Harbor Freight Tools 55525 Welder User Manual
Contents
1. EtECIRIC EL 220 VAC DUAL MIG WELDER ASSEMBLY AND OPERATION INSTRUCTIONS 3491 Mission Oaks Blvd Camarillo CA 9301 1 Visit our website at http www harborfreight com TO PREVENT SERIOUS INJURY READ AND UNDERSTAND ALL WARNINGS AND INSTRUCTIONS BEFORE USE Copyright 2007 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 or replacement parts please call 1 800 444 3353 220 VAC refers to input voltage Contents PRODUCT SPECIFICATIONS eee nnn 3 GENERAL SAFETY RULES 11 eeeee ree rennen nena nnn nnn 3 Specie Salem HU GS sessanta vertu ee eee EU nM E NE IDEE 6 EON em 9 Extension CordS onoiesee scade p OPEM tap MM NIMM NIE MU 10 VITO OY a 10 UNPACKING ir 10 ASSEMBLY INSTRUC TONS sia oukxxxREE VERE EM ENNUEMEENE EE 2E MER UEM ua ERE EE 11 To Attach The Handle 1 cere eere 11 Face Shield Assembly ecce eee eeeeieeeeiee esee enne n anna 11 To dastalra Wire SPOOL irienn a su pES UNE N CRFMS MEM 11 To Route The VU 12 To Change Wi2. DiIagraii cst rpc cece I 29 TROUBLESHOOTING L2 cosaxemcnEavii Sus uERduDEaNESEESNEMNEN OUS UI Us DNE URINE NR RHME 31 hl iugbe 33 SKU 55525 For technical questions please call 1 800 444 3353 Troubleshooting section at end of manual Page 2 PRODUCT SPECIFICATIONS Welding Current 35 110 Amps Duty Cycle 15 110 Amps 100 35 Amps Refer to chart and explanation on page 18 220 Volt 60 Hz Single Phase 24 5 Amps Should be connected to a 25 Amp minimum dedicated circuit Open Circuit Voltage 40 Volts Maximum Hequired Power Plug Type 3 Prong 220 VAC polarized twist lock not included NEMA L6 30 or equivalent Ground 6 Gauge 6 Torch 8 Gauge 6 Accessories Wire Spool Cylinder Strap Wire Brush amp Hammer Spare 8mm amp 1 0mm Welding Tips Hand Held Face Shield SAVE THIS MANUAL You will need this manual for the safety warnings and precautions assembly oper ating 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 GENERAL SAFETY RULES 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 1 Keep your
3. and Voltage Controls 18 19 See Figure L 8 Make sure the Power Switch is in its OFF position Then plug Power Cord of the Welder into a dedicated 220 VAC 25 amp line with delayed action type circuit breaker or fuse 9 While holding the Welding Torch 15 with the Welding Wire clearly out of the way of any grounded objects turn the Power Switch to its ON position 10 Momentarily squeeze the Trigger 15d of the Welding Torch 15 to test the wire feed speed If necessary adjust the speed by turning the Wire Speed Control Knob 17 See Figure L 11 Orient yourself on the area to be welded then place a Face Shield over your eyes HOLDING THE WELDING TORCH 13 Hold the Welding Torch 15 in one hand and the face shield in the other If a hands free welding shield is used then both hands can be used to WARNING Never look at the ignited arc without ANSI approved arc shaded eye protection in a full face shield Permanent eye damage or blindness can occur Skin burns can occur Never breathe arc fumes See page 8 12 control the Welding Torch Drag Angle 14 The Welding Wire should be directed straight into the joint ane ae This gives an angle of 90 degrees straight up and down for yuk groove end to end welds and an angle of 45 degrees for fillet T shaped welds Weld 15 The end of the Welding Torch should be tilted so that the Direction Welding Wire is angled anywhere in between str
4. extinguisher during the cutting process and for at least one half hour after the cutting is completed Do not weld or cut on materials having a combustible coating or combustible in ternal structure as in 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 spot welding make a thorough examination for evidence of fire Be aware that easily visible smoke or flame may not be present for some time after the fire has started Do not weld or cut in atmospheres containing dangerously reactive or flammable gases vapors liquids and dust Provide adequate ventilation in work areas to prevent accumulation of flammable gases vapors and 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 va pors Clean and purge containers before applying heat Vent closed containers including castings before preheating welding or cutting 11 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 e Where ventilation is questionable have a qualified technician take an air sam pling to determine the need for corrective measures Use mechan
5. remove the Wing Nut 40 and Spool Knob 39 3 Install a 2 Ib Spool not included onto the Wire Spool Axle 9 making sure the Welding Wire unwinds from the top counterclockwise Secure it to the shaft using the spring underneath and the Knob on top 4 Tighten the Knob 39 until only slight resistance is felt when turning the Spool Then tighten the Wing Nut 40 up against the Knob SKU 55525 For technical questions please call 1 800 444 3353 I 11 Troubleshooting section at end of manual age TO ROUTE THE WIRE Note When installing wire of different size or composition you will also need to change wire settings set gun polarity and possibly install gas cylinder See pages 14 16 1 IMPORTANT Securely hold onto the end of the Welding Wire and keep tension on Y it during the following steps If this is not gt a done the Welding Wire will spring backward creating a tangled bird s nest and resulting WELDING in wasted wire See Figure D iis e Hold the Welding Wire securely while you cut enough Wire off the end of the Spool to FIGURE D remove all bent and crimped Wire Make BEEN sure the cut end has no burrs or sharp edges cut again if needed See Figure D 3 Loosen and lower the Tension Adjusting Knob 10b on the Wire Feed Assembly Then raise the Swing Arm 10a See Figure E 4 Keep tension on the Welding Wire and guide at least 12 inches of Wire into the Wire Feed Leade
