ac/dc tig welder - 200 amp model 91149images.harborfreight.com/manuals/91000-91999/91149.pdf3....

AC/DC TIG WELDER - 200 AMP

Model 91149

ASSEMBLY AND OPERATING INSTRUCTIONS

3491 Mission Oaks Blvd., Camarillo, CA 93011Visit our Web site at: http://www.harborfreight.com

Copyright© 2005 by Harbor Freight Tools®. All rights reserved. No portion of thismanual or any artwork contained herein may be reproduced in any shape or formwithout the express written consent of Harbor Freight Tools.

For technical questions, please call 1-800-444-3353.

®

PRODUCT SPECIFICATIONS

GENERAL SAFETY RULES

WARNING!READ AND UNDERSTAND ALL INSTRUCTIONS

Failure to follow all instructions listed below may result inelectric shock, fire, and/or serious injury.

SAVE THESE INSTRUCTIONS

WORK AREA

1. Keep your work area clean and well lit. Cluttered benches and dark areasinvite accidents.

2. Do not operate welding equipment in explosive atmospheres, such as inthe presence of flammable liquids, gases, or dust. Welding equipment

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 frontcover. Keep this manual and invoice in a safe and dry place for future reference.

When unpacking, check to make sure all the parts shown on the Parts Lists on pages 23and 26 are included. If any parts are missing or broken, please call Harbor Freight Toolsat the number shown on the cover of this manual as soon as possible.

UNPACKING

SKU 91149 For technical questions, please call 1-800-444-3353. PAGE 2

Item Description Electrical Requirements Input Voltage: 220V / 60 Hz / 69 Input Amperage

Built-In Thermal Overload Protection Required Power Cord (not included) Rating: 6 AWG, Maximum length 25’ Must be direct wired to a 220V, 70 Amp, dedicated circuit

Welding Modes (4) AC MMA / DC MMA / AC TIG / DC TIG. Duty Cycles 40% @ 200 AMPs AC / 60% @ 165 AMPs AC / 100% @ 130 AMPs AC

40% @ 170 AMPs DC / 100% @ 110 AMPs DC Material Capacity Suitable for all ferrous and non-ferrous metals Welding Machine Coolant Type Forced Air Cooled Gun Gas Hose Length 16’ 9-1/2”Long Ground Clamp Cable Length 16’ 9-1/2”Long Accessories Welding Gloves / Welding Mask

Chipping Hammer / Wire Brush Weight 127.05 Pounds

creates sparks which may ignite the dust or fumes.

3. Keep bystanders, children, and visitors away while operating weldingequipment. Distractions can cause you to lose control. Protect others in thework area from arc rays, sparks, and slag. Provide barriers or shields asneeded.

ELECTRICAL SAFETY

1. This Tig Welder requires the connection of a 220 volt electrical cord (not included)wired directly from the Welder to a 220 volt, (70 Amp) dedicated electrical circuit.For safety purposes, a qualified, certified, electrician must do this wiringconnection.

2. Avoid body contact with grounded surfaces such as pipes, radiators,ranges, and refrigerators. There is an increased risk of electric shock if yourbody is grounded.

3. Do not expose welding equipment to rain or wet conditions. Water enteringwelding equipment will increase the risk of electric shock.

4. Do not abuse the Power Cord. 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.

PERSONAL SAFETY

1. Stay alert. Watch what you are doing, and use common sense whenoperating welding equipment. Do not use welding equipment while tired orunder the influence of drugs, alcohol, or medication. A moment of inattentionwhile operating welding equipment 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 hot or moving parts. Looseclothes, jewelry, or long hair can be caught in hot or moving parts.(See page 6, number 3, for recommended safety clothing.)

3. Remove adjusting keys or wrenches before turning on the weldingequipment. A wrench or a key that is left attached to an electrically charged partof the welding equipment may result in personal injury.

4. Do not overreach. Keep proper footing and balance at all times. Properfooting and balance enables better control of the welding equipment inunexpected situations.

TOOL USE AND CARE

1. Use clamps (not included) or other practical ways to secure and supportthe workpiece to a stable platform. Holding the work by hand or against yourbody is unstable and may lead to loss of control.

