Stark 55016 Original instruction manual

230V 195AMP DUAL MIG195 WELDING WELDER
SAVE THIS MANUAL: KEEP THIS MANUAL FOR SAFETY WARNINGS, PRECAUTIONS, ASSEMBLY,
OPERATING, INSPECTION, MAINTENANCE AND CLEANING PROCEDURES. WRITE THE PRODUCT’S
SERIAL NUMBER ON THE BACK OF THE MANUAL NEAR THE ASSEMBLY DIAGRAM (OR MONTH
AND YEAR OF PURCHASE IF PRODUCT HAS NO NUMBER).
OWNER’S MANUAL AND SAFETY INSTRUCTIONS
ITEM: 55016
FOR QUESTIONS PLEASE CALL OUR CUSTOMER SUPPORT: [phone] MON-FRI 9AM TO 3PM PSTFOR QUESTIONS PLEASE CALL OUR CUSTOMER SUPPORT: [phone] MON-FRI 9AM TO 3PM PST

IMPORTANT SAFETY INFORMATION
GENERAL SAFETY WARNINGS
Read all safety warnings and instructions. Failure to follow the warnings and instructions
may result in electric shock, re and/or serious injury. Save all warnings and instructions for
future reference.
SAFETY
The warnings, precautions, 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. Read carefully and understand all ASSEMBLY AND OPERATIONC INSTRUCTIONS
before operating. Failure to follow the safety rules and other basic safety precautions may result in
serious personal injury.
Stay alert, watch what you are doing, and use common sense when operating the tool. DO NOT use
the tool while you are tired or under the inuence of drugs, alcohol, or medication.
Wear the proper personal protective equipment when necessary. Use ANSI Z87.1 compliant safety
goggles (not safety glasses) with side shields. Leather leggings, re resistant shoes or boots should be
worn when using this product This applies to all persons in the work area. Keep clothing free of grease,
oil, solvents, or any ammable substances Wear dry, insulating gloves and protective clothing.
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Read and understand all instructions. Failure to follow all instructions may result in serious injury
or property damage.
DO NOT allow persons to operate or assemble the product until they have read this manual and
have developed a thorough understanding of how it works.
DO NOT modify this product in any way. Unauthorized modication may impair the function and/or
safety and could affect the life of the product. There are specic applications for which the product
was designed.
Use the right tool for the job. DO NOT attempt to force small equipment to do the work of larger
industrial equipment. There are certain applications for which this equipment was designed. This
product will be safer and do a better job at the capacity for which it was intended. DO NOT use
this equipment for a purpose for which it was not intended.
Inspect the work area before each use. Keep work area clean, dry, free of clutter, and well-lit.
Cluttered, wet, or dark work areas can result in injury.
Keep children and bystanders away from the work area while operating this product. DO NOT
allow children to handle the product.
Check for damaged parts before each use. Carefully check that the product will operate properly and
perform its intended function. Replace damaged or worn parts immediately. Never operate the
product with a damaged part.
Always keep guards in position, in good working order, correctly adjusted and aligned. Never attempt
to use a power tool without any guard supplied with it.

IMPORTANT SAFETY INFORMATION
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INHALATION HAZARD: 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 cutting exhaust fumes are: Early onset of Parkinson’s Disease • Heart
disease • Ulcers • Damage to the reproductive organs • Inammation 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.
Keep head out of fumes. DO NOT breathe exhaust fumes
Use enough ventilation, exhaust at arc, or both, to keep fumes and gases from breathing zone and
general area. If engineering controls are not feasible, use an approved respirator.
Always check to see that keys and adjusting wrenches are removed from power tool before turning on.
Standing on your power tool or its stand could cause serious injury if the tool is tipped or if the cutting tool
is accidentally contacted. DO NOT store materials above or near the tool so that it is necessary to stand
on the tool or its stand to reach them.
Feed work into a blade or cutter against the direction of rotation of the blade or cutter only.
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.
Connect to grounded, GFCI-protected power supply only.
People with pacemakers should consult their physician(s) before use. Electromagnetic elds in close
proximity to heart pacemaker could cause pacemaker interference or pacemaker failure.
DO NOT expose welders to rain or wet conditions. Water entering a welder will increase the risk of
electric shock.
DO NOT abuse the cord. Never use the cord for carrying, pulling or unplugging the welder. Keep cord
away from heat, oil, sharp edges or moving parts. Damaged or entangled cords increase the risk of
electric shock.
Insulate yourself from the work piece and ground. Use non-ammable, dry insulating material if possible,
or use dry rubber mats, dry wood or plywood, or other dry insulating material large enough to cover your
full area of contact with the work or ground.
Clear away or protect ammable objects. Remove or make safe all combustible materials for a radius
of 35 feet (10 meters) around the work area. Use a re resistant material to cover or block all open
doorways, windows, cracks, and other openings.
ALWAYS keep a re extinguisher nearby whenever operating the machine.
DO NOT operate welders in atmospheres containing dangerously reactive or ammable liquids, gases,
vapors, or dust. Provide adequate ventilation in work areas to prevent accumulation of such substances.
Welders create sparks which may ignite ammable substances or make reactive fumes toxic.
If working on a metal wall, ceiling, etc., prevent ignition of combustibles on the other side by moving the
combustibles to a safe location.

