Walter SURFOX 304 User manual

SURFOX 304
User’s guide
Manuel de l’utilisateur
Manual del usuario
Manual do Usuário
SURFOX website
(Link to surfox.com)

SURFOX 304 User’s Guide 1
Table of contents
Table of contents
1 Introduction 2
2 Safety instructions 3
3 Equipment controls 4
A) Control panel pictograms 4
B) Front and back view of the machine 5
C) Wand control buttons 6
D) Fume elimination system 6
E) Tip repositioning (comfort for operator) 6
4 Control panel 7
A) Main power switch 7
B) Wand and accessory selector knob 7
C) Current mode selector knob 7
D) Solution pump switch 7
E) Indicator lights 7
F) Accessory outlet 7
5 Start-up procedure 8
A) What is included in the box 8
B) Filling the reservoir 8
C) Connecting air supply 8
D) Plugging in the power cord 8
E) Plugging in the ground clamp 8
6 Using the large wand to electrochemically
clean, polish and passivate 9
A) Selecting the proper wand and accessory 9
B) Selecting the proper current type, AC or DC and
proper current level, STD or MAX 9
C) Selecting the proper pumping mode 9
D) Cleaning and passivating 9
E) Neutralizing 9
7 Large wand accessories 10
A) Selection and mounting of the cleaning
pads and tips 10
B) PTFE clamp rings 12
C) SURFOX electrolyte solutions 12
D) Mounting a cleaning pad 12
8 Using the micro wand (optional) to clean, polish
and passivate 13
A) Selecting the proper wand and accessory 13
B) Selecting the proper current type, AC or DC and
proper curent level, STD or MAX 13
C) Manual pumping mode 13
D) Cleaning and passivating 13
E) Neutralizing 13
9 Using the marking/etching wand (optional) 14
A) Marking kits 14
B) Selecting the proper wand and accessory 14
C) Selecting the proper current type, AC or DC and
proper curent level, STD or MAX 14
10 Neutralizing 15
A) Directions for neutralizing SURFOX
electrolyte cleaning solutions 15
B) SURFOX weld cleaning and neutralization
procedure 15
11 Safety features 16
A) Sparks on the tip/work piece 16
B) Internal temperature 16
C) AC/DC current basics 16
D) AC/DC settings on the SURFOX machine 17
E) Welds that cannot be cleaned 17
12 Technical data 18
13 Warranty and service 18
A) Warranty policy 18
B) Repair and service 18
Version française 20
Versión española 39
Versão Português 58

2
1
Congratulations on purchasing the finest electrochemical
weld cleaning and passivation equipment available today.
WALTER’s SURFOXTM weld cleaning equipment quickly,
easily and cost effectively removes the heat tint from heat
affected zones while completely passivating the stainless
steel surface.
Our new generation of SURFOX machines are equipped
with self-regulating inverter boards, automatically monitoring
and adjusting the current so as to ensure maximum
cleaning effectiveness without loss of productivity.
Before starting, please read the SURFOX owner’s manual
completely as we take you step-by-step through the start-
up, operating and maintenance procedures of your new
SURFOX equipment. Your new SURFOX machine has been
built with extra durability to stand up to the heavy demands
of industrial use. However, like any piece of electrical
equipment, care and safety should always be taken when
using and maintaining this valuable investment. With proper
care and maintenance your SURFOX equipment will provide
years of dependable service.
To learn more about other WALTER products, visit our
website: www.walter.com
1.1 General Information
This manual provides all the information required for a safe
installation, start-up and operation of the machine, along
with troubleshooting and maintenance instructions.
The manual is an integral part of the machine and must be
kept carefully with the machine until it is disposed of, to
allow for reference to future updates. Should your copy of
the manual be lost or unreadable, you can request a new
copy from: WALTER - walter.com or surfox.com
The present manual reflects the condition of the machine
at the time of manufacture and may not be deemed
inadequate in case of updates due to subsequent
experience.
WALTER reserves the right to update its products and
manuals without prior notification to users of previously
manufactured machines.
WALTER is not liable for any consequences of incorrect use
of its products, for example:
uIncorrect use of the machine or use by untrained
persons;
uUse in violation of the reference standards;
uIncorrect installation;
uUnsuitable main power supply;
uIncorrect maintenance;
uIncorrect maintenance;unauthorized modifications and
tampering;
uIncorrect maintenance;use of non-original spare parts
or spare parts not specified as suitable for the model in
question;
uIncorrect maintenance;partial or total failure to follow the
instructions;
uUnexpected events;
uAnd any other improper use.
Operation
The SURFOX machine works by an electrochemical
process to clean and passivate welds on stainless steel.
SURFOX electrolyte solutions are phosphoric acid based,
approved for food industry, and are activated by an electri-
cal current to clean welds. The process takes only a few
seconds without damaging or scratching the surface of the
parts to be cleaned.
Your SURFOX 304 machine can clean:
uTIG welds
uPlasma welds
uLaser welds
uSpot welds
uMIG welds
Basics of passivation:
uThe cleaning of the welds is not only for aesthetic
purposes but most importantly for passivation.
uPassivation is the treatment of stainless steel surfaces
to remove contaminants and promote the formation of
a thick and durable protective chromium oxyde layer.
uThis passive layer will insure the corrosion resistance of
stainless steel.
uIf passivation is not done properly, stainless steel and
heat affected zones may start to rust.
Introduction
Introduction

