Harbor Freight Tools 6098 Welder User Manual
Contents
1. ende FEED ELECTRIC t52 3 Jr MIG WELDER 131 Nfefe 11 06098 ASSEMBLY AND OPERATING INSTRUCTIONS 3491 Mission Oaks Blvd Camarillo CA 93011 Visit our Web site at http www harborfreight com Copyright 2003 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 and replacement parts please call 1 800 444 3353 Specifications ITEM DESCRIPTION Welding Current 25 85 amps 20 at 75 amps 45 at 50 amps 90 at 35 amps i 100 at 25 amps Thermal Overload Automatic shutdown and restart after cool down Protection with Light Wire Size 0 023 to 0 035 inch steel and stainless steel 0 030 to 0 035 inch aluminum 0 030 flux core Welding Material Size 22 gauge to 5 32 Wire Spool Size 4 inch spool diameter Weight 55 1 Ibs 1 Hand held shaded face shield 1 Brush Hammer 1 Wheel Kit 1 2 lb spool of flux wire Accessories Save This Manual You will need the manual for the safety warnings and precautions assembly instructions operating and maintenance procedures parts list and diagram Keep your invoice with this manual Write the invoice number on the inside of the front cover Keep the manual and invoice in a safe and dry place for future reference Safety Warnings and Precautions WARNING When using tool basic safety2. fixtures and any other condition that may affect proper operation Any part that is damaged should be properly repaired or replaced by a qualified technician Do not use the tool if any switch does not turn On and Off properly Guard against electric shock Prevent body contact with grounded surfaces such as pipes radiators ranges and refrigerator enclosures Replacement parts and accessories When servicing use only identical replacement parts Use of any other parts will void the warranty Only use accessories intended for use with this tool Approved accessories are available from Harbor Freight Tools Do not operate tool if under the influence of alcohol or drugs Read warning labels on prescriptions to determine if your judgment or reflexes are impaired while taking drugs SKU 06098 Page 3 19 20 21 lf there is any doubt do not operate the tool Maintenance For your safety service and maintenance should be performed regularly by a qualified technician Use proper size and type extension cord If an extension cord is required it must be of the proper size and type to supply the correct current to the tool without heating up Otherwise the extension cord could melt and catch fire or cause electrical damage to the tool This tool requires use of an 120 VAC extension cord of 20 amps minimum capability up to 30 feet with wire size rated at 10 AWG Longer extension cords require larger size wire If you are using the
3. Wire Spool over the Axle with the wire exiting the spool over the top Refer to photos above Replace the Spool Axle Nut 4 Open the Wire Feed Mechanism 10 as shown in the photo top right Feed and guide the spool wire into the Wire Feed Mechanism past the feed wheels C and into the Welding Torch Cable 15 It will help if the Welding Torch Cable 15 is straightened out as much as possible Push in until the wire comes out the Welding Torch head If it cannot be fed manually all the way out it can be fed automatically when the welding unit is powered up 6 Close the Feed Mechanism 10 over the wire and adjust the feed tension D if necessary 7 Check that cables to connection Knobs 29 are correct See photo top left When using non flux wire and protective gas connect wire cables as shown in photo For 0 9 flux cored wire no gas is required Reverse cable connections 8 Close the Side Panel B 1 SKU 06098 Page 6 Handheld Shaded Face Shield Assemble the Handheld Shaded Face Shield as illustrated in its Assembly Drawing at the end of this manual Operation Controls and Indicators Overload shutdown Indicator Lamp Min Max Switch On Off Switch 1 2 Power Level Switch Wire Feed Speed Control Line Cord u Ground Cable with Clamp 14 Welding Torch Cable 15 Welding Caution Before arc welding read and understand all safety precautions and warnings listed on pages 2 thr
4. ation 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 gasses 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 Safety precautions such as using natural or forced air ventilation and wearing an ANSI approved respirator are ESSENTIAL to reduce the risk of developing the above illnesses Unpacking When unpacking check to make sure the following parts are included Line Cord 13 Brush Hammer Handheld Shaded Face Shield elding Torch 15 Ground Cable with Clamp lf any parts are missing or broken please call Harbor Freight Tools at the number on the cover of this manual as soon as possible SKU 06098 Page 5 REV 05 04 Assembly MIG Welder Unit 1 Insert the Handle 4 into the Handle Sockets 3 and mount the Handle Sockets to the Side Panel B 1 top using supplied hardware 2 Lift Side Panel B 1 all the way to expose the wire spool and Wire Feed Mechanism 10 Side Panel B 1 Wire Spool Axle 9 Wire Spool Wire Feed Mechanism 10 3 Remove the Nut from the Wire Spool Axle 9 Place the
5. lable individually as replacement parts PLEASE READ THE FOLLOWING CAREFULLY THE MANUFACTURER AND OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY NEITHER THE MANUFACTURER NOR 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 UNDER TAKEN 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 INSTALLA SKU 06098 Page 10 Wire Feed Mechanism Assembly Drawing SKU 06098 Page 11 MIG Welder 131 Schematic Diagram SKU 06098 Page 12 Hand Held Shield Assembly Drawing SKU 06098 Page 13
