Harbor Freight Tools Welding System 67854 User Manual

AUTO-DARKENING  
WELDING HELMET  
Model 67854  
Model 91214  
SET Up AND OpERATING INSTRUcTIONS  
NOTE: YOUR Helmet may appear different from the Helmet pictured in this manual. The  
changes are only cosmetic, the warnings, operation instructions, and maintenance  
procedures will remain the same.  
Visit our website at: http://www.harborfreight.com  
Read this material before using this product.  
Failure to do so can result in serious injury.  
SAVE THIS MANUAL.  
Copyright© 2010 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. Diagrams within this manual may not be drawn proportionally. Due to continuing  
improvements, actual product may differ slightly from the product described herein. Tools required for  
assembly and service may not be included.  
For technical questions or replacement parts, please call 1-800-444-3353.  
 
5. Store idle equipment. When not in use,  
helmets must be stored in a dry location  
to inhibit rust. Always lock up helmets  
and keep out of reach of children.  
Approved accessories are available from  
Harbor Freight Tools.  
11. Do not weld if under the influence of  
alcohol or drugs. Read warning labels  
on prescriptions to determine if your  
judgment or reflexes are impaired while  
taking drugs. If there is any doubt, do not  
weld.  
6. Dress properly. Do not wear loose  
clothing or jewelry as they can be caught  
in moving parts. Protective gear is  
essential to protect against welding rays,  
some examples are: a leather welding  
apron, welding sleeves, jeans without  
cuffs, work boots. Wear restrictive hair  
covering to contain long hair.  
12. Maintenance. For your safety, service  
and maintenance should be performed  
regularly only by a qualified technician.  
13. This helmet provides protection for  
intended purposes only. There are  
certain applications for which this helmet  
was designed. Do not modify this helmet  
and do not use this helmet for a purpose  
for which it was not intended.  
7.  
Use eye and ear protection.  
When welding, wear ANSI-  
approved impact safety  
goggles under the Welding  
Helmet. Wear a NIOSH-approved  
respirator and hearing protection when  
welding.  
The Welding Helmet is not suitable for  
laser welding or Oxyacetylene Welding/  
Cutting processes.  
8. Stay alert. Watch what you are doing,  
use common sense. Do not weld when  
you are tired.  
The Welding Helmet will not protect  
against severe impact hazards.  
9. check for damaged parts. Before  
using any helmet, any part that appears  
damaged should be carefully checked  
to determine that it will operate properly  
and perform its intended function. Check  
for alignment and binding of moving  
parts; any broken parts or mounting  
fixtures; and any other condition that may  
affect proper operation. Any part that is  
damaged should be properly repaired  
or replaced by a qualified technician. Do  
not use the helmet if any switch does not  
operate properly.  
The Welding Helmet will not protect  
against explosive devices or corrosive  
liquids.  
14. Use only at temperatures within the  
operating range for your model as  
stated on the specifications chart in  
this manual.  
10. Replacement parts and accessories.  
When servicing, use only identical  
replacement parts. Use of any other  
parts can render helmet ineffective,  
possibly causing eye damage, and will  
void the warranty. Only use accessories  
intended for use with this helmet.  
Item 67854  
91214  
For technical questions, please call 1-800-444-3353.  
Page 3  
 
Regularly replace the Front Lens  
cover if it becomes cracked,  
scratched, pitted, or otherwise  
damaged.  
WARNING  
• Do not make any modifications to  
either the Auto-Darkening Filter or  
the rest of the helmet, other than  
those specified in this manual.  
Do not use any replacement parts  
other than those specified in this  
manual. Unauthorized modifications  
and replacement parts will void the  
warranty and expose the user to the  
risk of personal injury. Do not open  
or tamper with the Auto-Darkening  
Filter.  
INHALATION HAzARD:  
Welding and plasma cutting produce  
TOxIc FUMES.  
Exposure to welding or cutting exhaust  
fumes can increase the risk of developing  
certain cancers, such as cancer of the  
larynx and lung cancer. Also, some  
diseases that may be linked to exposure  
to welding or plasma cutting exhaust  
fumes are:  
16. Do not place the Welding Helmet’s  
Auto-Darkening Filter on a hot  
surface.  
• Early onset of Parkinson’s Disease  
• Heart disease  
• Ulcers  
• Damage to the reproductive organs  
• Inflammation of the small intestine or  
17. SEVERE pERSONAL INjURY and/  
or bLINDNESS may occur if the user  
fails to follow the aforementioned  
warnings and/or fails to follow the  
operation instructions.  
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.  
15. Maintain the helmet and lens correctly  
to help ensure reliable protection.  
• Clean filter’s surfaces regularly.  
Keep sensors and solar cells clean  
using a clean lint-free tissue/cloth. Do  
not use any solvents on filter’s screen or  
helmet components. Protect filter from  
liquid and dirt contact. Do not immerse  
the filter in water.  
Should the Auto-Darkening Welding  
Helmet not darken upon striking  
an arc, stop welding immediately  
and have the helmet checked by an  
authorized service technician.  
Item 67854  
91214  
Page 4  
For technical questions, please call 1-800-444-3353.  
 
