Owner’s Manual & Safety Instructions Save This Manual Keep this manual for the safety warnings and precautions, assembly, operating, inspection, maintenance and cleaning procedures. Write the product’s serial number in the back of the manual near the assembly diagram (or month and year of purchase if product has no number). Keep this manual and the receipt in a safe and dry place for future reference. MIG140 MIG170 64804 64805 64805 shown. Visit our website at: http://www.harborfreight.
table of contents SaFEty Safety ......................................................... 2 Specifications ............................................. 7 Setup .......................................................... 8 Basic Welding ............................................ 15 Welding Tips .............................................. 23 Maintenance .............................................. 27 Parts List and Diagram .............................. 30 Warranty ..................................
SaFEty Fume and gas Safety INHALATION HAZARD: Welding and plasma cutting produce toxic fumes. • Ulcers • Damage to the reproductive organs • Inflammation of the small intestine or stomach • Kidney damage • Respiratory diseases such as emphysema, bronchitis, or pneumonia Use natural or forced air ventilation and wear a respirator approved by NIOSH to protect against the fumes produced to reduce the risk of developing the above illnesses. 6.
Electrical Safety ElEctRic SHOcK can Kill. SaFEty 1. turn off, disconnect power, and discharge electrode to ground before setting down torch/electrode holder and before service. 6. do not expose welders to rain or wet conditions. Water entering a welder will increase the risk of electric shock. 2. do not touch energized electrical parts. Wear dry, insulating gloves. Do not touch electrode holder, electrode, welding torch, or welding wire with bare hand. Do not wear wet or damaged gloves. 7.
2. disconnect the plug from the power source before making any adjustments, changing accessories, or storing welders. Such preventive safety measures reduce the risk of starting the welder accidentally. 3. prevent unintentional starting. Ensure the switch is in the offposition before connecting to power source or moving the welder. Carrying or energizing welders that have the switch on invites accidents. 4.
grounding SaFEty tO pREVEnt ElEctRic SHOcK and dEatH FROM incORREct gROunding WiRE cOnnEctiOn: check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded. do not use the Welder if the power cord or plug is damaged. if damaged, have it repaired by a service facility before use. if the plug will not fit the outlet, have a proper outlet installed by a qualified electrician, do not use adapter plugs. SEtup 1.
Symbology ipM aWg Workpiece Ground Cable Inches Per Minute American Wire Gauge Electric Shock Hazard. Do not touch energized parts. Torch Cable Overheat Shutdown Indicator Fire Hazard. Keep flammable materials away during welding. Spatter can cause accidental fires. Volts Alternating Current Amperes Arc Ray Hazard. Wear welding helmet with properly rated filter lens. Open Circuit Voltage Kilovolt Amperes (Volts / 1000 * Amperes) Pacemaker Hazard. Welding processes may interfere with pacemakers.
Setup Read the EntiRE iMpORtant SaFEty inFORMatiOn section at the beginning of this manual including all text under subheadings therein before set up or use of this product. SaFEty tO pREVEnt SERiOuS inJuRy FROM accidEntal OpERatiOn: turn the power Switch off and unplug the Welder before setup. note: Remove the protective foam and cardboard from the Welder before setup. Wire Spool Installation / Wire Setup power Switch SEtup 1. turn the power Switch OFF and unplug the Welder before proceeding.
6. 10-12 pound Wire Spool installation: Remove the Wingnut, Keyed Washers, and Spring. If replacing a Spool, remove the old Spool and all remaining wire from the liners. Spool Knob Wingnut Keyed Washer 7. Place the Spool Adapter over the Spool Spindle and against the Spool Brake Pad as illustrated. 8. Place the new Wire Spool over the Adapter and line up pin on Adapter with hole in Spool. to prevent wire feed problems, set the Spool so that it will unwind counterclockwise.
SaFEty 12. dcEp direct current Electrode positive Wire Setup for Solid Core (gas shielded) welding: a. Connect the Wire Feed Connector to the Positive Terminal on the front of the Welder. Connect the Ground Cable to the Negative Terminal on the front of the Welder. connect Wire Feed to positive SEtup b. Determine which type of shielding gas would be appropriate for the welding you will do. Refer to the Settings Chart on the inside of the Welder door.
Feed tensioner idler arm Feed Roller Knob SEtup 14. Feed Roller instructions: Check that the Feed Roller is correct for the type of wire being used (solid core or fluxcored) and that it is turned to properly match the wire size marked on the Wire Spool: SaFEty 13. Turn the Feed Tensioner knob counterclockwise to loosen it enough to pull it down to remove tension. The spring-loaded Idler Arm will move up as shown. a BaSic WElding 0.025 V-groove 0.030 / 0.035 knurled groove b.
