Harbor Freight Tools 55167 Welder User Manual
Contents
1. 4 Ls Fixing Pte ay for Gun Boay 1 L6 Fixing Pole B tor Gun Body 1 Cra Power Switch wih ion 1 m wemnswn id Ls cover ooking spring 1 Le wie Feed Conti kop 1 wm o f L7 speed Cono Great Boara 1 2 Right Side Pan 1 15 Lettside Pane 1 Cia Base Fame 1 io thermostat 1 Ceo menter 1 Lm mioa Panion Board 1 La overtoad nacatortamp 1 B Ll LA L Ls A Lo L Il Tren on o 9v C mesmo 1 C wing nut MS 26 Reel Locking knob 1 Cor wene C2 Berno 1 L5 Serttapping Screw STAz2s 1 Cw mme 1 Tat cover Tae Powerco 1 Ls emwacee 1 a4 wie Feed roier 1 Css wire Feed Bearing 1 Cae wire Feed Swing arm 1 Tar adjustment screw 1 Ls raceSme shade 1 Cao wire Brush Hammer 1 Cao washer Sid Ta nt 3 Las wachine srw Sid 43 Contact Tip wrench 1 Caa Feed Roter Braet 1 Bo L lI I I I LA D LI LI l LI I PLEASE READ THE FOLLOWING CAREFULLY THE MANUFACTURER AND OR DISTRIBUTOR2. ELECTRIC HATIA 90 AMP FLUX WIRE WELDER Wfere 31155167 ASSEMBLY AND OPERATING INSTRUCTIONS TIT IA y wiki WELDER 3491 Mission Oaks Blvd Camarillo CA 93011 Visit our Web site 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 and replacement parts please call 1 800 444 3353 Contents OSDGCIIICallOfiS tic ceccceacccencencecsecpsssusscusvessaccanecsunssacacnesewescwecessanecanes 3 General Safety RUuleS cccsccceseseneeeeseeeneecnseceneeenseseneseneenees 3 Specific Safety RUIGS oco uiuo scone vndesaecasaceveucesgaocssuanaenesseussdcessenaces 5 EOIN his ssc RICETTE 8 SV ONO OY rossi catecenae tees an osenesancens gas suesaenue anmastunenngeonansasnengunacteonnaesane 10 UNDACKINO sons sen viscera cee TET DOE 11 PS SOIIONY c 11 Installing the Wire Fi CO sts tenccecicerseeanceennsnceonaeucamtetecawsueceeneanmesdesunensectuass 12 Changing Wire feed roller serere esse 13 Trigger Switch Replacement eee see esee eren 14 SF AU ON esses cuspis E E E NUMEN RUE ME 15 Before
3. wire Accessories Welding Face Shield Wire Brush Hammer combination 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 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 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 presence of flammable liquids gases or dust Power tools create sparks which may ignite the dust or fumes 3 Keep bystanders children and visitors away while operating a power tool SKU 55167 For technical questions please call 1 800 444 3353 Troubleshooting section at end of manual dde 10 11 12 13 14 SKU 55167 For technical questions please call 1 800 444 3353 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 Avoid body contact with grounded surfaces such as pipes radiators ranges and refrigerat
4. 37 Tighten the Tension Adjusting Screw until the Wire Feed Bearing 35 just touches the wire and then three full turns farther 8 Turn the Nozzle 3 counterclockwise while pulling to remove Using the third oval hole on the provided Wrench 43 turn the Contact Tip 2b counterclockwise and remove it 9 Install an appropriately sized Contact Tip 2b 0 9 mm over the wire and tighten to the Torch with the Wrench 43 10 Test and adjust the drive tension as explained in steps 12 14 on the previous page 11 Close the welder s cover and switch the Welder OFF Unplug the Welder if it is not to be used at this time TRIGGER SWITCH REPLACEMENT 1 WARNING Turn the welder OFF and unplug it before proceeding This procedure should be performed by a qualified technician E Turn the Handle Lock Ring 1d at the base of the torch handle counterclockwise and slide it down the cable 9 Pull the Front Handle 1b down to disengage the pin at its top see illustration below left 4 Pull the Front Handle 1b away from the Back Handle 1a exposing the wires and connections see illustration below center 9 Pull the Trigger Switch 1c out being careful not to stress or damage the wires Disconnect the terminals and replace the Switch see illustration below right Front Handle 1b Trigger Switch 1c Trigger Front Switch 1c Handle 1b SKU 55167 For technical questions please call 1 8
5. OFF and unplug it before proceeding 2 Press on the Cover Locking Spring 8 then lift the Cover 31 using Handle 30 to expose the Wire Feed Unit 23 3 Unscrew the Wing Nut 25 and remove the Reel Locking Knob 26 If replacing an old Heel remove the old Reel and all old wire from within the Torch 1 and Torch cable 4 Place the new flux core Wire Reel over the shaft and onto the Reel Spring 24 This welder can only weld using FLUX CORED wire IMPORTANT To help avoid wire feed problems the reel must be set so that it will unwind counterclockwise see photo above 5 Replace the Reel Locking Knob and the Wing Nut Tighten well Loosen the Tension Adjusting Screw 37 Press the Wire Feed Swing Arm 36 forward slightly and lift it to remove tension IMPORTANT Hold the wire securely while you cut enough wire off the end of the spool to remove all bent and crimped wire Make sure that the cut end has no burrs or sharp edges cut again if needed Keep tension on the wire and guide at least 12 inches of wire into the Torch Sheath Securely hold onto the end of the welding wire and keep tension on it during these steps If this is not done the welding wire will spring backwards and create a tangled bird s nest wasting wire Swing the Wire Feed Swing Arm 36 down while pressing it forward to latch it across the tip of the Tension Adjusting Screw 37 Tighten the Tension Adjusting Screw until the Wire Feed