6. work area clean and well lit Cluttered benches and dark areas invite accidents 2 Do not operate power tools in explosive atmospheres such as in the pres ence of flammable liquids gases or dust Power tools create sparks which may ignite the dust or fumes SKU 55525 For technical questions please call 1 800 444 3353 Troubleshooting section at end of manual ages 9 Keep bystanders children and visitors away while operating a power tool Distractions can cause you to lose control Protect others in the work area from debris such as chips and sparks Provide barriers or shields as needed ELECTRICAL SAFETY 1 Grounded tools 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 tools should electrically malfunction or break down grounding provides a low resistance path to carry electricity 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 power tools to rain or wet conditions Water entering a power tool will increase the risk of electric shock 4 Do not abuse the Power Cord Never use the Power Cord to carry the tools o
7. 1 ror wire Feed cade 1 Ls eotomPiate Sid Lar Temperature Conroe 31 Las versi dearum 1 Las Support she of Grout Board 1 ao wire Feed Speed Grout Board 1 Tat potentiometer Lo washer spg 2 Cas washer copper Pane 4 Cos washer nsaan 1 2 a7 wut Copper mees 2 Wire feed mechanism includes parts 10a 10j amp 11 h L L e l le I L e I ooh NO SKU 55525 For technical questions please call 1 800 444 3353 Page 28 Troubleshooting section at end of manual ASSEMBLY DIAGRAM NOTE Some parts are listed and shown for illustration purposes only and are not avail able individually as replacement parts SKU 55525 For technical questions please call 1 800 444 3353 Page 29 Troubleshooting section at end of manual ASSEMBLY DIAGRAM CONTINUED Wire Feed Mechanism 10 10c a CE c o SKU 55525 For technical questions please call 1 800 444 3353 Page 30 Troubleshooting section at end of manual TROUBLESHOOTING IMPORTANT Be CERTAIN to shut off the Welder disconnect it from power and discharge the torch to ground before adjusting cleaning or repairing the unit Wire feed motor runs but wire does not feed properly POSSIBLE CAUSES AND SOLUTIONS 1 Insufficient wire feed pressure Increase
8. 353 Page 21 Troubleshooting section at end of manual WELD DIAGNOSIS Weld Penetration EXCESS OR BURN THROUGH PROPER INADEQUATE Weld droops on top and Weld is visible underneath and Weld does not contact the joint underneath or falls through bulges slightly on top fully just on the surface entirely making a hole N CROSS SECTIONS Pa POSSIBLE CAUSES AND SOLUTIONS POSSIBLE CAUSES AND SOLUTIONS 1 Excessive material at weld 1 Workpieces too thick close Reduce wire feed speed Joint design must allow weld to reach bot 2 Overheating tom of groove and allow proper welding Increase welding speed and ensure that procedures welding speed is kept steady 2 Incorrect welding technique Maintain or less stickout a f Weld Not Adhering Properl a en OH teen egeret Due Gaps present between weld and previous bead or between weld and workpiece See areas below Hold gun at proper angles as stated under Holding The Torch on page 19 3 Insufficient weld material Increase wire feed speed 4 Insufficient weld heat Reduce Welding Speed ie Ben join POSSIBLE CAUSES AND SOLUTIONS end at joint 1 Dirty workpiece Make certain that workpiece is clean and cross free from oil coatings and other resi SECTION dues 2 Insufficient weld material 3 Incorrect welding technique 1 Improper clamping Place stringer bead at correct place in joint Make sure that pieces are clamped se Adjust workpi
9. For technical questions please call 1 800 444 3353 Page 31 TROUBLESHOOTING continued IMPORTANT Be CERTAIN to shut off the Welder disconnect it from power and discharge the torch to ground before adjusting cleaning or repairing the unit Welder does not function when switched on POSSIBLE CAUSES AND SOLUTIONS 1 Tripped thermal protection device Shut the welder s switch to off and allow it to cool for at least 20 minutes Reduce duration or frequency of welding periods to help reduce wear on the welder Hefer to Duty Cycle section on page 17 2 Faulty or improperly connected Switch Body 15e Have a technician check and secure replace Switch Body 15e 3 Internal fuse blown Have a qualified technician check replace Weak Arc strength POSSIBLE CAUSE AND SOLUTION Incorrect line voltage Check the line voltage and if insufficient have a licensed electrician remedy the situ ation Wire Feeds but arc does not ignite POSSIBLE CAUSES AND SOLUTIONS 1 Improper ground connection Make certain that the workpiece is contacted properly by the Ground Clamp and that the workpiece is properly cleaned near the ground clamp and the welding location 2 Improperly sized or excessively worn Contact Tip 159 Verify that Contact Tip 159 is the proper size for the welding wire used Check that the hole in the tip is not deformed or enlarged Also check that the tip is not dirty this would prevent a good connection If n
10. HER THE MANUFACTURER NOR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALI FIED 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 LIABIL ITY 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 55525 For technical questions please call 1 800 444 3353 Page 26 Troubleshooting section at end of manual PARTS LISTS AND DIAGRAMS WIRING SCHEMATIC SKU 55525 For technical questions please call 1 800 444 3353 Page 27 Troubleshooting section at end of manual PARTS LIST pat Description ay ran Description ay La jmee Ls f L3 Disce 1 Ls pra 3 18 rower cabs 1 7 Ree 3 19m juerrisins id Te mena 3 t oor 1 Ls wire spootante 3 17 we Feed Speed conma nob 1 710 wire Fesa menan 3 15 eswem o ioe swingarm Yt 19 nex sword ios Tension adusing Knob 1 20 Power swich win ugh 1 ios Fensioning am we Tension soing 1 we Tension Pusher 3
11. aight on and 15 degrees in the direction of the weld The amountoftiltis 1 called the drag angle See Figure M FIGURE M 16 The Welding Wire should extend no more than 1 2 past the Nozzle 15h of the Welding Torch 15 This distance is called stickout See Figure M SKU 55525 For technical questions please call 1 800 444 3353 Page 19 Troubleshooting section at end of manual WELD SETTINGS CHART FIGURE N Top figures are Voltage Settings Bottom number is Wire Speed Setting Material Thickness Steel NOTE The numbers within the spaces are the approximate wire feed voltage settings recom 035 947 047 075 075 125 125 157 157 250 mended for this wire size and material thickness Welding Instructions continued on next page MZ MIN 1 MIN 2 MAX 1 MAX 1 MAX 2 Wire Size 1 3 4 6 6 Flux Core Mild Steel ae MIN 1 MIN 2 MAX 1 MAX 1 MAX 2 1 2 3 5 5 4 5 8 MIN 2 MAX 1 MAX 1 MAX 2 MAX 2 Solid Core Mild Steel 2 5 6 5 7 ee MIN 2 MAX 1 MAX 1 MAX 2 MAX 2 1 2 3 4 5 This chart is only intended to show general guidelines for different wire sizes and for different thicknesses of material The settings should only be used at the beginning of a weld and must be adjusted after stopping and carefully inspecting the weld Proper welding takes good technique and practice P 2 Troubleshooting section at end of manual aged For technical