SURFOX 304 User’s Guide 3
2
15. Hold the wand firmly. Do not overreach, maintain good
footing and balance at all times.
16. Before use, all parts should be carefully examined to
determine that the unit will operate properly and
perform its intended function.
17. Parts that are damaged or defective should be repaired
or replaced by a WALTER Authorized Service Center.
18. Do not use the unit if the switch does not turn ON/OFF.
19. Use only the accessories recommended for this
system. Always check accessories before starting to
work and do not use if damaged.
20. CAUTION: WALTER SURFOX electrolyte weld cleaning
solutions contain phosphoric acid and may cause burns
when not handled properly. Avoid skin contact.
First aid Wash affected area with water.
Eye contact Flush with water for 15 minutes lifting
eyelids occasionally. Contact physician if necessary.
Ingestion DO NOT induce vomiting. Rinse mouth,
drink plenty of water and get medical attention.
Refer to WALTER product MSDS or SDS for complete
safety data information on walter.com or surfox.com.
21. Use only WALTER SURFOX electrolyte solutions with
this unit and NEVER mix it with any other products.
22. The use of the fume elimation system (page 6.) is highly
recommended when working in confided areas.
23. Do not use your SURFOX machine on the same struc-
ture when arc welding is in progress. Current could
ground back tot he SURFOX machine and cause irrepa-
rable damage.
24. Store solution in its original container and in a safe
place, out of the reach of children and other unquali-
fied persons. Keep container contents clean. Do not
reuse SURFOX electrolyte cleaning solutions.
25. Do not touch the wand tip or work piece while working
or immediately after use, they may be extremely hot
and could cause serious burns.
26. Do not abuse the power cord. Never pull or lift this unit
by its cord or yank to disconnect it from the receptacle.
Keep the cord away from heat, oil and sharp edges.
Inspect the cord periodically, if damaged, have it re-
placed by a WALTER Authorized Service Center.
27. When not in use, switch OFF and unplug the electrical
cord and air hose (if connected). It must remain un-
plugged when replacing cleaning pads and accessories,
while performing maintenance and before servicing.
28. Store the unit in a dry safe place, out of the reach of
children and other unqualified persons.
WALTER weld cleaning machines are produced in accor-
dance with applicable standards governing the manufac-
ture, performance and safety of industrial products.
WARNING: When using these machines, basic safety
precautions should always be observed to reduce the risk
of fire, electrical shocks and personal injuries.
Before using this machine, read all Safety and
Operating Instructions carefully and save this owner’s
manual for future reference.
1. Read this owner’s manual to familiarize yourself with
this unit’s operation, its particular features, applications
and limitations.
2. This unit is equipped with a 3-conductor power cord
and 3-prong electrical plug, it must be connected to
a correspondingly grounded receptacle.
3. Allow a minimum of 8” clearance around the unit to
keep all air openings clear of any obstruction. Free
airflow through the vent openings is required to
prevent the unit from overheating.
4.
Keep work area clean and well lit. A cluttered environ-
ment invites accidents. Remove any material that
may be ignited by sparks. Do not use this tool when
flammable liquids or gases are present. Keep handles
clean, dry and free from cleaning solution, oil and
grease. Do not use in rain, damp or wet locations.
5. Keep children and other persons at a safe distance
from the work. Make sure no one is under you when
working in high places. Do not let unqualified persons
handle this machine.
6. When working, always wear appropriate clothing
and safety gear, such as suitable and safety approved
chemical resistant gloves, overalls, safety shoes, etc.
7. Always wear approved safety goggles.
8. During the cleaning process, the wand tip and work
piece can reach very high temperatures, allow to cool
before coming in contact with exposed skin.
9. Avoid inhalation of fumes, use only in well ventilated
areas. Use a respirator, if necessary.
10. All electric shocks can be potentially dangerous.
11. Should you encounter an electrical problem, do not
use the unit until qualified personnel have inspected
the equipment.
12. Never operate the unit without its protective cover.
13. Stay alert at all times when handling this unit. Watch
what you are doing. Use common sense. Do not
operate the tool when you are tired. Never leave it
running unattended.
14. Make sure the switch is in its OFF position before
plugging in or when moving the unit to avoid uninten-
tional starting.
Safety instructions
Safety instructions

