Owner's Manual & Safety Instructions - Harbor Freight Tools

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Owner’s Manual & Safety InstructionsSave This Manual Keep this manual for the safety warnings and precautions, assembly, operating, inspection, maintenance and cleaning procedures. Write the product’s serial number in the back of the manual near the assembly diagram (or month and year of purchase if product has no number). Keep this manual and the receipt in a safe and dry place for future reference.

When unpacking, make sure that the product is intact and undamaged. If any parts are missing or broken,

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.

Diagrams within this manual may not be drawn proportionally. Due to continuing improvements, actual product may differ slightly from the product described herein.

Tools required for assembly and service may not be included.

Read this material before using this product. Failure to do so can result in serious injury. SAVE THIS MANUAL.

REV 16c

For technical questions, please call 1-888-866-5797. Item 62486

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Table of contentsSafety ......................................................... 2Specifications ............................................. 7Controls ...................................................... 8Basic Welding ............................................ 10

Welding Tips .............................................. 15Maintenance and Service .......................... 19Parts Lists and Diagrams .......................... 20Warranty .................................................... 27

WARNINg SyMBoLS ANd dEFINITIoNSThis is the Safety alert symbol. It is used to alert you to potential

personal injury hazards. Obey all Safety messages that follow this symbol to avoid possible injury or death.

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

Addresses practices not related to personal injury.

IMpoRTANT SAFETy INFoRMATIoN

Read all Safety warnings and instructions. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury. Save all warnings and instructions for future reference.

general SafetypRoTEcT yourself and others. Read and understand this information.

1. Before use, read and understand manufacturer′s instructions, Material Safety Data Sheets (MSDS′s), employer′s Safety practices, and ANSI Z49.1.

2. Keep out of reach of children. Keep children and bystanders away while operating.

3. place the welder on a stable location before use. If it falls while plugged in, severe injury, electric shock, or fire may result.

4. do not overreach. Keep proper footing and balance at all times.

5. Stay alert, watch what you are doing and use common sense when operating a welder. do not use a welder while you are tired or under the influence of drugs, alcohol or medication. A moment of inattention while operating welders may result in serious personal injury.

6. Avoid unintentional starting. Make sure you are prepared to begin work before turning on the Welder.

7. Never leave the Welder unattended while energized. Turn power off if you have to leave.

8. The warnings, precautions, and instructions discussed in this instruction manual cannot cover all possible conditions and situations that may occur. It must be understood by the operator that common sense and caution are factors which cannot be built into this product, but must be supplied by the operator.

9. WARNING: This product, when used for welding, plasma cutting, soldering, or similar applications, produces chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. (California Health & Safety Code § 25249.5, et seq.)

10. WARNING: The cord of this product contains lead and/or di (2-ethylhexyl) phthalate (DEHP), chemicals known to the State of California to cause cancer, and birth defects or other reproductive harm. Wash hands after handling. (California Health & Safety Code § 25249.5, et seq.)

For technical questions, please call 1-888-866-5797.Item 62486

Fume and gas SafetyINHALATION HAZARD:

Welding and plasma cutting produce toxic fumes.

1. Exposure to welding or cutting exhaust fumes 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 or plasma cutting exhaust fumes are:• Early onset of Parkinson’s Disease• Heart disease • Ulcers• Damage to the reproductive organs• Inflammation of the small intestine or stomach • Kidney damage• Respiratory diseases such as

emphysema, bronchitis, or pneumoniaUse natural or forced air ventilation and wear a respirator approved by NIOSH to protect against the fumes produced to reduce the risk of developing the above illnesses.

2. do not use near degreasing or painting operations.

3. Keep head out of fumes. Do not breathe exhaust fumes.

4. Use enough ventilation, exhaust at arc, or both, to keep fumes and gases from breathing zone and general area. If engineering controls are not feasible, use an approved respirator.

5. Work in a confined area only if it is well-ventilated, or while wearing an air-supplied respirator.

6. Have a recognized specialist in Industrial Hygiene or Environmental Services check the operation and air quality and make recommendations for the specific welding situation. Follow OSHA guidelines for Permissible Exposure Limits (PEL’s) and the American Conference of Governmental Industrial Hygienists recommendations for Threshold Limit Values (TLV’s) for fumes and gases.

Arc Ray SafetyARc RAyS can injure eyes and burn skin.

1. Wear ANSI-approved welding eye protection featuring at least a number 10 shade lens rating.

2. Wear leather leggings, fire resistant shoes or boots during use. Do not wear pants with cuffs, shirts with open pockets, or any clothing that can catch and hold molten metal or sparks.

3. Keep clothing free of grease, oil, solvents, or any flammable substances. Wear dry, insulating gloves and protective clothing.

4. 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.

5. Wear an approved welding jacket or long sleeves to protect forearms from radiation burns.

6. When welding/cutting overhead or in confined spaces, wear flame resistant ear plugs or ear muffs to keep sparks out of ears.

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Electrical SafetyELEcTRIc SHocK can KILL.

1. Turn off, disconnect power, and discharge electrode to ground before setting down torch/electrode holder and before service.