6. Outlet SKU 55167 For technical questions please call 1 800 444 3353 Page 8 Troubleshooting section at end of manual 3 SKU 55167 For technical questions please call 1 800 444 3353 Your tool must be plugged into an appropriate outlet properly installed and grounded in accordance with all codes and ordinances The plug and outlet should look like those in the following illustration See 3 Prong Plug and Outlet 3 Prong Plug and Outlet Outlets for 2 Prong Plug DOUBLE INSULATED TOOLS TOOLS WITH TWO PRONG PLUGS Tools marked Double Insulated do not require grounding They have a special double insulation system which satisfies OSHA requirements and complies with the applicable standards of Underwriters Laboratories Inc the Canadian Standard Association and the National Electrical Code See Outlets for 2 Prong Plug Double insulated tools may be used in either of the 120 volt outlets shown in the pre ceding illustration See Outlets for 2 Prong Plug EXTENSION CORDS Grounded tools require a three wire extension cord Double Insulated tools can use either a two or three wire extension cord 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 See Figure C next page The smaller the gauge number of the wire the greater the capa
7. 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 2 3 TOP I VIEW POSSIBLE CAUSES AND SOLUTIONS Stickout too long TOP E VIEW i POSSIBLE CAUSES AND SOLUTIONS CROOKED WAVY BEAD Reduce stickout Inaccurate welding Use two hands or rest hand on steady surface EXCESSIVE SPATTER Spatter that is grainy and large Fine spatter is normal Wire feeding too fast Reduce wire feed speed Stickout too long Reduce stickout Dirty workpiece or welding wire Make certain that workpiece and wire are both clean and free from oil coatings and other residues When the weld is complete lift the electrode wire clearly away from any grounded object set the Face Shield down turn toward the Flux Wire Welder and turn the Power Switch to the OFF position Unplug the Power Cord from the electrical outlet Be sure to set the torch down on a nonflammable nonconductive surface The Wire Brush Hammer 39 can now be used to clean up the weld CAUTION The weld may still be quite hot and sparks chips may fly when cleaning Be certain to continue to wear ANSI approved safety goggles and protective wear when cleaning a weld The Hammer can be used to knock off any excess spatter and to help knock down any ridges Be careful not to damage the weld or material when striking it The Wire Brush can then be use
8. You Start WV Sl CNC csse o odio XXE RERUM S VR IDE ENUII DRE PE REND EDISNMME 15 Duty Cycle Duration of Use eee eere rere rennen 15 Seming Up The WV aioe caren Share n En EO hti on deba EUR nance SIS DOLI Rex Us 16 Holding TING VOR gen e r AEE 17 Weld Semnas CDL eausa vinnpcutd n DR RRREUR EN RUUDI ID IN EtI DEN dE 18 Weld DIAGNOSIS 5 2220 42 005 08 55 2004 004952081124 0 0 050024200205 8 025 bu Uds R D SUUi Ns 19 MamtenanC Ouid eondbvdarks dus Sax E FEVER VRURNCC OE EXF NEECERUKUNRES ERAS RUK ERN ENE 21 Nozzle Inspection Cleaning and Replacement 21 Contact Tip Inspection Cleaning and Replacement 21 Parts Lists and Diagrams srxsste ccs acscnccecdacsnt gt seonsancsuundsnestecascdensasens 22 Wiring SChemoall6 usseoduse nra ursa eu EE vDebxisqeui unies tiv Ord n exi Us 22 Paris LISSE osse es aemcg eee cease ce E EIUS NENMMENF PN QE 23 AsSsembiV DNA GU aliscar 24 TFOUDISS NOOUIN O OPPETO RTT ETT 26 SKU 55167 For technical questions please call 1 800 444 3353 Page 2 Troubleshooting section at end of manual SPECIFICATIONS 10 at 80 amps 18 at 60 amps See explanation of Duty Cycle on page 15 Should be connected to a 20 amp minimum dedicated circuit 0 9 mm tips to account for thermal expansion of the wire 0 030 flux core wire Overall Dimensions 14 1 2 L x 8 1 2 W x 15 1 2 H inches 34 45 Ib Spare Welder Tip 0 9mm for 030