4
2
Amperage
Before connecting this unit, check that the amperage
shown on the rating plate is the same as the power supply.
Operating this unit on an amperage other than specified on
its rating plate may result in personal injury to the user and
damage the unit.
Preventive maintenance
After use, allow the tip to cool and remove the cleaning pad .
Neutralize with SURFOX-N and rinse the cleaning pad and
wand tip with water and dry. Clean dust and dirt deposits
from the exterior of the unit. Keep all airflow vent openings
free of any obstructions. Clean the power cord to prevent
deterioration and check for possible damage to cord and
plug.
Note: Damaged cords must be replaced immediately by
qualified personnel only. Refer to Spare Parts List for the
ordering number.
Transportation
Before transporting the machine, make sure the cleaning
solution reservoir and supply line are completely empty
and all connecting lines disconnected. The machine must
be carefully packed in a suitable container and properly
protected. WALTER will not be held responsible for any
damages resulting from leaked cleaning solution or rough
handling.
Storage
If the machine is to be stored for any length of time, the
cleaning solution reservoir and supply line must be emptied,
cleaning pad removed (neutralized, rinsed and left off) and
the tip neutralized, rinsed and dried. Store in a dry
safe place to avoid damage, especially to the electronic
components.
Waste disposal
Dispose of residual waste in compliance with Federal,
Provincial, State and local environmental regulations. Refer
to WALTER Material Safety Data Sheet of the SURFOX
electrolyte cleaning solutions on walter.com or surfox.com.
Extension cord
When an extension cord is needed, use wire size 14 (AWG)
for up to 50 feet (15 meters) and size 12 (AWG) for 50 to
100 feet (15 to 30 meters).
Safety instructions
Equipment controls
3
Equipment controls
A) Control panel pictograms
Outlet for micro-wand
or marking wand
Indicator for wand tip
power ON
Indicator for high internal
temperature
Indicator for LOW
solution level
Manual pumping mode Automatic pumping mode
Marking wand Micro-wand Large wand
Wand and Accessory
Selector Knob
Current mode selector
STD MAX
MAX STD

SURFOX 304 User’s Guide 5
3
Equipment controls
B) Front and back view of the machine
ON/OFF button
Accessory outlet
Ground connector
Large wand hose
(electrical and solution
supply lines)
Control panel
SURFOX electrolyte solution
filling and reservoir
Cleaning pad mounting unit
Compressed air
connector (for fume
elimination system)
Power cord

6
3
The ON button is used to give power to the cleaning
accessory. When the pumping mode is set to Manual, press
the ON button to activate the pump. Press and keep the
button pressed to get continuous flow of liquid.
However, if the pumping mode is set to automatic, press
the ON button once to activate the pump. To stop the
pump, press the OFF button. When finished working
with the machine (in either mode) make sure to press
the OFF button.
Once the ON button is pressed, there will be continuous
power at the tip until the OFF button is pressed.
The SURFOX 304 machine comes with the integrated fume
elimination system. This system provides for better work-
ing conditions. Although the fumes are non-toxic and non
hazardous, they can be uncomfortable when working in
confined areas.
To activate this feature simply connect a compressed air line
(150 PSI max., 80 PSI min.) to the fitting at the back of the
machine. The fume elimination system is automatically ac-
tivated when the ON button is pressed on the large wand.
The fume elimination system is turned OFF when the OFF
button on the large wand is pressed. If the fume elimination
system is not wanted, simply disconnect the compressed
air line.
The working principle is quite simple and highly effective;
the air comes out through the small openings behind the
cleaning accessory. This preset regulated air pressure con-
denses the vapors out of the air.
The tungsten tip may be rotated from the standard horizon-
tal position to a vertical position or anywhere in between to
make your cleaning as comfortable as possible. To loosen
the right hand threaded fume elimination sleeve, turn tip to
desired position and retighten sleeve.
Important: Always retighten fume elimination sleeve to
ensure a good electrical connection and avoid damaging
the contact points.
Equipment controls
C) Large wand control buttons
Cleaning
Accessory
ON OFF
D) Fume elimination system (patented)
E) Tip repositioning (comfort for operator)
Compressed
air line fitting
Small openings
Cleaning accessory close up