2. do not touch energized electrical parts. Wear dry, insulating gloves. Do not touch electrode holder, electrode, welding torch, or welding wire with bare hand. Do not wear wet or damaged gloves.

3. connect to grounded, gFcI-protected power supply only.

4. do not use near water or damp objects.

5. people with pacemakers should consult their physician(s) before use. Electromagnetic fields in close proximity to heart pacemaker could cause pacemaker interference or pacemaker failure.

6. do not expose welders to rain or wet conditions. Water entering a welder will increase the risk of electric shock.

7. do not abuse the cord. Never use the cord for carrying, pulling or unplugging the welder. Keep cord away from heat, oil, sharp edges or moving parts. Damaged or entangled cords increase the risk of electric shock.

8. do not use outdoors.

9. 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 large enough to cover your full area of contact with the work or ground.

Fire SafetyARc ANd SLAg can cause fire.

1. clear away or protect flammable objects. 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.

2. Keep ABc-type fire extinguisher near work area and know how to use it.

3. Maintain a safe working environment. Keep the work area well lit. Make sure there is adequate surrounding workspace. Keep the work area free of obstructions, grease, oil, trash, and other debris.

4. do not operate welders in atmospheres containing dangerously reactive or flammable liquids, gases, vapors, or dust. Provide adequate ventilation in work areas to prevent accumulation of such substances. Welders create sparks which may ignite flammable substances or make reactive fumes toxic.

5. 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 extinguisher, during the cutting process and for at least one half hour after the cutting is completed.

6. 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 hazard.

7. do not dispose of hot slag in containers holding combustible materials.

8. After welding, make a thorough examination for evidence of fire. Be aware that easily visible smoke or flame may not be present for some time after the fire has started.

9. 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.

Welder Use and care1. do not use the welder if the switch does not turn

it on and off. Any welder that cannot be controlled with the switch is dangerous and must be repaired.

2. disconnect the plug from the power source before making any adjustments, changing accessories, or storing welders. Such preventive Safety measures reduce the risk of starting the welder accidentally.

3. prevent unintentional starting. Ensure the switch is in the off-position before connecting to power source or moving the welder. Carrying or energizing welders that have the switch on invites accidents.

4. Store idle welders out of the reach of children and do not allow persons unfamiliar with the welder or these instructions to operate the welder. Welders are dangerous in the hands of untrained users.

5. Use the welder and accessories in accordance with these instructions, taking into account the working conditions and the work to be performed. Use of the welder for operations different from those intended could result in a hazardous situation.

Maintenance1. Maintain welders. check for misalignment or

binding of moving parts, breakage of parts and any other condition that may affect the welder’s operation. If damaged, have the welder repaired before use. Many accidents are caused by poorly maintained welders.

2. Have your welder serviced by a qualified repair person using only identical replacement parts. This will ensure that the Safety of the welder is maintained.

3. Maintain labels and nameplates on the Welder. These carry important information. If unreadable or missing, contact Harbor Freight Tools for a replacement.

4. Unplug before maintenance. Unplug the Welder from its electrical outlet before any inspection, maintenance, or cleaning procedures.

gas Shielded Welding - cylinder Safetycylinders can explode when damaged.

1. do not weld on a pressurized or closed cylinder.

2. do not allow an electrode holder, electrode, welding torch, or welding wire to touch the cylinder.

3. Keep cylinders away from any electrical circuits, including welding circuits.

4. Keep protective cap in place over the valve except when the cylinder is in use.

5. Use only correct gas shielding equipment designed specifically for the type of welding you will do. Maintain this equipment properly.

6. protect gas cylinders from heat, being struck, physical damage, slag, flames, sparks, and arcs.

7. Use proper procedures to move cylinders.

SAVE THESE INSTRUcTIoNS.

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grounding

To pREVENT ELEcTRIc SHocK ANd dEATH FRoM INcoRREcT gRoUNdINg WIRE coNNEcTIoN: check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded.

do not use the welder if the power cord or plug is damaged. If damaged, have it repaired by a service facility before use. If the plug will not fit the outlet, have a proper outlet installed by a qualified electrician, do not use adapter plugs.

1. The green wire inside the cord is connected to the grounding system in the Welder. The green wire in the cord must be the only wire connected to the Welder’s grounding system and must never be attached to an electrically “live” terminal. Never leave the grounding wire disconnected or modify the Power Cord Plug in any way.

2. Make sure the tool is connected to an outlet having the same configuration as the plug. If the tool must be reconnected for use on a different type of electric circuit, the reconnection should be made by qualified service personnel; and after reconnection, the tool should comply with all local codes and ordinances.

3. The plug shown (NEMA 6-50p) is for use on a 50 A circuit. A different 250 VAC plug and outlet combination may be used, provided it is rated to handle the electrical requirements of the tool and is installed by a certified electrician.

250 VAC 3-Prong Plug (6-50p) and Outlet (6-50r)(for up to 250 VAC and up to 50 A)

do NoT USE 125 VAc pLUg.