DO NOT weld or cut on materials having a combustible coating or combustible internal structure, as in
walls or ceilings, without an approved method for eliminating the hazard.
IMPORTANT SAFETY INFORMATION
DO NOT dispose of hot slag in containers holding combustible materials.
After welding, make a thorough examination for evidence of re. Be aware that easily visible smoke or
ame may not be present for some time after the re has started.
DO NOT apply heat to a container that has held an unknown substance or a combustible material whose
contents, when heated, can produce ammable or explosive vapors. Clean and purge containers before
applying heat. Vent closed containers, including castings, before preheating, welding, or cutting.
DO NOT use the welder if the switch does not turn it on and off. Any welder that cannot be controlled
with the switch is dangerous and must be repaired.
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.
Prevent unintentional starting. Ensure the switch is in the off position before connecting to power
source or moving the welder.
Store idle welders out of the reach of children and do not allow persons unfamiliar with the welder or
these instructions to operate the welder.
Use the welder and accessories in accordance with these instructions, taking into account the working
conditions and the work to be performed. Use of the welder for operations different from those intended
could result in serious injury or property damage.
DO NOT use the welder for pipe thawing.
Maintain welders. Check for misalignment or binding of moving parts, breakage of parts and any other
condition that may affect the welder’s operation. If damaged, have the welder repaired before use.
Have your welder serviced by a qualied repair person using only identical replacement parts.
Maintain labels and nameplates on the Welder. These carry important information. If unreadable or
missing, contact Stark Tools for a replacement.
Unplug the Welder from its electrical outlet before any inspection, maintenance, or cleaning procedures.
NEVER weld on a pressurized or a closed cylinder.
NEVER allow an electrode holder, electrode, welding torch, or welding wire to touch the cylinder.
Keep cylinders away from any electrical circuits, including welding circuits.
Keep protective cap in place over the valve except when the cylinder is in use.
Use only correct gas shielding equipment designed specically for the type of welding you will do.
Protect gas cylinders from heat, being struck, physical damage, slag, ames, sparks, and arcs.
ALWAYS use proper procedures to move cylinders.
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SPECIFICATIONS AND IMPORTANT INFORMATION
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1. ON/OFF SWITCH
2. OUTPUT SETTINGS
3. AMP SELECTOR
4. EARTH CLAMP
5. TORCH
Variable Feed Speed
Control
Torch With Full On / Off
Safety Control
Automatic Thermal Safety
Protection
Simple to operate-fan cooled
Easily converted to gas
operation
Weld mild steel, aluminum,
stainless steel and cast iron
1X welder machine
1X welding gun
1X Welding Wire
1X welding mask
1X hammer brush
FEATURES CONTENTS
Input voltage: 230V/60Hz AC, single
phase
Welding current: 60 to 190 amps
Duty cycle: 10% @ 180amps, 60% @
74amps, 100% @ 60 amps
Max open circuit voltage: 37v
Wire capacity: 0.031 (0.8mm) steel
& stainless steel, 0.030” to 0.039”
(1.0mm) aluminum, 0.047(1.2mm) ux
core
SPECIFICATIONS
1X torch
1X ground cord
with clamp

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OPERATION
ELECTRICAL SAFETY INFORMATION
The wires in this product are color coded:
BLUE: Neutral (N)
BROWN: Live (L)
GREEN/YELLOW: Earth (E)
As the colours may not correspond with the coloured markings identifying the terminals in your plug,
proceed as follows.
The wire which is coloured blue must be connected to the terminal which is marked with the letter N or
coloured black, the wire which is coloured brown must be connected to the terminal which is marked L
or coloured red.
This appliance must be protected by a suitable fuse.
To prevent re or shock hazard, do not expose this product to rain/water or moisture. There are no
user serviceable parts inside except those referred to in this manual. Always refer servicing to qualied
service personnel. Never remove any part of the casing unless qualied to do so; this unit contains
dangerous voltages.
Use of a residual current device (RCD) will reduce the risk of electric shock.
NEVER CONNECT THE BROWN OR BLUE WIRE TO THE EARTH PIN OF THE 13 AMP PLUG.
IF IN DOUBT CONSULT A QUALIFIED ELECTRICIAN.
THE FOLLOWING INSTRUCTIONS REFER ONLY TO MACHINES WHICH USE GAS.
Cylinder mounting brackets should be tted to the rear of the machine (where provided)
Connect the gas tube by pushing the free end into the connector on the regulator.
To t the gas cylinder to the regulator remove the cover from the cylinder thread, and carefully screw on
the regulator, gas will escape until the regulator is fully tted. Important always remove the gas cylinder
from the regulator when you have nished welding.
To set the gas ow regulator turn the knob fully clockwise and then anti-clockwise half to one turn
depending on welding conditions.
Voltage settings, the machine will have either two or four output settings depending on the model. These
are controlled by the switches on the front panel (see g. A). Switching from one setting to another
automatically increases or decreases the wire speed and therefore weld output. On materials from
0.6mm to 1.3mm select ‘low’ settings and ‘high’ for thicker materials.

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TROUBLESHOOTING

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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. IN FACT, THE MANUFACTURER AND/OR
DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE
UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS, AND NOT BY THE BUYER. THE BUYER
ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL
PRODUCT OR REPLACEMENT PARTS THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION
OF REPLACEMENT PARTS THERETO.
Record Product’s Serial Number Here:
Note: If product has no serial number, record month and year of purchase instead.
Note: Some parts are listed and shown for illustration purposes only and are not available individually
as replacement parts.
PLEASE READ THE FOLLOWING CAREFULLY