Wire Feed Mechanism SaFEty 15. Loosen the Knob on the Wire Feed mechanism, then insert the Gun Cable Connector through the hole on the Welder front and into the socket on the Wire Feed. SEtup 16. Ensure that the Gun Cable Connector is fully inserted into the socket on the Wire Feed mechanism as shown. no O-ring should be visible. Tighten the Knob securely. If Connector is not fully inserted, the gas connection will leak, preventing shielding gas from reaching the welding arc.
idler arm Feed tensioner SaFEty 20. Make sure the welding wire is resting in the groove of the Feed Roller, then push the wire Idler Arm down, and swing the Feed Tensioner up to latch it across the tip of the arm. After the wire is held by the Tensioner, you may release it. note: The tension should be 3 – 5 for solid wire and 2 – 3 for flux-cored wire. Too much force on flux-cored wire will crush it and may cause feeding issues. 21. Pull and twist the Nozzle to remove it. 23.
25. Set the MIG Flux / Spool Gun Switch to MIG Flux Gun. MIG Flux / Spool gun Switch SaFEty 26. Point the Gun away from all objects. Press and hold the Trigger until the wire feeds through the end of the Gun two inches. Mig gun 2" the wire liner may come out with the welding wire. this is normal, just turn off the Welder and push the wire liner back into the gun.
Read the EntiRE iMpORtant SaFEty inFORMatiOn section at the beginning of this manual including all text under subheadings therein before welding. tO pREVEnt SERiOuS inJuRy: protective gear must be worn when using the Welder; minimum shade number 10 full face shield (or welding mask), ear protection, welding gloves, sleeves and apron, NIOSH-approved respirator, and fire resistant work clothes without pockets should be worn when welding. light from the arc can cause permanent damage to the eyes and skin.
Front panel controls Work indicator SaFEty alarm indicator 2t / 4t Switch power indicator SEtup Wire Speed Knob inductance Knob Voltage Knob BaSic WElding Mig gun / Spool gun cable Socket positive terminal Wire Feed control Socket negative terminal Wire Feed power cable WElding tipS alarm indicator: Lights up if there is a problem with welder operation. See Alarm Indicator Error Codes on page 28.
Mig Flux / Spool Gun Switch gas Quick connector Wire Spool SaFEty interior controls Spool Knob Feed tensioner Wire inlet liner Wire Feed Mechanism note: When using an optional Spool Gun (sold separately), disconnect the Wire Feed Gas Hose from the Gas Quick Connector, thread the gas hose from the Spool Gun through the round hole in the front of the Welder and connect it to the Gas Quick Connector, and place the MIG Flux/Spool Gun Switch on the Spool Gun setting.
Duty Cycle (Duration of Use) SaFEty avoid damage to the Welder by not welding for more than the prescribed duty cycle time. The Duty Cycle defines the number of minutes, within a 10 minute period, during which a given welder can produce a particular welding current without overheating. For example, a welder with a 40% duty cycle at 90 A welding current must be allowed to rest for at least 6 minutes after every 4 minutes of continuous welding.
workpieces clean surfaces to bare metal. SEtup 2. Use clamps (not included) to hold the workpieces in position so that you can concentrate on proper welding technique. The distance (if any) between the two workpieces must be controlled properly to allow the weld to hold both sides securely while allowing the weld to penetrate fully into the joint. The edges of thicker workpieces may need to be chamfered (or beveled) to allow proper weld penetration. clamps chamfer thick workpieces.
SaFEty dangER! tO pREVEnt dEatH FROM aSpHyXiatiOn: do not open gas without proper ventilation. Fix gas leaks immediately. Shielding gas can displace air and cause rapid loss of consciousness and death. Shielding gas without carbon dioxide can be even more hazardous because asphyxiation can start without feeling shortness of breath. 5. gas shielded, solid-core wire only: a. Open gas cylinder valve all the way. SEtup b. Set Flow Gauge to SCFH value indicated on Settings Chart. BaSic WElding 6.
Basic Welding technique weave bead SaFEty stringer bead 2. For a narrow weld, you can usually draw the wire in a steady straight line. This is called a stringer bead. For a wider weld, draw the wire back and forth across the joint. This is called a weave bead and takes practice to perform properly. SEtup Weld Mig gun angles, viewed from front of weld joint. 3. Direct the welding wire straight into the joint.