9. explained above Using the third oval hole on the provided Wrench 43 turn the Contact Tip 2b counterclockwise and slide it off the welding wire Scrub the exterior of the Tip clean with a wire brush Check that the Tip is the proper type for the wire size used 0 9 mm for 030 wire Examine the hole at the end of the Contact Tip 3 for the following problems Shape The hole should be an even circle it should not be oblong or have any bulges in it Size The Tip will decrease in efficiency as the center hole enlarges A tip that measures 150 or more the original size should usually be replaced 13 5 mm or more for 0 9 mm Tips 2b If any problems are noted Contact Tip 2b replacement would be advisable Make sure to select a new Tip that is the correct size 0 9 mm for the welding wire used 030 Reinstall the Tip 2b and securely reinstall the Nozzle 3 as well SKU 55167 For technical questions please call 1 800 444 3353 Page 21 Troubleshooting section at end of manual PARTS LISTS AND DIAGRAMS WIRING SCHEMATIC Overload Indicator Light PT Lo FX PT SKU 55167 For technical questions please call 1 800 444 3353 Page 22 Troubleshooting section at end of manual PARTS LIST ms eem o 9v C mowHade 1 Te moserswen Sid Ta Mande toocring 1 Tite menu 1 C omm coraan 1 Cs Nowe 3 4 une
10. long hair Keep your hair clothing and gloves away from arc Loose clothes jewelry or long hair can catch fire 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 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 Do not overreach Keep proper footing and balance at all times Proper footing and balance enables better control of the power tool in unexpected situations Use safety equipment Always wear eye protection For welding safety equipment refer to number 7 on page 6 Tool Use and Care Troubleshooting section at end of manual Page 4 15 16 17 18 19 20 21 22 23 24 SKU 55167 For technical questions please call 1 800 444 3353 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 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 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 dange
11. of manual POEG For technical questions please call 1 800 444 3353 SKU 55167 WELD DIAGNOSIS WELD PENETRATION EXCESS OR BURN THROUGH Weld droops on top and underneath or falls through entirely making a hole N POSSIBLE CAUSES AND SOLUTIONS 1 Excessive material at weld Reduce wire feed speed 2 Overheating Increase welding speed and ensure that welding speed is kept steady WELD NOT ADHERING PROPERLY Gaps present between weld and previous bead or between weld and workpiece See areas below CROSS SECTION POSSIBLE CAUSES AND SOLUTIONS 1 Dirty workpiece Make certain that workpiece is clean and free from oil coatings and other resi dues 2 Insufficient weld material Increase wire feed speed 3 Incorrect welding technique Place stringer bead at correct place in joint Adjust workpiece position or weld angle to permit proper welding to bottom of piece Pause briefly at sides when using a weave bead Keep arc on leading edge of weld puddle Hold gun at proper angles as stated under Holding The Torch on page 17 SKU 55167 PROPER Weld is visible underneath and bulges slightly on top CROSS SECTIONS For technical questions please call 1 800 444 3353 Troubleshooting section at end of manual INADEQUATE Weld does not contact the joint fully just on the surface d POSSIBLE CAUSES AND SOLUTIONS 1 Workpieces too thick close Joint design must allow weld to rea
12. 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 55167 For technical questions please call 1 800 444 3353 Page 26 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 POWER SWITCH 7A DOES NOT LIGHT WHEN SWITCHED ON 1 POSSIBLE CAUSES AND SOLUTIONS Unit is not connected to outlet properly or outlet is unpowered Verify the voltage at the outlet and the connection to the outlet If voltage is not present at outlet check circuit breaker GFCI devices if any are tripped determine and remedy cause before resetting Verify that the circuit is designed to supply the required input amperage as detailed on the Specifications table POWER SWITCH 7A LIGHTS BUT WELDER DOES NOT FUNCTION WHEN SWITCHED ON POSSIBLE CAUSES AND SOLUTIONS 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 Refer to Duty Cycle section on page 15 Faulty or improperly connected Trigg
