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Harbor Freight Tools 91146 manual

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  • Page 1

    MIG WELDER - 250 AMP Model 91146 ASSEMBL Y AND OPERA TING INSTRUCTIONS 3491 Mission Oaks Blvd., Camarillo , CA 93011 Visit our W eb site at: http://www .harborfreight.com Copyright © 2005 by Harbor F reight T ools ® . All rights reser ved. No por tion of this manual or any artwor k contained herein ma y be reproduced in any shape or f or m withou[...]

  • Page 2

    SKU 91146 For technical questions, please call 1-800-444-3353. PAGE 2 PR ODUCT SPECIFICA TIONS GENERAL SAFETY RULES W ARNING! READ AND UNDERST AND ALL INSTRUCTIONS Failure to follow all instructions listed below may result in electric shock, fire, and/or serious injury . SA VE THESE INSTRUCTIONS W ORK AREA 1. Keep your work area clean and well lit.[...]

  • Page 3

    SKU 91146 For technical questions, please call 1-800-444-3353. PAGE 3 3. Keep bystanders, children, and visitors away while operating welding equipment. Distractions can cause you to lose control. Protect others in the work area from arc rays, sparks, and slag. Provide barriers or shields as needed. ELECTRICAL SAFETY 1. Grounded welding equipment m[...]

  • Page 4

    SKU 91146 For technical questions, please call 1-800-444-3353. PAGE 4 3. A v oid accidental star ting. Be sure the P ower Switch is off before plug ging in. Plugging in welding equipment with the Power Switch on invites accidents. 4. Remove adjusting keys or wrenches before turning on the welding equipment. A wrench or a k e y that is left attached[...]

  • Page 5

    SKU 91146 For technical questions, please call 1-800-444-3353. PAGE 5 8. Use only accessories that are recommended by the manufacturer for your model. Accessor ies that may be suitab le f or one type of welding equipment ma y become hazardous when used on another type of equipment SER VICE 1. Equipment service must be performed only by qualified re[...]

  • Page 6

    SKU 91146 For technical questions, please call 1-800-444-3353. PAGE 6 220 V OL T PO WER PLUG (NOT INCLUDED) 220 V OL T ELECTRICAL OUTLET (NOT INCLUDED) W ARNING! ONL Y A QU ALIFIED, CERTIFIED ELECTRICIAN SHOULD CONNECT A PO WER PLUG T O THE PO WER CORD. PO WER CORD FIGURE A Improperly connecting the grounding wire can result in the risk of electric[...]

  • Page 7

    SKU 91146 For technical questions, please call 1-800-444-3353. PAGE 7 SYMBOLOGY V ~ A xxxx/min. no Double Insulated Canadian Standards Association Underwriters Laboratories, Inc. V olts Alternating Current Amperes No Load Revolutions per Minute (RPM) FIGURE C EXTENSION CORDS The minim um extension cord size f or this tool is 6 GA UGE for cords UP T[...]

  • Page 8

    SKU 91146 For technical questions, please call 1-800-444-3353. PAGE 8 SPECIFIC SAFETY RULES 1. Maintain a safe working environment. Keep the work area well lit. Make sure there is adequate surrounding workspace. Alwa ys keep the work area free of obstructions, grease, oil, trash, and other debris . Do not use the W elder in areas near flammable che[...]

  • Page 9

    SKU 91146 For technical questions, please call 1-800-444-3353. PAGE 9 8. When welding or cutting, be aware that high frequency radiation may be produced which can interfere with radio navigation, safety devices, computers, and communications equipment. Before operating, have a qualified technician check out that possibility . 7. When welding or cut[...]

  • Page 10

    SKU 91146 For technical questions, please call 1-800-444-3353. PAGE 10 13. Never plug the Power Cord of this product into an electrical outlet while standing on a wet or damp surface. 22. Do not unplug the W elder by pulling on the P ower Cor d. Keep the P ower Cord away from heated surfaces. 12. Industrial applications must follow OSHA requirement[...]

  • Page 11

    SKU 91146 For technical questions, please call 1-800-444-3353. PAGE 11 27. Use the right tool or attachment for the right job. Do not attempt to force a small tool or attachment to do the work of a larger industrial tool or attachment. There are cer tain applications f or which this product was designed. It will do the job better and more safely at[...]

  • Page 12

    SKU 91146 For technical questions, please call 1-800-444-3353. PAGE 12 PR ODUCT O VER VIEW 1 . This W elder is designed for MIG/MA G welding on mild steel, stainless steel, and nonferrous materials up to 3/8” thickness. Additional features of this unit are as follows: (See Figure D.) A. Constant voltage transformer with step-up adjustment. B. Dig[...]

  • Page 13

    SKU 91146 For technical questions, please call 1-800-444-3353. PAGE 13 BACK P ANEL CONTROLS FIGURE E 29 30 Part # Description Part # Description 5D Post-Gas Timer 5G Pre-Gas Timer 5E Burn Back Timer 36A Inching Button 5F Soft Start Potentiometer 36B Gas Test Button SIDE P ANEL CONTROLS FIGURE F POST - GAS TIMER (5D) BURN BACK TIMER (5E) SOFT ST ART[...]

  • Page 14

    SKU 91146 For technical questions, please call 1-800-444-3353. PAGE 14 ASSEMBL Y INSTRUCTIONS NOTE: For additional references to the parts listed in the following pages, refer to the Assembly Diagrams on pages 26 and 28. T o Attac h A P o wer Cor d Plug: 1. W ARNING! Only a qualified, cer tified electrician should attach a 220 v olt P ower Plug (no[...]

  • Page 15

    SKU 91146 For technical questions, please call 1-800-444-3353. PAGE 15 T o Attac h The Gun P o wer Cab le And Gr ound Clamp Cab le: 1. Insert the plug of the Gun Power Cable (40A) firmly into the MIG Gun Outlet (2). (See Figure H.) 2. Insert the plug of the Ground Clamp Cable (201) firmly into the High Inductance Outlet (3A) or the Low Inductance O[...]

  • Page 16

    SKU 91146 For technical questions, please call 1-800-444-3353. PAGE 16 WIRE SPOOL (NOT INCLUDED) (40A) (40A) GAS NOZZLE (100A) CONT A CT TIP (90A) 6” 4.[...]

  • Page 17

    SKU 91146 For technical questions, please call 1-800-444-3353. PAGE 17 6 . T urn the Pressure Adjustment Knob clockwise to tighten the tension of the welding wire. NO TE: Use the Pressure Indicator Scale to set the desired dr iv e roll pressure. (See Figure I.) 7 . Remov e the Gas Nozzle (100A) and Contact Tip (90A). (See Figure I.) 8 . T ur n the [...]

  • Page 18

    SKU 91146 For technical questions, please call 1-800-444-3353. PAGE 18 7 . Adjust the flow r ate of the gas b y turning the Flow Adjust. The typical flow r ate is 20 CFH (cubic feet per hour). Check the w elding wire manufacturer’ s recommended flow rate. (See Figure J.) CYLINDER CAP CYLINDER V AL VE CHAIN PRESSURE REGULA T OR FLO W METER (43) GA[...]

  • Page 19

    SKU 91146 For technical questions, please call 1-800-444-3353. PAGE 19 The Four W elding Features: NO TE: The f ollowing f our welding f eatures are designed to optimize specific welding processes. (See Figure K.) 1. 2-TIME: T ypically , the standard welding pr ocess used. T o operate, turn the Wire Speed Mode Selector (6) to its 2-Time setting. Sq[...]

  • Page 20

    SKU 91146 For technical questions, please call 1-800-444-3353. PAGE 20 .024” to .047” Har d or Flux Cored Wires 60% Duty Cycle at 250 Amperes Using Mix ed Gases Relation Between Duty Cycle And W eld Amperes. WELD AMPERES DUTY CYCLE (%) FIGURE L 100 80 60 40 20 0 0 100 200 300 6 Min utes W elding 4 Minutes Resting Relation Between Thic kness, Di[...]

  • Page 21

    SKU 91146 For technical questions, please call 1-800-444-3353. PAGE 21 Relation Between Wire Feed Speed, Siz e Of Wire , & W elding Current: TROUBLESHOOTING GUIDE - WELDING MACHINE FIGURE N Use larger welding leads.[...]

  • Page 22

    SKU 91146 For technical questions, please call 1-800-444-3353. PAGE 22 TROUBLESHOOTING GUIDE - WELDING GUN & WIRE DRIVE Problem Possible Cause No arc. 1. Interruption of welding power circuit to welding gun or workpiece. 2. Power source or control defective. 3. Trigger wire broken, cut, or disconnected. 4. Power source contractor not activated.[...]

  • Page 23

    SKU 91146 For technical questions, please call 1-800-444-3353. PAGE 23 INSPECTION, MAINTENANCE, AND CLEANING - WELDING GUN 1. W ARNING! Make sure the P ower Switch (10) on the W elding Machine is in its “OFF” position. Unplug the Power from its electrical outlet, and allow the W elder to completely cool before perf or ming any inspection, maint[...]

  • Page 24

    SKU 91146 For technical questions, please call 1-800-444-3353. PAGE 24 5. T o replace the Gun Liner: Disconnect the Gun’ s P o wer Cab le from the Welding machine. Remov e the Nozzle, Contact Tip , Adapter , Gas Diffuser , and Wire Outlet Guide. Then, remov e the old Liner . La y the Gun’ s P ow er Cable out straight bef ore installing a new Li[...]

  • Page 25

    SKU 91146 For technical questions, please call 1-800-444-3353. PAGE 25 PLEASE READ THE FOLLO WING CAREFULL Y THE MANUF ACTURER AND/OR DISTRIB UTOR HAS PR O VIDED THE P AR TS LIST AND ASSEMBL Y DIA GRAM IN THIS MANUAL AS A REFERENCE TOOL ONL Y . NEITHER THE MANUF A CTURER OR DISTRIBUT OR MAKES ANY REPRESENT A TION OR W ARRANTY OF ANY KIND T O THE B [...]

  • Page 26

    SKU 91146 For technical questions, please call 1-800-444-3353. PAGE 26 P AR TS LIST - WELDING MA CHINE ASSEMBL Y DIA GRAM - WELDING MA CHINE NOTE: Some parts are listed and shown for illustration purposes onl y , and are not available individually as replacement parts. 44 45 46 43 19 18 17 16 2 3A 3B 4 5A 6 5B 5C 7 8 9 10 11 42 41 40 39 38 35 5D 5E[...]

  • Page 27

    SKU 91146 For technical questions, please call 1-800-444-3353. PAGE 27 P AR TS LIST - WELDING GUN Part # Description Part # Description 1A Swan Neck (MB 25 AK, 50 ° Bent) 58A Adapter Nut 4A Nozzle Spring 59A Central Adapter Block (KZ-2) 6A Gun Body, Brass 60A Nut (M10 x 1) 7A Gun Body, Plastic 61A O-Ring (4 x 1) 10A Ergonomic Handle 62A Trigger Wi[...]

  • Page 28

    SKU 91146 For technical questions, please call 1-800-444-3353. PAGE 28 ASSEMBL Y DIA GRAM - WELDING GUN NOTE: Some parts are listed and shown for illustration purposes onl y , and are not available individually as replacement parts. 201A: GROUND CLAMP CABLE NO T SHO WN. 202A: GAS HOSE NO T SHO WN. 90A 80A 4A 100A 200A 1A 7A 18A 10A 44A 45A 44A 45A [...]

  • Page 29

    SKU 91146 For technical questions, please call 1-800-444-3353. PAGE 29 ELECTRICAL SCHEMA TIC - WELDING MA CHINE[...]