12. ameplates on the Welder These carry important informa tion If unreadable or missing contact Harbor Freight Tools for a replacement 3 Avoid unintentional starting Make sure you are prepared to begin work before turning on the Welder 4 Do not force the Welder This tool will do the work better and safer at the speed and capacity for which it was designed 5 Never leave the Welder unattended when it is plugged into an electrical outlet Turn off the tool and unplug it from its electrical outlet before leaving 6 Industrial applications must follow OSHA guidelines T Never stand on the Welder Serious injury could result if the Welder is tipped or if hot surfaces are accidently contacted 8 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 ob structions grease oil trash and other debris Do not use a power tool in areas near flammable chemicals dusts and vapors Do not use this product in a damp or wet location Prevent eye injury and burns Wearing and using ANSI approved personal safety clothing and safety devices reduce the risk for injury i e Wear ANSI approved safety impact eye goggles with a welding helmet with protective lens e Leather leggings fire resistant shoes or boots should be worn when using this product Do not wear pants with cuffs shirts with open pockets or any clothing that can catch and hold mol
13. c O gt U O 10 20 30 40 50 60 70 80 90 100 Duration of Use FIGURE K Amperage 2 The duty cycle defines the number of minutes within a 10 minute period during which a given Welder can safely produce a particular welding current For example this Welder with a 15 duty cycle at 110 Amps setting Max 2 must be al lowed to rest for at least 8 minutes and 30 seconds after every minute and 30 seconds of continuous weld at 110 Amps See Figure K 3 Failure to carefully observe duty cycle limitations can easily over stress a Welder s power generation system contributing to premature Welder failure 4 This Welder is equipped with an internal thermal protection system to help prevent over stressing the unit When the unit overheats it automatically shuts down then automatically returns to service when it cools down Note Once the unit returns to service follow a more conservative duty cycle routine to help prevent excess wear to the Welder See Figure K SKU 55525 For technical questions please call 1 800 444 3353 Page 17 Troubleshooting section at end of manual SETTING UP THE WELD ZNWARNING Before welding make sure to read and understand all safety orecautions and warnings discussed on pages 3 through 10 1 Overload Indicator Light 28 If too much current is drawn from the Welder the Overload Protector will activate The RED Overload Indicator Light will illuminate and the Welder will automat
14. ces EXTENSION CORDS 1 AN EXTENSION CORD MUST NEVER BE USED WITH THIS ITEM Use of an extension cord could result in damage to the item or fire SYMBOLOGY Double Insulated 3 p Canadian Standards Association Underwriters Laboratories Inc Volts Alternating Current No Load Revolutions per Minute RPM UNPACKING When unpacking both boxes check to make sure all the parts shown on the Parts Lists on pages 28 through 30 are included in addition to the face shield wire brush hammer and strap for cylinder connection 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 SKU 55525 For technical questions please call 1 800 444 3353 Page 10 Troubleshooting section at end of manual ASSEMBLY INSTRUCTIONS TO ATTACH THE HANDLE Insert the Handle 4 into the Handle Sockets 3 Then attach the Handle Sockets to the center top of Side Panel 1 using the four Screws provided FACE SHIELD ASSEMBLY Attach the handle to the Face Shield by lining up the two rectangular tabs on the handle with the corresponding holes in the face shield and 1 pressing it upwards and then 2 pressing it forward from the back lock ing the round tab in place Face See numbered steps in illustration to the Shield right TO INSTALL A WIRE SPOOL 1 Lift the Access Panel 12 of the Welder to expose the Wire Feed Assembly 2 Unscrew and
15. ct the tool s operation If damaged have the tool serviced before using Many accidents are caused by poorly maintained tools 8 Use only accessories that are recommended by the manufacturer for your model Accessories that may be suitable for one tool may become hazardous when used on another tool SERVICE 1 Tool 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 a tool use only identical replacement parts Follow instruc tions 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 or injury SKU 55525 For technical questions please call 1 800 444 3353 Troubleshooting section at end of manual age SPECIFIC SAFETY RULES 1 Ground this product This Welder requires the attachment and use of a UL listed 220 volt grounded 3 prong electrical Power Cord Plug not included Only a quali fied electrician should install the Power Cord Plug Never remove the grounding prong or modify the Power Cord Plug in any way Do not use adapter plugs with this product 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 3 hole outlet that is properly grounded 2 Maintain labels and n
