ARC WELDER - 160 AMP AC 02665 ASSEMBLY AND OPERATING INSTRUCTIONS 3491 Mission Oaks Blvd., Camarillo, CA 93011 Visit our Web site at http://www.harborfreight.com Copyright © 2003 by Harbor Freight Tools®. All rights reserved. No portion of this manual or any artwork contained herein may be reproduced in any shape or form without the express written consent of Harbor Freight Tools.
Specifications ITEM DESCRIPTION Arc Welding Current 80 and 160 amp Power Requirement 220 VAC, 40 amps, single phase, 60 Hz Open Voltage 22 VAC at 80 amps; 28 VAC at 160 amps Duty Cycle 40% at 80 amps; 10% at 160 amps Thermal Overload Protection Automatic overload shutdown and reset Dimensions 16 (L) x 6-7/8 (W) x 12-1/4 (H) inches Ground Cable 4 AWG, single insulation, 6 foot Torch Cable 4 AWG, single insulation, 6 foot Power Cord 3-core, double insulated, 12 AWG, U.L.
around metal, wood, and chemical dusts and mists. Always wear ANSI approved welding gear: leather gloves, leather apron and shoes. 9. Maintain tools with care. Keep tools clean for better and safer performance. Follow instructions for lubricating and changing accessories. Inspect tool cords periodically and, if damaged, have them repaired by an authorized technician. The handles must be kept clean, dry, and free from oil and grease at all times. 10. Disconnect power. Unplug Arc Welder when not in use.
Additional Arc Welding Safety Warnings and Precautions Warning: This product, when used for welding and similar applications, produces chemicals known to the State of California to cause cancer and birth defects (or other reproductive harm). California Health & Safety Code 25249.5, et seq. 1. Avoid electrical shock. Do not permit electrically live parts, cables, or electrodes to contact skin, clothing, or gloves. Protective clothing should be hole-free, dry, and ANSI approved.
Note: Performance of this tool may vary depending on variations in local line voltage. Extension cord usage may also affect tool performance. Unpacking When unpacking, check to make sure the following parts are included. Arc Welder Unit Line Cord (3A) Ground Cable (2A) Torch Cable (1A) If any parts are missing or broken, please call Harbor Freight Tools at the number on the cover of this manual as soon as possible. Assembly 1. Connect an appropriate 220 VAC electrical plug to the Line Cord.
Thermal Overload (red) Indicator Power On (green) Indicator Switch (5) 160 Amp Connector 80 Amp Connector Ground Cable (2A) Torch Cable (1A) 4. Place the desired welding electrode rod securely into the jaws of the Torch Cable Clamp (1A). Generally, the higher the amperage, the thicker the welding rod. 5. Verify that the Power Switch is in the OFF position, then plug the Arc Welder 220 VAC plug into a dedicated, 50 amp line with delayed action type circuit breaker or fuses.
11. Remove the electrode from the Torch Cable Clamp after it cools. 12. Unplug the Torch Cable plug from the Arc Welding unit. 13. Turn the Arc Welder unit on to allow the fan to cool it down for 20 minutes. 14. Unplug the Arc Welder Power Cord from the electrical outlet. Maintenance Warning; Unplug the Arc Welder before performing any maintenance. 1. Periodically tighten all cable connection screws on the cable clamps and line cord plug. 2.
Parts List Item # Designation 1 T1 Power Transformer Description Qty 1 2 T2 Control Transformer 1 3 M Vane, 1,0 CB-1, 4-4-140 1 4 VS1 Triac TC242-80-5 1 5 SA1 Switch, T120-15A 1 6 XS1 Socket, CHTI58-16B-21-2-B 1 7 SP1 Plug, CHTI58-16P-20-0-B 1 Diodes 8 VD1-VD4, VD7 KA243 5 9 VD5, VD6 KA212A 2 10 VD8 LED, AJ1307 LM 1 11 VD9 LED, AJI307AM 1 Resistors 12 R1 MJIT-2-100 ohms 1 13 R2 MJIT-0, 25-2, 7K ohms 1 14 R3 MJIT-0, 25-100 ohms 1 15 R4, 12, 13 MJI
Schematic Drawing SKU 02665 Page 9