NOTE SIZE dIFFERENcE.

High Frequency grounding

1. The Welder must be properly grounded in accordance with all relevant electrical codes and standards before operation. Have the unit grounded by a qualified electrician if you are not qualified to do so.

2. To ground the Welder, connect a #12 AWG grounding wire (not included) from the Grounding Terminal on the side of the unit to a grounding rod (not included). The grounding rod must be an earth-driven copper or brass rod (electrode) which can adequately ground the Welder.

3. Refer to local regulations for ground source information.

Extension cordsdo not use an extension cord on this welder.

Replacement cords1. A qualified electrician can install either of the

following UL-listed, 3 wire cords as a replacement cord for this welder: 12 AWg up to 6 feet long, 10 AWg up to 75 feet long, or 6 AWg up to 175 feet long.

2. do not install a thinner or longer cord on this welder.

3. do not patch cords of any length together for this item, patches may allow moisture to penetrate the insulation, resulting in electric shock.

Specifications

Power Input 240VAC, 60Hz, 27A (MMA) / 20A (TIG)

Welding Current Range 10 ~ 165 A

Output Voltage (@ Rated Amps)

Stick 26VDC

TIG 14VDC

Maximum OCV 98

Duty Cycle60% @ 165 A80% @ 143 A

100% @ 128 AGas Inlet 5/8″-18 RH female

Electrode CapacityStick 1/16″-1/8″ diameterTungsten 1/16″-3/32″ diameter

Weldable Materials Mild Steel, Low Alloy Steel, Stainless Steelcannot weld aluminum (DC output only)

Material ThicknessStick up to 3/8″ thick (in a single pass)Tungsten 22 gauge ~ 3/16″ thick (0.029" ~ 0.187")

Required Accessories (for TIG Welding)

Argon Gas Cylinder (not included)Gas Regulator (not included)Gas Flow Gauge (not included)Inert Gas Hose with 5/8"-18 threads (not included)Filler Material (not included)#12 AWG Grounding Wire (not included)Grounding Rod (not included)

Symbology

Wire Feed (Speed)

Workpiece Ground Cable

Torch Cable

Overheat Shutdown Indicator

Cooling Fan

Housing Ground Point

VAc Volts Alternating Current

A Amperes

ocV Open Circuit Voltage

KVA Kilovolt Amperes(Volts / 1000 * Amperes)

IpM Inches Per Minute

AWg American Wire Gauge

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controls

Read the ENTIRE IMpoRTANT SAFETy INFoRMATIoN section at the beginning of this manual including all text under subheadings therein before set up or use of this product.

To pREVENT SERIoUS INJURy FRoM AccIdENTAL opERATIoN: Turn the power Switch off and unplug the welder before assembly.

components and controls

TIg Torch

grounding clampElectrode Holder

power Switch

digital display

current output Knob

overload Light

power Supply Light

Electrode Holder/TIg Torch connection

gas outletTIg control/Foot pedal connection

gas post Flow delay Switch

Stick/TIg Switch

ground cable connection

gas Inlet

grounding

cooling Fan

power Input

Foot pedal

Trigger

components

1. Power Switch: Powers the Welder. When “ON”, the Power Supply Light will light up and the Cooling Fan will turn on.

2. Stick/TIG Switch: Switch to top for TIG welding, to bottom for Stick welding.

3. Gas Post Flow Delay Switch: Allows control of how long shielding gas flows after the Trigger is released.

4. Current Output Knob: Sets the welding amperage.

5. Digital Display: Displays the welding settings or current output.

6. Ground Cable Connection: Connects Grounding Clamp to Welder.

7. TIG Control/Foot Pedal Connection: Connects Torch Control Cable or Foot Pedal, depending on which one will be used.

8. Gas Outlet: Connects TIG Torch to shielding gas.

9. Electrode Holder/TIG Torch Connection: Connects either TIG Torch or Electrode Holder Cable to Welder.

10. Gas Inlet: Attach argon cylinder via gas regulator, flow gauge, and hose (all not included) here.

11. Trigger: Turns arc on and off.

12. Foot Pedal: Turns arc on and off and controls current output during weld. Press pedal to increase amperage of arc.

Indicators

Overload: Long periods of use at high current may cause the unit to overheat. If this light illuminates, stop welding and keep the Welder powered to allow the fans to cool. When the Welder has sufficiently cooled, the light will go out, and welding may be resumed.

TIg Welding controls

1. Torch - Creates welding puddle and adds shielding gas, but does not add filler material. It is usually moved in a circular pattern to keep the weld puddle molten.

2. Filler Rod (required, but not included) - used to add material to the weld puddle. Avoid withdrawing from the shielding gas to prevent weld contamination.

3. Amperage Control (Foot Pedal, or Current Knob) - Controls the amount of heat the torch adds to the weld puddle.

Note: When foot pedal is in use, Digital Display will read 10 amps until welding begins.

4. Ground Clamp - Connects the workpiece back to the Welder to allow effective welding. Must be connected to workpiece to strike welding arc.

