VULCAN 63618 Owner's Manual & Safety Instructions

Owner’s Manual & Safety Instructions

Save This Manual%Keep this manual for the safety warnings and precautions, assembly,

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

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).

back of the manual near the assembly diagram (or month and year of purchase if product has no number).

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.

Keep this manual and the receipt in a safe and dry place for future reference.

Keep this manual and the receipt in a safe and dry place for future reference. 19h

!"#"$%&'(%)*+#"$*%,$-%.$$/-00)))1.,(+&(2(*"3.$14&5

65,"7%&'(%$*4.8"4,7%#'//&($%,$-%/(&9'4$#'//&($:.,(+&(2(*"3.$14&5

When unpacking, make sure that the product is intact

and undamaged. If any parts are missing or broken,

please call 1-<?>-1-888-866-5797 as soon as possible.

please call 1-888-866-5797 as soon as possible.

No portion of this manual or any artwork contained herein may be reproduced in

Diagrams within this manual may not be drawn proportionally. Due to continuing

improvements, actual product may differ slightly from the product described herein.

any shape or form without the express written consent of Harbor Freight Tools.

To ol s re q u ir e d fo r as s e mb l y a n d s e r vi c e m a y n o t b e in c l ud e d .

;*,9%$."#%5,$*(",7%+*2&(*%'#"83%$."#%/(&9'4$1%

Read this material before using this product.

<,"7'(*%$&%9&%#&%4,8%(*#'7$%"8%#*("&'#%"8='(>1%

Failure to do so can result in serious injury.

?@!6%ABC?%D@EF@G1

SAVE THIS MANUAL.

A,+7*%&2%R&8$*8$#

Safety ......................................................... 2

Specifications ............................................. 7

?@<6AQ D@CEA6E@ER6S@?CR%T6GUCEV T6GUCEV%ACW?SETUP?@<6AQ D@CEA6E@ER6S@?CR%T6GUCEV T6GUCEV%ACW?SETUP

Setup .......................................................... 8

Basic Welding ............................................ 12

Welding Tips .............................................. 20

Maintenance and Service .......................... 24

Parts List and Diagrams ............................ 25

Warranty .................................................... 28

T@;ECEV%?QDSXG?%@EU%U6<CECACXE?

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.

CDWX;A@EA%?@<6AQ%CE<X;D@ACXE

;*,9%,77%?,2*$>%),(8"83#%,89%"8#$('4$"&8#1%% <,"7'(*%$&%2&77&)%$.*%),(8"83#%,89%"8#$('4$"&8#%5,>%(*#'7$%"8%*7*4$("4%#.&4YI%2"(*%,890&(%#*("&'#%"8='(>1%%% ?,Z*%,77%),(8"83#%,89%"8#$('4$"&8#%2&(%2'$'(*%(*2*(*84*1

V*8*(,7%?,2*$>

W;XA6RA%>&'(#*72%,89%&$.*(#1%%;*,9%,89%'89*(#$,89%$."#%"82&(5,$"&81

1. S*2&(*%'#*I%(*,9%,89%'89*(#$,89%

manufacturer′s instructions, Material Safety Data Sheets (MSDS′s), employer′s Safety practices, and ANSI Z49.1.

2. [**/%&'$%&2%(*,4.%&2%4."79(*81%%% Keep children and bystanders away while operating.

3. W7,4*%$.*%)*79*(%&8%,%#$,+7*%7&4,$"&8%+*2&(*%'#*1%%% If it falls while plugged in, severe injury, electric shock, or fire may result.

4. U&%8&$%&Z*((*,4.1%%%

[**/%/(&/*(%2&&$"83%,89%+,7,84*%,$%,77%$"5*#1

5. ?$,>%,7*($I%),$4.%).,$%>&'%,(*%9&"83%,89%'#*% 4&55&8%#*8#*%).*8%&/*(,$"83%,%)*79*(1%% U&%8&$%'#*%,%)*79*(%)."7*%>&'%,(*%$"(*9%&(%'89*(% $.*%"827'*84*%&2%9('3#I%,74&.&7%&(%5*9"4,$"&81

A moment of inattention while operating welders may result in serious personal injury.

6. @Z&"9%'8"8$*8$"&8,7%#$,($"831%%Make sure you are prepared to begin work before turning on the Welder.

7. E*Z*(%7*,Z*%$.*%T*79*(%'8,$$*89*9%)."7*% *8*(3"\*91%Turn power off if you have to leave.

8. A.*%),(8"83#I%/(*4,'$"&8#I%,89%"8#$('4$"&8#%

9"#4'##*9%"8%$."#%"8#$('4$"&8%5,8',7%4,88&$% 4&Z*(%,77%/&##"+7*%4&89"$"&8#%,89%#"$',$"&8#% $.,$%5,>%&44'(1%%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.

Page 2 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKLMMKNOPO1 Item 63618

<'5*%,89%V,#%?,2*$>

T*79"83%,89%W7,#5,%R'$$"83%/(&9'4*%$&]"4%2'5*#1

INHALATION HAZARD:%

1. 6]/&#'(*%$&%)*79"83%&(%4'$$"83%*].,'#$%

2'5*#%4,8%"84(*,#*%$.*%("#Y%&2%9*Z*7&/"83% 4*($,"8%4,84*(#I%#'4.%,#%4,84*(%&2%$.*% 7,(>8]%,89%7'83%4,84*(1 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. U&%8&$%'#*%8*,(%9*3(*,#"83%&(%

/,"8$"83%&/*(,$"&8#1

3. [**/%.*,9%&'$%&2%2'5*#1%% Do not breathe exhaust fumes.

4. F#*%*8&'3.%Z*8$"7,$"&8I%*].,'#$%,$%,(4I%&(%

+&$.I%$&%Y**/%2'5*#%,89%3,#*#%2(&5%+(*,$."83% \&8*%,89%3*8*(,7%,(*,1%%If engineering controls

are not feasible, use an approved respirator.

5. T&(Y%"8%,%4&82"8*9%,(*,%&87>%"2%"$%

"#%)*77KZ*8$"7,$*9I%&(%)."7*%)*,("83% ,8%,"(K#'//7"*9%(*#/"(,$&(1

6. B,Z*%,%(*4&38"\*9%#/*4",7"#$%"8% C89'#$(",7%B>3"*8*%&(%68Z"(&85*8$,7%?*(Z"4*#%

4.*4Y%$.*%&/*(,$"&8%,89%,"(%H',7"$>% ,89%5,Y*%(*4&55*89,$"&8#% 2&(%$.*%#/*4"2"4%)*79"83%#"$',$"&81%%

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.

