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Harbor Freight Tools 55167 manual

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Table of contents for the manual

  • Page 1

    90 Amp flux wire welDer 55167 ASSEMBL Y AND OPERA TING INSTR UCTIONS 3491 Mission Oaks Blvd., Camarillo , CA 93011 Visit our W eb site at http://www .harborfreight.com ® Cop yr ight © 2007 b y Harbor F reight T ools ® . All r ights reser ved. No por tion of this manual or any ar twork contained herein may be reproduced in any shape or f or m wit[...]

  • Page 2

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 2 SKU 55167 Contents Specifications ............................................................................. 3 General Safety Rules .................................................................. 3 Specific Safety Rules .................[...]

  • Page 3

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 3 SKU 55167 SPECIFICA TIONS W elding Current 63 ~ 68 amps; High setting: 79 ~ 90 amps Duty Cycle 10% at 80 amps; 18% at 60 amps (See explanation of Duty Cyc le on page 15.) P ower Consumption 120 V AC , 24 amps peak, single phase Should be connect[...]

  • Page 4

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 4 SKU 55167 Distractions can cause you to lose control. Protect others in the wor k area from debris such as chips and sparks. Provide barriers or shields as needed. Electrical Safety 4. A vo id body contact with gr ounded surfaces such as pipes, [...]

  • Page 5

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 5 SKU 55167 15. Use c lamps (not inc luded) or other practical wa ys to secure and suppor t the workpiece to a stable platform. Holding the work by hand or against y our body is unstable and ma y lead to loss of control. 16. Do not for ce the tool[...]

  • Page 6

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 6 SKU 55167 4. Unplug befor e perform ing maintenance. Alwa ys unplug the W elder from its electrical outlet bef ore perf or ming any inspection, maintenance, or cleaning procedures . 5. Never leave the W elder unattended while energized . T ur n [...]

  • Page 7

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 7 SKU 55167 easily visib le smoke or flame ma y not be present for some time after the fire has star ted. Do not weld or cut in atmospheres containing dangerously reactive or flam- mable gases, vapors , liquids, and dust. Provide adequate venti[...]

  • Page 8

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 8 SKU 55167 12. Protect your self fr om electric shoc k. Do not use outdoors . Insulate y ourself from the wor kpiece and ground. Use nonflammable , dr y insulating material if possible, or use dr y rubber mats, dr y w ood or plyw ood, or other d[...]

  • Page 9

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 9 SKU 55167 Y our tool must be plugged into an appropr iate outlet, proper ly installed and grounded in accordance with all codes and ordinances . The plug and outlet should look like those in the f ollowing illustration. (See 3-Prong Plug and Out[...]

  • Page 10

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 10 SKU 55167 areas. RECOMMENDED MINIMUM WIRE GA UGE FOR EXTENSION CORDS* NAMEPLA TE AMPERES (At Full Load) EXTENSION CORD LENGTH 25 Feet 50 Feet 75 Feet 100 Feet 150 Feet 0 - 2.0 18 18 18 18 16 2.1 - 3.4 18 18 18 16 14 3.5 - 5.0 18 18 16 14 12 5.1[...]

  • Page 11

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 11 SKU 55167 ASSEMBL Y 1. Attach the Handle (30) to the Co ver (31) using scre w (29) inser ted from the Handle top-rear . Ref er to the photo at the top of the ne xt page, and the Assemb ly Diagram on page 24. 2. Attach the Co ver Loc king Spr in[...]

  • Page 12

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 12 SKU 55167 INST ALLING THE WIRE REEL 1. W ARNING! T urn the welder OFF and unplug it before pr oceeding. 2. Press on the Cov er Loc king Spring (8), then lift the Cov er (31) using Handle (30), to e xpose the Wire F eed Unit (23). 3. Unscrew the[...]

  • Page 13

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 13 SKU 55167 EXERC ISE EXTRE ME CA UTION - RISK OF FIR E AND/ OR ELE CTRI C SHOC K! The follo wing steps require applying power to the welder . Do not touch anything with the T orch Handle or welding wire or an arc will be ignited. Do not touch th[...]

  • Page 14

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 14 SKU 55167 5. Remov e the Wire Feed Roller (34) and install one with the proper size (.030”) facing up . 6. Reassemble the Roller Brack et (44), Scre ws (45), and W ashers (46). Put the welding wire into the top groo ve on the Roller , if it i[...]

  • Page 15

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 15 SKU 55167 6. Connect the new Switch (1c); polar ity does not matter . When reinstalling, make sure that the new Switch fits securely in place . 7. Reassemble , re versing the steps on the pre vious page. 8. Put on appropr iate safety equipment[...]

  • Page 16

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 16 SKU 55167 SETTING UP THE WELD W ARNING! Use care not to touch the welding tip to gr ounded material whenever the unit is plugged in. This unit is what is referred to as a “hot tip” welder , meaning that current is av ailable to the wire at [...]

  • Page 17

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 17 SKU 55167 objects, turn the P ower Switch to the ON position. 6. Orient yourself on the area to be welded, then place the F ace Shield ov er your e yes . W arning: Never look at the ignited arc without ANSI appro ved, arc shaded, eye pr otec- t[...]

  • Page 18

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 18 SKU 55167 WELD SETTINGS CHAR T NO TE: The numbers within the spaces are the appro ximate wire feed settings recommended* f or this wire siz e and material thickness. Material Thickness (Steel) 16 Gauge 14 Gauge 12 Gauge 1 / 8 ” Wire Size (Flu[...]

  • Page 19

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 19 SKU 55167 WELD DIA GNOSIS EXCESS OR BURN-THR OUGH W eld droops on top and underneath, or falls through entirely , making a hole. PROPER W eld is visible underneath and bulges slightl y on top. INADEQU A TE W eld does not contact the joint fully[...]

  • Page 20

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 20 SKU 55167 10. When the weld is complete, lift the electrode wire clearly aw ay from any grounded object, set the F ace Shield down, tur n toward the Flux Wire W elder , and tur n the P ow er Switch to the OFF position. 11. Unplug the P ower Cor[...]

  • Page 21

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 21 SKU 55167 MAINTENANCE W arning: Bef ore perf orming an y maintenance on the W elder , unplug the P ower Cord from the electrical outlet and allo w all parts of the welder to cool thoroughly . 1. P er iodically remov e the Right and Left side pa[...]

  • Page 22

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 22 SKU 55167 P AR TS LISTS AND DIA GRAMS WIRING SCHEMA TIC[...]

  • Page 23

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 23 SKU 55167 P ARTS LIST P ar t Description Q’ty 1a Back Handle 1 1b F ront Handle 1 1c T rigger Switch 1 1d Handle Lock Ring 1 1e T orch T ube 1 2b .9 mm Contact Tip 1 3 Nozzle 1 4 Liner 1 5 Fixing P ole (A) for Gun Body 1 6 Fixing P ole (B) fo[...]

  • Page 24

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 24 SKU 55167 NO TE : Some par ts are listed and shown for illustration pur poses only and are not av ail- able individually as replacement parts. ASSEMBL Y DIA GRAM[...]

  • Page 25

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 25 SKU 55167[...]

  • Page 26

    IMPORT ANT! Be CERT AIN to shut off the Welder , disconnect it from power , and discharge the torc h to ground bef ore adjusting, c leaning, or repairing the unit. SKU 55167 For technical questions, please call 1-800-444-3353. P age 26 If the steps above do not solve the pr oblem or if the repairs in volved are too complex, contact a qualified tec[...]

  • Page 27

    IMPORT ANT! Be CERT AIN to shut off the Welder , disconnect it from power , and discharge the torc h to ground bef ore adjusting, c leaning, or repairing the unit. SKU 55167 For technical questions, please call 1-800-444-3353. P age 27 If the steps above do not solve the pr oblem or if the repairs in volved are too complex, contact a qualified tec[...]

  • Page 28

    IMPORT ANT! Be CERT AIN to shut off the Welder , disconnect it from power , and discharge the torc h to ground bef ore adjusting, c leaning, or repairing the unit. SKU 55167 For technical questions, please call 1-800-444-3353. P age 28 If the steps above do not solve the pr oblem or if the repairs in volved are too complex, contact a qualified tec[...]