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operating Instructions

Wear protective gear during use; an ANSI-approved welding mask, at least shade 9, ear protection, welding gloves and apron, NIoSH-approved respirator, and

fire resistant work clothes without pockets should be worn when welding. Light from the arc can cause permanent damage to the eyes and skin. do not breathe arc fumes.

1. Place the Welder on a level surface that can bear its weight near the work area.

2. Connect a #12 AWG ground wire (not included) to the Ground Post on the rear of the Welder and route it to ground. If possible, ground the workpiece independent of the welder.

Duty Cycle (Duration of Use)Avoid damage to the Welder by not welding 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 produce a particular welding current without overheating. For example, this Welder with a 60% duty cycle at 165 A welding current must be allowed to rest for at least 4 minutes after every 6 minutes of continuous welding. 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 help prevent this sort of over-stress. When the unit overheats, it automatically shuts down and the Overload Indicator lights. The welder automatically returns to service after cooling off. Rest the electrode on an electrically non-conductive, heat-proof surface, such as a concrete slab, well clear of the ground clamp while allowing the welder to cool with the Power Switch on, so that the internal Fan will help cool the welder. When the welder can be used again, use shorter welding periods and longer rest periods to prevent needless wear.

60% duty cycle at 165 A 6 minutes welding

followed by at least 4 minutes of rest

80% Duty Cycle at 143 A 8 minutes welding

followed by at least 2 minutes of rest

100% duty cycle at 128 A continuous use

Setting up the Weldclamps

workpieces

chamfer thick workpieces.

clean surfaces to bare metal.

1. Make practice welds on pieces of scrap the same thickness as your intended workpiece to practice technique before welding anything of value. Clean the weld surfaces thoroughly with a wire brush or angle grinder; there must be no rust, paint, oil, or other materials on the weld surfaces, only bare metal.

2. Use clamps (not included) to hold the workpieces in position so that you can concentrate on proper welding technique. 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. The edges of thicker workpieces may need to be chamfered (or beveled) to allow proper weld penetration.

NOTICE: When welding equipment on a vehicle, disconnect the vehicle battery power from both the positive connection and the ground before welding. This prevents damage to some vehicle electrical systems and electronics due to the high voltage and high frequency bursts common in welding.

Stick Welding

grounding clamp

Electrode Holder

1. Connect the cable of the Electrode Holder to the Welder, as shown above and twist to lock in place.

WARNINg! Only plug a TIG Torch or Electrode Holder into the right Socket.

2. Plug the cable of the Grounding Clamp into the Welder and secure the clamp to a clean, exposed metal part of the workpiece.

WARNINg! Only plug the ground clamp into the left Socket.

3. Place the metal portion of the welding electrode inside the jaws of the Electrode Holder. Welding electrode types vary for welding different metals and welding methods.

Stick/TIgSwitch

overloadLight

current output Knob

4. Move the Stick or TIG Switch to “Arc” (top position).

5. Turn the Current Output Knob to meet the needs of the job: higher amps for thicker material, lower amps for thinner material.

6. Plug the power cord into a grounded 240V electric socket and turn the Welder on.

WARNINg! To prevent serious injury and death: If the operator is not holding the Electrode Holder, it must be sitting on a nonconductive, nonflammable surface. The Welder will immediately turn on when the power Switch is turned on.

7. Stroke the workpiece lightly to ignite the arc. Tips for igniting the arc:a. Stroke the surface with the electrode.b. Strike the surface like a match with the electrode.c. Tap the surface with the electrode.

8. When the arc ignites, tilt the electrode forward and hold it near the workpiece.

9. When finished welding; lift the electrode from the workpiece and turn the Welder off.

10. Place the Electrode Holder down on a nonflammable, nonconductive surface.

11. To prevent accidents, disconnect the tool from its power supply after use. Allow the tool to cool down, clean, then store the tool indoors out of children’s reach.

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TIg WeldingTIG welding is a complicated process, requiring experience and skill to achieve successful results. Training beyond the scope of this manual is required to TIG weld properly.

Assembling the Torch

1. Match Collet and Collet Body sizes to tungsten Electrode.

2. Thread Collet Body into the front of the Torch.

3. Match size of Ceramic Nozzle to shielding gas requirements for weld-piece material thickness (see Settings Chart). Thread correct Ceramic Nozzle onto Collet Body.

4. Insert Collet into Collet Body. Insert tungsten Electrode into Collet.

5. Lock Electrode in place with Back Cap. Electrode should protrude 1/8" to 1/4" beyond the Ceramic Nozzle.

collet Body

ceramic Nozzle

collet

Back cap

Insert tungsten Electrode here.