13. 00 444 3353 Page 14 Troubleshooting section at end of manual 6 Connect the new Switch 1c polarity does not matter When reinstalling make sure that the new Switch fits securely in place T Reassemble reversing the steps on the previous page 8 Put on appropriate safety equipment as explained in the safety section of this manual After the unit is fully assembled plug the Welder back in and turn it back ON Carefully point the torch away from yourself and conductive materials and check that the new switch functions properly 9 Shut the unit off and unplug it before storing OPERATION BEFORE YOU START WELDING Good welding takes a degree of skill and experience You should practice a few sample welds on scrap before you start welding your first project Additional practice periods are recommended whenever you weld a different thickness of material or weld a different type of connection DUTY CYCLE DURATION OF USE 18 Duty Cycle 10 Duty Cycle 60 amp setting 80 amp setting 1 minute 48 seconds ON 1 minute on followed by followed by at least 8 minutes 12 seconds OFF at least 9 minutes off Avoid damage to the Welder by not leaving it on for more than the prescribed duty cycle time 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 10 duty cycle at 80 amps must be allowed to rest fo
14. Bearing 35 just touches the wire and then three full turns farther After the wire is held by the Tensioner you may release it SKU 55167 For technical questions please call 1 800 444 3353 Page 12 Troubleshooting section at end of manual 10 11 Turn the Nozzle 3 counterclockwise while pulling to remove Using the third oval hole on the provided Wrench 43 turn the Contact Tip 2b counterclockwise and remove Lay the Torch Cable out in a straight line so that the wire K moves through it easily Leave the cover open so that the feed mechanism can be observed Trigger Contact Tip Nozzle 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 with it plugged in Plug the Power Cord into its electrical outlet and turn the welder ON Point the Torch Handle away from all objects and continue pressing the Trigger until the wire feeds through two inches Move the handle slightly in a circular motion to help the wire feed properly out the end If the wire does not feed properly and the reel is stationary turn the welder OFF unplug it slightly tighten the Wire Tension Adjusting Screw 37 and rewind the wire slightly before retrying To check the wire s drive tension feed the wire against a pi
15. 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 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 55167 For technical questions please call 1 800 444 3353 Troubleshooting section at end of manual Page 23 SKU 55167 ASSEMBLY DIAGRAM D s E a X mari A i Wy f Wy T y 4 Hoan bab 7 i a Mh t ff P ig Wow w f if z di suf 4D f e j a e co KO of L7 fe IU o G Ga i E oe o NOTE Some parts are listed and shown for illustration purposes only and are not avail able individually as replacement parts For technical questions please call 1 800 444 3353 Page 24 Troubleshooting section at end of manual 20 11 19 Detail of Part 23 36 37 35 44 34 46 45 23 SKU 55167 For technical questions please call 1 800 444 3353 Page 25 Troubleshooting section at end of man
16. KING When unpacking check to make sure the following parts are included Flux Wire Welder Shade 10 Face Shield 38 Torch 1 Ground Cable 33 Wire Brush Hammer 89 Power Cord 32 Wire Spool Spare Welding Tip and Contact Tip Wrench 43 This unit is packed with a protective light film of oil wipe the unit of with a clean rag prior to assembly If any parts are missing or broken please call Harbor Freight Tools at the number on the cover of this manual as soon as possible ASSEMBLY 1 Attach the Handle 30 to the Cover 31 using screw 29 inserted from the Handle top rear Refer to the photo at the top of the next page and the Assembly Diagram on page 24 2 Attach the Cover Locking Spring 8 to the front of the Base Frame 14 using the supplied Machine Screw 42 Washer 40 and Nut 41 3 Attach the handle to the Face Shield 38 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 locking the round tab in place See numbered steps in illustration to the Face right Shield For technical questions please call 1 800 444 3353 SKU 55167 Troubleshooting section at end of manual Page 11 Wire Feed Tension Adjusting _ Wire Sheath E Adjusting Spring 36 Screw 37 Cover 31 Handle 30 Cover Locking Spring 8 Wire Reel 27 1 WARNING Turn the welder
17. ages 3 through 10 ls 9 Securely clamp the Ground Cable Clamp 33 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 Set the Current Switch 7b to the desired current setting Refer to the chart on the face of the welder or the chart on page 18 of this manual DO NOT SWITCH THE CURRENT WHILE WELDING Verify that the Power Switch is in the OFF position then plug the Flux Wire Welder plug into a dedicated 110 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 use 8 AWG wire Over 50 feet use 6 AWG wire The workpieces should be firmly held together and in position while welding Use clamps not included to hold the workpieces so that 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 While holding the Torch with the wire and tip clearly out of the way of any grounded SKU 55167 For technical questions please call 1 800 444 3353 Page 16 Troubleshooting section at end of manual objects turn the Power Switch to the ON position 6 Orient yourself on the area to be welded then place the Face Shield over your eyes Warning Never look
