Manual For The 61888 170 Amp DC, 240 Volt, MIG/Flux Cored Welder

User Manual: Manual for the 61888 170 Amp-DC, 240 Volt, MIG/Flux Cored Welder 170 Amp-DC, 240 Volt, MIG/Flux Cored Welder

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REV 14g
Owner’s Manual & Safety Instructions
Save This Manual Keep this manual for the safety warnings and precautions, assembly,
operating, inspection, maintenance and cleaning procedures. Write the product’s serial number in the
back of the manual near the assembly diagram (or month and year of purchase if product has no number).
Keep this manual and the receipt in a safe and dry place for future reference.
When unpacking, make sure that the product is intact
and undamaged. If any parts are missing or broken,
please call 1-888-866-5797 as soon as possible.
Copyright© 2014 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.
Page 2 For technical questions, please call 1-888-866-5797. Item 61888
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP
Table of Contents
Safety ......................................................... 2
Specifications ............................................. 7
Setup .......................................................... 8
Basic Welding ............................................ 15
Welding Tips .............................................. 23
Maintenance .............................................. 27
Parts List and Diagrams ............................ 30
Warranty .................................................... 32
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.
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.
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.
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.
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.
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. WARNING: This product, when used for
welding, plasma cutting, soldering, or 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.)
10. WARNING: The cord of this product contains
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.)
Page 3For technical questions, please call 1-888-866-5797.Item 61888
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP
Fume and Gas Safety
INHALATION HAZARD:
Welding and Plasma Cutting Produce toxic fumes.
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 plasma cutting exhaust fumes are:
• Early onset of Parkinson’s Disease
• Heart disease
• Ulcers
• Damage to the reproductive organs
• Inflammation of the small intestine or stomach
• Kidney damage
• Respiratory diseases such as
emphysema, bronchitis, or pneumonia
Use natural or forced air ventilation and wear
a respirator approved by NIOSH to protect
against the fumes produced to reduce the
risk of developing the above illnesses.
2. 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.
Arc Ray Safety
ARC RAYS can injure eyes and burn skin.
1. Wear ANSI-approved welding eye protection
featuring at least a number 10 shade lens rating.
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.
Page 4 For technical questions, please call 1-888-866-5797. Item 61888
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP
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.
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.
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.
6. Do not expose welders to rain or wet conditions.
Water entering a welder will increase
the risk of electric shock.
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.
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.
Fire Safety
ARC AND HOT SLAG can cause fire.
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.
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.
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.
Page 5For technical questions, please call 1-888-866-5797.Item 61888
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP
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.
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
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.
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.
4. Unplug before maintenance. Unplug the Welder
from its electrical outlet before any inspection,
maintenance, or cleaning procedures.
Gas Shielded Welding - Cylinder Safety
Cylinders can explode when damaged.
1. Never weld on a pressurized or a closed cylinder.
2. Never allow an electrode holder,
electrode, welding torch, or welding
wire to touch the cylinder.
3. Keep cylinders away from any electrical circuits,
including welding circuits.
4. Keep protective cap in place over the valve
except when the cylinder is in use.
5. Use only correct gas shielding equipment
designed specifically for the type of welding
you will do. Maintain this equipment properly.
6. Protect gas cylinders from heat, being struck,
physical damage, slag, flames, sparks, and arcs.
7. Always use proper procedures
to move cylinders.
SAVE THESE INSTRUCTIONS.
Page 6 For technical questions, please call 1-888-866-5797. Item 61888
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP
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.
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.
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. The plug shown (NEMA 6-50p) is for use on a
50 A circuit. A different 250 VAC 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.
250 VAC 3-Prong Plug (6-50p) and Outlet (6-50r)
(for up to 250 VAC and up to 50 A)
DO NOT USE
125 VAC PLUG.
NOTE SIZE
DIFFERENCE.
Extension Cords
Do not use an extension cord on this welder.
Replacement Cords
1. A qualified electrician can install either of the
following UL-listed, 3 wire cords as a replacement
cord for this welder:
12 AWG up to 6 feet long,
10 AWG up to 75 feet long, or
6 AWG up to 175 feet long.
2. Do not install a thinner or longer
cord 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.
Page 7For technical questions, please call 1-888-866-5797.Item 61888
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP
Symbology
Wire Feed (Speed)
Workpiece Ground Cable
Torch Cable
Overheat Shutdown Indicator
Cooling Fan
Housing Ground Point
VAC Volts Alternating Current
AAmperes
OCV Open Circuit Voltage
KVA Kilovolt Amperes
(Volts / 1000 * Amperes)
IPM Inches Per Minute
AWG American Wire Gauge
Specifications
Power Input 240VAC / 60Hz / 20A
Welding Output DCEN/DCEP
30-170A
Capacity 22 gauge (0.031") to 1/4" (0.25") steel
Not for welding aluminum
Rated Duty Cycle 20% at 110A
(See explanation on page 17)
Open Circuit Voltage DC 38V
KVA 6
Wire Speed 120 – 800 IPM
Cable Sizes
Ground: 6′, 8 AWG
Torch: 6′, 8 AWG
Power: 3-wire, 6′, 12 AWG
6-50P NEMA plug type
Wire Spool Capacity up to 10 lb spool
(one 1 lb spool of flux-core wire included)
Accessories
Spare Welder Tips (one each for 0.023″ and 0.030″– 0.035″ wire)
Welding Face Shield
Combination Wire Brush / Chipping Hammer
Page 8 For technical questions, please call 1-888-866-5797. Item 61888
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP
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
a. press the tabs through the holes and then
b. slide the tabs forward from the back,
locking the round tab in place.
