Auto Darkening Welding Helmet

Solar Powered
Instruction Manual
 READ BEFORE USING UNPACKING & INSPECTION
It is the owner and/or operator’s responsibility to study all WARNINGS, operating, and maintenance
instructions contained on the product label and instruction manual prior to use of this product. The After opening the carton, unpack your new welding helmet and related parts & accessories. Please
owner/operator shall retain product instructions for future reference. inspect it carefully for any damage that may have occurred during transit. Please check it against the
photograph on carton. If any parts are missing, please call factory customer service at 1-800-386-0191.
The owner and/or operator are responsible for maintenance, maintaining all decals or warning labels and
while in use, maintaining the unit in good working order. If the owner and/or operator are not fluent in Packag e con ten ts:
English, the product warnings and instructions shall be read and discussed with the operator’s native 1 Helmet
language by the purchaser/owner or his designee. Make sure that the operator comprehends its con- 1 Instruction Manual
tents. Safety information shall be emphasized and understood prior to usage. The welding helmet shall
be inspected per the operating instructions. Do not use this product if damaged during shipment, handling or misuse. Do not operate the tool until
the parts have been replaced or the fault rectified. Failure to do so may result in serious personal injury
Users of this welding helmet must fully understand these instructions. Each person using this product or property damage.
must also be of sound mind and body and must not be under the influence of any substance that might
impair their vision, dexterity, or judgment. All damaged parts must be repaired or replaced as needed prior to operating this tool.

Protect yourself and others by observing all safety information. Check to see that all nuts, bolts and fittings are secure before putting this tool
into service. If you have any questions, or require assistance with damaged or
Failure to comply with instructions could result in personal injury and/or property damage! missing parts, please contact our factory customer service department at:

If you encounter any problems or difficulties, please contact our customer service department at: 1-800-386-0191

1-800-386-0191 Please have the model number and date of purchase available for reference when calling.

This manual is intended for your benefit. Please read and follow the safety, main- MODEL NUMBER: (Check box for model number)
tenance and troubleshooting steps described within to ensure your safety and DATE OF PURCHASE: ___________________________
satisfaction. The contents of this instruction manual are based upon the latest product information avail-
able at the time of publication. The manufacturer reserves the right to make product changes at any time
without notice.
GENERAL INFORMATION
SAFETY ALERT
Read and understand this entire instruction manual before attempting to assem- This helmet incorporates recent advances in science and technology including optoelectronics detection,
ble, install, operate or maintain this product. Failure to comply with the instruc- solar power, and microelectronics making it one of the most advanced welding helmets available. Under
tions may result in serious personal injury and/or property damage! normal welding conditions, it will protect the welder's eyes and face from harmful sparks and radiation.
It frees both hands while striking an arc, darkening the lens automatically when an arc is struck and then
The following signal words are used to emphasize safety warnings that must be followed when using this immediately going back to a light state when welding is done. With the time-delay adjustment feature,
welding helmet: the operator can adjust the time for filter to return from a dark state to normal state. With variable
shades ranging from DIN 9 to DIN 13, the amount of darkening can be adjusted accordingly to the job.
Indicates an imminently hazardous situation that, if not avoided, WILL result in The auto darkening lens filters are designed for arc welding and cutting applications and are suitable for
death or serious injury. most arc welding processes including Carbon Arc, Plasma Arc, MIG, TIG, MAG, and SMAW. Fail safe
Indicates a potentially hazardous situation that, if not avoided, COULD result in operation - in the event of electronic failure, the lens shade remains dark at Shade 13, protecting the
death or serious injury. welder against harmful ultraviolet (UV) and infrared (IR) radiation.
Indicates a potentially hazardous situation that, if not avoided, MAY result in
minor or moderate injury.
Indicates important information, which if not followed, MAY cause damage to
equipment.

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 SAVE THESE INSTRUCTIONS IMPORTANT WELDING SAFETY RULES
ARC Welding can be hazardous. Pr otect yourself and others fr om possible
serious injur y or death. Keep childr en away. Pacemaker wear ers should con -
s ult wit h t h eir do ct o r b ef o r e o p e r a t i n g . The following hazards can occur during the normal use of this product:

Read and understand all instructions. Failure to follow all instr uctions included with this product ELECTRIC SHOCK CAN KILL!
could r esult in serious personal injur y and/or property damage. Reduce the risk of death or serious injury from shock. Read, understand and follow ALL
safety instructions. Be sure that everyone who uses this welding equipment or who is a
F o r A d d i t i o n a l s a f e t y i n f o r m a t i o n , i t i s s t r ongl y r e c o m m e n d e d t h a t y o u c o n s u l t t h e f o l l o w i n g s a f e t y bystander in the welding area understands and follows ALL safety instructions as well.
publ ications :

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from American Welding Society, • Do not touch live electrical parts. The electrode and work piece clamp are electrically "hot" when the
550 NW LeJeune Rd, Miami FL 33126 (phone: 305-443-9353 or 800-443-9353, website: www.aws.org). welder is on.

Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, • Wear dry, hole-free insulating gloves and body protection.
American Welding Society Standard AWS F4.1 from the American Welding Society, 550 NW LeJeune Rd,
Miami FL 33126 (phone: 305-443-9353 or 800-443-9353, website: www.aws.org). • Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent
physical contact with the work peice or ground.
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, PO Box 9101, 1
Battery March Park, Quincy, MA 02269-9101 (phone: 617-770-3000, website: www.nfpa.org and • Do not use in damp areas, if movement is confined, or if there is a danger of falling.
www.sparky.org).
• Disconnect input power before installing or servicing this equipment.
Practice for Occupational and Educational Eye and Face Protection, ANSI Standard Z87.1, from American
National Standards Institute, 11 West 42nd St. New York, NY, 10036-8002 (phone: 212-642-4900, web- • Properly install and ground the welder according to its manual and national, state, and local codes.
site: www.ansi.org).
• Always verify the supply ground - check and be sure that input power cord ground wire is properly
Standard for Fire Prevention During Welding, Cutting and Other Hot Work, NFPA Standard 51B, from connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded
National Fire Protection Association, PO Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 receptacle outlet.
(phone: 617-770-3000, website: www.nfpa.org and www.sparky.org).
• Frequently inspect input power cord for damage or bare wiring - replace cord immediately if damaged.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Bare wiring can kill. Do not use worn, damaged, undersized, or poorly spliced cables.
Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from US Government Printing Office,
Superintendent of Documents PO Box 371954, Pittsburgh, PA 15250 (there are 10 Regional Offices - • Turn off all equipment when not in use.
phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).
• Do not drape cables over your body.
Follow all local electrical and safety codes as well as in the United States, the National Electrical
C od e s (NE C) and Occup ation al Safety a nd Heal t h A ct (OSH A ). • If earth grounding of the workpiece is required, ground it directly with a separate cable.

• Do not allow any part of your body to touch the electrode if you are in contact with the ground or
grounded work piece.

• Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according
to manual.

• Always keep all panels and covers securely in place when operating the welder.

• Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as
practical.

• Insulate work clamp when not connected to workpiece to prevent contact with any metal object.

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 IMPORTANT WELDING SAFETY RULES (continued)

FUMES AND GASES CAN BE HAZARDOUS!

Welding produces fumes and gases that are hazardous to your health.
• Keep your head out of the fumes. Do not breathe the fumes. The following hazards can occur during the normal use of this product:
• If inside, ventilate the area and/or exhaust at the arc to remove welding fumes and gases.
• If ventilation is poor, use an approved air-supplied respirator. FLYING METAL can injur e eyes!
• Read the Material Safety Data Sheets (MSDS) and the manufacturer's instructions for metals, consum- Welding, chipping, wire brushing and grinding cause sparks and flying metal. As welds
ables, coatings, cleaners, and degreasers. cool, they can throw off slag.
• Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always • Wear ANSI approved safety glasses with side shields under your welding helmet.
have a trained watchperson nearby. Welding fumes and gases can displace air and lower the oxygen
level causing injury or death. Be sure the breathing air is safe.
• Do not weld in locations near degreasing cleaning, or spraying operations. The heat and rays of the arc HOT PARTS can cause severe burns!
can react with vapors to form highly toxic and irritating gases. • Never touch hot parts bare-handed
• Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is • Allow adequate cooling period before touching work piece.
removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied-
respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.
MA G N ET I C F IE L D S c a n a f f e c t p a c e m a k e r s !
ARC RAYS can burn eyes! Electromagnetic fields (EMF) are generated around electric welding cables and welding
Never look at arc welding without proper eye protection. Arc rays from the welding machines. These EMF's can interfere with some pacemakers. Pacemaker wearers should
process produce intense visible and invisible (ultraviolet and infrared) rays that can burn consult their doctor before going near arc welding, gouging, or spot welding operations.
eyes and skin. Hot sparks fly off from the weld and can burn eyes and skin. To reduce magnetic fields in the workdplace, use the following procedures:
• Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes • Keep cables close together by twisting or taping them.
when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards.) • Arrange electrode and work piece cables to one side and away from the operator.
• Wear approved safety glasses with side shields under your helmet. • Do not coil or drape cables around your body.
• Use protective screens or barriers to protect others from flash and glare; warn others in the area not to • Keep welding power source and cables as far away from operator as practical.
watch the arc. • Connect work clamp to workpiece as close to the weld as possible.
• Wear protective clothing made from durable, flame resistant materials, leather welding gloves and full
foot protection. NOISE can damage hearing!
Noise from some processes or equipment can damage hearing.
W E L DI N G can cau s e fi r e o r e x p l o s i o n ! • Wear approved ear protection if noise level is high.
Welding on closed containers such as tanks, drums or pipes can cause them to explode.
Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equip-
ment can cause fires and burns. Accidental contact of electrode to metal objects can
cause sparks, explosions, overheating or fire. Check and be sure the area is safe before FIRE OR EXPLOSION hazard!
doing any welding. • Do not install or place unit on, over, or near combustible surfaces.
• Always keep a fire extinguisher readily available and watch for fire. • Do not install unit near flammables
• Protect yourself and others from flying sparks and hot metal. • Do not overload building wiring - be sure power supply system is properly sized, rated,
• Do not weld where flying sparks can strike flammable material. and protected to handle this unit.
• Remove all flammable materials from the welding area. If this is not possible, tightly cover them with
approved covers. OVERUSE can cause OVERHEATING!
• Be alert that welding sparks and hot materials from welding can easily go through small cracks and • Allow cooling period; follow rated duty cycle.
openings to adjacent areas. • Reduce current or reduce duty cycle before starting to weld again.
• Do not weld on closed containers such as tanks, drums or pipes unless they are properly prepared • Do not block or filter airflow to unit.
according to AWS F4.1 standards.
• Connect work cable to the work as close to the welding area as practical to prevent welding current C a l i f o r n i a P r o p os i t i o n 65 W a r n i n g s
from traveling long, possibly unknown paths and causing electric shock and fire hazards. PROP Welding or cutting equipment produces fumes or gases which contain chemicals known
•
to the State of California to cause birth defects and, in some cases, cancer. (California
• Never use arc welder to thaw frozen pipes.
• Remove electrode from holder when not in use. 65 Health & Safety Code section 25249.5 et seq.)
• Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and • Battery posts, terminals and related accessories contain lead and lead compounds,
a cap. chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.
• Remove any combustibles such as butane lighters or matches from your person before doing any Wash hands after handling.
welding.

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 WELDING HELMET SAFETY INFORMATION WELDING HELMET PARTS AND COMPONENTS
This helmet is not designed to protect against impact hazards such as fractured
grinding wheels, cutting discs or explosive devices or corrosive agents. Machine 1. Solar cell power supply
guards and eye splash protectors must be used when these hazards are present. 2. Auto Darkening Lens Filter
3. Outer Protection Plate (Repl. part # 41261 for Models 41254 & 41260)
• Failure to read, understand and follow these safety precautions and operating instructions could result (Repl. part # 41264 for 41262, 41265, 41266, 41267)
in severe personal injury, property damage or death. 4. Headband nut
• Do not open or tamper with the lens filter cartridge. 5. Angle adjustment stud
• Keep out of reach of children. 6. DIN Shade adjustment knob
• This helmet is not suitable for overhead welding positions, laser welding or laser cutting applications. 7. Outside sensitivity adjustment knob
• Care must be taken to avoid work positions that expose unprotected areas of the body to harmful
sparks or radiation, either direct or reflected.
• Impact resistant eye protection that meets current ANSI specifications must be worn at all times when
Front Left View
using this helmet.
• Both inner and outer cover lenses must be in place at all times when using this helmet.
• Never use the welding helmet at temperatures outside its operational range 23˚ to 131˚F (-5˚ to + 55˚C).

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HELMET SPECIFICATIONS
ANSI standard #: ANSI Z 87.1-2003
Viewing Area: Model 41254/41260: 3.85" x 1.70" (98mm x 43mm) 2
Viewing Area: Model 41262/41265/41266/41267: 3.86" x 2.17" (98 x 55mm)
Cartridge dimensions: 4.33" x 3.54" x 0.35" (110mm x 90mm x 9mm) 5
UV/IR protection: Up to Shade DIN #16 at all times
Sensitivity: Level of outside sensitivity adjustable from low to high 3
Operation temperature: 23° to 131°F (-5° to + 55°C) 6
Storage temparature: -4° to 158°F (-20° to + 70°C)
Light shade: DIN #4
Dark shade: DIN # 9 - 13 Variable
Power supply: Ssolar cells with 2 built-in 3V lithium back-up batteries
Power on/off: Fully Automatic
Switching time: Light to Dark: 1/30,000 sec. (-5° C – 0.0008 sec.)
Dark to Light: 0.25 ~ 0.8 sec. (short - middle - long)
Total weight: 450 g Front Right View

PREPARATION FOR USE

1. Inspect all parts for signs of damage. Any damaged parts should be replaced prior to use. 7
2. Make sure front Protection Plates, Outer (3) and Inner (9) are securely in place.
3. Remove protective film from Protection Plates.
4. Be sure Lens Filter (2) is clean and free of foreign matter.
5. Use Headband Crown Adjustment (11) and Longitudinal Adjustment (12) to obtain secure fit.
6. Adjust face-to-helmet angle using Angle Adjustment Stud (5). An angle between 10˚ and 12˚ is recom- 5
mended.
7. Select the proper darkening shade for your welding application using the Shade Adjustment Knob (6).
8. Set the Darkening Speed Selector Switch to "Slow" or "Fast" depending on your welding application.

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 WELDING HELMET PARTS AND COMPONENTS CARE AND MAINTENANCE
8. Welding/Grinding function switch 1. Regularly inspect the helmet and lens filter. Scratches or foreign matter on the lens protective plates
9. Dark-to-clear time delay switch can impair vision and should be cleaned or replaced as necessary before using.
10.Inner Protection Plate (Repl. part # 41261 for Models 41254 & 41260) Replacement lens protective plates are available - Part number 41621
(Repl. part # 41264 for 41262, 41265, 41266, 41267) 2. The lens filter may be cleaned with a soft, dry lint free cloth or tissue.
NOTE: DO NOT TOUCH LENS FILTER WITH YOUR HANDS
3. Never place the helmet on or near hot surfaces. Do not store helmet in moist or humid environments.
8 4. The helmet shell may be cleaned with a soft cloth moistened with mild soap and lukewarm water.
Rear View NEVER IMMERSE IN WATER!
(head band omitted 5. Occasionally remove the Sweatband (13) and allow to air out and dry.
for clarity) 9
8
Rear View
(head band omitted
for clarity) 9
TROUBLESHOOTING
Your welding helmet was constructed with the best quality materials and workmanship. With proper care,
it should give years of trouble-free use. However, from time to time, some adjustments may be neces-
sary to ensure peak performance. Use the chart below to locate possible problems and find their solu-
10 tions. If you do not see your problem listed below and still require assistance, please call our customer
service line at 1-800-386-0191.

Symptom Cause Solution

10 Uneven Darkening Headband out of Make sure sweatband is wrapped
adjustment causing evenly around headband
11.Headband crown adjustment band one eye to be closer Make sure headband assembly is
Head band 12.Headband longitudinal adjustment knob to lens than other eye properly aligned to helmet shell
13.Sweatband
Replacement Part#
11
41263 Filter flickers or does Front protection Clean or replace
not darken plate is dirty
Head
Fits: band
41247
Replacement Part# Light sensors are Clean with soft, lint free cloth
11
41254
41263 soiled or dirty
41260
12
41262
Fits: Poor vision through Protection Clean or replace protection plates
41265
41247 lens filter plates or lens dirty
41266
41254 Wipe lens with soft, lint free cloth
13
41267
41260
12
41262 Lighting conditions Use welding helmet only with
41265 are too low adequate lighting
41266
13
41267 Shade number not Check application chart and
matched to current readjust Shade Adjustment Knob
welding application

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 ONE YEAR LIMITED WARRANTY - STAR ASIA-USA, LLC POWER TOOLS

Star Asia-USA, LLC (hereinafter “seller”) warrants to the original purchaser only, that this product will be free from defects in mate-
rial or workmanship for a period of one year from date of purchase for home domestic use.

Warranty Performance
Warranty coverage is conditioned upon purchaser furnishing seller or its authorized service center with adequate written proof of
the original purchase date. Products returned, freight prepaid and insured, to our factory or to an Authorized Service Center will be
inspected and repaired or replaced, at seller’s option, free of charge if found to be defective and subject to warranty. Defective parts
not subject to normal wear and tear will be repaired or replaced, at our option during the above stated warranty periods. In any
event, reimbursement is limited to the purchase price paid. Other than the postage and insurance requirement, no charge will be
made for repairs or replacements covered by this warranty. Under no circumstances shall the manufacturer bear any responsibility
for loss of the unit, loss of time or rental, inconvenience, commercial loss or consequential damages. There are no warranties
which extend beyond the description of the face hereof.

Exclusions
This warranty does not cover parts damaged due to normal wear, abnormal conditions, misapplication, misuse, abuse, accidents,
operation at other than recommended pressures or temperatures, improper storage or freight damage. Parts damaged or worn by
operation in dusty environments are not warranted. Failure to follow recommended operating and maintenance procedures also
voids warranty.

Additional items not covered under this warranty: product failure caused by rain, excessive humidity, corrosive environments or
other contaminants; cosmetic defects that do not interfere with product’s functionality.

This warranty shall not apply when: the product has been used for commercial or rental purposes; defects in materials or work-
manship or damages result from repairs or alterations which have been made or attempted by others or the unauthorized use of
nonconforming parts; this damage is due to abuse, improper maintenance, neglect or accident; or the damage is due to use of the
product after partial failure or use with improper accessories. Warranty does not apply to accessory items such as polishing bon-
nets, saw blades, drill bits, router bits, sandpaper, grinding wheels and other related power tool accessories.

Seller will not be liable for: labor charges, loss or damage resulting from improper operation, maintenance or repairs made by per-
sons other than a Star Asia-USA, LLC Authorized Service Center.

The use of other than genuine Star Asia-USA, LLC Repair Parts will void warranty.

Warranty Disclaimers
NO WARRANTY, ORAL OR WRITTEN, OTHER THAN THE ABOVE WARRANTY IS MADE WITH REGARD TO THIS PRODUCT, ANY
IMPLIED WARRANTIES OF SELLER REGARDING THIS PRODUCT INCLUDING BUT NOT LIMITED TO, THE IMPLIED WARRANTIES
OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE EXCLUDED. BUYER’S OR USER’S REMEDIES ARE SOLE-
LY AND EXCLUSIVELY AS STATED ABOVE. STAR ASIA-USA, LLC SHALL IN NO EVENT BE LIABLE FOR INCIDENTAL, CONSEQUEN-
TIAL, INDIRECT, OR SPECIAL DAMAGES. IN NO EVENT, WHETHER AS A RESULT OF A BREACH OF CONTRACT, WARRANTY, TORT
(INCLUDING NEGLIGENCE) OR OTHERWISE, SHALL SELLER’S LIABILITY EXCEED THE PRICE OF THE PRODUCT WHICH HAS
GIVEN RISE TO THE CLAIM OR LIABILITY. ANY LIABILITY CONNECTED WITH THE USE OF THIS PRODUCT SHALL TERMINATE
UPON THE EXPIRATION OF THE WARRANTY PERIODS SPECIFIED ABOVE.

Limitations on Warranty Disclaimers

Any implied warranties shall be limited in duration to one year from the date of purchase. In some states of the U.S.A. and in some
provinces of Canada there is no limitation for how long an implied warranty is valid, so the aforementioned limitation may not apply
to you.

In no event shall seller be liable for any incidental or consequential damages (including but not limited to liability for loss of profits)
arising from the sale or use of this product. In some states of the U.S.A. and in some provinces of Canada the exclusion or limita-
tion of incidental or consequential damages is not allowed, so the aformentioned limitation or exclusion may not apply to you.

This limited warranty gives you specific legal rights, and you may also have other rights which vary from state to state in the
U.S.A., Canada and the Commonwealth of Puerto Rico. For warranty coverage within other countries, contact your local Star Asia-
USA, LLC dealer or importer.

Distributed by Star Asia-USA, LLC

P.O. Box 58399, Renton, WA 98058
Consumer Service: 800-386-0191
e-mail: info@titan-us.com

©2007 Star Asia-USA, LLC

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