Harbor Freight Tools Vulcan Migmax 215 Owner'S Manual & Safety Instructions Download

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Summary of Contents for Vulcan Migmax 215

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Page 2: ...d bystanders away while operating 3 Place the welder on a stable location before use If it falls while plugged in severe injury electric shock or fire may result 4 Do not overreach Keep proper footing and balance at all times 5 Stay alert watch what you are doing and use common sense when operating a welder Do not use a welder while you are tired or under the influence of drugs alcohol or medicati...

Page 3: ...trols are not feasible use an approved respirator 5 Work in a confined area only if it is well ventilated or while wearing an air supplied respirator 6 Have a recognized specialist in Industrial Hygiene or Environmental Services check the operation and air quality and make recommendations for the specific welding situation Follow OSHA guidelines for Permissible Exposure Limits PEL s and the Americ...

Page 4: ...d the work area Use a fire resistant material to cover or block all open doorways windows cracks and other openings 2 Keep ABC type fire extinguisher near work area and know how to use it 3 Maintain a safe working environment Keep the work area well lit Make sure there is adequate surrounding workspace Keep the work area free of obstructions grease oil trash and other debris 4 Do not operate welde...

Page 5: ... Maintenance 1 Maintain welders Check for misalignment or binding of moving parts breakage of parts and any other condition that may affect the welder s operation If damaged have the welder repaired before use Many accidents are caused by poorly maintained welders 2 Have your welder serviced by a qualified repair person using only identical replacement parts This will ensure that the safety of the...

Page 6: ...y wire connected to the Welder s grounding system and must never be attached to an electrically live terminal Never leave the grounding wire disconnected or modify the Power Cord Plug in any way 2 Make sure the tool is connected to an outlet having the same configuration as the plug If the tool must be reconnected for use on a different type of electric circuit the reconnection should be made by q...

Page 7: ...tilation 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 Specifications Power Input 120VAC 60Hz 240VAC 60Hz Current Input at Output 15A 20 7A at 100A 24 8A at 200...

Page 8: ...er Switch Door Latch Door Welder Wall Wingnut 2 lb Wire Spool Spool Brake Pad Spacer Spool Spindle 2 lb Spool Loading Setup Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before set up or use of this product TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION Turn the Power Switch off and unplug the Welder before se...

Page 9: ...secure Spool in place with the Wingnut Notice If Wire Spool can spin freely Wingnut is too loose This will cause the welding wire to unravel and unspool which can cause tangling and feeding problems 10 Screw the Spool Knob into the Spool Adapter 11 DCEN Direct Current Electrode Negative Wire Setup for Flux Cored gasless welding Remove the two Wingnuts securing the cables Connect the Black Ground C...

Page 10: ... until it is loose then thread Regulator onto cylinder and wrench tighten connection Note When using C100 shielding gas connect the enclosed CGA 580 320 adapter to the inlet connection of the Regulator and wrench tighten Thread the adapter onto the gas cylinder and wrench tighten f Attach the Gas Hose included to the Regulator s outlet and the Welder s gas inlet Wrench tighten both connections Res...

Page 11: ...it is turned to properly match the wire size marked on the Wire Spool a Unscrew the Feed Roller Knob counterclockwise b Remove the Feed Roller Knob to expose the Feed Roller c Flip or replace the Feed Roller as needed and confirm that it is the correct Roller for the type of wire being used and that the number showing is the same as the wire diameter on the Spool d Screw the Feed Roller Knob back ...

Page 12: ...o the Wire Feed Control Socket located on the front of the machine and tighten the lock ring on the Cable plug Note that the plug on the Cable fits into the Socket in one specific orientation only IMPORTANT Securely hold onto the end of the welding wire and keep tension on it during the following steps If this is not done the welding wire will unravel and unspool which can cause tangling and feedi...

Page 13: ...use feeding issues 21 Pull the Nozzle to remove it 22 Unscrew the Contact Tip counterclockwise and remove 23 Lay the MIG Gun Cable out in a straight line so that the welding wire moves through it easily Leave the cover open so that the feed mechanism can be observed 1 2 3 24 Plug either 120VAC or 240VAC Power Cord into Power Input Socket Note Plug will only fit one way Idler Arm Feed Tensioner Noz...