16. ead and understand all instructions and safety precautions as outlined in the manufacturer s manual for the material you will weld or cut 13 Do not touch live electrical parts Wear dry insulating gloves Do not touch elec trode or conductor tong with bare hand Do not wear wet or damaged gloves 14 Protect yourself from electric shock Do not use outdoors Insulate yourself from the workpiece and ground Use nonflammable dry insulating material if possible or use dry rubber mats dry wood or plywood or other dry insulating material big enough to cover your full area of contact with the work or ground 15 Ensure that the unit is placed on a stable location before use If this unit falls while plugged in severe injury electric shock or fire may result 16 Cylinders can explode when damaged e Never weld on a pressurized or a closed cylinder e Never lay a welding torch on a cylinder e Never allow a welding electrode to touch the cylinder e Keep cylinders away from any electrical circuits including welding circuits e Keep protective cap in place over the valve except when the cylinder is in use SKU 55525 For technical questions please call 1 800 444 3353 Page 8 Troubleshooting section at end of manual 17 18 19 20 e Use only correct gas shielding equipment designed specifically for the type of welding you will do Maintain this equipment properly e Always protect gas cylinders from heat being struck ph
17. ece position or weld angle curely in place to permit proper welding at bottom of Make tack welds to help hold pieces workpiece 2 Excessive heat Pausebriefly atsides whenusing weave bead Weld a small portion and allow to cool Keep arc on leading edge of weld puddle before proceeding Hold gun at proper angles as stated under Reduce wire feed speed Holding The Torch on page 19 Increase weld speed SKU 55525 For technical questions please call 1 800 444 3353 Page 22 Troubleshooting section at end of manual Porosity Small cavities or holes in the bead TOP VIEW POSSIBLE CAUSES AND SOLUTIONS 1 Stickout too long Reduce stickout 2 Dirty workpiece or welding wire Make certain that workpiece and wire are both clean and free from oil coatings and other residues 3 Insufficient gas flow at weld Increase flow of shielding gas 4 Dirty nozzle Clean nozzle by following the directions in the cleaning section of this manual 5 Wrong type of shielding gas Use only the correct welding gas for the application and wire STRIKE TEST A test weld on a PIECE OF SCRAP can be tested by using the following procedure WEAR ANSI GOGGLES DURING THIS PROCEDURE 1 After two scraps have been welded to gether and the weld has cooled clamp one scrap ina sturdy vise 2 Stay clear from underneath while you strike the opposite scrap with a heavy hammer preferably a dead blow hammer 3 A good weld will deform bu
18. eeded replace Contact Tip 15g with proper size and type If the steps above do not solve the problem or if the repairs involved are too complex contact a qualified technician SKU 55525 For technical questions please call 1 800 444 3353 Page 32 TROUBLESHOOTING continued IMPORTANT Be CERTAIN to shut off the Welder disconnect it from power and discharge the torch to ground before adjusting cleaning or repairing the unit Wire Feeds but Shielding gas does not Flow POSSIBLE CAUSES AND SOLUTIONS 1 Empty Gas Cylinder Check gas cylinder 2 Nozzle Plugged Clean nozzle If damaged replace 3 Regulator or cylinder valve closed Make sure both valves are adjusted properly 4 Gas line blocked Check external hose and hose within Torch cable 5 Gas solenoid broken or not connected properly Have a qualified technician check replace WARRANTY LN VAN YTAN YASTAN UYPsraeYPsrae Vi Y YD TKN Y j N N DY N CHICAGO VLO gt A ELECTRIC LE2ZAJAZLLEE DA KR A A LAS E Ww LIMITED 90 DAY 1 YEAR WARRANTY ss A NY C22 Harbor Freight Tools Co makes every effort to assure that its products meet high quality and durability standards SH and warrants to the original purchaser that for a period of ninety days from date of purchase that the torch liner VEX ZU wire feed mechanism if applicable welding clamps electrode holders cables and acces
19. gure F NOTE If the Welding Wire does not feed properly and the Spool is stationary turn the Welder off Unplug the Welder Slightly tighten the Tension Adjusting Knob 10b on the Wire Feed Assembly and rewind the Welding Wire slightly before retrying See Figure E To check the tension on the Wire Feed Assembly feed the Welding Wire against a piece of scrap wood from 2 to 3 inches away If the Wire stops instead of bending turn the Welder OFF Unplug the unit from its electrical outlet Then slightly tighten the Tension Adjusting Knob 10b on the Wire Feed Assembly See Figure E NOZZLE WELDING NOZZLE 15h WIRE CONTACT FIGURE F 12 Turn the Welder OFF unplug it and discharge the electrode to ground Insert the Contact Tip 15g onto the Welding Wire and screw it firmly into the Head Tube 15f of the Torch Handle Replace the Nozzle 15h and cut off any excess Weld ing Wire over 1 2 inch Then close the Access Panel 12 of the Welder See Figure F Note When installing wire of a different size or composition you will also need to change wire settings set the gun polarity and possibly install a gas cylinder See pages 14 16 SKU 55525 For technical questions please call 1 800 444 3353 Page 13 Troubleshooting section at end of manual TO CHANGE WIRE SETTINGS 1 A warnine Make sure to turn off the Welder and unplug it from its electrical outlet prior to changing wire settings 2 Open the Acce
20. ical ventilation to improve air quality If engineering controls are not feasible use an approved respirator e Work in a confined area only if it is well ventilated or while wearing an air sup plied respirator e Follow OSHA guidelines for Permissible Exposure Limits PELs for various fumes and gases SKU 55525 For technical questions please call 1 800 444 3353 Page 7 Troubleshooting section at end of manual J e Follow the American Conference of Governmental Industrial Hygienists recom mendations for Threshold Limit Values TLV s for fumes and gases e Have a recognized specialist in Industrial Hygiene or Environmental Services check the operation and air quality and make recommendations for the specific welding or cutting situation Inhalation Hazard Welding Produces TOXIC FUMES and GASSES Exposure to welding gasses can increase the risk of developing certain cancers such as cancer of the larynx and lung cancer Also some diseases that may be linked to exposure to welding gas ses or fumes are e Early onset of Parkinson s Disease e Heart Disease e Damage to the reproductive organs e Ulcers e Inflammation of the small intestine or stomach Kidney damage e Respiratory diseases such as emphysema bronchitis or pneumonia wearing a NIOSH approved respirator are ESSENTIAL to reduce the B Safety precautions such as using natural or forced air ventilation and N risk of developing the above illnesses 12 R
