Titanium Item 64806 Owner's manual

Category
Welding System
Type
Owner's manual

This manual is also suitable for

!"#"$%&'(%)*+#"$*%,$-%.$$/-00)))1.,(+&(2(*"3.$14&5
65,"7%&'(%$*4.8"4,7%#'//&($%,$-%/(&9'4$#'//&($:.,(+&(2(*"3.$14&5
64806
Owners 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.
Copyright
©
2018 by Harbor Freight Tools
®
. All rights reserved.
No portion of this manual or any artwork contained herein may be reproduced in
any shape or form without the express written consent of Harbor Freight Tools.
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.
Page 2 ;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?A@B?BA>@1 Item 64806
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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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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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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$("4%#.&4X1
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CT5+&7&3T
Wire Feed (Speed)
Workpiece Ground Cable
Torch Cable
Overheat Shutdown Indicator
Cooling Fan
Housing Ground Point
!DN
Volts Alternating Current
D
Amperes
PN!
Open Circuit Voltage
O!D
Kilovolt Amperes
(Volts / 1000 * Amperes)
JMR
Inches Per Minute
DGL
American Wire Gauge
Electric Shock Hazard.
Do not touch energized parts.
Inhalation Hazard.
Keep head out of fumes
and use proper ventilation.
Read manual before
setup and/or use.
Fire Hazard.
Keep flammable materials
away during welding. Spatter
can cause accidental fires.
Arc Ray Hazard.
Wear welding helmet with
properly rated filter lens.
Pacemaker Hazard.
Welding processes may
interfere with pacemakers.
Consult doctor before use.
C/*4"2"4,$"&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)"$4.- Use this to set the Gun Trigger
operation to either 2T or 4T mode:
2T (2 touch) mode:
1. Squeeze the trigger to start the welding current
2. Release trigger to stop the welding current.
4T (4 touch) mode:
1. Squeeze trigger to start welding.
2. Release trigger during welding.
3. Squeeze and release trigger to
shut welding current off.
G"(*%
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/ Spool Gun
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K&$*- 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&$"4*- If Wire Spool can spin freely, Wingnut is too
loose. This will cause the welding wire to unravel and
unspool which can cause tangling and feeding problems.
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K&$*-%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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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 cylinders 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&$*- When using C100 shielding gas, connect a CGA
580/320 adapter (not included) to the inlet connection
of the Regulator and wrench tighten. Thread the
adapter onto the gas cylinder and wrench tighten.
f. Attach the Gas Hose (included) to the
Regulator’s outlet and the Welder’s gas inlet.
Wrench-tighten both connections.
g. Connect the Wire Feed Gas Hose within
the Welder to the Gas Quick Connector.
The collar on the Gas Quick Connector must
click into place after attaching any hose to it.
L,#%^'"4X%
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2
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Solid Core (Gas Shielded) Polarity Setup
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13. Turn the Feed Tensioner knob counterclockwise to
loosen it enough to pull it down to remove tension.
The spring-loaded Idler Arm will move up as shown.
14. ;**9%Q&77*(%J8#$('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,'#*%$,837"83%,89%2**9"83%/(&+7*5#1
18. Cut off all bent and crimped wire.
The cut end must have no burrs or
sharp edges; cut again if needed.
19. Keep tension on the wire and guide
at least 12 inches of wire into the
Wire Inlet Liner and Feed Guide.
Incorrect – Connector not fully inserted
L'8%N,+7*%
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20. Make sure the welding wire is resting in the groove
of the Feed Roller, then push the wire Idler Arm
down, and swing the Feed Tensioner up to latch it
across the tip of the arm.
After the wire is held by the Tensioner,
you may release it.
K&$*- 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
2. I&%8&$%$&'4.%"8$*(8,7%G*79*(%4&5/&8*8$#%
)."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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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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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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"847'9"83%,77%$*W$%'89*(%#'+.*,9"83#%$.*(*"8%+*2&(*%)*79"831
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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
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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.
D77&)%$.*%G*79*(%$&%4&&7%)"$.%$.*%
M&)*(%C)"$4.%&8=%#&%$.,$%$.*%"8$*(8,7%
;,8%)"77%.*7/%4&&7%$.*%G*79*(1
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.
M&)*(%
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PU*(7&,9%
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non-conductive surface)
Page 19;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?A@B?BA>@1Item 64806
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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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;"W%3,#%7*,X#%"55*9",$*7T1
Shielding gas can displace air and cause rapid loss of
consciousness and death.
C."*79"83%3,#%)"$.&'$%4,(+&8%9"&W"9*%4,8%+*%*U*8%
5&(*%.,V,(9&'#%+*4,'#*%,#/.TW",$"&8%4,8%#$,($%%
)"$.&'$%2**7"83%#.&($8*##%&2%+(*,$.1
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.
JRMPQEDKE-%N.,83*%$.*%!&7$,3*%C)"$4.%&8%
$.*%+,4X%&2%$.*%G*79*(%$&%$.*%U&7$,3*%&2%$.*%
&'$7*$%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&$*- The circuit must be equipped with
delayed action-type circuit breaker or fuses.
7. Set MIG Gun down on nonconductive,
nonflammable surface away from any grounded
objects. Turn the Power Switch ON.
M&)*(%
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!&7$,3*%
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240V to 120V Plug Adapter
!&7$,3*%#)"$4.%,89%/7'3%8**9%$&%
+*%4.,83*9%,$%$.*%#,5*%$"5*1
M&)*(%
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Titanium Item 64806 Owner's manual

Category
Welding System
Type
Owner's manual
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