Instruction/ maintenance manual of the product 91146 Harbor Freight Tools
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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 .
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 .
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.
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.
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.
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.
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.
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 .
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.
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.
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.
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.
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 3.
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.
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).
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.
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.
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.
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.
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.
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.
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.
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.
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 .
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 .
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.
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 Sp.
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.
SKU 91146 For technical questions, please call 1-800-444-3353. PAGE 29 ELECTRICAL SCHEMA TIC - WELDING MA CHINE.
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