MIG/ARC WELDER Model 95424 DUAL MIG WELDER Model 95629 Assembly And Operation 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 injury, read and understand all warnings and instructions before use. Copyright© 2007 by Harbor Freight Tools®. All rights reserved.
Contents SPECIFICATIONS............................................................................. 3 GENERAL SAFETY RULES............................................................. 4 Specific Safety Rules................................................................................... 6 UNPACKING.................................................................................... 11 ASSEMBLY INSTRUCTIONS.......................................................... 11 Attaching the Wheels.................
PLEASE NOTE Models 95424 MIG/ARC WELDER and 95629 DUAL MIG WELDER have identical 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.
GENERAL SAFETY RULES WARNING! READ AND UNDERSTAND ALL INSTRUCTIONS Failure 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 presence of flammable liquids, gases, or dust. Power tools create sparks which may ignite the dust or fumes. 3.
PERSONAL SAFETY 1. Stay alert. Watch what you are doing, and use common sense when operating 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 moving parts. 3.
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. Tool service must be performed only by qualified repair personnel.
Prevent eye injury and burns. Wearing and using ANSI-approved personal safety clothing and safety devices reduce the risk for injury. 8. • 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.
material whose contents, when heated, can produce flammable or explosive vapors. 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.
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.
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 properly grounded. Do not modify power cord plug used with tool. Never remove grounding prong from plug.
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. ASSEMBLY INSTRUCTIONS WARNING! Always turn off the Welder and unplug the unit from its electrical outlet prior to performing any assembly, maintenance, or service. Attaching the Wheels Attaching wheels to case can be done for stationary cylinder use or mobile use.
ASSEMBLY INSTRUCTIONS (CONTINUED) Stationary 2. Mobile 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 Clips (38A). 4. Fix the Back Wheels (37A) with the Clips (38A). 4. Arm (5A) Washer and Bolt Set the Axle (36A) with the Back Wheels (37A) attached against the bottom of the case. Then, screw the Bolts through the Washers and into the bottom of the case. (See Figure 4, above left.
ASSEMBLY INSTRUCTIONS (CONTINUED) TO INSTALL THE WIRESpool SPOOL Installing a Wire 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) useSpool with300mm a 7” Spool: and forFor EN 759 (variant B) use. Variant A 1. Variant2.A 1. 2.
ASSEMBLY INSTRUCTIONS (CONTINUED) 4. 3. Insert the Spool onto the Spool′s Holder. Making sure the Spool's Welding Wire unwinds from the bottom (clockwise). 5. Attach a Spool with the help of latch. 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.
3. Loosen, 3. Loosen, and and lower lower the the Handle Handle (4D) (4D) on on the the Wire Wire Drive Drive Assembly. Assembly. Then, Then, raise raise the the Lever (3D). (See Figure B) Lever (3D). (See Figure B) ASSEMBLY INSTRUCTIONS (CONTINUED) Handle Handle (4D) Lever Lever (3D) FIGURE FIGURE BB 4. Keep tension Wire, and at 12 of Wire into Wire 4. Keep tension on the thethe Wire, and guide guide at least least 12 inches inches ofWire WireFeed into the the Wire Inlet InletThen, 3.
ASSEMBLY 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! The following steps require powering the Welder. Do not touch anything with Torch Handle or Welding Wire or an arc will be ignited.
. 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. Make sure turn off 4.1.Flip eachWARNING! Roller 180 degrees.
Setting Polarity for Welding Type WARNING! Always turn welder off and disconnect it from it’s electrical supply before opening the case or performing any adjustment, including the following procedure. 1. 2. Set for Electrode Positive (DCEP) for gas welding with solid-core wire - Red electrode cable (C) to positive terminal (A); - Black ground cable (D) to negative terminal (B). See illustration, top right initial Setup. SETTING THE GUN & ELECTRODE POL DCEP 1.
(See Figure G) 4. Remove the protective cap from the cylinder. Stand to the side of the cylinder valve, and open the valve slightly to blow dust and dirt from the valve. Then, close the valve. (See Figure G) 5. Make sure the Flow Adjust on the Pressure Regulator/Flow Meter is turned off. Then, Installing Gas Cylinder screw the Pressure Regulator/Flow Meter a firmly onto the cylinder valve. (See Figure G) WARNING: Using an oversized gas cylinder can cause tipping, result6.
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. Additional practice periods are recommended whenever you weld a different thickness of material, wire, or weld a different type of connection. Understanding Duty Cycle (Duration of Use) 1. CAUTION! Avoid damage to the Welder by not leaving the unit on for more than the prescribed duty cycle time.
Setting Up the Weld WARNING! Before welding, make sure to read and understand all safety precautions and warnings discussed on pages 4 through 10. 1. Power Switch (1C): Always make sure the Power Switch is in its “OFF” position before plugging the Welder into a 230 volt, grounded, electrical outlet. (See Figure J). 2. Overload Protector (2C): If too much current is drawn from the Welder, the Overload Protector will activate.
MIG Welding Set Up 7. If using solid-core wire, connect and secure an Argon/ CO2 gas hose to the rear of the Welder. (If using flux core wire, protective gas is not required.) OVERLOAD PROTECTOR (2C) POWER SWITCH (1C) WIRE FEED SPEED KNOB (3C) ELECTRODE WELDING INDICATOR (4C) VOLTAGE SELECTOR KNOB (5C) FIGURE K 8. 9. 9. 10. 11. 10. 12. 11. Set the desired welding voltage and wire speed for the thickness of metal being welded, the Voltage (5C) and Wire Then Feedplug Speed Knob (3C).
MIG Weld Settings Chart FIGURE J This Chart is intended to show general guidelines for different wire sizes and for different thickness of material. The settings shouldCHART only be used at the beginning of a weld WELD SETTINGS and must be adjusted after stopping and carefully inspecting the weld. Proper welding takes good technique practice. This Chartand is intended to show general guidelines for different wire sizes and for different thicknesses of material.
Arc (Stick) Welding Set Up (continued, for Model 95424 Only) 13. Turn the Power Switch (1C) to its “OFF” position. Clamp the bare end of the selected electrode in the electrode holder. Electrode NI-CL 308L 6011 6013 7014 7018 7024 Penetration Shallow Shallow Deep Shallow Moderate Shallow Shallow Attributes For cast Iron For stainless steel Little preparation needed, high spatter All purpose Easy to use, quick Creates stronger welds For flat/fillet welds, easy to use, quick 14.
If the electrode fuses to the workpiece, quickly twist to release it and lift it slightly farther on your next attempt. 19. The Welding Wire/Electrode should be directed straight into the joint. This gives an angle of 90 degrees (straight up and down) for groove (end to end) welds, and an angle of 45 degrees for fillet (T-shaped) welds. 20. The end of the Torch/Holder should be tilted so that the Welding Wire/Electrode is angled anywhere in between straight on and 15 degrees in the direction of the weld.
INSPECTION, MAINTENANCE, AND CLEANING WARNING! Before performing any maintenance on the Welder, unplug the Power Cord (1A) from its electrical outlet and allow all components of the Welder to completely cool. 1. Periodically open the Door (14A) from the unit and, using compressed air, blow out all dust and debris from the interior. 2. Always store the Welder in a clean, dry, safe location out of reach of children and other unauthorized people. 3.
REPLACING THE WELDING TORCH LINER Replacing the Welding Torch Liner (MIG Only) Remove NOZZLE, slip type. Remove TIP. 1.Disconnect GUN TERMINAL (11D) & TERMINAL (12D). 2.Untwist NUT (9D). 3.Remove GUN (20A) & CABLES (15A), (18A) & two SEALING WASHERS (8D). Remove LINER. Without bending, insert a new LINER. Pull LINER out the other end. Cut LINER off 5 mm from head tube. Install TIP (2E), NOZZLE (1E). 1. Install GUN (20A) & CABLES (15A), (18A) &two SEALING WASHERS (8D). 2. Secure NUT (9D).
PARTS LISTS and Diagrams PARTS LIST A Part Description Qty. Part Description Qty. 1A Power Cord (8 AWG x 3C: 250V)l 1 20A 1 2A Power Cord Clip 1 21A 3A Chain 1 4A Hose Connector 1 22A Gun (SB 250) Electrode Cable w/ Holder (only for 95424 MIG/ARC Welder) Ground Cable w/ Clamp 5A Arm 1 23A Front Pane;/Base (see Fig.
ASSEMBLY DIAGRAMS NOTE: Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts. Figure L For technical questions, please call 1-800-444-3353; questions, please call 1-800-444-3353; MIG DUAL 250For AMP –technical SKU Troubleshooting section at end of manual. SKU 95424, 95629 Troubleshooting section at end of manual.