2. Do not force the welding equipment. Use the correct equipment for yourapplication. The correct equipment will do the job better and safer at the rate forwhich it is designed.

3. Do not use the power tool if the Power Switch does not turn it on or off.Any equipment that cannot be controlled with the Power Switch is dangerous andmust be replaced.

4. Store idle welding equipment out of reach of children and other untrainedpersons. Welding equipment is dangerous in the hands of untrained users.

5. Maintain welding equipment with care. Keep equipmet clean and dry.Properly maintained equipment is less likely to malfunction and is easier tocontrol. Do not use damaged welding equipment. Tag damaged equipment “Donot use” until repaired.

6. Check for misalignment or binding of moving parts, breakage of parts, andany other condition that may affect the equipment’s operation. If damaged,have the equipment serviced before using. Many accidents are caused bypoorly maintained equipment.


7. Use only accessories that are recommended by the manufacturer for yourmodel. Accessories that may be suitable for one type of welding equipment maybecome hazardous when used on another type of equipment

SERVICE

1. Equipment service must be performed only by qualified repair personnel.Service or maintenance performed by unqualified personnel could result in a riskof injury.

2. When servicing welding equipment, use only identical replacement parts.Follow instructions in the “Inspection, Maintenance, And Cleaning” sectionof this manual. Use of unauthorized parts or failure to follow maintenanceinstructions may create a risk of electric shock, burns, or other injury.

ELECTRICAL CONNECTION

This Tig Welder requires the connection of a 220 volt electrical cord(not included) wired directly from the Welder to a 220 volt, (70 Amp) dedicatedelectrical circuit. For safety purposes, a qualified, certified, electrician must dothis wiring connection.

WARNING!

SYMBOLOGY

V ~Axxxx/min.

no

Double Insulated

Canadian StandardsAssociation

UnderwritersLaboratories, Inc.

Volts Alternating Current

Amperes

No Load Revolutionsper Minute (RPM)


Figure A

SPECIFIC SAFETY RULES

1. Maintain a safe working environment. Keep the work area well lit. Make surethere is adequate surrounding workspace. Always keep the work area free ofobstructions, grease, oil, trash, and other debris. Do not use the Welder in areasnear flammable chemicals, dusts, and vapors.

2. Maintain labels and nameplates on the Welder. These carry importantinformation. If unreadable or missing, contact Harbor Freight Tools for areplacement.

3. Prevent eye injury and burns. Wearing and using personal safety clothing andsafety devices reduce the risk of injury. Wear ANSI approved safety impacteyeglasses with a welding helmut featuring at least a number 10 shade lensrating. Leather leggings, rubber soled, fire resistant shoes or boots should beworn when using this Welder. Do not wear pants with cuffs, shirts with openpockets, or any clothing that can catch and hold molten metal or sparks. Keepclothing free of grease, oil, solvents, or any other flammable substances. Weardry, insulating gloves and protective clothing. Wear an approved head covering toprotect head and neck. Use aprons, cape, sleeves and shoulder covers, and bibsdesigned and approved for welding procedures. When welding overhead or inconfined spaces, wear flame resistant ear plugs or ear muffs to keep sparks out ofears.

4. Avoid overexposure to fumes and gases. Always keep your head out of thefumes. Do not breathe the fumes. Use enough ventilation or exhaust, or both, tokeep fumes and gases from your breathing zone and general area. Whereventilation is questionable, have a qualified technician take an air sampling todetermine the need for corrective measures. Use mechanical ventilation toimprove air quality. If engineering controls are not feasible, use an approvedrespirator. Work in a confined area only if it is well ventilated, or while wearing anair-supplied respirator. Follow OSHA guidelines for Permissible Exposure Limits(PEL’s) for various fumes and gases. Follow the American Conference ofGovernmental Industrial Hygienists recommendations for Threshold Limit Values(TLV’s) for fumes and gases. Have a recognized specialist in Industrial Hygieneor Environmental Services check the operation and air quality and makerecommendations for the specific welding situation.


5. Do not perform welding or cutting operations near chlorinated hydrocarbonvapors produced by degreasing or painting. The heat generated by arc rayscan react to form phosgene, a highly toxic gas.

6. Irritation of the eyes, nose, and throat are symptoms of inadequateventilation. Take immediate steps to improve ventilation. Do not continueoperations if symptoms persist.


7. When welding or cutting in small areas, the operator should be externallyaccompanied by another person (standing near the enclosed work area) toobserve accident prevention procedures.

8. When welding or cutting, be aware that high frequency radiation may beproduced which can interfere with radio navigation, safety devices,computers, and communications equipment. Before operating, have aqualified technician check out that possibility.

9. Keep high frequency source doors and panels tightly shut. Keep sparkgaps at the correct settings. Use proper grounding and shielding to minimize thepossibility of interference. Keep all cables close together and close to theground. Locate the welding or cutting operation as far as possible from sensitiveelectronic equipment, or have the electronic equipment shut down temporarily.

10. Prevent accidental fires. Remove any combustible material from the workarea. When possible, move the work to a location well away from combustiblematerials. If relocation is not possible, protect the combustibles with a covermade of fire resistant material. Remove or make safe all combustible materialsfor a radius of 35 feet (10 meters) around the work area. Use a fire resistantmaterial to cover or block all open doorways, windows, cracks, and otheropenings. Enclose the work area with portable fire resistant screens. Protectcombustible walls, ceilings, floors, etc., from sparks and heat with fire resistantcovers. If working on a metal wall, floor, ceiling, etc., prevent ignition ofcombustibles on the other side by moving the combustibles to a safe location. Ifrelocation of the combustibles is not possible, designate someone to serve as afire watch, equipped with a fire extinguisher, during the welding process and atleast one half hour after the welding is completed. Do not place the torch on anymaterial other than bare concrete until the torch is completely cooled. Do notweld on materials having a combustible coating or combustible internal structuresuch as walls or ceilings, without an approved method for eliminating the hazard.Do not dispose of hot slag in containers holding combustible materials. Keep afire extinguisher nearby, and know how to use it. After welding, make a thoroughexamination for evidence of fire. Be aware that easily visible smoke or flamemay not be present for some time after the fire has started. Do not weld inatmospheres containing dangerously reactive or flammable gasses, vapors,liquids, and dust. Provide adequate ventilation in work areas to preventaccumulation of flammable gases, vapors, or dust. Do not apply heat to acontainer that has held an unknown substance or a combustible material whosecontents, when heated, can produce flammable or explosive vapors. Clean andpurge containers before applying heat. Vent closed containers, includingcastings, before preheating or welding.

11. Read and understand all instructions and safety precautions as outlined inthe manufacturer’s manual for the material you will weld.

12. Industrial applications must follow OSHA requirements.

13. Connect the earth ground as near as possible to the operating area. Earthconnections to structural parts of the building or other places distant to theoperating area will reduce their effectiveness and increase the danger of electricshock.

14. In addition to grounding the workpiece with the Welder Grounding Clamp, anearth grounding of the workpiece is recommended. Ground it directly to anearth pipe or grounding rod with a separate cable of appropriate size.IMPORTANT: Only a qualified, certified electrician should perform thisprocedure.

15. Do not touch the welding wire if you are in contact with the workpiece,ground, or another welding wire from a different machine.

16. Do not allow the welding wire to touch earth ground. Accidental earthdischarges may cause overheating and fire hazards.

17. Do not pass equipment cables through or near lifting chains, crane cables,or any electrical lines.

18. Never use the Welder near water. Ensure that the surrounding area and cuttingobjects are dry. Do not spray water or other liquids on or near the Welder.

19. Avoid all direct contact between the skin and wet garments and metal partsunder electrical power. Check that gloves and protective clothing are dry.

20. Never leave the Welder unattended when it is turned ON.

21. Always turn off the Welder in the event of a power failure.

22. Significant DC electrical voltage exists after turning off the Welder.Discharge the electrode to ground before handling.

23. Performance of this Welder may vary depending on variations in local linevoltage.

24. Always turn OFF the Welder before performing any inspection, maintenance,or cleaning procedures.



25. Use the right tool or attachment for the right job. Do not attempt to force asmall tool or attachment to do the work of a larger industrial tool or attachment.There are certain applications for which this product was designed. It will do thejob better and more safely at the rate for which it was intended. Do not modifythis product, and do not use this product for a purpose for which it was notintended.

26. Proper cylinder care: Secure gas cylinders to the Base of the Welder, a wall, orpost to prevent them from falling. All cylinders should be used and stored in anupright position. Never drop or strike a cylinder. Do not use cylinders that havebeen dented. Cylinder caps should be used when moving or storing cylinders.Empty cylinders should be kept in specified areas and clearly marked “empty”.Never use oil or grease on any inlet connector, outlet connector, or cylindervalve. Additional specific instructions for the safe handling of cylinders should besupplied by your cylinder supplier and covered under local, state, and federalregulations governing pressurized gases.

27. WARNING! The brass components of this product contain lead, a chemicalknown to the State of Califormia to cause birth defects (or other reproductiveharm). (California Health & Safety code 25249.5, et seq.)

28. WARNING! This product, when used for welding, cutting, and similarapplications, produces chemicals known to the State of Califormia to causecancer and birth defects (or other reproductive harm).(California Health & Safety code 25249.5, et seq.)

29. WARNING! People with pacemakers should consult with their physician(s)before using this product. Operation of electrical equipment in close proximity toa heart pacemaker could cause interference or failure of the pacemaker.

30. WARNING! The warnings, precautions, and instructions discussed in thisinstruction manual cannot cover all possible conditions and situations that mayoccur. It must be understood by the operator that common sense and cautionare factors which cannot be built into this product, but must be supplied by theoperator.


PRODUCT OVERVIEW

1. This 200 AMP, AC/DC TIG Welder is designed for the TIG and stick welding process, bothin the AC and DC application.

2. Suitable for all ferrous and non-ferrous materials, including stainless steel, copper,aluminum and its alloys.

3. Designed with HF (HIgh Frequency) starting which provides non-contact arc starting.

4. Designed with reversible polarity for convenient DCEN or DCEP performance.

5. Current may be adjusted steplessly by magnetic shunt.

6. Pre-gas time is pre-set inside the machine. Post-gas time may be adjusted from 0-30seconds.

7. Other design features include; forced air cooling system by fan and overload protection.

6

3

1

4

12

10

Part # Description Part # Description1 Front Panel 6 MMA/TIG Selector3 Post-Gas Potentiometer 10 Power Switch4 Hand Wheel 12 AC/DC Main Selector

Figure B


51A51B

50

52

2

Part # Description Part # Description2 Front Cover 51B Negative Terminal50 2-Pin Socket 52 Gas Hose Outlet51A Positive Terminal

FRONTCOVER

CONTROLS

FIGURE C

BACKPANEL

CONTROLS

Part # Description34 Gas Hose Inlet35 Input Terminal Cover36 Cable Bracket

FIGURE D

3435

36


ASSEMBLY INSTRUCTIONS

NOTE: For additional references to the parts listed in the following pages, refer to theAssembly Diagrams on pages 24 and 26 and Electrical Schematic on page 25.

Electrical Connection:

1. WARNING! This Tig Welder requires the connection of a 220 voltelectrical cord (not included) wired directly from the Welder to a 220 volt, (70Amp) dedicated electrical circuit. For safety purposes, a qualified, certified,electrician must do this wiring connection. Required power cord rating:6 AWG, maximum length 25’.

To Attach The Rear Wheels And Front Castor Wheels:

1. WARNING! Prior to performing any further assembly procedures,make sure the Power Cord Plug of the Welder is unplugged from itselectrical outlet.

2. To attach the two Front Castor Wheels (53), open the Front Cover (2) of theWelder. Unscrew and remove the two Bolts that hold the front end of the Base(49) of the Welder to its shipping pallet. Remove the shipping pallet. Thenscrew the Castor Wheels into the threaded mounting holes in the Base.(See Figure E.)

3. To attach the two Rear Wheels (54) to the Welder, slide a Wheel onto each endof the Axle located at the rear of the Base (49). Secure both Wheels to theAxle by inserting one Roll Pin (55) through each end of the Axle.(See Figure E.)

ROLL PIN (55)

REAR WHEEL (54)FRONT CASTOR WHEEL

(53)

FIGURE E


To Install A Gas Cylinder:

1. CAUTION! Do not use the Argon/Mixed Pressure Regulator/FlowMeter (6A) with CO shielding gas. To use CO shielding gas, you mustinstall a CO gas Pressure Regulator/Flow Meter (not included).

2 22

2. With assistance, set the cylinder upright to the body of the Welder, wall, or otherstationary support. Secure cylinder with chain (not included). (See Figure F.)

3. Remove the Cap from the cylinder. Stand to the side of the cylinder Valve, andopen the Valve slightly to blow dust and dirt from the Valve. Then, close theValve. (See Figure F.)

4. Make sure the Flow Adjust on the Gas Regulator/Flow Meter (6A) is turnedoff. Then, screw the Gas Regulator/Flow Meter firmly onto the cylinder Valve.(See Figure F.)

5. Attach the Regulator Hose (7A) from the Gas Regulator/Flow Meter (6A) tothe Gas Hose Inlet (34) located on the Back Panel (33) of the Welding machine.(See Figure F.)

6. Adjust the flow rate of the gas by turning the Flow Adjust. The typical flow rate is20 cfh (cubic feet per hour). Check the welding wire manufacturer’srecommended flow rate. (See Figure F.)

FLOWADJUST

CHAIN(NOT INCLUDED)

BACK PANEL (33)

GAS HOSE INLET (34)

ARGON GASOR

MIXED GAS

CYLINDER VALVE

CYLINDER CAP

GAS REGULATOR/FLOW METER (6A)

FIGURE F

REGULATOR HOSE(7A)


Output Connections For A TIG Welding Process With DCEN:

Note: Always turn off the Welder before making connection changes.

DCEN = Direct Current Electrode Negative.

1. Raise the Front Cover (2) to expose the controls. (See Figure C.)

2. Connect the Welding Gun’s Power Cable (4A) to the Negative Terminal (51B).Connect the Welding Gun’s Switch Cable (3A) to the 2-Pin Socket (50). Then,connect the Welding Gun’s Gas Hose (2A) to the Gas Hose Outlet (52).(See Figure C.)

3. Connect the Ground Clamp Cable (5A) to the Positive Terminal (51A).(See Figure C.)

4. NOTE: The DCEN mode is for a narrow and deep weld penetration,concentrating 70% of heat on the workpiece and 30% heat on the Welding Gun.

DCEP = Direct Current Electrode Positive.

1. Raise the Front Cover (2) to expose the controls. (See Figure C.)

2. Connect the Welding Gun’s Power Cable (4A) to the Positive Terminal (51A).Connect the Welding Gun’s Switch Cable (3A) to the 2-Pin Socket (50). Then,connect the Welding Gun’s Gas Hose (2A) to the Gas Hose Outlet (52).(See Figure C.)

3. Connect the Ground Clamp Cable (5A) to the Negative Terminal (51B).(See Figure C.)

4. NOTE: The DCEP mode is for shallow penetration and a strong cleaning action,concentrating 30% of heat on the workpiece and 70% heat on the Welding Gun.

To Select The Welding Mode:

NOTE: This Welder features 4 welding modes.

1. AC MMA = The stick/electrode welding for mild steel. This is the simplestwelding procedure.

A. Move the TIG AC/TIG DC Selector (6) to this symbol:(See Figure B.)

Output Connections For A TIG Welding Process With DCEP:

B. Move the AC/DC Main Selector (12) to this symbol:(See Figure B.)

2. DC MMA = The stick/electrode welding for high tensile steel, stainless steel,aluminum, cast iron.



3. AC TIG = TIG welding for aluminum and magnesium.



4. DC TIG = TIG welding for most ferrous and non-ferrous material exceptaluminum and magnesium.



The Post-Gas Potentiometer:

1. The Post-Gas Potentiometer (3) is used to adjust the gas flow time after thewelding current stops. This helps cool the Welding Gun and the ending weldbead. (See Figure B.)

2. The higher the welding current, the longer the post-flow time should be adjusted(from 0 to 30 seconds). (See Figure B.)

To Adjust The Welding Current:

1. Rotating the Hand Wheel (4) raises and lowers the output current, allowing theoperator to dial the desired current. (See Figure B.)

2. A clockwise rotation increases the output current. A counterclockwise rotationdecreases the output current. Turning the Hand Wheel drives the pointer whichindicates the welding current. (See Figure B.)



Welding Gun Duty Cycle And Overheating:

1. IMPORTANT! Welding longer than the rated duty cycle for this Weldingequipment can damage the Gun and void its warranty.

2. Duty cycle is a percentage of 10 minutes that the unit can weld at its rated loadwithout overheating. (See Figure G.)

3. If the unit should overheat, the thermostat opens, output stops, and the coolingfans continue to run. Wait fifteen minutes for the unit to cool. Reduce amperageor voltage, or duty cycle, before welding.

4. This Welder, at its 40% duty cycle, can run continuously under load for 4 minutesout of each 10 minute period. (See Figure G.)

5. NOTE: Higher duty cycles can be used at lower currents.(See Rating Plate information on Front Panel.)

40% Duty Cycle at 200 Amperes (AC) Using Mixed Gases

4 Minutes Welding 6 Minutes Resting

Relation Between Duty Cycle And Weld Amperes.

DUTY CYCLE (%)

WELDING CURRENT (AMPs)FIGURE G

DC AC

Welding Current:

1. While the welding current intensity used depends upon size and type ofwelding rod, thickness of workpiece, and operating manner or posture, therelations between sizes of welding rod and operating current intensity, in general,are shown in Figure H and Figure I below.

Relation Between Size Of Electrode And Welding Current

FIGURE H

Relation Between Size Of Tungsten Electrode And Welding Current

FIGURE I



TROUBLESHOOTING GUIDE - WELDING MACHINE

Use larger welding leads.

See Figure L for proper size of tungsten.



Properly sharpen electrode.


TROUBLESHOOTING GUIDE - WELDING GUN

INSPECTION, MAINTENANCE, AND CLEANING - WELDING MACHINE

1. WARNING! Make sure the Power Switch (10) is in its “OFF” position.Unplug the Power Cord Plug from its electrical outlet, and allow the Welder tocompletely cool before performing any inspection, maintenance, or cleaningprocedures.

2. Before each use, inspect the general condition of the Welder. Check fordamaged electrical wiring, loose connections, cracked, burnt, or broken parts,and any other condition that may affect its safe operation. If abnormal noise orvibration occurs, have the problem corrected before further use.Do not use damaged equipment.

3. Every six months: Blow off or vacuum dirt and dust deposits on the WeldingTransformer (46) and other components. Dirt or dust deposits on the WeldingTransformer and other internal components may reduce the insulating property orcause overheated Transformer. During heavy usage, clean monthly.

4. To replace the 3 AMP, 250V Fuse: Failure of the Welder to operate may be

Problem Possible CauseNo arc. 1. Interruption of welding power circuit to welding

gun or workpiece.2. Power source or control defective.

Arc between gas nozzleand workpiece.

1. Spatter build-up inside gas nozzle.

Welding gun body orpower cable overheated.

1. Welding current too high.2. Contact tip not correctly tightened.3. Ground clamp making poor contact.

Welding wire meltedonto contact tip.

4. Contact tip too far away from workpiece.5. Burn-back time set too long.

caused by a blown 3 AMP, 250V Fuse (8) as indicated by its melted wire strandwithin the Fuse. To replace the Fuse, unscrew and remove the Fuse Cap.Remove the old Fuse, and install a new 3 AMP, 250V Fuse. Then, replace theFuse Cap.

5. When storing, make sure to store the Welder in a safe, clean, dry location out ofreach of children and unauthorized users.

6. All maintenance, service, and repairs not listed in thismanual are only to be attempted by a qualified service technician.


INSPECTION, MAINTENANCE, AND CLEANING - WELDING GUN

1. WARNING! Make sure the Power Switch (10) on the Welding Machine isin its “OFF” position. Unplug the Power from its electrical outlet, and allow theWelder to completely cool before performing any inspection, maintenance, orcleaning procedures.

2. Before each use: Inspect the general condition of the Welding Gun. Check fordamaged electrical wiring/gas hose, loose connections, cracked, burnt, orbroken parts, and any other condition that may affect its safe operation. Ifabnormal noise or vibration occurs, have the problem corrected before furtheruse.Do not use damaged equipment.