Settings chartMaterial Material

Thickness Amperage Tungsten Color Tungsten Diameter Filler Metal Filler Metal

DiameterCeramic

Nozzle SizeGas Post

FlowGas Flow

Rate (scfh)

Mild Steel 1/16″ 55-90 Grey, Orange, Red, White 1/16″ ER70S-2 1/16″ #4 2 11-12

Mild Steel 3/32″ 90-120 Grey, Orange, Red, White 1/16″ ER70S-2 1/16″ #4-5 2 11-12

Mild Steel 1/8″ 95-135 Grey, Orange, Red, White 1/16-3/32″ ER70S-2 3/32″ #5-6 10 11-12

Mild Steel 3/16″ 140-165+ Grey, Orange, Red, White 3/32″ ER70S-2 1/8″ #6-7 10 13-14

Stainless Steel 1/16″ 50-80 Grey, Orange,

Red, White 1/16″ ER308/308L 1/16″ #4 2 11-12

Red, White 1/16″ ER308/308L 1/16″ #4-5 2 11-12

Red, White 1/16-3/32″ ER308/308L 3/32″ #5-6 10 11-12

Stainless Steel 3/16″ 125-165+ Grey, Orange,

Red, White 3/32″ ER308/308L 1/8″ #6-7 10 13-14

Sharpening the Tungsten Electrode

To avoid electrode contamination, dedicate a fine grit grinding wheel exclusively to electrode grinding.

1. Shut off the welder and wait until Electrode and Torch have cooled enough to handle.

2. Remove Back Cap and Collet. Pull Electrode from front of Torch. (Pulling it from rear will damage Collet and create burrs on Electrode).

3. If Electrode has dulled or been otherwise contaminated, use pliers or a suitable tool to grip the Electrode above the contaminated section and snap off the end of the Electrode.

WARNINg! Some electrodes may have materials added to them that are hazardous to breathe. Wear a respirator and ANSI-approved Safety goggles when grinding an electrode.

4. Lightly press Electrode tip against the surface of the grinding wheel at an angle. Rotate Electrode tip until a blunt point is formed.

Note: Grinding direction must be parallel to length of electrode.

5. The conical portion of the ideal tip will be 2-1/2 times as long as the electrode diameter.

6. Re-insert Electrode into Collet with tip protruding 1/8"-1/4" beyond the Ceramic Nozzle, then re-tighten the Back Cap.

grinding Wheel

Electrode

connecting the components

grounding clamp1. Plug Grounding Clamp cable into Socket

on the left. Twist to lock in place.2. Secure clamp to a clean, exposed metal

part of the workpiece or worktable.WARNINg! Only plug the ground clamp into the left Socket.

grounding clamp

TIg TorchWARNINg! Only plug a TIG Torch or Electrode Holder into the right Socket.1. Plug TIG Torch Switch Cable, Welder

Cable, and Gas Cable into respective sockets. Twist to lock in place.

TIg Torch

Foot Pedal (optional)The Foot Pedal is an optional component that may be used to adjust the amperage of the arc hands-free.1. Unplug Torch Switch Cable. 2. Plug Foot Pedal Switch Cable into

socket. Twist to lock in place.

TIg Torch

Foot pedal

Note: With Foot Pedal attached, TIG Torch Trigger will not turn on welding arc. Amperage is controlled exclusively with the Foot Pedal.

TIg Welding controls

1. Torch - Creates welding puddle and adds shielding gas, but does not add filler material. It is usually moved in a circular pattern to keep the weld puddle molten.

2. Filler Rod (required, but not included) - used to add material to the weld puddle. Avoid withdrawing from the shielding gas to prevent weld contamination.

Note: When foot pedal is in use, Amperage Control will read 10 amps until welding begins.

3. Amperage Control (Foot Pedal, or Current Knob) - Controls the amount of heat the torch adds to the weld puddle.

4. Ground Clamp - Connects the workpiece back to the Welder to allow effective welding. Must be connected to workpiece to strike welding arc.

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preparing to Weld

TIg Torch

grounding clamp

1. Connect components, as shown above. If Foot Pedal is to be used, connect as shown in “Foot Pedal (optional)” on page 13. Twist cables to lock in place.

WARNINg! To prevent serious injury and electric shock: do not weld without grounding clamp.

2. Use a wire brush to thoroughly cleanse workpiece of contaminants.

3. Consult fill material supplier’s documentation to determine proper type and flow of shielding gas. Connect a hose and coupling from the gas regulator/flow meter on a shielding gas cylinder (all not included) to the shielding gas Inlet (5/8"-18 threads) on the back of the unit and adjust gas flow/PSI to proper level. Follow the gas cylinder manufacturer’s instructions for set-up and use.

4. The Gas Post Flow Delay Switch controls how long the shielding gas flows after the Trigger is released. Too little gas may make welds porous and create excessive spatter. Too much gas may waste gas. To conserve shielding gas switch it to “short”. If the welded surface is being tarnished, change the switch to “long”.

gas post Flow delay Switch

Stick/TIgSwitch

overloadLight

current output Knob

5. Turn the Current Output Knob to meet the needs of the job: higher amps for thicker material, lower amps for thinner material (refer to Settings Chart for more detail).

6. Move the Stick/TIG Switch to “TIG” (bottom position).

7. Plug the power cord into a grounded 240V/50A electrical socket and turn the Welder on.

WARNINg! To pREVENT SERIoUS INJURy ANd dEATH: The TIg Welder will immediately turn on when the trigger is held down. When the operator is not holding the Torch, it must be sitting on a nonconductive, nonflammable surface.

