Harbor Freight Tools 91146 User Manual

MIG WELDER - 250 AMP

Model 91146

ASSEMBLY AND OPERATING INSTRUCTIONS

3491 Mission Oaks Blvd., Camarillo, CA 93011

Visit our Web site at: http://www.harborfreight.com

without the express written consent of Harbor Freight Tools.

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

PRODUCT SPECIFICATIONS

Item Description

Electrical Requirements Input Voltage: 220V / 60 Hz / 45 Input Amperage

Power Cord: 10 AWG @ 6’ Long

Power Plug: 220V (not included), Requires 50 Amp Circuit Duty Cycles 60% @ 250 Amps / 100% @ 195 Amps Maximum Welding Thickness Capacity Welding Current 30 – 250 Amps Required Wire Sizes .024” To .047” Diameter Wire Control Settings Internal, Spot & Pause, 4 Time, & 2 Time Gun Coolant Type Air Cooled Fuse Type 3 AMP Bu ss Fuse Gun Power Cab le Length 13’ Ground Clamp Cable Length 13’ Wheels Front: Swivel Castors / 3-1/4” Diameter x 1” Thick

Accessories Gas Pressure Regulator w/Flow Meter

Weight 187 Pounds

Up To 3/8” Mild Steel

Rear: Rigid / 8” Diameter x 1-1/2” Thick on 7/8” Diameter Axle

Welding Gloves / Face Mask / 1 Torch Liner / 5 Spare Tips

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.

UNPACKING

When unpacking, check to make sure all the parts shown on the Parts Lists on pages 26 and 27 are included. If any parts are missing or broken, please call Harbor Freight Tools at the number shown on the cover of this manual as soon as possible.

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.

SA VE THESE INSTRUCTIONS

WORK AREA

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

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

creates sparks which may ignite the dust or fumes.

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3. Keep bystanders, children, and visitors away while operating welding equipment. Distractions can cause you to lose control. Protect others in the work area from arc rays, sparks, and slag. Provide barriers or shields as needed.

ELECTRICAL SAFETY

1. Grounded welding equipment must be plugged into an outlet properly installed and grounded in accordance with all codes and ordinances. Never remove the gr ounding 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 welding equipment

should electrically malfunction or break down, grounding provides a low resistance path to carry electricity away from the user .

2. Avoid body contact with gr ounded surfaces suc h as pipes, radiators, ranges, and refrigerators. There is an increased risk of electric shock if y our body is grounded.

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

4. Do not abuse the Power Cord. Never use the Power Cor d to carry welding

equipment or pull the Plug from an outlet. Keep the Power Cor d a wa y fr om heat, oil, sharp edges, or moving parts. Replace damaged P o wer Cords immediately. Damaged P o wer Cords increase the risk of electric shock.

5. When operating welding equipment 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.

The minimum extension cord size for this tool is 6 GAUGE for cords UP TO 25’ LONG.

CORDS LONGER THAN 25’ SHOULD NOT BE USED WITH THE WELDER.

PERSONAL SAFETY

1. Stay alert. W atc h what y ou are doing, and use common sense when operating welding equipment. Do not use welding equipment while tired or under the influence of drugs, alcohol, or medication. A moment of inattention

while operating welding equipment may result in serious personal injury.

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2. Dress properly . Do not wear loose c lothing or je welry. Contain long hair . Keep your hair, clothing, and gloves away from hot or moving parts. Loose clothes, jewelry, or long hair can be caught in hot or moving par ts.

(See page 8, number 3, for recommended safety clothing.)

3. Avoid accidental starting. Be sure the Power Switch is off before plugging in. Plugging in welding equipment with the Power Switch on invites accidents.

4. Remove adjusting keys or wrenches before turning on the welding equipment. A wrench or a k e y that is left attached to an electrically charged part

of the welding equipment 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 welding equipment in unexpected situations.

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 welding equipment. Use the correct equipment for your application. The correct equipment 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 equipment that cannot be controlled with the Power Switch is dangerous and must be replaced.

4. Disconnect the Power Cord Plug fr om the power source before making any

adjustments, changing accessories, or storing the welding equipment.

Such prev entive safety measures reduce the risk of starting the welding equipment accidentally.

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

6. Maintain welding equipment with care. K eep equipment clean and dry. Properly maintained equipment is less likely to malfunction and is easier to control. Do not use damaged w elding equipment. Tag damaged equipment “Do not use” until repaired.

7. Check for misalignment or binding of moving parts, breakage of parts, and

any other condition that may affect the equipment’s operation. If damaged, have the equipment serviced before using. Many accidents are caused by

poorly maintained equipment.

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8. Use only accessories that are recommended by the manufacturer for your model. Accessories that may be suitable for one type of welding equipment may become 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 risk of injury.

2. When servicing welding equipment, use only identical replacement parts.

Follow instructions in the of this manual. Use of unauthorized parts or failure to follo w maintenance

instructions may create a risk of electric shock, burns, or other injury .

“Inspection, Maintenance, And Cleaning”

section

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GROUNDING

WARNING!

