Harbor Freight Tools 55525 manual Weld Diagnosis Weld Penetration, Weld Not Adhering Properly

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Weld Diagnosis

Weld Penetration

Excess or burn-through

Proper

Inadequate

Weld droops on top and

Weld is visible underneath and

Weld does not contact the joint

underneath, or falls through

bulges slightly on top.

fully, just on the surface.

entirely, making a hole.

 

 

Cross Sections

Possible Causes and Solutions

1.Excessive material at weld: Reduce wire feed speed.

2.Overheating:

Increase welding speed and ensure that welding speed is kept steady.

Weld Not Adhering Properly

Gaps present between weld and previous bead or between weld and workpiece. See areas below.

Cross

Section

Possible Causes and Solutions

1.Dirty workpiece:

Make certain that workpiece is clean and free from oil, coatings, and other resi- dues.

2.Insufficient weld material: Increase wire feed speed.

3.Incorrect welding technique:

Place stringer bead at correct place in joint. Adjust workpiece position or weld angle to permit proper welding at bottom of workpiece.

Pausebrieflyatsideswhenusingweavebead. Keep arc on leading edge of weld puddle. Hold gun at proper angles as stated under Holding The Torch on page 19.

Possible Causes and Solutions

1.Workpieces too thick/close:

Joint design must allow weld to reach bot- tom of groove and allow proper welding procedures.

2.Incorrect welding technique: Maintain 1/2” or less stickout.

Keep arc on leading edge of weld pud- dle.

Hold gun at proper angles as stated under Holding The Torch on page 19.

3.Insufficient weld material: Increase wire feed speed.

4.Insufficient weld heat: Reduce Welding Speed.

Bend at joint

Cross

Section

Possible Causes and Solutions

1.Improper clamping:

Make sure that pieces are clamped se- curely in place.

Make tack welds to help hold pieces.

2.Excessive heat:

Weld a small portion and allow to cool before proceeding.

Reduce wire feed speed. Increase weld speed.

SKU 55525

For technical questions, please call 1-800-444-3353;

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Troubleshooting section at end of manual.

 

 

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Contents For technical questions or replacement parts, please call 220 VAC*DUAL MIG WelderContents Save this Manual Product SpecificationsGeneral Safety Rules Work AreaElectrical Safety Personal SafetyService Tool USE and CareSpecific Safety Rules Industrial applications must follow Osha guidelinesPage Cylinders can explode when damaged Welding Produces toxic fumes and gassesGrounding Extension Cords SymbologyUnpacking Grounded Tools Tools with Three Prong PlugsTo Install a Wire Spool Assembly InstructionsFace Shield Assembly To Attach The HandleTo Route The Wire See Figure EExercise Extreme Caution Risk of Fire AND/OR Electric Shock Figure FSee Figure G To Change Wire SettingsNozzle. See Figure F, previous Setting The Gun Polarity For Wire Type See Figure HTo Install a Gas Cylinder Duty Cycle Duration of Use Operating InstructionsBefore You Begin Welding See Figure KSetting Up The Weld See Figure LHolding The Welding Torch Figure MTop figures are Voltage OttomB number is WireHarsgCni ttSe eldW On ETPage Weld Not Adhering Properly Weld Diagnosis Weld PenetrationBend at joint Excessive Spatter PorosityStrike Test When the Weld is Completed Contact Tip Inspection, Cleaning, And Replacement INSPECTION, MAINTENANCE, and CleaningNozzle Inspection, Cleaning, and Replacement Or more for .030Tips .035 or more for .023 TipsReplacing The Welding Torch Liner Please Read the Following CarefullyParts Lists and Diagrams Wiring SchematicParts List Part Description QtyAssembly Diagram Assembly Diagram Wire Feed Mechanism Wire creates a bird’s nest During operation TroubleshootingWire feed motor runs but wire does not feed properly Welding arc not stableTroubleshooting Welder does not function when switched onWire Feeds, but arc does not ignite Weak Arc strengthNozzle Plugged Wire Feeds, but Shielding gas does not FlowWarranty Regulator or cylinder valve closed
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