?@<6AQD@CEA6E@ER6 S@?CR%T6GUCEVT6GUCEV%ACW? SETUP ?@<6AQD@CEA6E@ER6 S@?CR%T6GUCEVT6GUCEV%ACW? SETUP

@(4%;,>%?,2*$>

@;R%;@Q?%4,8%"8='(*%*>*#%,89%+'(8%#Y"81

1. T*,(%@E?CK,//(&Z*9%)*79"83%*>*%/(&$*4$"&8%

2*,$'("83%,$%7*,#$%,%8'5+*(%J^%#.,9*%7*8#%(,$"831

2. T*,(%7*,$.*(%7*33"83#I%2"(*%(*#"#$,8$%#.&*#% &(%+&&$#%9'("83%'#*1%%Do not wear pants with

cuffs, shirts with open pockets, or any clothing that can catch and hold molten metal or sparks.

3. [**/%47&$."83%2(**%&2%3(*,#*I%&"7I%

#&7Z*8$#I%&(%,8>%27,55,+7*%#'+#$,84*#1%%

Wear dry, insulating gloves and protective clothing.

4. T*,(%,8%,//(&Z*9%.*,9%4&Z*("83%$&%/(&$*4$% $.*%.*,9%,89%8*4Y1%Use aprons, cape, sleeves, shoulder covers, and bibs designed and approved for welding and cutting procedures.

5. T*,(%,8%,//(&Z*9%)*79"83%=,4Y*$%&(%7&83%#7**Z*#%

$&%/(&$*4$%2&(*,(5#%2(&5%(,9",$"&8%+'(8#1%

6. T.*8%)*79"8304'$$"83%&Z*(.*,9%&(%"8%4&82"8*9% #/,4*#I%)*,(%27,5*%(*#"#$,8$%*,(%/7'3#%&(% *,(%5'22#%$&%Y**/%#/,(Y#%&'$%&2%*,(#1

Page 3<&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKLMMKNOPO1Item 63618

67*4$("4,7%?,2*$>

6G6RA;CR%?BXR[%4,8%[CGG1

1. A'(8%&22I%9"#4&88*4$%/&)*(I%,89%

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9"#4.,(3*%67*4$(&9*%$&%3(&'89%+*2&(*%#*$$"83% 9&)8%$&(4.067*4$(&9*%.&79*(%,89%+*2&(*%#*(Z"4*1

2. U&%8&$%$&'4.%*8*(3"\*9%*7*4$("4,7%/,($#1%% 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. R&88*4$%$&%3(&'89*9I%V<RCK/(&$*4$*9%

/&)*(%#'//7>%&87>1

4. U&%8&$%'#*%8*,(%),$*(%&(%9,5/%&+=*4$#1

5. W*&/7*%)"$.%/,4*5,Y*(#%#.&'79%4&8#'7$%$.*"(% physician(s) before use. Electromagnetic fields in close proximity to heart pacemaker could cause pacemaker interference or pacemaker failure.

<"(*%?,2*$>

1. R7*,(%,),>%&(%/(&$*4$%27,55,+7*%&+=*4$#1%%% 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. [**/%@SRK$>/*%2"(*%*]$"83'"#.*(%8*,(%

)&(Y%,(*,%,89%Y8&)%.&)%$&%'#*%"$1

3. D,"8$,"8%,%#,2*%)&(Y"83%*8Z"(&85*8$1%%% 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. U&%8&$%&/*(,$*%)*79*(#%"8%,$5&#/.*(*#%

4&8$,"8"83%9,83*(&'#7>%(*,4$"Z*%&(% 27,55,+7*%7"H'"9#I%3,#*#I%Z,/&(#I%&(%9'#$1%%

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.

6. U&%8&$%*]/&#*%)*79*(#%$&%(,"8%&(%)*$%4&89"$"&8#1%%% Water entering a welder will increase the risk of electric shock.

7. U&%8&$%,+'#*%$.*%4&(91%%E*Z*(%'#*%$.*%4&(9%

2&(%4,((>"83I%/'77"83%&(%'8/7'33"83%$.*%)*79*(1%% [**/%4&(9%,),>%2(&5%.*,$I%&"7I%#.,(/%*93*#% &(%5&Z"83%/,($#1%%Damaged or entangled

cords increase the risk of electric shock.

8. U&%8&$%'#*%&'$9&&(#1

9. C8#'7,$*%>&'(#*72%2(&5%$.*%)&(Y/"*4*%,89% 3(&'891%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.

@;R%@EU%?G@V%4,8%4,'#*%2"(*1

5. C2%)&(Y"83%&8%,%5*$,7%),77I%4*"7"83I%*$41I% /(*Z*8$%"38"$"&8%&2%4&5+'#$"+7*#%&8%$.*% &$.*(%#"9*%+>%5&Z"83%$.*%4&5+'#$"+7*#%$&%,% #,2*%7&4,$"&81 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. U&%8&$%)*79%&(%4'$%&8%5,$*(",7#%.,Z"83%

,%4&5+'#$"+7*%4&,$"83%&(%4&5+'#$"+7*% "8$*(8,7%#$('4$'(*I%,#%"8%),77#%&(%4*"7"83#I%)"$.&'$% ,8%,//(&Z*9%5*$.&9%2&(%*7"5"8,$"83%$.*%.,\,(91

7. U&%8&$%9"#/&#*%&2%.&$%#7,3%"8%4&8$,"8*(#% .&79"83%4&5+'#$"+7*%5,$*(",7#1

8. @2$*(%)*79"83I%5,Y*%,%$.&(&'3.%*],5"8,$"&8% 2&(%*Z"9*84*%&2%2"(*1%%Be aware that easily

visible smoke or flame may not be present for some time after the fire has started.

9. U&%8&$%,//7>%.*,$%$&%,%4&8$,"8*(%$.,$%.,#%.*79%

,8%'8Y8&)8%#'+#$,84*%&(%,%4&5+'#$"+7*% 5,$*(",7%).&#*%4&8$*8$#I%).*8%.*,$*9I% 4,8%/(&9'4*%27,55,+7*%&(%*]/7&#"Z*%Z,/&(#1%%

Clean and purge containers before applying heat. Vent closed containers, including castings, before preheating, welding, or cutting.

Page 4 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKLMMKNOPO1 Item 63618

T*79*(%F#*%,89%R,(*

1. U&%8&$%'#*%$.*%)*79*(%"2%$.*%#)"$4.%9&*#%8&$%$'(8%

"$%&8%,89%&221%%Any welder that cannot be controlled

with the switch is dangerous and must be repaired.

2. U"#4&88*4$%$.*%/7'3%2(&5%$.*%/&)*(%

#&'(4*%+*2&(*%5,Y"83%,8>%,9='#$5*8$#I%

4.,83"83%,44*##&("*#I%&(%#$&("83%)*79*(#1%%

Such preventive Safety measures reduce the risk of starting the welder accidentally.