SaFEty note: If Welder is used too long, the Overload Indicator lights up and the unit automatically shuts down. The Welder automatically returns to service after cooling off. Should this occur, rest the MIG Gun on an electrically nonconductive, heat-proof surface, such as a concrete slab, away from the ground clamp. Overload indicator Mig gun allow the Welder to cool with the power Switch on, so that the internal Fan will help cool the Welder.
A typical flux-cored wire (FCAW) weld before cleaning. weld bead slag base metal A typical solid wire (GMAW) weld before cleaning. spatter weld bead tO pREVEnt SERiOuS inJuRy: continue to wear anSi-approved safety goggles and protective wear when cleaning a weld. Sparks or chips may fly when cleaning. chipping Hammer 1. A weld from flux-cored wire will be covered by slag. Use a chipping hammer to knock this off. Be careful not to damage the weld or base material. Wire Brush 2.
Weld diagnosis Workpiece Heat control / Weld penetration SaFEty SEtup inadEQuatE pEnEtRatiOn pROpER pEnEtRatiOn EXcESS pEnEtRatiOn OR BuRn-tHROugH not hot enough ideal heat too hot How to increase workpiece heat and increase penetration: How to reduce workpiece heat and limit penetration: (to weld tHicKER workpieces properly) (to weld tHinnER workpieces properly) a. increase weld current c. use faster wire feed a. decrease weld current c. use slower wire feed b. decrease travel speed d.
Weld problems EXcESS pEnEtRatiOn OR BuRn-tHROugH Weld droops on top and underneath, or falls through entirely, making a hole. pROpER pEnEtRatiOn Weld is visible underneath and bulges slightly on top. inadEQuatE pEnEtRatiOn Weld does not penetrate the joint fully, just on the surface. SaFEty Penetration (Workpiece Heat Control) 3. 4. PROFILE VIEW Weld not adhering properly pOSSiBlE cauSES and SOlutiOnS 1. improper clamping: Clamp workpieces securely. Make tack welds to hold workpieces. 2.
porosity Excessive Spatter SaFEty Small cavities or holes in the bead. TOP VIEW 1. 2. SEtup 3. 4. BaSic WElding 5. 6. Fine spatter is normal. Spatter that is grainy and large is a problem. TOP VIEW pOSSiBlE cauSES and SOlutiOnS incorrect polarity: Check that polarity is set correctly for type of welding. Insufficient shielding gas (MIG only): Increase flow of gas. Clean nozzle. Maintain proper CTWD. Incorrect shielding gas (MIG only): Use shielding gas recommended by wire supplier.
tO pREVEnt SERiOuS inJuRy, FiRE and BuRnS: unplug the Welder, rest the Mig gun on a heat-proof, electrically non-conductive surface, and allow all parts of the Welder to cool thoroughly before service. • loose hardware • misalignment or binding of moving parts 2. Periodically, have a qualified technician remove the Rear Panel and use compressed air to blow out all dust from the interior. • damaged cord / electrical wiring 3. Store in a clean and dry location. • frayed or damaged cables 4.
alarm indicator Error codes code Meaning SaFEty Err Uol Solution (64805 only) Input voltage and Voltage Switch setting do not match. (64805 only) Flip Voltage Switch. Welder is using too much current. Welder may pull too much current from supply. Reduce current/wire speed using Wire Speed Knob. Electrode has shorted against workpiece, no arc is detected. The electrode is stuck against the workpiece, allowing all current to go directly through without welding. Free the electrode from the plate.
Weak arc strength When switched on, Power Indicator lights but Welder does not function Power ON Indicator does not light when switched on 1. Wire not feeding properly. 1. See first Troubleshooting section above. 2. Incorrect Contact Tip or liner size or excessive wear. 2. Replace with the proper tip or liner size for wire used. 3. Incorrect wire feed speed. 3. Adjust wire feed speed to achieve a more stable arc. 4. Loose MIG Gun cable or ground cable. 4.
Troubleshooting (continued) SaFEty iMpORtant! Be cERtain to shut off the Welder, disconnect it from power, and discharge the Mig gun to ground before adjusting, cleaning, or repairing the unit. problem Wire feeds, but arc does not ignite SEtup Porosity in the weld metal possible causes likely Solutions BaSic WElding 1. Improper ground connection. 1.
Record Serial number Here: note: If product has no serial number, record month and year of purchase instead. Item 64804 64805 note: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts. Parts may not be interchangeable. Specify number when ordering. For technical questions, please call 1-888-380-0318.
plEaSE REad tHE FOllOWing caREFully THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER OR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT, OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT.