WARNINg! Only hold the filler rod using a thermally insulated welding glove.

8. Hold the Trigger down and begin welding.

NOTICE: TIG welding is a complicated process, requiring experience and skill to achieve successful results. Training beyond the scope of this manual is required to TIG weld properly.

9. Move the torch in a small circle, creating a welding puddle. Keep filler material tip near the weld puddle.

NoTE: Maintain a constant distance between the Electrode and the workpiece: between 1 and 1.5 times the diameter of the Electrode.

10. When welding puddle is hot enough, tilt torch backward about 10-15 degrees from vertical and move it back slightly. Add filler material as needed to the front end of the weld puddle.

11. Alternate between advancing the torch/weld puddle and adding the filler material.

NoTE: Remove the filler rod each time the electrode is advanced, but do not remove it from the gas shield. This prevents oxidation from contaminating the weld.

12. If duty cycle is reached, the Thermal Overload protector will activate, the Overload Light will turn on, and the welder will turn off until it cools down. If this happens, rest the electrode on an electrically non-conductive, heat-resistant surface, such as a concrete slab, well clear of the ground clamp. Wait about 8-10 minutes with the Power Switch to ON for the welder to cool. When the welder can be used again, use shorter welding periods and longer rest periods to help prevent needless wear.

13. When finished welding, release the trigger, but keep Torch on weld puddle until gas flow ends. Turn the Current Output Knob to the lowest setting, and turn the Power Switch off.

gas Inlet

Welding Tips

A good way to test welding technique is to examine a weld’s appearance after it has cooled and the slag has been removed. Then, better welding can be learned by adjusting your weld technique to remedy any problems found.

After practice welding a couple of welding beads, STop and examine

your weld using the guidelines starting on the next page.

NOTICE: TIG welding is a complicated process, requiring experience and skill to achieve successful results. Training beyond the scope of this manual is required to TIG weld properly.

Strike TestA test weld on a pIEcE oF ScRAp can be tested by using the following procedure.

WEAR ANSI-AppRoVEd SAFETy goggLES dURINg THIS pRocEdURE.

WARNINg! This test WILL damage the weld it is performed on. This test is oNLy an indicator of weld technique and is not intended to test working welds.

1. After two scraps have been welded together and the weld has cooled, clamp one scrap in a 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 but not break, as shown on top. A pooR WELd will be brittle and snap at the weld, as shown on bottom.

clampScRAp

workpiece

good WELd bends and is not brittle

dead-blow hammer

clampScRAp

workpiece

pooR WELd snaps or cracks

dead-blow hammer

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Stick Weld diagnosis - Workpiece Heat control / Weld penetrationEXcESS pENETRATIoN oR

BURN-THRoUgHpRopER pENETRATIoNINAdEQUATE pENETRATIoN

Not hot enough Too hotIdeal heat

How to increase workpiece heat and increase penetration:

(to weld THIcKER workpieces properly)a. Increase current. b. Weld more slowly.

How to reduce workpiece heat and limit penetration:

(to weld THINNER workpieces properly)c. Decrease current. d. Weld more quickly.

Example Stick Weld diagramscLEAN WELdS FIRST!

Stick welds will have a coat of slag over them until cleaned.

good Weld

current Too Low

To coRREcT: Increase the

current

To coRREcT: Decrease the current

current Too High

To coRREcT:Weld slower

Weld Speed Too Fast

To coRREcT:Weld faster

Weld Speed Too Slow

Arc Length Too Short

To coRREcT:Increase distance

Arc Length Too Long

To coRREcT:Decrease distance

Stick Weld Penetration (Workpiece Heat Control)

EXcESS pENETRATIoN oR BURN-THRoUgH

Weld droops on top and underneath or falls through

entirely, making a hole.

pRopER pENETRATIoNWeld is visible underneath and

bulges slightly on top.

INAdEQUATE pENETRATIoNWeld does not contact the joint

fully, just on the surface.

PROFILE VIEWS

poSSIBLE cAUSES ANd SoLUTIoNS FoR

1. Workpiece overheating: Reduce current.

2. Welding speed too slow: Increase welding speed and ensure that welding speed is kept steady.

poSSIBLE cAUSES ANd SoLUTIoNS FoR

1. Incorrect welding technique: Keep arc on leading edge of weld puddle. Hold torch at proper angles.

2. Insufficient weld heat: Slow down so fill material has time to melt into the weld location. Increase current.

3. Workpieces too thick/close: Bevel thick workpieces, allow slight gap, and weld in several passes.

4. Insufficient weld material: Increase amount of fill material.

Weld Not Adhering properly - Stick Weldgaps present between weld and previous bead or between weld and workpiece. See areas below.

poSSIBLE cAUSES ANd SoLUTIoNS

PROFILE VIEW

1. 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. Keep arc on leading edge of weld puddle. Hold electrode and fill material at proper angles.

2. Insufficient weld heat: Increase current.

3. dirty workpiece: Clean workpiece down to bare metal.

4. Insufficient weld material: Increase amount of fill material.

Bend at Joint - Stick WeldpoSSIBLE cAUSES ANd SoLUTIoNS

PROFILE VIEW

1. Improper clamping: Clamp workpieces securely. Make tack welds to hold workpieces.

2. Excessive heat: Weld a small portion and allow to cool before proceeding. Increase weld speed.

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coat of Slag over Weld - Stick Weld

TOP VIEW

PARTIALLY CHIPPED AWAY TO SHOW WELD

Slag is a necessary part of a stick weld. It shields the weld from impurities. clean off the slag with the chipping Hammer and Wire Brush after welding.

porosity - Stick Weld - Small cavities or holes in the bead.

TOP VIEW

1. dirty workpiece or fill material: Clean workpiece down to bare metal. Make certain that fill material and electrode are clean and free from oil, coatings, and other residues.

2. Inconsistent welding speed: Maintain steady weld speed.

crooked/Wavy Bead - Stick WeldpoSSIBLE cAUSES ANd SoLUTIoNS

TOP VIEW

1. Inaccurate welding: Use two hands or rest hand on steady surface.

2. Inconsistent welding speed: Maintain steady weld speed.

Excessive Spatter - Stick WeldpoSSIBLE cAUSES ANd SoLUTIoNS

TOP VIEW

Fine spatter is normal. Spatter that is grainy and large is a problem.

dirty workpiece or fill material: Clean workpiece down to bare metal. Make certain that fill material and electrode are clean and free from oil, coatings, and other residues.

Burn-Through - Stick Weld - Base material melts away, leaving a hole in the weld.

TOP VIEW

1. Workpiece overheating: Reduce current.

2. Welding speed too slow: Increase welding speed and ensure that welding speed is kept steady.

3. Excessive material at weld: Reduce amount of fill material.

Maintenance and Service

To pREVENT SERIoUS INJURy, FIRE ANd BURNS: Unplug the Welder, rest the tool on a heat-proof, electrically non-conductive surface, and allow all parts of the Welder to cool thoroughly before service.

1. Periodically remove the Top Housing, and using compressed air, blow out all dust from the interior.

2. Store in a clean and dry location.

3. For optimal weld quality, clean and inspect the contact points before each use.

Troubleshooting

IMpoRTANT!Be cERTAIN to shut off the Welder, disconnect it from power, and discharge the

electrode to ground before adjusting, cleaning, or repairing the unit.

problem possible causes Likely SolutionsPower Supply Light Illuminates, But Welder Does Not Function When Switched On

1. Tripped thermal protection device.

2. Faulty or improperly connected Trigger.

3. Ground Clamp not attached to workpiece.

4. Shielding Gas not connected.

1. Reduce duration or frequency of welding periods to help reduce wear on the welder. Refer to Duty Cycle (Duration of Use) on page 10.

2. Qualified technician must check and secure/replace Trigger.

3. Attach Ground Clamp to workpiece.

4. Connect shielding gas to Welder.Power Supply Light Does Not Illuminate When Switched On

1. Unit is not connected to outlet properly.

2. Outlet is unpowered.

1. Verify the voltage at the outlet and the connection to the outlet.

2. 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 in Specifications on page 7.

Weak Arc Strength 1. Incorrect line voltage.

2. Improper gauge or length of extension cord.

1. Check the line voltage and, if insufficient, have a licensed electrician remedy the situation.

2. Extension cords are not recommended. If possible, eliminate the use of an extension cord. If an extension cord is needed, refer to the guidelines on 6.

Welding Arc Not Stable.

1. Loose electrode cable or ground cable.

2. Damaged electrode holder or loose connection within electrode holder.

3. Adjust current setting.

4. Shielding gas getting low.

1. Check to ensure that all connections are tight.

2. Have a qualified technician inspect and repair/replace as necessary.

3. Make sure setting matches recommended setting on chart.

4. Replace shielding gas cylinder.

Follow all Safety precautions whenever diagnosing or servicing the tool. disconnect power supply before service.

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part description Qty1 Handle 12 Top-Housing 13 Ground Clamp Subassembly 14 Electrode Holder Subassembly 15 Temperature Protector 16 Digital Display 17 LED Cover 28 Switch 19 Potentiometer 1

10 Amperage Control 111 Type Switch 212 Switch Support Bar 113 Connector 114 Air Connector 115 M12 Nut 116 Terminal 117 Quick Connector Subassembly 218 Current Sensor 119 Connector 120 Bottom-Housing 121 Air Connector 2

part description Qty22 Solenoid Valve 123 Temperature Protector Shield 124 Supporting Foot 425 Fan 126 Power Cord 127 Locator 128 Air Interface 129 Rectifying Tube Radiator 130 Fan Hood 131 Radiator Support Bar 132 Grommet 133 IGBT Radiator 234 Rectifying Diode 635 IGBT 436 Main PCB Assembly 137 Panel 138 PCB Assembly 139 Grommet 240 TIG Torch 141 Foot Pedal 1

parts Lists and diagrams

pLEASE REAd THE FoLLoWINg cAREFULLyTHE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER OR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT, OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER AND/OR DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS, AND NOT BY THE BUYER. THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO.

parts List and

Record product’s Serial Number Here: Note: If product has no serial number, record month and year of purchase instead.