3. Before each use: Clean welding spatter from the inside of the Gas Nozzle andspray with an anti-spatter fluid (not included).

4. To replace the Gun Contact Tip: Remove the Nozzle. Remove the old ContactTip (8A), and install a new Contact Tip. Then, replace the Nozzle.(See Figure J.)

CONTACT TIP (8A)

NOZZLEFIGURE J

5. To clean exterior of Welding Gun: Use a damp cloth with a mild detergent.Then, dry. Do not use solvents to clean the Gun.

6. When storing: Make sure to store the Welding Gun in a safe, clean, and drylocation out of reach of children and unauthorized users.

7. CAUTION! All maintenance, service, and repairs not listed in this manualare only to be performed by a qualified service technician.


PARTS LIST - WELDING MACHINE

Part # Description Part # Description1 Front Panel 30 PCB2 Front Cover 31 Capacitor3 Post-Gas Potentiometer 32 HV Capacitor4 Hand Wheel 33 Back Panel------- ----------------------------------------------------------------- 34 Gas Hose Inlet6 MMA/TIG Mode Selector 35 Input Terminal Cover7 Operating LED 36 Cable Bracket8 3 AMP, 250V Fuse 37 Input Terminal9 Overheating LED 38 Fan10 Power Switch 39 Solenoid Valve11 Handle 40 Auxiliary Transformer12 AC/DC Main Selector 41 Partition13 Guide Rail 42 Resistor14 Magnetic Shunt 43 Spark Gap15 Spring 44 Rectifier16 Shunt Support 45 Choke17 HV Coil 46 Welding Transformer18 Left Side Panel 47 Magnetic Contractor19 Frame Support 48 Right Side Panel20 Roof 49 Base21 Rubber Pad 50 2-Pin Socket22 HV Transformer 51 (A) Positive Terminal / (B) Negative Terminal23 8-Pin Relay Socket 52 5/8” Gas Hose Outlet24 8-Pin Relay 53 Castor Wheels25 8-Pin Relay 54 Rear Wheels26 11-Pin Relay Socket 55 Roll Pins27 11-Pin Relay28 PCB29 PCB

PLEASE READ THE FOLLOWING CAREFULLY

THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LISTAND ASSEMBLY DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY.NEITHER THE MANUFACTURER OR DISTRIBUTOR MAKES ANY REPRESENTATIONOR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TOMAKE ANY REPAIRS TO THE PRODUCT, OR THAT HE OR SHE IS QUALIFIED TOREPLACE ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER AND/OR DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTSREPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSEDTECHNICIANS, AND NOT BY THE BUYER. THE BUYER ASSUMES ALL RISK ANDLIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT ORREPLACEMENT PARTS THERETO, OR ARISING OUT OF HIS OR HER INSTALLATIONOF REPLACEMENT PARTS THERETO.

NOTE:Some parts are listed and shown

for illustration purposes only,and are not available individually

as replacement parts.


ASSEMBLY DIAGRAM - WELDING MACHINE




55

54

53


ELECTRICAL SCHEMATIC - WELDING MACHINE





PARTS LIST - WELDING GUN & ACCESSORIES




ASSEMBLY DIAGRAM - WELDING GUN & ACCESSORIES

1A

5A

6A

7A

8A 8A 8A9A: WELDING GLOVES NOT SHOWN.10A: CHIPPING HAMMER NOT SHOWN.11A: WIRE BRUSH NOT SHOWN.12A: WELDING MASK NOT SHOWN.

2A

3A4A

Part # Description Part # Description1A Welding Gun 7A Regulator Hose2A Gas Hose 8A Contact Tip3A Switch Cable 9A Welding Gloves (not shown)4A Power Cable 10A Chipping Hammer (not shown)5A Ground Clamp Cable 11A Wire Brush (not shown)6A Gas Regulator/Flow Meter 12A Welding Mask (not shown)

(Quantity = 3)

ac/dc tig welder - 200 amp model 91149images.harborfreight.com/manuals/91000-91999/91149.pdf3....

Documents