Professional Documents
Culture Documents
Save 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. 20a
general Safety
pROTEcT yourself and others. Read and understand this information.
1. Before use, read and understand 5. Stay alert, watch what you are doing and use
manufacturer′s instructions, common sense when operating a welder.
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Material Safety Data Sheets (MSDS′s), do not use a welder while you are tired or under
employer′s Safety practices, and ANSI Z49.1. the influence of drugs, alcohol or medication.
2. Keep out of reach of children. A moment of inattention while operating welders
Keep children and bystanders away while operating. may result in serious personal injury.
3. place the welder on a stable location before use. 6. Avoid unintentional starting. Make sure you are
If it falls while plugged in, severe injury, prepared to begin work before turning on the Welder.
electric shock, or fire may result. 7. Never leave the Welder unattended while
4. do not overreach. energized. Turn power off if you have to leave.
Keep proper footing and balance at all times. 8. The warnings, precautions, and instructions
discussed in this instruction manual cannot
cover all possible conditions and situations
MAINTENANcE
SAFETy
1. Exposure to welding or cutting exhaust 3. Keep head out of fumes.
fumes can increase the risk of developing Do not breathe exhaust fumes.
certain cancers, such as cancer of the
larynx and lung cancer. Also, some diseases 4. Use enough ventilation, exhaust at arc, or
that may be linked to exposure to welding both, to keep fumes and gases from breathing
or plasma cutting exhaust fumes are: zone and general area. If engineering controls
are not feasible, use an approved respirator.
• Early onset of Parkinson’s Disease
• Heart disease 5. Work in a confined area only if it
is well-ventilated, or while wearing
• Ulcers an air-supplied respirator.
• Damage to the reproductive organs
6. Have a recognized specialist in
• Inflammation of the small intestine or stomach
SETUP
Industrial Hygiene or Environmental Services
• Kidney damage check the operation and air quality
• Respiratory diseases such as and make recommendations
emphysema, bronchitis, or pneumonia for the specific welding situation.
Follow OSHA guidelines for
Use natural or forced air ventilation and wear
Permissible Exposure Limits (PEL’s) and
a respirator approved by NIOSH to protect
the American Conference of Governmental
against the fumes produced to reduce the
Industrial Hygienists recommendations for
risk of developing the above illnesses.
Threshold Limit Values (TLV’s) for fumes and gases.
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2. do not use near degreasing or
painting operations.
1. Wear ANSI-approved welding eye protection 4. Wear an approved head covering to protect
featuring at least a number 10 shade lens rating. the head and neck. Use aprons, cape, sleeves,
shoulder covers, and bibs designed and
2. Wear leather leggings, fire resistant shoes approved for welding and cutting procedures.
or boots during use. Do not wear pants with
cuffs, shirts with open pockets, or any clothing 5. Wear an approved welding jacket or long sleeves
that can catch and hold molten metal or sparks. to protect forearms from radiation burns.
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3. Keep clothing free of grease, oil, 6. When welding/cutting overhead or in confined
solvents, or any flammable substances. spaces, wear flame resistant ear plugs or
Wear dry, insulating gloves and protective clothing. ear muffs to keep sparks out of ears.
MAINTENANcE
1. Turn off, disconnect power, and 6. do not expose welders to rain or wet conditions.
SAFETy
discharge Electrode to ground before setting Water entering a welder will increase
down torch/Electrode holder and before service. the risk of electric shock.
2. do not touch energized electrical parts. 7. do not abuse the cord. Never use the cord
Wear dry, insulating gloves. Do not touch Electrode for carrying, pulling or unplugging the welder.
holder, Electrode, welding torch, or welding wire with Keep cord away from heat, oil, sharp edges
bare hand. Do not wear wet or damaged gloves. or moving parts. Damaged or entangled
cords increase the risk of electric shock.
3. connect to grounded, gFcI-protected
power supply only. 8. do not use outdoors.
4. do not use near water or damp objects. 9. Insulate yourself from the workpiece and
ground. Use nonflammable, dry insulating
SETUP
5. people with pacemakers should consult their material if possible, or use dry rubber mats,
physician(s) before use. Electromagnetic fields dry wood or plywood, or other dry insulating
in close proximity to heart pacemaker could cause material large enough to cover your full
pacemaker interference or pacemaker failure. area of contact with the work or ground.
Fire Safety
ARc ANd SLAg can cause fire.
