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Page 10

For technical questions, please call 1-888-380-0318.

Item 64806

Sa
FE
ty

lding

tig
/ Stick

ontrol

Wir

Maint

nanc

turn the power Switch oFF and unplug
the Welder before proceeding.

2. Pull up on the Door Latch,

then open the Door.

2 pound Wire Spool installation:

Remove the Wingnut, Keyed Washers, and
Spring. If replacing a Spool, remove the old
Spool and all remaining wire from the liners.

4. Place the new Wire Spool over the Spool Spindle

and against the Spool Brake Pad as illustrated.

to prevent wire feed problems, set the Spool
so that it will unwind counterclockwise.

5. Line up the Keyed Washers with

the groove on the Spindle. Replace
the Keyed Washers and Spring
over the Spool Spindle and 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.

power

Switch

door

latch

door

Welder

Wall

Wingnut

2 lb

Wire Spool

Spool

Brake pad

keyed

Washer

keyed

Washer

Spring

Spool

Spindle

2 lb Spool loading

Wire Welding

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 setup.

note:

Remove the protective foam and cardboard from the Welder before setup.

Wire Spool Installation / Wire Setup

Содержание UNLIMITED 200

Страница 1: ...uture reference 18g 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 2018 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 ...

Страница 2: ... Safety 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 sho...

Страница 3: ...ontrols 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 Amer...

Страница 4: ...und 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 wel...

Страница 5: ...ng 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 t...

Страница 6: ...he 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 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 mad...

Страница 7: ...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 120 240VAC 60Hz current input 120V GMAW FCAW 22A SMAW 24 9A GTAW 20 8A 240V GMAW FCAW 36A SMAW 33 6A GTAW 28 7A Welding current range 1...

Страница 8: ...shielding gas if performing MIG feed to the welding gun through here Wire Feed control Socket Connect the Wire Feed Control Cable here 2T 4T Switch Use this to set the Gun Trigger operation to either 2T or 4T mode 2T 2 touch mode 1 Squeeze the trigger to start the welding current 2 Release trigger to stop the welding current 4T 4 touch mode 1 Squeeze trigger to start welding 2 Release trigger duri...

Страница 9: ... the Gas Quick Connector and place the MIG Flux Spool Gun Switch on the Spool Gun setting For all other welding place the MIG Flux Spool Gun Switch on the MIG Flux Gun setting and connect the Wire Feed Gas Hose to the Gas Quick Connector The collar on the Gas Quick Connector must click into place after attaching any hose to it Weld Settings Refer to the Settings Chart on the inside of the Welder d...

Страница 10: ...on the Spindle Replace the Keyed Washers and Spring over the Spool Spindle and 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 power Switch door latch door Welder Wall Wingnut 2 lb Wire Spool Spool Brake pad keyed Washer keyed Washer Spring Spool Sp...

Страница 11: ...e Replace the Keyed Washers and Spring over the Spool Spindle and 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 Conn...

Страница 12: ...nd 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 e Locate the Regulator included and close its valve until it is loose then thread Regulator onto cylinder and wrench tighten connection note When using C100 shielding gas connect a CGA 580 320 adapter not included to the inlet connection of the Regulator and wrench ...

Страница 13: ...ire 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 note The knurled groove is used for flux cored wire The V grooves are ...

Страница 14: ... Feed Control Socket located on the front of the machine Press it in until the collar snaps into place Note that the plug on the Cable fits into the Socket in one specific orientation only To disconnect it pull the collar back first 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 unspoo...

Страница 15: ...p the gun cable straight while feeding stainless steel wire Warning The following steps require applying power to the Welder with the cover open to prevent serious injury from fire or electric shock 1 do not touch anything especially not the ground clamp with the gun or welding wire or an arc will be ignited 2 do not touch internal Welder components while it is plugged in 24 Turn the Power Switch ...

Страница 16: ...e s drive tension press and hold Trigger to 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 32 Turn OFF the Power Switch and unplug the Power Cord from its electrical outlet 33 Select a Contact Tip...

Страница 17: ...ut 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 scra...

Страница 18: ...duty cycles 120VAC 40 Use at 90A For 10 continuous Minutes 240VAC 15 Use at 200A For 10 continuous Minutes 4 Minutes Welding 6 Minutes resting 1 1 2 Minutes Welding 8 1 2 Minutes resting 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 retur...

Страница 19: ...nt 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 Grou...

Страница 20: ...art 6 Turn the Power Switch off and do not touch the Gun s Trigger and before connecting Power Cord iMportant change the Voltage Switch on the back of the Welder to the voltage of the outlet you will use If using 120VAC connect the included adapter to the end of the Power Cord If using 240VAC do not use the adapter Plug the Power Cord into a properly grounded and rated receptacle that matches the ...

Страница 21: ...ing 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 wel...

Страница 22: ...ry adjustments continue to weld while carefully following the DUTY CYCLE guidelines as explained on page 18 caUtion Weld will 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 ...

Страница 23: ...setup note Remove the protective foam and cardboard from the Welder before setup 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 tig Setup connect cables ground clamp cable in positive Socket ground clamp tig torch cable in negative Socket tig torch Shielding gas Hose 1 Plug Ground Clamp Cable into Positive Socket Tw...

Страница 24: ...rench tighten Thread the adapter onto the gas cylinder and wrench tighten 5 Attach the Gas Hose included to the Regulator s outlet and the Welder s gas inlet Wrench tighten both connections 6 Connect the Gas Hose from the TIG Torch Cable through the round hole in the front of the Welder to the Gas Quick Connector inside The collar on the Gas Quick Connector must click into place after attaching an...

Страница 25: ...rface of the grinding wheel at an angle Rotate Electrode tip until a blunt point is formed note Grinding direction must be parallel to length of Electrode 6 The conical portion of the ideal tip will be 2 1 2 times as long as the Electrode diameter 7 Re insert Electrode into Collet with tip protruding 1 8 1 4 beyond the Ceramic Nozzle then re tighten the Back Cap to secure the Electrode in place as...

Страница 26: ...he way to lock in place connect power cord 1 Turn the Power Switch off before connecting Power Cord 2 iMportant change the Voltage Switch on the back of the Welder to the voltage of the outlet you will use 3 If using 120VAC connect the included adapter to the end of the Power Cord If using 240VAC do not use the adapter 4 Plug the Power Cord into a properly grounded and rated receptacle that matche...

Страница 27: ...s DC TIG Welding is used to weld mild steel and stainless steel using a TIG Rod and shielding gas AC TIG Welding is used to weld aluminum using a TIG Rod and shielding gas Stick Welding is used to weld mild steel and stainless steel using a Stick Electrode without shielding gas Good welding takes a degree of skill and experience Practice a few sample welds on scrap before welding your first projec...

Страница 28: ...inutes 120VAC 40 Use at 70A For 10 continuous Minutes 240VAC 15 Use at 170A For 10 continuous Minutes 4 Minutes Welding 6 Minutes resting 1 1 2 Minutes Welding 8 1 2 Minutes resting 4 Minutes Welding 6 Minutes resting 1 1 2 Minutes Welding 8 1 2 Minutes resting Setting up the Weld clamps workpieces chamfer thick workpieces clean surfaces to bare metal 1 Make practice welds on pieces of scrap the s...

Страница 29: ... welding mask ear protection welding gloves sleeves and apron nioSH approved respirator and fire resistant work clothes without pockets should be worn when welding light from the arc can cause permanent damage to the eyes and skin do not breathe arc fumes After practice welding on scrap stop and check your progress Perform Strike Test according to Strike test on page 31 After making any necessary ...

Страница 30: ...xperience Warning to prEVEnt SErioUS inJUry protective gear must be worn when using the Welder minimum shade number 10 full face shield or welding mask ear protection welding gloves sleeves and apron nioSH approved respirator and fire resistant work clothes without pockets should be worn when welding light from the arc can cause permanent damage to the eyes and skin do not breathe arc fumes After ...

Страница 31: ... weld 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 v...

Страница 32: ...l 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 tra...

Страница 33: ...e 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 pudd...

Страница 34: ... 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 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 tra...

Страница 35: ... and 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...

Страница 36: ...ep 31 on page 16 2 Flip roller to correct size follow the Feed Roller instructions on page 13 3 Have a qualified technician inspect these parts and replace as necessary 4 Loosen Feed Tensioner so it applies only enough pressure to prevent continued spinning after the Gun Trigger is released Wire creates a bird s nest during operation 1 Excess wire feed tension 2 Incorrect Contact Tip size 3 MIG Gu...

Страница 37: ...ss When switched on Power Indicator lights but Welder does not function 1 Tripped thermal protection device 2 Faulty or improperly connected Trigger 3 Machine is in low or over voltage protection 4 Machine is in the incorrect mode 1 If the Alarm Indicator is illuminated without an error code Welder has overheated and shut down Stop and wait with the Power Switch ON for the Welder to cool The Welde...

Страница 38: ...he unit problem possible causes likely Solutions Wire feeds but arc does not ignite 1 Improper ground connection 2 Improperly sized Contact Tip 3 Excessively worn Contact Tip 4 Dirty Contact Tip 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...

Страница 39: ...rolS WirE record Serial number Here note If product 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 Parts may not be interchangeable Specify number when ordering assembly diagram ...

Страница 40: ... 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 l...

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