3. W(*Z*8$%'8"8$*8$"&8,7%#$,($"831%

68#'(*%$.*%#)"$4.%"#%"8%$.*%&22K /&#"$"&8%+*2&(*%4&88*4$"83%$&%/&)*(% #&'(4*%&(%5&Z"83%$.*%)*79*(1 Carrying

or energizing welders that have the switch on invites accidents.

D,"8$*8,84*

1. D,"8$,"8%)*79*(#1%%R.*4Y%2&(%5"#,7"385*8$%&(%

+"89"83%&2%5&Z"83%/,($#I%+(*,Y,3*%&2%/,($#% ,89%,8>%&$.*(%4&89"$"&8%$.,$%5,>%,22*4$%$.*% )*79*(_#%&/*(,$"&81%%C2%9,5,3*9I%.,Z*%$.*% )*79*(%(*/,"(*9%+*2&(*%'#*1 Many accidents

are caused by poorly maintained welders.

2. B,Z*%>&'(%)*79*(%#*(Z"4*9%+>%,%H',7"2"*9%

(*/,"(%/*(#&8%'#"83%&87>%"9*8$"4,7% (*/7,4*5*8$%/,($#1%%This will ensure that

the Safety of the welder is maintained.

4. ?$&(*%"97*%)*79*(#%&'$%&2%$.*%(*,4.%&2%

4."79(*8%,89%9&%8&$%,77&)%/*(#&8#%'82,5"7",(% )"$.%$.*%)*79*(%&(%$.*#*%"8#$('4$"&8#%$&% &/*(,$*%$.*%)*79*(1%%Welders are dangerous

in the hands of untrained users.

5. F#*%$.*%)*79*(%,89%,44*##&("*#%"8%

,44&(9,84*%)"$.%$.*#*%"8#$('4$"&8#I%$,Y"83% "8$&%,44&'8$%$.*%)&(Y"83%4&89"$"&8#%,89% $.*%)&(Y%$&%+*%/*(2&(5*91 Use of the welder

for operations different from those intended could result in a hazardous situation.

6. U&%8&$%'#*%$.*%)*79*(%2&(%/"/*%$.,)"831

3. D,"8$,"8%7,+*7#%,89%8,5*/7,$*#%&8%$.*%T*79*(1%%% These carry important information. If unreadable or missing, contact Harbor Freight Tools for a replacement.

4. F8/7'3%+*2&(*%5,"8$*8,84*1%Unplug the Welder from its electrical outlet before any inspection, maintenance, or cleaning procedures.

?@<6AQD@CEA6E@ER6 S@?CR%T6GUCEVT6GUCEV%ACW? SETUP ?@<6AQD@CEA6E@ER6 S@?CR%T6GUCEVT6GUCEV%ACW? SETUP

V,#%?."*79*9%T*79"83%K%R>7"89*(%?,2*$>

R>7"89*(#%4,8%*]/7&9*%).*8%9,5,3*91

1. U&%8&$%)*79%&8%,%/(*##'("\*9%&(%47&#*9%4>7"89*(1

2. U&%8&$%,77&)%,8%67*4$(&9*%.&79*(I%

67*4$(&9*I%)*79"83%$&(4.I%&(%)*79"83% )"(*%$&%$&'4.%$.*%4>7"89*(1

3. [**/%4>7"89*(#%,),>%2(&5%,8>%*7*4$("4,7%4"(4'"$#I%

"847'9"83%)*79"83%4"(4'"$#1

4. [**/%/(&$*4$"Z*%4,/%"8%/7,4*%&Z*(%$.*%Z,7Z*%

*]4*/$%).*8%$.*%4>7"89*(%"#%"8%'#*1

5. F#*%&87>%4&((*4$%3,#%#."*79"83%*H'"/5*8$% 9*#"38*9%#/*4"2"4,77>%2&(%$.*%$>/*%&2%)*79"83% >&'%)"77%9&1%%Maintain this equipment properly.

6. W(&$*4$%3,#%4>7"89*(#%2(&5%.*,$I%+*"83%#$('4YI% /.>#"4,7%9,5,3*I%#7,3I%27,5*#I%#/,(Y#I%,89%,(4#1

7. F#*%/(&/*(%/(&4*9'(*#%$&%5&Z*%4>7"89*(#1

%?@!6%AB6?6%CE?A;FRACXE?1

Page 5<&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKLMMKNOPO1Item 63618

V(&'89"83

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AX%W;6!6EA%6G6RA;CR%?BXR[%@EU%U6@AB%% <;XD%CERX;;6RA%V;XFEUCEV%TC;6%RXEE6RACXE-% R.*4Y%)"$.%,%H',7"2"*9%*7*4$("4",8%"2%>&'%,(*%"8%9&'+$%,#%$&%).*$.*(%$.*%&'$7*$%"#%

/(&/*(7>%3(&'89*91%%% U&%8&$%'#*%$.*%)*79*(%"2%$.*%/&)*(%4&(9%&(%/7'3%"#%9,5,3*91%%C2%9,5,3*9I%.,Z*%"$%(*/,"(*9%+>%,%#*(Z"4*% 2,4"7"$>%+*2&(*%'#*1%%C2%$.*%/7'3%)"77%8&$%2"$%$.*%&'$7*$I%.,Z*%,%/(&/*(%&'$7*$%"8#$,77*9%+>%,%H',7"2"*9%*7*4$("4",8I% 9&%8&$%'#*%,9,/$*(%/7'3#1

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.

B"3.%<(*H'*84>%V(&'89"83

1. The Welder has internal grounding, there

is no need to ground the Welder.

2. The metal work bench must be properly grounded

in accordance with all relevant electrical codes and standards before operation. Have the work bench grounded by a qualified electrician if you are not qualified to do so.

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. To ground the work bench, connect a #12 AWG grounding wire (not included) from the work bench to a grounding rod (not included). The grounding rod must be an earth-driven copper or brass rod (electrode) which can adequately ground the work bench.

4. Refer to local regulations for ground source information.

B"3.%<(*H'*84>%;,9",$"&8

1. The operator of welding equipment that causes harmful interference to radio services shall promptly take appropriate measures to correct the problem.

2. If the operator of welding equipment is notified by the FCC that operation of such equipment is endangering the functioning of a radio navigation or safety service, the operator shall immediately cease operating the equipment. Operation may be resumed on a temporary basis only for the purpose of eliminating the harmful interference. Operation may be resumed on a regular basis only after the harmful interference has been eliminated and approval from the FCC obtained.

