Chicago Electric 95424 Assembly and Specifications

MIG/ARC WELDER Model 95424
DUAL MIG WELDER Model 95629
Assembly And Operation Instructions
Model 95424 shown.
Due to continuing improvements, actual product may differ slightly from the product described herein.
®
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit our website at: http://www.harborfreight.com
To prevent serious injury, read and understand
all warnings and instructions before use.
Copyright© 2007 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.
For technical questions or replacement parts, please call 1-800-444-3353.
Contents
SPECIFICATIONS............................................................................. 3
GENERAL SAFETY RULES............................................................. 4
Specific Safety Rules................................................................................... 6
UNPACKING.................................................................................... 11
ASSEMBLY INSTRUCTIONS.......................................................... 11
Attaching the Wheels.................................................................................. 11
Installing a Wire Spool................................................................................ 13
Routing the Wire.......................................................................................... 14
Changing Wire Settings.............................................................................. 17
Attaching the Ground Cable with Clamp................................................... 17
Attaching the Electrode Cable (Arc Welder Only)..................................... 17
Setting Polarity for Welding Type............................................................... 18
Installing a Gas Cylinder............................................................................. 19
OPERATING INSTRUCTIONS......................................................... 20
Before You Begin Welding........................................................................... 20
Understanding Duty Cycle (Duration of Use)........................................... 20
Setting Up the Weld..................................................................................... 21
MIG Welding Set Up..................................................................................... 22
Arc (Stick) Welding Set Up (for Model 95424 Only).................................. 22
MIG Weld Settings Chart............................................................................. 23
Holding the Welding Torch/Electrode Holder (for all welding types)..... 24
When the Weld is Completed...................................................................... 25
INSPECTION, MAINTENANCE, AND CLEANING.......................... 26
Nozzle Inspection, Cleaning, and Replacement....................................... 26
Contact Tip Inspection, Cleaning, and Replacement............................... 26
Replacing the Welding Torch Liner............................................................ 27
WARRANTY..................................................................................... 27
PARTS LISTS and Diagrams..................................................... 28
MIG/Arc Welder (95424) – Electrical Schematic........................................ 34
MIG Dual Welder (95629) – Electrical Schematic...................................... 35
TROUBLESHOOTING..................................................................... 37
SKU 95424, 95629
For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual.
Page PLEASE NOTE
Models 95424 MIG/ARC WELDER and 95629 DUAL MIG WELDER have identical features except for the ARC option mode available in the 95424 MIG/ARC Welder.
The other features are the same, as shown in the Specifications chart below.
SPECIFICATIONS
Model
95424 MIG/ARC Welder
95629 Dual MIG Welder
Welding Current
30 ~ 250 A
Duty Cycle
100% @ 125 Amps / 30% @ 250 A
Power Consumption
230V / 60 Hz / Single Phase / 40 A
Open Voltage
16 - 36 V
Power Plug Type
3-Prong, 220 VAC, polarized, twist lock (not included) NEMA #L6-40 or equivalent
Power Cord Rating
8 AWG x 3C
1/
Gas Inlet Size
Ground Cable
4” Diameter (Barbed Fitting)
8’ 7” L with grounding clamp
Torch Power Cable
8’ 7” L including torch
Welding Wire Size
0.03” to 0.045”
Thermal Overload
Protection
Auto shutdown, indicator light, and restart after cool down
Wire Drive Assembly
Protection
If welding wire jams, auto shutdown, unit beeps, and wire automatically restarts
after jam remedied
Torch Tip Size
0.03”
35-1/
Overall Dimensions
2” L
Wire Speed
X 14” W x 27-1/4” H
1-10 Wire Speed Settings
Net Weight
124.6 lb.
122 lb.
Both products include: Wheel Kit, Grounding Head, Bottle Rack, Torches and two wire reels (without wire).
ARC Mode Features, 95424 Model Only
Electrode Holder Cable
8’ 7” L with electrode holder
Electrode Size
1/16” to 3/16” Diameter
Welding Current
30 ~ 200 Amps, AC Voltage
n/a
SAVE THIS MANUAL
You will need this manual for the safety warnings and precautions, assembly, operating, inspection, maintenance and cleaning procedures, parts list and assembly diagram.
Keep your invoice with this manual. Write the invoice number on the inside of the front
cover. Keep this manual and invoice in a safe and dry place for future reference.
SKU 95424, 95629
For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual.
Page GENERAL SAFETY RULES
WARNING!
READ AND UNDERSTAND ALL INSTRUCTIONS
Failure to follow all instructions listed below may result in
electric shock, fire, and/or serious injury.
SAVE THESE INSTRUCTIONS
WORK AREA
1.
Keep your work area clean and well lit. Cluttered benches and dark areas invite
accidents.
2.
Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases, or dust. Power tools create sparks which may
ignite the dust or fumes.
3.
Keep bystanders, children, and visitors away while operating a power tool.
Distractions can cause you to lose control. Protect others in the work area from
debris such as chips and sparks. Provide barriers or shields as needed.
ELECTRICAL SAFETY
1.
Grounded tools must be plugged into an outlet properly installed and grounded
in accordance with all codes and ordinances. Never remove the grounding
prong or modify the plug in any way. Do not use any adapter plugs. Check with
a qualified electrician if you are in doubt as to whether the outlet is properly
grounded. If the tools should electrically malfunction or break down, grounding
provides a low resistance path to carry electricity away from the user.
2.
Avoid body contact with grounded surfaces such as pipes, radiators, ranges,
and refrigerators. There is an increased risk of electric shock if your body is
grounded.
3.
Do not expose power tools to rain or wet conditions. Water entering a power
tool will increase the risk of electric shock.
4.
Do not abuse the Power Cord. Never use the Power Cord to carry the tools or
pull the Plug from an outlet. Keep the Power Cord away from heat, oil, sharp
edges, or moving parts. Replace damaged Power Cords immediately. Damaged Power Cords increase the risk of electric shock.
5.
When operating a power tool outside, use an outdoor extension cord marked
“W-A” or “W”. These extension cords are rated for outdoor use, and reduce the
risk of electric shock.
SKU 95424, 95629
For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual.
Page PERSONAL SAFETY
1.
Stay alert. Watch what you are doing, and use common sense when operating a power tool. Do not use a power tool while tired or under the influence
of drugs, alcohol, or medication. A moment of inattention while operating power
tools may result in serious personal injury.
2.
Dress properly. Do not wear loose clothing or jewelry. Contain long hair.
Keep your hair, clothing, and gloves away from moving parts. Loose clothes,
jewelry, or long hair can be caught in moving parts.
3.
Avoid accidental starting. Be sure the Power Switch is off before plugging
in. Carrying power tools with your finger on the Power Switch, or plugging in power
tools with the Power Switch on, invites accidents.
4.
Remove adjusting keys or wrenches before turning the power tool on. A
wrench or a key that is left attached to a rotating part of the power tool may result
in personal injury.
5.
Do not overreach. Keep proper footing and balance at all times. Proper footing
and balance enables better control of the power tool in unexpected situations.
6.
Always wear eye, hearing, and breathing protection. For welding safety equipment, refer to number 9 on page 7.
TOOL USE AND CARE
1.
Use clamps (not included) or other practical ways to secure and support the
workpiece to a stable platform. Holding the work by hand or against your body
is unstable and may lead to loss of control.
2.
Do not force the tool. Use the correct tool for your application. The correct
tool will do the job better and safer at the rate for which it is designed.
3.
Do not use the power tool if the Power Switch does not turn it on or off. Any
tool that cannot be controlled with the Power Switch is dangerous and must be
replaced.
4.
Disconnect the Power Cord Plug from the power source before making any
adjustments, changing accessories, or storing the tool. Such preventive safety
measures reduce the risk of starting the tool accidentally.
5.
Store idle tools out of reach of children and other untrained persons. Tools
are dangerous in the hands of untrained users.
6.
Maintain tools with care. Keep tools in good condition. Properly maintained
tools will get the job done better. Do not use a damaged tool. Tag damaged tools
“Do not use” until repaired.
SKU 95424, 95629
For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual.
Page 7.
Check for misalignment or binding of moving parts, breakage of parts, and any
other condition that may affect the tool’s operation. If damaged, have the tool
serviced before using. Many accidents are caused by poorly maintained tools.
8.
Use only accessories that are recommended by the manufacturer for your
model. Accessories that may be suitable for one tool may become hazardous
when used on another tool.
SERVICE
1.
Tool service must be performed only by qualified repair personnel. Service or
maintenance performed by unqualified personnel could result in a risk of injury.
2.
When servicing a tool, use only identical replacement parts. Follow instructions in the “Inspection, Maintenance, And Cleaning” section of this manual.
Use of unauthorized parts or failure to follow maintenance instructions may create
a risk of electric shock or injury.
Specific Safety Rules
1.
Ground this product. This Welder requires the attachment and use of a UL-listed,
230 volt, grounded, 3-prong, electrical Power Cord Plug (not included). Only a qualified electrician should install the Power Cord Plug. Never remove the grounding
prong or modify the Power Cord Plug in any way. Do not use adapter plugs with
this product. To comply with the National Electric Code, and to provide additional
protection from the risk of electrical shock, this product should only be connected
to a 230 volt, 3-hole outlet that is properly grounded.
2.
Maintain labels and nameplates on the Welder. These carry important information. If unreadable or missing, contact Harbor Freight Tools for a replacement.
3.
Avoid unintentional starting. Make sure you are prepared to begin work before
turning on the Welder.
4.
Never leave the Welder unattended when it is plugged into an electrical outlet.
Turn off the tool, and unplug it from its electrical outlet before leaving.
5.
Industrial applications must follow OSHA guidelines.
6.
Never stand on the Welder. Serious injury could result if the Welder is tipped or
if hot surfaces are accidently contacted.
7.
Maintain a safe working environment. Keep the work area well lit. Make sure
there is adequate surrounding workspace. Always keep the work area free of obstructions, grease, oil, trash, and other debris. Do not use a power tool in areas
near flammable chemicals, dusts, and vapors. Do not use this product in a damp
or wet location.
SKU 95424, 95629
For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual.
Page Prevent eye injury and burns. Wearing and using ANSI-approved
personal safety clothing and safety devices reduce the risk for injury.
8.
• Wear ANSI-approved safety impact eye goggles underneath welding eye
protection featuring at least a Number 10 shade lens rating.
• Leather leggings, fire resistant shoes or boots should be worn when using this
product. Do not wear pants with cuffs, shirts with open pockets, or any clothing
that can catch and hold molten metal or sparks.
• Keep clothing free of grease, oil, solvents, or any flammable substances. Wear
dry, insulating gloves and protective clothing.
• 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.
• When welding/cutting overhead or in confined spaces, wear flame resistant ear
plugs or ear muffs to keep sparks out of ears.
Prevent accidental fires. Remove any combustible material from the
work area.
10.
• When possible, move the work to a location well away from combustible
materials. If relocation is not possible, protect the combustibles with a
cover made of fire resistant material.
• 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.
• Enclose the work area with portable fire resistant screens. Protect combustible
walls, ceilings, floors, etc., from sparks and heat with fire resistant covers.
• 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.
• 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.
• Do not dispose of hot slag in containers holding combustible materials. Keep a
fire extinguisher nearby and know how to use it.
• After spot 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. Do not weld or cut in atmospheres containing dangerously reactive
or flammable gases, vapors, liquids, and dust. Provide adequate ventilation in
work areas to prevent accumulation of flammable gases, vapors, and dust. Do not
apply heat to a container that has held an unknown substance or a combustible
SKU 95424, 95629
For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual.
Page 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.
11.
Avoid overexposure to fumes and gases. Always keep your head out of the
fumes. Do not breathe the fumes. Use enough ventilation or exhaust, or both, to
keep fumes and gases from your breathing zone and general area.
• Where ventilation is questionable, have a qualified technician take an air sampling to determine the need for corrective measures. Use mechanical ventilation
to improve air quality. If engineering controls are not feasible, use an approved
respirator.
• Work in a confined area only if it is well ventilated, or while wearing an air-supplied respirator.
• Follow OSHA guidelines for Permissible Exposure Limits (PEL’s) for various fumes
and gases.
• Follow the American Conference of Governmental Industrial Hygienists recommendations for Threshold Limit Values (TLV’s) for fumes and gases.
• Have a recognized specialist in Industrial Hygiene or Environmental Services
check the operation and air quality and make recommendations for the specific
welding or cutting situation.
Inhalation Hazard
Welding Produces toxic fumes and gasses.
Exposure to welding gasses 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 gasses or fumes are:
• Early onset of Parkinson’s Disease
• Heart Disease
• Damage to the reproductive organs
• Ulcers
• Inflammation of the small intestine or stomach • Kidney damage
• Respiratory diseases such as emphysema, bronchitis or pneumonia
Safety precautions, such as using natural or forced air ventilation and
wearing a NIOSH-approved respirator, are essential to reduce the
risk of developing the above illnesses.
12.
Read and understand all instructions and safety precautions as outlined in
the manufacturer’s manual for the material you will weld or cut.
13.
Do not touch live electrical parts. Wear dry, insulating gloves. Do not touch electrode or conductor tong with bare hand. Do not wear wet or damaged gloves.
SKU 95424, 95629
For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual.
Page 14.
Protect yourself from electric shock. Do not use outdoors. 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 big
enough to cover your full area of contact with the work or ground.
15.
Ensure that the unit is placed on a stable location before use. If this unit falls
while plugged in, severe injury, electric shock, or fire may result.
Cylinders can explode when damaged:
16.
• Never weld on a pressurized or a closed cylinder.
• Never lay a welding torch on a cylinder.
• Never allow a welding electrode to touch the cylinder.
• Keep cylinders away from any electrical circuits, including welding circuits.
• Keep protective cap in place over the valve except when the cylinder is in use.
• Use only correct gas shielding equipment designed specifically for the type of
welding you will do. Maintain this equipment properly.
• Always protect gas cylinders from heat, being struck, physical damage, slag,
flames, sparks, and arcs.
• Always use proper procedures to move cylinders.
17.
Use the right tool for the job. Do not attempt to force small equipment to do the
work of larger industrial equipment. There are certain applications for which this
Welder was designed. It will do the job better and more safely at the rate for which it
was intended. Do not modify this Welder, and do not use this Welder for a purpose
for which it was not intended.
18.
WARNING! People with pacemakers should consult their physician(s) before
using this product. Electromagnetic fields in close proximity to a heart pacemaker
could cause interference to or failure of the pacemaker.
19.
WARNING! The warnings and cautions discussed in this 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.
20.
WARNING! This product, when used for welding and similar applications, produces chemicals known to the State of California to cause cancer and birth defects
(or other reproductive harm).
(California Health & Safety Code § 25249.5, et seq.)
SAVE THESE INSTRUCTIONS
SKU 95424, 95629
For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual.
Page Grounding
NOTE: This Welder requires the installation of a 3-Prong, 230 VAC, polarized, twistlock
Power Cord Plug (not included). NEMA configuration # L6-40 or equivalent. The Plug must
be installed by a certified electrician.
WARNING!
Improperly connecting the grounding wire can result in risk of electric shock.
Check with a qualified electrician if you are in doubt as to whether outlet is properly grounded. Do not modify power cord plug used with tool. Never remove
grounding prong from plug. Do not use tool 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.
GROUNDED TOOLS: TOOLS WITH THREE PRONG PLUGS
1.
Tools marked with “Grounding Required” have a three wire cord and three prong
grounding plug. The plug must be connected to a properly grounded outlet. If the tool
should electrically malfunction or break down, grounding provides a low resistance
path to carry electricity away from the user, reducing the risk of electric shock.
2.
The grounding prong in the plug is connected through the green wire inside the
cord to the grounding system in the tool. The green wire in the cord must be the
only wire connected to the tool’s grounding system and must never be attached to
an electrically “live” terminal.
3.
Your tool must be plugged into an appropriate outlet, properly installed by a certified electrician and grounded in accordance with all codes and ordinances.
Extension Cords
An extension cord must never be used with this item. Use of an
extension cord could result in damage to the item or fire.
Symbology
Double Insulated
Canadian Standards Association
Underwriters Laboratories, Inc.
V~
A
SKU 95424, 95629
Volts Alternating Current
Amperes
For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual.
Page 10
UNPACKING
When unpacking, make sure all parts shown on the Parts Lists near the end of
this manual are included. If any parts are missing or broken, call Harbor Freight Tools.
ASSEMBLY INSTRUCTIONS
WARNING! Always turn off the Welder and unplug the unit from its electrical outlet prior to performing any assembly, maintenance, or service.
Attaching the Wheels
Attaching wheels to case can be done for stationary cylinder use or mobile use.