18. 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 breathe arc fumes HOLDING THE TORCH 7 Hold the Torch 1 in one hand and the face shield in the other If a hands free welding shield not included see 7 page 6 for Drag Angle guidelines is used then both hands can be used to control the Up to 15 Torch The welding wire should be directed straight into the joint Angle in Weld This gives an angle of 90 straight up and down for groove d end to end welds and an angle of 45 for fillet T shaped welds The end of the gun should be tilted so that the wire is e angled anywhere in between straight on and 15 in the direction Diredi on of the weld The amount of tilt is called the drag angle sece em illustration right The welding wire should extend no more than 1 7 past the tip this distance is called stickout 8 Set the Wire Feed Control Knob 9 to the recommended start setting as shown in the chart on the next page Press and hold the Trigger Switch 1c 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 will cause the welding wire to stick to the workpiece For a narrow weld you can usually draw the wire in a steady straight line this is called a stringer bead For a wider weld draw the wir
19. ch bot tom of groove and allow proper welding procedures 2 Incorrect welding technique Maintain or less stickout Keep arc on leading edge of weld pud dle Hold gun at proper angles as stated under Holding The Torch on page 17 3 Insufficient weld material Increase wire feed speed 4 Insufficient weld heat Reduce Welding Speed BEND AT JOINT CROSS SECTION POSSIBLE CAUSES AND SOLUTIONS 1 Improper clamping Make sure that pieces are clamped se curely in place Make tack welds to help hold pieces 2 Excessive heat Weld a small portion and allow to cool before proceeding Reduce wire feed speed Increase weld speed Page 19 TOP i VIEW POROSITY Small cavities or holes in the bead POSSIBLE CAUSES AND SOLUTIONS 1 2 Stickout too long Reduce stickout Dirty workpiece or welding wire Make certain that workpiece and wire are both clean and free from oil coatings and other residues STRIKE TEST A test weld on a PIECE OF SCRAP can be tested WEAR ANSI GOGGLES DURINGTHIS PROCEDURE 1 10 11 12 SKU 55167 by using the following procedure After two scraps have been welded to gether and the weld has cooled clamp one scrap in a sturdy vise Stay clear from underneath while you strike the opposite scrap with a heavy hammer preferably a dead blow hammer A good weld will deform but not break A poor weld will be brittle and snap at the weld
20. city of the cord For example a 14 gauge cord can carry a higher current than a 16 gauge cord See Figure C 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 See Figure C lf you are using one extension cord for more than one tool add the nameplate amperes and use the sum to determine the required minimum cord size See Figure C lf 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 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 Protect your extension cords from sharp objects excessive heat and damp or wet i P Troubleshooting section at end of manual AUE areas RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS NAMEPLATE AMPERES EXTENSION CORD LENGTH At Full Load 75 Feet 100 Feet Based on limiting the line voltage drop to five volts at FIGURE C 150 of the rated amperes SYMBOLOGY E Double Insulated Canadian Standards Association Underwriters Laboratories Inc V Volts Alternating Current no xxxx min No Load Revolutions per Minute RPM For technical questions please call 1 800 444 3353 Page 10 SKU 55167 Troubleshooting section at end of manual UNPAC
21. d to help remove oxidation and some fine spatter For technical questions please call 1 800 444 3353 Troubleshooting section at end of manual Faga ee MAINTENANCE Warning Before performing any maintenance on the Welder unplug the Power Cord from the electrical outlet and allow all parts of the welder to cool thoroughly 1 Periodically remove the Right and Left side panels 12 and 13 and using compressed air blow out all dust from the interior Store in a clean and dry location For optimal weld quality clean and inspect the Contact Tip 2b and Nozzle 3 before each use as follows Nozzle Inspection Cleaning and Replacement Make sure that the entire Torch parts 1a through 3 is completely cool and that the Power Cord is unplugged from the electrical outlet before proceeding Turn the Nozzle 3 counterclockwise while pulling to remove Scrub the interior of the Nozzle clean with a wire brush Examine the end of the Nozzle 3 The end should be flat and even If the end is uneven chipped melted cracked or otherwise damaged the Nozzle will adversely effect the weld and should be replaced Reinstall the Nozzle 3 after inspecting and cleaning the Contact Tip 2b Contact Tip Inspection Cleaning and Replacement Make sure that the entire Torch parts 1a through 3 is completely cool and that the Power Cord is unplugged from the electrical outlet before proceeding Remove the Nozzle as