6]$*8#"&8%R&(9#

U&%8&$%'#*%,8%*]$*8#"&8%4&(9%&8%$."#%)*79*(1

;*/7,4*5*8$%R&(9#

1. F#*%&87>%&8*%&2%$.*%#'//7"*9%/&)*(%4&(9#%2&(% $."#%)*79*(%&(%,8%"9*8$"4,7%(*/7,4*5*8$%4&(91

2. U&%8&$%"8#$,77%,%$."88*(%&(%7&83*(% 4&(9%&8%$."#%)*79*(1

3. When notified by the FCC that a particular installation is causing harmful interference, the operator or manufacturer shall arrange for an engineer skilled in techniques of interference measurement and control to make an investigation to ensure that the harmful interference has been eliminated. The Regional Director may require the engineer making the investigation to furnish proof of his or her qualifications.

3. U&%8&$%/,$4.%4&(9#%&2%,8>%7*83$.%

$&3*$.*(%2&(%$."#%"$*51%%W,$4.*#%5,>%,77&)% 5&"#$'(*%$&%/*8*$(,$*%$.*%"8#'7,$"&8I% (*#'7$"83%"8%*7*4$("4%#.&4Y1

Page 6 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKLMMKNOPO1 Item 63618

?>5+&7&3>

!@R

@

XR!

[!@

CWD

Wire Feed (Speed)

Workpiece Ground Cable

Torch Cable

Overheat Shutdown Indicator

Cooling Fan

Volts Alternating Current

Amperes

Open Circuit Voltage

Kilovolt Amperes (Volts / 1000 * Amperes)

Inches Per Minute

@TV

American Wire Gauge

Electric Shock Hazard. Do not touch energized parts.

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Inhalation Hazard. Keep head out of fumes and use proper ventilation.

Read manual before setup and/or use.

Fire Hazard. Keep flammable materials away during welding. Spatter can cause accidental fires.

Arc Ray Hazard. Wear welding helmet with properly rated filter lens.

Pacemaker Hazard. Welding processes may interfere with pacemakers. Consult doctor before use.

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Power Input 120VAC / 60Hz 240VAC / 60Hz 120VAC / 60Hz 240VAC / 60Hz

Current Input at Output 21.4A at 130A 14.7A at 165A 21.4A at 90A 22.4A at 165A

Welding Current Range 10A - 130A 10A - 165A 10A - 90A 10A - 165A

Rated Duty Cycles

Maximum OCV 103VDC 82VDC

Weldable Materials

TIG Stick

25% @ 130A 100% @ 65A

Mild Steel, Stainless Steel,

Chrome Moly

30% @ 165A 100% @ 90A

25% @ 90A

100% @ 55A

Mild Steel, Stainless Steel

30% @ 165A 100% @ 90A

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Place the Welder on a level surface that can bear its weight near the work area. Leave space around the Welder for proper air flow.

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1. Plug Ground Clamp cable into Positive Socket. Twist clockwise all the way to lock in place.

2. Plug TIG Torch cable into Negative Socket. Twist clockwise all the way to lock in place.

3. Plug Foot Pedal cable into Foot Pedal Socket. Secure by turning collar clockwise until tight.

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1. Thread end of Strap through slot on end of Welder.

2. Thread same end through bottom of buckle.

3. Repeat for other side.

4. Adjust Strap as necessary.

5. Pull on both ends of strap to make sure it is secure.

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Power Input

Gas Inlet

Power Input

Gas Inlet

1. With assistance, place an 100% Argon cylinder (not included) onto a cabinet or cart near the Welder and secure the cylinder in place with two straps (not included) to prevent tipping.

2. Remove the cylinder’s cap. Stand to the side of the valve opening, then open the valve briefly to blow dust and dirt from the valve opening. Close the cylinder valve.

3. Close the Regulator’s valve by backing off knob until it is loose, then thread Regulator onto cylinder and wrench tighten connection.

4. Attach the Gas Hose (included) to the Regulator’s Outlet and the Welder’s Gas Inlet. Wrench-tighten both connections.

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Plug either 120VAC or 240VAC cord into Power Input Socket.

E&$*- Plug will only fit one way.

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plug cord into wall outlet at this time.

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To avoid Electrode contamination, dedicate a fine grit grinding wheel exclusively to Electrode grinding.

T@;ECEVc Some Electrodes may have

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materials added to them that are hazardous to breathe. Wear a respirator and ANSI-approved Safety goggles when grinding an Electrode.

1. Shut off the welder and wait until Electrode and Torch have cooled enough to handle.

2. Remove Back Cap. Pull Electrode from front of Torch. (Pulling it from rear will damage Collet and create burrs on Electrode).

3. If Electrode has dulled or been otherwise contaminated, use pliers or a suitable tool to grip the Electrode above the contaminated section and snap off the end of the Electrode.

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1. Consult Settings Chart, on top of Welder, to determine proper Tungsten Electrode size to be used with thickness of material to be welded.

2. Match Collet and Collet Body sizes to Tungsten Electrode size.

4. Lightly press Electrode tip against the surface of

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the grinding wheel at an angle. Rotate Electrode tip until a blunt point is formed.

E&$*- Grinding direction must be parallel to length of Electrode.

5. The conical portion of the ideal tip will be 2-1/2 times as long as the Electrode diameter.

6. Re-insert Electrode into Collet with tip

protruding 1/8″-1/4″ beyond the Ceramic

Nozzle, then re-tighten the Back Cap.

8. Lock Electrode in place with Back Cap.

Electrode should protrude 1/8″ to 1/4″

beyond the Ceramic Nozzle.

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3. Thread Collet Body into the front of the Torch.

4. Make sure Ceramic Nozzle size is appropriate for application.

5. Thread Ceramic Nozzle onto Collet Body.

6. Insert Collet into back of Torch and into Collet Body.

7. Insert tungsten Electrode into Collet on front of Torch.

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Power Input

Gas Inlet

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1. Plug Ground Clamp cable into Negative Socket. Twist clockwise all the way to lock in place.

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Plug either 120VAC or 240VAC cord into Power Input Socket.

E&$*- Plug will only fit one way.

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plug cord into wall outlet at this time.

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2. Plug Electrode Holder cable into Positive Socket. Twist clockwise all the way to lock in place.

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(or welding mask), ear protection, welding gloves, sleeves and apron, NIOSH-approved respirator, and fire

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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:

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• DC TIG Welding is used to weld mild steel and stainless steel using a TIG Rod and shielding gas. (To weld aluminum, an AC TIG Welder must be used.)

• Stick Welding is used to weld mild steel and stainless steel using a Stick Electrode without shielding gas.

• a different thickness of material

• a different type of material

• a different type of connection

• using a different process

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Controls output amperage.

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Push to cycle through processes.

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1. 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.

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Attach Ground Clamp to bare metal on the workpiece near the weld area, or to metal work bench where the workpiece is clamped.

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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.