SpEcIFIcATIONS  
Description  
Auto-Darkening Welding Helmet  
Power Source  
Operating Temp.  
Resting Shade  
Shade Range  
UV/IR Protection  
Lens Type  
Solar powered cells with battery assistance (not rechargeable)  
23° to 131° F  
Shade # 4  
9 to 13  
up to DIN 16 at all times  
ANSI Z87.1-2003 approved  
3.86” x 1.73”  
Viewing Area  
For Processes including MIG/Flux welding, stick welding, TIG welding (10+  
amps), plasma arc welding/cutting and air carbon cutting. Not for Laser Welding or  
Oxyacetylene Welding/Cutting  
Welding Protection  
Types  
Lens Switching  
Speed (Clear to Dark)  
1/25,000 second  
Sensitivity Adjustment  
Grinding Mode  
High / Low  
Transforms helmet to grinding shield without shade flickering  
Fully Automatic  
Power ON / OFF  
Shell Material  
High Impact-Resistant Plastic Polyamide Nylon  
-4° to 158° F  
Storing Temperature  
Ratcheting headband with replaceable padded sweatband, spare External cover lens,  
2 independent arc sensors which reduce the risk of blocked sensors during out-of-  
position welding, variable Shade Control Knob adjusts from #9 to #13 with a #4 resting  
shade, Delay Control Switch, Sensitivity Control Switch  
Features  
Weight  
1.3 lb.  
Unpacking: When unpacking, make sure all the parts are included. Refer to the Parts List and  
Assembly Diagram at the end of this manual. If any parts are missing or broken, please  
call Harbor Freight Tools at 1-800-444-3353 as soon as possible.  
SHADE GUIDE cHART  
Arc current (Amperes)  
Welding  
process  
10  
20  
40  
80  
125  
175  
250  
300  
450  
350 500  
5
15  
30  
9
60  
10  
100  
150  
225  
275  
Stick/Arc  
11  
12  
12  
13  
13  
Mild Steel MIG  
(argon shielded)  
10  
11  
Mild Steel MIG,  
10  
11  
10  
12  
11  
12  
10  
13  
(CO2 shielded)  
Aluminum MIG  
TIG  
12  
13  
10  
11  
13  
12  
Flux Core  
11  
12  
13  
Plasma Cutting  
Plasma Welding  
11  
12  
13  
9
10  
11  
13  
Item 67854  
91214  
For technical questions, please call 1-800-444-3353.  
Page 5  
 
Shade Number  
& Grinding Mode Selection  
FUNcTION  
The Auto-Darkening Welding Helmet  
is designed to protect the eyes and face  
from sparks, splatter, and harmful radiation  
under normal welding conditions. The Auto-  
Darkening Filter automatically changes from  
a clear state to a dark state when an arc is  
struck, and it returns to the clear state when  
welding stops.  
Shade Number  
Shade  
Control  
Knob  
bEFORE WELDING  
Tension  
Adjustment  
Knob  
The Auto-Darkening Welding Helmet  
comes ready for use. The only things you  
need to do before welding are to remove the  
protective film from both sides of the lens (if  
not already done), adjust the position of the  
headband, select the correct shade number  
for your application, and test the helmet for  
proper operation as described following.  
Figure 1  
Select the shade number you need (see  
Shade Guide Chart on the previous  
page) by turning the Shade Control  
Knob. Be sure that the shade number of  
the Welding Helmet is the correct shade  
number for your application.  
Check the Front Cover Lens to makes  
sure that it is clean, and that no dirt is  
covering the two sensors on the front of the  
Filter Cartridge. Also check the Front/Inside  
Cover Lens and the Front Lens Retaining  
Frame, and make sure that they are secured  
in place.  
Note: If a selection of shades are  
recommended for your application, try  
the darkest setting first.  
The shade number can be set from 9 to  
13 by turning the Shade Control Knob  
until the arrow points to the desired  
shade number. See Figure 1.  
Remember to check with the Shade  
Guide Chart on the previous page to  
determine the proper shade number for  
your application.  
Inspect all operating parts before  
each use for signs of wear or damage. Any  
scratched, cracked, or pitted parts should be  
replaced immediately before using again to  
avoid severe personal injury.  
IMpORTANT NOTE: Test the helmet auto-  
darkening filter lens before welding.  
While wearing the helmet, briefly  
strike an arc, keeping your face and  
eyes turned slightly away, and to one  
side. The lens should darken evenly  
when not directly facing the arc. If it  
does not darken properly, do not use  
the Welding Helmet.  
Item 67854  
91214  
Page 6  
For technical questions, please call 1-800-444-3353.  
 