21. ically turn off until it cools down If this happens turn the Power Switch to its OFF position and wait approximately 20 minutes See Figure L 2 Wire Speed Control Knob 17 The Scale surrounding the Knob is relative value not wire feed speed See Figure L 3 Voltage Controls 18 19 Adjust the Voltage Controls based on thickness of metal being welded See Figure L 4 If using solid core wire connect and secure an Argon CO gas hose to the rear of the Welder If using flux core wire protective gas is not required OVERLOAD INDICATOR LIGHT 28 POWER SWITCH 19 VOLTAGE CONTROLS 18 19 WIRE SPEED CONTROL KNOB FIGURE L 5 Securely clamp the Ground Clamp 14 as close as possible to the metal object to be welded or to the metal workbench where the object is mounted and electrically connected See Figure L SKU 55525 For technical questions please call 1 800 444 3353 Page 18 Troubleshooting section at end of manual 6 NOTE The workpieces should be firmly held together and in position while welding Use clamps not included to hold the workpieces so you can concentrate on the job at hand The distance if any between the two workpieces must be controlled properly to allow the weld to hold both sides securely while allowing the weld to penetrate fully into the joint T Set the desired welding current 35 to 140 amps for the type of metal being welded using the Wire Speed Control Knob 17
22. l be quite hot and sparks chips may fly when cleaning Make sure to continue wearing ANSI approved safety impact eye goggles and other protective wear when cleaning a weld a he hammer can be used to knock off any excess spatter and to help knock down any ridges Make sure not to damage the weld or material when striking it b The wire brush can then be used to help remove oxidation and some fine spat ter SKU 55525 For technical questions please call 1 800 444 3353 Page 24 Troubleshooting section at end of manual INSPECTION MAINTENANCE AND CLEANING ZNWARNING Before performing any maintenance on the Welder unplug the Power Cord 13 from its electrical outlet and allow all components of the Welder to completely cool 1 Periodically open the Access Panel 12 from the unit and using compressed air blow out all dust and debris from the interior 2 Always store the Welder in a clean dry safe location out of reach of children and other unauthorized people 3 For optimal weld quality clean and inspect the Contact Tip 15g and Nozzle 15h before each use as follows NOZZLE INSPECTION CLEANING AND REPLACEMENT 1 Turn the Nozzle 15h counterclockwise while pulling to remove 2 Scrub the interior of the Nozzle 15h clean with a wire brush 3 Examine the end of the Nozzle 15h The end should be flat and even If the end is uneven chipped melted cracked or otherwise damaged the Nozzle will ad
23. lectrician 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 used 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 SKU 55525 For technical questions please call 1 800 444 3353 have a proper outlet installed by a qualified electrician i i Page Troubleshooting section at end of manual agan GROUNDED TOOLS TOOLS WITH THREE PRONG PLUGS 1 Tools marked with Grounding Required have a three wire cord and three prong grounding plug The plug must be connected to a properly grounded outlet If the tool should electrically malfunction or break down grounding provides a low resistance path to carry electricity away from the user reducing the risk of electric shock 2 The grounding prong in the plug is connected through the green wire inside the cord to the grounding system in the tool The green wire in the cord must be the only wire connected to the tool s grounding system and must never be attached to an electrically live terminal 3 Your tool must be plugged into an appropriate outlet properly installed by a certi fied electrician and grounded in accordance with all codes and ordinan
24. off the torch and onto the Protective Sleeve 15a Slide the Upper Housing 15m forward and off the Lower Housing 15c 4 Remove the four Screws 10g that hold the Cable Clamp 10h in place Set aside the Cable Clamp Screws and the Liner Sleeve 10i underneath the cable clamp Lay torch cable out straight to allow the cable to twist within the sleeve Press in on the Push lock Coupler 15i and remove the Liner from the gun end Install a new Liner and Fitting from the gun end with the end without a Fitting first po N om e Attach the Fitting at the end of the Liner 15k to the Push lock Coupler 15i on the Switch Body 15e 9 Slide the Liner Sleeve 10i back onto the end of the liner Reinstall the Cable Clamp 10h and Screws 10g Trim off the Liner that extends past the Clamp 10 Make sure that all torch parts lay back into place properly including the Protective Sleeve 15a Head Tube 15f and Trigger 15d See Assembly Diagram on page 30 While all parts are properly in place carefully put the Upper Housing 15m back onto the Lower Housing 15c and slide back to secure Slide the Locking Collar 15b back onto the Housings 15c 15m and twist to secure 11 Check the Torch 15 carefully for proper operation 12 Route the Wire as instructed on page 12 PLEASE READ THE FOLLOWING CAREFULLY THE MANUFACTURER AND OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY NEIT
25. questions please call 1 800 444 3353 SKU 55525 17 Set the Wire Speed and Voltage Controls 17 18 19 to the recommended start settings as shown in the Weld Settings Chart on the next page See Figure N 18 Squeeze and hold the Trigger Switch 15d of the Welding Torch 15 and stroke the area to be welded with the Welding Wire to ignite the arc a Never tap the Welding Wire into the welding surface to ignite the arc This will cause the Welding Wire to stick to the workpiece b Fora narrow weld you can usually draw the Welding Wire in a steady straight line This is called a stringer bead c For a wider weld draw the Welding Wire back and forth across the joint in a curve This is called a weave bead Note If too much current is drawn from the Welder the internal Thermal Overload Protec tor will activate The Overload Indicator Light 28 will illuminate and the Welder will automatically turn off If this happens turn the Power Switch to its OFF position and wait 3 to 5 minutes for the unit to cool down See Figure P 20 After a few seconds stop Switch off the Welder and check your progress Com pare your weld s appearance with the diagrams and descriptions shown in the Weld Diagnosis section beginning on page 22 After making any necessary adjustments continue the weld while carefully following the DUTY CYCLE guidelines See Figure N SKU 55525 For technical questions please call 1 800 444 3
26. r 10f See Figure E 9 Lower the Swing Arm 10a on the Wire Feed Assembly Lower and tighten the Tension Adjusting Knob 10b Once the Wire is held in place you may release it See Figure E SWING ARM TENSION ADJUSTING KNOB 10a 10b SWING ARM WIRE FEED LEADER WIRE FEED LEADER 10f TENSION ADJUSTING KNOB e FIGURE E 6 Lay the Torch Cable out in a straight line so that the Welding Wire moves through it easily Leave the Access Panel 12 of the Welder open so that the Wire Feed Assembly can be observed 7h Hemove the Gun Nozzle 15h and Contact Tip 15g See Figure F next page SKU 55525 For technical questions please call 1 800 444 3353 Page 12 Troubleshooting section at end of manual e WARNING e EXERCISE EXTREME CAUTION RISK OF FIRE AND OR ELECTRIC SHOCK The following steps require applying power to the Welder Do not touch anything with the Torch Handle or Welding Wire or an arc will be ignited Do not touch the internal components of the unit while it is plugged in Plug the Power Cord 13 into its 220 volt grounded electrical outlet Then turn the Welder ON Point the Torch Handle away from all objects Then squeeze the Trigger Switch 15d on the Torch Handle until the Welding Wire feeds through the Head Tube 15f of the Torch Handle about 2 inches If necessary move the Torch Handle slightly in a circular motion to help feed the Welding Wire properly out of the Head Tube See Fi
27. r pull the Plug from an outlet Keep the Power Cord away from heat oil sharp edges or moving parts Replace damaged Power Cords immediately Dam aged Power Cords increase the risk of electric shock 5 When operating a power tool 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 PERSONAL SAFETY 1 Stay alert Watch what you are doing and use common sense when operat ing a power tool Do not use a power tool while tired or under the influence of drugs alcohol or medication A moment of inattention while operating power tools may result in serious personal injury 2 Dress properly Do not wear loose clothing or jewelry Contain long hair Keep your hair clothing and gloves away from moving parts Loose clothes jewelry or long hair can be caught in moving parts 3 Avoid accidental starting Be sure the Power Switch is off before plugging in Carrying power tools with your finger on the Power Switch or plugging in power tools with the Power Switch on invites accidents 4 Remove adjusting keys or wrenches before turning the power tool on A wrench or a key that is left attached to a rotating part of the power tool may result in personal injury SKU 55525 For technical questions please call 1 800 444 3353 i P 4 Troubleshooting section at end of manual aoe 5 Do not overreach Keep proper footing and balance at all
28. re SettingS ccsssccsesseccesseecesseeceseescenseseensesenseesenseesonsenses 14 Setting The Gun Polarity For Wire Type 15 To Install A Gas Cy Weer eonun repas ERR ODE na 16 OPERATING INSTRUCTIONS eere nnn 17 Before You Begin Welding eee eere eee e rennen 17 Duty Cycle Duration of Use 1 ecce crees rere nee e enne n nna 17 SOS Tire UP TNE WEI e tte rec cemnwene nee teewncucceateanectecasmuccensesunatteusaeerente 18 Holding The Welding Torch eee eee eee eee 19 Weld Settings Chart 1 e lile Leeeeeieeeeie enne eene n nnne nnne n nans 20 Weld Diagnosis ete Lt 22 When the Weld is Completed eere eee 24 INSPECTION MAINTENANCE AND CLEANING 25 Nozzle Inspection Cleaning and Replacement 25 Contact Tip Inspection Cleaning And Replacement 25 Replacing The Welding Torch Liner 26 Parts Lists and Diagrams eee rere 27 Wing SCIP AUG cucesesese paz rendre Rue ipvaxEUM Isi nuEk s xS Seu desde r demEUR KM SS 27 mci Re m 28 PAS SOTTO
29. sories packed with the IZ LA N welder are free of defects in materials and workmanship This Limited 90 Day 1 Year Warranty shall not apply RN AY to consumable parts such as tips welding wire and gas nozzles Harbor Freight Tools also warrants to the N y Y original purchaser for a period of one year from date of purchase that the transformer and rectifier are free from ND dim CZ defects in materials and workmanship This warranty does not apply to damage due directly or indirectly to misuse On Yd abuse negligence or accidents repairs or alterations outside our facilities or to lack of maintenance We shall in f YA ANS no event be liable for death injuries to persons or property or for incidental contingent special or consequential c XY damages arising from the use of our product Some states do not allow the exclusion or limitation of incidental INS KN or consequential damages so the above limitation of exclusion may not apply to you THIS WARRANTY IS yy CS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES kee V LZ VIS GA OF MERCHANTABILITY AND FITNESS N EXP To take advantage of this warranty the product or part must be returned to us with transportation charges prepaid YZ KN Proof of purchase date and an explanation of the complaint must accompany the merchandise If our inspection WSs AN verifies the defect we will either repair or replace the product at our election or we may elect to ref
30. ss Panel 12 of the Welder to expose the Wire Feed Assembly TENSION SWING ARM ADJUSTING ae SCREW 4 E 101 M FIGURE G 3 Loosen and lower the Tension Adjusting Knob 10b on the Wire Feed Assembly Then raise the Swing Arm 10a See Figure G 4 Remove the two Screws 101 that secure the Feed Roller Bracket 10k in place Then remove the Feed Roller Bracket See Figure G 9 Install a Wire Feed Roller 11 with the proper groove size facing towards the Inner Panel 8 of the welder 6 Heplace the Feed Roller Bracket 10k and secure in place with the Screws See Figure G 7 Lower the Swing Arm 10a on the Wire Feed Assembly Then lower and tighten the Tension Adjusting Knob 10b See Figure G 8 Remove the Gun Nozzle 15h and Contact Tip 15g Install a Contact Tip that is one size larger than the diameter of Welding Wire used Then replace the Gun Nozzle See Figure F previous page This accommodates thermal expansion of the wire 9 Install the Spool of Welding Wire and route the Wire to the Torch Gun Then test and if necessary adjust the Wire Feed Assembly as discussed in the previous pages of this manual SKU 55525 For technical questions please call 1 800 444 3353 Page 14 Troubleshooting section at end of manual SETTING THE GUN POLARITY FOR WIRE TYPE 1 Set for Electrode Positive DCEP for gas welding with solid core wire Positive elec trode C negati
31. sure the Flow Adjust on the Pressure Regulator Flow Meter is turned off Then screw the Pressure Regulator Flow Meter not included firmly onto the cyl inder valve 6 Attach the Gas Line 41 to the Pressure Regulator Flow Meter from the Gas Inlet located on the Back Panel 6 of the Welder fs Adjust the flow rate of the gas by turning the Flow Adjust The typical flow rate is 10 30 CFH cubic feet per hour Make sure to check the Welding Wire manu facturer s recommended flow rate WARNING RISK OF EXPLOSION While the Gas Cylinder is attached this unit must only be transported using an appropriate welding cart not included Transporting this welder any other way could result in the cylinder being damaged or ruptured causing an explosion and potentially SEVERE PERSONAL INJURY SKU 55525 For technical questions please call 1 800 444 3353 Page 16 Troubleshooting section at end of manual OPERATING INSTRUCTIONS BEFORE YOU BEGIN WELDING Good welding requires a high degree of skill and experience You should practice a few sample welds on scrap metal before you begin welding your first project Ad ditional practice periods are recommended whenever you weld a different thickness of material wire or weld a different type of connection DUTY CYCLE DURATION OF USE 1 CAUTION Avoid damage to the Welder by not leaving the unit on for more than the prescribed duty cycle time 0 O C 5 o
32. t not break A poor weld will be brittle and snap at the weld This test WILL damage the weld it is performed on This test is ONLY an indicator of weld tech nique and is not intended to test working welds TOP VIEW TOP VIEW Crooked wavy bead POSSIBLE CAUSES AND SOLUTIONS Stickout too long Heduce stickout Inaccurate welding Use two hands or rest hand on steady surface Excessive Spatter Spatter that is grainy and large Fine spatter is normal POSSIBLE CAUSES AND SOLUTIONS Wire feeding too fast Reduce wire feed speed Stickout too long Heduce stickout Dirty workpiece or welding wire Make certain that workpiece and wire are both clean and free from oil coatings and other residues Insufficient gas flow at weld Increase flow of shielding gas Shielding gas being blown away from weld area Protect the weld area from drafts SKU 55525 For technical questions please call 1 800 444 3353 Page 23 Troubleshooting section at end of manual WHEN THE WELD IS COMPLETED 21 Liftthe Welding Wire completely away from any grounded object Set the face shield down Then turn the Power Switch to its OFF position 22 Unplug the Power Cord 13 from the electrical outlet Then make sure to set the Welding Torch 15 on a nonflammable nonconductive surface 23 NOTE The wire brush hammer can now be used to clean up the weld 1 CAUTION The weld may stil
33. ten metal or sparks e Keep clothing free of grease oil solvents or any flammable substances Wear dry insulating gloves and protective clothing e Wear an approved head covering to protect the head and neck Use aprons cape sleeves shoulder covers and bibs designed and approved for welding and cut ting procedures e When welding cutting overhead or in confined spaces wear flame resistant ear plugs or ear muffs to keep sparks out of ears SKU 55525 For technical questions please call 1 800 444 3353 i p Troubleshooting section at end of manual geo 10 Prevent accidental fires Remove any combustible material from the work area e 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 ceiling etc prevent ignition of combustibles on the other side by moving the combustibles to a safe location If relocation of combus tibles is not possible designate someone to serve as a fire watch equipped with a fire
34. times Proper footing and balance enables better control of the power tool in unexpected situations 6 Always wear eye hearing and breathing protection For welding safety equip ment refer to number 9 on page 6 TOOL USE AND CARE 1 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 2 Do not force the tool Use the correct tool for your application The correct tool will do the job better and safer at the rate for which it is designed 3 Do not use the power tool if the Power Switch does not turn it on or off Any tool that cannot be controlled with the Power Switch is dangerous and must be replaced 4 Disconnect the Power Cord Plug from the power source before making any adjustments changing accessories or storing the tool Such preventive safety measures reduce the risk of starting the tool accidentally D Store idle tools out of reach of children and other untrained persons Tools are dangerous in the hands of untrained users 6 Maintain tools with care Keep cutting tools sharp and clean Properly main tained tools with a sharp cutting edge are less likely to bind and are easier to control Do not use a damaged tool Tag damaged tools Do not use until repaired 7 Check for misalignment or binding of moving parts breakage of parts and any other condition that may affe
35. und the purchase INN NZ N price if we cannot readily and quickly provide you with a replacement We will return repaired products at our NX CZ expense but if we determine there is no defect or that the defect resulted from causes not within the scope of VX KA our warranty then you must bear the cost of returning the product WVA This warranty gives you specific legal rights and you may also have other rights which vary from state to state S I A 3491 Mission Oaks Blvd PO Box 6009 Camarillo CA 93011 800 444 3353 y gt RZA CANKCNCANJICAZANSSCANNJICANSSCANNSICANSSOCANSSJWN VY Y Y Y VY Y vA CENSUS SPAN SPAN SARIS UBS MBCA SY If the steps above do not solve the problem or if the repairs involved are too complex contact a qualified technician SKU 55525 For technical questions please call 1 800 444 3353 Page 33
36. ve ground D SHOWN IN ILLUSTRATION INITIAL SETUP See Figure H 2 Set for Electrode Negative DCEN for gasless flux core wire Negative electrode C positive ground D See Figure H 3 When connecting to the weld output terminals do not place anything between the welding Cable Terminals A and C and their copper connections See Figure H 4 Always read and follow wire manufacturers recom mended polarity 5 A Positive Output Terminal Polarity Changeover Label Negative Output Terminal Red Cable Black Cable moo wo SKU 55525 For technical questions please call 1 800 444 3353 Page 15 Troubleshooting section at end of manual TO INSTALL A GAS CYLINDER N WARNING Maximum cylinder height is 1 feet 7 inches 0 5m Maximum cyl inder weight is 22 Ib including gas NEVER exceed either of these maximums 1 CAUTION Do not use an Argon Mixed pressure regulator flow meter with CO shielding gas To use CO shielding gas you must install a CO gas pressure regu lator flow meter neither one included 2 Thread the provided strap through the slots on the back of the welder With assis tance set the cylinder onto the shelf at the back of the welder 3 Secure the cylinder in place with the strap 4 Remove the protective 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 9 Make
37. versely effect the weld and should be replaced 4 Reinstall the Nozzle 15h after inspecting and cleaning the Contact Tip 159 CONTACT TIP INSPECTION CLEANING AND REPLACEMENT 1 Make sure the entire Welding Torch 15 is completely cool before proceeding 2 Remove the Nozzle 15h as explained above Then remove the Contact Tip 159 3 Scrub the exterior of the Contact Tip 15g clean with a wire brush Check that the Contact Tip is the proper type for the wire size used 4 Examine the hole at the end of the Contact Tip 15g for the following problems Shape The hole should be an even circle and should not be oblong or have any bulges in it Size The Contact Tip will decrease in efficiency as the center hole enlarges A Contact Tip that measures 150 or more the original size should be replaced 045 or more for 030 Tips 035 or more for 023 Tips 5 If any problems are noted with a Contact Tip 159 have it replaced 6 When inspection and maintenance is completed reinstall the Contact Tip 159 and Nozzle 15h SKU 55525 For technical questions please call 1 800 444 3353 Page 25 Troubleshooting section at end of manual REPLACING THE WELDING TORCH LINER 1 Switch welder off disconnect power and discharge electrode to ground before proceeding 2 Secure welding wire to the spool cut it near the spool and remove it from the torch and cable 3 Gently twist and slide the Locking Collar 15b
38. wire feed pressure properly follow instructions on page 12 13 2 Incorrect wire feed roll size Replace with the proper one follow the Wire Settings instructions on page 14 3 Damaged torch cable or liner assembly Have a qualified technician inspect these parts and replace as necessary Wire creates a bird s nest During operation POSSIBLE CAUSES AND SOLUTIONS 1 Excess wire feed pressure Adjust wire feed pressure properly follow instructions on page 12 13 2 Incorrect contact tip size Replace with the proper tip for the wire size used 3 Gun end not inserted into drive housing properly Loosen gun securing bolt and push gun end into housing just enough so that it does not touch wire feed mechanism 4 Damaged liner Have a qualified technician inspect and repair replace as necessary Welding arc not stable POSSIBLE CAUSES AND SOLUTIONS 1 Wire not feeding properly See first Troubleshooting section above 2 Incorrect contact tip size Replace with the proper tip for the wire size used 3 Incorrect wire feed speed Adjust wire feed speed to achieve a more stable arc 4 Loose torch cable or ground cable Check to ensure that all connections are tight 5 Damaged torch or loose connection within torch Have a qualified technician inspect and repair replace as necessary If the steps above do not solve the problem or if the repairs involved are too complex contact a qualified technician SKU 55525
39. ysical damage slag flames sparks and arcs e Always use proper procedures to move cylinders Use the right tool for the job Do not attempt to force small equipment to do the work of larger industrial equipment There are certain applications for which this Welder was designed It will do the job better and more safely at the rate for which it was intended Do not modify this Welder and do not use this Welder for a purpose for which it was not intended A warnine People with pacemakers should consult their physician s before using this product Electromagnetic fields in close proximity to a heart pacemaker could cause interference to or failure of the pacemaker WARNING The warnings and cautions discussed in this 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 A warnine This product when used for welding and similar applications pro duces 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 SAVE THESE INSTRUCTIONS GROUNDING NOTE This Welder requires the installation of a 3 Prong 220 VAC polarized twistlock Power Cord Plug not included NEMA configuration L6 30 or equivalent The Plug must be installed by a certified e
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