VULCAN 63793 Owner's Manual & Safety Instructions

Owner’s Manual & Safety Instructions

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

operating, inspection, maintenance and cleaning procedures. Write the product’s serial number in the

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. 17e

!"#"$%&'(%)*+#"$*%,$-%.$$/-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-<?>-1-888-380-0318 as soon as possible.

please call 1-888-380-0318 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%

;*,9%$."#%5,$*(",7%+*2&(*%'#"83%$."#%/(&9'4$1% <,"7'(*%$&%9&%#&%4,8%(*#'7$%"8%#*("&'#%"8='(>1%

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

<,"7'(*%$&%9&%#&%4,8%(*#'7$%"8%#*("&'#%"8='(>1% ?@!6%ABC?%D@EF@G1

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

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

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

Specifications ............................................. 5

?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?SETUP?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?SETUP

Setup .......................................................... 6

CDUV;A@EA%?@<6AO%CE<V;D@ACVE

Maintenance and Service .......................... 17

Parts List and Diagram .............................. 19

Warranty .................................................... 20

R@;ECET%?ODQVG?%@ES%S6<CECACVE?

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.

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

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

U;VA6PA%>&'(#*72%,89%&$.*(#1%%;*,9%,89%'89*(#$,89%$."#%"82&(5,$"&81

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

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

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

3. U7,4*%$.*%)*79*(%&8%,%#$,+7*%7&4,$"&8%+*2&(*%'#*1%%% If it falls while plugged in, severe injury, electric shock, or fire may result.

4. S&%8&$%&X*((*,4.1%%%

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

5. ?$,>%,7*($I%),$4.%).,$%>&'%,(*%9&"83%,89%'#*% 4&55&8%#*8#*%).*8%&/*(,$"83%,%)*79*(1%% S&%8&$%'#*%,%)*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. @X&"9%'8"8$*8$"&8,7%#$,($"831%%Make sure you are prepared to begin work before turning on the Welder.

7. E*X*(%7*,X*%$.*%R*79*(%'8,$$*89*9%)."7*% *8*(3"Z*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&X*(%,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%JKLLLKMLNKNMJL1 Item 63793

<'5*%,89%T,#%?,2*$>

R*79"83%,89%U7,#5,%P'$$"83%/(&9'4*%$&["4%2'5*#1

INHALATION HAZARD:%

1. 6[/&#'(*%$&%)*79"83%&(%4'$$"83%*[.,'#$% 2'5*#%4,8%"84(*,#*%$.*%("#W%&2%9*X*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.

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

2. S&%8&$%'#*%8*,(%9*3(*,#"83%&(% /,"8$"83%&/*(,$"&8#1

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

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

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

are not feasible, use an approved respirator.

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

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

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

4.*4W%$.*%&/*(,$"&8%,89%,"(%H',7"$>% ,89%5,W*%(*4&55*89,$"&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.

?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU? SETUP ?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU? SETUP

@;P%;@O?%4,8%"8='(*%*>*#%,89%+'(8%#W"81

1. R*,(%@E?CK,//(&X*9%)*79"83%*>*%/(&$*4$"&8% 2*,$'("83%,$%7*,#$%,%8'5+*(%JN%#.,9*%7*8#%(,$"831

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

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

Wear dry, insulating gloves and protective clothing.

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

6G6PA;CP%?BVPY%4,8%YCGG1

1. A'(8%&22I%9"#4&88*4$%/&)*(I%,89% 9"#4.,(3*%67*4$(&9*%$&%3(&'89%+*2&(*%#*$$"83% 9&)8%$&(4.067*4$(&9*%.&79*(%,89%+*2&(*%#*(X"4*1

2. S&%8&$%$&'4.%*8*(3"Z*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. P&88*4$%$&%3(&'89*9I%T<PCK/(&$*4$*9%

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

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

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

4. R*,(%,8%,//(&X*9%.*,9%4&X*("83%$&%/(&$*4$% $.*%.*,9%,89%8*4W1%Use aprons, cape, sleeves, shoulder covers, and bibs designed and approved for welding and cutting procedures.

5. R*,(%,8%,//(&X*9%)*79"83%=,4W*$%&(%7&83%#7**X*#%

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

6. R.*8%)*79"8304'$$"83%&X*(.*,9%&(%"8%4&82"8*9% #/,4*#I%)*,(%27,5*%(*#"#$,8$%*,(%/7'3#%&(% *,(%5'22#%$&%W**/%#/,(W#%&'$%&2%*,(#1

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

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

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

cords increase the risk of electric shock.

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

9. C8#'7,$*%>&'(#*72%2(&5%$.*%)&(W/"*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.

Page 3<&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1Item 63793

<"(*%?,2*$>

@;P%@ES%?G@T%4,8%4,'#*%2"(*1

1. P7*,(%,),>%&(%/(&$*4$%27,55,+7*%&+=*4$#1%%%

?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?SETUP?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?SETUP

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. Y**/%@QPK$>/*%2"(*%*[$"83'"#.*(%8*,(%

)&(W%,(*,%,89%W8&)%.&)%$&%'#*%"$1

3. D,"8$,"8%,%#,2*%)&(W"83%*8X"(&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. S&%8&$%&/*(,$*%)*79*(#%"8%,$5&#/.*(*#%

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

5. C2%)&(W"83%&8%,%5*$,7%),77I%4*"7"83I%*$41I% /(*X*8$%"38"$"&8%&2%4&5+'#$"+7*#%&8%$.*% &$.*(%#"9*%+>%5&X"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. S&%8&$%)*79%&(%4'$%&8%5,$*(",7#%.,X"83%

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

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

8. @2$*(%)*79"83I%5,W*%,%$.&(&'3.%*[,5"8,$"&8% 2&(%*X"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. S&%8&$%,//7>%.*,$%$&%,%4&8$,"8*(%$.,$%.,#%.*79%

,8%'8W8&)8%#'+#$,84*%&(%,%4&5+'#$"+7*% 5,$*(",7%).&#*%4&8$*8$#I%).*8%.*,$*9I% 4,8%/(&9'4*%27,55,+7*%&(%*[/7&#"X*%X,/&(#1%%

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

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

1. S&%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. S"#4&88*4$%$.*%/7'3%2(&5%$.*%/&)*(% #&'(4*%+*2&(*%5,W"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. U(*X*8$%'8"8$*8$"&8,7%#$,($"831% 68#'(*%$.*%#)"$4.%"#%"8%$.*%&22K /&#"$"&8%+*2&(*%4&88*4$"83%$&%/&)*(% #&'(4*%&(%5&X"83%$.*%)*79*(1 Carrying

or energizing welders that have the switch on invites accidents.

D,"8$*8,84*

1. D,"8$,"8%)*79*(#1%%P.*4W%2&(%5"#,7"385*8$%&(% +"89"83%&2%5&X"83%/,($#I%+(*,W,3*%&2%/,($#% ,89%,8>%&$.*(%4&89"$"&8%$.,$%5,>%,22*4$%$.*% )*79*(\#%&/*(,$"&81%%C2%9,5,3*9I%.,X*%$.*% )*79*(%(*/,"(*9%+*2&(*%'#*1 Many accidents

are caused by poorly maintained welders.

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

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

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

2. B,X*%>&'(%)*79*(%#*(X"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.

Page 4 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1 Item 63793

3. D,"8$,"8%7,+*7#%,89%8,5*/7,$*#%&8%$.*%R*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.

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

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

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

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

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

3. Y**/%4>7"89*(#%,),>%2(&5%,8>%*7*4$("4,7%4"(4'"$#I% "847'9"83%)*79"83%4"(4'"$#1

4. Y**/%/(&$*4$"X*%4,/%"8%/7,4*%&X*(%$.*%X,7X*% *[4*/$%).*8%$.*%4>7"89*(%"#%"8%'#*1

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

Wire Feed (Speed)

Workpiece Ground Cable

Torch Cable

Overheat Shutdown Indicator

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

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

@RT

American Wire Gauge

Electric Shock Hazard. Do not touch energized parts.

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

?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU? SETUP ?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU? SETUP

!@P

@

VP!

CUD

?/*4"2"4,$"&8#

Wire Types Aluminum and Steel alloys

Wire Capacity 4" Spool, - 1lb aluminum and 2lb steel, 0.030" / 0.035"diameter

Rated Duty Cycle 35% @ 160 A

Cooling Fan

Volts Alternating Current

Amperes

Open Circuit Voltage

Inches Per Minute

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.

Page 5<&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1Item 63793

?*$'/

Reset

Power Input

Gas Inlet

% ;*,9%$.*%6EAC;6%CDUV;A@EA%?@<6AO%CE<V;D@ACVE%#*4$"&8%,$%$.*%+*3"88"83%&2%$."#%

?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?SETUP

5,8',7%"847'9"83%,77%$*[$%'89*(%#'+.*,9"83#%$.*(*"8%+*2&(*%#*$%'/%&(%'#*%&2%$."#%/(&9'4$1

AV%U;6!6EA%?6;CVF?%CE]F;O%<;VD%@PPCS6EA@G%VU6;@ACVE-% A'(8%$.*%U&)*(%?)"$4.%&22%,89%'8/7'3%$.*%)*79*(%+*2&(*%#*$%'/1

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.

E&$*- A.*%2&77&)"83%"8#$('4$"&8#%,(*%2&(%)*79"83%)"$.%@7'5"8'5%)"(*1

P&88*4$%?."*79"83%T,#

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.

J

Q("*27>%&/*8%X,7X*%

^

$&%47*,8I%%

$.*8%47&#*%%

X,7X*1

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

4

M

Page 6 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1 Item 63793

?*$%F/%?/&&7%T'8

1. Pull the Nozzle to remove it.

2. Unscrew the Contact Tip counterclockwise and remove.

E&ZZ7*

3. Press Spool Cover Release Button, then open Spool Cover.

4. Remove Spool Lock Knob by turning clockwise.

5. Loosen Spool Tension Knob without removing.

E&$*- To prevent unraveling, leave wire secured to Spool.

6. Install Spool so wire will feed over top of Spool.

7. Tighten Spool Tension Knob until Spool cannot spin freely.

P&8$,4$%

A"/

9. Hold end of wire while releasing from Spool. Cut off any bent wire.

10. Keeping tension on Spool, feed Wire into Inlet Guide.

11. Loosen Tension Knob.

12. Push on Tension Knob enough to create a space, between Driver Roller and Tension Roller, large enough so that Wire will pass through.

13. Push Wire 1/4" into Inlet.

14. Tighten Tension Knob.

A*8# "&8%

S("X*%

;&77*(

A*8# "&8%

?/("83

A*8# "&8%

@(5

?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU? SETUP

Y8&+

C87*$%

T'"9*

8. Replace Spool Lock Knob by turning counterclockwise.

?/&&7%P&X*(%

;*7*,#*%Q'$$&8

G&4W%Y8&+

?/&&7%

A*8#"&8%

Y8&+

C87*$

15. Close Spool Cover.

16. Set Spool Gun down on nonconductive, nonflammable surface away from any grounded objects.

A*8# "&8%

;&77*(

R"(*

Page 7<&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1Item 63793

Connect to Vulcan MIGMAX 140

1. Turn Power Switch OFF and unplug welder.

2. Open Door on side of Welder.

?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?SETUP

3. Remove MIG Gun and Wire Spool, if present.

S&&(

4. Set Polarity to DCEP (Direct Current Electrode Positive):

a. Connect Black Ground Cable

to Negative Terminal (-).

b. Connect Red Electrode Cable

to Positive Terminal (+).

c. Make sure Cables sit flush in grooves.

5. P&88*4$%?/&&7%T'8-

a. Loosen Knob without removing.

b. Plug Spool Gun Connector

into Spool Gun Socket.

c. Tighten Knob, do not over tighten.

d. Pull on Spool Gun Connector to ensure tight

connection. Re-seat if connection is not tight.

E&$*- If connection is not tight, arc will not ignite.

Y8&+

?/&&7%T'8%

?&4W*$%

6. Plug Wire Feed Control Cable into Wire Feed Control Socket. Secure by turning collar clockwise until tight.

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

7. Plug Gas Cable into Gas Outlet. Secure by wrench tightening.

?/&&7%T'8% P&88*4$&(

T(&&X*

?/&&7%T'8%

?&4W*$%

R"(*%<**9%

P&8$(&7%

P,+7*

Page 8 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1 Item 63793

R"(*%<**9%

P&8$(&7%

?&4W*$

T,#%

V'$7*$

T,#%

P,+7*

S@ET6;

Gun

MIG

U@;A?%D@O%Q6%@A%R6GSCET%!VGA@T6

AV%U;6!6EA%6G6PA;CP%?BVPY%@ES%S6@AB-

1. Y**/%.,89#%,),>%2(&5%R"(*%<**9%5*4.,8"#51

2. P7&#*%9&&(%+*2&(*%/7'33"83%"8I%

3. ?$,>%47*,(%&2%)"(*%)."7*%2**9"83%)"(*%$.(&'3.%3'81

AV%U;6!6EA%?6;CVF?%CE]F;O-%U(&$*4$"X*%3*,(%5'#$%+*%)&(8%).*8%'#"83%$.*%R*79*(_%5"8"5'5%

shade number 10 full face shield (or welding mask), ear protection, welding gloves, sleeves and apron,

ECV?BK,//(&X*9%(*#/"(,$&(I%,89%2"(*%(*#"#$,8$%)&(W%47&$.*#%)"$.&'$%/&4W*$#%#.&'79%+*%)&(8%).*8%)*79"831%% G"3.$%2(&5%$.*%,(4%4,8%4,'#*%/*(5,8*8$%9,5,3*%$&%$.*%*>*#%,89%#W"81%%S&%8&$%+(*,$.*%,(4%2'5*#1

8. P7&#*%S&&(%&8%#"9*%&2%R*79*(I% 5,W"83%#'(*%"$%7,$4.*#1

9. Plug either 120 VAC or 240 VAC Power Cord into Power Input Socket on back of welder.

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

10. Plug Welder into properly grounded, GFCI

protected, 120 VAC (20 amp rated) outlet or 240 V outlet. The circuit must be equipped with

delayed action-type circuit breaker or fuses.

11. Turn Power Switch ON.

12. On inside of welder, toggle Spool Gun/MIG Gun switch to ?/&&7%T'8.

Spool

13. P.*4W%R"(*%S("X*%A*8#"&8-

a. Hold Spool Gun and point it

away from all objects.

b. Press and hold Trigger until at least 2"

of wire sticks out of the Gun. Release Trigger. Trim wire to 2" as needed.

c. Hold Gun 2 - 3" away from piece of wood.

d. Press Trigger. When Wire touches wood,

it should bend instead of stopping.

• If Wire stops instead of bending, turn off and unplug welder.

• Slightly tighten Tension Knob.

• Plug welder in and turn power on.

• Repeat steps c. and d. until Wire bends instead of stopping. Trim wire to 2" as needed.

A*8# "&8%

Y8&+

?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU? ?6AFU

Gun

a. Turn Amperage to A and Voltage to 1.

^KM`

14. Turn Power Switch OFF and unplug welder.

15. Choose Contact Tip same size as Wire. Slide Contact Tip over Wire.

16. Replace Nozzle, trim wire to 1/2".

17. Set Spool Gun down on nonconductive, nonflammable surface away from any grounded objects.

18. Go to V/*(,$"&8%&8%/,3*%141

R"(*%?.&'79%

Q*89

Page 9<&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1Item 63793

P&88*4$%$&%!'74,8%DCTD@a%^Jb

1. Turn Power Switch OFF and unplug welder.

2. Open Door on side of welder.

?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?SETUP

3. Remove MIG Gun and Wire Spool, if present.

S&&(

4. Set Polarity to DCEP (Direct Current Electrode Positive):

a. Connect Black Ground Cable

to Negative Terminal (-).

b. Connect Red Electrode Cable

to Positive Terminal (+).

c. Make sure Cables sit flush in grooves.

5. P&88*4$%?/&&7%T'8-

a. Loosen Knob without removing.

b. Plug Spool Gun Connector

into Spool Gun Socket.

c. Tighten Knob, do not over tighten.

d. Pull on Spool Gun Connector to ensure tight

connection. Re-seat if connection is not tight.

E&$*- If connection is not tight, arc will not ignite.

Y8&+

?/&&7%T'8%

?&4W*$%

6. Plug Wire Feed Control Cable into Wire Feed Control Socket. Secure by turning collar clockwise until tight.

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

7. Plug Gas Cable into Gas Outlet. Secure by wrench tightening.

?/&&7%T'8% P&88*4$&(

T(&&X*

?/&&7%T'8%

?&4W*$%

R"(*%<**9%

P&8$(&7%

P,+7*

Page 10 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1 Item 63793

R"(*%<**9%

P&8$(&7%

?&4W*$

T,#%

V'$7*$

T,#%

P,+7*

S@ET6;

U@;A?%D@O%Q6%@A%R6GSCET%!VGA@T6

AV%U;6!6EA%6G6PA;CP%?BVPY%@ES%S6@AB-

1. Y**/%.,89#%,),>%2(&5%R"(*%<**9%5*4.,8"#51

2. P7&#*%9&&(%+*2&(*%/7'33"83%"8I%

3. ?$,>%47*,(%&2%)"(*%)."7*%2**9"83%)"(*%$.(&'3.%3'81

AV%U;6!6EA%?6;CVF?%CE]F;O-%U(&$*4$"X*%3*,(%5'#$%+*%)&(8%).*8%'#"83%$.*%R*79*(_%5"8"5'5%

shade number 10 full face shield (or welding mask), ear protection, welding gloves, sleeves and apron,

ECV?BK,//(&X*9%(*#/"(,$&(I%,89%2"(*%(*#"#$,8$%)&(W%47&$.*#%)"$.&'$%/&4W*$#%#.&'79%+*%)&(8%).*8%)*79"831%% G"3.$%2(&5%$.*%,(4%4,8%4,'#*%/*(5,8*8$%9,5,3*%$&%$.*%*>*#%,89%#W"81%%S&%8&$%+(*,$.*%,(4%2'5*#1

8. P7&#*%S&&(%&8%#"9*%&2%R*79*(I% 5,W"83%#'(*%"$%7,$4.*#1

9. Plug either 120 VAC or 240 VAC Power Cord into Power Input Socket on back of welder.

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

10. Plug welder into a properly grounded, GFCI

protected, 120 VAC (20 amp rated) outlet or 240 V outlet. The circuit must be equipped with

delayed action-type circuit breaker or fuses.

11. Turn Power Switch ON.

12. Turn Process Selection Knob to ?/&&7%T'81

13. Turn Voltage to 1, Amperage to A and Wire Diameter to MANUAL.

U(&4*##%

?*7*4$"&8%Y8&+

14. P.*4W%R"(*%S("X*%A*8#"&8-

a. Hold Spool Gun and point it

away from all objects.

b. Press and hold Trigger until at least 2"

of wire sticks out of the Gun. Release Trigger. Trim wire to 2" as needed.

c. Hold Gun 2 - 3" away from piece of wood.

d. Press Trigger. When Wire touches

wood, it should bend instead of stopping. Release Trigger.

• If Wire stops instead of bending, turn off and unplug welder.

• Slightly tighten Tension Knob.

• Plug welder in and turn power on.

• Repeat steps c. and d. until Wire bends instead of stopping. Trim wire to 2" as needed.

A*8# "&8%

Y8&+

?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU? ?6AFU

^KM`

15. Turn Power Switch OFF and unplug welder.

16. Choose Contact Tip same size as Wire. Slide Contact Tip over Wire.

17. Replace Nozzle, trim wire to 1/2".

18. Set Spool Gun down on nonconductive, nonflammable surface away from any grounded objects.

19. Go to V/*(,$"&8%&8%/,3*%141

R"(*%?.&'79%

Q*89

Page 11<&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1Item 63793

P&88*4$%$&%!'74,8%VDECU;V%^^N

1. Turn Power Switch OFF and unplug Welder.

2. Open Door on side of Welder.

?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?SETUP

S&&(

3. P&88*4$%?/&&7%T'8-

a. Loosen Knob without removing.

b. Plug Spool Gun Connector

into Spool Gun Socket.

c. Tighten Knob, do not over tighten.

d. Pull on Spool Gun Connector to ensure tight

connection. Re-seat if connection is not tight.

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

7. Plug Wire Feed Power Cable into Positive Socket. Twist clockwise all the way to lock in place.

T(&'89%

P7,5/%

P,+7*

R"(*%<**9%

U&)*(%P,+7*

E&$*- If connection is not tight, arc will not ignite.

4. Plug Wire Feed Control Cable into Wire Feed Control Socket. Secure by turning collar clockwise until tight.

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

5. Plug Gas Cable into Gas Outlet. Secure by wrench tightening.

?/&&7%T'8% P&88*4$&(

?/&&7%T'8%

?&4W*$%

Y8&+

R"(*%<**9%

P&8$(&7%

P,+7*

Page 12 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1 Item 63793

R"(*%<**9%

P&8$(&7%

?&4W*$

T,#%

V'$7*$

T,#%

P,+7*

S@ET6;

U@;A?%D@O%Q6%@A%R6GSCET%!VGA@T6

AV%U;6!6EA%6G6PA;CP%?BVPY%@ES%S6@AB-

1. Y**/%.,89#%,),>%2(&5%R"(*%<**9%5*4.,8"#51

2. P7&#*%9&&(%+*2&(*%/7'33"83%"8I%

3. ?$,>%47*,(%&2%)"(*%)."7*%2**9"83%)"(*%$.(&'3.%3'81

AV%U;6!6EA%?6;CVF?%CE]F;O-%U(&$*4$"X*%3*,(%5'#$%+*%)&(8%).*8%'#"83%$.*%R*79*(_%5"8"5'5%

shade number 10 full face shield (or welding mask), ear protection, welding gloves, sleeves and apron,

ECV?BK,//(&X*9%(*#/"(,$&(I%,89%2"(*%(*#"#$,8$%)&(W%47&$.*#%)"$.&'$%/&4W*$#%#.&'79%+*%)&(8%).*8%)*79"831%% G"3.$%2(&5%$.*%,(4%4,8%4,'#*%/*(5,8*8$%9,5,3*%$&%$.*%*>*#%,89%#W"81%%S&%8&$%+(*,$.*%,(4%2'5*#1

8. P7&#*%S&&(%&8%#"9*%&2%R*79*(I% 5,W"83%#'(*%"$%7,$4.*#1

9. Plug either 120 VAC or 240 VAC Power Cord into Power Input Socket on back of welder.

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

10. Plug Welder into properly grounded, GFCI

protected, 120 VAC (20 amp rated) outlet or 240 V outlet. The circuit must be equipped with

delayed action-type circuit breaker or fuses.

11. Turn Power Switch ON.

12. Push Home button.

13. Turn Main Knob until desired Spool Gun/Wire Type process appears on screen.

14. Press Main Knob. Confirm correct Gas is connected to welder.

17. P.*4W%R"(*%S("X*%A*8#"&8-

a. Hold Spool Gun and point it

away from all objects.

b. Press and hold Trigger until at least 2" of wire

sticks out of the Gun. Trim wire to 2" as needed.

c. Hold Gun 2 - 3" away from piece of wood.

d. Press Trigger. When Wire touches wood,

it should bend instead of stopping.

• If Wire stops instead of bending, turn off and unplug welder.

• Slightly tighten Tension Knob.

• Plug welder in and turn power on.

• Reset Welder to desired process and check settings.

• Repeat steps c. and d. until Wire bends instead of stopping. Trim wire to 2" as needed.

A*8# "&8%

Y8&+

?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU? ?6AFU

15. Press Main Knob. Make sure Diameter and Thickness are set to lowest settings by turning Left and Right Knobs.

Spool Gun 4043 Al

1NMN` JcT,

16. Press Main Knob. Ready to check Wire Drive Tension.

348 Jb1b

N

Spool Gun 4043 Al

JNNd%@(

^b b

N1N

1NMN`

JcT,

N1N

^KM`

R"(*%?.&'79%

Q*89

18. Turn Power Switch OFF and unplug welder.

19. Choose Contact Tip same size as Wire. Slide Contact Tip over Wire.

20. Replace Nozzle, trim wire to 1/2".

21. Set Spool Gun down on nonconductive, nonflammable surface away from any grounded objects.

Page 13<&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1Item 63793

V/*(,$"&8

% ;*,9%$.*%6EAC;6%CDUV;A@EA%?@<6AO%CE<V;D@ACVE%#*4$"&8%,$%$.*%+*3"88"83%&2%$."#%

?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?SETUP

AV%U;6!6EA%?6;CVF?%CE]F;O%@ES%S6@AB-%%% S&%8&$%)*79%)"$.&'$%T(&'89"83%P7,5/1%% R.*8%$.*%&/*(,$&(%"#%8&$%.&79"83%$.*%?/&&7%T'8I%"$%5'#$%+*%#"$$"83%&8%,%8&84&89'4$"X*I%8&827,55,+7*% #'(2,4*1% V87>%.&79%?/&&7%T'8%)"$.%,8%*7*4$("4,77>%"8#'7,$*9%)*79"83%37&X*1% AV%U;6!6EA%?6;CVF?%CE]F;O-% U(&$*4$"X*%3*,(%5'#$%+*%)&(8%).*8%'#"83%$.*%R*79*(_%5"8"5'5%#.,9*%8'5+*(%JN%2'77%2,4*%

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

(*#/"(,$&(I%,89%2"(*%(*#"#$,8$%)&(W%47&$.*#%)"$.&'$%/&4W*$#%#.&'79%+*%)&(8%).*8%)*79"831%%

AV%U;6!6EA%S6@AB%<;VD%@?UBOaC@ACVE-% S&%8&$%&/*8%3,#%)"$.&'$%/(&/*(%X*8$"7,$"&81%%<"[%3,#%7*,W#%"55*9",$*7>1 Shielding gas can displace air and cause rapid loss of consciousness and death. ?."*79"83%3,#%)"$.&'$%4,(+&8%9"&["9*%4,8%+*% *X*8%5&(*%.,Z,(9&'#%+*4,'#*%,#/.>[",$"&8%4,8%#$,($%)"$.&'$%2**7"83%#.&($8*##%&2%+(*,$.1

5,8',7%"847'9"83%,77%$*[$%'89*(%#'+.*,9"83#%$.*(*"8%+*2&(*%#*$%'/%&(%'#*%&2%$."#%/(&9'4$1

%%%

;*2*(%$&%Q,#"4%R*79"83%#*4$"&8%"8%>&'(%!'74,8%)*79*(\#%5,8',7%

2&(%DCT%S'$>%P>47*I%?*$$"83%F/%A.*%R*79I%T(&'89"83%R&(W/"*4*I%

?*$$"83#I%?."*79"83%T,#%F#*%,89%Q,#"4%R*79"83%A*4.8"H'*1

?'+#$"$'$*%"8#$('4$"&8#%+*7&)%2&(%Q,#"4%R*79"83%A*4.8"H'*%"8%)*79*(\#%5,8',71%%

Q,#"4%R*79"83%A*4.8"H'*

1. Press (and hold) Spool Gun Trigger and contact the area to be welded with wire to ignite arc.

• E,((&)%R*79- Push the wire in a steady straight line. This is called a stringer bead.

?$("83*(%Q*,9

• R"9*%R*79: Push the wire back and forth across the joint. This is called a weave bead and takes practice to perform properly.

R*,X*%Q*,9

2. Direct the welding wire straight into the join:.

• 45° angle for fillet welds.

• 90° angle for butt welds,

R*79%DCT%T'8%,837*#I%%

X"*)*9%2(&5%2(&8$%&2%)*79%=&"8$1

45°

2"77*$%)*79%=&"8$

+'$$%)*79%=&"8$

90°

Page 14 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1 Item 63793

3. The Spool Gun should be tilted so that wire is angled anywhere from straight on and 15° away from the direction you are welding. The amount of tilt is called the push angle.

U'#.%@837*

0-15°

R*79%

S"(*4$"&8

;*2*(%$&%Q,#"4%R*79"83%#*4$"&8%"8%>&'(%!'74,8%)*79*(\#%

5,8',7%2&(%(*5,"8"83%)*79"83%"8#$('4$"&8#1

4. The Contact Tip should remain within 1/2" of the work surface. This distance is called CTWD - Contact Tip to Work Distance.

PARS%%

(up to 1/2")

?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU? SETUP

Page 15<&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1Item 63793

R*79%U(&+7*5#

?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?SETUP

U&(&#"$>

6[4*##"X*%?/,$$*(

?5,77%4,X"$"*#%&(%.&7*#%"8%$.*%+*,91

TOP

VIEW

UV??CQG6%P@F?6?%@ES%?VGFACVE?

1. C84&((*4$%/&7,("$>- Check that polarity is set correctly for type of welding.

2. Insufficient shielding gas (MIG only): Increase flow of gas. Clean nozzle. Maintain proper CTWD.

3. Incorrect shielding gas (MIG only): Use shielding gas recommended by wire supplier.

4. S"($>%)&(W/"*4*%&(%)*79"83%)"(*- Clean workpiece down to bare metal. Make certain that wire is clean and free from oil, coatings, and other residues.

5. C84&8#"#$*8$%$(,X*7%#/**9-% Maintain steady travel speed.

6. PARS%$&&%7&83- Reduce CTWD.

<"8*%#/,$$*(%"#%8&(5,71%

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

TOP

VIEW

UV??CQG6%P@F?6?%@ES%?VGFACVE?

1. S"($>%)&(W/"*4*%&(%)*79"83%)"(*- Clean workpiece down to bare metal. Make certain that wire is clean and free from oil, coatings, and other residues.

2. C84&((*4$%/&7,("$>- Check that polarity is set correctly for type of welding.

3. Insufficient shielding gas (MIG only): Increase flow of gas. Clean nozzle. Maintain proper CTWD.

4. R"(*%2**9"83%$&&%2,#$-% Reduce wire feed speed.

5. PARS%$&&%7&83- Reduce CTWD.

P(&&W*90R,X>%Q*,9

TOP

VIEW

UV??CQG6%P@F?6?%@ES%?VGFACVE?

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

2. C84&8#"#$*8$%$(,X*7%#/**9-% Maintain steady travel speed.

3. PARS%$&&%7&83- Reduce CTWD.

Q'(8KA.(&'3.

Q,#*%5,$*(",7%5*7$#%,),>I%% 7*,X"83%,%.&7*%"8%$.*%)*791

TOP

VIEW

UV??CQG6%P@F?6?%@ES%?VGFACVE?

1. R&(W/"*4*%&X*(.*,$"83-% Reduce current and/or wire feed speed.

2. A(,X*7%#/**9%$&&%#7&)- Increase travel speed and ensure that travel speed is kept steady.

3. 6[4*##"X*%5,$*(",7%,$%)*79-% Reduce wire feed speed.

Page 16 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1 Item 63793

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

AV%U;6!6EA%?6;CVF?%CE]F;OI%<C;6%@ES%QF;E?-% F8/7'3%$.*%)*79*(I%(*#$%$.*%?/&&7%T'8%&8%,%.*,$K/(&&2I%*7*4$("4,77>%8&8K4&89'4$"X*%#'(2,4*I% ,89%,77&)%,77%/,($#%&2%$.*%R*79*(%$&%4&&7%$.&(&'3.7>%+*2&(*%#*(X"4*1%

?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU? SETUP

1. Q6<V;6%6@PB%F?6I inspect the general condition of the Spool Gun. Check for:

• loose hardware,

• misalignment or binding of moving parts,

• damaged cord/electrical wiring,

• frayed or damaged cables,

• cracked or broken parts, and

• any other condition that may

affect its safe operation.

2. @<A6;%6!6;O%F?6I%inspect and clean Nozzle and Contact Tip.%%

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

4. U6;CVSCP@GGOI clean Barrel, replace Inlet Guide

E&ZZ7*%,89%P&8$,4$%A"/%C8#/*4$"&8%,89%P7*,8"83

1. D,W*%#'(*%$.,$%$.*%?/&&7%T'8%"#%4&5/7*$*7>% 4&&7%,89%$.,$%$.*%U&)*(%P&(9%"#%'8/7'33*9% 2(&5%$.*%*7*4$("4,7%&'$7*$%+*2&(*%/(&4**9"831

2. Pull the Nozzle to remove it.

3. Scrub the interior of the Nozzle clean with a wire brush.

4. Examine the end of the Nozzle. The end should be flat and even. If the end is uneven, chipped, melted, cracked, or otherwise damaged, replace Nozzle.

5. Unscrew the Contact Tip counterclockwise and slide it off the welding wire to remove.

6. Scrub the outside of the Tip clean with a wire brush. Clean out the inside of the tip with a tip cleaner (sold separately).

7. Examine the shape of the hole at the end of the Contact Tip. It should be an even circle; if it is oblong or has any bulges in it, replace Contact Tip.

P7*,8"83%Q,((*7

1. Remove Nozzle and Contact Tip.

2. Remove Hex Bolt, then pull Barrel out.

3. Using compressed air, blow out Barrel.

4. Replace Barrel, Contact Tip and Nozzle.

;*/7,4"83%C87*$%T'"9*

1. Remove Hex Set Screw.

2. Pull out Inlet Guide.

3. Replace Inlet Guide.

4. Replace Hex Set Screw.

SV%EVA%&X*($"3.$*81%%68#'(*%C87*$%T'"9*% "#%#8'31%%VX*($"3.$*8"83%)"77%4,'#*% /*(5,8*8$%9,5,3*%$&%C87*$%T'"9*1

B*[% Q&7$

Q,((*7

B*[%?*$%

?4(*)

C87*$%

T'"9*

Page 17<&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1Item 63793

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

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

?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?SETUP

Wire feed motor runs but wire does not feed properly

Wire creates a bird’s nest during operation

Wire stops during welding

Wire feeds, but arc does not ignite

Porosity in the weld metal

Welding arc not stable

1. Tension Knob is too tight.

2. Damaged Gun, cable, or liner assembly.

3. Tension Knob is too tight.

1. Tension Knob is too tight.

2. Incorrect Contact Tip size.

3. Damaged liner.

1. Gun liner is clogged or worn.

2. Wire is tangled on the spool.

3. Tension Roller is not making enough contact with wire.

1. Improper ground connection.

2. Improperly sized Contact Tip.

3. Excessively worn Contact Tip.

4. Dirty Contact Tip.

1. Gun is being used too far away from workpiece.

2. Dirty welding wire is introducing contamination into the weld.

1. Wire not feeding properly.

2. Incorrect or damaged Contact Tip.

3. Loose Gun cable or ground cable.

4. Damaged Gun or loose connection within Gun.

5. Gas coverage may be insufficient or too high.

6. Poor connection with workpiece.

1. Tighten Tension Knob so it applies only enough pressure to prevent continued spinning after the Gun Trigger is released.

2. Have a qualified technician inspect these parts and replace as necessary.

3. Loosen Tension Knob so it applies only enough pressure to prevent continued spinning after the Gun Trigger is released.

1. Loosen Tension Knob

2. Replace with the proper tip for wire used.

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

1. Check gun liner for obstruction, blow out with compressed air. Have liner replaced if necessary.

2. Check wire for cross winding or tangled spool.

3. Check Tension Knob and ensure it is set properly.

1. Make certain that the workpiece is contacted properly by the Ground Clamp and that the workpiece is properly cleaned near the ground clamp and the welding location.

2. Verify that Contact Tip is the proper size for welding wire. If needed, replace Contact Tip with proper size and type.

3. Check that the hole in the tip is not deformed or enlarged. If needed, replace Contact Tip with proper size and type.

4. Properly clean Contact Tip.

1. Check CTWD (contact tip to work distance).

2. Make certain that welding wire is clean and free of rust and residues.

1. See first Troubleshooting section above.

2. Replace Contact Tip.

3. Check to ensure that all connections are tight.

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

5. Ensure gas flow rate is set according to Settings Chart. Make sure Gun Cable Connector is fully inserted into Wire Feed mechanism with no O-Rings exposed.

6. Check the ground clamp connection to the workpiece and machine. Ensure the Gun is properly secured.

<&77&)%,77%#,2*$>%/(*4,'$"&8#%).*8*X*(%9",38&#"83%&(%#*(X"4"83%$.*%*H'"/5*8$1

Page 18 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1 Item 63793

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

U,($ S*#4("/$"&8 e$>

1 Handle 1 2 Trigger 1 3 Block 1 4 Cover 1 5 Hanger Hook 1 6 Spool Shaft 1 7 Spool Tensioner 1 8 Spacer 1

9 Spool Tension Knob 1 10 Spool Lock Knob 1 11 Latch 1 12 Spool Cover Release Button 1 14 Drive Roller 1 15 Tension Spring 1 16 Bushing 1 17 Tension Roller 1 18 Tension Knob 1 19 Inlet Guide 1 20 Tension Arm 1 21 Tension Arm Shaft 1 22 Bracket 1

4

U,($ S*#4("/$"&8 e$>

23 Motor And Gear Box 1 24 Gas Connector 1 25 Wire Feeder Assembly 1 26 Conducting Bar 1 27 Liner Assembly 1 28 O-Ring 7.65X1.78 2 29 Barrel 1 30 Insulator 1 31 Gas Diffuser 1 32 Contact Tip 4 33 Nozzle 12mm 1 35 Internal Gas Hose 1 36 Front Spring Cable Support 1 37 Cable Assembly 1 38 Back Spring Cable Support 1 39 Connector 1 40 Connector Insulator 1 41 Connector 1 42 Gas Hose Plug 1 43 Wire Feed Plug 1

?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU? SETUP

5

3

6

7

8

9

10

16

2

1

27

28

29

30

31

32

33

25 26

35

36

17

18

15

23

24

19

20

221421

1

11

12

43

38

42

41

40

39

37

;*4&(9%U(&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.

Page 19<&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1Item 63793

Limited 90 Day Warranty

Harbor Freight Tools Co. makes every effort to assure that its products meet high quality and durability standards, and warrants to the original purchaser that this product is free from defects in materials and workmanship for the period of 90 days from the date of purchase. This warranty does not apply to damage due directly or indirectly, to misuse, abuse, negligence or accidents, repairs or alterations outside our facilities, criminal activity, improper installation, normal wear and tear, or to lack of maintenance. We shall in no event be liable for death, injuries to persons or property, or for incidental, contingent, special or consequential damages arising from the use of our product. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation of exclusion may not apply to you. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS.

To take advantage of this warranty, the product or part must be returned to us with transportation charges prepaid. Proof of purchase date and an explanation of the complaint must accompany the merchandise. If our inspection verifies the defect, we will either repair or replace the product at our election or we may elect to refund the purchase price if we cannot readily and quickly provide you with a replacement. We will return repaired products at our expense, but if we determine there is no defect, or that the defect resulted from causes not within the scope of our warranty, then you must bear the cost of returning the product.

This warranty gives you specific legal rights and you may also have other rights which vary from state to state.

UG6@?6%;6@S%AB6%<VGGVRCET%P@;6<FGGO

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.

3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • 1-888-380-0318

VULCAN 63793 Owner's Manual & Safety Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual