Harbor Freight Tools Vulcan VA-SPLG Owner's manual

Brand: Harbor Freight Tools

Model: Vulcan VA-SPLG

Category: Welding System

Type: Owner's manual

This manual is also suitable for

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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.

When unpacking, make sure that the product is intact

and undamaged. If any parts are missing or broken,

please call 1-<?>-1-888-380-0318 as soon as possible.

2017 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.

;*,9%$."#%5,$*(",7%+*2&(*%'#"83%$."#%/(&9'4$1%

<,"7'(*%$&%9&%#&%4,8%(*#'7$%"8%#*("&'#%"8='(>1%

?@!6%ABC?%D@EF@G1

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.

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.

2017 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.

Too ls r eq ui re d for a ss em bl y and s er vi ce m ay not be i nc lu de d.

;*,9%$."#%5,$*(",7%+*2&(*%'#"83%$."#%/(&9'4$1%

<,"7'(*%$&%9&%#&%4,8%(*#'7$%"8%#*("&'#%"8='(>1%

?@!6%ABC?%D@EF@G1

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.

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.

2017 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.

Too ls r eq ui re d for a ss em bl y and s er vi ce m ay not be i nc lu de d.

;*,9%$."#%5,$*(",7%+*2&(*%'#"83%$."#%/(&9'4$1%

<,"7'(*%$&%9&%#&%4,8%(*#'7$%"8%#*("&'#%"8='(>1%

?@!6%ABC?%D@EF@G1

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.

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.

2017 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.

Too ls r eq ui re d for a ss em bl y and s er vi ce m ay not be i nc lu de d.

;*,9%$."#%5,$*(",7%+*2&(*%'#"83%$."#%/(&9'4$1%

<,"7'(*%$&%9&%#&%4,8%(*#'7$%"8%#*("&'#%"8='(>1%

?@!6%ABC?%D@EF@G1

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. 17e

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.

2017 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.

Too ls r eq ui re d for a ss em bl y and s er vi ce m ay not be i nc lu de d.

;*,9%$."#%5,$*(",7%+*2&(*%'#"83%$."#%/(&9'4$1%

<,"7'(*%$&%9&%#&%4,8%(*#'7$%"8%#*("&'#%"8='(>1%

?@!6%ABC?%D@EF@G1

Page 2 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1 Item 63793

?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?SETUP?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?SETUP

A,+7*%&2%P&8$*8$#

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

Specifications ............................................. 5

Setup .......................................................... 6

Maintenance and Service .......................... 17

Parts List and Diagram .............................. 19

Warranty .................................................... 20

R@;ECET%?ODQVG?%@ES%S6<CECACVE?

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.

CDUV;A@EA%?@<6AO%CE<V;D@ACVE

;*,9%,77%?,2*$>%),(8"83#%,89%"8#$('4$"&8#1%%

<,"7'(*%$&%2&77&)%$.*%),(8"83#%,89%"8#$('4$"&8#%5,>%(*#'7$%"8%*7*4$("4%#.&4WI%2"(*%,890&(%#*("&'#%"8='(>1%%%

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

T*8*(,7%?,2*$>

U;VA6PA%>&'(#*72%,89%&$.*(#1%%;*,9%,89%'89*(#$,89%$."#%"82&(5,$"&81

1. Q*2&(*%'#*I%(*,9%,89%'89*(#$,89%

manufacturer′s instructions,

Material Safety Data Sheets (MSDS′s),

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

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

Keep children and bystanders away while operating.

3. U7,4*%$.*%)*79*(%&8%,%#$,+7*%7&4,$"&8%+*2&(*%'#*1%%%

If it falls while plugged in, severe injury,

electric shock, or fire may result.

4. S&%8&$%&X*((*,4.1%%%

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

5. ?$,>%,7*($I%),$4.%).,$%>&'%,(*%9&"83%,89%'#*%

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

S&%8&$%'#*%,%)*79*(%)."7*%>&'%,(*%$"(*9%&(%'89*(%

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

A moment of inattention while operating welders

may result in serious personal injury.

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

prepared to begin work before turning on the Welder.

7. E*X*(%7*,X*%$.*%R*79*(%'8,$$*89*9%)."7*%

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

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

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

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

$.,$%5,>%&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<&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1Item 63793

?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU? SETUP ?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU? SETUP

<'5*%,89%T,#%?,2*$>

INHALATION HAZARD:%

R*79"83%,89%U7,#5,%P'$$"83%/(&9'4*%$&["4%2'5*#1

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

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

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

7,(>8[%,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. S&%8&$%'#*%8*,(%9*3(*,#"83%&(%

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

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

Do not breathe exhaust fumes.

4. F#*%*8&'3.%X*8$"7,$"&8I%*[.,'#$%,$%,(4I%&(%

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

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

are not feasible, use an approved respirator.

5. R&(W%"8%,%4&82"8*9%,(*,%&87>%"2%"$%

"#%)*77KX*8$"7,$*9I%&(%)."7*%)*,("83%

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

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

C89'#$(",7%B>3"*8*%&(%68X"(&85*8$,7%?*(X"4*#%

4.*4W%$.*%&/*(,$"&8%,89%,"(%H',7"$>%

,89%5,W*%(*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.