6. ough 5 1 If using non flux core wire connect and secure the Argon CO2 gas hose to the rear of the MIG Welder If using flux core wire protective gas is not required 2 Attach the Ground Cable with Clamp 14 as close as possible to the metal object to be welded or to the metal work bench where the object is mounted and electrically connected 3 Set the desired welding current 30 120 amps for the type of metal being welded using the Min Max Switch and 1 2 Power Level Switch Refer to the power setting table on the next page Thinner metals use lower current Heavier metals use higher current 4 Verify that the On Off Switch is in the OFF position then plug the MIG Welder Line Cord into a dedicated 120 VAC 20 amp line with delayed action type circuit breaker or fuses If an extension cord is used it must have the following wire size up to 30 feet use 10 AWG size wire 30 to 50 feet 8 AWG wire Over 50 feet 6 AWG wire SKU 06098 Page 7 Rated DC Output Set Power Switches Aires om Duty Cycle TE a 5 While holding the Welding Torch handle with the electrode wire clearly out of the way of any grounded objects turn the On Off Switch to the ON position 6 Momentarily press the Welding Torch trigger switch to test the wire feed speed Adjust the speed by turning the Wire Feed Speed Control knob 7 Orient yourself on the area to be welded then hold the Arc Shaded Face Shield over your eyes Warning Neve
7. precautions should always be followed to reduce the risk of personal injury and damage to equipment Read all instructions before using this tool 1 Keep work area clean Cluttered areas invite injuries 2 Observe work area conditions Do not use machines or power tools in damp or wet locations Don t expose to rain Keep work area well lighted Do not use electrically powered tools in the presence of flammable gases or liquids 3 Keep children away Children must never be allowed in the work area Do not let them handle machines tools or extension cords SKU 06098 Page 2 12 03 10 11 12 13 14 15 16 17 18 Store idle equipment When not in use tools must be stored in a dry location to inhibit rust Always lock up tools and keep out of reach of children Do not force tool It will do the job better and more safely at the rate for which it was intended Do not use inappropriate attachments in an attempt to exceed the tool capacity Use the right tool for the job Do not attempt to force a small tool or attachment to do the work of a larger industrial tool There are certain applications for which this tool was designed Do not modify this tool and do not use this tool for a purpose for which it was not intended Dress properly Do not wear loose clothing or jewelry as they can be caught in moving parts Protective electrically non conductive clothes and non skid footwear are recommended when working Wea
8. r look at the ignited arc without ANSI approved arc shaded eye protec tion in a full face shield Permanent eye damage or blindness can occur Skin burns can occur Never breath arc fumes 8 Press and hold the Torch Trigger Switch and stroke the area to be welded with the electrode wire to ignite the arc Never tap the electrode wire into the welding surface to ignite the arc This damages its external coating on the electrode which prevents oxygen in the air from coming into contact with the molten metal causing it to oxidize 9 Once the arc is ignited tilt the electrode wire forward at an angle of about 35 Refer to the illustration at right The wire feeds automatically at a soeed dependent on the Min or Max current setting The wire speed can also be adjusted using the Wire Feed Speed Control Note If too much current is drawn from the MIG Welder the Ther mal Overload protector will activate the red Overload indicator will light and the Arc Welder will turn off until it cools down If this happens turn the On Off Switch to the OFF position and wait about 3 5 minutes 10 When the weld is complete lift the Welding Torch handle electrode wire clearly away from any grounded object remove your Face Shield and turn the On Off Switch to the OFF position 11 Unplug the power Line Cord from the electrical outlet SKU 06098 Page 8 Symptom MIG Welder does not work when turned on Troubleshooting Possible Ca
9. r restrictive hair covering to contain long hair Use eye and ear protection Always wear ANSI approved arc shaded impact safety full face shield when arc welding Wear an ANSI approved dust mask or respirator when working around metal chemical dusts fumes and mists Do not overreach Keep proper footing and balance at all times Do not reach over or across running machines Maintain tools with care Keep tools sharp and clean for better and safer performance Follow instructions for lubricating and changing accessories Inspect tool cords periodically and if damaged have them repaired by an authorized technician The handles must be kept clean dry and free from oil and grease at all times Disconnect power Unplug tool when not in use Remove adjusting keys and wrenches Check that keys and adjusting wrenches are removed from the tool or machine work surface before plugging it in Avoid unintentional starting Be sure the switch is in the Off position when not in use and before plugging in Do not carry any tool with your finger on the trigger whether it is plugged in or not Stay alert Watch what you are doing use common sense Do not operate any tool when you are tired Check for damaged parts Before using any tool any part that appears damaged should be carefully checked to determine that it will operate properly and perform its intended function Check for alignment and binding of moving parts any broken parts or mounting