NOTICE: When welding equipment on a vehicle, disconnect the vehicle battery power from both the positive connection and the ground before welding. This prevents damage to some vehicle electrical systems and electronics due to the high voltage and high frequency bursts common in welding.

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Page 14 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKLMMKNOPO1 Item 63618

Duty Cycle (Duration of Use)

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Cycle defines the number of minutes, within a 10 minute period, during which a given welding process can produce a particular welding current without overheating.

For example, a 30% duty cycle at 165 A welding current must be allowed to rest for at least 7 minutes after every 3 minutes of continuous welding.

Failure to carefully observe duty cycle limitations can easily over-stress a welder’s power generation system contributing to premature welder failure.

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240VAC

30% Use at 165 A

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100% Continuous Use at 90 A

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25% Use at 130 A

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This welder has an internal thermal protection system to help prevent this sort of over-stress. When the Welder overheats, it automatically shuts down and the Overload Indicator lights. The welder automatically returns to service after cooling off. Rest the Tig Torch or Electrode Holder on an electrically non-conductive, heat-proof surface, such as a concrete slab, well clear of the ground clamp.

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When the Overload Indicator is no longer lit and the Welder can be used again, use shorter welding periods and longer rest periods to prevent needless wear.

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EXACR6-% TIG welding is a complicated process,

requiring experience and skill to achieve successful results. Training beyond the scope of this manual is required to TIG weld properly.

1. Open gas cylinder’s valve all the way.

2. Set Flow Gauge to SCFH value indicated on Settings Chart on top of Welder.

3. Turn the Power Switch to the OFF position, then plug the Welder into a properly grounded, GFCI

protected, 120 VAC (20 amp rated) outlet or 240V

outlet. The circuit must be equipped with delayed action-type circuit breaker or fuses.

4. Set TIG Torch down on nonconductive, nonflammable surface away from any grounded objects.

5. Turn the Power Switch ON.

6. Set amperage according to Settings Chart on top of Welder. Set to high end of amperage range. For example: Range is 80-100A, set amperage to 100A.

EXA6- Settings are approximate. Adjust as necessary.

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amperage according to settings on white band. If Welder is plugged into 240V outlet, set amperage according to settings on orange band.

7. ?*7*4$%W(&4*##- Press Process Select Button until desired process(es) light up:

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and ACV%B<%,89%ACV%WFG?6%%

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Usual way to initiate arc. Pulse welding reduces heat input to minimize distortion and allows for faster travel speeds.

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Frequency Grounding on page 6).

EXACR6- When welding close to sensitive electronics or on vehicles, use Lift Start instead of High Frequency.

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Use when High Frequency Start cannot be used.

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Page 16 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKLMMKNOPO1 Item 63618

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(or welding mask), ear protection, welding gloves,

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After practice welding on scrap, stop,

and check your progress. Perform

Strike Test according to ?$("Y*%A*#$%&8%

/,3*%b^1 After making any necessary

adjustments, continue to weld while

carefully following the DUTY CYCLE

guidelines as explained on page 14.

EXA6- Maintain a constant distance between the Tungsten Electrode and the workpiece: between 1 and 1.5 times the diameter of the Electrode.

10. When welding puddle is hot enough, tilt torch backward about 10-15 degrees from vertical and move it back slightly. Add TIG Rod material as needed to the front end of the weld puddle.

11. Alternate between pushing the torch/weld puddle and adding the TIG Rod material.

EXA6- Back the TIG Rod off each time the Electrode is advanced, but do not remove it from the gas shield. This prevents oxidation from contaminating the weld.

12. When finished welding, release the Foot Pedal, but keep Torch on weld puddle until gas flow ends.

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8. Hold TIG Torch in one gloved hand and TIG Rod in other gloved hand.

9. Specific Welding Techniques:

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• Hold Torch ,),>%2(&5%$.*%)&(Y/"*4* the same distance as 1 to 1.5 times the diameter of the Tungsten Electrode.

E&$*- To prevent Tungsten Electrode contamination, do not touch Torch to workpiece before arc initiates.

• Press Foot Pedal down slowly until arc initiates. Then, press Foot Pedal down all the way to reach maximum amperage. Let up on Foot Pedal to lower amperage.

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• Touch Tungsten Electrode to workpiece.

• Press Foot Pedal down 1 - 2 seconds. Then, lift Electrode off workpiece the same distance as 1 to 1.5 times the diameter of the Electrode, to initiate the arc.

• Press Foot Pedal down all the way to reach maximum amperage. Let up on Foot Pedal to lower amperage.

13. Set TIG Torch down on nonconductive, nonflammable surface away from any grounded objects.

14. Turn the Amperage Knob to the lowest setting, then turn the Power Switch off.

15. To prevent accidents, after use:

• Allow Welder to cool down.

• Unplug Welder’s power cord from outlet.

• Remove Ground Clamp from workpiece or table.

• Disconnect TIG Torch, Ground and Foot Pedal Cables.

• Close gas cylinder’s valve securely, remove regulator and replace cap.

• Disconnect Gas Hose from Welder.

• Store and secure gas cylinder.

• Clean, then store Welder and its accessories indoors out of children’s reach.

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• After arc is initiated, Welder will pulse between Peak Amperage and Background Current at a rate of 2 PPS.

• Peak Amperage Time is 50%. Background Current is 30% of Peak Amperage Current.

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1. Turn the Power Switch to the OFF position, then plug the Welder into a properly grounded, GFCI

protected, 120 VAC (20 amp rated) outlet or 240V

outlet. The circuit must be equipped with delayed action-type circuit breaker or fuses.

2. Set Electrode Holder down on nonconductive, nonflammable surface away from any grounded objects.

3. Turn the Power Switch ON.

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Button until %%?ACR[%process lights up.

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(white)

240V

@5/*(,3*%

?*$$"83#

(orange)

5. Set Amperage according to Stick Settings Chart.

EXA6- Settings are approximate. Adjust as necessary.

CDWX;A@EA- If Welder is plugged into 120V outlet, set

amperage according to settings on white band. If Welder is plugged into 240V outlet, set amperage according to settings on orange band.