SURFOX 304 User’s Guide 7
4
Control panel
Control panel
A) Main power switch
Turns the main power to the unit ON
and OFF.
B) Wand and accessory selector
knob
Marking and etching wand. Select this
icon when using a marking/etching wand
which has been plugged into the accessory
outlet.
Micro wand. Select this icon when using
the micro wand which has been plugged
into the accessory outlet. Select the right
accessory, either the tungsten insert, the
brush or the large insert.
Large wand. Select this icon when using
the large wand attached to the SURFOX
unit.
C) Current mode selector
Selecting the proper current type, AC
or DC, STD or MAX. AC for cleaning
and passivating the weld. DC for cleaning,
passivating and polishing the weld. STD is
recommended when using the tungsten
inserts and pads, MAX is recommended
when using the brush or the large graphite
insert.
D) Solution pump switch
Manual pumping mode. Choose the man-
ual pumping mode to control the amount of
solution pumping to the tip. Hold the large
wand ON button down to pump solution to
the tip. Release the ON button to stop the
pumping cycle. Always use enough solution
to keep the cleaning pad wet. Too little solu-
tion will reduce the cleaning accessory's life.
Automatic pumping mode. To start the
automatic pumping mode, press the ON
button on the wand. Once it is activated,
it will automatically pump the liquid. The
quantity of liquid can be selected from less
to more. Pumping will continue in this mode
until the OFF button is pressed.
E) Indicator lights
Large wand power ON indicator. The
green light goes ON when the large wand
ON button is pressed and there is power
to the tip. Power to the tip is OFF when the
large wand OFF button is pressed.
If the operating temperature is too high, the
yellow light goes on and the machine will
shut down and restart by itself when the
temperature reaches an acceptable level.
Low solution level indicator. When
solution level is low, the red indicator light
will go on.
F) Accessory outlet
Outlet for optional micro wand or
marking/etching wand. The marking/
etching wand is used to permanently etch/
mark your company name, logo, part
number or other desired information onto
stainless steel surfaces. The micro-wand
is used to access hard to reach areas for
cleaning and passivating, which are too
small for the large wand.
AB
C
D
E
F
STD MAX
MAX STD

8
5
A) What is included in the box
u1 x Large wand and connecting hose
u1 x 48-R 136 Ground clamp
u1 x 54-B 094 Wand Holder for Surfox 204/304
uAccessory kit containing:
• 1 x 54-B 095 Carbon Fiber Brush for Large Wand
• 1 x 54-B 099 Large Wand Brush Adaptor
• 1 x 54-B 101 Triangular Sleeve
• 1 x 54-B 102 Cylindrical Sleeve
• 1 x 48-R 133 Tungsten Insert
(Already mounted on the large wand)
• 3 x 54-B 026 High Conductivity Standard
Cleaning Pads
• 1 x 54-B 002 PTFE Clamping Ring
• 1 x 2.5 mm hexagonal key for changing tungsten insert
• 1 x 5.0 mm hexagonal key for mounting the
wand holder
B) Filling the reservoir
Fill the reservoir in the back of the machine with SURFOX
electrolyte solution. The reservoir holds 1.9 L of SURFOX
electrolyte solution.
C) Connecting air supply
Connect the air supply at the back of the machine. Note
that the maximum allowed pressure is 150 PSI max.,
80 PSI min. (1000 KPa). If the air supply is not plugged into
the machine, the machine will still work but there will not be
any fume elimination.
D) Plugging in the power cord
When an extension cord is needed, use wire size 14 (AWG)
for up to 50 feet (15 meters) and size 12 (AWG) for 50 to
100 feet (15 to 30 meters).
E) Plugging in the ground clamp
Plug the ground clamp at the front of the unit. Attach the
clamp to the work piece being cleaned. The cleaning and
passivating process will not work if the part is not properly
grounded.
Start-up procedure
Start-up procedure
Reservoir Air supply
connector
Ground
clamp

