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MIG/ARC WELDER
Model 95424
DUAL MIG WELDER
Model 95629
AssEMbL y AnD OpERA tIOn InstRUCtIOns
Model 95424 shown.
Due to continuing improvements, actual product may differ slightly from the product described herein.
®
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit our website at: http://www.harborfreight.com
tO pREVEnt sERIOUs InjUR y, READ AnD UnDERst AnD
ALL WARnInGs AnD InstRUCtIOns bEfORE UsE.
© ®
Copyright 2007 by Harbor Freight Tools . All rights reserved. No portion of this
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Contents spECIfICA tIOns ............................................................................ 3 GEnERAL sAfEty RULEs ............................................................ 4 specific safety Rules .................................................................................. 6 UnpACKInG ................................................................................... 11 AssEMbL y InstRUCtIOns ......................................................... 11 Attaching the Wheels ...
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pLEAsE nO tE Models 95424 MIG/ARC WELDER and 95629 DUAL MIG WELDER have identi- cal features except for the ARC option mode available in the 95424 MIG/ARC Welder. The other features are the same, as shown in the Specifications chart below. spECIfICA tIOns Model 95424 MIG/ARC Welder 95629 Dual MIG Welder Welding Current 30 ~ 250 A Duty Cycle 100% @ 125 Amps / 30% @ 250 A Power Consumption 230V / 60 Hz / Single Phase / 40 A Open Voltage 16 - 36 V Power Plug Type 3-Prong, 220 VAC, polarized, twist
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GEnERAL sAfEty RULEs WARnInG! READ AnD UnDERst AnD ALL InstRUCtIOns f ailure to follow all instructions listed below may result in electric shock, fire, and/or serious injury. sAVE tHEsE InstRUCtIOns WORK AREA 1. Keep your work area clean and well lit. Cluttered benches and dark areas invite accidents. 2. Do not operate power tools in explosive atmospheres, such as in the pres- ence of flammable liquids, gases, or dust. Power tools create sparks which may ignite the dust or fumes. 3. Keep b
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pERsOnAL sAfEty 1. stay alert. Watch what you are doing, and use common sense when operat- ing a power tool. Do not use a power tool while tired or under the influence of drugs, alcohol, or medication. A moment of inattention while operating power tools may result in serious personal injury. 2. Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep your hair, clothing, and gloves away from moving parts. Loose clothes, jewelry, or long hair can be caught in mov
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7. Check for misalignment or binding of moving parts, breakage of parts, and any other condition that may affect the tool’s operation. If damaged, have the tool serviced before using. Many accidents are caused by poorly maintained tools. 8. Use only accessories that are recommended by the manufacturer for your model. Accessories that may be suitable for one tool may become hazardous when used on another tool. sERVICE 1. t ool service must be performed only by qualified repair personnel.
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prevent eye injury and burns. Wearing and using ANSI-approved 8. personal safety clothing and safety devices reduce the risk for injury. • Wear ANSI-approved safety impact eye goggles underneath welding eye protection featuring at least a Number 10 shade lens rating. • Leather leggings, fire resistant shoes or boots should be worn when using this product. Do not wear pants with cuffs, shirts with open pockets, or any clothing that can catch and hold molten metal or sparks. • Keep clothin
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material whose contents, when heated, can produce flammable or explosive va- pors. Clean and purge containers before applying heat. Vent closed containers, including castings, before preheating, welding, or cutting. 11. Avoid overexposure to fumes and gases. Always keep your head out of the fumes. Do not breathe the fumes. Use enough ventilation or exhaust, or both, to keep fumes and gases from your breathing zone and general area. • Where ventilation is questionable, have a qualified te
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14. protect yourself from electric shock. Do not use outdoors. Insulate yourself from the workpiece and ground. Use nonflammable, dry insulating material if possible, or use dry rubber mats, dry wood or plywood, or other dry insulating material big enough to cover your full area of contact with the work or ground. 15. Ensure that the unit is placed on a stable location before use. If this unit falls while plugged in, severe injury, electric shock, or fire may result. 16. Cylinders can expl
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Grounding nOtE: this Welder requires the installation of a 3-prong, 230 VAC, polarized, twistlock power Cord plug (not included). nEMA configuration # L6-40 or equivalent. the plug must be installed by a certified electrician. WARnInG! Improperly connecting the grounding wire can result in risk of electric shock. Check with a qualified electrician if you are in doubt as to whether outlet is prop- erly grounded. Do not modify power cord plug used with tool. never remove grounding prong fro
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UnpACKInG When unpacking, make sure all parts shown on the parts Lists near the end of this manual are included. If any parts are missing or broken, call Harbor Freight Tools. AssEMbL y InstRUCtIOns WARnInG! Always turn off the Welder and unplug the unit from its electri- cal outlet prior to performing any assembly, maintenance, or service. Att ACHInG tHE WHEELs Attaching wheels to case can be done for stationary cylinder use or mobile use. stationary Mobile Attach the two Swivel Wheels (27A)
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AssEMbL y InstRUCtIOns (COntInUED) stationary Mobile 2. 2. Install the Back Wheels (37A) at the Axle (36A). Install the Back Wheels (37A) at the Axle (36A). 3. 3. Fix the Back Wheels(37A) with the Fix the Back Wheels (37A) with the Clips (38A). Clips (38A). 4. 4. Arm (5A) Washer and Bolt Set the Axle (36A) with the Back Wheels Set Arm (5A) against the top back of the (37A) attached against the bottom of the welder case. Screw the Bolts through case. Then, screw the Bolts through the W
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AssEMbL y InstRUCtIOns (COntInUED) TO INSTALL THE WIRE SPOOL Inst ALLInG A WIRE spOOL TO INSTALL THE WIRE SPOOL Assembling the Wire Spool depends on whether you are using a 7” Spool or an 11” Two variants to expose the Wire Drive Assembly are probable for Spool 200mm (variant A) Spool. and for EN 759 Spool 300mm (variant B) use. Two variants to expose the Wire Drive Assembly are probable for Spool 200mm (variant A) for use with a 7” spool: and for EN 759 Spool 300mm (variant B) use. Varia
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AssEMbL y InstRUCtIOns (COntInUED) 3. 4. Insert the Spool onto the Spool ′s Holder. Making sure the Spool's Welding Wire Attach a Spool with the help of latch. unwinds from the bottom (clockwise). 5. Screw the Fixing Cover into the Threaded Shaft (11A). ROUtInG tHE WIRE note: When installing wire of different size or composition, you will also need to change wire settings, set gun polarity, and, possibly, install gas cylinder. (see pages 18 to 20.) Welding Wire Spool Figure A 1. IMpORt An
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3. Loosen, and lower the Handle (4D) on the Wire Drive Assembly. Then, raise the 3. Loosen, and lower the Handle (4D) on the Wire Drive Assembly. Then, raise the 3. Loosen, and lower the Handle (4D) on the Wire Drive Assembly. Then, raise the Lever (3D). (See Figure B) Lever (3D). (See Figure B) Lever (3D). (See Figure B) AssEMbL y InstRUCtIOns (COntInUED) Handle Handle (4D) Handle Lever Lever (3D) Lever FIGURE B FIGURE B FIGURE B 4. Keep tension on the Wire, and guide at least 12 inches of
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AssEMbL y InstRUCtIOns (COntInUED) 6. Lay Torch Cable out in a straight line so Welding Wire moves through it easily. Leave Door (14A) of the Welder open so Wire Feed Assembly can be observed. 7. Remove the Gun Nozzle (1E) and Contact Tip (2E). (see figure E.) WARnInG! ExERCIsE ExtREME CAUtIOn - RIsK Of fIRE AnD/OR ELECtRIC sHOCK! t he following steps require powering the Welder. Do not touch anything with t orch Handle or Welding Wire or an arc will be ignited. Do not touch internal c
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TO CHANGE WIRE SETTINGS . WARNING! Make sure to turn off the Welder and unplug it from its electrical outlet prior to changing wire settings. 1. Lift the Door (14A) of the Welder to expose the Wire Drive Assembly. 2. Loosen, and lower the Handle (4D) on the Wire Drive Assembly. CHAnGInG WIRE sEttInGs 3. Remove the Screw that secures the Roller (5D) in place. Then, remove the two Rollers. 1. WARnInG! Make sure to turn off the Welder and unplug it from its electrical 4. Flip each Roller 180
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TO INSTALL A GAS CYLINDER 1. CAUTION! Do not use an Argon/Mixed pressure regulator/flow meter with CO2 shielding gas. To use CO2 shielding gas, you must install a CO2 gas pressure regula- tor/flow meter (neither one included). 2. USING AN OVERSIZED GAS CYLINDER CAN CAUSE TIPPING resulting in cylin- der and equipment damage and personal injury. Do not exceed maximum cylinder weight of 100 lbs. (45 kg). 3. With assistance, set the cylinder upright against a solid post or other stationary obje
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OpERAtInG InstRUCtIOns bEfORE yOU bEGIn WELDInG Good welding requires a high degree of skill and experience. You should practice a few sample welds on scrap metal before you begin welding your first project. Ad- ditional practice periods are recommended whenever you weld a different thickness of material, wire, or weld a different type of connection. UnDERst AnDInG DUty CyCLE (DURA tIOn Of UsE) 1. CAUtIOn! Avoid damage to the Welder by not leaving the unit on for more than the prescribed d