22. e Welder These carry important information If unreadable or missing contact Harbor Freight Tools for a replacement 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 a power tool in areas near flammable chemicals dusts and vapors Do not use this product in a damp or wet location Avoid unintentional starting Make sure you are prepared to begin work before turning on the Welder Troubleshooting section at end of manual Page 5 4 Unplug before performing maintenance Always unplug the Welder from its electrical outlet before performing any inspection maintenance or cleaning procedures 5 Never leave the Welder unattended while energized Turn power off if you have to leave the Welder 6 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 Prevent eye injury and burns Wearing and using ANSI approved personal safety clothing and safety devices reduce the risk for injury e Wear ANSI approved safety impact eye goggles underneath welding eye protection featuring at least a number 10 shade lens rating such as the one included e Leather leggings fire resistant shoes or boots should be worn when using this product Do
23. e 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 e 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 e Follow the American Conference of Governmental Industrial Hygienists recommenda tions 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 gasses or fumes are Early onset of Parkinson s Disease Heart Disease Damage to the reproductive organs e Ulcers Inflammation of the small intestine or stomach Kidney damage 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 10 Read and understand all instructions and sa
24. e back and forth across the joint in a curve this is called a weave bead Note If too much current is drawn from the Flux Wire Welder the Thermal Overload protector will activate the amber indicator will light and the Arc Welder will turn off until it cools down If this happens turn the Power Switch to the OFF position and wait about 3 5 minutes 9 After a few seconds stop switch off the welder and check the progress Compare your weld s appearance with the diagrams and descriptions in the Weld Diagnosis section starting on page 19 After making any necessary adjustments continue the weld while carefully following the DUTY CYCLE guidelines as explained on page 15 SKU 55167 For technical questions please call 1 800 444 3353 Page 17 Troubleshooting section at end of manual WELD SETTINGS CHART Material Thickness Steel NOTE The numbers within the spaces are the approximate wire feed settings recommended for this wire size and material thickness 16 Gauge 14 Gauge Wire Size Minimum Minimum Minimum Maximum Flux Core Mild Steel Fen sureni Current Current J 030 1 4 7 6 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 1 Troubleshooting section at end
25. eaning or repairing the unit WIRE FEEDS BUT ARC DOES NOT IGNITE POSSIBLE CAUSES AND SOLUTIONS 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 Improperly sized or excessively worn Contact Tip 2b Verify that Contact Tip 2b is the proper size for 030 wire 0 9 mm Check that the hole in the tip is not deformed or enlarged Also check that the tip is not dirty this would pre vent a good connection If needed replace Contact Tip 2b with proper size and type WEAK ARC STRENGTH POSSIBLE CAUSES AND SOLUTIONS Incorrect line voltage Check the line voltage and if insufficient have a licensed electrician remedy the situa tion Improper gauge or length of extension cord Extension cords are not recommended If possible eliminate the use of an extension cord If an extension cord is needed refer to the gauge and length chart on page 10 and in relation to the required input amperage stated on the Specifications table If the steps above do not solve the problem or if the repairs involved are too complex contact a qualified technician SKU 55167 For technical questions please call 1 800 444 3353 Page 28