SURFOX 304 User’s Guide 9
6
C) Selecting the proper pumping mode
Manual pumping mode. Choose the manual pumping
mode to control the amount of solution pumping to the tip.
Hold the large wand ON button down to pump solution to
the tip. Release the ON button to stop the pumping cycle.
Always use enough solution to keep the cleaning pad wet.
Automatic pumping mode. To start the automatic
pumping mode, press the ON button on the wand. Once
it is activated, it will automatically pump the liquid. The
quantity of liquid can be selected from less to more.
D) Cleaning and passivating
To clean and passivate, press the large wand ON button.
Make sure the cleaning accessory is saturated with
SURFOX electrolyte cleaning solution before starting to
work. If the cleaning accessory is too dry, it will wear
prematurely. Start working when solution drips from the
cleaning pad.
Do not press hard, let the electrochemical process do the
work. Do not use the cleaning accessory like an abrasive
pad.
WARNING! When using the machine for the first time, there
could be water in the system from factory testing. Adjust
the liquid pump setting to automatic at maximum speed
and let the liquid drip into a disposal cup for 2 minutes
(amount of time required to empty the hose from the tank
to the wand). Then, adjust the liquid pump setting back to
desired pumping speed.
E) Neutralizing
1. Remove any excess of SURFOX electrolyte cleaning
solution using a soft clean cloth.
2. Spray SURFOX-N on the surface.
3. Wipe dry with another soft clean cloth to avoid cross
contamination.
Refer to neutralization procedure in neutralization section for
instructions on how to properly neutralize (page 15).
A) Selecting the proper wand and accessory
B) Selecting the proper current type, AC or DC
and proper current level, STD or MAX
AC for cleaning and passivating the weld.
DC for cleaning, passivating and polishing the weld.
STD is recommended when using the tungsten inserts and
pads, MAX is recommended when using the brush or the
large graphite insert.
WARNING! DC mode is used to polish the weld bead to
match the mirror finish of the parent material.
Note: When using DC setting, the SURFOX electrolyte
solution will become slightly yellow or will darken.
Using the large wand to electrochemically clean, polish and passivate
Using the large wand to electrochemically clean, polish
and passivate
Manual
mode
Automatic
mode
Large
wand
Tungsten
insert
Brush
Large
graphite
insert
TIP! When using the polishing mode (DC), use plenty
of SURFOX electrolyte solution.
STD MAX
MAX STD

10
7
Large wand accessories
Large Wand Accessories
A) Selection and mounting
of the cleaning pads and tips
Tungsten tips are made from high quality tungsten alloy
material. Other materials will not resist the harsh environ-
ment created by the electrochemical process.
WARNING! When the insert is too worn, it can
cause damage to the cleaning pads.
In this example of a worn insert, there are only two
contact points. All the current comes out of these
two points. Because of the lower available cross
section, the temperature will be higher at the two
points and the cleaning pads may become dam-
aged or wear out prematurely.
Note: Be sure to install the O-Ring located at the back of
the insert whenever they are changed.
O-Ring
TIP! Resurface the insert using a bench grinding wheel
or angle grinder.
Tungsten insert 90°
No: 48-R 133
Use with cleaning pads 54-B 026
or 54-B 040 and clamp ring
54-B 002 or boot 54-B 005
Tungsten insert 60°
No: 54-B 016
Use with cleaning pad 54-B 027
and clamp ring 54-B 002 or boot
54-B 006
Narrow tungsten insert 90°
No: 54-B 017
Use with cleaning pad 54-B 028
or 54-B 041 and clamp ring
54-B 020 or boot 54-B 007.
Narrow tungsten insert 60°
No: 54-B 018
Use with cleaning pad 54-B 028
and clamp ring 54-B 020 or boot
54-B 008.
Large pad for graphite
insert for SURFOX 304
Order No.: 54-B 052
Pack of 5
Wand holder for
SURFOX 304 and 204
Order No.: 54-B 094
Large pads for large
graphite insert
Order No.: 54-B 043
90 mm L X 50 mm W X 2 mm H
Pack of 10 with O-ring
Spare brush adaptor for large
wand on SURFOX 304
Order No.: 54-B 099
Tungsten insert kit for
SURFOX 104, 204 and 304
Order No.: 54-B 012
Includes:
1 x 48-R 133
1 X 54-B 017
1 X 54-B 016
1 X 54-B 018
Inserts
Large graphite insert for
SURFOX 204 and 304
Order No.: 54-B 009
45 mm W - Ideal for surface
renewing or restoring, and to
clean the back of MIG welds
Carbon fiber brush for large
wand on SURFOX 304
Order No.: 54-B 095
Without adaptor - Pack of 5
Triangular sleeve for large
wand carbon fiber brush
Order No.: 54-B 101
Cylindrical sleeve for large
wand carbon fiber brush
Order No.: 54-B 102

SURFOX 304 User’s Guide 11
7
Large wand accessories
Cleaning pads are made of a complex blend of highly
conductive synthetic polymer which is very resistant to wear
and which offers excellent thermal stability. For longer life,
remove the cleaning pad and neutralize with SURFOX-N at
the end of each working day.
Cleaning pads are available in four types:
Standard cleaning pad
No: 54-B 026
Use with insert 48-R 133
Inside corners cleaning pad
No: 54-B 027
Use with insert 54-B 016
Narrow cleaning pad
No: 54-B 028
Use with inserts 54-B 017
and 54-B 018
Large cleaning pad
No: 54-B 043
Use with large graphite insert
54-B 009
Features
• Flexible: Can be folded many ways
• Soft on surfaces
• Can be used both sides
• Long lasting
• Highly conductive (4x more conductive than previous
generation)
High conductivity cleaning pads

Note: When mounting classic pads, ensure the Ωsign
is facing up on step 2.
12
7
Large wand accessories
D) Mounting a cleaning pad
1. Squeeze and insert clamp ring.
3. Firmly press in tungsten tip.
2. Insert cleaning pad.
4. Remove tip with installed pad and clamp ring.
B) PTFE clamp rings
PTFE clamp rings are designed to hold the cleaning pads
on the tungsten inserts.
They are available in two sizes:
C) SURFOX electrolyte solutions
Surfox electrolyte solutions are specially formulated phos-
phoric acid cleaning solutions designed to be used only in
Walter SURFOX systems.
Clamp ring for standard cleaning pads
No: 54-B 002
Use with standard inserts. 10 per package.
Narrow clamp ring for narrow pads
No: 54-B 020
Use with narrow inserts. 10 per package.
Cleans up to 3-5 feet per minute.
Cleans up to 3-5 feet per minute.
SURFOX-G
Electrolyte Cleaning Solution
SURFOX-T
Heavy-Duty Electrolyte Cleaning Solution
1.5 L/50.7 oz. No: 54-A 065
STD Pack: 1 STD Carton: 4
5 L/1.3 gal. No: 54-A 066
1 STD Pack: 1 STD Carton: 1
20 L/5.2 gal. No: 54-A 067
STD Pack: 1 STD Carton: 1
208 L/55 gal. No: 54-A 068
STD Pack: 1 STD Carton: 1
1.5 L/50.7 oz. No: 54-A 005
STD Pack: 1 STD Carton: 4
5 L/1.3 gal No: 54-A 006
1 STD Pack: 1 STD Carton: 1
20 L/5.2 gal. No: 54-A 007
STD Pack: 1 STD Carton: 1
208 L/55 gal. No: 54-A 008
STD Pack: 1 STD Carton: 1

SURFOX 304 User’s Guide 13
8
Use the micro-wand to get into tight places where the large
wand cannot go. Plug the micro wand into the accessory
outlet on the front panel.
A) Selecting the proper wand and accessory
When this mode is selected, it automatically cuts the power
to the large wand, stops the solution pump and the fume
elimination system (if connected) from operating. Only
power is provided to the micro wand/marking wand outlet.
Be sure work piece is grounded.
B) Selecting the proper current type, AC or DC
and proper current level, STD or MAX
AC for cleaning and passivating the weld.
DC for cleaning, passivating and polishing the weld.
STD is recommended when using the tungsten inserts and
pads, MAX is recommended when using the brush or the
large graphite insert.
WARNING! DC mode is used to polish the weld bead to
match the mirror finish of the parent material.
Note: When using DC setting, the SURFOX electrolyte solu-
tion will become slightly yellow or will darken.
Using the micro wand (optional) to clean and passivate
Using the micro-wand (optional) to clean, polish and passivate.
54-B 033 and 54-B 133
C) Manual pumping mode
The micro-wand uses a manual pumping mode only. One (1)
press equals one (1) stroke. To pump more liquid, press re-
peatedly. See micro wand instructions for more information.
D) Cleaning and passivating
Screw in SURFOX electrolyte solution 100 ml tube onto the
micro-wand. Make sure the cleaning pad is saturated with
solution before starting to work.
If the cleaning pad is too dry,
it will wear prematurely. Start
working when solution drips
from the cleaning pad.
Do not press hard, let the
electrochemical process do
the work. The cleaning pad is
a bridge between the machine
and the weld. Do not use the
cleaning pad like an abrasive
pad.
E) Neutralizing
1. Remove any excess of SURFOX electrolyte cleaning
solution using a soft clean cloth.
2. Spray SURFOX-N on the surface.
3. Wipe dry with another soft clean cloth to avoid cross
contamination.
Refer to neutralization procedure in neutralization section for
instructions on how to properly neutralize.
TIP! When using the polishing mode (DC), use plenty
of SURFOX electrolyte solution.
STD MAX
MAX STD
Micro-
wand
Tungsten
insert
Brush
Large
graphite
insert