Note: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts.

2225 15

Assembly diagram

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Wiring Schematic A

C9 2.2N

D8 RHRP1560

RHRP1560

R6 R5W

1 2SR2

1 2SR3

1 2SR4

R12W-22R-5%

D2 FGH40N60SFD

FGH40N60SFD

CBB21-1UF-630V

4.7NF-250V

34 K3B

12V-5A

34 K5B

12V-5A

123J3 *

123J4 *

AC1VALVE

1921 9

20T1 EE

4-VH3.96MM

LE LG2

03CWST

STTH3003CW

vR2 511K

R3 R18W

C2 4.7N

0VC3 4.

C6 470U

S0 SW D

1/4R14

1/4R12

1/4R11

D21 1N

220UF-35V

C25 100N

C06 47

1/4R17

1/2R02

12 9 7

3/4R15

1/4R18

:44-Φ

2-3.96MM

3/4R19

7 1N41

Wiring Schematic B

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Q3 IRFD

1/4R102

1/4R104

1/4R106

5 6 7 8

EF20-4MH-54:48:54-WS4+4

WIW3296W-504I

1 2 3 4

LE LG2

Wiring Schematics c and d

0.1UF/2000V

S1 157/

J3 6.3 1 2

J4 6.3

C1 10U

C2 10U

C3 10U

C4 10U

C5 10U

R2 RJ1/

R3 RJ1/

R4 RJ1/

R5 RJ1/

4R6 RJ

R7 RJ1/

4R8 RJ

R9 RJ1/

5R1 R5

R0 RJ1/

4W-0Ω

12345CN

C08 0.1UF/2000V

1/4R030

TLP627-1

1/4 R023

56KD011

1/4 R026

1/4 R027

1/4 R0284.7K

100NF1/4 R024

1/4 R0254.7K

Protect

22UF-50V

R0141W-39

R010287K

1/4R015

1/4R021

1/4R020

IgGZ_POWER

t JC1*

1U IF～

GND-AProtect

1/4R022

R0161K

1/4R012

360K1/4R013

123456789

1011121314151617

3-3.96MM

2-3.96MM

yellow

VR2100K

SRS-12VDC-SL-3A

1/4R041

D0141N4148

Protect

5-3.96MM

TIG_K_K

100UF-50V

5foot pedal

1/4R017

30KC036*

R011287K

D01818V

C037100NF

C040100NF

IF_IG_t

1/4R038

1/4R32

15K1/4R018

1/4R036 470R

current

Wiring Schematic E

R09100R

C2 E 3D11AM.

C651pF

R05100R

B1D53906

R02220K

R074.7K

R1315K

MC3307410

MC33074

R1410K

Protect

GZ_POWERRT/CT

R244.7K C15

C141nF

Protect

MC33074

GZ_POWER

10KB1 C

D101AM

D151AM

R194.7K C12

C16100nF

R227.15K C13

KS_TSL

R47620R

COMP 1

ISENCE 3

RT/CT 4PowerGND5

VREF8U1

UC3845

KS_TSL

A 2A1 K3

1234567891011121314151617

1/8R01

1/8R10

Wiring Schematic F

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SRSB-12VDC-SL-A-5A

1112 13

1/4R209

SRSB-12VDC-SL-A-5A

1/4R215

2 BC817-25

1/4R219

1/4R220

100K C2

3 BC817-25

13 1214

10N C2

1/4R232

1/4R233

1/4R240

1/4R237

4 BC817-25

1/4R238

1/4R239

M/T开关

123CN3

3-3.96MM

07TG1/4

Wiring Schematic g

Limited 90 day Warranty

Harbor Freight Tools Co. makes every effort to assure that its products meet high quality and durability standards, and warrants to the original purchaser that this product is free from defects in materials and workmanship for the period of 90 days from the date of purchase. This warranty does not apply to damage due directly or indirectly, to misuse, abuse, negligence or accidents, repairs or alterations outside our facilities, criminal activity, improper installation, normal wear and tear, or to lack of maintenance. We shall in no event be liable for death, injuries to persons or property, or for incidental, contingent, special or consequential damages arising from the use of our product. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation of exclusion may not apply to you. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS.To take advantage of this warranty, the product or part must be returned to us with transportation charges prepaid. Proof of purchase date and an explanation of the complaint must accompany the merchandise. If our inspection verifies the defect, we will either repair or replace the product at our election or we may elect to refund the purchase price if we cannot readily and quickly provide you with a replacement. We will return repaired products at our expense, but if we determine there is no defect, or that the defect resulted from causes not within the scope of our warranty, then you must bear the cost of returning the product.This warranty gives you specific legal rights and you may also have other rights which vary from state to state.

3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • 1-888-866-5797

Owner's Manual & Safety Instructions - Harbor Freight Tools

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Transcript of Owner's Manual & Safety Instructions - Harbor Freight Tools

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