If there is any doubt, do not operate the tool. 18. Pacemaker safety warning. People with pacemakers should consult with their physician(s) before using this product; operation of equipment in close proximity to a heart pacemaker could cause interference or failure of the pacemaker. 19. Use proper size and type extension cord. If an extension cord is required, it must be of the proper size and type to supply the correct current to the tool without heating up. Otherwise, the extension cord could melt and catch fire, or cause electrical damage to the tool. This tool requires use of an extension cord with up to 50 amps capability (up to 50 feet), with wire size rated at 8 AWG. Longer extension cords require larger size wire. If you are using the tool outdoors, use an extension cord rated for outdoor use. (signified by “WA” on the jacket). 20. Maintenance. For your safety, service and maintenance should be performed regularly by a qualified technician. SKU 02665 Page 3 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. This unit draws enough current to cause serious injury or death. Before turning the Arc Welder on, check the electrode holder to be sure that there are no protruding screw heads, and that all insulation is secure, covering all conductors. Do not weld unless you are insulated from ground and the work piece. 2. Avoid breathing fumes or gases. They can cause serious health problems. Use an active ventilation system directly above the welding area. Keep your head out of the fumes. 3. Avoid eye and body damage. Arc rays and infrared radiation can injure eyes and burn skin. Wear ANSI approved eye and body protection. Do not allow viewing by visitors without proper eye and body protection. Use a Face Shield with an arc shaded filter plate. 4. Know proper arc welding practices. Read and understand the manufacturer’s instructions, and well as your employer’s safety practices for arc welding. 5. Connect only to a code approved power source. Connect only to a grounding power source conforming to the National Electrical Code and Local Codes. 6. Avoid fire and explosion. Remove flammable and explosive material from at least 35 feet from the welding arc to prevent welding sparks or molten metal from starting a fire. Keep a type ABC fire extinguisher within easy reach. Thoroughly clean the object being welded of any paint, grease, or other foreign material. Warning:The warnings, cautions, and instructions discussed in this instruction manual cannot cover all possible conditions and situations that may occur. It must be understood by the operator that common sense and caution are factors which cannot be built into this product, but must be supplied by the operator. REV 05/04 SKU 02665 Page 4 Ground Cable (2A) Torch Cable (1A) Arc Welder Unit Ground Cable (2A) Torch Cable (1A) Arc Welder Unit Unpacking When unpacking, check to make sure the following parts are included. Line Cord (3A) 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. This should only be done by a licensed electrician. 2. Connect a AWG # 6 solid wire from the ground screw terminal (screw not included) on the back of the unit to earth ground before welding. This grounds the internal transformer in case of short circuits. Operation Caution: Before arc welding, read and understand all safety precautions and warnings listed on pages 2 through 5. 1. Secure the pieces of metal to be welded so they cannot move. 2. Connect the Torch Cable (1A) to the Arc Welder connector for either 80 amp or 160 amp operation. See photo at the top of the next page. 3. Securely clamp the Ground Cable Clamp (2A) as close as possible to the metal object to be welded, or to the metal work bench where the object is mounted and electrically connected. SKU 02665 Page 5 Ground Cable (2A) Ground Cable (2A) Switch (5) 160 Amp Connector 80 Amp Connector 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. If an extension cord is used, it must have the following wire size: up to 30 feet, use 10 AWG size wire; 30 to 50 feet, use 8 AWG wire; Over 50 feet, use 6 AWG wire. 6. While holding the Torch Cable Clamp wit...