10. rs A qualified technician should open the unit and check for burnt rectifiers and replace Check presence of gas and supply line and pressure Clear clogged holes using compressed air A qualified technician should open the unit and check solenoid operation and electrical connection Gas must be very dry Use a moisture filter Use a different type of wire A qualified technician should open the unit and dismantle valve clean orifice and seating element A qualified technician should open the unit and remove the torch connection plug and short circuit the poles Check and repair control cables A qualified technician should open the unit and replace the overload controller Maintenance Caution Before performing any maintenance on the MIG Welder unplug the power Line Cord from the electrical outlet 1 Periodically using compressed air open the top and side panels and blow out all dust from the interior SKU 06098 Page 9 2 Store the unit in a clean and dry location 3 Periodically clean out the Torch Head Replacing the Wire Reel When the wire on the Feed Reel is used up you will need to replace it as described on page 6 step 5 through step 9 Parts List 2 fringe SSCS 6 ReotifierRack OoOo 8 _ rectifier Rack o 9 Wire Spool Axle oO Ground Cable With Clamp Transformer Carriage NOTE Some parts are listed and shown for illustration purposes only and are not avai
11. tool outdoors use an extension cord rated for outdoor use signified by WA on the jacket Pacemaker safety warning People with pacemakers should consult with their physician s before using this product operation of equipment in close proximity to a heart pacemaker could cause interference or failure of the pacemaker Note Performance of this tool may vary depending on variations in local line voltage Exten sion cord usage may also affect tool performance Warning The warnings cautions and instructions discussed in this instruction manual cannot cover all possible conditions and situations that may occur It must be under stood by the operator that common sense and caution are factors which cannot be built into this product but must be supplied by the operator Arc Welding Safety Warnings and Precautions Warning This product when used for welding and similar applications produces chemi cals known to the State of California to cause cancer and birth defects or other repro ductive harm California Health amp Safety Code 25249 5 et seq i Avoid electrical shock Do not permit electrically live parts cables or electrodes to contact skin clothing or gloves Protective clothing should be free of holes dry and ANSI approved This unit draws enough current to cause serious injury or death Before turning the welder on check the electrode holder to be sure that there are no protruding screw heads and that all ins
12. ulation is secure Do not weld unless you are insulated from ground and the work piece Avoid breathing fumes or gases They can cause serious health problems Use an active ventilation system directly above the welding area Keep your head out of the fumes Avoid eye and body damage Arc rays and infrared radiation can injure eyes and burn skin Wear ANSI approved eye and body protection Do not allow viewing by visitors without proper eye and body protection Use a Face Shield with arc shaded filter plate Know proper arc welding practices Read and understand this instruction manual as well as your employer s safety practices for arc welding Connect only to a code approved power source Connect only to a grounding power source conforming to the National Electrical Code and Local Codes SKU 06098 Page 4 6 Avoid fire and explosion Remove flammable and explosive material from at least 35 feet from the welding arc to prevent welding sparks or molten metal from starting a fire Keep a type ABC fire extinguisher within easy reach Thoroughly clean the object being welded of any paint grease or other foreign material 7 Avoid being burned Always wear ANSI approved welding gear leather gloves leather apron and shoes 8 Wear proper clothing when welding Use flameproof welding type gloves Wear cuffless pants and pocketless shirt Both must be free of oil and grease Wear high topped safety to shoes with rubber soles Inhal
13. use No power to MIG Welder Checks and Remedies Check Line Cord and plug Check facility circuit breaker Wire does not feed properly Reduced welding power Porous or spongy welds Gas supply does not switch off Pressing Welding Torch trigger produces no result Overheated during use Insufficient wire feed spring tension Wire guide sheath blocked Wire spool axle nut too tight Braking on wire reel excessive Wire reel has oxidized poorly wound or quality wire Ground Cable not connected or poor connection Internal connection loose on switches Faulty contactor One or more rectifiers failed No gas Little gas Clogged holes in Welding Torch head diffuser Solenoid valve blocked Poor quality gas or wire Worn or dirty solenoid valve Faulty Welding Torch trigger Disconnected or broken control cables Overload controller defective In overload mode Allow to cool down Tighten spring tension knob See photo on page 6 Clean or replace wire sheath Loosen nut so reel moves freely Loosen brake using adjusting screw Replace wire reel Check that the Ground Cable Clamp is securely attached to the metal being welded This area should be cleaned down to the metal and free of paint dirt and grease A qualified technician should open the unit and check and tighten any loose connectors Check the state of the contacts and the mechanical operation of the contacto
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