1. clear away or protect flammable objects. 5. If working on a metal wall, ceiling, etc.,
BASIc WELdINg
Remove or make safe all combustible materials for a prevent ignition of combustibles on the
radius of 35 feet (10 meters) around the work area. other side by moving the combustibles to a
Use a fire resistant material to cover safe location. If relocation of combustibles is
or block all open doorways, windows, not possible, designate someone to serve as
cracks, and other openings. a fire watch, equipped with a fire extinguisher,
during the cutting process and for at least one
2. Keep ABc-type fire extinguisher near half hour after the cutting is completed.
work area and know how to use it.
6. do not weld or cut on materials having
3. Maintain a safe working environment. a combustible coating or combustible
Keep the work area well lit. internal structure, as in walls or ceilings, without
Make sure there is adequate an approved method for eliminating the hazard.
surrounding workspace. Keep the work area free
of obstructions, grease, oil, trash, and other debris. 7. do not dispose of hot slag in containers
WELdINg TIpS
SAFETy
operate the welder. Welders are dangerous
2. disconnect the plug from the power in the hands of untrained users.
source before making any adjustments,
changing accessories, or storing welders. 5. Use the welder and accessories in
Such preventive Safety measures reduce the accordance with these instructions, taking
risk of starting the welder accidentally. into account the working conditions and
the work to be performed. Use of the welder
3. prevent unintentional starting. for operations different from those intended
Ensure the switch is in the off- could result in a hazardous situation.
position before connecting to power
source or moving the welder. Carrying 6. do not use the welder for pipe thawing.
or energizing welders that have the
switch on invites accidents.
SETUP
Maintenance
1. Maintain welders. check for misalignment or 3. Maintain labels and nameplates on the Welder.
binding of moving parts, breakage of parts These carry important information.
and any other condition that may affect the If unreadable or missing, contact
welder’s operation. If damaged, have the Harbor Freight Tools for a replacement.
welder repaired before use. Many accidents
are caused by poorly maintained welders. 4. Unplug before maintenance. Unplug the Welder
BASIc WELdINg
from its electrical outlet before any inspection,
2. Have your welder serviced by a qualified maintenance, or cleaning procedures.
repair person using only identical
replacement parts. This will ensure that
the Safety of the welder is maintained.
1. do not weld on a pressurized or closed cylinder. 5. Use only correct gas shielding equipment
designed specifically for the type of welding
2. do not allow an Electrode holder, you will do. Maintain this equipment properly.
Electrode, welding torch, or welding
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wire to touch the cylinder. 6. protect gas cylinders from heat, being struck,
physical damage, slag, flames, sparks, and arcs.
3. Keep cylinders away from any electrical circuits,
including welding circuits. 7. Use proper procedures to move cylinders.
1. The green wire inside the cord is connected to 2. Make sure the tool is connected to an outlet having
the grounding system in the welder. The green the same configuration as the plug. If the tool must
wire in the cord must be the only wire connected be reconnected for use on a different type of electric
to the welder’s grounding system and must never circuit, the reconnection should be made by qualified
be attached to an electrically “live” terminal. service personnel; and after reconnection, the tool
SETUP
Never leave the grounding wire disconnected should comply with all local codes and ordinances.
or modify the Power Cord Plug in any way.
1. The Welder has internal grounding, there 3. To ground the work bench, connect a #12 AWG
is no need to ground the Welder. grounding wire (not included) from the work
bench to a grounding rod (not included).
2. The metal work bench must be properly grounded The grounding rod must be an earth-driven
in accordance with all relevant electrical codes
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1. The operator of welding equipment that causes 3. When notified by the FCC that a particular
harmful interference to radio services shall promptly installation is causing harmful interference, the
take appropriate measures to correct the problem. operator or manufacturer shall arrange for an
engineer skilled in techniques of interference
2. If the operator of welding equipment is notified measurement and control to make an investigation
by the FCC that operation of such equipment is to ensure that the harmful interference has
endangering the functioning of a radio navigation
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Extension cords
do not use an extension cord on this welder.
MAINTENANcE
Replacement cords
1. Use only one of the supplied power cords for 3. do not patch cords of any length
this welder or an identical replacement cord. together for this item. patches may allow
moisture to penetrate the insulation,
2. do not install a thinner or longer resulting in electric shock.
cord on this welder.
SAFETy
Workpiece Ground Cable Electric Shock Hazard.
Do not touch energized parts.
SETUP
VAc Volts Alternating Current Fire Hazard.
Keep flammable materials
away during welding. Spatter
A Amperes can cause accidental fires.
Arc Ray Hazard.
OcV Open Circuit Voltage Wear welding helmet with
properly rated filter lens.
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Welding processes may
interfere with pacemakers.
IpM Inches Per Minute Consult doctor before use.
Specifications
TIg dc Stick
120VAC / 60Hz 240VAC / 60Hz 120VAC / 60Hz 240VAC / 60Hz
power Input at Output 21.4A at 115A 22A at 205A 21A at 80A 25A at 175A
15A: 10A - 115A
Welding current Range 10A - 205A 10A - 80A 10A - 175A
20A: 10A - 130A
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35% @ 115A
15A:
100% @ 63A 25% @ 205A 20% @ 80A 20% @ 175A
Rated duty cycles
25% @ 120A(AC)/130A(DC) 100% @ 102A 100% @ 50A 100% @ 78A
20A:
100% @ 63A
Maximum OcV 13.5VDC (with VRD) 13.5VDC (with VRD)
AC: Aluminum Mild Steel, Stainless
Weldable Materials
DC: Mild Steel, Stainless Steel, Chrome Moly Steel, Cast Materials
MAINTENANcE
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.
SAFETy
Place the Welder on a level surface that can bear its weight near the work
area. Leave space around the Welder for proper air flow.
TIg Setup
connect cables
SETUP
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Negative
Socket
Foot pedal
Socket
TIg
Torch
positive
ground Socket
clamp
Foot
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pedal
1. Plug Ground Clamp cable into Positive Socket. 3. Plug Foot Pedal cable into Foot Pedal Socket.
Twist clockwise all the way to lock in place. Secure by turning collar clockwise until tight.
SAFETy
two straps (not included) to prevent tipping.
1
SETUP
3. Close the Regulator’s valve by backing off knob
until it is loose, then thread Regulator onto
cylinder and wrench tighten connection.
4
3
4. Attach the Gas Hose (included) to the
Regulator’s Outlet and the Welder’s Gas Inlet.
Wrench-tighten both connections. Power Input
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Gas Inlet
Reset
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FROM AccIdENTAL OpERATION: Do not Gas Inlet Power Input
power
plug cord into wall outlet at this time. Reset
Input
MAINTENANcE
section and snap off the end of the Electrode. Nozzle, then re-tighten the Back Cap.
1. Consult Settings Chart, on top of Welder, to 8. Lock Electrode in place with Back Cap.
determine proper Tungsten Electrode size to be Electrode should protrude 1/8″ to 1/4″
used with thickness of material to be welded. beyond the Ceramic Nozzle.
SAFETy
Negative
SETUP
Socket
ground
clamp
positive
Socket
Electrode
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Holder
1. Plug Ground Clamp cable into Negative Socket. 2. Plug Electrode Holder cable into Positive Socket.
Twist clockwise all the way to lock in place. Twist clockwise al the way to lock in place.
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plug cord into wall outlet at this time. Reset
Input
MAINTENANcE
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.
SAFETy
power
On
=
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anything of value.
SAFETy
display
process parameter
Button Button
SETUP
Settings
Knob
Storage
compartment
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power
Switch
ground Workpiece
Attach Ground Clamp to bare metal on the
workpiece near the weld area, or to metal work
bench where the workpiece is clamped.
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Workpiece
clean
surface to
ground bare metal.
clamp
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MAINTENANcE
SAFETy
produce a particular welding current without overheating. automatically returns to service after cooling
For example, a 360% duty cycle at 165 A welding off. Rest the Tig Torch or Electrode Holder on an
current must be allowed to rest for at least 7 minutes electrically non-conductive, heat-proof surface, such
after every 3 minutes of continuous welding. as a concrete slab, well clear of the ground clamp.
Failure to carefully observe duty cycle limitations Allow the Welder to cool with the power Switch on,
can easily over-stress a welder’s power generation so that the internal Fan will help cool the welder.
system contributing to premature welder failure. When the Overload Indicator is no longer lit and the
Welder can be used again, use shorter welding periods
and longer rest periods to prevent needless wear.
SETUp
240VAC 120VAc 240VAC 120VAc
25% Use at 205 A 25% Use at 130 A 20% Use at 175 A 20% Use at 80 A
For 10 continuous Minutes For 10 continuous Minutes For 10 continuous Minutes For 10 continuous Minutes
100% Continuous Use at 102 A 100% Continuous Use at 63 A 100% Continuous Use at 78 A 100% Continuous Use at 50 A
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MAINTENANcE
When the operator is not holding the Torch, it must be sitting on a nonconductive, nonflammable surface.
Only hold TIg Rod with an electrically insulated welding glove.
NOTIcE: TIG welding is a complicated process, Note: push process Button to select process.
requiring experience and skill to achieve Turn Setting Knob to set parameters.
SETUP
successful results. Training beyond the scope of push parameter Button to cycle through parameters.
this manual is required to TIG weld properly.
process parameter
1. Open gas cylinder’s valve all the way. Button Button
SAFETy
For example: Range is 50-120A, will automatically adjust to the factory default
set amperage to 120A. setting based on the pre-set welding amperage.
NOTE: Amperage Settings are
approximate. Adjust as necessary.
SETUP
2. pRE FLOW - The number of seconds (0.3 - 20) that
gas will flow once the pedal is pushed. The arc will
not started for that pre-set time, but gas will flow.
Once the pre-set time expires, the arc will start.
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Peak Amperage (pre-set) and a Background
Amperage. The lower the background amperage
is set to reduces the overall heat input.
3. AC FREQUENCY (Hz) - Controls the width of
the welding arc. For groove welds, use low
frequency. For narrow welds set to 120 or above.
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Increasing peak time increases time spent at the
peak amperage, which increases overall heat input.
4. % EN (AC BALANCE) - Controls the
amount of oxide cleaning. A higher number
reduces the amount of oxide cleaning.
SAFETy
(or welding mask), ear protection, welding gloves,
sleeves and apron, NIOSH-approved respirator, 3. When welding puddle is hot enough, tilt torch
and fire resistant work clothes without pockets backward about 10-15 degrees from vertical and
should be worn when welding. Light from the move it back slightly. Add TIG Rod material as
arc can cause permanent damage to the eyes needed to the front end of the weld puddle.
and skin. do not breathe arc fumes.
NOTE: When welding aluminum, if black spots
appear in the weld puddle, reduce AC Balance.
After practice welding on scrap, stop,
and check your progress. Perform 4. Alternate between pushing the torch/weld
Strike Test according to Strike Test on puddle and adding the TIG Rod material.
page 22. After making any necessary
adjustments, continue to weld while NOTE: Back the TIG Rod off each time the Electrode
SETUP
carefully following the DUTY CYCLE is advanced, but do not remove it from the gas shield.
guidelines as explained on page 14. This prevents oxidation from contaminating the weld.
WARNINg! Metal work bench must be 5. When finished welding, release the Foot Pedal, but
grounded when TIg welding (see High keep Torch on weld puddle until gas flow ends.
Frequency Grounding on page 6).
6. Set TIG Torch down on nonconductive,
1. Hold TIG Torch in one gloved hand and nonflammable surface away from
the TIG Rod in other gloved hand. any grounded objects.
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2. Specific Welding Techniques:
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Peak Amperage and Background Current.
• Clean, then store Welder and its accessories
indoors out of children’s reach.
MAINTENANcE
1. Turn the Power Switch to the OFF position, then NOTE: Settings are approximate. Adjust as necessary.
plug the Welder into a properly grounded GFCI
protected, 120 VAC (20 amp rated) or 240VAC Stick Settings chart
receptacle that matches the plug. Electrode Electrode Amperage
The circuit must be equipped with delayed Type diameter Range
action-type circuit breaker or fuses.
1/16" 25-40
2. Set Electrode Holder down on 3/32" 50-90
nonconductive, nonflammable surface E6013 dc+
1/8" 90-130
SETUP
Settings
Knob
SAFETy
should be worn when welding. Light from the puddle to deposit material as needed.
arc can cause permanent damage to the eyes
and skin. do not breathe arc fumes. 5. When finished welding; lift the Electrode from
the workpiece, then set Electrode Holder
After practice welding on scrap, stop, down on nonconductive, nonflammable
and check your progress. Perform surface away from any grounded objects.
Strike Test, then clean and compare your
6. Turn the Power Switch off.
weld’s appearance with the diagrams and
descriptions in the Welding Tips section 7. To prevent accidents, after use:
starting on the next page. After making any
necessary adjustments, continue to weld • Allow Welder to cool down.
while carefully following the DUTY CYCLE • Unplug Welder’s power cord from outlet.
SETUP
guidelines as explained on page 14.
• Remove Ground Clamp.
• Disconnect Electrode Holder
2. Place the bare metal end of the Stick
and Ground Cables.
Electrode (sold separately) inside the
jaws of the Electrode Holder. • Clean, then store Welder and its accessories
indoors out of children’s reach.
3. Stroke the workpiece lightly to ignite the arc.
Tips for igniting the arc:
a. Tap the surface with the Electrode.
BASIc WELdINg
b. Stroke the surface with the Electrode.
c. Strike the surface like a match with the Electrode.
