Harbor Freight Tools 225 Amp_AC, 240 Volt, Stick Welder Product manual

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.
Visit our website at: http://www.harborfreight.com
Email our technical support at: tech@harborfreight.com
When unpacking, make sure that the product is intact
and undamaged. If any parts are missing or broken,
please call 1-800-444-3353 as soon as possible.
Copyright© 2011 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 and service may not be included.
Read this material before using this product.
Failure to do so can result in serious injury.
SAVE THIS MANUAL.
Table of Contents
SAFETY
Safety.......................................................... 2
Setup........................................................... 7
Specifications.............................................. 7
Basic Welding.............................................. 8
Welding Tips................................................ 9
Maintenance............................................... 13
Parts List and Diagram............................... 14
Warranty..................................................... 16
WARNING SYMBOLS AND DEFINITIONS
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.
SETUP
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.
BASIC WELDING
IMPORTANT SAFETY INFORMATION
Read all safety warnings and instructions.
Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.
Save all warnings and instructions for future reference.
General Safety
PROTECT yourself and others. Read and understand this information.
WELDING TIPS
1. Before use, read and understand
manufacturer′s instructions,
Material Safety Data Sheets (MSDS′s),
employer′s safety practices, and ANSI Z49.1.
2. Keep out of reach of children.
Keep children and bystanders away while operating.
3. Place the welder on a stable location before use.
If it falls while plugged in, severe injury,
electric shock, or fire may result.
MAINTENANCE
4. Do not overreach.
Keep proper footing and balance at all times.
5. Stay alert, watch what you are doing and use
common sense when operating a welder.
Do not use a welder while you are tired or under
the influence of drugs, alcohol or medication.
A moment of inattention while operating welders
may result in serious personal injury.
6. Avoid unintentional starting. Make sure you are
prepared to begin work before turning on the Welder.
Page 2
7. Never leave the Welder unattended while
energized. Turn power off if you have to leave.
8. The warnings, precautions, and instructions
discussed in this instruction manual cannot
cover all possible conditions and situations
that may occur. It must be understood by the
operator that common sense and caution are
factors which cannot be built into this product,
but must be supplied by the operator.
9. This product, when used for welding and similar
applications, contains or produces a chemical
known to the State of California to cause cancer
and birth defects (or other reproductive harm).
(California Health & Safety Code § 25249.5, et seq.)
10. Handling the cord on this product will
expose you to lead, a chemical known to
the State of California to cause cancer, and
birth defects or other reproductive harm.
Wash hands after handling. (California Health
& Safety Code § 25249.5, et seq.)
For technical questions, please call 1-800-444-3353.
SKU 69029
Fume and Gas Safety
2. Do not use near degreasing or
painting operations.
3. Keep head out of fumes.
Do not breathe exhaust fumes.
4. Use enough ventilation, exhaust at arc, or
both, to keep fumes and gases from breathing
zone and general area. If engineering controls
are not feasible, use an approved respirator.
5. Work in a confined area only if it
is well-ventilated, or while wearing
an air-supplied respirator.
6. Have a recognized specialist in
Industrial Hygiene or Environmental Services
check the operation and air quality
and make recommendations
for the specific welding situation.
Follow OSHA guidelines for
Permissible Exposure Limits (PEL’s) and
the American Conference of Governmental
Industrial Hygienists recommendations for
Threshold Limit Values (TLV’s) for fumes and gases.
SETUP
1. Exposure to welding or cutting
exhaust fumes can increase the risk
of developing certain cancers, such as
cancer of the larynx and lung cancer.
Also, some diseases that may be linked to exposure
to welding or 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
SAFETY
FUMES AND GASES can be hazardous to your health.
2. Wear leather leggings, fire resistant shoes
or boots during use. Do not wear pants with
cuffs, shirts with open pockets, or any clothing
that can catch and hold molten metal or sparks.
3. Keep clothing free of grease, oil,
solvents, or any flammable substances.
Wear dry, insulating gloves and protective clothing.
4. Wear an approved head covering to protect
the head and neck. Use aprons, cape, sleeves,
shoulder covers, and bibs designed and
approved for welding and cutting procedures.
5. When welding/cutting overhead or in confined
spaces, wear flame resistant ear plugs or
ear muffs to keep sparks out of ears.
Electrical Safety
ELECTRIC SHOCK can KILL.
1. Turn off, disconnect power, and
discharge electrode to ground before setting
down torch/electrode holder and before service.
6. Do not expose welders to rain or wet conditions.
Water entering a welder will increase
the risk of electric shock.
2. Do not touch energized electrical parts.
Wear dry, insulating gloves. Do not touch electrode
holder, electrode, welding torch, or welding wire with
bare hand. Do not wear wet or damaged gloves.
7. Do not abuse the cord. Never use the cord
for carrying, pulling or unplugging the
welder. Keep cord away from heat, oil, sharp
edges or moving parts. Damaged or entangled
cords increase the risk of electric shock.
3. Connect to grounded, GFCI‑protected
power supply only.
4. Do not use near water or damp objects.
5. People with pacemakers should consult their
physician(s) before use. Electromagnetic fields
in close proximity to heart pacemaker could cause
pacemaker interference or pacemaker failure.
SKU 69029
8. Do not use outdoors.
9. Insulate yourself from the workpiece and ground.
Use nonflammable, dry insulating material if possible,
or use dry rubber mats, dry wood or plywood, or
other dry insulating material large enough to cover
your full area of contact with the work or ground.
For technical questions, please call 1-800-444-3353.
Page 3
WELDING TIPS
1. Wear ANSI-approved welding eye protection
featuring at least a number 10 shade lens rating.
MAINTENANCE
ARC RAYS can injure eyes and burn skin.
BASIC WELDING
Arc Ray Safety
Fire Safety
ARC AND HOT SLAG can cause fire.
SAFETY
1. Clear away or protect flammable objects.
Remove or make safe all combustible materials for a
radius of 35 feet (10 meters) around the work area.
Use a fire resistant material to cover or block all open
doorways, windows, cracks, and other openings.
2. Keep ABC-type fire extinguisher near
work area and know how to use it.
SETUP
3. Maintain a safe working environment.
Keep the work area well lit.
Make sure there is adequate surrounding workspace.
Keep the work area free of obstructions,
grease, oil, trash, and other debris.
4. Do not operate welders in atmospheres
containing dangerously reactive or
flammable liquids, gases, vapors, or dust.
Provide adequate ventilation in work areas
to prevent accumulation of such substances.
Welders create sparks which may ignite flammable
substances or make reactive fumes toxic.
5. If working on a metal wall, ceiling, etc.,
prevent ignition of combustibles on the
other side by moving the combustibles to a
safe location. If relocation of combustibles is
not possible, designate someone to serve as
a fire watch, equipped with a fire extinguisher,
during the cutting process and for at least one
half hour after the cutting is completed.
6. Do not weld or cut on materials having
a combustible coating or combustible
internal structure, as in walls or ceilings, without
an approved method for eliminating the hazard.
7. Do not dispose of hot slag in containers
holding combustible materials.
8. After welding, make a thorough examination
for evidence of fire. Be aware that easily
visible smoke or flame may not be present
for some time after the fire has started.
BASIC WELDING
9. Do not apply heat to a container that has held
an unknown substance or a combustible
material whose contents, when heated,
can produce flammable or explosive vapors.
Clean and purge containers before applying heat.
Vent closed containers, including castings,
before preheating, welding, or cutting.
Welder Use and Care
1. Do not use the welder if the switch does not turn
it on and off. Any welder that cannot be controlled
with the switch is dangerous and must be repaired.
WELDING TIPS
2. Disconnect the plug from the power
source before making any adjustments,
changing accessories, or storing welders.
Such preventive safety measures reduce the
risk of starting the welder accidentally.
3. Prevent unintentional starting. Ensure the switch
is in the off-position before connecting to power
source or moving the welder. Carrying or energizing
welders that have the switch on invites accidents.
4. Store idle welders out of the reach of children and
do not allow persons unfamiliar with the welder or
these instructions to operate the welder. Welders
are dangerous in the hands of untrained users.
5. Use the welder and accessories in accordance
with these instructions, taking into account the
working conditions and the work to be performed.
Use of the welder for operations different from those
intended could result in a hazardous situation.
MAINTENANCE
Page 4
For technical questions, please call 1-800-444-3353.
SKU 69029
4. Unplug before maintenance. Unplug the Welder
from its electrical outlet before any inspection,
maintenance, or cleaning procedures.
SETUP
SAVE THESE INSTRUCTIONS.
Grounding
TO PREVENT ELECTRIC SHOCK AND DEATH
FROM INCORRECT GROUNDING WIRE CONNECTION:
Check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded.
Have a plug installed by a certified electrician.
Do not use the welder if the power cord or plug is damaged. If damaged, have it repaired by a service facility
before use. If the plug will not fit the outlet, have a proper outlet installed by a qualified electrician,
do not use adapter plugs.
1. The green wire inside the cord is connected to
the grounding system in the welder. The green
wire in the cord must be the only wire connected
to the welder’s grounding system and must never
be attached to an electrically “live” terminal.
Never leave the grounding wire disconnected
or modify the Power Cord Plug in any way.
DO NOT USE
125 V~ PLUG.
NOTE SIZE
DIFFERENCE.
2. Make sure the tool is connected to an outlet having
the same configuration as the plug. If the tool must
be reconnected for use on a different type of electric
circuit, the reconnection should be made by qualified
service personnel; and after reconnection, the tool
should comply with all local codes and ordinances.
3. A 250 V~ plug will need to be installed
by a certified electrician before use.
250 V~ 3-Prong Plug (6-50p) and Outlet (6-50r)
(for up to 250 V~ and up to 50 A)
MAINTENANCE
4. The plug shown (NEMA 6-50p) is for use on a
50 A circuit. A different 250 V~ plug and outlet
combination may be used, provided it is rated
to handle the electrical requirements of the tool
and is installed by a certified electrician.
Note: Although 125 V~ plugs may look similar, the
required plug is much larger, see illustration.
SKU 69029
For technical questions, please call 1-800-444-3353.
BASIC WELDING
2. Have your welder serviced by a qualified
repair person using only identical
replacement parts. This will ensure that
the safety of the welder is maintained.
3. Maintain labels and nameplates on the Welder.
These carry important information.
If unreadable or missing, contact
Harbor Freight Tools for a replacement.
WELDING TIPS
1. Maintain welders. Check for misalignment or
binding of moving parts, breakage of parts
and any other condition that may affect the
welder’s operation. If damaged, have the
welder repaired before use. Many accidents
are caused by poorly maintained welders.
SAFETY
Maintenance
Page 5
Extension Cords
Do not use an extension cord on this welder.
SAFETY
Replacement Cords
1. A qualified electrician can install a UL‑listed, 3
wire cords of the same thickness and length
as the one already installed on this welder.
3. Do not patch cords of any length together for this
item, patches may allow moisture to penetrate
the insulation, resulting in electric shock.
SETUP
2. Do not install a thinner or longer
cord on this welder.
Symbology
Workpiece Ground Cable
Electrode Cable
BASIC WELDING
Overheat Shutdown Indicator
Cooling Fan
Housing Ground Point
V~
A
OCV
KVA
AWG
Volts Alternating Current
Amperes
Open Circuit Voltage
Kilovolt Amperes
(Volts / 1000 * Amperes)
American Wire Gauge
WELDING TIPS
Specifications
MAINTENANCE
Power Input
240V~, 60Hz, 47A (A 50A dedicated circuit is required)
Max OCV
48V
Output Current
60 - 225 A, AC (270 A peak)
Capacity
1/16" to 1/4" thick and up mild steel
Rated Duty Cycle
20% @ 225 amps
Weldable Materials
Steel, Cast Iron
Electrode Diameter
1/16" - 1/4"
Included Accessories
Handheld face shield, Chipping hammer with wire brush, five electrodes
Page 6
For technical questions, please call 1-800-444-3353.
SKU 69029
Setup
SAFETY
Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this
manual including all text under subheadings therein before set up or use of this product.
TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION:
Turn the Power Switch off and unplug the welder before assembly.
Face Shield Assembly
B
A
A. press the tabs through the holes and then
Round
Tab
B
A
B. slide the tabs forward from the back,
locking the round tab in place.
Handle
2. Wear heavy-duty work gloves, the edges of the
filter lens may be sharp. Remove any protective
film from both sides of the filter lens. Slide the
filter lens into the helmet behind the holding tabs.
Make sure that the filter lens fits securely and
that light cannot leak around its edges.
Filter Lens
Face Shield
(viewed from back)
Components and Controls
Current
Indicator
WELDING TIPS
Power
Light
BASIC WELDING
Face Shield
(viewed from front)
Overload
Light
Power
Switch
MAINTENANCE
Current
Knob
Grounding Clamp
Electrode Holder
SKU 69029
SETUP
1. Attach the handle to the Face Shield by lining up
the two rectangular tabs on the handle with the
corresponding holes in the face shield and
For technical questions, please call 1-800-444-3353.
Page 7
Basic Welding
SAFETY
To Prevent Serious Injury and Permanent Eye Damage:
Wear protective gear during use; an ANSI-approved welding mask shade 10, ear protection, welding
gloves and apron, NIOSH-approved respirator, and fire resistant work clothes without pockets.
Light from the arc can cause permanent damage to the eyes and skin. Do not breathe arc fumes.
Duty Cycle (Duration of Use)
SETUP
20% RATED (225A)
DUTY CYCLE
2 minutes welding
followed by
at least 8 minutes of rest
BASIC WELDING
Avoid damage to the Welder by not welding for more than
the prescribed duty cycle time. The duty cycle defines the
number of minutes, within a 10 minute period, during
which a given welder can produce a particular welding
current without overheating. For example, this Welder, at
its rated output, has a 20% duty cycle and must be
allowed to rest for at least 8 minutes after every
2 minutes of continuous welding. Failure to carefully
observe duty cycle limitations can easily over‑stress a
welder’s power generation system contributing to
premature welder failure.
Thermal Overload Protection - This Welder has an
internal thermal protection system to help prevent
this sort of over-stress. When the unit overheats, it
automatically shuts down and the Overload Light
turns on. The Welder automatically returns to service
after cooling off. Rest the Electrode Holder on an
electrically non-conductive, heat‑proof surface, such as
a concrete slab, well clear of the ground clamp while
allowing the welder to cool with the Power Switch on, so
that the internal fan will help cool the Welder. When the
Welder can be used again, use shorter welding periods
and longer rest periods to prevent needless wear.
Setting up the Weld
WELDING TIPS
1. Make practice welds on pieces of scrap the same
thickness as your intended workpiece to practice
technique before welding anything of value.
Clean the weld surfaces thoroughly with a wire brush
or angle grinder; there must be no rust, paint, oil, or
other materials on the weld surfaces, only bare metal.
MAINTENANCE
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.
Page 8
clamps
workpieces
Clean surfaces
to bare metal.
Chamfer thick workpieces.
For technical questions, please call 1-800-444-3353.
SKU 69029
1. Place the Welder on a level surface that
can bear its weight near the work area.
6. Stroke the workpiece lightly to ignite the arc.
Tips for igniting the arc:
2. Secure the Grounding Clamp to a clean,
exposed metal part of the workpiece.
a. Stroke the surface with the electrode.
3. Place the uncoated end of the electrode
inside the jaws of the Electrode Holder.
Electrode types vary for welding different metals.
c. Tap the surface with the electrode.
b. Strike the surface like a match with the electrode.
7. When the arc ignites, tilt the electrode
forward and hold it near the workpiece.
4. Turn the Current Knob to adjust the welding current.
The approximate current setting can
be read on the Current Indicator.
8. When finished welding; lift the electrode from
the workpiece and turn the Welder off.
9. Place the handle down on a nonflammable,
nonconductive surface.
10. To prevent accidents disconnect the tool
from its power supply after use. Allow the
tool to cool down, clean, then store the
tool indoors out of children’s reach.
Welding Tips
A good way to test welding technique is to examine a weld’s appearance after it has cooled and the slag has been
removed. Then, better welding can be learned by adjusting your weld technique to remedy any problems found.
Cleaning the Weld
A typical Weld before cleaning.
weld bead
slag
spatter
WELDING TIPS
TO PREVENT SERIOUS INJURY:
Continue to wear ANSI-approved safety
goggles and protective wear when
cleaning a weld.
Sparks or chips may fly when cleaning.
BASIC WELDING
WARNING! TO PREVENT SERIOUS INJURY
AND DEATH: If the operator is not holding
the Electrode Holder, it must be sitting on
a nonconductive, nonflammable surface.
The Stick Welder will immediately turn on
when the Power Switch is turned on.
SETUP
After practice welding for
a few seconds, STOP and
examine your weld using the
guidelines starting below.
IMPORTANT: A 50A dedicated circuit is required.
5. Plug the power cord into a grounded
240V outlet and turn the Welder on.
SAFETY
Basic Welding Technique
base metal
1. A weld will be covered by slag:
use a Chipping Hammer to knock this off.
Be careful not to damage the
weld or base material.
MAINTENANCE
2. Then, use a Wire Brush to further
clean the weld or use an angle grinder
(sold separately) to shape the weld.
SKU 69029
For technical questions, please call 1-800-444-3353.
Page 9
Strike Test
SAFETY
A test weld on a PIECE OF SCRAP can be
tested by using the following procedure.
WEAR ANSI-APPROVED SAFETY GOGGLES
DURING THIS PROCEDURE.
clamp
dead-blow hammer
WARNING! This test WILL damage the weld it is
performed on. This test is ONLY an indicator of weld
technique and is not intended to test working welds.
1. After two scraps have been welded together and the
weld has cooled, clamp one scrap in a sturdy vise.
2. Stay clear from underneath while you strike
the opposite scrap with a heavy hammer,
preferably a dead-blow hammer.
SETUP
3. A GOOD WELD will deform but not break, as shown
on top.
A POOR WELD will be brittle and snap at the
weld, as shown on bottom.
BASIC WELDING
Example Weld Diagrams
dead-blow hammer
SCRAP
workpiece
GOOD WELD
bends and is not brittle
clamp
SCRAP
workpiece
POOR WELD
snaps or cracks
CLEAN WELDS FIRST! Stick welds will have a coat of slag over them until cleaned.
Good
Weld
WELDING TIPS
Current
Too Low
Current
Too High
Weld Speed
Too Fast
Weld Speed
Too Slow
Arc Length
Too Short
Arc Length
Too Long
TO CORRECT:
TO CORRECT:
Use
Current Knob
to increase
Current
Use
Current Knob
to decrease
Current
TO CORRECT:
Weld slower
TO CORRECT:
Weld faster
TO CORRECT:
Increase
distance
TO CORRECT:
Decrease
distance
MAINTENANCE
Page 10
For technical questions, please call 1-800-444-3353.
SKU 69029
Diagnosis - Workpiece Heat Control / Weld Penetration
PROPER PENETRATION
EXCESS PENETRATION OR
BURN-THROUGH
Not hot enough
Ideal heat
Too hot
SAFETY
INADEQUATE PENETRATION
How to increase workpiece heat
and increase penetration:
How to reduce workpiece heat
and limit penetration:
a.Increase current.
b.Weld more slowly.
(to weld THINNER workpieces properly)
a.Decrease current.
b.Weld more quickly.
SETUP
(to weld THICKER workpieces properly)
Penetration (Workpiece Heat Control)
PROPER PENETRATION
Weld is visible underneath and
bulges slightly on top.
INADEQUATE PENETRATION
Weld does not contact the joint
fully, just on the surface.
BASIC WELDING
EXCESS PENETRATION OR
BURN-THROUGH
Weld droops on top and
underneath or falls through
entirely, making a hole.
PROFILE VIEWS
Weld Not Adhering Properly
POSSIBLE CAUSES AND SOLUTIONS
1. Incorrect welding technique:
Keep arc on leading edge of weld puddle.
Hold electrode at proper angles.
2. Insufficient weld heat:
Slow down so fill material has time to melt
into the weld location. Increase current.
3. Workpieces too thick/close:
Bevel thick workpieces, allow slight
gap, and weld in several passes.
4. Insufficient weld material:
Increase amount of fill material.
WELDING TIPS
POSSIBLE CAUSES AND SOLUTIONS
1. Workpiece overheating:
Reduce current.
2. Welding speed too slow:
Increase welding speed and ensure
that welding speed is kept steady.
POSSIBLE CAUSES AND SOLUTIONS
PROFILE
VIEW
SKU 69029
1. Incorrect welding technique:
Place stringer bead at correct place in joint.
Adjust workpiece position or weld angle to permit
proper welding to bottom of piece.
Keep arc on leading edge of weld puddle.
Hold gun at proper angles.
2. Insufficient weld heat:
Increase current.
3. Dirty workpiece:
Clean workpiece down to bare metal.
For technical questions, please call 1-800-444-3353.
Page 11
MAINTENANCE
Gaps present between weld and previous bead or between weld and workpiece. See areas below.
Bend at Joint
POSSIBLE CAUSES AND SOLUTIONS
SAFETY
PROFILE
VIEW
Coat of Slag Over Weld
1. Improper clamping:
Clamp workpieces securely.
Make tack welds to hold workpieces.
2. Excessive heat:
Weld a small portion and allow to cool
before proceeding.
Increase weld speed.
Slag is a necessary part of a stick weld. It shields
the weld from impurities. Clean off the slag with the
Chipping Hammer and Wire Brush after welding.
TOP
VIEW
SETUP
PARTIALLY CHIPPED AWAY TO SHOW WELD
Porosity - Small cavities or holes in the bead.
POSSIBLE CAUSES AND SOLUTIONS
BASIC WELDING
TOP
VIEW
1. Dirty workpiece or electrode:
Clean workpiece down to bare metal.
Make certain that fill material and electrode are clean
and free from oil, coatings, and other residues.
2. Inconsistent welding speed:
Maintain steady weld speed.
Crooked/Wavy Bead
POSSIBLE CAUSES AND SOLUTIONS
TOP
VIEW
1. Inaccurate welding:
Use two hands or rest hand on steady surface.
2. Inconsistent welding speed:
Maintain steady weld speed.
WELDING TIPS
Excessive Spatter
POSSIBLE CAUSES AND SOLUTIONS
Dirty workpiece or electrode:
Clean workpiece down to bare metal.
Make certain that electrode is clean and free
from oil, coatings, and other residues.
TOP
VIEW
MAINTENANCE
Burn-Through -
Base material melts away, leaving a hole in the weld.
POSSIBLE CAUSES AND SOLUTIONS
TOP
VIEW
Page 12
Fine spatter is normal. Spatter that is
grainy and large is a problem.
1. Workpiece overheating:
Reduce current.
2. Welding speed too slow:
Increase welding speed and ensure
that welding speed is kept steady.
3. Excessive material at weld:
Reduce amount of fill material.
For technical questions, please call 1-800-444-3353.
SKU 69029
TO PREVENT SERIOUS INJURY, FIRE AND BURNS:
Unplug the Welder, rest the tool on a heat-proof, electrically non-conductive surface, and allow
all parts of the Welder to cool thoroughly before service.
SAFETY
Maintenance and Service
1. Periodically remove the Right and Left side panels, and using compressed air, blow out all dust from the interior.
2. Store in a clean and dry location.
Problem
Power Switch Lights, but
Welder Does Not Function
When Switched ON
Power Switch Does Not
Light When Switched On
Possible Cause
1. Tripped thermal
protection device.
2. Faulty connection.
Unit is not connected
to outlet properly or
outlet is unpowered
Solution
1. Reduce duration or frequency of welding periods
to help reduce wear on the welder.
Refer to Duty Cycle (Duration of Use)
on page 8.
2. Qualified technician must check connection.
Verify the voltage at the outlet and the connection to
the outlet.
If voltage is not present at outlet, check circuit
breaker/GFCI devices; if any are tripped, determine
and remedy cause before resetting. Verify that the
circuit is designed to supply the required input
1. Incorrect line voltage.
Weak Arc Strength
Welding Arc Not Stable
SKU 69029
1. Check the line voltage and, if insufficient, have
a licensed electrician remedy the situation.
2. Improper gauge or length 2. Extension cords are not recommended.
of extension cord.
If possible, eliminate the use of an extension cord.
If an extension cord is needed, refer
to the guidelines on page 5.
1. Loose Electrode Handle
cable or Ground cable.
2. Damaged Electrode
Handle or loose
connection within
Electrode Handle.
3. Adjust current setting.
1. Check to ensure that all connections are tight.
2. Have a qualified technician inspect and
repair or replace, as necessary.
3. Make sure setting matches recommended setting.
For technical questions, please call 1-800-444-3353.
Page 13
WELDING TIPS
IMPORTANT!
Be CERTAIN to shut off the Welder, disconnect it from power, and discharge the Electrode Holder to ground
before adjusting, cleaning, or repairing the unit.
MAINTENANCE
Troubleshooting
BASIC WELDING
SETUP
3. For optimal weld quality, clean and inspect the Contact points before each use.
Parts List and Diagrams
SAFETY
PLEASE READ THE FOLLOWING CAREFULLY
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM IN THIS MANUAL
AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER NOR 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.
SETUP
Parts List
Part
BASIC WELDING
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Description
Handle
Current Indicator
Cover
Pointer
Spring
Rod Spring
Plunger Bracket
Grommet
Front Panel
Overload Light
Power Light
Electrode Holder Cable
Current Knob
Ground Clamp Cable
Qty
1
1
1
1
2
1
1
1
1
1
1
1
1
1
Part
15
16
17
18
19
20
21
22
23
24
25
26
27
28
Description
Base
Power Switch
Screw Rod
Foot
Plunger
Grommet
Power Cord
Nylon Cover Grommet
Fan
Nylon Cover
Transformer Bracket
Transformer
Plunger Slider
Thermostat
Qty
1
1
1
4
2
3
1
4
1
4
2
1
2
1
WELDING TIPS
Record Product’s Serial Number Here:
Note: If product has no serial number, record month and year of purchase instead.
Note: Some parts are listed and shown for illustration purposes only, and
are not available individually as replacement parts.
MAINTENANCE
Page 14
For technical questions, please call 1-800-444-3353.
SKU 69029
MAINTENANCE
WELDING TIPS
BASIC WELDING
SETUP
SAFETY
Assembly Diagram
SKU 69029
For technical questions, please call 1-800-444-3353.
Page 15
Limited 90 Day Warranty
Harbor Freight Tools Co. makes every effort to assure that its products meet high quality and durability standards,
and warrants to the original purchaser that this product is free from defects in materials and workmanship for the
period of 90 days from the date of purchase. This warranty does not apply to damage due directly or indirectly,
to misuse, abuse, negligence or accidents, repairs or alterations outside our facilities, criminal activity, improper
installation, normal wear and tear, or to lack of maintenance. We shall in no event be liable for death, injuries
to persons or property, or for incidental, contingent, special or consequential damages arising from the use of
our product. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the
above limitation of exclusion may not apply to you. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS.
To take advantage of this warranty, the product or part must be returned to us with transportation charges
prepaid. Proof of purchase date and an explanation of the complaint must accompany the merchandise.
If our inspection verifies the defect, we will either repair or replace the product at our election or we
may elect to refund the purchase price if we cannot readily and quickly provide you with a replacement.
We will return repaired products at our expense, but if we determine there is no defect, or that the defect resulted
from causes not within the scope of our warranty, then you must bear the cost of returning the product.
This warranty gives you specific legal rights and you may also have other rights which vary from state to state.
3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-3353