@(4%;,>%?,2*$>

@;P%;@O?%4,8%"8='(*%*>*#%,89%+'(8%#W"81

1. R*,(%@E?CK,//(&X*9%)*79"83%*>*%/(&$*4$"&8%

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

2. R*,(%7*,$.*(%7*33"83#I%2"(*%(*#"#$,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. Y**/%47&$."83%2(**%&2%3(*,#*I%&"7I%

#&7X*8$#I%&(%,8>%27,55,+7*%#'+#$,84*#1%%

Wear dry, insulating gloves and protective clothing.

4. R*,(%,8%,//(&X*9%.*,9%4&X*("83%$&%/(&$*4$%

$.*%.*,9%,89%8*4W1%Use aprons, cape, sleeves,

shoulder covers, and bibs designed and

approved for welding and cutting procedures.

5. R*,(%,8%,//(&X*9%)*79"83%=,4W*$%&(%7&83%#7**X*#%

$&%/(&$*4$%2&(*,(5#%2(&5%(,9",$"&8%+'(8#1%

6. R.*8%)*79"8304'$$"83%&X*(.*,9%&(%"8%4&82"8*9%

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

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

67*4$("4,7%?,2*$>

6G6PA;CP%?BVPY%4,8%YCGG1

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

9"#4.,(3*%67*4$(&9*%$&%3(&'89%+*2&(*%#*$$"83%

9&)8%$&(4.067*4$(&9*%.&79*(%,89%+*2&(*%#*(X"4*1

2. S&%8&$%$&'4.%*8*(3"Z*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. P&88*4$%$&%3(&'89*9I%T<PCK/(&$*4$*9%

/&)*(%#'//7>%&87>1

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

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

physician(s) before use. Electromagnetic fields

in close proximity to heart pacemaker could cause

pacemaker interference or pacemaker failure.

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

Water entering a welder will increase

the risk of electric shock.

7. S&%8&$%,+'#*%$.*%4&(91%%E*X*(%'#*%$.*%4&(9%

2&(%4,((>"83I%/'77"83%&(%'8/7'33"83%$.*%)*79*(1%%

Y**/%4&(9%,),>%2(&5%.*,$I%&"7I%#.,(/%*93*#%

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

cords increase the risk of electric shock.

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

9. C8#'7,$*%>&'(#*72%2(&5%$.*%)&(W/"*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.

Page 4 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1 Item 63793

?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?SETUP?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?SETUP

<"(*%?,2*$>

@;P%@ES%?G@T%4,8%4,'#*%2"(*1

1. P7*,(%,),>%&(%/(&$*4$%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. Y**/%@QPK$>/*%2"(*%*[$"83'"#.*(%8*,(%

)&(W%,(*,%,89%W8&)%.&)%$&%'#*%"$1

3. D,"8$,"8%,%#,2*%)&(W"83%*8X"(&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. S&%8&$%&/*(,$*%)*79*(#%"8%,$5&#/.*(*#%

4&8$,"8"83%9,83*(&'#7>%(*,4$"X*%&(%

27,55,+7*%7"H'"9#I%3,#*#I%X,/&(#I%&(%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. C2%)&(W"83%&8%,%5*$,7%),77I%4*"7"83I%*$41I%

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

&$.*(%#"9*%+>%5&X"83%$.*%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. S&%8&$%)*79%&(%4'$%&8%5,$*(",7#%.,X"83%

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

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

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

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

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

8. @2$*(%)*79"83I%5,W*%,%$.&(&'3.%*[,5"8,$"&8%

2&(%*X"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. S&%8&$%,//7>%.*,$%$&%,%4&8$,"8*(%$.,$%.,#%.*79%

,8%'8W8&)8%#'+#$,84*%&(%,%4&5+'#$"+7*%

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

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

Clean and purge containers before applying heat.

Vent closed containers, including castings,

before preheating, welding, or cutting.

R*79*(%F#*%,89%P,(*

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

#&'(4*%+*2&(*%5,W"83%,8>%,9='#$5*8$#I%

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

Such preventive Safety measures reduce the

risk of starting the welder accidentally.

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

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

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

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

or energizing welders that have the

switch on invites accidents.

4. ?$&(*%"97*%)*79*(#%&'$%&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. F#*%$.*%)*79*(%,89%,44*##&("*#%"8%

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

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

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

for operations different from those intended

could result in a hazardous situation.

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

D,"8$*8,84*

1. D,"8$,"8%)*79*(#1%%P.*4W%2&(%5"#,7"385*8$%&(%

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

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

)*79*(\#%&/*(,$"&81%%C2%9,5,3*9I%.,X*%$.*%

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

are caused by poorly maintained welders.

2. B,X*%>&'(%)*79*(%#*(X"4*9%+>%,%H',7"2"*9%

(*/,"(%/*(#&8%'#"83%&87>%"9*8$"4,7%

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

the Safety of the welder is maintained.

Page 5<&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1Item 63793

?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU? SETUP ?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU? SETUP

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

These carry important information.

If unreadable or missing, contact

Harbor Freight Tools for a replacement.

4. F8/7'3%+*2&(*%5,"8$*8,84*1%Unplug the Welder

from its electrical outlet before any inspection,

maintenance, or cleaning procedures.

T,#%?."*79*9%R*79"83%K%P>7"89*(%?,2*$>

P>7"89*(#%4,8%*[/7&9*%).*8%9,5,3*91

1. S&%8&$%)*79%&8%,%/(*##'("Z*9%&(%47&#*9%4>7"89*(1

2. S&%8&$%,77&)%,8%67*4$(&9*%.&79*(I%

67*4$(&9*I%)*79"83%$&(4.I%&(%)*79"83%

)"(*%$&%$&'4.%$.*%4>7"89*(1

3. Y**/%4>7"89*(#%,),>%2(&5%,8>%*7*4$("4,7%4"(4'"$#I%

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

4. Y**/%/(&$*4$"X*%4,/%"8%/7,4*%&X*(%$.*%X,7X*%

*[4*/$%).*8%$.*%4>7"89*(%"#%"8%'#*1

5. F#*%&87>%4&((*4$%3,#%#."*79"83%*H'"/5*8$%

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

>&'%)"77%9&1%%Maintain this equipment properly.

6. U(&$*4$%3,#%4>7"89*(#%2(&5%.*,$I%+*"83%#$('4WI%

/.>#"4,7%9,5,3*I%#7,3I%27,5*#I%#/,(W#I%,89%,(4#1

7. F#*%/(&/*(%/(&4*9'(*#%$&%5&X*%4>7"89*(#1

%?@!6%AB6?6%CE?A;FPACVE?1

Wire Feed (Speed)

Workpiece Ground Cable

Torch Cable

Overheat Shutdown Indicator

Cooling Fan

!@P

Volts Alternating Current

Amperes

VP!

Open Circuit Voltage

CUD

Inches Per Minute

@RT

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.

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

Wire Types Aluminum and Steel alloys

Wire Capacity 4" Spool, - 1lb aluminum and 2lb steel, 0.030" / 0.035"diameter

Rated Duty Cycle 35% @ 160 A

Page 6 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1 Item 63793

?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?SETUP

?*$'/

% ;*,9%$.*%6EAC;6%CDUV;A@EA%?@<6AO%CE<V;D@ACVE%#*4$"&8%,$%$.*%+*3"88"83%&2%$."#%

5,8',7%"847'9"83%,77%$*[$%'89*(%#'+.*,9"83#%$.*(*"8%+*2&(*%#*$%'/%&(%'#*%&2%$."#%/(&9'4$1

AV%U;6!6EA%?6;CVF?%CE]F;O%<;VD%@PPCS6EA@G%VU6;@ACVE-%

A'(8%$.*%U&)*(%?)"$4.%&22%,89%'8/7'3%$.*%)*79*(%+*2&(*%#*$%'/1

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.

E&$*- A.*%2&77&)"83%"8#$('4$"&8#%,(*%2&(%)*79"83%)"$.%@7'5"8'5%)"(*1

P&88*4$%?."*79"83%T,#

1. With assistance, place an 100% Argon 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.

2. 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.

3. Close the Regulator’s valve by backing off knob

until it is loose, then thread Regulator onto

cylinder and wrench tighten connection.

4. Attach the Gas Hose (included) to the

Regulator’s Outlet and the Welder’s Gas Inlet.

Wrench-tighten both connections.

Reset

Power Input

Gas Inlet

Q("*27>%&/*8%X,7X*%

$&%47*,8I%%

$.*8%47&#*%%

X,7X*1

Page 7<&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1Item 63793

?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU? SETUP

?*$%F/%?/&&7%T'8

1. Pull the Nozzle to remove it.

2. Unscrew the Contact Tip

counterclockwise and remove.

E&ZZ7*

P&8$,4$%

A"/

3. Press Spool Cover Release Button,

then open Spool Cover.

4. Remove Spool Lock Knob by turning clockwise.

5. Loosen Spool Tension Knob without removing.

E&$*- To prevent unraveling, leave

wire secured to Spool.

6. Install Spool so wire will feed over top of Spool.

7. Tighten Spool Tension Knob until

Spool cannot spin freely.

8. Replace Spool Lock Knob by

turning counterclockwise.

?/&&7%

G&4W%Y8&+

?/&&7%

A*8#"&8%

Y8&+

?/&&7%P&X*(%

;*7*,#*%Q'$$&8

9. Hold end of wire while releasing from

Spool. Cut off any bent wire.

10. Keeping tension on Spool, feed

Wire into Inlet Guide.

11. Loosen Tension Knob.

12. Push on Tension Knob enough to create a

space, between Driver Roller and Tension Roller,

large enough so that Wire will pass through.

13. Push Wire 1/4" into Inlet.

14. Tighten Tension Knob.

A*8#"&8%

Y8&+

A*8#"&8%

@(5

A*8#"&8%

;&77*(

R"(*

C87*$%

T'"9*

S("X*%

;&77*(

C87*$

A*8#"&8%

?/("83

15. Close Spool Cover.

16. Set Spool Gun down on nonconductive,

nonflammable surface away from

any grounded objects.

Page 8 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1 Item 63793

?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?SETUP

Connect to Vulcan MIGMAX 140

1. Turn Power Switch OFF and unplug welder.

2. Open Door on side of Welder.

3. Remove MIG Gun and Wire Spool, if present.

S&&(

4. Set Polarity to DCEP (Direct

Current Electrode Positive):

a. Connect Black Ground Cable

to Negative Terminal (-).

b. Connect Red Electrode Cable

to Positive Terminal (+).

c. Make sure Cables sit flush in grooves.

T(&&X*

5. P&88*4$%?/&&7%T'8-

a. Loosen Knob without removing.

b. Plug Spool Gun Connector

into Spool Gun Socket.

c. Tighten Knob, do not over tighten.

d. Pull on Spool Gun Connector to ensure tight

connection. Re-seat if connection is not tight.

E&$*- If connection is not tight, arc will not ignite.

Y8&+

?/&&7%T'8%

P&88*4$&(

?/&&7%T'8%

?&4W*$%

6. Plug Wire Feed Control Cable into

Wire Feed Control Socket. Secure by

turning collar clockwise until tight.

E&$*- Plug will only fit one way.

7. Plug Gas Cable into Gas Outlet.

Secure by wrench tightening.

?/&&7%T'8%

?&4W*$%

R"(*%<**9%

P&8$(&7%

?&4W*$

T,#%

V'$7*$

R"(*%<**9%

P&8$(&7%

P,+7*

T,#%

P,+7*

Page 9<&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1Item 63793

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S@ET6;

U@;A?%D@O%Q6%@A%R6GSCET%!VGA@T6

AV%U;6!6EA%6G6PA;CP%?BVPY%@ES%S6@AB-

1. Y**/%.,89#%,),>%2(&5%R"(*%<**9%5*4.,8"#51

2. P7&#*%9&&(%+*2&(*%/7'33"83%"8I%

3. ?$,>%47*,(%&2%)"(*%)."7*%2**9"83%)"(*%$.(&'3.%3'81

AV%U;6!6EA%?6;CVF?%CE]F;O-%U(&$*4$"X*%3*,(%5'#$%+*%)&(8%).*8%'#"83%$.*%R*79*(_%5"8"5'5%

shade number 10 full face shield (or welding mask), ear protection, welding gloves, sleeves and apron,

ECV?BK,//(&X*9%(*#/"(,$&(I%,89%2"(*%(*#"#$,8$%)&(W%47&$.*#%)"$.&'$%/&4W*$#%#.&'79%+*%)&(8%).*8%)*79"831%%

G"3.$%2(&5%$.*%,(4%4,8%4,'#*%/*(5,8*8$%9,5,3*%$&%$.*%*>*#%,89%#W"81%%S&%8&$%+(*,$.*%,(4%2'5*#1

8. P7&#*%S&&(%&8%#"9*%&2%R*79*(I%

5,W"83%#'(*%"$%7,$4.*#1

9. Plug either 120 VAC or 240 VAC Power Cord

into Power Input Socket on back of welder.

E&$*- Plug will only fit one way.

10. Plug Welder into properly grounded, GFCI

protected, 120 VAC (20 amp rated) outlet or

240 V outlet. The circuit must be equipped with

delayed action-type circuit breaker or fuses.

11. Turn Power Switch ON.

12. On inside of welder,

toggle Spool Gun/MIG Gun switch

to ?/&&7%T'8.

Spool

Gun

MIG

Gun

Cold

Wire Feed

a. Turn Amperage to A and Voltage to 1.

13. P.*4W%R"(*%S("X*%A*8#"&8-

a. Hold Spool Gun and point it

away from all objects.

b. Press and hold Trigger until at least 2"

of wire sticks out of the Gun. Release

Trigger. Trim wire to 2" as needed.

c. Hold Gun 2 - 3" away from piece of wood.

d. Press Trigger. When Wire touches wood,

it should bend instead of stopping.

• If Wire stops instead of bending,

turn off and unplug welder.

• Slightly tighten Tension Knob.

• Plug welder in and turn power on.

• Repeat steps c. and d. until Wire bends instead

of stopping. Trim wire to 2" as needed.

^KM`

A*8#"&8%

Y8&+

R"(*%?.&'79%

Q*89

14. Turn Power Switch OFF and unplug welder.

15. Choose Contact Tip same size as

Wire. Slide Contact Tip over Wire.

16. Replace Nozzle, trim wire to 1/2".

17. Set Spool Gun down on nonconductive,

nonflammable surface away from

any grounded objects.

18. Go to V/*(,$"&8%&8%/,3*%141

Page 10 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1 Item 63793

?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?SETUP

P&88*4$%$&%!'74,8%DCTD@a%^Jb

1. Turn Power Switch OFF and unplug welder.

2. Open Door on side of welder.

3. Remove MIG Gun and Wire Spool, if present.

S&&(

4. Set Polarity to DCEP (Direct

Current Electrode Positive):

a. Connect Black Ground Cable

to Negative Terminal (-).

b. Connect Red Electrode Cable

to Positive Terminal (+).

c. Make sure Cables sit flush in grooves.

T(&&X*

5. P&88*4$%?/&&7%T'8-

a. Loosen Knob without removing.

b. Plug Spool Gun Connector

into Spool Gun Socket.

c. Tighten Knob, do not over tighten.

d. Pull on Spool Gun Connector to ensure tight

connection. Re-seat if connection is not tight.

E&$*- If connection is not tight, arc will not ignite.

Y8&+

?/&&7%T'8%

P&88*4$&(

?/&&7%T'8%

?&4W*$%

6. Plug Wire Feed Control Cable into

Wire Feed Control Socket. Secure by

turning collar clockwise until tight.

E&$*- Plug will only fit one way.

7. Plug Gas Cable into Gas Outlet.

Secure by wrench tightening.

?/&&7%T'8%

?&4W*$%

R"(*%<**9%

P&8$(&7%

?&4W*$

T,#%

V'$7*$

R"(*%<**9%

P&8$(&7%

P,+7*

T,#%

P,+7*

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?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU? ?6AFU

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1. Y**/%.,89#%,),>%2(&5%R"(*%<**9%5*4.,8"#51

2. P7&#*%9&&(%+*2&(*%/7'33"83%"8I%

3. ?$,>%47*,(%&2%)"(*%)."7*%2**9"83%)"(*%$.(&'3.%3'81

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shade number 10 full face shield (or welding mask), ear protection, welding gloves, sleeves and apron,

ECV?BK,//(&X*9%(*#/"(,$&(I%,89%2"(*%(*#"#$,8$%)&(W%47&$.*#%)"$.&'$%/&4W*$#%#.&'79%+*%)&(8%).*8%)*79"831%%

G"3.$%2(&5%$.*%,(4%4,8%4,'#*%/*(5,8*8$%9,5,3*%$&%$.*%*>*#%,89%#W"81%%S&%8&$%+(*,$.*%,(4%2'5*#1

8. P7&#*%S&&(%&8%#"9*%&2%R*79*(I%

5,W"83%#'(*%"$%7,$4.*#1

9. Plug either 120 VAC or 240 VAC Power Cord

into Power Input Socket on back of welder.

E&$*- Plug will only fit one way.

10. Plug welder into a properly grounded, GFCI

protected, 120 VAC (20 amp rated) outlet or

240 V outlet. The circuit must be equipped with

delayed action-type circuit breaker or fuses.

11. Turn Power Switch ON.

12. Turn Process Selection Knob to ?/&&7%T'81

13. Turn Voltage to 1, Amperage to A and

Wire Diameter to MANUAL.

U(&4*##%

?*7*4$"&8%Y8&+

14. P.*4W%R"(*%S("X*%A*8#"&8-

a. Hold Spool Gun and point it

away from all objects.

b. Press and hold Trigger until at least 2"

of wire sticks out of the Gun. Release

Trigger. Trim wire to 2" as needed.

c. Hold Gun 2 - 3" away from piece of wood.

d. Press Trigger. When Wire touches

wood, it should bend instead of

stopping. Release Trigger.

• If Wire stops instead of bending,

turn off and unplug welder.

• Slightly tighten Tension Knob.

• Plug welder in and turn power on.

• Repeat steps c. and d. until Wire bends instead

of stopping. Trim wire to 2" as needed.

^KM`

A*8#"&8%

Y8&+

R"(*%?.&'79%

Q*89

15. Turn Power Switch OFF and unplug welder.

16. Choose Contact Tip same size as

Wire. Slide Contact Tip over Wire.

17. Replace Nozzle, trim wire to 1/2".

18. Set Spool Gun down on nonconductive,

nonflammable surface away from

any grounded objects.

19. Go to V/*(,$"&8%&8%/,3*%141

Page 12 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1 Item 63793

?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?SETUP

P&88*4$%$&%!'74,8%VDECU;V%^^N

1. Turn Power Switch OFF and unplug Welder.

2. Open Door on side of Welder.

S&&(

3. P&88*4$%?/&&7%T'8-

a. Loosen Knob without removing.

b. Plug Spool Gun Connector

into Spool Gun Socket.

c. Tighten Knob, do not over tighten.

d. Pull on Spool Gun Connector to ensure tight

connection. Re-seat if connection is not tight.

E&$*- If connection is not tight, arc will not ignite.

4. Plug Wire Feed Control Cable into

Wire Feed Control Socket. Secure by

turning collar clockwise until tight.

E&$*- Plug will only fit one way.

5. Plug Gas Cable into Gas Outlet.

Secure by wrench tightening.

Y8&+

?/&&7%T'8%

P&88*4$&(

T,#%

P,+7*

?/&&7%T'8%

?&4W*$%

R"(*%<**9%

P&8$(&7%

?&4W*$

R"(*%<**9%

P&8$(&7%

P,+7*

T,#%

V'$7*$

6. Plug Ground Clamp Cable into Negative Socket.

Twist clockwise all the way to lock in place.

7. Plug Wire Feed Power Cable into Positive Socket.

Twist clockwise all the way to lock in place.

T(&'89%

P7,5/%

P,+7*

R"(*%<**9%

U&)*(%P,+7*

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?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU? ?6AFU

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1. Y**/%.,89#%,),>%2(&5%R"(*%<**9%5*4.,8"#51

2. P7&#*%9&&(%+*2&(*%/7'33"83%"8I%

3. ?$,>%47*,(%&2%)"(*%)."7*%2**9"83%)"(*%$.(&'3.%3'81

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shade number 10 full face shield (or welding mask), ear protection, welding gloves, sleeves and apron,

ECV?BK,//(&X*9%(*#/"(,$&(I%,89%2"(*%(*#"#$,8$%)&(W%47&$.*#%)"$.&'$%/&4W*$#%#.&'79%+*%)&(8%).*8%)*79"831%%

G"3.$%2(&5%$.*%,(4%4,8%4,'#*%/*(5,8*8$%9,5,3*%$&%$.*%*>*#%,89%#W"81%%S&%8&$%+(*,$.*%,(4%2'5*#1

8. P7&#*%S&&(%&8%#"9*%&2%R*79*(I%

5,W"83%#'(*%"$%7,$4.*#1

9. Plug either 120 VAC or 240 VAC Power Cord

into Power Input Socket on back of welder.

E&$*- Plug will only fit one way.

10. Plug Welder into properly grounded, GFCI

protected, 120 VAC (20 amp rated) outlet or

240 V outlet. The circuit must be equipped with

delayed action-type circuit breaker or fuses.

11. Turn Power Switch ON.

12. Push Home button.

13. Turn Main Knob until desired

Spool Gun/Wire Type process

appears on screen.

14. Press Main Knob. Confirm correct

Gas is connected to welder.

15. Press Main Knob. Make sure Diameter

and Thickness are set to lowest settings

by turning Left and Right Knobs.

1NMN` JcT,

Spool Gun 4043 Al

16. Press Main Knob. Ready to

check Wire Drive Tension.

348 Jb1b

N1N

1NMN`

N1N

^b b

JcT,

Spool Gun 4043 Al

JNNd%@(

17. P.*4W%R"(*%S("X*%A*8#"&8-

a. Hold Spool Gun and point it

away from all objects.

b. Press and hold Trigger until at least 2" of wire

sticks out of the Gun. Trim wire to 2" as needed.

c. Hold Gun 2 - 3" away from piece of wood.

d. Press Trigger. When Wire touches wood,

it should bend instead of stopping.

• If Wire stops instead of bending,

turn off and unplug welder.

• Slightly tighten Tension Knob.

• Plug welder in and turn power on.

• Reset Welder to desired process

and check settings.

• Repeat steps c. and d. until Wire bends instead

of stopping. Trim wire to 2" as needed.

^KM`

A*8#"&8%

Y8&+

R"(*%?.&'79%

Q*89

18. Turn Power Switch OFF and unplug welder.

19. Choose Contact Tip same size as

Wire. Slide Contact Tip over Wire.

20. Replace Nozzle, trim wire to 1/2".

21. Set Spool Gun down on nonconductive,

nonflammable surface away from

any grounded objects.

Page 14 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1 Item 63793

?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?SETUP

V/*(,$"&8

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U(&$*4$"X*%3*,(%5'#$%+*%)&(8%).*8%'#"83%$.*%R*79*(_%5"8"5'5%#.,9*%8'5+*(%JN%2'77%2,4*%

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

(*#/"(,$&(I%,89%2"(*%(*#"#$,8$%)&(W%47&$.*#%)"$.&'$%/&4W*$#%#.&'79%+*%)&(8%).*8%)*79"831%%

%%%

AV%U;6!6EA%S6@AB%<;VD%@?UBOaC@ACVE-%

S&%8&$%&/*8%3,#%)"$.&'$%/(&/*(%X*8$"7,$"&81%%<"[%3,#%7*,W#%"55*9",$*7>1 Shielding gas can displace

air and cause rapid loss of consciousness and death. ?."*79"83%3,#%)"$.&'$%4,(+&8%9"&["9*%4,8%+*%

*X*8%5&(*%.,Z,(9&'#%+*4,'#*%,#/.>[",$"&8%4,8%#$,($%)"$.&'$%2**7"83%#.&($8*##%&2%+(*,$.1

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Q,#"4%R*79"83%A*4.8"H'*

1. Press (and hold) Spool Gun Trigger and contact

the area to be welded with wire to ignite arc.

• E,((&)%R*79- Push the wire in a steady

straight line. This is called a stringer bead.

?$("83*(%Q*,9

• R"9*%R*79: Push the wire back and forth

across the joint. This is called a weave bead

and takes practice to perform properly.

R*,X*%Q*,9

2. Direct the welding wire straight into the join:.

• 45° angle for fillet welds.

• 90° angle for butt welds,

R*79%DCT%T'8%,837*#I%%

X"*)*9%2(&5%2(&8$%&2%)*79%=&"8$1

45°

2"77*$%)*79%=&"8$

90°

+'$$%)*79%=&"8$

Page 15<&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1Item 63793

?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU? SETUP

3. The Spool Gun should be tilted so that wire

is angled anywhere from straight on and 15°

away from the direction you are welding. The

amount of tilt is called the push angle.

R*79%

S"(*4$"&8

U'#.%@837*

0-15°

4. The Contact Tip should remain within 1/2"

of the work surface. This distance is called

CTWD - Contact Tip to Work Distance.

PARS%%

(up to 1/2")

;*2*(%$&%Q,#"4%R*79"83%#*4$"&8%"8%>&'(%!'74,8%)*79*(\#%

5,8',7%2&(%(*5,"8"83%)*79"83%"8#$('4$"&8#1

Page 16 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1 Item 63793

?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?SETUP

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Q,#*%5,$*(",7%5*7$#%,),>I%%

7*,X"83%,%.&7*%"8%$.*%)*791

UV??CQG6%P@F?6?%@ES%?VGFACVE?

1. R&(W/"*4*%&X*(.*,$"83-%

Reduce current and/or wire feed speed.

2. A(,X*7%#/**9%$&&%#7&)-

Increase travel speed and ensure

that travel speed is kept steady.

3. 6[4*##"X*%5,$*(",7%,$%)*79-%

Reduce wire feed speed.

TOP

VIEW

P(&&W*90R,X>%Q*,9

UV??CQG6%P@F?6?%@ES%?VGFACVE?

1. C8,44'(,$*%)*79"83-

Use two hands or rest hand on steady surface.

2. C84&8#"#$*8$%$(,X*7%#/**9-%

Maintain steady travel speed.

3. PARS%$&&%7&83-

Reduce CTWD.

TOP

VIEW

U&(&#"$>

?5,77%4,X"$"*#%&(%.&7*#%"8%$.*%+*,91

UV??CQG6%P@F?6?%@ES%?VGFACVE?

1. C84&((*4$%/&7,("$>-

Check that polarity is set correctly

for type of welding.

2. Insufficient shielding gas (MIG only):

Increase flow of gas.

Clean nozzle.

Maintain proper CTWD.

3. Incorrect shielding gas (MIG only):

Use shielding gas recommended by wire supplier.

4. S"($>%)&(W/"*4*%&(%)*79"83%)"(*-

Clean workpiece down to bare metal.

Make certain that wire is clean and free

from oil, coatings, and other residues.

5. C84&8#"#$*8$%$(,X*7%#/**9-%

Maintain steady travel speed.

6. PARS%$&&%7&83-

Reduce CTWD.

TOP

VIEW

6[4*##"X*%?/,$$*(

<"8*%#/,$$*(%"#%8&(5,71%

?/,$$*(%$.,$%"#%3(,"8>%,89%7,(3*%"#%,%/(&+7*51

UV??CQG6%P@F?6?%@ES%?VGFACVE?

1. S"($>%)&(W/"*4*%&(%)*79"83%)"(*-

Clean workpiece down to bare metal.

Make certain that wire is clean and free

from oil, coatings, and other residues.

2. C84&((*4$%/&7,("$>-

Check that polarity is set correctly

for type of welding.

3. Insufficient shielding gas (MIG only):

Increase flow of gas.

Clean nozzle.

Maintain proper CTWD.

4. R"(*%2**9"83%$&&%2,#$-%

Reduce wire feed speed.

5. PARS%$&&%7&83-

Reduce CTWD.

TOP

VIEW

R*79%U(&+7*5#

Page 17<&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1Item 63793

?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU? SETUP

D,"8$*8,84*%,89%?*(X"4*

AV%U;6!6EA%?6;CVF?%CE]F;OI%<C;6%@ES%QF;E?-%

F8/7'3%$.*%)*79*(I%(*#$%$.*%?/&&7%T'8%&8%,%.*,$K/(&&2I%*7*4$("4,77>%8&8K4&89'4$"X*%#'(2,4*I%

,89%,77&)%,77%/,($#%&2%$.*%R*79*(%$&%4&&7%$.&(&'3.7>%+*2&(*%#*(X"4*1%

1. Q6<V;6%6@PB%F?6I inspect the general

condition of the Spool Gun. Check for:

• loose hardware,

• misalignment or binding of moving parts,

• damaged cord/electrical wiring,

• frayed or damaged cables,

• cracked or broken parts, and

• any other condition that may

affect its safe operation.

2. @<A6;%6!6;O%F?6I%inspect and

clean Nozzle and Contact Tip.%%

3. @<A6;%6!6;O%F?6I Store in a

clean and dry location.

4. U6;CVSCP@GGOI clean Barrel, replace Inlet Guide

E&ZZ7*%,89%P&8$,4$%A"/%C8#/*4$"&8%,89%P7*,8"83

1. D,W*%#'(*%$.,$%$.*%?/&&7%T'8%"#%4&5/7*$*7>%

4&&7%,89%$.,$%$.*%U&)*(%P&(9%"#%'8/7'33*9%

2(&5%$.*%*7*4$("4,7%&'$7*$%+*2&(*%/(&4**9"831

2. Pull the Nozzle to remove it.

3. Scrub the interior of the Nozzle

clean with a wire brush.

4. Examine the end of the Nozzle. The end should be

flat and even. If the end is uneven, chipped, melted,

cracked, or otherwise damaged, replace Nozzle.

5. Unscrew the Contact Tip counterclockwise

and slide it off the welding wire to remove.

6. Scrub the outside of the Tip clean

with a wire brush. Clean out the inside of the

tip with a tip cleaner (sold separately).

7. Examine the shape of the hole at the end of the

Contact Tip. It should be an even circle; if it is

oblong or has any bulges in it, replace Contact Tip.