Grinding mode setting:  
Once the Headband is properly adjusted,  
lower the Helmet over your face until the  
proper angle is found. Then turn the Tension  
Adjustment Knobs on either side of the  
helmet, locking the helmet’s angle in place.  
See Figure 3.  
GRIND  
9
13  
10  
product Features  
Time Delay and Sensitivity:  
Figure 2  
12  
11  
At the moment the welding operation  
is started, the filter screen automatically  
changes from clear to dark.  
To change to Grinding Mode, rotate the  
Shade Control Knob counterclockwise to  
Grind. This turns off the shade function  
so the helmet lens stays clear. Use  
this function to provide protection while  
grinding.  
The operator can vary the amount of  
time it takes the filter to return to a clear state  
and the sensitivity of the sensor using the  
controls inside the helmet.  
cAUTION: Be sure to set the helmet to the  
proper shade setting before welding  
again.  
Dark to clear Adjustment Switch  
Adjusts the speed the lens changes.  
In FAST position: .25 - .45 seconds  
In SLOW position: .65 - .80 seconds  
Adjusting Headband  
Adjust the Headband so that the helmet  
is seated securely on your head as low as  
possible and close to your face.  
ANSI Z87.1-2003  
Variable Shade 4/9-13  
SKU 67854  
SENSITIVITY  
DELAY TIME  
SLOW <  
> FAST  
LOW <  
> HIGH  
Ratcheting  
Headband  
Sensitivity Adjustment Switch  
Adjusts the amount of light needed to  
activate the lens to darken.  
Knob  
Figure 4  
Tension  
Top  
Adjustment  
Strap  
Knob  
The Sensitivity setting changes the  
amount of light needed to make the filter  
react.  
Figure 3  
Solar cells:  
Adjust the Headband width by turning the  
Ratcheting Headband Knob to make sure the  
Front Cover Lens is aligned with your eyes.  
This Welding Helmet utilizes high  
performance solar cells as power supply, and  
has two built-in 3V lithium batteries as power  
backup. No change of battery is needed.  
Under normal welding conditions, users can  
expect a battery lifetime of more than 6 years.  
Adjust the Headband height by tightening  
or loosening the top strap until the Helmet fits  
snug on your head.  
Item 67854  
91214  
For technical questions, please call 1-800-444-3353.  
Page 7  
 
Shades  
User-selectable variable shades from  
9 to 13 are adjusted at the turn of a shade  
knob (shade variable). This product is in  
full conformity with related DIN, ISO, EN379  
safety standards and ANSI Z87.1-2003  
standard.  
cOMMON pRObLEMS AND  
REMEDIES  
1. Irregular Darkening or Dimming  
a. Headband has been set unevenly on  
both sides of helmet (unequal distances  
from the eyes to filter’s lens).  
b. Reset Headband to reduce difference in  
Filters  
distances to filter, if necessary.  
The ultra high performance of UV and IR  
Auto-Darkening filters provides to user’s eyes  
and face full protection against UV and IR  
radiation during entire welding process, even  
in clear state. The UV/IR protection level is  
up to shade 16 at all times.  
2. Auto-Darkening Filter Does Not  
Darken Or Flickers  
a. Front Cover Lens is soiled or damaged  
(change the cover lens).  
b. Sensors are soiled (clean surface of the  
sensors).  
Magnifying cheater Lens  
c. Welding current is too low (turn Dark to  
Clear Adjustment switch to the “SLOW”  
position, if necessary).  
3. Slow Response  
Operating temperature is too low (do not  
use at temperatures below 23° F).  
4. poor Vision  
a. Front/Inside Cover Lens and/or filter  
soiled (change it).  
Figure 5  
b. Insufficient ambient light.  
A Cheater Lens (sold separately) can  
be attached to the inside of the helmet by  
unhooking the wire bar at the bottom of the  
Inside Lens Cover, sliding the Cheater Lens in  
place, then securing it with the wire bar.  
c. Shade number is incorrectly set (reset  
shade number).  
5. Welding Helmet Slips  
Headband is not adjusted properly (must  
be lowered).  
WARNING: Stop using the Helmet  
immediately if any of the  
mentioned problems cannot be  
corrected.  
Item 67854  
91214  
Page 8  
For technical questions, please call 1-800-444-3353.  
 