Improperly connecting the grounding wire can result in the risk of electric shock. Check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded. Do not modify the power cord plug provided with the tool. Never remove the grounding prong from the plug. Do not use the 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 EQUIPMENT: EQUIPMENT WITH THREE PRONG PLUGS

1. W ARNING! The P ow er Cord requires the attachment of a 220 v olt, grounded, 3-Prong Plug (not included). For safety purposes, only a qualified,

certified, electrician should attach a Plug to the Power Cord. Never modify the Plug in any way. 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 220 volt electrical outlet that is protected by a Ground Fault Circuit Interrupter (GFCI).

2. The grounding prong in the plug is connected to the green wire inside the cord to the grounding system in the welding equipment. The green wire in the cord must be the only wire connected to the equipment’s grounding system and must never be attached to an electrically “live” terminal. (See Figure A.)

3. Your welding equipment must be plugged into an appropriate outlet, properly installed and grounded in accordance with all codes and ordinances. The plug and outlet should look like those in the following illustration. (See Figure A.)

POWER CORD

220 VOL T

POWER PLUG

(NOT INCLUDED)

ONL Y A QU ALIFIED, CERTIFIED

ELECTRICIAN SHOULD CONNECT A

POWER PLUG TO THE POWER CORD.

WARNING!

220 VOL T

ELECTRICAL OUTLET

(NOT INCLUDED)

FIGURE A

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EXTENSION CORDS

The minimum extension cord size f or this tool is 6 GAUGE for cords UP TO 25’ LONG.

CORDS LONGER THAN 25’ SHOULD NOT BE USED WITH THIS WELDER.

2. As the distance from the supply outlet increases, you must use a heavier gauge

3. The smaller the gauge number of the wire, the greater the capacity of the cord.

4. When using more than one extension cord to make up the total length, make sure

5. If you are using one extension cord for more than one tool, add the nameplate

6. If you are using an extension cord outdoors, make sure it is marked with the suffix

7. Make sure your extension cord is properly wired and in good electrical condition.

Grounded

extension cord. Using extension cords with inadequately sized wire causes a serious drop in voltage, resulting in loss of power and possible tool damage.

The minimum extension cor d gauge for this tool is 6 AWG for cor ds up to 25’ long. Cor ds longer than 25’ should not be used with this welder.

For example, a 14 gauge cord can carry a higher current than a 16 gauge cord.

each cord contains at least the minimum wire size required.

amperes and use the sum to determine the required minimum cord size.

“W-A” (“W” in Canada) to indicate it is acceptab le f or outdoor use.

Always replace a damaged extension cord or have it repaired by a qualified electrician before using it.

welding equipment require a three wire extension cord.

8. Protect your extension cords from sharp objects, excessive heat, and damp or wet areas.

SYMBOLOGY

Double Insulated

Canadian Standards Association

Underwriters Laboratories, Inc.

V ~

FIGURE C

SKU 91146 For technical questions, please call 1-800-444-3353. PAGE 7

xxxx/min.

Volts Alternating Current

Amperes

No Load Revolutions per Minute (RPM)

SPECIFIC SAFETY RULES

1. 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 the Welder in areas near flammable chemicals, dusts, and vapors.

2. Maintain labels and nameplates on the W elder . These carry important information. If unreadable or missing, contact Harbor Freight Tools for a replacement.

3. Prevent eye injury and burns. Wearing and using personal safety clothing and safety devices reduce the risk of injur y. Wear ANSI approved safety impact eyeglasses with a welding helmet featuring at least a number 10 shade lens rating. Leather leggings, rubber soled, fire resistant shoes or boots should be worn when using this Welder. 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 other flammable substances. Wear dry, insulating gloves and protective clothing. Wear an approved head covering to protect head and neck. Use aprons, cape, sleeves and shoulder covers, and bibs designed and approved for welding procedures. When welding overhead or in confined spaces, wear flame resistant ear plugs or ear muffs to keep sparks out of ears.

4. 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 z one and gener al 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 (PEL’s) for various fumes and gases. F ollow the American Conference of Governmental Industrial Hygienists recommendations for (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 situation.

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

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

Permissible Exposure Limits

Threshold Limit Values

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7. When welding or cutting in small areas, the operator should be externally

near

accompanied by another person (standing observe accident prevention procedures.

8. When welding or cutting, be aware that high frequency radiation may be produced which can interfere with radio navigation, safety devices, computers, and communications equipment. Before operating, have a

qualified technician check out that possibility.

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

10. Prevent accidental fires. Remove any combustible material from the work area. 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, floor, ceiling, etc., prev ent ignition of combustibles on the other side by moving the combustibles to a safe location. If relocation of the combustibles is not possible, designate someone to serve as a fire watch, equipped with a fire extinguisher, during the welding process and at least one half hour after the welding is completed. Do not place the torch on any material other than bare concrete until the torch is completely cooled. Do not weld on materials having a combustible coating or combustible internal structure such as 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 welding, make a thorough examination for evidence of fire. Be aware that easily visible smoke or flame may not be present f or some time after the fire has started. Do not w eld in atmospheres containing dangerously reactive or flammable gasses, vapors, liquids, and dust. Provide adequate ventilation in work areas to prevent accumulation of flammable gases, vapors, or dust. 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 or welding. Note: Use caution when welding galvanized metal; toxic gases are formed and must be ventilated properly.

the enclosed work area) to

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

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