Wait fifteen minutes for the unit to cool Reduce amperage or voltage or duty cycle before welding 4 This Welder at its 60 duty cycle can run continuously under load for 6 minutes out of each 10 minute period See Figure L 5 NOTE Higher duty cycles can be used at lower currents See Rating Plate information on Front Panel SKU 91146 For technical questions please call 1 800 444 3353 PAGE 18 The Four Welding Features NOTE The following four welding features are designed to optimize specific welding processes See Figure K 1 2
22. or Environmental Services check the operation and air quality and make recommendations for the specific welding situation 5 Do not perform welding or cutting operations near chlorinated hydrocarbon vapors produced by degreasing or painting The heat generated by arc rays can react to form phosgene a highly toxic gas 6 Irritation of the eyes nose and throat are symptoms of inadequate ventilation Take immediate steps to improve ventilation Do not continue operations if symptoms persist SKU 91146 For technical questions please call 1 800 444 3353 PAGE 8 Ye When welding or cutting in small areas the operator should be externally accompanied by another person standing nearthe enclosed work area to observe accident prevention procedures 8 When welding or cutting be aware that high frequency radiation may be produced which can interfere with radio navigation safety devices computers and communications equipment Before operating have a qualified technician check out that possibility 9 Keep high frequency source doors and panels tightly shut Keep spark gaps at the correct settings Use proper grounding and shielding to minimize the possibility of interference Keep all cables close together and close to the ground Locate the welding or cutting operation as far as possible from sensitive electronic equipment or have the electronic equipment shut down temporarily 10 Prevent accidental fires Remove any combustible material
23. perly installed and grounded in accordance with all codes and ordinances The plug and outlet should look like those in the following illustration See Figure A 220 VOLT ZN WARNING Pai ONLY A QUALIFIED CERTIFIED ELECTRICIAN SHOULD CONNECT A POWER PLUGTOTHE POWER CORD 220 VOLT ELECTRICAL OUTLET NOT INCLUDED POWER CORD FIGURE A SKU 91146 For technical questions please call 1 800 444 3353 PAGE 6 EXTENSION CORDS The minimum extension cord size for this tool is 6 GAUGE for cords UPTO 25 LONG CORDS LONGER THAN 25 SHOULD NOT BE USED WITH THIS WELDER le Grounded welding equipment require a three wire extension cord 2 As the distance from the supply outlet increases you must use a heavier gauge extension cord Using extension cords with inadequately sized wire causes a serious drop in voltage resulting in loss of power and possible tool damage The minimum extension cord gauge for this tool is 6 AWG for cords up to 25 long Cords longer than 25 should not be used with this welder 3 The smaller the gauge number of the wire the greater the capacity of the cord For example a 14 gauge cord can carry a higher current than a 16 gauge cord 4 When using more than one extension cord to make up the total length make sure each cord contains at least the minimum wire size required 5 If you are using one extension cord for more than one tool add the nameplate amperes and use the sum to determi
24. r moving parts Loose clothes jewelry or long hair can be caught in hot or moving parts See page 8 number 3 for recommended safety clothing Avoid accidental starting Be sure the Power Switch is off before plugging in Plugging in welding equipment with the Power Switch on invites accidents Remove adjusting keys or wrenches before turning on the welding equipment A wrench or a key that is left attached to an electrically charged part of the welding equipment may result in personal injury Do not overreach Keep proper footing and balance at all times Proper footing and balance enables better control of the welding equipment in unexpected situations TOOL USE AND CARE Use clamps not included or other practical ways to secure and support the workpiece to a stable platform Holding the work by hand or against your body is unstable and may lead to loss of control Do not force the welding equipment Use the correct equipment for your application The correct equipment will do the job better and safer at the rate for which it is designed Do not use the power tool if the Power Switch does not turn it on or off Any equipment that cannot be controlled with the Power Switch is dangerous and must be replaced Disconnect the Power Cord Plug from the power source before making any adjustments changing accessories or storing the welding equipment Such preventive safety measures reduce the risk of starting the welding equipment acc
25. ted and shown for illustration purposes only and are not available individually as replacement parts SKU 91146 For technical questions please call 1 800 444 3353 PAGE 26 PARTS LIST WELDING GUN Pat ___Deseription ____ _Part _ _____Deseription 44_____ Nozzle Spring SQA Central Adapter Block KZ 2 Nut M10 x 4 al SKU 91146 For technical questions please call 1 800 444 3353 PAGE 27 ASSEMBLY DIAGRAM WELDING GUN NA 201A GROUND CLAMP CABLE NOT SHOWN 202A GAS HOSE NOT SHOWN r e eau 90A 80A 1A CI 100a a O o 200A l O 120A SS a amer gar ar ect HO 130A 131A 132A 133A De SE Ee EOE OT A H5 i _ ss R K 3 NOTE Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts SKU 91146 For technical questions please call 1 800 444 3353 PAGE 28 ELECTRICAL SCHEMATIC WELDING MACHINE eN 8 s fi gt O po oO a N a fe a cE wv a co e 53 3o 3 a as E 5 UN el B pp 58 _2 a a ee u CO ze 3 oO DE Ee Je zE ya o ws a gt a a x Y Sie mis abe ets az ts os CNI ai a a Lan 225 aineelesaezt E bbb bbb dd PAN l I gt syt Pa To l 4 E A
26. ter fluid 4 To replace the Gun Contact Tip Cut off the welding wire at the Contact Tip 90A Remove the Nozzle Remove the old Contact Tip and install a new Contact Tip Then replace the Nozzle See Figure O AE CONTACT TIP 90A Q nozze 100A FIGURE O SKU 91146 For technical questions please call 1 800 444 3353 PAGE 23 5 To replace the Gun Liner Disconnect the Gun s Power Cable from the Welding machine Remove the Nozzle Contact Tip Adapter Gas Diffuser and Wire Outlet Guide Then remove the old Liner Lay the Gun s Power Cable out straight before installing a new Liner Blow out the Gun Casing with compressed air Install and tighten the new Liner Cut Liner off 3 4 from the Head Tube 3 8 for aluminum Then reinstall the Wire Outlet Guide Gas Diffuser Adapter Contact Tip and Nozzle See Figure P Deg REMOVE NOZZLE 100A WAN NECK 1A CONTACT TIP 90A ADAPTER GAS DIFFUSER WIRE OUTLET GUIDE REMOVE OLD LINER 130A BLOW OUT GUN om LAY GUN POWER CABLE 40A OUT STRAIGHT BEFORE INSTALLING NEW LINER FIGURE P SKU 91146 For technical questions please call 1 800 444 3353 PAGE 24 6 To clean exterior of Welding Gun Use a damp cloth with a mild detergent Then dry Do not use solvents to clean the Gun Te When storing Make sure to store the Welding Gun in a safe clean and dry location out of reach of children and unauthorized users 8 WARNING
27. ter the fire has started Do not weld in atmospheres containing dangerously reactive or flammable gasses vapors liquids and dust Provide adequate ventilation in work areas to prevent accumulation of flammable gases vapors or dust Do not apply heat to a container that has held an unknown substance or a combustible material whose contents when heated can produce flammable or explosive vapors Clean and purge containers before applying heat Vent closed containers including castings before preheating or welding Note Use caution when welding galvanized metal toxic gases are formed and must be ventilated properly 11 Read and understand all instructions and safety precautions as outlined in the manufacturer s manual for the material you will weld SKU 91146 For technical questions please call 1 800 444 3353 PAGE 9 20 21 22 23 24 Industrial applications must follow OSHA requirements Never plug the Power Cord of this product into an electrical outlet while standing on a wet or damp surface Connect the earth ground as near as possible to the operating area Earth connections to structural parts of the building or other places distant to the operating area will reduce their effectiveness and increase the danger of electric shock In addition to grounding the workpiece with the Welder Grounding Clamp an earth grounding of the workpiece is recommended Ground it directly to an earth pipe or grounding rod with a s
28. turn the Wire Speed Mode Selector 6 to its Interval setting By squeezing the Welding Gun Trigger 18A the operator can weld in one cycle according to the preset welding time See Figures D F and K SPOT AND PAUSE 6 A a FIGURE K INTERVAL SKU 91146 For technical questions please call 1 800 444 3353 PAGE 19 024 to 047 Hard or Flux Cored Wires 60 Duty Cycle at 250 Amperes Using Mixed Gases 6 Minutes Welding 4 Minutes Resting Relation Between Duty Cycle And Weld Amperes 100 80 60 DUTY CYCLE 207 FIGURE L 100 200 WELD AMPERES Material Welding Thickness rene A E y META Current FIGURE M Do not change voltage while welding Wire speed is a starting value only and can be adjusted while welding Weld conditions also depend on other variables such as stickout travel speed weld angle cleanliness of metal etc SKU 91146 For technical questions please call 1 800 444 3353 PAGE 20 Relation Between Wire Feed Speed Size Of Wire amp Welding Current Wire Feed Speed m min FIGURE N Welding Current A ee ioscan innit 1 2 mm TROUBLESHOOTING GUIDE WELDING MACHINE SKU 91146 Trouble Causes Welder does not operate Line switch not turned On Corrective Action Place line switch in On position Supply line fuse blown Replace Also find the cause Power circuit dead Check supply li
29. ty away from the user 2 Avoid body contact with grounded surfaces such as pipes radiators ranges and refrigerators There is an increased risk of electric shock if your body is grounded 3 Do not expose welding equipment to rain or wet conditions Water entering welding equipment will increase the risk of electric shock 4 Do not abuse the Power Cord Never use the Power Cord to carry welding equipment or pull the Plug from an outlet Keep the Power Cord away from heat oil sharp edges or moving parts Replace damaged Power Cords immediately Damaged Power Cords increase the risk of electric shock 5 When operating welding equipment outside use an outdoor extension cord marked W A or W These extension cords are rated for outdoor use and reduce the risk of electric shock The minimum extension cord size for this tool is 6 GAUGE for cords UP TO 25 LONG CORDS LONGER THAN 25 SHOULD NOT BE USED WITH THE WELDER PERSONAL SAFETY 1 Stay alert Watch what you are doing and use common sense when operating welding equipment Do not use welding equipment while tired or under the influence of drugs alcohol or medication A moment of inattention while operating welding equipment may result in serious personal injury SKU 91146 For technical questions please call 1 800 444 3353 PAGE 3 Dress properly Do not wear loose clothing or jewelry Contain long hair Keep your hair clothing and gloves away from hot o
30. z a F un e nz gt v z a ce 3 te a a Ez 4 J o a _ G 1 pa zZ Y ie a 1 a 2 rs P Be fun ll a i de E J TI 101 26 Rectifier s 2 ag I Alleko 3 3 a F TTT E a IN s ze 5 SE x Zo 3 wes ee a a5 485 Dn ER pa se E D FU 7 5 e a Y E de eee 11 11111 mm mM m sa a a a xX 14 5 rh 5 l c g E m ot ae alla 3 By 7 me ape See oer 2e z e zA Mm 2 Ske wl 223 a E A as A e 5 8 aad 5 WG i E jaa Za 2d e F gt a us a lt qa SKU 91146 For technical questions please call 1 800 444 3353 PAGE 29
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