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67*4$(&9*%

A>/*

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a0abh 40-70

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a0JMh 140-225

J0JMh 25-40

a0abh 40-90

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N0abh J^NKJON

a0abh ONKJJ^

J0Lh J^NKJM^

N0abh JN^Kb^^

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a0abh 100-145

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@5/*(,3*%

;,83*

Page 18 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKLMMKNOPO1 Item 63618

T@;ECEVc%%AX%W;6!6EA%?6;CXF?%CE`F;Q-%% W(&$*4$"Z*%3*,(%5'#$%+*%)&(8%).*8%'#"83%$.*% T*79*(d%5"8"5'5%#.,9*%8'5+*(%J^%2'77%2,4*%#."*79%

(or welding mask), ear protection, welding gloves,

#7**Z*#%,89%,/(&8I%ECX?BK,//(&Z*9%(*#/"(,$&(I% ,89%2"(*%(*#"#$,8$%)&(Y%47&$.*#%)"$.&'$%/&4Y*$#% #.&'79%+*%)&(8%).*8%)*79"831%%G"3.$%2(&5%$.*% ,(4%4,8%4,'#*%/*(5,8*8$%9,5,3*%$&%$.*%*>*#% ,89%#Y"81%%U&%8&$%+(*,$.*%,(4%2'5*#1

After practice welding on scrap, stop,

and check your progress. Perform

Strike Test, then clean and compare your

weld’s appearance with the diagrams and

descriptions in the T*79"83%A"/# 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 14.

6. Place the bare metal end of the Stick Electrode (sold separately) inside the jaws of the Electrode Holder.

7. Stroke the workpiece lightly to initiate the arc. Tips for igniting the arc:

a. Tap the surface with the Electrode.

b. Stroke the surface with the Electrode.

c. Strike the surface like a match with the Electrode.

8. After the arc initiates:

a. Lift the Electrode off workpiece the same

distance as the diameter of the bare metal end.

b. Tilt Electrode back 10 to 20 degrees.

c. Drag Electrode to the back end of the weld

puddle to deposit material as needed.

9. When finished welding; lift the Electrode from the workpiece, then set Electrode Holder down on nonconductive, nonflammable surface away from any grounded objects.

10. Turn the Power Switch off.

11. To prevent accidents, after use:

• Allow Welder to cool down.

• Unplug Welder’s power cord from outlet.

• Remove Ground Clamp.

• Disconnect TIG Torch and Ground Cables.

• Close gas cylinder’s valve securely and replace cap.

• Disconnect Gas Hose from Welder. Store and secure gas cylinder.

• Clean, then store Welder and its accessories indoors out of children’s reach.

?@<6AQD@CEA6E@ER6 S@?CR%T6GUCEVT6GUCEV%ACW? SETUP

Page 19<&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKLMMKNOPO1Item 63618

T*79"83%A"/#

A good way to test welding technique is to examine a weld’s appearance after it has cooled and the slag has been removed (for Stick welds). Then, better welding can be

?@<6AQ D@CEA6E@ER6S@?CR%T6GUCEV T6GUCEV%ACW?SETUP

learned by adjusting your weld technique to remedy any problems found.

NOTICE: TIG welding is a complicated process, requiring experience and skill to achieve successful results. Training beyond the scope of this manual is required to TIG weld properly.

@2$*(%/(,4$"4*%)*79"83%,%4&'/7*%

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$.*%2&77&)"83%3'"9*7"8*#1

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T6@;%@E?CK@WW;X!6U%?@<6AQ%VXVVG6?%

UF;CEV%ABC?%W;XR6UF;61

T@;ECEVc A."#%$*#$%TCGG%9,5,3*%$.*%)*79%"$%"#% /*(2&(5*9%&81%%A."#%$*#$%"#%XEGQ%,8%"89"4,$&(%&2%)*79% $*4.8"H'*%,89%"#%8&$%"8$*89*9%$&%$*#$%)&(Y"83%)*79#1

1. After two scraps have been welded together and the weld has cooled, clamp one side in a sturdy vise.

2. Stay clear from underneath while you strike the opposite side with a heavy hammer, preferably a dead-blow hammer.

3. A VXXU%T6GU will deform but not break, as shown on top. A WXX;%T6GU will be brittle and snap at the weld, as shown on bottom.

R7*,8"83%?$"4Y%T*79

U*,9KS7&)%B,55*(

!"#*

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VXXU%T6GU%%

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!"#*

?R;@W%

T&(Y/"*4*

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?8,/#%&(%R(,4Y#

AX%W;6!6EA%?6;CXF?%CE`F;Q-% T*,(%@E?CK,//(&Z*9%#,2*$>%3&337*#% ,89%/(&$*4$"Z*%)*,(%).*8%47*,8"83%,% )*791%% ?/,(Y#%&(%4."/#%5,>%27>%).*8%47*,8"831

1. A weld from Stick welding will be covered by slag. Use a chipping hammer to knock this off. S*%4,(*2'7%8&$%$&%9,5,3*%

$.*%)*79%&(%+,#*%5,$*(",71

2. Use a wire brush to further clean the weld or use an angle grinder (sold separately) to shape the weld.

Page 20 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKLMMKNOPO1 Item 63618

R."//"83%

B,55*(

T"(*%S('#.

?$"4Y%T*79%U",38&#"#%K%T&(Y/"*4*%B*,$%R&8$(&7%0%T*79%W*8*$(,$"&8

W;XW6;%W6E6A;@ACXECE@U6iF@A6%W6E6A;@ACXE

E&$%.&$%*8&'3. A&&%.&$C9*,7%.*,$

B&)%$&%"84(*,#*%)&(Y/"*4*%.*,$%%

,89%"84(*,#*%/*8*$(,$"&8-%%

g$&%)*79%ABCR[6; workpieces properly)

a. Increase current. b. Weld more slowly.

?$"4Y%T*79%6],5/7*%U",3(,5#

RG6@E%T6GU?%<C;?Ac

?$"4Y%)*79#%)"77%.,Z*%,%4&,$%&2%#7,3%&Z*(%$.*5%'8$"7%47*,8*91

6fR6??%W6E6A;@ACXE%X;%

SF;EKAB;XFVB

?@<6AQD@CEA6E@ER6 S@?CR%T6GUCEVT6GUCEV%ACW? SETUP

B&)%$&%(*9'4*%)&(Y/"*4*%.*,$%%

,89%7"5"$%/*8*$(,$"&8-%%

g$&%)*79%ABCEE6; workpieces properly)

a. Decrease current. b. Weld more quickly.

V&&9%

T*79

R'((*8$%%

A&&%G&)%

AX%RX;;6RA-%

Increase the

current

R'((*8$%%

A&&%B"3.

AX%RX;;6RA-%

Decrease

the current

T*79%?/**9%

A&&%<,#$

AX%RX;;6RA-

Weld slower

T*79%?/**9%

A&&%?7&)

AX%RX;;6RA-

Weld faster

@(4%G*83$.%%

A&&%?.&($%

AX%RX;;6RA-

Increase

distance

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A&&%G&83%

AX%RX;;6RA-

Decrease

distance

Page 21<&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKLMMKNOPO1Item 63618

Stick Weld Penetration (Workpiece Heat Control)

6fR6??%W6E6A;@ACXE%X;%

?@<6AQ D@CEA6E@ER6S@?CR%T6GUCEV T6GUCEV%ACW?SETUP

6fR6??%W6E6A;@ACXE%X;%SF;EKAB;XFVB

1. T&(Y/"*4*%&Z*(.*,$"83-%

2. T*79"83%#/**9%$&&%#7&)-

SF;EKAB;XFVB

T*79%9(&&/#%&8%$&/%,89%

'89*(8*,$.%&(%2,77#%$.(&'3.%

*8$"(*7>I%5,Y"83%,%.&7*1

WX??CSG6%R@F?6?%@EU%?XGFACXE?%<X;%

Reduce current.