26. ece of wood from 2 to 3 inches away If the wire stops instead of bending turn the welder OFF unplug it and slightly tighten the Wire Tension Adjusting Screw 37 15 16 17 Turn the welder OFF Slide the Contact Tip over the wire and screw it into Torch Handle Tighten the Contact Tip 2b using the provided Wrench 43 Replace the Nozzle and cut off any excess wire over Secure the Cover CHANGING WIRE FEED ROLLER WARNING Turn the welder OFF and unplug it before proceeding Press on the Cover Locking Spring 8 then lift the Cover 31 using Handle 30 to expose the Wire Feed Unit 23 Loosen the Tension Adjusting Screw 37 Press the Wire Feed Swing Arm 36 forward slightly and lift it to remove tension Remove Screws 45 and Washers 46 A lt gt Remove the Feed Roller Bracket 44 o lo Wire Feed Roller 34 1 1 Feed Roller ras Bracket 44 Screws 45 and Washers 46 SKU 55167 For technical questions please call 1 800 444 3353 Page 13 Troubleshooting section at end of manual 5 Hemove the Wire Feed Roller 34 and install one with the proper size 030 facing up 6 Heassemble the Roller Bracket 44 Screws 45 and Washers 46 Put the welding wire into the top groove on the Roller if it is not already in place 7 Swing the Wire Feed Adjusting Spring 86 down while pressing it forward to latch it over the Tension Adjusting Screw
27. er Switch 1c Check and secure replace Trigger Switch 1c according to the instructions outlined on page 14 of this manual Internal fuse blown Check replace according to the following directions a WARNING Turn the welder OFF and unplug it before proceeding b Press on the Cover Locking Spring 8 then lift the Cover 31 using Handle 30 Remove Left Side Panel 13 c Examine fuse on panel to see if metal wire inside is broken or not See illustration to the right NOTE The circuit board is very delicate and will be damaged if it is not supported while the fuse is being removed replaced If you are have any doubts about doing this without damaging the welder have a qualified technician replace the fuse d Ifthe fuse is broken carefully support the circuit board with a gloved hand while you remove the old fuse Support the circuit board from behind while you install a new 2 Amp 250 Volt fuse of the same type NEVER use another type or size fuse in this unit e Reinstall the Left Side Panel 13 close the Cover 31 and test the unit for proper function before use If the steps above do not solve the problem or if the repairs involved are too complex contact a qualified technician SKU 55167 For technical questions please call 1 800 444 3353 Page 27 TROUBLESHOOTING continued IMPORTANT Be CERTAIN to shut off the Welder disconnect it from power and discharge the torch to ground before adjusting cl
28. fety precautions as outlined in the manufacturer s manual for the material you will weld or cut 11 Donottouch live electrical parts Wear dry insulating gloves Do not touch electrode or conductor tong with bare hand Do not wear wet or damaged gloves SKU 55167 For technical questions please call 1 800 444 3353 Page 7 Troubleshooting section at end of manual J 12 13 14 15 16 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 WARNING 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 Use care not to touch the welding tip to grounded material whenever the unit is plugged in This unit is what is referred to as a hot tip welder meaning that current is available to the wire at all times that the power Switch 7a is in the ON position Electric shock fire or burns may happen if appropriate precautions are not taken 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 WARNING This product when used f
29. not wear pants with cuffs shirts with open pockets or any clothing that can catch and hold molten 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 cutting procedures e When welding cutting overhead or in confined spaces wear flame resistant ear plugs or ear muffs to keep sparks out of ears 8 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 e 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 e Enclose the work area with portable fire resistant screens Protect combustible walls ceilings floors etc from sparks and heat with fire resistant covers e 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 combustibles is not possible designate someone to serve as a fire watch equipped with a fire extin guisher during
30. or welding and similar applications contains or produces a chemical 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 GROUNDING 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 facil ity before use If the plug will not fit the outlet have a proper outlet installed by a qualified electrician GROUNDED TOOLS TOOLS WITH THREE PRONG PLUGS Tools marked with Grounding Required have a three wire cord and three prong ground ing 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 See 3 Prong Plug and Outlet 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 See 3 Prong Plug and