Assembly Diagrams (continued) Power Block #32A PARTS DIAGRAMS DescriptionLISTS & ASSEMBLY Qty. Part Description Part 1B Part2B # 1B 3B 2B 3B 4B 4B Main Transformer Rectifier Qty. Power1Block # 5B 32A Filter Reactor w/ Thermo Resistor Qty. 2 Description Main Transformer Tr1 Fixing Corner Rectifier Fixing Hosecorner Connector Thermo Resistor Connector 1 12 14 1 Part #6B Description Tr2 Auxiliary Transformer 1 Qty.
Assembly Diagrams (continued) Front Panel #23A PARTS LISTS & ASSEMBLY DIAGRAMS Part Description Description Qty. Part 1C Part # 2C Power Switch Front 1Panel # 7C 23A Terminal Ground Overload Indicator Description 1 Qty.
Assembly Diagrams (continued) Wire Drive Assembly #16A Part 1D 2D Part # 3D 1D 4D 2D 3D 4.1D 4D 4.2D 4.1D 4.3D 4.2D 4.3D 4.4D 4.4D 5D 5D 6D 6D 7D 7D Description Gear Motor Qty. Part 1 8D Description Qty. PARTS LISTS & ASSEMBLY DIAGRAMS Sealing Washer 2 Wire Drive Assy.
Assembly Diagrams (continued) Gun (SB 25) #20A Part Description Qty. Part Description Qty. 1E Nozzle (Slip Type) 1 9E Nut (M12) 1 2E Contact Tip 1 10E Liner 1 3E Spring 4E Head Tube # 5E PartSealant PARTS LISTS & DIAGRAMS 1 ASSEMBLY 11E Liner Terminal 1 Gun 1 (SB 250) 12E# 20A Switch Trigger Terminal 1 1 Description 1E Nozzle (Slip Type) 6E 2ESpring Contact Tip Spring 7E 3ETerminal; 4E Head Tube 8E 5EFeeder Connector Sealant 6E Spring 7E Terminal 8E Feeder Connector Qty.
SKU 95424, 95629 R3 1k For technical questions, please call 1-800-444-3353; Troubleshooting section at end of manual. For technical questions, please call 1-800-444-3353; Troubleshooting section at end of manual. + Power Electrode Cable #18A Power Positive Cable #15A “+” Cable Eltctrode With Holder GUN Vd49...
MIG Dual Welder (95629)SCHEMATIC – Electrical Schematic ELECTRICAL MIG DUAL 250 AMP WELDER MIG&ARC 250 AMP - SKU 95424 MIG DUAL 250 AMP – SKU SKU 95424, 95629 For technical questions, please call 1-800-444-3353; Troubleshooting section at end of manual. For technical questions, please call 1-800-444-3353; Troubleshooting section at end of manual.
POWER CORD, CONNECTION BLOCK BC-4 & TRANSFORMERS CONNECTIONBLOCK SCHEMATIC POWER CORD, CONNECTION BC-4 & TRANSFORMERS CONNECTION SCHEMATIC MIG&ARC 250 AMP - SKU 95424 MIG DUAL 250 AMP – SKU SKU 95424, 95629 For technical questions, please call 1-800-444-3353; Troubleshooting section at end of manual. For technical questions, please call 1-800-444-3353; Troubleshooting section at end of manual.
TROUBLESHOOTING Important! Be CERTAIN to shut off the Welder, disconnect it from power, and discharge the torch to ground before adjusting, cleaning, or repairing the unit. Welder does not function when switched on Possible Causes and Solutions 1. Tripped thermal protection device: Shut the welder’s switch to off and allow it to cool for at least 20 minutes. Reduce duration or frequency of welding periods to help reduce wear on the welder. Refer to Duty Cycle section on page 20. 2.
Troubleshooting (continued) Important! Be CERTAIN to shut off the Welder, disconnect it from power, and discharge the torch to ground before adjusting, cleaning, or repairing the unit. Wire feed motor runs but wire does not feed (MIG welding only) Possible Causes and Solutions 1. Insufficient wire feed pressure: Increase wire feed pressure properly - follow instructions on page 14 - 17. 2.
Troubleshooting (continued) Important! Be CERTAIN to shut off the Welder, disconnect it from power, and discharge the torch to ground before adjusting, cleaning, or repairing the unit. Wire feeds, but shielding gas does not flow (MIG welding only) 1. 2. 3. 4. 5. Possible Causes and Solutions Empty Gas Cylinder: Check gas cylinder. Nozzle Plugged: Clean nozzle. If damaged, replace. Regulator or cylinder valve closed: Make sure both valves are adjusted properly.