Increase welding speed and ensure that welding speed is kept steady.

W;XW6;%W6E6A;@ACXE

T*79%"#%Z"#"+7*%'89*(8*,$.%,89%

+'73*#%#7"3.$7>%&8%$&/1

PROFILE VIEWS

WX??CSG6%R@F?6?%@EU%?XGFACXE?%<X;

CE@U6iF@A6%W6E6A;@ACXE

1. C84&((*4$%)*79"83%$*4.8"H'*- Keep arc on leading edge of weld puddle. Hold torch at proper angles.

2. C8#'22"4"*8$%)*79%.*,$-% Slow down so fill material has time to melt into the weld location. Increase current.

3. T&(Y/"*4*#%$&&%$."4Y047&#*- Bevel thick workpieces, allow slight gap, and weld in several passes.

4. C8#'22"4"*8$%)*79%5,$*(",7-% Increase amount of fill material.

CE@U6iF@A6%W6E6A;@ACXE

T*79%9&*#%8&$%4&8$,4$%$.*%=&"8$%

2'77>I%='#$%&8%$.*%#'(2,4*1

?$"4Y%T*79%K%T*79%E&$%@9.*("83%W(&/*(7>%

V,/#%/(*#*8$%+*$)**8%)*79%,89%/(*Z"&'#%+*,9%&(%+*$)**8%)*79%,89%)&(Y/"*4*1%%?**%,(*,#%+*7&)1

WX??CSG6%R@F?6?%@EU%?XGFACXE?

PROFILE

VIEW

1. C84&((*4$%)*79"83%$*4.8"H'*- Place stringer bead at correct place in joint. Adjust workpiece position or weld angle to permit proper welding to bottom of piece. Keep arc on leading edge of weld puddle. Hold Electrode and fill material at proper angles.

2. C8#'22"4"*8$%)*79%.*,$-% Increase current.

3. U"($>%)&(Y/"*4*- Clean workpiece down to bare metal.

4. C8#'22"4"*8$%)*79%5,$*(",7-% Increase amount of fill material.

5. G,89%$&&%$,77-% Increase bevel to decrease land.

?$"4Y%T*79%K%S*89%,$%`&"8$%

WX??CSG6%R@F?6?%@EU%?XGFACXE?

PROFILE

VIEW

1. C5/(&/*(%47,5/"83- Clamp workpieces securely. Make tack welds to hold workpieces.

2. 6]4*##"Z*%.*,$- Weld a small portion and allow to cool before proceeding. Increase weld speed.

Page 22 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKLMMKNOPO1 Item 63618

?$"4Y%T*79%K%R&,$%&2%?7,3%XZ*(%T*79%

?7,3%"#%,%8*4*##,(>%/,($%&2%,%#$"4Y%)*791%%C$%#."*79#%

TOP

VIEW

PARTIALLY CHIPPED AWAY TO SHOW WELD

$.*%)*79%2(&5%"5/'("$"*#1%%R7*,8%&22%$.*%#7,3%)"$.%$.*% R."//"83%B,55*(%,89%T"(*%S('#.%,2$*(%)*79"831

?$"4Y%T*79%K%W&(&#"$>%K%?5,77%4,Z"$"*#%&(%.&7*#%"8%$.*%+*,91

?@<6AQD@CEA6E@ER6 S@?CR%T6GUCEVT6GUCEV%ACW? SETUP

WX??CSG6%R@F?6?%@EU%?XGFACXE?

TOP

VIEW

?$"4Y%T*79%K%R(&&Y*90T,Z>%S*,9%

WX??CSG6%R@F?6?%@EU%?XGFACXE?

TOP

VIEW

?$"4Y%T*79%K%6]4*##"Z*%?/,$$*(%

WX??CSG6%R@F?6?%@EU%?XGFACXE?

1. U"($>%)&(Y/"*4*%&(%2"77%5,$*(",7- Clean workpiece down to bare metal. Make certain that fill material and Electrode are clean and free from oil, coatings, and other residues.

2. C84&8#"#$*8$%)*79"83%#/**9-% Maintain steady weld speed.

1. C8,44'(,$*%)*79"83- Use two hands or rest hand on steady surface.

2. C84&8#"#$*8$%)*79"83%#/**9-% Maintain steady weld speed.

<"8*%#/,$$*(%"#%8&(5,71%?/,$$*(%$.,$%"#% 3(,"8>%,89%7,(3*%"#%,%/(&+7*51%

TOP

VIEW

U"($>%)&(Y/"*4*%&(%2"77%5,$*(",7- Clean workpiece down to bare metal. Make certain that fill material and Electrode are clean and free from oil, coatings, and other residues.

?$"4Y%T*79%K%S'(8KA.(&'3.%K%S,#*%5,$*(",7%5*7$#%,),>I%7*,Z"83%,%.&7*%"8%$.*%)*791

WX??CSG6%R@F?6?%@EU%?XGFACXE?

TOP

VIEW

1. T&(Y/"*4*%&Z*(.*,$"83-% Reduce current.

2. T*79"83%#/**9%$&&%#7&)- Increase welding speed and ensure that welding speed is kept steady.

3. 6]4*##"Z*%5,$*(",7%,$%)*79-% Reduce amount of fill material.

Page 23<&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKLMMKNOPO1Item 63618

D,"8$*8,84*%,89%?*(Z"4*

?@<6AQ D@CEA6E@ER6S@?CR%T6GUCEV T6GUCEV%ACW?SETUP

AX%W;6!6EA%?6;CXF?%CE`F;QI%<C;6%@EU%SF;E?-% F8/7'3%$.*%T*79*(I%(*#$%$.*%ACV%A&(4.%&8%,%.*,$K/(&&2I%*7*4$("4,77>%8&8K4&89'4$"Z*%#'(2,4*I%,89% ,77&)%,77%/,($#%&2%$.*%T*79*(%$&%4&&7%$.&(&'3.7>%+*2&(*%#*(Z"4*1%

1. S6<X;6%6@RB%F?6I inspect the general condition of the welder. Check for:

• loose hardware,

• misalignment or binding of moving parts,

• damaged cord/electrical wiring,

2. W6;CXUCR@GGQI Have a qualified technician unplug the Welder, remove the Back Housing, and using compressed air, blow out all dust from the interior.