14
Use the marking/etching wand to permanently mark or etch
your company name, logo, part number or other desired
information onto the surface of stainless steel, using perma-
nent or disposable stencils. Plug the marking/etching wand
into the accessory outlet on the front panel.
Using the marking/etching wand (optional)
Marking/etching
wand
B) Selecting the proper wand and accesssory
Turn the selector knob to the marking/etching wand icon.
• 1 marking/etching wand with
graphite insert
• 35 mm X 10 mm
and connecting cable
• 20 marking pads
• 5 O-Rings
• 1 SURFOX-M, 100 ml
solution
• 1 SURFOX-E, 100 ml
solution
PRO kit (54-B 081) includes:
• 1 marking/etching wand with
graphite insert
• 35 mm X 10 mm
and connecting cable
• 20 marking pads
• 5 O-Rings
• 1 SURFOX-M, 100 ml solution
• 1 SURFOX-E, 100 ml solution
• 1 Stencil printer and software
• 1 Stencil paper roll 100 mm (W) X 20 m (L)
C) Selecting the proper current type, AC or DC
and proper current level, STD or MAX
AC for marking using Surfox-M.
DC for etching using Surfox-E.
STD current level is recommended for marking or etching.
TECHNICAL BULLETINS AVAILABLE ON OUR WEB SITE.
A) Marking kits
Standard kit (54-B 080) includes:
9
Using the marking/etching wand (optional)
STD MAX
MAX STD

SURFOX 304 User’s Guide 15
10
Neutralizing
The SURFOX-N liquid is a specially formulated neutral-
izer for the SURFOX electrolyte solutions. It is a powerful
ready-to-use formula which leaves no residue, is non-toxic,
solvent free, water-based and biodegradable.
A) Directions for neutralizing SURFOX
electrolyte cleaning solutions
1. Remove any excess SURFOX electrolyte solution using a
soft clean cloth.
2. Spray SURFOX-N on the surface.
3. Wipe dry with another soft clean cloth.
For more information about this product, refer to product
MSDS or SDS on walter.com or surfox.com.
WARNING! Be sure to wipe off all excess SURFOX electro-
lyte solution from the surface and neutralize otherwise the
inorganic salt from the phosphoric acid will adhere to the
surface and cause deposits.
B) SURFOX weld cleaning and neutralization
procedure
Clean the weld using the SURFOX machine and SURFOX
electrolyte solutions. Work only 2 feet at a time.
Note: The cleaning pad should be kept moist – not
dripping.
1. After weld cleaning, use a clean cloth or paper towel
and wipe the affected area in a squeegee action from left
to right. Then discard the cloth or paper towel.
After cleaning the weld with the SURFOX weld cleaning
machine, the electrolyte solution must be neutralized.
1. Spray the affected area with SURFOX-N neutralizer.
Allow to sit for 15 seconds on the surface.
2. Use a clean cloth or paper towel and wipe the affected
area in a squeegee action from left to right. Then discard
the cloth or paper towel.
Note: Failure to neutralize or neutralize properly will result in
clouding, hazing and dulling of the surface.
Neutralizing
Salt deposits due to unproper
neutralization and rinsing.
SURFOX-N neutralizer Part No.
500 ml 54-A 023
5 L 54-A 026
20 L 54-A 027
208 L 54-A 028