Page 14: ...unplug the Welder and slightly tighten the Feed Tensioner clockwise before retrying 27 To check the wire s drive tension feed the wire against a piece of wood from 2 to 3 inches away If the wire stops instead of bending unplug the Welder slightly tighten the Feed Tensioner clockwise and try again If the wire bends from the feed pressure then the tension is set properly 28 Turn OFF the Power Switch...

Page 15: ... shielding gas MIG welding uses solid wire and shielding gas and is used to weld mild steel and stainless steel MIG welding can also be used to weld thinner workpieces than flux cored welding can Aluminum welding can be performed with an optional Spool Gun sold separately using aluminum wire and shielding gas Good welding takes a degree of skill and experience Practice a few sample welds on scrap ...

Page 16: ...ding current and shielding gas if performing MIG feed to the weld through here Wire Feed Control Socket The MIG Gun and Spool Gun Control Cables connect here Ground Cable This connects to the base metal to provide a good connection for the current to travel back to the Welder Spool Gun Gas Outlet When using optional Spool Gun sold separately gas hose connects here Wire Diameter Selection Knob Sets...

Page 17: ...l Gun sold separately connect the Spool Gun gas hose to the Spool Gun Gas Outlet see Front Panel Controls on previous page Weld Settings Refer to the Settings Chart on the inside of the Welder door for Flux Cored and MIG Weld settings The chart is only intended to show general guidelines for different wire sizes and for different thicknesses of material The initial settings used at the beginning o...

Page 18: ...m 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 Should this occur rest the MIG Gun on an electrically non conductive heat proof surface such as a concrete slab well clear of the ground clamp Allow the Welder to cool with the Power Switch on so that the in...

Page 19: ...t 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 3 Clamp Groun...

Page 20: ...is incorrect refer to Settings Chart for proper weld settings b Manual Settings Set Process Set Wire Diameter to MANUAL Set Wire Feed Speed according to Settings Chart Set Voltage according to Settings Chart Note The initial settings may need to be adjusted after stopping and carefully inspecting the weld Proper welding takes experience DANGER TO PREVENT DEATH FROM ASPHYXIATION Do not open gas wit...

Page 21: ...using solid wire and shielding gas the end of the MIG Gun should be tilted so that wire is angled anywhere in between straight on and 15 away from the direction you are welding The amount of tilt is called the push angle 5 When using flux cored wire without shielding gas the end of the MIG Gun should be tilted so that wire is angled anywhere in between straight on and 15 in the direction you are w...

Page 22: ...be hot do not touch 8 When welding is complete set the MIG Gun down on a heat proof electrically non conductive surface Turn the Power Switch OFF 9 Allow Welder to cool down then unplug the Power Cord 10 Remove Ground Clamp from workpiece or table and disconnect MIG Gun 11 Respool wire by clipping wire removing gas nozzle contact tip on MIG gun releasing Idler Arm on Wire Feed mechanism and rotati...

Page 23: ...eld Strike Test A test weld on a PIECE OF SCRAP can be tested by using the following procedure WEAR ANSI APPROVED SAFETY GOGGLES DURING THIS PROCEDURE WARNING This test WILL damage the weld it is performed on This test is ONLY an indicator of weld technique and is not intended to test working welds 1 After two scraps have been welded together and the weld has cooled clamp one scrap in a sturdy vis...

Page 24: ...Speed Too Fast Travel Speed Too Slow CTWD Too Long or Wrong Polarity Example Weld Diagrams How to increase workpiece heat and increase penetration to weld THICKER workpieces properly How to reduce workpiece heat and limit penetration to weld THINNER workpieces properly a Increase weld current b Decrease travel speed c Use faster wire feed d Use shorter CTWD a Decrease weld current b Increase trave...

Page 25: ...Heat Control Weld Not Adhering Properly Gaps present between weld and previous bead or between weld and workpiece See areas below POSSIBLE CAUSES AND SOLUTIONS 1 Incorrect welding technique Place stringer bead at correct place in joint Adjust workpiece position or weld angle to permit proper welding to bottom of piece Pause briefly at sides during weave bead Keep arc on leading edge of weld puddle...

Page 26: ...orrectly 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 Dirty workpiece or welding wire Clean workpiece down to bare metal Make certain that wire is clean and free from oil coatings and other residues 5 Inconsistent travel speed Maintain steady trave...

Page 27: ...nd Contact Tip Inspection and Cleaning 1 Make sure that the entire MIG Gun is completely cool and that the Power Cord is unplugged from the electrical outlet before proceeding 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 the N...

Page 28: ...ntact with wire or is crushing flux cored wire 1 Straighten Gun cable 2 Check gun liner for obstruction Replace if necessary 3 Check that gun liner is correct size for wire 4 Check wire for cross winding or tangled spool 5 Check Feed Rollers and ensure correct groove for wire diameter is being used 6 Check Feed Tensioner and ensure it is set properly Welding arc not stable 1 Wire not feeding prope...

Page 29: ...e and amperage as detailed on the Specifications table If the Voltage Input Thermal Overload Indicator is illuminated on machine check the input voltage to ensure it is within specified range 4 Make sure installed plug is correct rating See Specifications on page 7 5 Press Reset Button on back of machine to reset circuit breaker 6 Ensure the twist lock input Power Cord is fully secured Wire feeds ...

Page 30: ... Base 1 4 Hinge Right 2 5 Hinge Left 2 6 Left Cover 1 7 Door Latch 1 8 Middle Panel 1 9 PFC Inductor 1 10 Spool 1 11 Wire Feeder 1 12 Remote Control PCB 1 13 Insulation Block 1 14 Display PCB 1 15 Front Handle Cover Plate 1 16 Ground Clamp Subassembly 1 17 Control Panel 1 18 Knob 2 19 Knob 2 20 Switch 1 21 Front Plate 1 22 Plug Connector 1 23 Bottom Housing 1 24 MIG Welding Torch 1 25 Output Induc...

Page 31: ...t has no serial number record month and year of purchase instead Note Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts Assembly Diagram 47 30 46 45 44 5 6 7 3 2 1 53 52 51 50 49 54 40 42 41 39 43 38 37 36 35 34 32 33 31 29 27 25 23 22 21 20 17 18 15 14 13 11 10 9 12 8 16 28 26 48 24 4 55 19 56 ...

Page 32: ...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...

Page 33: ...rence 17i When unpacking make sure that the product is intact and undamaged If any parts are missing or broken please call 1 888 380 0318 as soon as possible Copyright 2017 by Harbor Freight Tools All rights reserved No portion of this manual or any artwork contained herein may be reproduced in any shape or form without the express written consent of Harbor Freight Tools Diagrams within this manua...

Page 34: ...afety PROTECT yourself and others Read and understand this information 1 Before use read and understand manufacturer s instructions Material Safety Data Sheets MSDS s employer s safety practices and ANSI Z49 1 2 Keep out of reach of children Keep children and bystanders away while operating 3 Place the welder on a stable location before use If it falls while plugged in severe injury electric shock...

Page 35: ...trols are not feasible use an approved respirator 5 Work in a confined area only if it is well ventilated or while wearing an air supplied respirator 6 Have a recognized specialist in Industrial Hygiene or Environmental Services check the operation and air quality and make recommendations for the specific welding situation Follow OSHA guidelines for Permissible Exposure Limits PEL s and the Americ...

Page 36: ...d the work area Use a fire resistant material to cover or block all open doorways windows cracks and other openings 2 Keep ABC type fire extinguisher near work area and know how to use it 3 Maintain a safe working environment Keep the work area well lit Make sure there is adequate surrounding workspace Keep the work area free of obstructions grease oil trash and other debris 4 Do not operate welde...

Page 37: ... Maintenance 1 Maintain welders Check for misalignment or binding of moving parts breakage of parts and any other condition that may affect the welder s operation If damaged have the welder repaired before use Many accidents are caused by poorly maintained welders 2 Have your welder serviced by a qualified repair person using only identical replacement parts This will ensure that the safety of the...

Page 38: ...y wire connected to the Welder s grounding system and must never be attached to an electrically live terminal Never leave the grounding wire disconnected or modify the Power Cord Plug in any way 2 Make sure the tool is connected to an outlet having the same configuration as the plug If the tool must be reconnected for use on a different type of electric circuit the reconnection should be made by q...

Page 39: ...tilation 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 Specifications Power Input 120VAC 60Hz 240VAC 60Hz Current Input at Output 15A 20 7A at 100A 24 8A at 200...

Page 40: ...er Switch Door Latch Door Welder Wall Wingnut 2 lb Wire Spool Spool Brake Pad Spacer Spool Spindle 2 lb Spool Loading Setup Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before set up or use of this product TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION Turn the Power Switch off and unplug the Welder before se...

Page 41: ...secure Spool in place with the Wingnut Notice If Wire Spool can spin freely Wingnut is too loose This will cause the welding wire to unravel and unspool which can cause tangling and feeding problems 10 Screw the Spool Knob into the Spool Adapter 11 DCEN Direct Current Electrode Negative Wire Setup for Flux Cored gasless welding Remove the two Wingnuts securing the cables Connect the Black Ground C...

Page 42: ... until it is loose then thread Regulator onto cylinder and wrench tighten connection Note When using C100 shielding gas connect the enclosed CGA 580 320 adapter to the inlet connection of the Regulator and wrench tighten Thread the adapter onto the gas cylinder and wrench tighten f Attach the Gas Hose included to the Regulator s outlet and the Welder s gas inlet Wrench tighten both connections Res...

Page 43: ...it is turned to properly match the wire size marked on the Wire Spool a Unscrew the Feed Roller Knob counterclockwise b Remove the Feed Roller Knob to expose the Feed Roller c Flip or replace the Feed Roller as needed and confirm that it is the correct Roller for the type of wire being used and that the number showing is the same as the wire diameter on the Spool d Screw the Feed Roller Knob back ...

Page 44: ...o the Wire Feed Control Socket located on the front of the machine and tighten the lock ring on the Cable plug Note that the plug on the Cable fits into the Socket in one specific orientation only IMPORTANT Securely hold onto the end of the welding wire and keep tension on it during the following steps If this is not done the welding wire will unravel and unspool which can cause tangling and feedi...

Page 45: ...use feeding issues 21 Pull the Nozzle to remove it 22 Unscrew the Contact Tip counterclockwise and remove 23 Lay the MIG Gun Cable out in a straight line so that the welding wire moves through it easily Leave the cover open so that the feed mechanism can be observed 1 2 3 24 Plug either 120VAC or 240VAC Power Cord into Power Input Socket Note Plug will only fit one way Idler Arm Feed Tensioner Noz...

Page 46: ...re retrying 27 To check the wire s drive tension press and hold Trigger to feed the wire against a piece of wood from 2 to 3 inches away Note After pressing Trigger wire will stop feeding after 3 seconds if there is no arc Check tension for less than 3 seconds If the wire stops instead of bending unplug the Welder slightly tighten the Feed Tensioner clockwise and try again If the wire bends from t...

Page 47: ... shielding gas MIG welding uses solid wire and shielding gas and is used to weld mild steel and stainless steel MIG welding can also be used to weld thinner workpieces than flux cored welding can Aluminum welding can be performed with an optional Spool Gun sold separately using aluminum wire and shielding gas Good welding takes a degree of skill and experience Practice a few sample welds on scrap ...

Page 48: ...ding current and shielding gas if performing MIG feed to the weld through here Wire Feed Control Socket The MIG Gun and Spool Gun Control Cables connect here Ground Cable This connects to the base metal to provide a good connection for the current to travel back to the Welder Spool Gun Gas Outlet When using optional Spool Gun sold separately gas hose connects here Wire Diameter Selection Knob Sets...

Page 49: ...l Gun sold separately connect the Spool Gun gas hose to the Spool Gun Gas Outlet see Front Panel Controls on previous page Weld Settings Refer to the Settings Chart on the inside of the Welder door for Flux Cored and MIG Weld settings The chart is only intended to show general guidelines for different wire sizes and for different thicknesses of material The initial settings used at the beginning o...

Page 50: ... 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 Should this occur rest the MIG Gun on an electrically non conductive heat proof surface such as a concrete slab well clear of the ground clamp Allow the Welder to coo...

Page 51: ...t 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 3 Clamp Groun...

Page 52: ...is incorrect refer to Settings Chart for proper weld settings b Manual Settings Set Process Set Wire Diameter to MANUAL Set Wire Feed Speed according to Settings Chart Set Voltage according to Settings Chart Note The initial settings may need to be adjusted after stopping and carefully inspecting the weld Proper welding takes experience DANGER TO PREVENT DEATH FROM ASPHYXIATION Do not open gas wit...

Page 53: ...using solid wire and shielding gas the end of the MIG Gun should be tilted so that wire is angled anywhere in between straight on and 15 away from the direction you are welding The amount of tilt is called the push angle 5 When using flux cored wire without shielding gas the end of the MIG Gun should be tilted so that wire is angled anywhere in between straight on and 15 in the direction you are w...

Page 54: ...be hot do not touch 8 When welding is complete set the MIG Gun down on a heat proof electrically non conductive surface Turn the Power Switch OFF 9 Allow Welder to cool down then unplug the Power Cord 10 Remove Ground Clamp from workpiece or table and disconnect MIG Gun 11 Respool wire by clipping wire removing gas nozzle contact tip on MIG gun releasing Idler Arm on Wire Feed mechanism and rotati...

Page 55: ...eld Strike Test A test weld on a PIECE OF SCRAP can be tested by using the following procedure WEAR ANSI APPROVED SAFETY GOGGLES DURING THIS PROCEDURE WARNING This test WILL damage the weld it is performed on This test is ONLY an indicator of weld technique and is not intended to test working welds 1 After two scraps have been welded together and the weld has cooled clamp one scrap in a sturdy vis...

Page 56: ...Speed Too Fast Travel Speed Too Slow CTWD Too Long or Wrong Polarity Example Weld Diagrams How to increase workpiece heat and increase penetration to weld THICKER workpieces properly How to reduce workpiece heat and limit penetration to weld THINNER workpieces properly a Increase weld current b Decrease travel speed c Use faster wire feed d Use shorter CTWD a Decrease weld current b Increase trave...

Page 57: ...Heat Control Weld Not Adhering Properly Gaps present between weld and previous bead or between weld and workpiece See areas below POSSIBLE CAUSES AND SOLUTIONS 1 Incorrect welding technique Place stringer bead at correct place in joint Adjust workpiece position or weld angle to permit proper welding to bottom of piece Pause briefly at sides during weave bead Keep arc on leading edge of weld puddle...

Page 58: ...orrectly 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 Dirty workpiece or welding wire Clean workpiece down to bare metal Make certain that wire is clean and free from oil coatings and other residues 5 Inconsistent travel speed Maintain steady trave...

Page 59: ...nd Contact Tip Inspection and Cleaning 1 Make sure that the entire MIG Gun is completely cool and that the Power Cord is unplugged from the electrical outlet before proceeding 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 the N...

Page 60: ...ntact with wire or is crushing flux cored wire 1 Straighten Gun cable 2 Check gun liner for obstruction Replace if necessary 3 Check that gun liner is correct size for wire 4 Check wire for cross winding or tangled spool 5 Check Feed Rollers and ensure correct groove for wire diameter is being used 6 Check Feed Tensioner and ensure it is set properly Welding arc not stable 1 Wire not feeding prope...

Page 61: ...e and amperage as detailed on the Specifications table If the Voltage Input Thermal Overload Indicator is illuminated on machine check the input voltage to ensure it is within specified range 4 Make sure installed plug is correct rating See Specifications on page 7 5 Press Reset Button on back of machine to reset circuit breaker 6 Ensure the twist lock input Power Cord is fully secured Wire feeds ...

Page 62: ... Base 1 4 Hinge Right 2 5 Hinge Left 2 6 Left Cover 1 7 Door Latch 1 8 Middle Panel 1 9 PFC Inductor 1 10 Spool 1 11 Wire Feeder 1 12 Remote Control PCB 1 13 Insulation Block 1 14 Display PCB 1 15 Front Handle Cover Plate 1 16 Ground Clamp Subassembly 1 17 Control Panel 1 18 Knob 2 19 Knob 2 20 Switch 1 21 Front Plate 1 22 Plug Connector 1 23 Bottom Housing 1 24 MIG Welding Torch 1 25 Output Induc...

Page 63: ...t has no serial number record month and year of purchase instead Note Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts Assembly Diagram 47 30 46 45 44 5 6 7 3 2 1 53 52 51 50 49 54 40 42 41 39 43 38 37 36 35 34 32 33 31 29 27 25 23 22 21 20 17 18 15 14 13 11 10 9 12 8 16 28 26 48 24 4 55 19 56 ...

Page 64: ...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...

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Harbor Freight Tools Vulcan Migmax 215, Owner'S Manual & Safety Instructions

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