Stationary
Attach the two Swivel Wheels (27A) at the
front and two Back Wheels (37A) and Axle
(36A) at the Base (28A) of the unit, using the
Clips (38A), Bolts and Washers provided.
(See Assembly Diagram on page 32 and
the following steps.)
1.
Mobile
Attach the two Swivel Wheels (27A) at front
of the Support (35A), Arm (5A), two Back
Wheels (37A) and Axle (36A) at the rear of
the Base (28A) of the unit, using the Clips
(38A), Bolts and Washers provided. (See
Assy. Diagram on page 32 and the following steps.)
For both Stationary and Mobile modes, set the Swivel Wheel (27A) against the front
corner of the case, making sure to align the holes. Screw the Bolts through the
Washers and into the Case. (See Figures 1.)
SKU 95424, 95629
For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual.
Page 11
ASSEMBLY INSTRUCTIONS (CONTINUED)
Stationary
2.
Mobile
2.
Install the Back Wheels (37A) at the Axle (36A). Install the Back Wheels (37A) at the Axle (36A).
3.
3.
Fix the Back Wheels(37A) with the
Clips (38A).
4.
Fix the Back Wheels (37A) with the
Clips (38A).
4.
Arm (5A)
Washer and Bolt
Set the Axle (36A) with the Back Wheels
(37A) attached against the bottom of the
case. Then, screw the Bolts through the
Washers and into the bottom of the case.
(See Figure 4, above left.)
Set Arm (5A) against the top back of the
welder case. Screw the Bolts through
Washers and into the welder case.
(See Figure 4, above right.)
Set the Support (35A) against the bottom back of the case. Align the holes and
screw the Bolts through the Washers and
into the case.
Set the Axle (36A) with the Back Wheels
(37A) against the bottom of the Support
(35A). Screw the Bolts through the Washers and into the Support.
SKU 95424, 95629
For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual.
Page 12
ASSEMBLY INSTRUCTIONS (CONTINUED)
TO INSTALL THE
WIRESpool
SPOOL
Installing
a Wire
TO INSTALL
THE WIRE
SPOOL
Assembling the Wire Spool depends
on whether
you are
using a 7” Spool or an 11”
Two variants to expose the Wire Drive Assembly are probable for Spool 200mm (variant A)
Spool.
and for EN 759 Spool 300mm (variant B) use.
Two variants to expose the Wire Drive Assembly are probable for Spool 200mm (variant A)
useSpool
with300mm
a 7” Spool:
and forFor
EN 759
(variant B) use.
Variant A
1.
Variant2.A
1.
2.
Lift the Door (14A) of the Welder to expose
the Wire
Lift the Door
(14A)Drive
of theAssembly.
Welder to expose
the Wire Drive Assembly.
3.
3.
Insert the Spool and the Pressing Cartridge
ontothe
theSpool
Threaded
Shaft
(11A). Making
Insert
and the
Pressing
Cartridge
sure
Welding
Wire unwinds
ontothe
the Spool's
Threaded
Shaft (11A).
Making
from
the bottom
(clockwise).
sure the
Spool's
Welding
Wire unwinds
from the bottom (clockwise).
4.
4.
When a slight force is needed to turn Spool, Screw the Fixing Cover into the Threaded
tension
is set. to turn Spool,
Shaft
(11A).
When a slight force
is needed
Screw the Fixing
Cover
into the Threaded
tension is set.
Shaft (11A).
Variant B
For use with
a 11”
Spool:
Variant
1.
2.B
1.
2.
Lift the Door (14A) of the Welder to expose
the Wire
Lift the Door
(14A)Drive
of theAssembly.
Welder to expose
the Wire Drive Assembly.
MIG&ARC 250 AMP - SKU 95424
MIG DUAL 250 AMP – SKU
MIG&ARC 250 AMP - SKU 95424
MIG DUAL 250 AMP – SKU
SKU 95424, 95629
Insert the Spool′s Holder onto the
Shaft
(11A).
Insert Threaded
the Spool′s
Holder
onto the
Threaded Shaft (11A).
For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual.
For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual.
For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual.
Page 14
Page 14
Page 13
ASSEMBLY INSTRUCTIONS (CONTINUED)
4.
3.
Insert the Spool onto the Spool′s Holder.
Making sure the Spool's Welding Wire
unwinds from the bottom (clockwise).
5.
Attach a Spool with the help of latch.
Screw the Fixing Cover into the Threaded Shaft (11A).
Routing the Wire
Note: When installing wire of different size or composition, you will also need to change
wire settings, set gun polarity, and, possibly, install gas cylinder. (See pages 18
to 20.)
Welding Wire
Spool
Figure A
1.
IMPORTANT: Securely hold onto the end of the Welding Wire and keep tension on it
during the following steps. If this is not done the Welding Wire will spring backward,
creating a tangled “bird’s nest” and resulting in wasted wire. (See Figure A.)
2.
Hold the Welding Wire securely while you cut enough Wire off the end of the
Spool to remove all bent and crimped Wire. Make sure the cut end has no burrs
or sharp edges (cut again, if needed). (See Figure A.)
SKU 95424, 95629
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Troubleshooting section at end of manual.
Page 14
3.
Loosen,
3.
Loosen, and
and lower
lower the
the Handle
Handle (4D)
(4D) on
on the
the Wire
Wire Drive
Drive Assembly.
Assembly. Then,
Then, raise
raise the
the
Lever
(3D).
(See
Figure
B)
Lever (3D). (See
Figure
B)
ASSEMBLY INSTRUCTIONS (CONTINUED)
Handle
Handle (4D)
Lever
Lever (3D)
FIGURE
FIGURE BB
4.
Keep
tension
Wire,
and
at
12
of
Wire
into
Wire
4.
Keep
tension
on the
thethe
Wire,
and guide
guide
at least
least
12 inches
inches
ofWire
WireFeed
into the
the
Wire Inlet
InletThen,
3.
Loosen
and on
lower
Tension
Adjusting
Knob
on the
Assembly.
Guide.
(See
Figure
C)
Guide. raise
(See Figure
C) Arm. (See Figure B.)
the Swing
Wire
Wire Inlet
Inlet Guide
Guide
Welding
Welding Wire
Wire
FIGURE
FIGURE C
C
5.
Lower
(3D)
the
Drive
Assembly.
tighten
the
5.
Lower
the Lever
Lever
(3D)
on
the Wire
Wire
Drive
Assembly.
Raise
andinches
tightenof
the
4.
Keep the
tension
on
theon
Welding
Wire,
and
guide atRaise
least and
12
Wire into the
Handle
(4D).
Once
the
is
in
place,
you
may
release
it.
(See
Figure
D)
HandleWire
(4D).Feed
OnceLeader.
the Wire
Wire(See
is held
held
in
place,
you
may
release
it.
(See
Figure
D)
Figure C.)
Handle
Handle (4D)
Welding
Welding Wire
Wire
Lever
Lever (3D)
FIGURE
FIGURE D
D
5.
Lower the Level on the Wire Drive Assembly. Raise and tighten the Handle. Once
Wire
is 95424
held in place,
you may
release
it. (See
Figure D.)
For technical
questions,
please
call 1-800-444-3353;
MIG&ARCthe
250 AMP
- SKU
Page 16
MIG DUAL 250 AMP – SKU
Troubleshooting section at end of manual.
SKU 95424, 95629
For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual.
Page 15
ASSEMBLY INSTRUCTIONS (CONTINUED)
6.
Lay Torch Cable out in a straight line so Welding Wire moves through it easily.
Leave Door (14A) of the Welder open so Wire Feed Assembly can be observed.
7.
Remove the Gun Nozzle (1E) and Contact Tip (2E). (See Figure E.)
WARNING!
EXERCISE EXTREME CAUTION - RISK OF FIRE AND/OR ELECTRIC SHOCK!
The following steps require powering the Welder. Do not touch
anything with Torch Handle or Welding Wire or an arc will be ignited.
Do not touch internal components of while unit is plugged in.
8.
After having certified electrician install power cord plug, insert the Power Cord
(1A) into its 230 volt, grounded, electrical outlet. Turn Power Switch (1C) to
ON.
9.
Point Torch Handle away from all objects. Squeeze Trigger Switch (13E) on Torch
Handle until Welding Wire feeds through the Head Tube (4E) of the Torch Handle
about 2 inches. If necessary, move the Torch Handle slightly in a circular motion
to help feed the Welding Wire properly out of the Head Tube. (See Figure E.)
10.
NOTE: If the Welding Wire does not feed properly, and the Spool is stationary,
turn the Welder off. Unplug the Welder. Slightly tighten the Handle (4D) on the
Wire Feed Assembly. (See Figure D.)
11.
To check the tension on the Wire Feed Assembly, feed the Welding Wire against
a piece of scrap wood from 2 to 3 inches away. If the Wire stops instead of bending, turn the Welder OFF. Unplug the unit from its electrical outlet. Then, slightly
tighten the Handle (4D) on the Wire Feed Assembly.
Reminder: When installing wire of a different size or composition, you will also
need to change wire settings, set the gun polarity, and possibly install a gas cylinder.
HEAD TUBE (4E)
CONTACT TIP (2E)
CONTACT TIP (2E)
HEAD
TUBE (4E)
NOZZLE (1E)
NOZZLE (1E)
WELDING WIRE
TRIGGER SWITCH (13E)
TRIGGER SWITCH
(13E)
FIGURE E
12.
Turn the Welder OFF, unplug it, and discharge the electrode to ground. Insert the
Contact Tip (2E) onto the Welding Wire and screw it firmly into the Head Tube (4E)
of the Torch Handle. Replace the Nozzle (1E), and cut off any excess Welding Wire
over 1/2 inch. Then, close the Access Panel of the Welder. (See Figure E.)
SKU 95424, 95629
For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual.
Page 16
.
WARNING! Make sure to turn off the Welder and unplug it from its electrical outlet
prior to changing wire settings.
1. Lift the Door (14A) of the Welder to expose the Wire Drive Assembly.
2. Loosen, and lower the Handle (4D) on the Wire Drive Assembly.
Changing Wire Settings
3. Remove the Screw that secures the Roller (5D) in place. Then, remove the two Rollers.
Make sure
turn off
4.1.Flip eachWARNING!
Roller 180 degrees.
(SeetoFigure
F)the Welder and unplug it from its electrical
outlet
to changing
wire settings.
NOTE:
Theprior
two Rollers
are “keyed”,
meaning they can only be reinstalled one way.
5.2.Reinstall
the Door
two Rollers,
and
the
place
with
theAssembly.
Screw. (See Figure F)
Lift the
(14A) of
thesecure
Welder
toRollers
exposeinthe
Wire
Feed
6.3.InstallLoosen,
the Spool
oflower
Welding
and(4D)
route
the Torch
Gun. Then, test and, if
and
theWire,
Handle
onthe
theWire
WiretoFeed
Assembly.
necessary, adjust the Wire Drive Assembly as discussed in the previous pages of this
Remove the Screw that secures the Roller (5D) in place. Then remove the two
4.manual.
Rollers.
WELDING WIRE
ROLLERS (5D)
FLIP
180°°
FIGURE F
5.
Flip each Roller 180 degrees. (See Figure F.)
Note: The
Rollers are
“keyed”,
whichCABLE
means they
can CLAMP
only be reinstalled one
TOtwo
ATTACH
THE
GROUND
WITH
way.
Insert the Connecting Plug of the Ground Cable (22A) into the Terminal Ground (7C) and
the Plug
two Rollers
and
secure(See
the Rollers
in page
place34)
with the Screw.
6. theReinstall
twist
Connecting
to lock it
in place.
Part List
(See Figure F.)
.
7.
Install the Spool of Welding Wire and route the Wire to the Torch Gun. Then, test
and, if necessary, adjust the Wire Feed Assembly as discussed in the previous
TO ATTACH THE ELECTRODE CABLE
pages of this manual.
(Only MIG/ ARC 250 AMP)
Insert the Connecting
Plug of the
Electrode
CableCable
(21A) intowith
the Terminal
Electrode (6C)
Attaching
the
Ground
Clamp
and twist the Connecting Plug to lock it in place. (See Part List page 34)
Insert the Connecting Plug to the Ground Cable (22A) into the Terminal Ground (7C)
and twist the Connecting Plug to lock in place. (See Parts List on Page 31).
For technical questions, please call 1-800-444-3353;
MIG&ARC 250 AMP - SKU 95424
Page 18
MIG DUAL 250 AMP – SKU
Troubleshooting section at end of manual.
Attaching the Electrode Cable (Arc Welder Only)
Insert the Connecting Plug to the Ground Cable (22A) into the Terminal Electrode
(6C) and twist the Connecting Plug to lock in place. (See Parts List on Page 31).
SKU 95424, 95629
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Troubleshooting section at end of manual.
Page 17
Setting Polarity for Welding Type
WARNING! Always turn welder off and disconnect it from it’s electrical supply before
opening the case or performing any adjustment, including the following procedure.
1.
2.
Set for Electrode Positive (DCEP) for gas
welding with solid-core wire
- Red electrode cable (C) to positive terminal (A);
- Black ground cable (D) to negative terminal (B).
See illustration, top right initial
Setup.
SETTING THE GUN & ELECTRODE POL
DCEP
1.Set for Elec
for gas weld
-Red Electrod
-Black Ground
SHOWN IN IL
To reverse polarity
1. Remove the nuts.
2. Change the places of the cables (C, D).
3. Replace and tighten the nuts.
2. SETTING
1.Turn off the
2. Change by
3.Strongly twir
When connecting the weld output terminals,
you should keep the square washers in
place.
When connect
is necessary to
DCEN
3.
Set for Electrode Negative (DCEN) for
gasless flux core wire:
- Red electrode cable (C) to negative terminal (B);.
- Black ground cable (D) to positive terminal
(A).
(See illustration, bottom right.)
3. Set for Ele
for gas-less f
-Red Electrod
-Black Ground
A. Positive (+) Output Terminal
4.
Always read and follow wire manufacturer’s
recommended polarity.
SKU 95424, 95629
b. Negative (–) Output Terminal
C. Red Cable - Electrode
D. Black Cable - Ground
For technical questions, please call 1-800-444-3353;
MIG&ARC 250 AMP - SKU 95424
Troubleshooting section at end
of manual.
MIG DUAL
250 AMP – SKU
4. Always read
ommended
A. Po
B. N
C. R
D. B
Page
18
For technical
questions,
pleas
Troubleshooting section
(See Figure G)
4. Remove the protective cap from the cylinder. Stand to the side of the cylinder valve, and
open the valve slightly to blow dust and dirt from the valve. Then, close the valve. (See
Figure G)
5. Make sure the Flow Adjust on the Pressure Regulator/Flow Meter is turned off. Then,
Installing
Gas
Cylinder
screw the Pressure Regulator/Flow
Meter a
firmly
onto
the cylinder valve. (See Figure G)
WARNING: Using an oversized gas cylinder can cause tipping, result6. Attach the Gas Hose from the Pressure Regulator/Flow Meter to the Gas Inlet Valve loing in cylinder and equipment damage and personal injury. NEVER exceed
cated on the Rear Panel of the Welder. (See Figure G)
maximum cylinder weight of 100 lb.
7. Adjust the flow rate of the gas by turning the Flow Adjust. The typical flow rate is 20 cfh
1.
DoMake
not use
pressure
regulator/flow
meterrecomwith CO2
(cubic CAUTION!
feet per hour).
surean
to Argon/Mixed
check the Welding
Wire
manufacturer’s
shielding
gas.
To
use
CO
shielding
gas,
you
must
install
a
CO
gas
pressure
2
mended flow rate. (See Figure G)2
regulator/flow meter (neither one included).
Cap.
Cylinder Valve.
Remove Cap, stand to side of valve
slightly. Gas flow blows dust and dirt
from valve. Close valve.
3. Cylinder.
4. Regulator/ Flowmeter
Install so face is vertical.
5. Regulator/Flowmeter Gas.
6. Hose Connection.
Connect customer supplied gas hose
between regulator/flowmeter hose connection, and fitting of welder.
7. Flow Adjust.
8. Solid post or other stationary object.
9. Chain or strap.
1.
2.
FIGURE G
2.
With help, set cylinder (not included) upright against post or other stationary obFor technical questions, please call 1-800-444-3353;
Page
or heavy-duty
strap (neither
to secure cylinder
in 20
place.
Troubleshooting
section atincluded)
end of manual.
(See Figure G.)
3.
Remove the protective cap from the cylinder. Stand to the side of the cylinder
valve, and open the valve slightly to blow dust and dirt from the valve. Then,
close the valve. (See Figure G.)
4.
Make sure the Flow Adjust on the Pressure Regulator/Flow Meter is turned off.
Then, screw the Pressure Regulator/Flow Meter (not included) firmly onto the
cylinder valve. (See Figure G.)
5.
Attach the Gas Hose for the Pressure Regulator/Flow Meter to the Gas Inlet
Valve located on the Rear Panel of the Welder. (See Figure G.)
6.
Adjust the flow rate of the gas by turning the Flow Adjust. The typical flow rate is 20
CFH (cubic feet per hour). Make sure to check the Welding Wire manufacturer’s
recommended flow rate.
MIG&ARC 250 AMP - SKU 95424
ject.
MIG DUAL 250
AMP –Use
SKU chain
SKU 95424, 95629
For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual.
Page 19
OPERATING INSTRUCTIONS
Before You Begin Welding
Good welding requires a high degree of skill and experience. You should practice
a few sample welds on scrap metal before you begin welding your first project. Additional practice periods are recommended whenever you weld a different thickness
of material, wire, or weld a different type of connection.
Understanding Duty Cycle (Duration of Use)
1.
CAUTION! Avoid damage to the Welder by not leaving the unit on for more than
the prescribed duty cycle time.
100% Duration of use
at 125 Amp Setting
Continuous
use
30% Duration of use
at 250 Amp Setting
3 minutes in use
followed by
at least
7 minutes OFF
in a single 10 minute period
Other settings fall between these two ranges.
FIGURE H
2.
The duty cycle defines the number of minutes, within a 10 minute period, during
which a given Welder can safely produce a particular welding current. For example,
this Welder, with a 30% duty cycle at 250 Amps must be allowed to rest for at
least 7 minutes after every 3 minutes of continuous weld at 250 Amps. (See
Figure H.)
3.
Failure to carefully observe duty cycle limitations can easily over-stress a Welder’s
power generation system, contributing to premature Welder failure.
4.
This Welder is equipped with an internal thermal protection system to help prevent
over stressing the unit. When the unit overheats, it automatically shuts down, then
automatically returns to service when it cools down.
Note: Once the unit returns to service, follow a more conservative duty cycle routine to
help prevent excess wear to the Welder. (See Figure H.)
SKU 95424, 95629
For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual.
Page 20
Setting Up the Weld
WARNING!
Before welding, make sure to read and understand all safety
precautions and warnings discussed on pages 4 through 10.
1.
Power Switch (1C): Always make sure the Power Switch is in its “OFF” position before plugging the Welder into a 230 volt, grounded, electrical outlet. (See
Figure J).
2.
Overload Protector (2C): If too much current is drawn from the Welder, the Overload Protector will activate. The RED Overload Indicator Light will illuminate and
the Welder will automatically turn off until it cools down. If this happens, turn the
Power Switch (1C) to its “OFF” position and wait approximately 2 to 5 minutes.
(See Figure H.) When the RED Overload Indicator illuminates and the sound is
audible, the welding wire that was welded on the NOZZLE (1E) or the Wire Drive
Assembly (16A) has failed.
3.
Wire Speed Control Knob (3C): The Scale surrounding the Knob is relative value,
not wire feed speed. Adjust the Wire Feed Speed Knob based on thickness of the
metal being welded. (See Figure L.)
4.
Voltage Selector Knob (5C):
WARNING!
DO NOT SWITCH THE VOLTAGE SELECTOR KNOB DURING THE WELDING!
WARNING!
BEFORE USING THE WELDER, SET THE VOLTAGE SELECTOR KNOB IN
THE 3-5 RANGE AND KEEP IN THAT SETTING FOR 10-15 MINUTES!
The Scale surrounding the Knob is relative value, not voltage. Adjust the Voltage
Selector Knob based on thickness of the metal being welded. (See Figure J.)
5.
Securely clamp the Ground Clamp (22A) as close as possible to the metal object
to be welded, or to the metal workbench where the object is mounted and electrically connected.
6.
NOTE: The workpieces should be firmly held together and in position while welding.
Use clamps (not included) to hold the workpieces so you can concentrate on the
job at hand. 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.
SKU 95424, 95629
For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual.
Page 21
MIG Welding Set Up
7.
If using solid-core wire, connect and secure an Argon/ CO2 gas hose to the rear of
the Welder. (If using flux core wire, protective gas is not required.)
OVERLOAD PROTECTOR (2C)
POWER SWITCH (1C)
WIRE FEED
SPEED KNOB (3C)
ELECTRODE
WELDING
INDICATOR (4C)
VOLTAGE SELECTOR KNOB (5C)
FIGURE K
8.
9.
9.
10.
11.
10.
12.
11.
Set the desired welding voltage and wire speed for the thickness of metal being
welded,
the Voltage
(5C) and
Wire Then
Feedplug
Speed
Knob
(3C).
Make
sureusing
the Power
SwitchSelector
(1C) is inKnob
its “OFF”
position.
Power
Cord
(1A)
of(See
the Welder
into
230 VAC, 40 AMP line with delayed action type circuit
Figures
K a&dedicated,
J.)
breaker or fuse. (See page 32.)
While
holding
Welding
Gun(10C),
(20A),with
withthe
theWelding
WeldingWire
Wireclearly
clearlyout
outofofthe
theway
wayof
While
holding
thethe
Welding
Torch
of any
grounded
objects,
turnPower
the Power
Switch
(1C)
its position.(See
“ON” position.
any
grounded
objects,
turn the
Switch
(1C) to
its to
“ON”
Figure G)
(See Figure
K.)
Momentarily
squeeze
the Trigger Switch (13E) of the to test the wire feed speed. If
necessary, adjust the speed by turning the Wire Feed Speed Knob (3C).
Momentarily
(See
Figure G)squeeze the Trigger (13E) of the Welding Torch to test the wire feed
speed.
If necessary,
adjust
speedthen
by turning
Wire
Speed
Knob
Orient
yourself
on the area
to bethe
welded,
place a the
Face
Shield
over Control
your eyes.
(3C). (See Figure K.)
WARNING! Never look at the ignited arc without ANSI-approved, arcOrient yourself
on the
to be welded,
then
place
a Face
Shield over
eyes.
shaded,
eyearea
protection
in a full
face
shield.
Permanent
eyeyour
damage
or blindness can occur. Skin burns can occur. Never breathe arc
fumes.Welding Set Up (for Model 95424 Only)
Arc (Stick)
Turn the Wire Feed Speed Knob (3C) to the appropriate sector. The RED
For
switching
in ARC(4C)
mode
Wire
Feed
sector.
Red
Electrode
Indicator
will
light
up Speed
and theKnob
wire (3C)
will in
notappropriate
move. (See
Figure
ELECTRODE
WELDING
INDICATOR
(4C)
will
light
up.
(See
Figure
G)
K.) Below are recommended positions of the Voltage Selector Knob (5C.)
14. NOTE: Welder MIG DUAL 250 AMP has no about the WIRE FEED SPEED KNOB
(3C) sectorDiameter
"Electrode"
and ELECTRODE WELDING
INDICATOR
of electrode
Voltage Selector
Knob(4C)
position
1/16”
1-4
1/8”
3-6
3/16”
5-8
12.
13.
SKU 95424, 95629
For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual.
Page 22
MIG Weld Settings Chart
FIGURE J
This Chart is intended to show general guidelines for different wire sizes and for
different thickness of material.
The settings
shouldCHART
only be used at the beginning of a weld
WELD
SETTINGS
and must be adjusted after stopping and carefully inspecting the weld. Proper welding takes
good technique
practice.
This Chartand
is intended
to show general guidelines for different wire sizes and for different thicknesses of material. The settings should only be used at the beginning of a weld
and must be adjusted after stopping and carefully inspecting the weld. Proper welding
takes good technique and practice.
FIGURE J
For technical questions, please call 1-800-444-3353;
sectioncall
at end
of manual.
technical Troubleshooting
questions, please
1-800-444-3353;
MIG&ARC 250 AMP - SKU 95424
MIG DUAL 250 AMP – SKU
SKU 95424, 95629
For
Troubleshooting section at end of manual.
Page 25
Page 23
Arc (Stick) Welding Set Up (continued, for Model 95424 Only)
13.
Turn the Power Switch (1C) to its “OFF” position. Clamp the bare end of the
selected electrode in the electrode holder.
Electrode
NI-CL
308L
6011
6013
7014
7018
7024
Penetration
Shallow
Shallow
Deep
Shallow
Moderate
Shallow
Shallow
Attributes
For cast Iron
For stainless steel
Little preparation needed, high spatter
All purpose
Easy to use, quick
Creates stronger welds
For flat/fillet welds, easy to use, quick
14.
To prevent fire or electric shock:
Trim all welding wire off the end of the Welding Gun (20A). Insulate the MIG
Welding Gun (20A) wrapping it in electrical tape so that an arc is not accidentally ignited. Coil Welding Gun cable up away from all conductive objects.
15.
While holding the Electrode Holder (21A), with the electrode clearly out of the way
of any grounded objects, turn the Power Switch (1C) to its “ON” position.
16.
Orient yourself on the area to be welded, then place a Face Shield over your
eyes.
Holding the Welding Torch/Electrode Holder
(for all welding types)
WARNING! Never look at the ignited arc without ANSI-approved,
arc-shaded, eye protection in a full face shield with appropriate
shaded lens. Permanent eye damage or blindness can occur. Skin
burns can occur. Never breathe arc fumes. (See page 8.)
17.
Hold the Welding Torch/Electrode Holder in one hand and a one-handed face shield
in the other. If a hands-free welding shield is used, then both hands can be used
to control the Torch/Holder.
18.
Starting a weld arc (for stick (arc) welding only):
There are two usual methods to ignite an arc when stick welding: scratch or tap.
• Scratch – stroke the Electrode across work piece like striking a match, then lift
electrode slightly.
• Tap – Bring electrode straight down against workpiece and then back up slightly.
If either of these methods are done properly, an arc is ignited.
If the arc goes out, the electrode was lifted too far from the workpiece.
SKU 95424, 95629
For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual.
Page 24
If the electrode fuses to the workpiece, quickly twist to release it and lift it slightly
farther on your next attempt.
19.
The Welding Wire/Electrode should be directed straight into the joint. This gives an
angle of 90 degrees (straight up and down) for groove (end to end) welds, and an
angle of 45 degrees for fillet (T-shaped) welds.
20.
The end of the Torch/Holder should be tilted so that the
Welding Wire/Electrode is angled anywhere in between
straight on and 15 degrees in the direction of the weld.
The amount of tilt is called the “drag angle”.
(See Figure L.)
21.
MIG welding only:
The Welding Wire should extend no more than 1/2” past
the Nozzle (1E) of the Welding Torch. This distance is
called “stickout”. (See Figure L.)
22.
FIGURE L
For a wider weld, draw the Welding Wire/Electrode back and forth across the joint
in a curve. This is called a “weave bead”. For arc (stick) welding, the weave
width must not be more than 2.5 times the electrode diameter.
Note: If too much current is drawn from the Welder, the internal Thermal Overload Protector will activate. The Overload Indicator Light (2C) will illuminate and the Welder will
automatically turn off. If this happens, turn the Power Switch to its “OFF” position
and wait 3 to 5 minutes for the unit to cool down.
23.
After a few seconds, stop. Switch off the Welder, and check your progress. Compare
your weld’s appearance with the diagrams and descriptions shown in the included
“Weld Diagnosis” pamphlet. After making any necessary adjustments, continue the
weld while carefully following the DUTY CYCLE guidelines.
When the Weld is Completed
24.
Lift the Welding Wire/Electrode completely away from any grounded object. Set the
face shield down. Then, turn the Power Switch (1C) to its “OFF” position.
25.
Unplug the Power Cord (1A) from the electrical outlet. Then, make sure to set the
Welding Torch/Electrode Holder on a nonflammable, nonconductive surface.
26.
A wire brush/hammer (not included) can now be used to clean up the weld.
CAUTION! The weld may still be quite hot, and sparks/chips may fly
when cleaning. Make sure to continue wearing ANSI-approved safety
impact eye goggles and other protective wear when cleaning a weld.
SKU 95424, 95629
For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual.
Page 25
INSPECTION, MAINTENANCE, AND CLEANING
WARNING!
Before performing any maintenance on the Welder, unplug the
Power Cord (1A) from its electrical outlet and allow all components of
the Welder to completely cool.
1.
Periodically open the Door (14A) from the unit and, using compressed air, blow out
all dust and debris from the interior.
2.
Always store the Welder in a clean, dry, safe location out of reach of children and
other unauthorized people.
3.
For optimal MIG weld quality, clean and inspect the Contact Tip (2E) and Nozzle
(1E) before each use, as follows:
Nozzle Inspection, Cleaning, and Replacement (MIG Only)
1.
Turn the Nozzle (1E) counterclockwise while pulling to remove.
2.
Scrub the interior of the Nozzle (1E) clean with a wire brush.
3.
Examine the end of the Nozzle (1E). The end should be flat and even. If the end is
uneven, chipped, melted, cracked, or otherwise damaged, the Nozzle will adversely
effect the weld and should be replaced.
4.
Reinstall the Nozzle (1E) after inspecting and cleaning the Contact Tip (2E).
Contact Tip Inspection, Cleaning, and Replacement (MIG Only)
1.
Make sure the entire Welding Gun (20A) is completely cool before proceeding.
2.
Remove the Nozzle (1E) as explained above. Then remove the Contact Tip (2E).
3.
Scrub the exterior of the Contact Tip (2E) clean with a wire brush. Check that the
Contact Tip is the proper type for the wire size used.
4.
Examine the hole at the end of the Contact Tip (2E) for the following problems:
Shape: The hole should be an even circle, and should not be oblong or have any
bulges in it.
Size: The Contact Tip will decrease in efficiency as the center hole enlarges. A
Contact Tip that measures 150% or more the original size* should be replaced.
(*.045” or more for .030” Tips; .067” or more for .045” Tips.)
5.
If any problems are noted with a Contact Tip (2E), have it replaced.
6.
When inspection and maintenance is completed, reinstall the Contact Tip (2E)
and Nozzle (1E).
SKU 95424, 95629
For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual.
Page 26
REPLACING THE WELDING TORCH LINER
Replacing the Welding Torch Liner (MIG Only)
Remove NOZZLE, slip type.
Remove TIP.
1.Disconnect GUN TERMINAL (11D) &
TERMINAL (12D).
2.Untwist NUT (9D).
3.Remove GUN (20A) & CABLES (15A),
(18A) & two SEALING WASHERS (8D).
Remove LINER.
Without bending, insert a new LINER.
Pull LINER out the other end.
Cut LINER off 5 mm from head tube.
Install TIP (2E), NOZZLE (1E).
1. Install GUN (20A) & CABLES (15A),
(18A) &two SEALING WASHERS (8D).
2. Secure NUT (9D).
WARRANTY
Limited 90 day/1 Year 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 for a period of ninety days from date of purchase that the torch, liner, wire feed mechanism (if applicable), welding clamps, electrode
holders, cables and accessories packed with the welder are free of defects in materials and workmanship. This Limited 90 Day/1 Year Warranty
shall not apply to consumable parts such as tips, welding wire, and gas nozzles. Harbor Freight Tools also warrants to the original purchaser,
for a period of one year from date of purchase, that the transformer and rectifier are free from defects in materials and workmanship. This warranty
does not apply to damage due directly or indirectly to misuse, abuse, negligence or accidents; repairs or alterations outside our facilities; 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
SKU 95424, 95629
For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual.
Page 27
PARTS LISTS and Diagrams
PARTS LIST A
Part
Description
Qty.
Part
Description
Qty.
1A
Power Cord (8 AWG x 3C: 250V)l
1
20A
1
2A
Power Cord Clip
1
21A
3A
Chain
1
4A
Hose Connector
1
22A
Gun (SB 250)
Electrode Cable w/ Holder
(only for 95424 MIG/ARC Welder)
Ground Cable w/ Clamp
5A
Arm
1
23A
Front Pane;/Base (see Fig. N)
1
6A
Rear Panel/Base
1
24A
Voltage Selector Switch w/ Cable
1
7A
Fan w/ Cable
1
25A
1
8A
1
10A
Filter Reactor
Valve (12VAC, 2-Way Custom
Port)
Valve Connection Cable
11A
Threaded Shaft
1
29A
Power Negative Cable
Wire Speed Selector w/ Cable
(only for 95424 MIG/ARC Welder)
Swivel Wheel
Base w/ Front Panel, Rear Panel,
Center Baffle
Power Switch Cable
12A
Polarity Switch
1
30A
Trigger Switch Cable
1
13A
Square Washer
2
31A
Controller Block BCN-4U
1
14A
Door
1
32A
Power Block (see Fig. M)
1
15A
Power Positive Cable
1
33A
Cable BCN-4U-BC-4 connection
1
16A
Wire Drive Assembly (See Fig. O)
1
34A
Side Panel (B)
1
17A
Gear Motor Cable w/ Beeper
Power Connection Cable
(Only for 95424 MIG/ARC Welder)
Liner Sleeve
1
35A
Support
1
36A
Axle
1
37A
Back Wheel
2
38A
Clip
2
9A
18A
19A
1
1
1
1
26A
27A
28A
1
1
1
2
1
1
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.
SKU 95424, 95629
For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual.
Page 28
ASSEMBLY DIAGRAMS
NOTE: Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts.
Figure L
For technical questions, please call 1-800-444-3353;
questions,
please call 1-800-444-3353;
MIG DUAL 250For
AMP –technical
SKU
Troubleshooting section at end of manual.
SKU 95424, 95629
Troubleshooting section at end of manual.
MIG&ARC 250 AMP - SKU 95424
Page 32
Page 29
Assembly Diagrams (continued)
Power Block #32A
PARTS
DIAGRAMS
DescriptionLISTS & ASSEMBLY
Qty.
Part
Description
Part
1B
Part2B
#
1B
3B
2B
3B
4B
4B
Main Transformer
Rectifier
Qty.
Power1Block # 5B
32A Filter Reactor w/ Thermo Resistor
Qty.
2
Description
Main Transformer Tr1
Fixing Corner
Rectifier
Fixing
Hosecorner
Connector
Thermo Resistor Connector
1
12
14
1
Part #6B
Description Tr2
Auxiliary Transformer
1
Qty. 1
5B
Filter Reactor w/Thermo Resistor
7B Auxiliary
Basis Transformer Tr2
6B
7B 8B Basis
Connection Block BC-4
8B
Connection Block BC-4
Figure M
1
1
1
1 1
1
4B
5B
3B
6B
2B
7B
1B
8B
Figure M
MIG&ARC 250 AMP - SKU 95424
MIG DUAL 250 AMP – SKU
SKU 95424, 95629
For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual.
For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual.
Page 33
Page 30
Assembly Diagrams (continued)
Front Panel #23A
PARTS
LISTS & ASSEMBLY
DIAGRAMS
Part
Description
Description
Qty.
Part
1C
Part # 2C
Power Switch
Front 1Panel # 7C
23A Terminal Ground
Overload Indicator
Description
1
Qty.
1C 3CPower
Switch
Wire
Feed Speed Knob
2C
Overload
Indicator
Electrode
Welding Indicator
3C 4CWire(only
Feedfor
Speed
Knob
95424
MIG/ARC Welder)
Electrode Welding Indicator
4C 5C Voltage Selector Knob
(only for MIG/ARC 250 AMP)
Terminal
Electrode
5C 6CVoltage
Selector
Knob
(only
for
95424
Terminal Electrode MIG/ARC Welder)
6C
(only for MIG/ARC 250 AMP)
11
1
11
11
1
Part8C
#
Front Panel Description
7C
Ground
20A Terminal
Gun (SB
250) (see Fig. P)
8C
Front
Panel
Electrode Cable w/ Holder
21A Gun (SB 250) (see Figure P )
20A
(only for 95424 MIG/ARC Welder)
Electrode Cable w/Holder
22A Ground Cable w/ Clamp
21A
(only for MIG/ARC 250 AMP)
22A Ground Cable w/Clamp
Qty.
1
1
Qty.
11
1
11
11
1
1
Figure N
1C
2C
3C
4C
5C
20A
6C
7C
8C
21A
22A
SKU 95424, 95629
For technical questions, please call 1-800-444-3353;
Figure Nat end of manual.
Troubleshooting section
MIG&ARC 250 AMP - SKU 95424
For technical questions, please call 1-800-444-3353;
Page 31
Assembly Diagrams (continued)
Wire Drive Assembly #16A
Part
1D
2D
Part
#
3D
1D
4D
2D
3D
4.1D
4D
4.2D
4.1D
4.3D
4.2D
4.3D
4.4D
4.4D
5D
5D
6D
6D
7D
7D
Description
Gear Motor
Qty.
Part
1
8D
Description
Qty.
PARTS LISTS & ASSEMBLY DIAGRAMS
Sealing Washer
2
Wire Drive
Assy.
1
9D # 16A
Nut (M10)
Base
Description
Lever
Gear Motor
Drive Handle (4D)
Base
Lever
Handle (4D)
Drive Handle (4D)
Spring
Handle (4D)
Axle
Spring
Axle
Washer (Semi-Spherical)
Washer (Semi-Spherical)
Roller
Roller
Top Isolator
Top Isolator
BottomIsolator
Isolator
Bottom
1 Qty.
1
1 1
1 1
1
1
1
1 1
1 1
1
2
2
2
2
2 2
Part
20A#
8D
11D
9D
20A
12D
11D
13D
12D
14D
13D
14D
15D
15D
18A
18A
15A
15A
1
Gun (SB 250)Description
Sealing Washer
Gun
Terminal (OHU-2)
Nut (M10)
Gun (SB (Flat
250) Cable-10 WF-2)
Terminal
Gun Terminal (OHU-2)
Gear Motor Power Connector
Terminal (Flat Cable-10 WF-2)
Sealing
RingPower Connector
Gear Motor
Sealing Ring
Connector
Gun Block
Connector Gun Block
Power Connection Cable
Power Connection Cable
(only for 95424 MIG/ARC Welder)
(only for MIG/ARC 250 AMP)
Power
Power Positive
Positive Cable
Cable
1 Qty.
2
1 1
1 1
1
1
1
1 1
1 1
1
1
1
1 1
Figure O
2D
1D
3D
4D
4.1D
15D
4.2D
14D
4.3D
13D
18A
4.4D
15A
12D
11D
5D
20A
SKU 95424, 95629
9D
8D
7D
6D
Figure O
For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual.
MIG&ARC 250 AMP - SKU 95424
MIG DUAL 250 AMP – SKU
For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual.
Page 32
Page 35
Assembly Diagrams (continued)
Gun (SB 25) #20A
Part
Description
Qty.
Part
Description
Qty.
1E
Nozzle (Slip Type)
1
9E
Nut (M12)
1
2E
Contact Tip
1
10E
Liner
1
3E
Spring
4E
Head Tube
#
5E PartSealant
PARTS LISTS &
DIAGRAMS
1 ASSEMBLY
11E Liner Terminal
1
Gun
1 (SB 250)
12E# 20A
Switch Trigger Terminal
1
1
Description
1E
Nozzle (Slip Type)
6E 2ESpring
Contact Tip
Spring
7E 3ETerminal;
4E
Head Tube
8E 5EFeeder
Connector
Sealant
6E
Spring
7E
Terminal
8E
Feeder Connector
Qty.
Part # Trigger SwitchDescription
13E
Qty.
1
1
9E
Nut (M12)
1
14E
Base
1
10E Liner
1 15E
11E Complete
Liner Terminal
Torch Assembly
1
1
12E Switch Trigger Terminal
1
1
13E Trigger Switch
1
14E Base
2
Figure
P15E Complete Torch Assembly
1
5E
4E
1
11
11
1
1
1
1
7E
6E
8E
3E
2E
1E
14E
13E
12E
11E
10E
9E
Figure P
For technical questions, please call 1-800-444-3353;
SKU 95424, 95629
For technical questions, please call 1-800-444-3353;
MIG&ARC 250 AMP - SKU 95424
Troubleshooting
section section
at endatof
manual.
MIG DUAL 250 AMP – SKU
Troubleshooting
end
of manual.
Page 36
Page 33
SKU 95424, 95629
R3
1k
For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual.
For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual.
+
Power Electrode
Cable #18A
Power Positive
Cable #15A
“+”
Cable Eltctrode
With Holder
GUN
Vd49...Vd96
#2B
gr
Tr2 #6B
5
4
3
2
1
Power Cord #1A
6
5
4
3
2
1
XS24
Power Negative
Cable #25A
“-”
XS8
Tr1 #1B
Cable Graund
With Clamp
XS1
X2
X3
#5B
FR3
X1
XS7
Vd100
1N4007
Thermoreley
FR1
#8A
Vd1...Vd48
#2B
Beeper Block
Polarity
Switch #12A
XS25
+
C1
100,0 63V
230 Volt / 60 Hz
Single Phase / 40 Amps
MIG&ARC 250 AMP - SKU 95424
MIG DUAL 250 AMP – SKU
6
5
4
3
2
1
XS2
XS3
XS4
XS5
7
8
6
5
3
4
2
1
5 1
R11
R10
R9
R8
B1
1
O2
O1
R5
k4-1
R7
k3-1
R4
k2-1
R12
k4-2
k2-2
k1-2
R6
R3
k1-1
R2
R1
2-2
2-1

Tr1
1
DA1
4-1
4-2
Vt1
Vd19
3-1
Vd20
Vd21
R11
R10
Vd15 Vd16
Vd13 Vd14
Vd11 Vd12
Vd9 Vd10
8
7
6
5
4
3
XS23
1
2
3
XS19
« +12 V Fan» 2
« -12 V Fan » 1
«0"
«Out A»
«ON A»
y
w
gr
p
s
bl
r
br
gr
y
w
M1
XS16
S4
“Power”
#1C
t
Fan
XS20...XS22
R2
XS15
XS14
S2
gr
y
bl
w
r
s
br
Wire Speed Selector,
Overload Indicator,
Electrode Indicator
w/Cable #26A
3
4
8
5
1
6
2
7
XS10
s
XS18
1
5
4
3
2
CableBCN-4U - BC-4
Connection #33A
gr
w
y
s
2
3
4
1
XS13
2
1
Controller Block
BCN-4U
«+ 15 V Start»
«- 15 V Start»
«0"
«Inp F»
Thermoresistor
Thermoresistor
Valve
Valve
Start
Start
Electrode ON-OFF
Wire Feed Speed
Wire Feed Speed
-15 V
Overload
Electrode light
-15 V
Motor
Motor
+ Motor
- Motor
w - White
s - Grey
r – Red
gr – Green
y - Yellow
br – Brown
bl – Blue
p - Pink
The color of the wire in cables are designation:
gr
y
w
s
w
w
s
w
S3
Trigger Switch Cable #30A
“Start”
(in the Gun)
XS12
XS11
Valve Cable #9A
Power Switch
Cable #29A
Vl1
Valve
“Overload
Protection”
Vd98
Vd97
XS9
1
4
3
2
Gear Motor Cable w\ Beeper #17A
M1
S1
“U voltage select”
R1
“Wire Feed
Speed”
Voltage Selector
Switch w\cable #24A
XS17
8
4
5
6
7
1
2
3
XS6
«+ 15 V Start» 4
«- 15V Start» 3
«230 V»
2
«230 V»
1
2
«- 12V»
Connection Block BC-4-250
Vd1...Vd4

1-2
1-1
Vd7 Vd8
Vd18
Vd17
Vd5 Vd6
Vd98
+
C2 10,0 25V
Bipper
Vd99
HCM 1206X BZX55  18V
MIG/Arc Welder (95424) – Electrical Schematic
ELECTRICAL SCHEMATIC
MIG/ARC 250 AMP WELDER
Page 37
Page 34
MIG Dual Welder
(95629)SCHEMATIC
– Electrical Schematic
ELECTRICAL
MIG DUAL 250 AMP WELDER
MIG&ARC 250 AMP - SKU 95424
MIG DUAL 250 AMP – SKU
SKU 95424, 95629
For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual.
For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual.
Page 38
Page 35
POWER CORD, CONNECTION BLOCK BC-4 & TRANSFORMERS
CONNECTIONBLOCK
SCHEMATIC
POWER CORD, CONNECTION
BC-4 & TRANSFORMERS
CONNECTION SCHEMATIC
MIG&ARC 250 AMP - SKU 95424
MIG DUAL 250 AMP – SKU
SKU 95424, 95629
For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual.
For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual.
Page 39
Page 36
TROUBLESHOOTING
Important!
Be CERTAIN to shut off the Welder, disconnect it from power, and discharge the torch to
ground before adjusting, cleaning, or repairing the unit.
Welder does not function when switched on
Possible Causes and Solutions
1. Tripped thermal protection device:
Shut the welder’s switch to off and allow it to cool for at least 20 minutes.
Reduce duration or frequency of welding periods to help reduce wear on the welder.
Refer to Duty Cycle section on page 20.
2. Faulty or improperly connected Trigger Switch (13E):
Have a technician check and secure/replace Trigger Switch (13E).
3. Internal fuse blown:
Have a qualified technician check/replace.
Weak arc strength
Possible Cause and Solution
Incorrect line voltage:
Check the line voltage and, if insufficient, have a licensed electrician remedy the situation.
Welding arc not stable
1.
2.
3.
4.
5.
Possible Causes and Solutions
Wire not feeding properly (MIG welding only):
See first Troubleshooting section above.
Incorrect contact tip size (MIG welding only):
Replace with the proper tip for the wire size used.
Incorrect wire feed speed (MIG welding only):
Adjust wire feed speed to achieve a more stable arc.
Loose torch cable or ground cable:
Check to ensure that all connections are tight.
Damaged torch or loose connection within torch:
Have a qualified technician inspect and repair/replace as necessary.
If the steps above do not solve the problem or if the repairs involved are too
complex, contact a qualified technician.
SKU 95424, 95629 For technical questions, please call 1-800-444-3353.
Page 37
Troubleshooting (continued)
Important!
Be CERTAIN to shut off the Welder, disconnect it from power, and discharge the torch to
ground before adjusting, cleaning, or repairing the unit.
Wire feed motor runs but wire does not feed (MIG welding only)
Possible Causes and Solutions
1. Insufficient wire feed pressure:
Increase wire feed pressure properly - follow instructions on page 14 - 17.
2. Incorrect wire feed roll size:
Replace with the proper one - follow the Installing The Wire Spool instructions on
page 14.
3. Damaged torch, cable, or liner assembly:
Have a qualified technician inspect these parts and replace as necessary.
Wire creates a bird’s nest during operation (MIG welding only)
1.
2.
3.
4.
Possible Causes and Solutions
Excess wire feed pressure:
Adjust wire feed pressure properly - follow instructions on page 14 -17.
Incorrect contact tip size:
Replace with the proper tip for the wire size used.
Gun end not inserted into drive housing properly:
Loosen gun securing bolt and push gun end into housing just enough so that it does
not touch wire feed mechanism.
Damaged liner:
Have a qualified technician inspect and repair/replace as necessary.
Wire feeds, but arc does not ignite (MIG welding only)
Possible Causes and Solutions
1. Improper ground connection:
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. Improperly sized or excessively worn Contact Tip (2E):
Verify that Contact Tip (2E) is the proper size for the welding wire used. Check that
the hole in the tip is not deformed or enlarged. Also, check that the tip is not dirty; this
would prevent a good connection. If needed, replace Contact Tip (2E) with proper size
and type.
If the steps above do not solve the problem or if the repairs involved are too
complex, contact a qualified technician.
SKU 95424, 95629 For technical questions, please call 1-800-444-3353.
Page 38
Troubleshooting (continued)
Important!
Be CERTAIN to shut off the Welder, disconnect it from power, and discharge the torch to
ground before adjusting, cleaning, or repairing the unit.
Wire feeds, but shielding gas does not flow (MIG welding only)
1.
2.
3.
4.
5.
Possible Causes and Solutions
Empty Gas Cylinder:
Check gas cylinder.
Nozzle Plugged:
Clean nozzle. If damaged, replace.
Regulator or cylinder valve closed:
Make sure both valves are adjusted properly.
Gas line blocked:
Check external hose, and hose within Torch cable.
Gas solenoid broken or not connected properly:
Have a qualified technician check/replace.
Wire feed motor does not run (MIG welding only)
Possible Causes and Solutions
1. If beeping is heard, the wire is likely jammed somewhere in the torch, cable, or
wire feed mechanism.
Carefully examine welding wire and welding wire route to determine the cause of the
jam. Whenever possible, keep the welder off while the jam is being remedied to help
prevent injury when the wire restarts.
2. (Model 95424 only.) Wire Feed Speed Knob (3C) in stick (arc) position.
Change knob setting to proper speed.
Electrode Fuses to Work (Stick/Arc welding, model 95424, only)
Possible Causes and Solutions
1. Electrode too close to workpiece:
Hold electrode slightly farther from workpiece.
2. Moist or damaged electrodes:
Use dry electrodes that have been stored correctly.
If the steps above do not solve the problem or if the repairs involved are too
complex, contact a qualified technician.
SKU 95424, 95629 For technical questions, please call 1-800-444-3353.
Page 39