16
A) Sparks on the tip/work piece
To avoid short circuits (arcing), the machine automatically
stops when the insert touches the work piece (metal to
metal contact). There is an inverter board that monitors the
voltage every millisecond. If the voltage sharply increases
creating a short, the system will automatically cut the power
to the tip to avoid any damage to the equipment.
To restart the machine, simply press the large wand ON
button.
WARNING! To avoid drawing too much amperage and
automatically stopping the power to the tip, make sure that
you touch only one surface at a time. The machine is set
to work at a maximum of 30 amps. If the amperage goes
above 30 amps, the machine automatically shuts down. C) AC/DC current basics
Alternating Current (AC) flows one way, then the other
way, continually reversing direction. An AC voltage is con-
tinually changing between positive (+) and negative (-).
Direct Current (DC) always flows in the same direction, but
it may increase and decrease. A DC voltage is always posi-
tive, but may increase and decrease.
B) Internal temperature
To protect the internal components of the machine, there
are temperature sensors inside the machine. If the operating
temperature is too high, the machine will shut down and re-
start by itself when the temperature reaches an acceptable
level. There is an internal fan inside the machine to keep all
the components cool.
WARNING! The inside temperature can increase for many
reasons: high ambient temperature, lack of proper air circu-
lation around the machine, fluctuations in voltage, electrical
set-up in the shop, etc.
Example: On a flat surface, the amperage is around
24 amps. The contact surface area is relatively small.
Example: An internal angle, which if you touch 2 sides
simultaneously, the contact surface area is doubled, amper-
age goes above 30 amps and the machine stops.
Note: Automatic shut off if ground is not detected within
20 seconds.
Safety features
11
Safety features

SURFOX 304 User’s Guide 17
11
Safety features
D) AC/DC settings on the SURFOX machine
Example of cleaning and passivation with SURFOX in AC
mode:
Example of cleaning and passivation with SURFOX in DC
mode:
E) Welds that cannot be cleaned
If the area around the weld is black (not blue) from contami-
nation, this is a problem of high heat generated during the
welding process. The contaminated areas do not conduct
electricity. If there is no conductivity in the material, the
SURFOX system cannot work.
If there are two welds on top of the other, the structure of
the material has been seriously altered. These areas may
not be cleaned.
The quality of the weld is critical. The better the weld, the
easier it will be to clean.
Oxide
layer to be
removed
Oxide
layer to be
removed Alteration of the
material due to
the DC setting
Cleaning and passivation is
perfect. Cleans every crack in
the material.
Cleaning and passivation is
perfect. Cleans every crack in
the material.
BEFORE
BEFORE
AFTER
AFTER
Microscopic view of the material
Microscopic view of the material

18
1312
Technical data
MODEL: SURFOX 304
PART NUMBER: 54-D 314
INPUT VOLTAGE: 120 V, 50/60 Hz
OUTPUT VOLTAGE: 30 V, AC/DC
INPUT CURRENT: 7.5 Amps
OUTPUT CURRENT: 30 Amps Max, AC/DC
MAX. OUTPUT VOLTAGE: 33 V, AC/DC
DIMENSIONS: 525 mm x 370 mm x 250 mm
(20-2/3” x 9.84” x 14.57”)
RESERVOIR CAPACITY: 1.9 L
WEIGHT: 22 kg (48.5 lbs.)
INPUT AIR PRESSURE: 150 PSI max., 80 PSI min.
A) Warranty policy
All WALTER SURFOX cleaning systems and accessories
are inspected and tested before shipment and are war-
ranted to be free from any defect in material and faulty
workmanship. Should any malfunction occur within six (6)
months from the date of original purchase, return the com-
plete system prepaid with proof of purchase, to the near-
est WALTER Authorized Service Center. If an examination
shows that the malfunction was caused by defective mate-
rial or faulty workmanship, WALTER will repair (or at our
option, replace the unit) without charge. This warranty does
not apply when; normal maintenance is required, repairs or
replacements have been made or were attempted by any-
one other than WALTER authorized service personnel, and
does not cover any damage caused by accidents, modifica-
tions, use of improper accessories, abuse or misuse, which
also includes overloading the tool beyond its rated capacity
as well as its continued use after partial failure. No other
warranty, written or verbal, is authorized.
In no event shall WALTER be liable for any indirect, inciden-
tal or consequential damages from the sale of the product.
This disclaimer applies both during and after the term of this
warranty.
This warranty gives you specific rights. The provisions
contained in this warranty are not intended to limit, modify,
take away from, disclaim or exclude any warranties set forth
in any Provincial or State legislation. To the extent required
by law, the provisions in any Provincial, State or Federal
legislation with respect to warranties take precedence over
the provisions in this warranty.
B) Repair and service
When shipping:
• Drain the SURFOX electrolyte solution from the reservoir
• Use original shipping case
• Use sufficient packing
• Ship on a small pallet
• Give detailed description of the problem as well as
company name, address, phone and fax numbers and
contact person
Warranty and service
Warranty and serviceTechnical data