31. ors There is an increased risk of electric shock if your body is grounded Do not expose power tools to rain or wet conditions Water entering a power tool will increase the risk of electric shock 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 Do not abuse the Power Cord Never use the Power Cord to carry the tools 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 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 Stay alert Watch what you are doing and use common sense when operating 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 Dress properly Do not wear loose clothing or jewelry Contain
32. r at least 9 minutes after every minute of continuous weld at 80 amps Failure to carefully observe duty cycle limitations can easily over stress a welder s power generation system contributing to premature welder failure This welder has an internal thermal protection system to assist with preventing this sort of over stress When the unit overheats it automatically shuts down then automatically returns to service when it cools down When it returns to service follow a more conservative duty cycle routine to help prevent excess wear to the welder SKU 55167 For technical questions please call 1 800 444 3353 Page 15 Troubleshooting section at end of manual SETTING UP THE WELD WARNING Use care not to touch the welding tip to grounded material whenever the unit is plugged in This unit is what is referred to as a hot tip welder meaning that current is available to the wire at all times that the power Switch 7a is in the ON position ELECTRIC SHOCK FIRE or BURNS may happen if appropriate precautions are not taken The Flux Wire Welder is used to weld sheet metal and light carbon steel Wire Feed Speed Knob 9 Torch 1 Cable g Overload Indicator Light 22 Power On Off Switch 7a Wage CED SrEED Current Min Max Switch 7b 90AMP FLUX WIRE WELDER 60Hz EIL Ground Cable 33 Power Cord 32 Made In China Warning Before arc welding read and understand all safety precautions and warnings listed on p
33. rous and must be replaced Unless explicitly instructed otherwise 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 Store idle tools out of reach of children and other untrained persons Tools are dangerous in the hands of untrained users Maintain tools with care Keep tools in good repair Properly maintained tools will get the job done better Do not use a damaged tool Tag damaged tools Do not use until repaired Check for breakage of parts and any other condition that may affect the tool s operation If damaged have the tool serviced before using Many accidents are caused by poorly maintained tools 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 Tool service must be performed only by qualified repair personnel Service or maintenance performed by unqualified personnel could result in a risk of injury When servicing a tool 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 or injury SPECIFIC SAFETY RULES Maintain labels and nameplates on th
34. the cutting process and for at least one half hour after the cutting is completed e Do not weld or cut on materials having a combustible coating or combustible internal structure as in walls or ceilings without an approved method for eliminating the haz ard Do not dispose of hot slag in containers holding combustible materials Keep a fire extinguisher nearby and know how to use it e After spot welding make a thorough examination for evidence of fire Be aware that SKU 55167 For technical questions please call 1 800 444 3353 i P Troubleshooting section at end of manual agen 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 flam mable 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 vapors Clean and purge containers before applying heat Vent closed containers including castings before preheating welding or cutting 9 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 hav
35. ual 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 wire feed pressure properly follow steps 12 15 on page 13 2 Incorrect wire feed roll size Replace with the proper one 8 mm 030 follow the Installing The Wire Reel instruc tions starting on page 12 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 steps 12 15 on page 13 2 Incorrect contact tip size Replace with the proper tip for 030 wire 0 9 mm 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 030 wire 0 9 mm 3 Incorrect wire feed speed Adjust wire feed speed to achieve a more
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