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 Face
Shield behind the holding tabs. Make sure
that the filter lens fits securely and that
light cannot leak around its edges.
Handle
Face Shield
(viewed from front)
AA
BB
Round
Tab
Face Shield
(viewed from back)
Filter Lens
Setup
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.
Note: Remove the protective foam and cardboard from the welder before setup.
Face Shield Assembly
Page 9For technical questions, please call 1-888-866-5797.Item 61888
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP
Wire Spool Installation
1. Turn the Welder OFF and unplug
it before proceeding.
2. Pull up on the door latch,
then open the Door.
3. Remove the Spool Knob, Spool Spring, and upper
Spool Plate. If replacing a Spool, remove the old
Spool and all remaining wire from the liners.
4. Place the new Wire Spool over the Spool Spindle
and on top of the lower Spool Plate as illustrated.
To prevent wire feed problems, set the
Spool so that it will unwind clockwise.
5. Secure Spool in place with the upper Spool Plate
(narrower end against the Spool),
then the Spool Spring and Spool Knob.
MIG 170
WIRE FEED WELDER
ITEM 61888
WIRE FEED SPEED
20A
240VAC
Specications
Wire 0.023″- 0.035″
(Tip and roller change required)
Capacity 22 Ga. – 1/4″ Steel Plate
Material
Types
Mild Steel and Stainless Steel
(Not for welding Aluminum.)
I
O
door
latch
Door
Spool Knob
Wire Spool
Lower
Spool Plate
Upper
Spool Plate
Spool Spring
Spool Spindle
wire must
unwind this
direction
Page 10 For technical questions, please call 1-888-866-5797. Item 61888
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP
6a. Flux Core (Gasless) Wire Setup:
Remove the two Knobs securing the cables.
Connect the Black Ground Cable to the rear, red,
positive Terminal using the Knob.
Connect the Red Torch Cable to the front, black,
negative Terminal using the other Knob.
This is the initial setup, called
Direct Current Electrode Negative (DCEN).
6b. Solid Core (Gas Shielded) Wire Setup:
a. Remove the two Knobs securing the cables.
Connect the Black Ground Cable to the front,
black, negative Terminal using the Knob.
Connect the Red Torch Cable to the rear, red,
positive Terminal using the other Knob.
This is called Direct Current Electrode Positive
(DCEP).
b. Determine which type of shielding gas
would be appropriate for the welding
you will do - see chart on welder.
c. With assistance, set the cylinder
(not included) onto a shelf or cart near
the welder and secure the cylinder in
place with two straps (not included).
d. Remove the protective cap from the
cylinder (if present). Stand to the side of
the valve opening, and open the valve
briefly to blow dust and dirt from the valve
opening. Close the cylinder valve.
e. Obtain an appropriate Regulator/Flowmeter
(not included) and close its valve completely.
Thread its inlet connector onto the
cylinder and wrench tighten.
Note: If the threads do not match, then the Regulator/
Flowmeter is likely for a different type of cylinder/gas.
f. Attach the Gas Hose securely to the
outlet of the Regulator/Flowmeter
using a hose clamp (sold separately).
–+
Ground Polarity: +
Ground
(Black)
Flux Core (Gasless) Polarity Setup
DCEN
Torch Polarity: –
Knobs
Torch
(Red)
–+
Ground Polarity: –
Torch
(Red)
Solid Core (Gas Shielded) Polarity Setup
DCEP
Torch Polarity: +
Knobs
Ground
(Black)
fe
c
Briefly open valve
to clean,
then close
valve.
d
Page 11For technical questions, please call 1-888-866-5797.Item 61888
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP
7. Turn the Feed Tensioner knob counterclockwise to
loosen it enough to pull it down to remove tension.
(Do not loosen the Tensioner knob too much, or the
Tensioner will come apart.)
Then, swing the Feed Swing Arm up.
8. Feed Roller Instructions:
Check that the Feed Roller is turned to properly
match the wire size marked on the Wire Spool:
a. Twist the Feed Roller Knob about 1/3 of a
turn counterclockwise until it stops.
b. Pull the Feed Roller Knob straight
off to expose the Feed Roller.
c. Flip the Feed Roller as needed and
confirm that the number facing you is the
same as the wire diameter on the Spool.
(0.8mm = 0.030" & 0.6mm = 0.023")
d. Place the Feed Roller Knob back into place in
the same orientation it was removed in, and twist
it about 1/3 of a turn clockwise to secure it.
Feed Swing
Arm
Feed
Tensioner
Feed
Roller
Knob
Feed
Roller
A
C
B
D
0.030/0.035 groove
and stamp
0.023 groove
and stamp
Page 12 For technical questions, please call 1-888-866-5797. Item 61888
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP
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 unravel and create a tangled
“bird’s nest”, wasting wire.
9. Cut off all bent and crimped wire.
The cut end must have no burrs or
sharp edges; cut again if needed.
10. Keep tension on the wire and guide at least
12 inches of wire into the Wire Liners.
11. Swing the wire feed swing arm down, and swing
the feed tensioner up to latch it across the tip
of the arm. Make sure the Welding Wire is
resting in the bottom groove of the Feed Roller,
then turn the feed tensioner knob clockwise a
couple of turns.
After the wire is held by the tensioner,
you may release it.
12. Pull the Nozzle to remove it.
13. Turn the Contact Tip counterclockwise
and remove.
14. Lay the Torch Cable out in a straight
line so that the wire moves through it
easily. Leave the cover open, so that the
feed mechanism can be observed.
Wire
Spool
welding
wire
HOLD WIRE
SECURELY
Wire
Liner
leader
wire liner
feed
swing arm
feed
tensioner
Feed Roller
Torch
Nozzle
Contact
Tip
Page 13For technical questions, please call 1-888-866-5797.Item 61888
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP
WARNING
The following steps require applying power
to the welder with the cover open.
To prevent serious injury from fire or electric shock:
1. Do not touch anything (especially not the Ground Clamp)
with the Torch or welding wire, or an arc may be ignited.
2. Do not touch internal welder components
while it is plugged in.
15. Do not touch the Torch’s Trigger.
Plug the Power Cord into its electrical
outlet and turn the welder ON.
16. Point the Torch away from all objects and press the
trigger until the wire feeds through two inches.
The wire liner may come out with
the welding wire, this is normal,
just push the wire liner back into the Torch.
If the wire does not feed properly and the Spool is
stationary, turn the welder OFF, unplug it, and slightly
tighten the feed tensioner clockwise before retrying.
MIG 170
WIRE FEED WELDER
ITEM 61888
WIRE FEED SPEED
20A
240VAC
Specications
Wire 0.023″- 0.035″
(Tip and roller change required)
Capacity 22 Ga. – 1/4″ Steel Plate
Material
Types
Mild Steel and Stainless Steel
(Not for welding Aluminum.)
I
O
Welding
Wire
Torch
2″
IMPORTANT
Stainless steel wire is less flexible than
other welding wire. Therefore, it is more
difficult to feed through the liner and torch.
It is especially important to keep the torch cable
straight while feeding stainless steel wire.
Page 14 For technical questions, please call 1-888-866-5797. Item 61888
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP
17. To check the wire’s drive tension, feed the wire
against a piece of wood from 2 to 3 inches away.
If the wire stops instead of bending,
turn the welder OFF, unplug it,
slightly tighten the feed tensioner clockwise,
and try again.
If the wire bends from the feed pressure,
then the tension is set properly.
18. TURN THE WELDER OFF.
19. Select a Contact Tip that is compatible with the
welding wire used. The pre-installed Tip is 0.035″.
Slide the Contact Tip over the wire and thread it
clockwise into the Torch. Tighten the Contact Tip.
20. Replace the Nozzle and cut the wire
off at 1/2″ from tip (1/2″ stickout).
21. Swing the Door closed, lift the door latch, press
on the bottom center of the Door until the door
is completely closed, and release the latch.
MIG 170
WIRE FEED WELDER
ITEM 61888
WIRE FEED SPEED
20A
240VAC
Specications
Wire 0.023″- 0.035″
(Tip and roller change required)
Capacity 22 Ga. – 1/4″ Steel Plate
Material
Types
Mild Steel and Stainless Steel
(Not for welding Aluminum.)
I
O
Torch
Nozzle
Contact
Tip
door
latch
Door
2-3″
Incrementally
increase tension
until
wire bends.
Page 15For technical questions, please call 1-888-866-5797.Item 61888
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP
Basic Welding
Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual
including all text under subheadings therein before welding.
TO PREVENT SERIOUS INJURY:
Protective gear must be worn when using the Welder; minimum shade number 10 full face shield
(or welding mask), ear protection, welding gloves, sleeves and apron, NIOSH-approved respirator, and fire
resistant work clothes without pockets should be worn when welding.
Light from the arc can cause permanent damage to the eyes and skin.
Do not breathe arc fumes.
Flux-core wire welding is used to weld sheet
metal and low carbon steel without shielding gas.
MIG welding uses solid-core wire and shielding gas,
and is used to weld sheet metal and low carbon steel.
MIG welding can also be used to weld thinner
workpieces than flux-core welding can.
Good welding takes a degree of skill and experience.
Practice a few sample welds on scrap before
welding your first project. Additional practice
periods are recommended whenever you weld:
• a different thickness of material
• a different type of material
• a different type of connection
• using a different technique (MIG vs. flux)
Make practice welds on pieces of scrap to practice
technique before welding anything of value.
Practice your welding
technique on scrap
pieces before welding
anything of value.
TO PREVENT SERIOUS INJURY,
FIRE AND BURNS:
Keep welding tip clear of grounded
objects whenever unit is plugged in.
MIG 170
WIRE FEED WELDER
ITEM 61888
WIRE FEED SPEED
20A
240VAC
Specications
Wire 0.023″- 0.035″
(Tip and roller change required)
Capacity 22 Ga. – 1/4″ Steel Plate
Material
Types
Mild Steel and Stainless Steel
(Not for welding Aluminum.)
I
O=
Page 16 For technical questions, please call 1-888-866-5797. Item 61888
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP
Control Panel Layout
Overload Indicator:
This lights up if duty cycle work period is exceeded,
resulting in overheating the welder.
Rest the Torch on an electrically non-conductive,
heat-resistant surface, such as a concrete slab, well
clear of the ground clamp while allowing the welder
to cool with the Power Switch on, so the Fan can
help cool the welder. Once the welder cools enough
to be used again, use shorter welding periods and
longer rest periods to prevent needless wear.
Power Switch:
This turns on power to the welding Torch and
internal cooling fan. The welding Torch is
energized whenever the Power Switch is on.
Current Switch:
This controls the output amperage of the welder.
Adjust this according to the weld settings
chart to achieve a good weld.
Wire Speed Dial:
This controls the speed that the welding wire
feeds out of the welding Torch and
adapts output amperage somewhat.
Adjust this according to the weld settings
chart to achieve a good weld.
Power Cord:
Plug the Power Cord into a properly grounded
240 VAC (at least 30 amp rating) outlet with
delayed action type circuit breaker or fuses.
Torch Cable:
The welding Torch connects here.
The wire and welding current feeds to
the weld through here. The welding Torch is
energized whenever the Power Switch is on.
Ground Cable:
This connects to the base metal to provide a good
connection for the current to travel back to the welder.
MIG 170
WIRE FEED WELDER
ITEM 61888
WIRE FEED SPEED
20A
240VAC
Specications
Wire 0.023″- 0.035″
(Tip and roller change required)
Capacity 22 Ga. – 1/4″ Steel Plate
Material
Types
Mild Steel and Stainless Steel
(Not for welding Aluminum.)
I
O
Wire
Speed
Dial
Torch
Cable
Ground
Cable
Power
Switch
Current
Switches
Overload
Indicator
Power
Cord
Page 17For technical questions, please call 1-888-866-5797.Item 61888
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP
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
with a 20% duty cycle at rated output (110A)
must be allowed to rest for at least 8 minutes
after every 2 minutes of continuous welding.
Failure to carefully observe any duty cycle limitations
can easily over-stress a welder’s power generation
system contributing to premature welder failure.
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
Indicator lights, then the welder automatically returns
to service after cooling off. Rest the Torch 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.
20% Rated Duty Cycle
at 110A output
2 minutes welding
followed by
at least 8 minutes
of rest
MIG 170
ITEM 61888
I
O
Torch
concrete slab
(or other heat-proof,
non-conductive
surface)
Duty Cycle (Duration of Use)
Page 18 For technical questions, please call 1-888-866-5797. Item 61888
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP
MIG Weld Settings
DCEP
Polarity
GAS
Material
Being
Welded
Wire
Type
Wire
Diameter
Shielding
Gas
Suggested
Settings
22 Ga
0.030″
0.8mm
18 Ga
0.048″
1.2mm
16 Ga
0.060″
1.5mm
14 Ga
0.075″
2.0mm
1/8″
3.2mm
3/16″
4.8mm
1/4″
6.4mm
Mild
Steel
Solid
(E70S-6)
0.023″ 25% CO2
+75% Argon
6-8L / MIN
Current MIN 1 MIN 2
Wire Feed 5 6
0.030″ 25% CO2
+75% Argon
8-10L / MIN
Current MIN 1 MIN 2 MIN 2 MAX 1 MAX 1
Wire Feed 4 5 6 7 8.5
0.035″ 25% CO2
+75% Argon
8-10L / MIN
Current MIN 2 MIN 2 MAX 1 MAX 1 MAX 2 MAX 2
Wire Feed 2 2.5 3 5 8 10
Metal Thickness
Note: The charts below are only 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 experience.
Flux Weld Settings
DCEN
Polarity
NO
GAS
Material
Being
Welded
Wire
Type
Shielding
Gas
Wire
Diameter
Suggested
Settings
22 Ga
0.030″
0.8mm
18 Ga
0.048″
1.2mm
16 Ga
0.060″
1.5mm
14 Ga
0.075″
2.0mm
1/8″
3.2mm
3/16″
4.8mm
1/4″
6.4mm
Mild
Steel
Flux-core
(E71T-GS)
NO
GAS
Required
0.030″ Current MIN 1 MIN 2 MIN 2 MAX 1
Wire Feed 2 3 4 5
0.035″ Current MIN 1 MIN 1 MAX 1 MAX 1 MAX 1
Wire Feed 2 3 4 6 6
Metal Thickness
Page 19For technical questions, please call 1-888-866-5797.Item 61888
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP
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.
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.
3. Clamp Ground Cable to bare metal on the
workpiece near the weld area, or to metal work
bench where the workpiece is clamped.
4. Set the Wire Speed Dial and the Current Switch to
the desired settings.
Refer to the chart on the welder or the chart on the
previous page.
DO NOT SWITCH THE CURRENT
WHILE WELDING.
clamps
workpieces
Chamfer thick workpieces.
Clean
surfaces to
bare metal.
MIG 170
WIRE FEED WELDER
ITEM 61888
WIRE FEED SPEED
20A
240VAC
Specications
Wire 0.023″- 0.035″
(Tip and roller change required)
Capacity 22 Ga. – 1/4″ Steel Plate
Material
Types
Mild Steel and Stainless Steel
(Not for welding Aluminum.)
I
O
Workpiece
Ground
Clamp
Clean
surface to
bare metal.
Setting Up The Weld
+
MIG 170
WIRE FEED WELDER
ITEM 61888
WIRE FEED SPEED
20A
240VAC
Specications
Wire 0.023″- 0.035″
(Tip and roller change required)
Capacity 22 Ga. – 1/4″ Steel Plate
Material
Types
Mild Steel and Stainless Steel
(Not for welding Aluminum.)
I
O
MIG 170
WIRE FEED WELDER
ITEM 61888
WIRE FEED SPEED
20A
240VAC
Specications
Wire 0.023″- 0.035″
(Tip and roller change required)
Capacity 22 Ga. – 1/4″ Steel Plate
Material
Types
Mild Steel and Stainless Steel
(Not for welding Aluminum.)
I
O
Page 20 For technical questions, please call 1-888-866-5797. Item 61888
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP
DANGER! TO PREVENT DEATH
FROM ASPHYXIATION:
Do not open gas without proper ventilation. Fix
gas leaks immediately.
Shielding gas can displace air and cause rapid loss of
consciousness and death.
Shielding gas without carbon dioxide can be even
more hazardous because asphyxiation can start
without feeling shortness of breath.
5. Gas shielded, solid-core wire only:
Open gas tank valve and adjust regulator/
flowmeter to flow rate indicated on chart.
6. Flip the Power Switch to the OFF position, then
plug the Welder into a dedicated, 240 VAC
receptacle that matches the plug.
The circuit must be equipped with delayed
action type circuit breaker or fuses.
7. Hold the Torch, without touching the Trigger,
with the wire and tip clearly out of the way of any
grounded objects.
Then, turn the Power Switch ON.
MIG 170
WIRE FEED WELDER
ITEM 61888
WIRE FEED SPEED
20A
240VAC
Specications
Wire 0.023″- 0.035″
(Tip and roller change required)
Capacity 22 Ga. – 1/4″ Steel Plate
Material
Types
Mild Steel and Stainless Steel
(Not for welding Aluminum.)
I
O
MIG 170
WIRE FEED WELDER
ITEM 61888
WIRE FEED SPEED
20A
240VAC
Specications
Wire 0.023″- 0.035″
(Tip and roller change required)
Capacity 22 Ga. – 1/4″ Steel Plate
Material
Types
Mild Steel and Stainless Steel
(Not for welding Aluminum.)
I
O
HOLD
TORCH
CLEAR
Page 21For technical questions, please call 1-888-866-5797.Item 61888
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP
1. Press (and hold) Trigger and contact area to
be welded with electrode wire to ignite arc.
2. For a narrow weld, you can usually draw the wire in
a steady straight line,
this is called a stringer bead.
For a wider weld, draw the wire back and forth
across the joint.
This is called a weave bead and takes
practice to perform properly.
3. Hold Torch in one hand and the face shield in
the other. If a hands-free welding shield (not
included, see #6, page 4 for guidelines) is used,
then both hands can be used to control Torch.
4. Direct the welding wire straight into the joint.
This gives an angle of 90° (straight up and
down) for butt (end to end) welds, and an
angle of 45° for fillet (T-shaped) welds.
5. The end of torch should be tilted so that wire
is angled anywhere in-between straight on
and 15° in the direction you are welding. The
amount of tilt is called the drag angle.
6. The welding wire should extend no more than 1/2″
past the tip.
This distance is called stickout or CTWD
- Contact Tip to Work Distance.
stringer bead weave bead
Weld Torch angles,
viewed from front of weld joint.
45°
fillet weld joint
90°
butt weld joint
Stickout
(up to 1/2″)
Weld
Direction
Drag Angle
0-15°
Basic Welding Technique
Page 22 For technical questions, please call 1-888-866-5797. Item 61888
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP
Note: If Welder is used too long, the amber Overload
Indicator will light and the Welder Torch will shut off
until the welder cools. If this happens, rest the Torch
on an electrically non-conductive, heat-resistant
surface, such as a concrete slab, well clear of the
ground clamp. Wait about 8-10 minutes with the
Power Switch ON for the welder to cool. When the
welder can be used again, use shorter welding periods
and longer rest periods to help prevent needless wear.
7. After welding the test weld on a piece
of scrap for a few seconds, stop, and
check your progress. Clean, then compare
your weld’s appearance with the diagrams
and descriptions in the Welding Tips section
starting on the next page. After making any
necessary adjustments, continue to weld
while carefully following the DUTY CYCLE
guidelines as explained on page 17.
CAUTION! Weld will be hot, do not touch.
8. When the weld is complete, lift the Torch and
welding wire clearly away from any grounded
object, and turn the Power Switch off.
9. Set the Torch down on a heat-
proof, electrically non-conductive
surface. Unplug the Power Cord.
10. MIG ONLY:
Close shielding gas tank valve completely.
MIG 170
ITEM 61888
I
O
Torch
concrete slab
(or other heat-proof,
non-conductive
surface)
After practice welding for a few
seconds, STOP and examine
your weld using the guidelines
starting on the next page.
FOLLOW DUTY CYCLE!
up to 2 minutes
welding at rated output
MIG 170
WIRE FEED WELDER
ITEM 61888
WIRE FEED SPEED
20A
240VAC
Specications
Wire 0.023″- 0.035″
(Tip and roller change required)
Capacity 22 Ga. – 1/4″ Steel Plate
Material
Types
Mild Steel and Stainless Steel
(Not for welding Aluminum.)
I
O
HOLD
TORCH
CLEAR
Torch
concrete slab
(or other heat-proof,
non-conductive
surface)
Page 23For technical questions, please call 1-888-866-5797.Item 61888
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP
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.
A typical solid wire (GMAW) weld
before cleaning.
base metal
weld bead spatter
A typical flux-core wire (FCAW) weld
before cleaning.
base metal
weld bead
slag spatter
Cleaning the Weld
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.
1. A weld from flux core wire will be covered
by slag, use the Chipping Hammer
to knock this off. Be careful not to
damage the weld or base material.
2. Then, use the Wire Brush to further
clean the weld or use an angle grinder
(sold separately) to shape the weld.
Chipping
Hammer
Wire Brush
Strike Test
A test weld on a PIECE OF SCRAP can be tested by
using the following procedure.
WEAR ANSI-APPROVED SAFETY GOGGLES
DURING THIS PROCEDURE.
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.
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.
clamp
SCRAP
workpiece
GOOD WELD
bends and is not brittle
dead-blow hammer
clamp
SCRAP
workpiece
POOR WELD
snaps or cracks
dead-blow hammer
Page 24 For technical questions, please call 1-888-866-5797. Item 61888
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP
EXCESS PENETRATION OR
BURN-THROUGH
PROPER PENETRATIONINADEQUATE PENETRATION
Not hot enough Too hotIdeal heat
Weld Diagnosis
Workpiece Heat Control / Weld Penetration
Good
Weld
Current
Too Low or
Wire Feed
Too Slow
Current
Too High or
Wire Feed
Too Fast
Weld Speed
Too Fast
Weld Speed
Too Slow
Stickout
Too Long
or
Wrong Polarity
Example Weld Diagrams
TO CORRECT:
weld
slower
TO CORRECT:
weld
faster
How to increase workpiece heat
and increase penetration:
(to weld THICKER workpieces properly)
How to reduce workpiece heat
and limit penetration:
(to weld THINNER workpieces properly)
a. Increase weld current
b. Weld more slowly
c. Use faster wire feed
d. Use shorter stickout
a. Decrease weld current
b. Weld more quickly
c. Use slower wire feed
d. Use longer stickout
TO CORRECT:
MIG 170
WIRE FEED WELDER
ITEM 61888
WIRE FEED SPEED
20A
240VAC
Specications
Wire 0.023″- 0.035″
(Tip and roller change required)
Capacity 22 Ga. – 1/4″ Steel Plate
Material
Types
Mild Steel and Stainless Steel
(Not for welding Aluminum.)
I
O
TO CORRECT:
MIG 170
WIRE FEED WELDER
ITEM 61888
WIRE FEED SPEED
20A
240VAC
Specications
Wire 0.023″- 0.035″
(Tip and roller change required)
Capacity 22 Ga. – 1/4″ Steel Plate
Material
Types
Mild Steel and Stainless Steel
(Not for welding Aluminum.)
I
O
TO CORRECT:
maintain
less
than 1/2″
stickout
Check Polarity
and
Decrease
Current
Max2 -> Max1
Max1 -> Min2
Min2 -> Min1
or
Increase
Current
Min1 -> Min2
Min2 -> Max1
Max1 -> Max2
or
Page 25For technical questions, please call 1-888-866-5797.Item 61888
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP
EXCESS PENETRATION OR
BURN-THROUGH
Weld droops on top and
underneath, or falls through
entirely, making a hole.
PROPER PENETRATION
Weld is visible underneath and
bulges slightly on top.
INADEQUATE PENETRATION
Weld does not contact the joint
fully, just on the surface.
POSSIBLE CAUSES AND SOLUTIONS
1. Workpiece overheating:
Reduce wire feed speed.
Decrease weld current.
2. Welding speed too slow:
Increase welding speed and ensure
that welding speed is kept steady.
3. Excessive material at weld:
Reduce wire feed speed.
POSSIBLE CAUSES AND SOLUTIONS
1. Incorrect welding technique:
Maintain 1/2″ or less stickout.
Keep arc on leading edge of weld puddle.
Hold torch at proper angles.
2. Insufficient weld heat:
Reduce welding speed.
Increase weld current.
3. Workpieces too thick/close:
Bevel thick workpieces, allow slight
gap, and weld in several passes.
4. Insufficient weld material:
Increase wire feed speed.
PROFILE VIEWS
Weld Problems
Penetration (Workpiece Heat Control)
Weld Not Adhering Properly
Gaps present between weld and previous bead or
between weld and workpiece. See areas below.
POSSIBLE CAUSES AND SOLUTIONS
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.
Pause briefly at sides during weave bead.
Keep arc on leading edge of weld puddle.
Hold torch at proper angles.
2. Insufficient weld heat:
Increase current.
Increase wire feed speed.
3. Dirty workpiece:
Clean workpiece down to bare metal.
4. Insufficient weld material:
Increase wire feed speed.
PROFILE
VIEW
Bend at Joint
POSSIBLE CAUSES AND SOLUTIONS
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.
Reduce wire feed speed.
PROFILE
VIEW
Coat of Slag Over Weld
Slag is a necessary part of a flux-core wire
weld. It shields the weld from impurities.
Clean off the slag with the Chipping
Hammer and Wire Brush after welding.
Gas-shielded MIG welds are protected by the
shielding gas and do not need slag to protect them.
TOP
VIEW
PARTIALLY CHIPPED AWAY TO SHOW WELD
Page 26 For technical questions, please call 1-888-866-5797. Item 61888
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP
Burn-Through
Base material melts away,
leaving a hole in the weld.
POSSIBLE CAUSES AND SOLUTIONS
1. Workpiece overheating:
Reduce current and/or wire feed speed.
2. Welding speed too slow:
Increase welding speed and ensure
that welding speed is kept steady.
3. Excessive material at weld:
Reduce wire feed speed.
TOP
VIEW
Crooked/Wavy Bead
POSSIBLE CAUSES AND SOLUTIONS
1. Inaccurate welding:
Use two hands or rest hand on steady surface.
2. Inconsistent welding speed:
Maintain steady weld speed.
3. Stickout too long:
Reduce stickout.
TOP
VIEW
Porosity
Small cavities or holes in the bead.
POSSIBLE CAUSES AND SOLUTIONS
1. Incorrect polarity:
Check that polarity is set correctly
for type of welding.
2. Insufficient shielding gas (MIG only):
Increase flow of gas.
Clean nozzle.
Maintain proper stickout.
3. Incorrect shielding gas (MIG only):
Use shielding gas recommended by wire supplier.
4. Dirty workpiece or welding wire:
Clean workpiece down to bare metal.
Make certain that wire is clean and free
from oil, coatings, and other residues.
5. Inconsistent welding speed:
Maintain steady weld speed.
6. Stickout too long:
Reduce stickout.
TOP
VIEW
Excessive Spatter
Fine spatter is normal.
Spatter that is grainy and large is a problem.
POSSIBLE CAUSES AND SOLUTIONS
1. Dirty workpiece or welding wire:
Clean workpiece down to bare metal.
Make certain that wire is clean and free
from oil, coatings, and other residues.
2. Incorrect polarity:
Check that polarity is set correctly
for type of welding.
3. Insufficient shielding gas (MIG only):
Increase flow of gas.
Clean nozzle.
Maintain proper stickout.
4. Wire feeding too fast:
Reduce wire feed speed.
5. Stickout too long:
Reduce stickout.
TOP
VIEW
Page 27For technical questions, please call 1-888-866-5797.Item 61888
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP
Maintenance
TO PREVENT SERIOUS INJURY, FIRE AND BURNS:
Unplug the welder, rest the Torch on a heat-proof, electrically non-conductive surface, and
allow all parts of the Welder to cool thoroughly before service.
1. Periodically remove the Side Panel, and using
compressed air, blow out all dust from the interior.
2. Store in a clean and dry location.
3. For optimal weld quality, clean and
inspect the Contact Tip and Nozzle
before each use, as explained below:
Torch
concrete slab
(or other heat-proof,
non-conductive
surface)
+
Nozzle and Contact Tip Inspection and Cleaning
1. Make sure that the entire Torch is completely
cool and that the Power Cord is unplugged
from the electrical outlet before proceeding.
2. Turn the Nozzle counterclockwise
while pulling to remove.
3. Scrub the interior of the Nozzle
clean with a wire brush.
4. Examine the end of the Nozzle. The end should be
flat and even. If the end is uneven, chipped, melted,
cracked, or otherwise damaged, the Nozzle will
adversely effect the weld and should be replaced.
5. Turn the Contact Tip counterclockwise
and slide it off the welding wire.
6. Scrub the outside of the Tip clean with a wire brush.
Clean out the inside of the tip with a tip
cleaner (sold separately). Check that the Tip
is the proper type for the wire size used.
7. Examine the shape of the hole at the end of
the Contact Tip. It should be an even circle; it
should not be oblong or have any bulges in it.
8. If any problems are noted, replace the
Contact Tip. Select a new Tip of the
correct size for the welding wire used.
9. Reinstall the Tip and securely
reinstall the Nozzle as well.
Torch
Nozzle
Contact
Tip
Page 28 For technical questions, please call 1-888-866-5797. Item 61888
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP
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.
Problem Possible Causes Likely Solutions
Wire feed motor
runs but wire does
not feed properly
1. Insufficient wire feed pressure.
2. Incorrect wire feed roll size.
3. Damaged Torch, cable, or liner assembly.
1. Increase wire feed pressure properly
- follow step 17 on page 14.
2. Flip roll to correct size, follow the Wire
Spool Installation instructions on page 9.
3. Have a qualified technician inspect
these parts and replace as necessary.
Wire creates a
bird’s nest during
operation
1. Excess wire feed pressure.
2. Incorrect contact tip size.
3. Torch end not inserted into drive housing
properly.
4. Damaged liner.
1. Adjust wire feed pressure properly
- follow step 17 on page 14.
2. Replace with the proper tip for wire used.
3. Loosen torch securing bolt and push torch
end into housing just enough so that it
does not touch wire feed mechanism.
4. Have a qualified technician inspect
and repair/replace as necessary.
Welding arc
not stable
1. Wire not feeding properly.
2. Incorrect contact tip size.
3. Incorrect wire feed speed.
4. Loose Torch cable or ground cable.
5. Damaged Torch or loose
connection within Torch.
1. See first Troubleshooting section above.
2. Replace with the proper tip for wire used.
3. Adjust wire feed speed to
achieve a more stable arc.
4. Check to ensure that all
connections are tight.
5. Have a qualified technician inspect
and repair/replace as necessary.
Weak Arc strength
1. Incorrect line voltage.
2. Improper gauge or length of cord.
3. Not enough current.
1. Check the line voltage and, if
insufficient, have a licensed
electrician remedy the situation.
2. Do not use an extension cord on this welder.
If a longer cord is needed, refer to the
replacement cord guidelines on page 6.
3. Switch current to proper setting
for metal thickness.
Follow all safety precautions whenever diagnosing or servicing the equipment.
Page 29For technical questions, please call 1-888-866-5797.Item 61888
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP
PLEASE READ THE FOLLOWING CAREFULLY
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM
IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER OR DISTRIBUTOR
MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS
QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT, OR THAT HE OR SHE IS QUALIFIED TO REPLACE
ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER AND/OR DISTRIBUTOR EXPRESSLY
STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND
LICENSED TECHNICIANS, AND NOT BY THE BUYER. THE BUYER ASSUMES ALL RISK AND LIABILITY
ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS
THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO.
Problem Possible Causes Likely Solutions
Power switch
lights, but welder
does not function
when switched on
1. Tripped thermal protection device.
2. Faulty or improperly connected Trigger.
1. Stop welding and wait about 8-10 minutes
with the Power Switch ON for the welder
to cool. Reduce duration or frequency
of welding periods to help reduce wear
on the welder. Refer to Duty Cycle
(Duration of Use) on page 17.
2. Qualified technician must check
and secure/replace Trigger.
Power switch
does not light
when switched on
1. Unit is not connected to outlet properly.
2. Outlet is unpowered.
3. Circuit supplies insufficient input voltage or
amperage.
4. Plug does not have correct rating.
1. Verify the voltage at the outlet and
the connection to the outlet.
2. Check circuit breaker/GFCI devices;
if any are tripped, determine and
remedy cause before resetting.
3. Verify that the circuit is designed to supply
the required input voltage and amperage
as detailed on the Specifications table.
4. Make sure installed plug is correct
rating (250 VAC, 50A recommended)
- see Specifications on page 7.
Wire feeds, but
arc does not ignite
1. Improper ground connection.
2. Improperly sized Contact Tip.
3. Excessively worn Contact Tip.
4. Dirty Contact Tip.
1. Make certain that the workpiece is
contacted properly by the Ground
Clamp and that the workpiece is
properly cleaned near the ground
clamp and the welding location.
2. Verify that Contact Tip is the proper
size for welding wire. If needed, replace
Contact Tip with proper size and type.
3. Check that the hole in the tip is not
deformed or enlarged. If needed, replace
Contact Tip with proper size and type.
4. Properly clean Contact Tip.
Follow all safety precautions whenever diagnosing or servicing the equipment.
Troubleshooting (cont’d)
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.
Page 30 For technical questions, please call 1-888-866-5797. Item 61888
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP
Parts List and Diagrams
Wiring Diagram
R6
1.1K (3.3KX3)
R3
10
C3
0.1uF/250V
A K
G
SCR1 TYN412
R15
0.5/ 10W
R7
10K
R8
10
D2
1N4007
C4
10uF/63V
TR1 2N3440
Z1
K50
D3
1N4007
C5100n/63V
R10
10k
D4
1N4007
D5 1N4007
C8 100n/63V
R14
430
KP1 1K
C9
100n/63V
C6
100uF/63V
C7 100n/63VR13
100
D6
1N4007
R9 10
R11
820 /0.5W
S1
FM Overheat
Indicator
t/
TH
L
PE
N
1
2
3
4
D
+
_
TR2
C2
22uF/50V
CR1
CMP8-S-DC12V-A
C1
104K630V
Touch
CN3CN2
P1
P5P2
P7
1
2
3
4
D2
W08
0.5A
FUSE2
P4
CR2-2
CR2
G5LC-14
CN4
P6
CR2-1
3.15A
FUSE1
A
-
+Wire Feeder
DC 24V Moto
r
R12
51/0.25W
S1
1
S3
MIN
2
MAX
TR1
L1
S2
A
C240V 60Hz
Parts List
Record 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.
Part Description Qty
1 Handle Screw 2
2 Handle 1
3 Housing 1
4 Self-Tapping Screw 14
5 Reactor 1
6Main Transformer 1
7 Thermal Cut-Off 1
8 Screw 4
9 Transformer Support 2
10 Screw 4
11 Wire Spool 1
12 Wire Motor 1
13 Black Terminal 1
14 Ring 1
15 Divider 1
16 Rectifier 1
17 Air Inlet 1
18 Base 1
19 Fan 1
Part Description Qty
20 Screw 4
21 Screw 4
22 Foot 4
23 PCB Board 1
24 PCB Board Support 1
25 Red Terminal 1
26 Overload Indicator 1
27 Current Adjustment Switch 2
28 Power Switch 1
29 Wire Speed Knob 1
30 Torch Cable Sleeve 1
31 Grommet 2
32 Torch 1
33 Ground Clamp 1
34 Power Cord 1
35 Face Shield 1
36 Face Shield Handle 1
37 Filter Lens 1
38 Wire Brush / Chipping Hammer 1
Page 31For technical questions, please call 1-888-866-5797.Item 61888
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP
Assembly Diagram
1
2
4
3
5
6
16
17
18
8
7
9
10
29
31
11
12
13
14
1
519
20
23
24
25
28
27
26
30
33
34
2
2
32
21
36
37
38
35
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 • 1-888-866-5797

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