3. @<A6;%6!6;Q%F?6I Store in a clean and dry location.

• frayed or damaged cables,

• cracked or broken parts, and

• any other condition that may affect its safe operation.

A(&'+7*#.&&$"83%

CDWX;A@EAc

S*%R6;A@CE%$&%#.'$%&22%$.*%T*79*(I%9"#4&88*4$%"$%2(&5%/&)*(I%,89%9"#4.,(3*%$.*%

*7*4$(&9*%$&%3(&'89%+*2&(*%,9='#$"83I%47*,8"83I%&(%(*/,"("83%$.*%'8"$1

W(&+7*5 W&##"+7*%R,'#*# G"Y*7>%?&7'$"&8#

When Switched On Power Indicator Lights, But Welder Does Not Function

When Switched On Power Indicator Does Not Light

Weak Arc Strength 1. Incorrect line voltage.

Welding Arc Not Stable. 1. Loose electrode cable or ground cable.

1. Tripped thermal protection device.

2. Ground Clamp not attached to workpiece.

3. Machine is in low- or over-voltage protection.

4. Shielding Gas not connected.

1. Unit is not connected to outlet properly.

2. Outlet is unpowered.

3. Circuit supplies insufficient input voltage or amperage.

4. Circuit breaker has tripped due to high input amperage.

2. Improper gauge or length of cord.

2. Damaged electrode holder or loose connection within electrode holder.

3. Adjust current setting.

4. Shielding gas getting low.

1. Reduce duration or frequency of welding periods to help reduce wear on the welder. Refer to Duty Cycle (Duration of Use) on page 14.

2. Attach Ground Clamp to workpiece.

3. If Voltage Input/Thermal Overload Indicator is illuminated, check input voltage and ensure it falls within the specified range. If input voltage is correct, press Reset Button on back of machine.

4. Connect shielding gas to Welder.

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 amperage as detailed in Specifications on page 7.

4. Press Reset Button on back of machine to reset circuit breaker.

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. Use only one of the supplied power cords for this Welder or an identical replacement cord.

1. Check to ensure that all connections are tight.

2. Have a qualified technician inspect and repair/replace as necessary.

3. Make sure setting matches recommended setting on chart.

4. Replace shielding gas cylinder.

% <&77&)%,77%?,2*$>%/(*4,'$"&8#%).*8*Z*(%9",38&#"83%&(%#*(Z"4"83%$.*%$&&71%%%

U"#4&88*4$%/&)*(%#'//7>%+*2&(*%#*(Z"4*1

Page 24 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKLMMKNOPO1 Item 63618

W,($#%G"#$%,89%U",3(,5#

W,($#%G"#$

W,($ U*#4("/$"&8 i$>

1 Arc PCB 1 2 Rectifier Radiator 1 3 Air Duct 1 4 Radiator Support Bar 2 5 Rectifier Radiator 1 6 Bridge Rectifier 2 7 120 Volt Power Cord 1 8 240 Volt Power Cord 1

9 Fan 1 10 Power Socket 1 11 Rear Handle Cover 1 12 Rear Panel 1 13 Nut 1 14 Flat Washer 1 15 Solenoid Valve 1 16 IGBT 2

@##*5+7>%U",3(,5

12

11

13 14 15

W,($ U*#4("/$"&8 i$>

17 Power PCB 1 18 Main PCB 1 19 Beam 1 20 Top Handle Cover 1 21 Top Handle Base 1 22 Top Housing 1 23 Front Panel 1 24 Display PCB 1 25 Control Panel 1 26 Foot Pedal 1 27 Settings Knob 1 28 Positive Socket 1 29 Power Switch 1 30 Foot Pedal Socket 1 31 Gas Socket 1 32 Copper Anode 1

16

17

18

W,($ U*#4("/$"&8 i$>

33 Transformer 1 34 Bottom Housing 1 35 Electrode Holder 1 36 Ground Clamp 1 37 High Frequency

Rectifier 38 TIG Torch 1 39 IGBT Right Radiator 1 40 Rectifier Radiator 1 41 High Frequency

Rectifier 42 IGBT Left Radiator 1 43 Insulation 1 44 Negative Socket 1 45 Strap (not shown) 1

19 21

20

5

2

22

?@<6AQD@CEA6E@ER6 S@?CR%T6GUCEVT6GUCEV%ACW? SETUP

10

23

9

24

8

7

6

5

4

3

2

1

25

26

27

28

29

30

43

42 39

41 34

40

44

36 3538

323337

31

Page 25<&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKLMMKNOPO1Item 63618

T"("83%U",3(,5

+

-

?@<6AQ D@CEA6E@ER6S@?CR%T6GUCEV T6GUCEV%ACW?SETUP

G

AC2

AC1

2

1

FAN

POWER

6 5 4 3

Power Board

M2

234

1

CN2

SW1

STICK

LED4

TIG PULSE

LED2

TIG LIFT

LED3

control panel

M3

LED6

VR1

LED5

2 1

1

POWER

1 2 3

CN5

9 8 7 6 5 4 3 2 1

LED1

TIG HF

CN3

6 5 4 3 2 1

CN1

10

9 8 7 6 5 4 3 2 1

4 5 6

CN5

1 2 3 4 5 6 7 8 9

CN3-2 1 2 3 4 5 6

CN3-1 1 2 3 4 5 6 7 8 9 10

2

FAN

J

2 1

v

15V

34

-t

1

3

〜

+

-

4

2

PFC

IGBT

Switch

3

1

RECITIFIER

〜

+

-

4

2

Main Board

High Frequency And Remote Control Board

1 2 3 4 5

CN3 6 7

Remote control plug

2

3

1

4

5

7

6

CN3

2 1

CN1

M4

8 7 6 5 4 3 2 1

2

1

2

HF2

HF1

CN7 1 2 3 4 5 6 7 8

CN9

1 2 3 4

5

6

4

1

2

T1

314

5

Hall Sensor

*

OUT

1

OUT

Page 26 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKLMMKNOPO1 Item 63618

WG6@?6%;6@U%AB6%<XGGXTCEV%R@;6<FGGQ

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.

;*4&(9%W(&9'4$_#%?*(",7%E'5+*(%B*(*-%

E&$*- If product has no serial number, record month and year of purchase instead.

E&$*- Some parts are listed and shown for illustration purposes only,

and are not available individually as replacement parts.

?@<6AQD@CEA6E@ER6 S@?CR%T6GUCEVT6GUCEV%ACW? SETUP

Page 27<&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKLMMKNOPO1Item 63618

G"5"$*9%P^%U,>%T,((,8$>

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.

26541 Agoura Road • Calabasas, CA 91302 • 1-888-866-5797

VULCAN 63618 Owner's Manual & Safety Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual