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Harbor Freight Tools 55525 manual

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Table of contents for the manual

  • Page 1

    220 V A C * DU AL MIG WELDER Model 55525 ASSEMBL Y AND OPERA TION INSTRUCTIONS Due to continuing impro vements , actual product ma y diff er slightly from the product described herein. ® 3491 Mission Oaks Blvd., Camarillo , CA 93011 Visit our website at: http://www .harborfreight.com T O PREVENT SERIOUS INJUR Y , READ AND UNDERST AND ALL W ARNINGS[...]

  • Page 2

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 2 SKU 55525 Contents PR ODUCT SPECIFICA TIONS ......................................................... 3 GENERAL SAFETY R ULES ............................................................ 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 55525 PR ODUCT SPECIFICA TIONS W elding Current 35 ~ 110 Amps Duty Cycle 15% @ 110 Amps / 100% @ 35 Amps (Ref er to char t and explanation on page 18) P ower Consumption 220 V olt / 60 Hz / Single Phase / 24.5 Amps (Should be connected to a [...]

  • Page 4

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 4 SKU 55525 Keep bystander s, children, and visitors awa y while operating a power tool. Distractions can cause you to lose control. Protect others in the work area from debris such as chips and spar ks. Provide barriers or shields as needed. ELEC[...]

  • Page 5

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 5 SKU 55525 Do not overr each. Keep proper f ooting and balance at all times. Proper f ooting and balance enables better control of the po wer tool in une xpected situations. Alwa ys wear eye, hearing, and breathing pr otection. F or welding saf e[...]

  • Page 6

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 6 SKU 55525 SPECIFIC SAFETY R ULES Ground this product. This W elder requires the attachment and use of a UL-listed, 220 v olt, groun ded, 3-prong, elec tr ical P ow er Cord Plug (not inclu ded). Only a quali- fied electr ician should install the[...]

  • Page 7

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 7 SKU 55525 Prevent accidental fires. Remov e any combustib le mater ial from the work area. When possible, mov e the work to a location well aw ay from combustib le materials. If relocation is not possib le, protect the comb ustibles with a cov [...]

  • Page 8

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 8 SKU 55525 F ollow the American Conf erence of Gov er nmental Industrial Hygienists recom- mendations f or Threshold Limit V alues (TL V’ s) for fumes and gases . Hav e a recognized specialist in Industrial Hygiene or En vironmental Ser vices c[...]

  • Page 9

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 9 SKU 55525 Use only correct gas shielding equipment designed specifically f or the type of welding y ou will do . Maintain this equipment proper ly . Alwa ys protect gas cylinders from heat, being struck, ph ysical damage, slag, flames, sparks,[...]

  • Page 10

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 10 SKU 55525 GROUNDED T OOLS: T OOLS WITH THREE PRONG PLUGS T ools marked with “Grounding Required” hav e a three wire cord and three prong gr ound ing plu g. Th e plug m ust b e conne cted to a pr operly gr ound ed outl et. If th e tool shoul[...]

  • Page 11

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 11 SKU 55525 ASSEMBL Y INSTRUCTIONS W ARNING! Alwa ys turn off the W elder and unplug the unit from its electri - cal outlet prior to performing an y assembl y , maintenance, or ser vice. T O A TT A CH THE HANDLE Inser t the Handle (4) into the Ha[...]

  • Page 12

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 12 SKU 55525 T O ROUTE THE WIRE Note: When installing wire of different size or composition, you will also need to change wire settings, set gun polarity , and, possib ly , install gas cylinder . See pages 14-16. IMPORT ANT : Securely hold onto th[...]

  • Page 13

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 13 SKU 55525 W ARNING! EXERCISE EXTREME CA UTION - RISK OF FIRE AND/OR ELECTRIC SHOCK! Th e f ol lo win g st eps req uir e ap pl yin g po wer to t he W eld er . Do not tou ch an yth ing wit h th e T or ch Han dle or W el din g Wir e or an ar c wi [...]

  • Page 14

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 14 SKU 55525 T O CHANGE WIRE SETTINGS W ARNING! Make sure to tur n off the W elder and unplug it from its electr ical outlet prior to changing wire settings. Open the Access P anel (12) of the W elder to expose the Wire F eed Assembly . FIGURE G S[...]

  • Page 15

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 15 SKU 55525 SETTING THE GUN POLARITY FOR WIRE TYPE Set f or El ectro de P osi tiv e (DCE P) f or ga s weldi ng wit h soli d-cor e wire . P ositi ve elec- trode (C), negativ e ground (D). SHO WN IN ILLUSTRA TION, INITIAL SETUP . (See Figure H.) Se[...]

  • Page 16

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 16 SKU 55525 T O INST ALL A GAS CYLINDER W AR NIN G: Max im um c yli nd er he igh t i s 1 f ee t 7 in ch es (0 .5m ). Max im um cy l- ind er weig ht is 22 lb. , inc ludin g gas. NEVE R exc eed eit her of th ese max imu ms. CA UTION! Do not use an [...]

  • Page 17

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 17 SKU 55525 OPERA TING INSTR UCTIONS BEFORE Y OU BEGIN WELDING Good welding requires a high degree of skill and experience. Y ou should practice a f ew sample welds on scrap metal before you begin welding your first project. Ad- ditional practic[...]

  • Page 18

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 18 SKU 55525 SETTING UP THE WELD W ARNING! Before welding, make sure to read and understand all saf ety precautions and warnings discussed on pages 3 through 10. Overload Indicator Light (28): If too much current is dra wn from the Welder , the Ov[...]

  • Page 19

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 19 SKU 55525 NO TE: The workpieces should be firmly held together and in position while weldi ng. Use clamps (not included) to hold the workpieces so you can concentrate on the job at hand. The distance (if any) between the tw o wor kpieces must [...]

  • Page 20

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 20 SKU 55525 WELD SETTINGS CHAR T FIGURE N W elding Instructions continued on next page. T op figures are V oltage Settings. Bottom number is Wire Speed Setting. NO TE: The numbers within the spaces are the appro ximate wire feed/v oltage setting[...]

  • Page 21

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 21 SKU 55525 Set the Wire Speed and V oltage Controls (17, 18, 19) to the recommended star t settings as shown in the W eld Settings Char t on the ne xt page. (See Figure N.) Squeeze (and hold) the T r igger Switch (15d) of the W elding T orch (15[...]

  • Page 22

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 22 SKU 55525 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 slightly on top. INADEQU A TE W eld does not contact the joint fully[...]

  • Page 23

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 23 SKU 55525 Cr ooked/wavy bead POSSIBLE CA USES AND SOLUTIONS Stick out too long: Reduce stick out. Inaccurate welding: Use two hands or rest hand on steady surf ace. 1. 2. T OP VIEW P orosity Small cavities or holes in the bead. POSSIBLE CA USES[...]

  • Page 24

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 24 SKU 55525 WHEN THE WELD IS COMPLETED Lift the W elding Wire comple tely aw a y from an y groun ded object. Set the fac e shield down. Then, tur n the P ower Switch to its “OFF” position. Unplug the P ower Cord (13) from the electrical outle[...]

  • Page 25

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 25 SKU 55525 INSPECTION, MAINTENANCE, AND CLEANING W ARNING! Before perf orming any maintenance on the W elder , unplug the P ower Cor d (13) from its electrical outlet and allo w all components of the W elder to completely cool. P er iodically op[...]

  • Page 26

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 26 SKU 55525 REPLA CING THE WELDING T ORCH LINER Switch welder off , disconnect po wer , and discharge electrode to ground bef ore proceeding. Secure welding wire to the spool, cut it near the spool, and remov e it from the torch and cable . Gentl[...]

  • Page 27

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 27 SKU 55525 P ARTS LISTS AND DIA GRAMS WIRING SCHEMA TIC[...]

  • Page 28

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 28 SKU 55525 P ARTS LIST P ar t Description Qty . 1 Side P anel 1 2 Hinge 2 3 Handle Sock et 2 4 Handle 1 5 F an 1 6 Back P anel 1 7 Rectifier 1 8 Inner P anel 1 9 Wire Spool Axle 1 10 Wire F eed Mechanism* 1 10a Swing Ar m 1 10b T ension Adjusti[...]

  • Page 29

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 29 SKU 55525 NO TE : Some par ts are listed and shown f or illustration pur poses only and are not av ail- able individually as replacement parts. ASSEMBL Y DIA GRAM[...]

  • Page 30

    For technical questions, please call 1-800-444-3353; T roub leshooting section at end of manual. P age 30 SKU 55525 ASSEMBL Y DIA GRAM (CONTINUED) 10d 10e 10c 10a 10f 11 10k 10l 10h 10 g 10b 10i 10j Wire Feed Mechanism (10)[...]

  • Page 31

    IMPORT ANT! Be CERT AIN to shut off the W elder , disconnect it from power , and discharge the torch to ground bef ore adjusting, cleaning, or repairing the unit. SKU 55525 For technical questions, please call 1-800-444-3353. P age 31 If the steps above do not solve the pr oblem or if the repairs in volved are too complex, contact a qualified tech[...]

  • Page 32

    IMPORT ANT! Be CERT AIN to shut off the W elder , disconnect it from power , and discharge the torch to ground bef ore adjusting, cleaning, or repairing the unit. SKU 55525 For technical questions, please call 1-800-444-3353. P age 32 If the steps above do not solve the pr oblem or if the repairs in volved are too complex, contact a qualified tech[...]

  • Page 33

    IMPORT ANT! Be CERT AIN to shut off the W elder , disconnect it from power , and discharge the torch to ground bef ore adjusting, cleaning, or repairing the unit. SKU 55525 For technical questions, please call 1-800-444-3353. P age 33 If the steps above do not solve the pr oblem or if the repairs in volved are too complex, contact a qualified tech[...]