Titanium Item 64806 Owner's manual

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65,"7%&'(%$*4.8"4,7%#'//&($%,$-%/(&9'4$#'//&($:.,(+&(2(*"3.$14&5

™

64806

Owner’s Manual & Safety Instructions

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. 18l

When unpacking, make sure that the product is intact

and undamaged. If any parts are missing or broken,

please call 1-888-380-0318 as soon as possible.

2018 by Harbor Freight Tools

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 an d se rv ic e may n ot b e in cl uded.

Read this material before using this product.

Failure to do so can result in serious injury.

SAVE THIS MANUAL.

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Safety ......................................................... 2

Specifications ............................................. 7

Setup ......................................................... 10

Basic Welding ............................................ 17

Welding Tips .............................................. 31

Maintenance .............................................. 35

Parts List and Diagram .............................. 38

Warranty .................................................... 40

GDQKJKL%CFRSPHC%DKI%I6;JKJEJPKC

This 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.

JRMPQEDKE%CD;6EF%JK;PQRDEJPK

Q*,9%,77%#,2*$T%),(8"83#%,89%"8#$('4$"&8#1%%

Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.

C,U*%,77%),(8"83#%,89%"8#$('4$"&8#%2&(%2'$'(*%(*2*(*84*1

L*8*(,7%C,2*$T

MQPE6NE%T&'(#*72%,89%&$.*(#1%%Q*,9%,89%'89*(#$,89%$."#%"82&(5,$"&81

1. S*2&(*%'#*=%(*,9%,89%'89*(#$,89%

manufacturer′s instructions,

Material Safety Data Sheets (MSDS′s),

employer′s safety practices, and ANSI Z49.1.

2. O**/%&'$%&2%(*,4.%&2%4."79(*81%%%

Keep children and bystanders away while operating.

3. M7,4*%$.*%)*79*(%&8%,%#$,+7*%7&4,$"&8%+*2&(*%'#*1%%%

If it falls while plugged in, severe injury,

electric shock, or fire may result.

4. I&%8&$%&U*((*,4.1%%%

O**/%/(&/*(%2&&$"83%,89%+,7,84*%,$%,77%$"5*#1

5. C$,T%,7*($=%),$4.%).,$%T&'%,(*%9&"83%,89%'#*%

4&55&8%#*8#*%).*8%&/*(,$"83%,%)*79*(1%%

I&%8&$%'#*%,%)*79*(%)."7*%T&'%,(*%$"(*9%&(%'89*(%

$.*%"827'*84*%&2%9('3#=%,74&.&7%&(%5*9"4,$"&81

A moment of inattention while operating welders

may result in serious personal injury.

6. DU&"9%'8"8$*8$"&8,7%#$,($"831%%Make sure you are

prepared to begin work before turning on the Welder.

7. K*U*(%7*,U*%$.*%G*79*(%'8,$$*89*9%)."7*%

*8*(3"V*91%Turn power off if you have to leave.

8. E.*%),(8"83#=%/(*4,'$"&8#=%,89%"8#$('4$"&8#%

9"#4'##*9%"8%$."#%"8#$('4$"&8%5,8',7%4,88&$%

4&U*(%,77%/&##"+7*%4&89"$"&8#%,89%#"$',$"&8#%

$.,$%5,T%&44'(1%%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.

Page 3;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?A@B?BA>@1Item 64806

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;'5*%,89%L,#%C,2*$T

INHALATION HAZARD:%

G*79"83%,89%M7,#5,%N'$$"83%M(&9'4*%$&W"4%2'5*#1

1. 6W/&#'(*%$&%)*79"83%&(%4'$$"83%*W.,'#$%

2'5*#%4,8%"84(*,#*%$.*%("#X%&2%9*U*7&/"83%

4*($,"8%4,84*(#=%#'4.%,#%4,84*(%&2%$.*%

7,(T8W%,89%7'83%4,84*(1 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 pneumonia

Use 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. I&%8&$%'#*%8*,(%9*3(*,#"83%&(%

/,"8$"83%&/*(,$"&8#1

3. O**/%.*,9%&'$%&2%2'5*#1%%

Do not breathe exhaust fumes.

4. Y#*%*8&'3.%U*8$"7,$"&8=%*W.,'#$%,$%,(4=%&(%

+&$.=%$&%X**/%2'5*#%,89%3,#*#%2(&5%+(*,$."83%

V&8*%,89%3*8*(,7%,(*,1%%If engineering controls

are not feasible, use an approved respirator.

5. G&(X%"8%,%4&82"8*9%,(*,%&87T%"2%"$%

"#%)*77?U*8$"7,$*9=%&(%)."7*%)*,("83%

,8%,"(?#'//7"*9%(*#/"(,$&(1

6. Z,U*%,%(*4&38"V*9%#/*4",7"#$%"8%

J89'#$(",7%ZT3"*8*%&(%68U"(&85*8$,7%C*(U"4*#%

4.*4X%$.*%&/*(,$"&8%,89%,"(%<',7"$T%

,89%5,X*%(*4&55*89,$"&8#%

2&(%$.*%#/*4"2"4%)*79"83%#"$',$"&81%%

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.

D(4%Q,T%C,2*$T

DQN%QDFC%4,8%"8['(*%*T*#%,89%+'(8%#X"81

1. G*,(%DKCJ?,//(&U*9%)*79"83%*T*%/(&$*4$"&8%

2*,$'("83%,$%7*,#$%,%8'5+*(%>B%#.,9*%7*8#%(,$"831

2. G*,(%7*,$.*(%7*33"83#=%2"(*%(*#"#$,8$%#.&*#%

&(%+&&$#%9'("83%'#*1%%Do not wear pants with

cuffs, shirts with open pockets, or any clothing

that can catch and hold molten metal or sparks.

3. O**/%47&$."83%2(**%&2%3(*,#*=%&"7=%

#&7U*8$#=%&(%,8T%27,55,+7*%#'+#$,84*#1%%

Wear dry, insulating gloves and protective clothing.

4. G*,(%,8%,//(&U*9%.*,9%4&U*("83%$&%/(&$*4$%

$.*%.*,9%and neck. Use aprons, cape, sleeves,

shoulder covers, and bibs designed and

approved for welding and cutting procedures.

5. G.*8%)*79"8304'$$"83%&U*(.*,9%&(%"8%4&82"8*9%

#/,4*#=%)*,(%27,5*%(*#"#$,8$%*,(%/7'3#%&(%

*,(%5'22#%$&%X**/%#/,(X#%&'$%&2%*,(#1

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1. E'(8%&22=%9"#4&88*4$%/&)*(=%,89%

9"#4.,(3*%*7*4$(&9*%$&%3(&'89%+*2&(*%#*$$"83%

9&)8%$&(4.0*7*4$(&9*%.&79*(%,89%+*2&(*%#*(U"4*1

2. I&%8&$%$&'4.%*8*(3"V*9%*7*4$("4,7%/,($#1%%

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. N&88*4$%$&%3(&'89*9=%L;NJ?/(&$*4$*9%

/&)*(%#'//7T%&87T1

4. I&%8&$%'#*%8*,(%),$*(%&(%9,5/%&+[*4$#1

5. M*&/7*%)"$.%/,4*5,X*(#%#.&'79%4&8#'7$%$.*"(%

physician(s) before use. Electromagnetic fields

in close proximity to heart pacemaker could cause

pacemaker interference or pacemaker failure.

6. I&%8&$%*W/&#*%)*79*(#%$&%(,"8%&(%)*$%4&89"$"&8#1%%%

Water entering a welder will increase

the risk of electric shock.

7. I&%8&$%,+'#*%$.*%4&(91%%K*U*(%'#*%$.*%4&(9%

2&(%4,((T"83=%/'77"83%&(%'8/7'33"83%$.*%)*79*(1%%

O**/%4&(9%,),T%2(&5%.*,$=%&"7=%#.,(/%*93*#%

&(%5&U"83%/,($#1%%Damaged or entangled

cords increase the risk of electric shock.

8. I&%8&$%'#*%&'$9&&(#1

9. J8#'7,$*%T&'(#*72%2(&5%$.*%)&(X/"*4*%,89%

3(&'891%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.

;"(*%C,2*$T

DQN%DKI%ZPE%CHDL%4,8%4,'#*%2"(*1

1. N7*,(%,),T%&(%/(&$*4$%27,55,+7*%&+[*4$#1%%%

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. O**/%DSN?$T/*%2"(*%*W$"83'"#.*(%8*,(%

)&(X%,(*,%,89%X8&)%.&)%$&%'#*%"$1

3. R,"8$,"8%,%#,2*%)&(X"83%*8U"(&85*8$1%%%

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. I&%8&$%&/*(,$*%)*79*(#%"8%,$5&#/.*(*#%

4&8$,"8"83%9,83*(&'#7T%(*,4$"U*%&(%

27,55,+7*%7"<'"9#=%3,#*#=%U,/&(#=%&(%9'#$1%%

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. J2%)&(X"83%&8%,%5*$,7%),77=%4*"7"83=%*$41=%

/(*U*8$%"38"$"&8%&2%4&5+'#$"+7*#%&8%$.*%

&$.*(%#"9*%+T%5&U"83%$.*%4&5+'#$"+7*#%$&%,%

#,2*%7&4,$"&81 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. I&%8&$%)*79%&(%4'$%&8%5,$*(",7#%.,U"83%

,%4&5+'#$"+7*%4&,$"83%&(%4&5+'#$"+7*%

"8$*(8,7%#$('4$'(*=%,#%"8%),77#%&(%4*"7"83#=%)"$.&'$%

,8%,//(&U*9%5*$.&9%2&(%*7"5"8,$"83%$.*%.,V,(91

7. I&%8&$%9"#/&#*%&2%.&$%#7,3%"8%4&8$,"8*(#%

.&79"83%4&5+'#$"+7*%5,$*(",7#1

8. D2$*(%)*79"83=%5,X*%,%$.&(&'3.%*W,5"8,$"&8%

2&(%*U"9*84*%&2%2"(*1%%Be aware that easily

visible smoke or flame may not be present

for some time after the fire has started.

9. I&%8&$%,//7T%.*,$%$&%,%4&8$,"8*(%$.,$%.,#%.*79%

,8%'8X8&)8%#'+#$,84*%&(%,%4&5+'#$"+7*%

5,$*(",7%).&#*%4&8$*8$#=%).*8%.*,$*9=%

4,8%/(&9'4*%27,55,+7*%&(%*W/7&#"U*%U,/&(#1%%

Clean and purge containers before applying heat.

Vent closed containers, including castings,

before preheating, welding, or cutting.

Page 5;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?A@B?BA>@1Item 64806

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G*79*(%Y#*%,89%N,(*

1. I&%8&$%'#*%$.*%)*79*(%"2%$.*%#)"$4.%9&*#%8&$%$'(8%

"$%&8%,89%&221%%Any welder that cannot be controlled

with the switch is dangerous and must be repaired.

2. I"#4&88*4$%$.*%/7'3%2(&5%$.*%/&)*(%

#&'(4*%+*2&(*%5,X"83%,8T%,9['#$5*8$#=%

4.,83"83%,44*##&("*#=%&(%#$&("83%)*79*(#1%%

Such preventive safety measures reduce the

risk of starting the welder accidentally.

3. M(*U*8$%'8"8$*8$"&8,7%#$,($"831%

68#'(*%$.*%#)"$4.%"#%"8%$.*%&22?

/&#"$"&8%+*2&(*%4&88*4$"83%$&%/&)*(%

#&'(4*%&(%5&U"83%$.*%)*79*(1 Carrying

or energizing welders that have the

switch on invites accidents.

4. C$&(*%"97*%)*79*(#%&'$%&2%$.*%(*,4.%&2%

4."79(*8%,89%9&%8&$%,77&)%/*(#&8#%'82,5"7",(%

)"$.%$.*%)*79*(%&(%$.*#*%"8#$('4$"&8#%$&%

&/*(,$*%$.*%)*79*(1%%Welders are dangerous

in the hands of untrained users.

5. Y#*%$.*%)*79*(%,89%,44*##&("*#%"8%

,44&(9,84*%)"$.%$.*#*%"8#$('4$"&8#=%$,X"83%

"8$&%,44&'8$%$.*%)&(X"83%4&89"$"&8#%,89%

$.*%)&(X%$&%+*%/*(2&(5*91 Use of the welder

for operations different from those intended

could result in a hazardous situation.

6. I&%8&$%'#*%$.*%)*79*(%2&(%/"/*%$.,)"831

R,"8$*8,84*

1. R,"8$,"8%)*79*(#1%%N.*4X%2&(%5"#,7"385*8$%&(%

+"89"83%&2%5&U"83%/,($#=%+(*,X,3*%&2%/,($#%

,89%,8T%&$.*(%4&89"$"&8%$.,$%5,T%,22*4$%$.*%

)*79*(\#%&/*(,$"&81%%J2%9,5,3*9=%.,U*%$.*%

)*79*(%(*/,"(*9%+*2&(*%'#*1 Many accidents

are caused by poorly maintained welders.

2. Z,U*%T&'(%)*79*(%#*(U"4*9%+T%,%<',7"2"*9%

(*/,"(%/*(#&8%'#"83%&87T%"9*8$"4,7%

(*/7,4*5*8$%/,($#1%%This will ensure that

the safety of the welder is maintained.

3. R,"8$,"8%7,+*7#%,89%8,5*/7,$*#%&8%$.*%G*79*(1%%%

These carry important information.

If unreadable or missing, contact

Harbor Freight Tools for a replacement.

4. Y8/7'3%+*2&(*%5,"8$*8,84*1%Unplug the Welder

from its electrical outlet before any inspection,

maintenance, or cleaning procedures.

L,#%C."*79*9%G*79"83%]%NT7"89*(%C,2*$T

NT7"89*(#%4,8%*W/7&9*%).*8%9,5,3*91

1. K*U*(%)*79%&8%,%/(*##'("V*9%&(%,%47&#*9%4T7"89*(1

2. K*U*(%,77&)%,8%*7*4$(&9*%.&79*(=%

*7*4$(&9*=%)*79"83%$&(4.=%&(%)*79"83%

)"(*%$&%$&'4.%$.*%4T7"89*(1

3. O**/%4T7"89*(#%,),T%2(&5%,8T%*7*4$("4,7%4"(4'"$#=%

"847'9"83%)*79"83%4"(4'"$#1

4. O**/%/(&$*4$"U*%4,/%"8%/7,4*%&U*(%$.*%U,7U*%

*W4*/$%).*8%$.*%4T7"89*(%"#%"8%'#*1

5. Y#*%&87T%4&((*4$%3,#%#."*79"83%*<'"/5*8$%

9*#"38*9%#/*4"2"4,77T%2&(%$.*%$T/*%&2%)*79"83%

T&'%)"77%9&1%%Maintain this equipment properly.

6. M(&$*4$%3,#%4T7"89*(#%2(&5%.*,$=%+*"83%#$('4X=%

/.T#"4,7%9,5,3*=%#7,3=%27,5*#=%#/,(X#=%,89%,(4#1

7. D7),T#%'#*%/(&/*(%/(&4*9'(*#%

$&%5&U*%4T7"89*(#1

%CD!6%EZ6C6%JKCEQYNEJPKC1

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EP%MQ6!6KE%6H6NEQJN%CZPNO%DKI%I6DEZ%%

;QPR%JKNPQQ6NE%LQPYKIJKL%GJQ6%NPKK6NEJPK-%

N.*4X%)"$.%,%<',7"2"*9%*7*4$("4",8%"2%T&'%,(*%"8%9&'+$%,#%$&%).*$.*(%$.*%&'$7*$%"#%

/(&/*(7T%3(&'89*91%%%

I&%8&$%'#*%$.*%G*79*(%"2%$.*%/&)*(%4&(9%&(%/7'3%"#%9,5,3*91%%J2%9,5,3*9=%.,U*%"$%(*/,"(*9%+T%,%#*(U"4*%

2,4"7"$T%+*2&(*%'#*1%%J2%$.*%/7'3%)"77%8&$%2"$%$.*%&'$7*$=%.,U*%,%/(&/*(%&'$7*$%"8#$,77*9%+T%,%<',7"2"*9%*7*4$("4",8=%

9&%8&$%'#*%,9,/$*(%/7'3#1

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.

6W$*8#"&8%N&(9#

I&%8&$%'#*%,8%*W$*8#"&8%4&(9%&8%$."#%G*79*(1

Q*/7,4*5*8$%N&(9#

1. Y#*%&87T%$.*%#'//7"*9%/&)*(%4&(9%2&(%$."#%

G*79*(%&(%,8%"9*8$"4,7%(*/7,4*5*8$%4&(91

2. I&%8&$%"8#$,77%,%$."88*(%&(%7&83*(%

4&(9%&8%$."#%G*79*(1

3. I&%8&$%/,$4.%4&(9#%&2%,8T%7*83$.%

$&3*$.*(%2&(%$."#%"$*51%%M,$4.*#%5,T%,77&)%

5&"#$'(*%$&%/*8*$(,$*%$.*%"8#'7,$"&8=%

(*#'7$"83%"8%*7*4$("4%#.&4X1

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CT5+&7&3T

Wire Feed (Speed)

Workpiece Ground Cable

Torch Cable

Overheat Shutdown Indicator

Cooling Fan

Housing Ground Point

!DN

Volts Alternating Current

Amperes

PN!

Open Circuit Voltage

O!D

Kilovolt Amperes

(Volts / 1000 * Amperes)

JMR

Inches Per Minute

DGL

American Wire Gauge

Electric Shock Hazard.

Do not touch energized parts.

Inhalation Hazard.

Keep head out of fumes

and use proper ventilation.

Read manual before

setup and/or use.

Fire Hazard.

Keep flammable materials

away during welding. Spatter

can cause accidental fires.

Arc Ray Hazard.

Wear welding helmet with

properly rated filter lens.

Pacemaker Hazard.

Welding processes may

interfere with pacemakers.

Consult doctor before use.

C/*4"2"4,$"&8#

M&)*(%J8/'$ 120/240 VAC / 60 Hz

N'((*8$%J8/'$

@ 120V

GMAW/FCAW: 22A

SMAW: 24.9A

GTAW: 20.8A

@ 240V

GMAW/FCAW: 36A

SMAW 33.6A

GTAW: 28.7A

G*79"83%N'((*8$%Q,83*

@ 120V

GMAW/FCAW: 30-140A

SMAW: 30-70A

GTAW: 20-90A

@ 240V

GMAW/FCAW: 30-200A

SMAW: 30-170A

GTAW: 20-200A

Q,$*9%I'$T%NT47*

@ 120V

GMAW/FCAW: 40% @ 90A

SMAW: 40% @ 70A

GTAW: 40% @ 90A

@ 240V

GMAW/FCAW: 15% @ 200A

SMAW: 15% @ 170A

GTAW: 15% @ 200A

P/*8%N"(4'"$%!&7$,3* 69 VDC

G"(*%C/**9 80 – 400 IPM

G*79"83%G"(*%N,/,4"$T

Solid Core: 0.025" / 0.030" / 0.035"

Flux Cored: 0.030" / 0.035"

G"(*%C/&&7%N,/,4"$T Up to 12 lb spool

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N&8$(&7#

;(&8$%M,8*7%N&8$(&7#

D7,(5%J89"4,$&(- Lights up if there

is a problem with welder operation.

See Alarm Indicator Error Codes on page 36.

G"(*%C/**9%O8&+- Controls the speed that the

welding wire feeds out of the MIG Gun or Spool

Gun and the output amperage of the Welder.

RJL Gun / Spool Gun Cable Socket-%The MIG Gun

and Spool Gun Cables connect here. The wire,

welding current, and shielding gas (if performing MIG)

feed to the welding gun through here.

G"(*%;**9%N&8$(&7%C&4X*$- Connect the

Wire Feed Control Cable here.

2T/4T%C)"$4.- Use this to set the Gun Trigger

operation to either 2T or 4T mode:

2T (2 touch) mode:

1. Squeeze the trigger to start the welding current

2. Release trigger to stop the welding current.

4T (4 touch) mode:

1. Squeeze trigger to start welding.

2. Release trigger during welding.

3. Squeeze and release trigger to

shut welding current off.

G"(*%

C/**9%

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O8&+

2T / 4T

C)"$4.

R&9*%

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/ Spool Gun

C)"$4.

L,#%^'"4X%

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K&$*- When using an optional Spool Gun (sold separately), disconnect the Wire Feed Gas Hose from the

Gas Quick Connector, thread the gas hose from the Spool Gun through the round hole in the front of the Welder and

connect it to the Gas Quick Connector, and place the MIG Flux/Spool Gun Switch on the Spool Gun setting.

For all other welding, place the MIG Flux/Spool Gun Switch on the MIG Flux Gun setting

and connect the Wire Feed Gas Hose to the Gas Quick Connector. The collar on the

Gas Quick Connector must click into place after attaching any hose to it.

G*79%C*$$"83#

Refer to the Settings Chart on the inside of the Welder door for MIG Weld settings.

The chart is only intended to show general guidelines for different wire/electrode sizes and for

different thicknesses of material. The initial settings used at the beginning of a weld may need to be

adjusted after stopping and carefully inspecting the weld. Proper welding takes experience.

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1. E'(8%$.*%M&)*(%C)"$4.%P;;%,89%'8/7'3%

$.*%G*79*(%+*2&(*%/(&4**9"831

2. Pull up on the Door Latch,

then open the Door.

3. _%M&'89%G"(*%C/&&7%J8#$,77,$"&8-

Remove the Wingnut, Keyed Washers, and

Spring. If replacing a Spool, remove the old

Spool and all remaining wire from the liners.

4. Place the new Wire Spool over the Spool Spindle

and against the Spool Brake Pad as illustrated.

E&%/(*U*8$%)"(*%2**9%/(&+7*5#=%#*$%$.*%C/&&7%

#&%$.,$%"$%)"77%'8)"89%4&'8$*(47&4X)"#*1

5. Line up the Keyed Washers with

the groove on the Spindle. Replace

the Keyed Washers and Spring

over the Spool Spindle and secure

Spool in place with the Wingnut.

K&$"4*- If Wire Spool can spin freely, Wingnut is too

loose. This will cause the welding wire to unravel and

unspool which can cause tangling and feeding problems.

M&)*(%

C)"$4.

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"847'9"83%,77%$*W$%'89*(%#'+.*,9"83#%$.*(*"8%+*2&(*%#*$%'/%&(%'#*%&2%$."#%/(&9'4$1

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E'(8%$.*%M&)*(%C)"$4.%&22%,89%'8/7'3%$.*%G*79*(%+*2&(*%#*$'/1

K&$*-%Remove the protective foam and cardboard from the Welder before setup.

Wire Spool Installation / Wire Setup

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6. >B?>_%M&'89%G"(*%C/&&7%J8#$,77,$"&8-%

Remove the Wingnut, Keyed Washers, and Spring.

If replacing a Spool, remove the old Spool

and all remaining wire from the liners.

7. Place the Spool Adapter over the Spool Spindle

and against the Spool Brake Pad as illustrated.

8. Place the new Wire Spool over the Adapter and

line up pin on Adapter with hole in Spool.

E&%/(*U*8$%)"(*%2**9%/(&+7*5#=%#*$%$.*%C/&&7%

#&%$.,$%"$%)"77%'8)"89%4&'8$*(47&4X)"#*1

9. Line up the Keyed Washers with the groove

on the Spindle. Replace the Keyed Washers

and Spring over the Spool Spindle and

secure Spool in place with the Wingnut.

K&$"4*- If Wire Spool can spin freely, Wingnut

is too loose. This will cause the welding

wire to unravel and unspool which can

cause tangling and feeding problems.

10. Screw the Spool Knob into the Spool Adapter.

11. IN6K%I"(*4$%N'((*8$%67*4$(&9*%K*3,$"U*%%

Wire Setup for Flux-Cored (gasless) welding:

Connect the Wire Feed Connector to the

Negative Terminal on the front of the Welder.

Connect the Ground Cable to the

Positive Terminal on the front of the Welder.

>B?>_%7+%C/&&7%H&,9"83

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Flux-Cored (Gasless) Polarity Setup

4&88*4$%

G"(*%;**9%

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4&88*4$%

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/&#"$"U*

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12. IN6M%I"(*4$%N'((*8$%67*4$(&9*%M&#"$"U*%G"(*%

Setup for Solid Core (gas shielded) welding:

a. Connect the Wire Feed Connector to the

Positive Terminal on the front of the Welder.

Connect the Ground Cable to the

Negative Terminal on the front of the Welder.

b. Determine which type of shielding gas

would be appropriate for the welding

you will do. Refer to the Settings Chart

on the inside of the Welder door.

c. With assistance, set the cylinder (not included)

onto a cabinet or cart near the Welder

and secure the cylinder in place with two

straps (not included) to prevent tipping.

d. Remove the cylinder’s cap. Stand to the

side of the valve opening, then open the

valve briefly to blow dust and dirt from the

valve opening. Close the cylinder valve.

e. Locate the Regulator (included) and close its

valve until it is loose, then thread Regulator

onto cylinder and wrench tighten connection.

K&$*- When using C100 shielding gas, connect a CGA

580/320 adapter (not included) to the inlet connection

of the Regulator and wrench tighten. Thread the

adapter onto the gas cylinder and wrench tighten.

f. Attach the Gas Hose (included) to the

Regulator’s outlet and the Welder’s gas inlet.

Wrench-tighten both connections.

g. Connect the Wire Feed Gas Hose within

the Welder to the Gas Quick Connector.

The collar on the Gas Quick Connector must

click into place after attaching any hose to it.

L,#%^'"4X%

N&88*4$&(

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Solid Core (Gas Shielded) Polarity Setup

4&88*4$%

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13. Turn the Feed Tensioner knob counterclockwise to

loosen it enough to pull it down to remove tension.

The spring-loaded Idler Arm will move up as shown.

14. ;**9%Q&77*(%J8#$('4$"&8#-%

Check that the Feed Roller is correct for the

type of wire being used (solid core or flux-

cored) and that it is turned to properly match

the wire size marked on the Wire Spool:

a. Unscrew the Feed Roller Knob counterclockwise.

b. Remove the Feed Roller Knob to

expose the Feed Roller.

c. Flip or replace the Feed Roller as needed and

confirm that it is the correct Roller for the type of

wire being used and that $.*%8'5+*(%#.&)"83%

"#%$.*%#,5*%,#%$.*%)"(*%9",5*$*(%&8%$.*%C/&&71

K&$*- The knurled groove is used for flux-cored wire.

The V-grooves are used for solid / MIG wire.

d. Screw the Feed Roller Knob back into

place to secure the Feed Roller.

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15. Loosen the Knob on the Wire Feed

mechanism, then insert the Gun Cable

Connector through the hole on the Welder

front and into the socket on the Wire Feed.

16. Ensure that the Gun Cable Connector is fully

inserted into the socket on the Wire Feed

mechanism as shown.

K&%P?("83%#.&'79%+*%U"#"+7*1

Tighten the Knob securely.

If Connector is not fully inserted, the gas

connection will leak, preventing shielding

gas from reaching the welding arc.

KPEJN6- To prevent damage,

do not overtighten the Knob.

17. Connect the Wire Feed Control Cable to the

Wire Feed Control Socket located on the front

of the machine. Press it in until the collar snaps

into place. Note that the plug on the Cable fits

into the Socket in one specific orientation only.

To disconnect it, pull the collar back first.

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)."4.%4,8%4,'#*%$,837"83%,89%2**9"83%/(&+7*5#1

18. Cut off all bent and crimped wire.

The cut end must have no burrs or

sharp edges; cut again if needed.

19. Keep tension on the wire and guide

at least 12 inches of wire into the

Wire Inlet Liner and Feed Guide.

Incorrect – Connector not fully inserted

L'8%N,+7*%

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Correct – Connector fully inserted

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20. Make sure the welding wire is resting in the groove

of the Feed Roller, then push the wire Idler Arm

down, and swing the Feed Tensioner up to latch it

across the tip of the arm.

After the wire is held by the Tensioner,

you may release it.

K&$*- The tension should be 3 – 5 for solid wire and

2 – 3 for flux-cored wire. Too much force on flux-cored

wire will crush it and may cause feeding issues.

21. Pull and twist the Nozzle to remove it.

22. Unscrew the Contact Tip

counterclockwise and remove.

23. Lay the MIG Gun Cable out in a straight line so

that the welding wire moves through it easily.

Leave the cover open, so that the feed

mechanism can be observed.

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The following steps require applying power to the Welder

with the cover open.

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1. I&%8&$%$&'4.%,8T$."83=%*#/*4",77T%8&$%$.*%L(&'89%N7,5/=%

)"$.%$.*%L'8%&(%)*79"83%)"(*%&(%,8%,(4%)"77%+*%"38"$*91

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)."7*%"$%"#%/7'33*9%"81

24. Turn the Power Switch off and do not touch the

Gun’s Trigger and before connecting Power Cord.

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&8%$.*%+,4X%&2%$.*%G*79*(%$&%$.*%

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26. If using 120VAC, connect the included adapter to the

end of the Power Cord.

If using 240VAC, do not use the adapter.

27. Plug the Power Cord into a properly grounded

and rated receptacle that matches the plug and

selected voltage and turn the Power Switch ON.

K&$*- The circuit must be equipped with delayed

action-type circuit breaker or fuses.

28. Set the Mode Switch to the bottom,

wire welding setting.

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240V to 120V Plug Adapter

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29. Set the MIG Flux / Spool Gun Switch

to MIG Flux Gun.

30. Point the Gun away from all objects.

Press and hold the Trigger until the wire feeds

through the end of the Gun two inches.

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,89%/'#.%$.*%)"(*%7"8*(%+,4X%"8$&%$.*%L'81

If the wire does not feed properly and

the Spool is stationary, turn OFF and

unplug the Welder and slightly tighten the

Feed Tensioner clockwise before retrying.

31. To check the wire’s drive tension, press and

hold Trigger to feed the wire against a piece of

wood from 2 to 3 inches away.

If the wire stops instead of bending,

unplug the Welder, slightly tighten the

Feed Tensioner clockwise, and try again.

If the wire bends from the feed pressure,

then the tension is set properly.

32. Turn OFF the Power Switch and unplug the

Power Cord from its electrical outlet.

33. Select a Contact Tip that is compatible with

the welding wire used. Slide the Contact

Tip over the wire and thread it clockwise into

the MIG Gun. Tighten the Contact Tip.

34. Replace the Nozzle and cut the wire

off at 1/2" from tip (1/2" stickout).

35. Close the Door. Make sure

Door is securely latched.

MIG Flux / %

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S,#"4%G*79"83

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(or welding mask), ear protection, welding gloves, sleeves and apron, NIOSH-approved respirator, and fire

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Flux-cored wire welding is used to weld mild steel

and stainless steel without shielding gas.

MIG welding uses solid wire and shielding gas,

and is used to weld mild steel and stainless steel.

MIG welding can also be used to weld thinner

workpieces than flux-cored welding can.

Aluminum welding can be performed with an

optional Spool Gun (sold separately) using

aluminum wire and shielding gas.

Good welding takes a degree of skill and experience.

Practice a few sample welds on scrap before

welding your first project. Additional practice

periods are recommended whenever you weld:

• a different thickness of material

• a different type of material

• a different type of connection

• using a different process (MIG vs. Flux)

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Duty Cycle (Duration of Use)

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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, a welder with a 40% duty cycle at 90 A

welding current must be allowed to rest for at least

6 minutes after every 4 minutes of continuous welding.

Failure to carefully observe any duty cycle limitations

can easily over-stress a welder’s power generation

system contributing to premature welder failure.

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120 VAC

40% Use at 90A

;&(%>B%N&8$"8'&'#%R"8'$*#

240 VAC

15% Use at 200A

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This Welder has an internal thermal protection

system to help prevent this sort of over-stress.

When the Welder overheats, it automatically

shuts down and the Overload Indicator lights.

The Welder automatically returns to service

after cooling off. Should this occur, rest the

MIG Gun on an electrically non-conductive,

heat-proof surface, such as a concrete

slab, well clear of the ground clamp.

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M&)*(%C)"$4.%&8=%#&%$.,$%$.*%"8$*(8,7%

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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.

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non-conductive surface)

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1. R,X*%/(,4$"4*%)*79#%&8%/"*4*#%&2%#4(,/%$.*%

#,5*%$."4X8*##%,#%T&'(%"8$*89*9%)&(X/"*4*%

$&%/(,4$"4*%$*4.8"<'*%+*2&(*%)*79"83%,8T$."83%

&2%U,7'*1%%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.

K&$"4*- 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.

3. Clamp Ground Cable to bare metal on the

workpiece near the weld area, or to metal work

bench where the workpiece is clamped.

4. Set the Wire Speed, Voltage, and Inductance Knobs

to the desired settings. Refer to the Settings

Chart on the inside of the Welder door.

K&$*- The initial settings may need to be adjusted

after stopping and carefully inspecting the weld.

Proper welding takes experience.

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Page 20 ;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?A@B?BA>@1 Item 64806

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Shielding gas can displace air and cause rapid loss of

consciousness and death.

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5. L,#%#."*79*9=%#&7"9?4&(*%)"(*%&87T-

a. Open gas cylinder valve all the way.

b. Set Flow Gauge to SCFH value

indicated on Settings Chart.

6. Turn the Power Switch off and do not touch the

Gun’s Trigger and before connecting Power Cord.

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&'$7*$%T&'%)"77%'#*1 If using 120VAC, connect

the included adapter to the end of the Power

Cord. If using 240VAC, do not use the adapter.

Plug the Power Cord into a properly grounded

and rated receptacle that matches the plug and

selected voltage and turn the Power Switch ON.

K&$*- The circuit must be equipped with

delayed action-type circuit breaker or fuses.

7. Set MIG Gun down on nonconductive,

nonflammable surface away from any grounded

objects. Turn the Power Switch ON.

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Titanium Item 64806, 64806, MIG 140, MIG 170, UNLIMITED 200 Owner's manual

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