P7*,8"83%Q,((*7

1. Remove Nozzle and Contact Tip.

2. Remove Hex Bolt, then pull Barrel out.

3. Using compressed air, blow out Barrel.

4. Replace Barrel, Contact Tip and Nozzle.

B*[%

Q&7$

Q,((*7

;*/7,4"83%C87*$%T'"9*

1. Remove Hex Set Screw.

2. Pull out Inlet Guide.

3. Replace Inlet Guide.

4. Replace Hex Set Screw.

SV%EVA%&X*($"3.$*81%%68#'(*%C87*$%T'"9*%

"#%#8'31%%VX*($"3.$*8"83%)"77%4,'#*%

/*(5,8*8$%9,5,3*%$&%C87*$%T'"9*1

B*[%?*$%

?4(*)

C87*$%

T'"9*

Page 18 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1 Item 63793

?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?SETUP

A(&'+7*#.&&$"83

U(&+7*5 U&##"+7*%P,'#*# G"W*7>%?&7'$"&8#

Wire feed motor

runs but wire does

not feed properly

1. Tension Knob is too tight.

2. Damaged Gun, cable, or liner assembly.

3. Tension Knob is too tight.

1. Tighten Tension Knob so it applies only

enough pressure to prevent continued

spinning after the Gun Trigger is released.

2. Have a qualified technician inspect these

parts and replace as necessary.

3. Loosen Tension Knob so it applies only

enough pressure to prevent continued

spinning after the Gun Trigger is released.

Wire creates a bird’s

nest during operation

1. Tension Knob is too tight.

2. Incorrect Contact Tip size.

3. Damaged liner.

1. Loosen Tension Knob

2. Replace with the proper tip for wire used.

3. Have a qualified technician inspect

and repair/replace as necessary.

Wire stops

during welding

1. Gun liner is clogged or worn.

2. Wire is tangled on the spool.

3. Tension Roller is not making

enough contact with wire.

1. Check gun liner for obstruction, blow out with

compressed air. Have liner replaced if necessary.

2. Check wire for cross winding or tangled spool.

3. Check Tension Knob and ensure it is set properly.

Wire feeds, but arc

does not ignite

1. Improper ground connection.

2. Improperly sized Contact Tip.

3. Excessively worn Contact Tip.

4. Dirty Contact Tip.

1. Make certain that the workpiece is contacted

properly by the Ground Clamp and that

the workpiece is properly cleaned near the

ground clamp and the welding location.

2. Verify that Contact Tip is the proper size

for welding wire. If needed, replace

Contact Tip with proper size and type.

3. Check that the hole in the tip is not

deformed or enlarged. If needed, replace

Contact Tip with proper size and type.

4. Properly clean Contact Tip.

Porosity in the

weld metal

1. Gun is being used too far away from workpiece.

2. Dirty welding wire is introducing

contamination into the weld.

1. Check CTWD (contact tip to work distance).

2. Make certain that welding wire is clean

and free of rust and residues.

Welding arc

not stable

1. Wire not feeding properly.

2. Incorrect or damaged Contact Tip.

3. Loose Gun cable or ground cable.

4. Damaged Gun or loose connection within Gun.

5. Gas coverage may be insufficient or too high.

6. Poor connection with workpiece.

1. See first Troubleshooting section above.

2. Replace Contact Tip.

3. Check to ensure that all connections are tight.

4. Have a qualified technician inspect

and repair/replace as necessary.

5. Ensure gas flow rate is set according to Settings Chart.

Make sure Gun Cable Connector is fully inserted into

Wire Feed mechanism with no O-Rings exposed.

6. Check the ground clamp connection to the workpiece

and machine. Ensure the Gun is properly secured.

<&77&)%,77%#,2*$>%/(*4,'$"&8#%).*8*X*(%9",38&#"83%&(%#*(X"4"83%$.*%*H'"/5*8$1

Page 19<&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1Item 63793

?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU? SETUP

U,($#%G"#$%,89%S",3(,5

U,($ S*#4("/$"&8 e$>

1 Handle 1

2 Trigger 1

3 Block 1

4 Cover 1

5 Hanger Hook 1

6 Spool Shaft 1

7 Spool Tensioner 1

8 Spacer 1

9 Spool Tension Knob 1

10 Spool Lock Knob 1

11 Latch 1

12 Spool Cover Release Button 1

14 Drive Roller 1

15 Tension Spring 1

16 Bushing 1

17 Tension Roller 1

18 Tension Knob 1

19 Inlet Guide 1

20 Tension Arm 1

21 Tension Arm Shaft 1

22 Bracket 1

U,($ S*#4("/$"&8 e$>

23 Motor And Gear Box 1

24 Gas Connector 1

25 Wire Feeder Assembly 1

26 Conducting Bar 1

27 Liner Assembly 1

28 O-Ring 7.65X1.78 2

29 Barrel 1

30 Insulator 1

31 Gas Diffuser 1

32 Contact Tip 4

33 Nozzle 12mm 1

35 Internal Gas Hose 1

36 Front Spring Cable Support 1

37 Cable Assembly 1

38 Back Spring Cable Support 1

39 Connector 1

40 Connector Insulator 1

41 Connector 1

42 Gas Hose Plug 1

43 Wire Feed Plug 1

;*4&(9%U(&9'4$\#%?*(",7%E'5+*(%B*(*-%

E&$*- If product has no serial number, record month and year of purchase instead.

E&$*- Some parts are listed and shown for illustration purposes only,

and are not available individually as replacement parts.

3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • 1-888-380-0318

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.

UG6@?6%;6@S%AB6%<VGGVRCET%P@;6<FGGO

THE 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.

Harbor Freight Tools Vulcan VA-SPLG Owner's manual

Brand: Harbor Freight Tools

Model: Vulcan VA-SPLG

Category: Welding System

Type: Owner's manual

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Harbor Freight Tools Vulcan VA-SPLG Owner's manual

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