Chicago Electric 91149 User manual

AC/DCTIG WELDER - 200 AMP
Model 91149
ASSEMBLY AND OPERATING INSTRUCTIONS
3491 Mission Oaks Blvd., Camarillo, CA 93011
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manual or any artwork contained herein may be reproduced in any shape or form
withoutthe expresswrittenconsent ofHarbor FreightTools.
For technical questions, please call 1-800-444-3353.
®

PRODUCT SPECIFICATIONS
GENERAL SAFETY RULES
WARNING!
READ AND UNDERSTAND ALL INSTRUCTIONS
Failure to follow all instructions listed below may result in
electric shock,fire,and/or serious injury.
SAVE THESE INSTRUCTIONS
WORK AREA
1. Keep your work area clean and well lit. Cluttered benches and dark areas
invite accidents.
2. Do not operate welding equipment in explosive atmospheres, such as in
the presence of flammable liquids, gases, or dust. Welding equipment
SAVE THIS MANUAL
You will need this manual for the safety warnings and precautions, assembly, operating,
inspection, maintenance and cleaning procedures, parts list and assembly diagram.
Keep your invoice with this manual. Write the invoice number on the inside of the front
cover. Keep this manual and invoice in a safe and dry place for future reference.
When unpacking, check to make sure all the parts shown on the Parts Lists on pages 23
and 26 are included. If any parts are missing or broken, please call Harbor Freight Tools
at the number shown on the cover of this manual as soon as possible.
UNPACKING
SKU 91149 For technical questions, please call 1-800-444-3353. PAGE 2
Item Description
Electrical Requirements Input Voltage: 220V / 60 Hz / 69 Input Amperage
Built-In Thermal Overload Protection
Required Power Cord (not included) Rating: 6 AWG, Maximum length 25’
Must be direct wired to a 220V, 70 Amp, dedicated circuit
Welding Modes (4) AC MMA / DC MMA / AC TIG / DC TIG.
Duty Cycles 40% @ 200 AMPs AC / 60% @ 165 AMPs AC / 100% @ 130 AMPs AC
40% @ 170 AMPs DC / 100% @ 110 AMPs DC
Material Capacity Suitable for all ferrous and non-ferrous metals
Welding Machine Coolant Type Forced Air Cooled
Gun Gas Hose Length 16’ 9-1/2”Long
Ground Clamp Cable Length 16’ 9-1/2”Long
Accessories Welding Gloves / Welding Mask
Chipping Hammer / Wire Brush
Weight 127.05 Pounds
creates sparks which may ignite the dust or fumes.

3. Keep bystanders, children, and visitors away while operating welding
equipment. Distractions can cause you to lose control. Protect others in the
work area from arc rays, sparks, and slag. Provide barriers or shields as
needed.
ELECTRICAL SAFETY
1. This Tig Welder requires the connection of a 220 volt electrical cord (not included)
wired directly from the Welder to a 220 volt, (70 Amp) dedicated electrical circuit.
For safety purposes, a qualified, certified, electrician must do this wiring
connection.
2. Avoid body contact with grounded surfaces such as pipes, radiators,
ranges, and refrigerators. There is an increased risk of electric shock if your
body is grounded.
3. Do not expose welding equipment to rain or wet conditions. Water entering
welding equipment will increase the risk of electric shock.
4. Do not abuse the Power Cord. Keep the Power Cord away from heat, oil,
sharp edges, or moving parts. Replace damaged Power Cords immediately.
Damaged Power Cords increase the risk of electric shock.
PERSONAL SAFETY
1. Stay alert. Watch what you are doing,and use common sense when
operating welding equipment. Do not use welding equipment while tired or
under the influence of drugs, alcohol, or medication. A moment of inattention
while operating welding equipment may result in serious personal injury.
SKU 91149 For technical questions, please call 1-800-444-3353. PAGE 3
2. Dress properly. Do not wear loose clothing or jewelry. Contain long hair.
Keep your hair, clothing, and gloves away from hot or moving parts. Loose
clothes, jewelry, or long hair can be caught in hot or moving parts.
(See page 6, number 3, for recommended safety clothing.)

3. Remove adjusting keys or wrenches before turning on the welding
equipment. A wrench or a key that is left attached to an electrically charged part
of the welding equipment may result in personal injury.
4. Do not overreach. Keep proper footing and balance at all times. Proper
footing and balance enables better control of the welding equipment in
unexpected situations.
TOOL USE AND CARE
1. Use clamps (not included) or other practical ways to secure and support
the workpiece to a stable platform. Holding the work by hand or against your
body is unstable and may lead to loss of control.
2. Do not force the welding equipment. Use the correct equipment for your
application. The correct equipment will do the job better and safer at the rate for
which it is designed.
3. Do not use the power tool if the Power Switch does not turn it on or off.
Any equipment that cannot be controlled with the Power Switch is dangerous and
must be replaced.
4. Store idle welding equipment out of reach of children and other untrained
persons. Welding equipment is dangerous in the hands of untrained users.
5. Maintain welding equipment with care. Keep equipmet clean and dry.
Properly maintained equipment is less likely to malfunction and is easier to
control. Do not use damaged welding equipment. Tag damaged equipment “Do
not use” until repaired.
6. Check for misalignment or binding of moving parts, breakage of parts, and
any other condition that may affect the equipment’s operation. If damaged,
have the equipment serviced before using. Many accidents are caused by
poorly maintained equipment.
SKU 91149 For technical questions, please call 1-800-444-3353. PAGE 4

7. Use only accessories that are recommended by the manufacturer for your
model. Accessories that may be suitable for one type of welding equipment may
become hazardous when used on another type of equipment
SERVICE
1. Equipment service must be performed only by qualified repair personnel.
Service or maintenance performed by unqualified personnel could result in a risk
of injury.
2. When servicing welding equipment, use only identical replacement parts.
Follow instructions in the “Inspection,Maintenance,And Cleaning” section
of this manual. Use of unauthorized parts or failure to follow maintenance
instructions may create a risk of electric shock, burns, or other injury.
ELECTRICAL CONNECTION
ThisTig Welder requires the connection of a 220 volt electrical cord
(not included) wired directly from the Welder to a 220 volt, (70 Amp) dedicated
electricalcircuit. For safety purposes, a qualified, certified, electrician must do
this wiring connection.
WARNING!
SYMBOLOGY
V ~
A
xxxx/min.
no
Double Insulated
CanadianStandards
Association
Underwriters
Laboratories, Inc.
Volts Alternating Current
Amperes
No Load Revolutions
per Minute (RPM)
SKU 91149 For technical questions, please call 1-800-444-3353. PAGE 5
Figure A

SPECIFIC SAFETY RULES
1. Maintain a safe working environment. Keep the work area well lit. Make sure
there is adequate surrounding workspace. Always keep the work area free of
obstructions, grease, oil, trash, and other debris. Do not use the Welder in areas
near flammable chemicals, dusts, and vapors.
2. Maintain labels and nameplates on theWelder. These carry important
information. If unreadable or missing, contact Harbor FreightTools for a
replacement.
3. Prevent eye injury and burns. Wearing and using personal safety clothing and
safety devices reduce the risk of injury. Wear ANSI approved safety impact
eyeglasses with a welding helmut featuring at least a number 10 shade lens
rating. Leather leggings, rubber soled, fire resistant shoes or boots should be
worn when using this Welder. Do not wear pants with cuffs, shirts with open
pockets, or any clothing that can catch and hold molten metal or sparks. Keep
clothing free of grease, oil, solvents, or any other flammable substances. Wear
dry, insulating gloves and protective clothing. Wear an approved head covering to
protect head and neck. Use aprons, cape, sleeves and shoulder covers, and bibs
designed and approved for welding procedures. When welding overhead or in
confined spaces, wear flame resistant ear plugs or ear muffs to keep sparks out of
ears.
4. Avoid overexposure to fumes and gases. Always keep your head out of the
fumes. Do not breathe the fumes. Use enough ventilation or exhaust, or both, to
keep fumes and gases from your breathing zone and general area. Where
ventilation is questionable, have a qualified technician take an air sampling to
determine the need for corrective measures. Use mechanical ventilation to
improve air quality. If engineering controls are not feasible, use an approved
respirator. Work in a confined area only if it is well ventilated, or while wearing an
air-supplied respirator. Follow OSHA guidelines for
Permissible Exposure Limits
(PEL’s) for various fumes and gases. Follow the American Conference of
Governmental Industrial Hygienists recommendations for Threshold Limit Values
(TLV’s) for fumes and gases. Have a recognized specialist in Industrial Hygiene
or Environmental Services check the operation and air quality and make
recommendations for the specific welding situation.
SKU 91149 For technical questions, please call 1-800-444-3353. PAGE 6
5. Do not perform welding or cutting operations near chlorinated hydrocarbon
vapors produced by degreasing or painting. The heat generated by arc rays
can react to form phosgene, a highly toxic gas.
6. Irritation of the eyes, nose, and throat are symptoms of inadequate
ventilation. Take immediate steps to improve ventilation. Do not continue
operations if symptoms persist.

SKU 91149 For technical questions, please call 1-800-444-3353. PAGE 7
7. When welding or cutting in small areas, the operator should be externally
accompanied by another person (standing near the enclosed work area) to
observe accident prevention procedures.
8. When welding or cutting, be aware that high frequency radiation may be
produced which can interfere with radio navigation, safety devices,
computers, and communications equipment. Before operating, have a
qualified technician check out that possibility.
9. Keep high frequency source doors and panels tightly shut. Keep spark
gaps at the correct settings. Use proper grounding and shielding to minimize the
possibility of interference. Keep all cables close together and close to the
ground. Locate the welding or cutting operation as far as possible from sensitive
electronic equipment, or have the electronic equipment shut down temporarily.
10. Prevent accidental fires. Remove any combustible material from the work
area. When possible, move the work to a location well away from combustible
materials. If relocation is not possible, protect the combustibles with a cover
made of fire resistant material. Remove or make safe all combustible materials
for a radius of 35 feet (10 meters) around the work area. Use a fire resistant
material to cover or block all open doorways, windows, cracks, and other
openings. Enclose the work area with portable fire resistant screens. Protect
combustible walls, ceilings, floors, etc., from sparks and heat with fire resistant
covers. If working on a metal wall, floor, ceiling, etc., prevent ignition of
combustibles on the other side by moving the combustibles to a safe location. If
relocation of the combustibles is not possible, designate someone to serve as a
fire watch, equipped with a fire extinguisher, during the welding process and at
least one half hour after the welding is completed. Do not place the torch on any
material other than bare concrete until the torch is completely cooled. Do not
weld on materials having a combustible coating or combustible internal structure
such as walls or ceilings, without an approved method for eliminating the hazard.
Do not dispose of hot slag in containers holding combustible materials. Keep a
fire extinguisher nearby, and know how to use it. After welding, make a thorough
examination for evidence of fire. Be aware that easily visible smoke or flame
may not be present for some time after the fire has started. Do not weld in
atmospheres containing dangerously reactive or flammable gasses, vapors,
liquids, and dust. Provide adequate ventilation in work areas to prevent
accumulation of flammable gases, vapors, or dust. Do not apply heat to a
container that has held an unknown substance or a combustible material whose
contents, when heated, can produce flammable or explosive vapors. Clean and
purge containers before applying heat. Vent closed containers, including
castings, before preheating or welding.
11. Read and understand all instructions and safety precautions as outlined in
the manufacturer’s manual for the material you will weld.

12. Industrial applications must follow OSHA requirements.
13. Connect the earth ground as near as possible to the operating area. Earth
connections to structural parts of the building or other places distant to the
operating area will reduce their effectiveness and increase the danger of electric
shock.
14. In addition to grounding the workpiece with theWelder Grounding Clamp,an
earth grounding of the workpiece is recommended. Ground it directly to an
earth pipe or grounding rod with a separate cable of appropriate size.
IMPORTANT: Only a qualified, certified electrician should perform this
procedure.
15. Do not touch the welding wire if you are in contact with the workpiece,
ground, or another welding wire from a different machine.
16. Do not allow the welding wire to touch earth ground. Accidental earth
discharges may cause overheating and fire hazards.
17. Do not pass equipment cables through or near lifting chains, crane cables,
or any electrical lines.
18. Never use theWelder near water. Ensure that the surrounding area and cutting
objects are dry. Do not spray water or other liquids on or near theWelder.
19. Avoid all direct contact between the skin and wet garments and metal parts
under electrical power. Check that gloves and protective clothing are dry.
20. Never leave theWelder unattended when it is turned ON.
21. Always turn off theWelder in the event of a power failure.
22. Significant DC electrical voltage exists after turning off theWelder.
Discharge the electrode to ground before handling.
23. Performance of thisWelder may vary depending on variations in local line
voltage.
24. Always turn OFF theWelder before performing any inspection, maintenance,
or cleaning procedures.
SKU 91149 For technical questions, please call 1-800-444-3353. PAGE 8

SKU 91149 For technical questions, please call 1-800-444-3353. PAGE 9
25. Use the right tool or attachment for the right job. Do not attempt to force a
small tool or attachment to do the work of a larger industrial tool or attachment.
There are certain applications for which this product was designed. It will do the
job better and more safely at the rate for which it was intended. Do not modify
this product, and do not use this product for a purpose for which it was not
intended.
26. Proper cylinder care: Secure gas cylinders to the Base of theWelder, a wall, or
post to prevent them from falling. All cylinders should be used and stored in an
upright position. Never drop or strike a cylinder. Do not use cylinders that have
been dented. Cylinder caps should be used when moving or storing cylinders.
Empty cylinders should be kept in specified areas and clearly marked “empty”.
Never use oil or grease on any inlet connector, outlet connector, or cylinder
valve. Additional specific instructions for the safe handling of cylinders should be
supplied by your cylinder supplier and covered under local, state, and federal
regulations governing pressurized gases.
27. WARNING! The brass components of this product contain lead, a chemical
known to the State of Califormia to cause birth defects (or other reproductive
harm). (California Health & Safety code 25249.5, et seq.)
28. WARNING! This product, when used for welding, cutting, and similar
applications, produces chemicals known to the State of Califormia to cause
cancer and birth defects (or other reproductive harm).
(California Health & Safety code 25249.5, et seq.)
29. WARNING! People with pacemakers should consult with their physician(s)
before using this product. Operation of electrical equipment in close proximity to
a heart pacemaker could cause interference or failure of the pacemaker.
30. WARNING! 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.

SKU 91149 For technical questions, please call 1-800-444-3353. PAGE 10
PRODUCT OVERVIEW
1. This 200 AMP,AC/DCTIGWelder is designed for theTIG and stick welding process, both
in the AC and DC application.
2. Suitable for all ferrous and non-ferrous materials,including stainless steel, copper,
aluminum and its alloys.
3. Designed with HF (HIgh Frequency) starting which provides non-contact arc starting.
4. Designed with reversible polarity for convenient DCEN or DCEP performance.
5. Current may be adjusted steplessly by magnetic shunt.
6. Pre-gas time is pre-set inside the machine. Post-gas time may be adjusted from 0-30
seconds.
7. Other design features include; forced air cooling system by fan and overload protection.
6
3
1
4
12
10
Part # Description Part # Description
1 Front Panel 6 MMA/TIG Selector
3 Post-Gas Potentiometer 10 Power Switch
4 Hand Wheel 12 AC/DC Main Selector
Figure B

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51A51B
50
52
2
Part # Description Part # Description
2 Front Cover 51B Negative Terminal
50 2-Pin Socket 52 Gas Hose Outlet
51A Positive Terminal
FRONT
COVER
CONTROLS
FIGURE C
BACK
PANEL
CONTROLS
Part # Description
34 Gas Hose Inlet
35 Input Terminal Cover
36 Cable Bracket
FIGURE D
34
35
36

SKU 91149 For technical questions, please call 1-800-444-3353. PAGE 12
ASSEMBLY INSTRUCTIONS
NOTE: For additional references to the parts listed in the following pages, refer to the
Assembly Diagrams on pages 24 and 26 and Electrical Schematic on page 25.
Electrical Connection:
1. WARNING! ThisTigWelder requires the connection of a 220 volt
electrical cord (not included) wired directly from theWelder to a 220 volt,(70
Amp) dedicated electrical circuit. For safety purposes, a qualified, certified,
electrician must do this wiring connection. Required power cord rating:
6 AWG,maximum length 25’.
To AttachThe Rear Wheels And Front CastorWheels:
1. WARNING! Prior to performing any further assembly procedures,
make sure the Power Cord Plug of theWelder is unplugged from its
electrical outlet.
2. To attach the two Front Castor Wheels (53), open the Front Cover (2) of the
Welder. Unscrew and remove the two Bolts that hold the front end of the Base
(49) of the Welder to its shipping pallet. Remove the shipping pallet. Then
screw the Castor Wheels into the threaded mounting holes in the Base.
(See Figure E.)
3. To attach the two Rear Wheels (54) to the Welder, slide a Wheel onto each end
of the Axle located at the rear of the Base (49). Secure both Wheels to the
Axle by inserting one Roll Pin (55) through each end of the Axle.
(See Figure E.)
ROLL PIN (55)
REARWHEEL(54)
FRONTCASTORWHEEL
(53)
FIGURE E

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To Install A Gas Cylinder:
1. CAUTION! Do not use the Argon/Mixed Pressure Regulator/Flow
Meter (6A) with CO shielding gas. To use CO shielding gas, you must
install a CO gas Pressure Regulator/Flow Meter (not included).
22
2
2. With assistance, set the cylinder upright to the body of the Welder, wall, or other
stationary support. Secure cylinder with chain (not included). (See Figure F.)
3. Remove the Cap from the cylinder. Stand to the side of the cylinder Valve, and
open the Valve slightly to blow dust and dirt from the Valve. Then, close the
Valve. (See Figure F.)
4. Make sure the Flow Adjust on the Gas Regulator/Flow Meter (6A) is turned
off. Then, screw the Gas Regulator/Flow Meter firmly onto the cylinder Valve.
(See Figure F.)
5. Attach the Regulator Hose (7A) from the Gas Regulator/Flow Meter (6A) to
the Gas Hose Inlet (34) located on the Back Panel (33) of the Welding machine.
(See Figure F.)
6. Adjust the flow rate of the gas by turning the Flow Adjust. The typical flow rate is
20 cfh (cubic feet per hour). Check the welding wire manufacturer’s
recommended flow rate. (See Figure F.)
FLOW
ADJUST
CHAIN
(NOT INCLUDED)
BACKPANEL (33)
GAS HOSE INLET (34)
ARGONGAS
OR
MIXED GAS
CYLINDERVALVE
CYLINDERCAP
GASREGULATOR/FLOW METER (6A)
FIGURE F
REGULATORHOSE
(7A)

SKU 91149 For technical questions, please call 1-800-444-3353. PAGE 14
Output Connections For ATIGWelding ProcessWith DCEN:
Note: Always turn off theWelder before making connection changes.
DCEN = Direct Current Electrode Negative .
1. Raise the Front Cover (2) to expose the controls. (See Figure C.)
2. Connect the Welding Gun’s Power Cable (4A) to the Negative Terminal (51B).
Connect the Welding Gun’s Switch Cable (3A) to the 2-Pin Socket (50). Then,
connect the Welding Gun’s Gas Hose (2A) to the Gas Hose Outlet (52).
(See Figure C.)
3. Connect the Ground Clamp Cable (5A) to the Positive Terminal (51A).
(See Figure C.)
4. NOTE: The DCEN mode is for a narrow and deep weld penetration,
concentrating 70% of heat on the workpiece and 30% heat on theWelding Gun.
DCEP = Direct Current Electrode Positive .
1. Raise the Front Cover (2) to expose the controls. (See Figure C.)
2. Connect the Welding Gun’s Power Cable (4A) to the Positive Terminal (51A).
Connect the Welding Gun’s Switch Cable (3A) to the 2-Pin Socket (50). Then,
connect the Welding Gun’s Gas Hose (2A) to the Gas Hose Outlet (52).
(See Figure C.)
3. Connect the Ground Clamp Cable (5A) to the Negative Terminal (51B).
(See Figure C.)
4. NOTE: The DCEP mode is for shallow penetration and a strong cleaning action,
concentrating 30% of heat on the workpiece and 70% heat on the Welding Gun.
To SelectTheWelding Mode:
NOTE: This Welder features 4 welding modes.
1. AC MMA = The stick/electrode welding for mild steel. This is the simplest
welding procedure.
A. Move the TIG AC/TIG DC Selector (6) to this symbol:
(See Figure B.)
Output Connections For ATIG Welding ProcessWith DCEP:
B. Move the AC/DC Main Selector (12) to this symbol:
(See Figure B.)

2. DC MMA = The stick/electrode welding for high tensile steel, stainless steel,
aluminum, cast iron.
A. Move the TIG AC/TIG DC Selector (6) to this symbol:
(See Figure B.)
B. Move the AC/DC Main Selector (12) to this symbol:
(See Figure B.)
3. ACTIG = TIG welding for aluminum and magnesium.
A. Move the TIG AC/TIG DC Selector (6) to this symbol:
(See Figure B.)
B. Move the AC/DC Main Selector (12) to this symbol:
(See Figure B.)
4. DCTIG = TIG welding for most ferrous and non-ferrous material except
aluminum and magnesium.
A. Move the TIG AC/TIG DC Selector (6) to this symbol:
(See Figure B.)
B. Move the AC/DC Main Selector (12) to this symbol:
(See Figure B.)
The Post-Gas Potentiometer:
1. The Post-Gas Potentiometer (3) is used to adjust the gas flow time after the
welding current stops. This helps cool the Welding Gun and the ending weld
bead. (See Figure B.)
2. The higher the welding current, the longer the post-flow time should be adjusted
(from 0 to 30 seconds). (See Figure B.)
To Adjust The Welding Current:
1. Rotating the Hand Wheel (4) raises and lowers the output current, allowing the
operator to dial the desired current. (See Figure B.)
2. A clockwise rotation increases the output current. A counterclockwise rotation
decreases the output current. Turning the Hand Wheel drives the pointer which
indicates the welding current. (See Figure B.)
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Welding Gun Duty Cycle And Overheating:
1. IMPORTANT! Welding longer than the rated duty cycle for this Welding
equipment can damage the Gun and void its warranty.
2. Duty cycle is a percentage of 10 minutes that the unit can weld at its rated load
without overheating. (See Figure G.)
3. If the unit should overheat, the thermostat opens, output stops, and the cooling
fans continue to run. Wait fifteen minutes for the unit to cool. Reduce amperage
or voltage, or duty cycle, before welding.
4. This Welder, at its 40% duty cycle, can run continuously under load for 4minutes
out of each 10 minute period. (See Figure G.)
5. NOTE: Higher duty cycles can be used at lower currents.
(See Rating Plate information on Front Panel.)
40% Duty Cycle at 200 Amperes (AC) Using Mixed Gases
4 Minutes Welding 6 Minutes Resting
Relation Between Duty Cycle AndWeld Amperes.
DUTY CYCLE (%)
WELDINGCURRENT (AMPs)
FIGURE G
DC AC

Welding Current:
1. While the welding current intensity used depends upon size and type of
welding rod, thickness of workpiece, and operating manner or posture, the
relations between sizes of welding rod and operating current intensity, in general,
are shown in Figure H and Figure I below.
Relation Between Size Of Electrode AndWelding Current
FIGURE H
Relation Between Size OfTungsten Electrode AndWelding Current
FIGURE I
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SKU 91149 For technical questions, please call 1-800-444-3353. PAGE 18
TROUBLESHOOTING GUIDE - WELDING MACHINE
Uselarger welding leads.
See Figure L for proper size of tungsten.
See Figure L for proper size of tungsten.
See Figure L for proper size of tungsten.
Properly sharpen electrode.

SKU 91149 For technical questions, please call 1-800-444-3353. PAGE 19
TROUBLESHOOTING GUIDE - WELDING GUN
INSPECTION,MAINTENANCE,AND CLEANING -WELDING MACHINE
1. WARNING! Make sure the Power Switch (10) is in its “OFF” position.
Unplug the Power Cord Plug from its electrical outlet, and allow theWelder to
completely cool before performing any inspection, maintenance, or cleaning
procedures.
2. Before each use, inspect the general condition of the Welder. Check for
damaged electrical wiring, loose connections, cracked, burnt, or broken parts,
and any other condition that may affect its safe operation. If abnormal noise or
vibration occurs, have the problem corrected before further use.
Do not use damaged equipment.
3. Every six months: Blow off or vacuum dirt and dust deposits on the Welding
Transformer (46) and other components. Dirt or dust deposits on the Welding
Transformer and other internal components may reduce the insulating property or
cause overheated Transformer. During heavy usage, clean monthly.
4. To replace the 3 AMP, 250V Fuse: Failure of the Welder to operate may be
Problem Possible Cause
No arc. 1. Interruption of welding power circuit to welding
gun or workpiece.
2. Power source or control defective.
Arc between gas nozzle
and workpiece. 1. Spatter build-up inside gas nozzle.
Welding gun body or
power cable overheated. 1. Welding current too high. 2. Contact tip not correctly tightened.
3. Ground clamp making poor contact.
Welding wire melted
onto contact tip. 4. Contact tip too far away from workpiece. 5. Burn-back time set too long.
caused by a blown 3 AMP, 250V Fuse (8) as indicated by its melted wire strand
within the Fuse. To replace the Fuse, unscrew and remove the Fuse Cap.
Remove the old Fuse, and install a new 3 AMP, 250V Fuse. Then, replace the
Fuse Cap.
5. When storing, make sure to store theWelder in a safe, clean, dry location out of
reach of children and unauthorized users.
6. All maintenance, service, and repairs not listed in this
manual are only to be attempted by a qualified service technician.

SKU 91149 For technical questions, please call 1-800-444-3353. PAGE 20
INSPECTION, MAINTENANCE, AND CLEANING - WELDING GUN
1. WARNING! Make sure the Power Switch (10) on theWelding Machine is
in its “OFF” position. Unplug the Power from its electrical outlet, and allow the
Welder to completely cool before performing any inspection, maintenance, or
cleaning procedures.
2. Before each use: Inspect the general condition of the Welding Gun. Check for
damaged electrical wiring/gas hose, loose connections, cracked, burnt, or
broken parts, and any other condition that may affect its safe operation. If
abnormal noise or vibration occurs, have the problem corrected before further
use.
Do not use damaged equipment.
3. Before each use: Clean welding spatter from the inside of the Gas Nozzle and
spray with an anti-spatter fluid (not included).
4. To replace the Gun Contact Tip: Remove the Nozzle. Remove the old Contact
Tip (8A), and install a new Contact Tip. Then, replace the Nozzle.
(See Figure J.)
CONTACTTIP (8A)
NOZZLE
FIGURE J
5. To clean exterior ofWelding Gun: Use a damp cloth with a mild detergent.
Then, dry. Do not use solvents to clean the Gun.
6. When storing: Make sure to store the Welding Gun in a safe, clean, and dry
location out of reach of children and unauthorized users.
7. CAUTION! All maintenance,service,and repairs not listed in this manual
are only to be performed by a qualified service technician.