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MAINTENANcE
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 Test
SETUP
weld has cooled, clamp one side in a sturdy vise. Bends and is Not Brittle
Vise
2. Stay clear from underneath while you strike dead-Blow Hammer
the opposite side with a heavy hammer, ScRAp
preferably a dead-blow hammer. Workpiece
SAFETy
Not hot enough Ideal heat Too hot
SETUP
a. Increase current. b. Weld more slowly. a. Decrease current. b. Weld more quickly.
BASIc WELdINg
good current current Weld Speed Weld Speed Arc Length Arc Length
Weld Too Low Too High Too Fast Too Slow Too Short Too Long
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TO cORREcT: TO cORREcT: TO cORREcT: TO cORREcT: TO cORREcT: TO cORREcT:
Increase the Decrease Weld slower Weld faster Increase Decrease
current the current distance distance
MAINTENANcE
PROFILE VIEWS
pOSSIBLE cAUSES ANd SOLUTIONS FOR pOSSIBLE cAUSES ANd SOLUTIONS FOR
EXcESS pENETRATION OR BURN-THROUgH INAdEQUATE pENETRATION
SETUP
SAFETy
PARTIALLY CHIPPED AWAY TO SHOW WELD
SETUP
Stick Weld - crooked/Wavy Bead
pOSSIBLE cAUSES ANd SOLUTIONS 1. Inaccurate welding:
Use two hands or rest hand on steady surface.
2. Inconsistent welding speed:
Maintain steady weld speed.
TOP
BASIc WELdINg
VIEW
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Stick Weld - Burn-Through - Base material melts away, leaving a hole in the weld.
1. BEFORE EAcH USE, inspect the general 2. pERIOdIcALLy, Have a qualified technician unplug
condition of the welder. Check for: the Welder, remove the Back Housing, and using
• loose hardware, compressed air, blow out all dust from the interior.
SAFETy
problem possible causes Likely Solutions
Fault Code F01 Tripped thermal protection device Reduce duration or frequency of welding periods
due to exceeding Duty Cycle. to help reduce wear on the welder. Refer to
Duty Cycle (Duration of Use) on page 15.
Fault Code F02 Incorrect input voltage. Voltage Check the service voltage at the outlet and ensure it is
is too high or too low. within the range as detailed in Specifications on page 7.
Fault Code F05 Torch triggered before welder is turned on. Torch trigger is stuck on. Turn welder off and reset trigger.
Fault Code F09 Output short circuited. Check ground clamp, torch or electrode holder connection.
Keep torch or electrode holder away from grounded surfaces.
When Switched On 1. Ground Clamp not attached 1. Attach Ground Clamp to workpiece.
Power Indicator to workpiece.
SETUP
Lights, But Welder 2. Shielding Gas not connected. 2. Connect shielding gas to Welder.
Does Not Function
When Switched On 1. Unit is not connected to outlet properly. 1. Verify the voltage at the outlet and
Power Indicator the connection to the outlet.
Does Not Light 2. Outlet is unpowered. 2. Check circuit breaker/GFCI devices; if any are tripped,
determine and remedy cause before resetting.
3. Circuit supplies insufficient 3. Verify that the circuit is designed to supply the required input
input voltage or amperage. amperage as detailed in Specifications on page 7.
4. Circuit breaker has tripped due 4. Press Reset Button on back of machine
to high input amperage. to reset circuit breaker.
Weak Arc Strength 1. Incorrect line voltage. 1. Check the line voltage and, if insufficient, have
BASIc WELdINg
a licensed electrician remedy the situation.
2. Improper gauge or length of cord. 2. Do not use an extension cord on this Welder. Use
only one of the supplied power cords for this
Welder or an identical replacement cord.
Welding Arc Not Stable. 1. Loose electrode cable or ground cable. 1. Check to ensure that all connections are tight.
2. Damaged electrode holder or loose 2. Have a qualified technician inspect and
connection within electrode holder. repair/replace as necessary.
3. Adjust current setting. 3. Make sure setting matches recommended setting on chart.
4. Shielding gas getting low. 4. Replace shielding gas cylinder.
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MAINTENANcE
parts List
SAFETy
SAFETy
9
10
11
12
13 37
14 36
SETUP
15
38
16
17 35
18
39 40 41 34
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19
42 43 33
20 32
21 44 45 31
22 30
29
28
23 24 25 26 27
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MAINTENANcE
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.
SETUP
BASIc WELdINg
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MAINTENANcE
Note: Some parts are listed and shown for illustration purposes only,
and are not available individually as replacement parts.
SAFETy
SETUP
BASIc WELdINg
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MAINTENANcE