4. Do not remove the auto-darkening  
filter from the Auto-Darkening Welding  
Helmet. Do not try to open the filter.  
LENS AND HELMET  
MAINTENANcE  
Replace the Front Lens Cover if it is  
damaged (cracked, scratched, soiled or  
pitted).  
5. Storage temperature: -4° to 158° F.  
Figure 6  
1. To Replace the Cover:  
a. Remove the Front Lens Cover by gently  
pulling up the central part of the Lens.  
See Figure 6. If the unit has a frame  
over the front of the lens, lift up on the  
tab at the bottom of the frame to access  
the lens cover.  
b. Remove the protection film from both  
sides of the new Lens if it comes with a  
film covering. Place the new Lens into  
place by bending it slightly and sliding  
it between the tabs at each side of the  
lens until it snaps into place.  
c. Make sure that the Lens is securely  
installed. If the unit has a frame, make  
sure that the frame is snapped securely  
into place.  
2. Clean the Filter Lens with a clean lint-  
free tissue or cotton cloth.  
3. Do not immerse the lens in water or  
any other liquid. Do not use abrasives,  
solvents or oil based cleaners.  
Item 67854  
91214  
For technical questions, please call 1-800-444-3353.  
Page 9  
 
pARTS LIST AND ASSEMbLY DIAGRAM  
part  
Description  
Shell (Welding Mask)  
Front Cover Lens  
Auto-Darkening Filter  
Inside Cover Lens  
Flat Washer  
Qty  
1
1
1
1
2
2
2
part  
Description  
Qty  
1
2
3
4
5
6
7
8
9
Washer  
Tension Adjustment Knob  
2
2
2
1
1
1
10 Screw  
11 Ratcheting Headband  
12 Sweatband  
Limitation Washer  
Large Limitation Washer  
13 Shade Control Knob  
Note: Some parts are listed and shown for illustration purposes only and are not available  
individually as replacement parts.  
pLEASE READ THE FOLLOWING cAREFULLY  
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM IN THIS MANUALAS A  
REFERENCETOOLONLY. NEITHERTHE MANUFACTURER NOR DISTRIBUTOR MAKESANYREPRESENTATION  
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. IN  
FACT, THE MANUFACTURER AND/OR DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS  
REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIEDAND LICENSED TECHNICIANSAND NOT BYTHE  
BUYER. THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE  
ORIGINALPRODUCT OR REPLACEMENT PARTS THERETO, ORARISING OUT OF HIS OR HER INSTALLATION  
OF REPLACEMENT PARTS THERETO.  
Item 67854  
91214  
Page 10  
For technical questions, please call 1-800-444-3353.  
 
LIMITED 90 DAY WARRANTY  
Harbor Freight Tools Co. makes every effort to assure that its products meet high quality and  
durability standards, and warrants to the original purchaser that this product is free from defects in  
materials and workmanship for the period of 90 days from the date of purchase. This warranty does  
not apply to damage due directly or indirectly, to misuse, abuse, negligence or accidents, repairs  
or alterations outside our facilities, criminal activity, improper installation, normal wear and tear, or  
to lack of maintenance. We shall in no event be liable for death, injuries to persons or property, or  
for incidental, contingent, special or consequential damages arising from the use of our product.  
Some states do not allow the exclusion or limitation of incidental or consequential damages, so  
the above limitation of exclusion may not apply to you. THIS WARRANTY IS EXPRESSLY IN LIEU  
OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF  
MERCHANTABILITY AND FITNESS.  
To take advantage of this warranty, the product or part must be returned to us with transportation  
charges prepaid. Proof of purchase date and an explanation of the complaint must accompany the  
merchandise. If our inspection verifies the defect, we will either repair or replace the product at our  
election or we may elect to refund the purchase price if we cannot readily and quickly provide you with  
a replacement. We will return repaired products at our expense, but if we determine there is no defect,  
or that the defect resulted from causes not within the scope of our warranty, then you must bear the  
cost of returning the product.  
This warranty gives you specific legal rights and you may also have other rights which vary from  
state to state.  
3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-3353  
Item 67854  
91214  
For technical questions, please call 1-800-444-3353.  
Page 11  
 

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