Chicago Welding 94164 Installation manual

220 VAC* DUAL
MIG WELDER
94164
SET UP AND OPERATING INSTRUCTIONS
Visit our website at: http://www.harborfreight.com
Read this material before using this product.
Failure to do so can result in serious injury.
SAVE THIS MANUAL.
Copyright©2006 by Harbor Freight Tools®. All rights reserved. No portion of this manual or any artwork
contained herein may be reproduced in any shape or form without the express written consent of
Harbor Freight Tools. Diagrams within this manual may not be drawn proportionally. Due to continuing
improvements, actual product may differ slightly from the product described herein. Tools required for
assembly and service may not be included.
For technical questions or replacement parts, please call 1-800-444-3353.
*220 VAC refers to input voltage.
Revised Manual 10f

For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual. Page 2SKU 94164
Contents
PRODUCT SPECIFICATIONS..........................................................3
GENERAL SAFETY RULES.............................................................3
Specic Safety Rules .................................................................................. 6
Grounding .................................................................................................... 9
Extension Cords ......................................................................................... 10
Symbology .................................................................................................. 10
UNPACKING ....................................................................................10
ASSEMBLY INSTRUCTIONS..........................................................11
To Attach The Handle ................................................................................. 11
Face Shield Assembly................................................................................ 11
To Install a Wire Spool ............................................................................... 11
To Route The Wire ...................................................................................... 12
To Change Wire Settings ........................................................................... 14
Setting The Gun Polarity For Wire Type................................................... 15
To Install A Gas Cylinder ........................................................................... 16
OPERATING INSTRUCTIONS ........................................................17
Before You Begin Welding......................................................................... 17
Duty Cycle (Duration of Use)..................................................................... 17
Setting Up The Weld................................................................................... 18
Holding The Welding Torch ....................................................................... 19
Weld Settings Chart ................................................................................... 20
Weld Diagnosis........................................................................................... 22
When the Weld is Completed .................................................................... 24
INSPECTION, MAINTENANCE, AND CLEANING .........................25
Nozzle Inspection, Cleaning, and Replacement ...................................... 25
Contact Tip Inspection, Cleaning, And Replacement ............................. 25
Replacing The Welding Torch Liner ......................................................... 26
Parts Lists and Diagrams ..............................................................27
Wiring Schematic ....................................................................................... 27
Parts List ..................................................................................................... 28
Assembly Diagram ..................................................................................... 29
TROUBLESHOOTING.....................................................................31
WARRANTY.....................................................................................33

For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual. Page 3SKU 94164
PRODUCT SPECIFICATIONS
Welding Current 30 ~ 110 Amps
Duty Cycle 15% @ 110 Amps / 100% @ 30 Amps
(Refer to chart and explanation on page 18)
Power Consumption 220 Volt / 60 Hz / Single Phase / 24.5 Amps
(Should be connected to a 25 Amp minimum dedicated circuit)
Open Circuit Voltage 40 Volts Maximum
Required Power Plug Type 3-Prong, 220 VAC, polarized, twist lock (not included)
NEMA #L6-30 or equivalent
Power Cord Rating 14 AWG x 3C x 6’ Long
Gas Inlet Size 1/4”
Cables Ground: 6 Gauge, 6’.................Torch: 8 Gauge, 6’
Welding Wire Size 0.23” to 0.035”
Wire Spool Size 4” Diameter
Included Torch Tip Size 0.030”
Accessories Wire Spool / Cylinder Strap / Wire Brush & Hammer /
Spare .8mm & 1.0mm Welding Tips / Hand-Held Face Shield
Net Weight 53.5 Pounds
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.
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
Keep your work area clean and well lit. Cluttered benches and dark areas invite1.
accidents.
Do not operate power tools in explosive atmospheres, such as in the presence of2.
flammable liquids, gases, or dust. Power tools create sparks which may ignite the
dust or fumes.
REV 09a
Revise to: “ .6mm & .9mm ”

For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual. Page 4SKU 94164
Keep bystanders, children, and visitors away while operating a power tool.3.
Distractions can cause you to lose control. Protect others in the work area from
debris such as chips and sparks. Provide barriers or shields as needed.
ELECTRICAL SAFETY
Grounded tools must be plugged into an outlet properly installed and grounded in1.
accordance with all codes and ordinances. Never remove the grounding prong or
modify the plug in any way. Do not use any adapter plugs. Check with a qualied
electrician if you are in doubt as to whether the outlet is properly grounded. If
the tools should electrically malfunction or break down, grounding provides a low
resistance path to carry electricity away from the user.
Avoid body contact with grounded surfaces such as pipes, radiators, ranges,2.
and refrigerators. There is an increased risk of electric shock if your body is
grounded.
Do not expose power tools to rain or wet conditions. Water entering a power tool3.
will increase the risk of electric shock.
Do not abuse the Power Cord. Never use the Power Cord to carry the tools or pull4.
the Plug from an outlet. 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.
When operating a power tool outside, use an outdoor extension cord marked “W-5.
A” or “W”. These extension cords are rated for outdoor use, and reduce the risk
of electric shock.
PERSONAL SAFETY
Stay alert. Watch what you are doing, and use common sense when operating a1.
power tool. Do not use a power tool while tired or under the inuence of drugs,
alcohol, or medication. A moment of inattention while operating power tools may
result in serious personal injury.
Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep2.
your hair, clothing, and gloves away from moving parts. Loose clothes, jewelry, or
long hair can be caught in moving parts.
Avoid accidental starting. Be sure the Power Switch is off before plugging in.3.
Carrying power tools with your nger on the Power Switch, or plugging in power
tools with the Power Switch on, invites accidents.
Remove adjusting keys or wrenches before turning the power tool on. A wrench or4.
a key that is left attached to a rotating part of the power tool may result in personal
injury.

For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual. Page 5SKU 94164
Do not overreach. Keep proper footing and balance at all times. Proper footing and5.
balance enables better control of the power tool in unexpected situations.
Always wear eye, hearing, and breathing protection. For welding safety equipment,6.
refer to number 9 on page 6.
TOOL USE AND CARE
Use clamps (not included) or other practical ways to secure and support the1.
workpiece to a stable platform. Holding the work by hand or against your body is
unstable and may lead to loss of control.
Do not force the tool. Use the correct tool for your application. The correct tool will2.
do the job better and safer at the rate for which it is designed.
Do not use the power tool if the Power Switch does not turn it on or off. Any tool that3.
cannot be controlled with the Power Switch is dangerous and must be replaced.
Disconnect the Power Cord Plug from the power source before making any4.
adjustments, changing accessories, or storing the tool. Such preventive safety
measures reduce the risk of starting the tool accidentally.
Store idle tools out of reach of children and other untrained persons. Tools are5.
dangerous in the hands of untrained users.
Maintain tools with care. Keep cutting tools sharp and clean. Properly maintained6.
tools with a sharp cutting edge are less likely to bind and are easier to control. Do
not use a damaged tool. Tag damaged tools “Do not use” until repaired.
Check for misalignment or binding of moving parts, breakage of parts, and any other7.
condition that may affect the tool’s operation. If damaged, have the tool serviced
before using. Many accidents are caused by poorly maintained tools.
Use only accessories that are recommended by the manufacturer for your model.8.
Accessories that may be suitable for one tool may become hazardous when used
on another tool.
SERVICE
Tool service must be performed only by qualied repair personnel. Service or 1.
maintenance performed by unqualied personnel could result in a risk of injury.
When servicing a tool, use only identical replacement parts. Follow instructions2.
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 or injury.

For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual. Page 6SKU 94164
SPECIFIC SAFETY RULES
Ground this product. This Welder requires the attachment and use of a UL-listed,1.
220 volt, grounded, 3-prong, electrical Power Cord Plug (not included). Only a
qualied electrician should install the Power Cord Plug. Never remove the grounding
prong or modify the Power Cord Plug in any way. Do not use adapter plugs with
this product. To comply with the National Electric Code, and to provide additional
protection from the risk of electrical shock, this product should only be connected
to a 220 volt, 3-hole outlet that is properly grounded.
Maintain labels and nameplates on the Welder. These carry important information.2.
If unreadable or missing, contact Harbor Freight Tools for a replacement.
Avoid unintentional starting. Make sure you are prepared to begin work before3.
turning on the Welder.
Do not force the Welder. This tool will do the work better and safer at the speed4.
and capacity for which it was designed.
Never leave the Welder unattended when it is plugged into an electrical outlet. Turn5.
off the tool, and unplug it from its electrical outlet before leaving.
Industrial applications must follow OSHA guidelines.6.
Never stand on the Welder. Serious injury could result if the Welder is tipped or if7.
hot surfaces are accidently contacted.
Maintain a safe working environment. Keep the work area well lit. Make sure there8.
is adequate surrounding workspace. Always keep the work area free of obstruc-
tions, grease, oil, trash, and other debris. Do not use a power tool in areas near
ammable chemicals, dusts, and vapors. Do not use this product in a damp or wet
location.
9. Prevent eye injury and burns. Wearing and using ANSI-approved per-
sonal safety clothing and safety devices reduce the risk for injury.
Wear ANSI-approved safety impact eye goggles with a welding helmet•
with protective lens.
Leather leggings, re resistant shoes or boots should be worn when using this •
product. 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 ammable substances. Wear •
dry, insulating gloves and protective clothing.
Wear an approved head covering to protect the head and neck. Use aprons,•
cape, sleeves, shoulder covers, and bibs designed and approved for welding and
cutting procedures.
When welding/cutting overhead or in conned spaces, wear ame resistant ear •
plugs or ear muffs to keep sparks out of ears.

For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual. Page 7SKU 94164
10. Prevent accidental res. 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 re resistant material.
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.
Enclose the work area with portable re resistant screens. Protect combustible •
walls, ceilings, oors, etc., from sparks and heat with re resistant covers.
If working on a metal wall, ceiling, etc., prevent ignition of combustibles on the other•
side by moving the combustibles to a safe location. If relocation of combustibles
is not possible, designate someone to serve as a re watch, equipped with a re
extinguisher, during the cutting process and for at least one half hour after the
cutting is completed.
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.
Do not dispose of hot slag in containers holding combustible materials. Keep a•
re extinguisher nearby and know how to use it.
After spot 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 weld or cut in atmospheres containing dangerously reactive
or ammable gases, vapors, liquids, and dust. Provide adequate ventilation in
work areas to prevent accumulation of ammable gases, vapors, and dust. 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.
Avoid overexposure to fumes and gases.11. 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 qualied 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 conned 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.

For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual. Page 8SKU 94164
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 specic
welding or cutting situation.
Inhalation Hazard
Welding Produces TOXIC FUMES and GASSES.
Exposure to welding gasses 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 gasses
or fumes are:
• Early onset of Parkinson’s Disease • Heart Disease
• Damage to the reproductive organs • Ulcers
• Inammation of the small intestine or stomach • Kidney damage
• Respiratory diseases such as emphysema, bronchitis or pneumonia
Safety precautions, such as using natural or forced air ventilation and
wearing a NIOSH-approved respirator, are ESSENTIAL to reduce the
risk of developing the above illnesses.
12. Read and understand all instructions and safety precautions as outlined in the
manufacturer’s manual for the material you will weld or cut.
Do not touch live electrical parts. Wear dry, insulating gloves. Do not touch electrode13.
or conductor tong with bare hand. Do not wear wet or damaged gloves.
Protect yourself from electric shock. Do not use outdoors. Insulate yourself from14.
the workpiece and ground. Use nonammable, dry insulating material if possible,
or use dry rubber mats, dry wood or plywood, or other dry insulating material big
enough to cover your full area of contact with the work or ground.
Ensure that the unit is placed on a stable location before use. If this unit falls while15.
plugged in, severe injury, electric shock, or re may result.
16. Cylinders can explode when damaged:
Never weld on a pressurized or a closed cylinder.•
Never lay a welding torch on a cylinder.•
Never allow a welding electrode 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.•

For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual. Page 9SKU 94164
Use only correct gas shielding equipment designed specically for the type of •
welding you will do. Maintain this equipment properly.
Always protect gas cylinders from heat, being struck, physical damage, slag,•
ames, sparks, and arcs.
Always use proper procedures to move cylinders.•
Use the right tool for the job. Do not attempt to force small equipment to do the work17.
of larger industrial equipment. There are certain applications for which this Welder
was designed. It will do the job better and more safely at the rate for which it was
intended. Do not modify this Welder, and do not use this Welder for a purpose for
which it was not intended.
18. WARNING! People with pacemakers should consult their physician(s) before
using this product. Electromagnetic elds in close proximity to a heart pacemaker
could cause interference to or failure of the pacemaker.
19. WARNING! The warnings and cautions discussed in this 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.
20. WARNING! This product, when used for welding and similar applications,
produces chemicals known to the State of California to cause cancer and birth
defects (or other reproductive harm).
(California Health & Safety Code § 25249.5, et seq.)
SAVE THESE INSTRUCTIONS
GROUNDING
NOTE:
This Welder requires the installation of a 3-Prong, 220 VAC, polarized,
twistlock Power Cord Plug (not included).
NEMA conguration # L6-30 or equivalent
The Plug must be installed by a certied electrician.
WARNING!
Improperly connecting the grounding wire can result in the risk of electric
shock. Check with a qualied electrician if you are in doubt as to whether
the outlet is properly grounded. Do not modify the power cord plug used
with the tool. Never remove the grounding prong from the plug. Do not
use the tool if the power cord or plug is damaged. If damaged, have it
repaired by a service facility before use. If the plug will not t the outlet,
have a proper outlet installed by a qualied electrician.

For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual. Page 10SKU 94164
GROUNDED TOOLS: TOOLS WITH THREE PRONG PLUGS
Tools marked with “Grounding Required” have a three wire cord and three prong1.
grounding plug. The plug must be connected to a properly grounded outlet. If the tool
should electrically malfunction or break down, grounding provides a low resistance
path to carry electricity away from the user, reducing the risk of electric shock.
The grounding prong in the plug is connected through the green wire inside the2.
cord to the grounding system in the tool. The green wire in the cord must be the
only wire connected to the tool’s grounding system and must never be attached to
an electrically “live” terminal.
Your tool must be plugged into an appropriate outlet, properly installed by a certied 3.
electrician and grounded in accordance with all codes and ordinances.
EXTENSION CORDS
AN EXTENSION CORD MUST1. NEVER BE USED WITH THIS ITEM. Use of an
extension cord could result in damage to the item or re.
SYMBOLOGY
Double Insulated
Canadian Standards Association
Underwriters Laboratories, Inc.
V~ Volts Alternating Current
AAmperes
n0xxxx/min. No Load Revolutions per Minute (RPM)
UNPACKING
When unpacking both boxes, check to make sure all the parts shown on the Parts
Lists on pages 28 through 30 are included, in addition to the face shield, wire brush/
hammer, and strap (for cylinder connection). 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.

For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual. Page 11SKU 94164
ASSEMBLY INSTRUCTIONS
WARNING! Always turn off the Welder and unplug the unit from its elec-
trical outlet prior to performing any assembly, maintenance, or service.
TO ATTACH THE HANDLE
Insert the Handle (4) into the Handle Sockets (3). Then attach the Handle Sockets
to the center top of Side Panel (1), using the four Screws provided.
FACE SHIELD ASSEMBLY
Attach the handle to the Face Shield by
lining up the two rectangular tabs on the
handle with the corresponding holes in the
face shield and
1) pressing it upwards
and then
2) pressing it forward from the back,
locking the round tab in place.
See numbered steps in illustration to the
right.
TO INSTALL A WIRE SPOOL
Lift the Access Panel (12) of the Welder to expose the Wire Feed Assembly.1.
2. Unscrew and remove the Wing Nut (40) and Spool Knob (39).
Install a 2 lb. Spool (not included) onto3.
the Wire Spool Axle (9), making sure
the Welding Wire unwinds from the top
(counterclockwise). Secure it to the shaft
using the spring underneath and the Knob
on top.
Tighten the Knob (39) until only slight4.
resistance is felt when turning the Spool.
Then, tighten the Wing Nut (40) up against
the Knob.
Handle
Face
Shield
Round
Tab
FIGURE C
SPOOL
WING
NUT (40)
WELDING
WIRE
SPOOL
KNOB (39)

For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual. Page 12SKU 94164
TO ROUTE THE WIRE
Note: When installing wire of different size or composition, you will also need to change
wire settings, set gun polarity, and, possibly, install gas cylinder. See pages 14-16.
IMPORTANT: Securely hold onto the end1.
of the Welding Wire and keep tension on
it during the following steps. If this is not
done the Welding Wire will spring backward,
creating a tangled “bird’s nest” and resulting
in wasted wire. (See Figure D.)
Hold the Welding Wire securely while you2.
cut enough Wire off the end of the Spool to
remove all bent and crimped Wire. Make
sure the cut end has no burrs or sharp
edges (cut again, if needed). (See Figure D.)
Loosen and lower the Tension Adjusting Knob (10b) on the Wire Feed Assembly.3.
Then, raise the Swing Arm (10a). (See Figure E.)
Keep tension on the Welding Wire, and guide at least 12 inches of Wire into the4.
Wire Feed Leader (10f). Be sure not to bend the end of the wire because that will
cause it to not feed properly. (See Figure E.)
Lower the Swing Arm (10a) on the Wire Feed Assembly. Then raise and tighten5.
the Tension Adjusting Knob (10b). Once the Wire is held in place, you may release
it. (See Figure E.)
Remove the Gun Nozzle (15h) and Contact Tip (15g). (See Figure F, next page.)6.
SWING ARM
(10a)
SWING ARM
(10a)
TENSION ADJUSTING KNOB
(10b)
TENSION ADJUSTING KNOB
(10b)
WIRE FEED
LEADER
(10f)
WIRE FEED
LEADER
(10f)
WIRE
FIGURE E
7. Lay the Torch Cable out in a straight line so that the Welding Wire moves through
it easily. Leave the Access Panel (12) of the Welder open so that the Wire Feed
Assembly can be observed.
SPOOL
WELDING
WIRE
FIGURE D
REV 08j

For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual. Page 13SKU 94164
WARNING!
EXERCISE EXTREME CAUTION - RISK OF FIRE AND/OR ELECTRIC SHOCK!
The following steps require applying power to the Welder. Do not touch
anything with the Torch Handle or Welding Wire or an arc will be ignited.
Do not touch the internal components of the unit while it is plugged in.
Plug the Power Cord (13) into its 220 volt, grounded, electrical outlet. Then, turn8.
the Welder ON.
Point the Torch Handle away from all objects. Then, squeeze the Trigger Switch9.
(15d) on the Torch Handle until the Welding Wire feeds through the Head Tube
(15f) of the Torch Handle about 2 inches. If necessary, move the Torch Handle
slightly in a circular motion to help feed the Welding Wire properly out of the Head
Tube. (See Figure F.)
NOTE: If the Welding Wire does not feed properly, and the Spool is stationary,10.
turn the Welder off. Unplug the Welder. Slightly tighten the Tension Adjusting
Knob (10b) on the Wire Feed Assembly, and rewind the Welding Wire slightly
before retrying. (See Figure E.)
To check the tension on the Wire Feed Assembly, feed the Welding Wire against11.
a piece of scrap wood from 2 to 3 inches away. If the Wire stops instead of
bending, turn the Welder OFF. Unplug the unit from its electrical outlet. Then,
slightly tighten the Tension Adjusting Knob (10b) on the Wire Feed Assembly. Do
not over-tighten; this can stop the wheel completely and harm the drive motor.
(See Figure E.)
FIGURE F
CONTACT
TIP
(15g)
NOZZLE
(15h)
WELDING
WIRE
HEAD
TUBE
(15f)
NOZZLE
(15h)
CONTACT
TIP
(15g)
HEAD
TUBE
(15f)
12. Turn the Welder OFF, unplug it, and discharge the electrode to ground. Insert the
Contact Tip (15g) onto the Welding Wire and screw it rmly into the Head Tube (15f)
of the Torch Handle. Replace the Nozzle (15h), and cut off any excess Welding
Wire over 1/2 inch. Then, close the Access Panel (12) of the Welder.
(See Figure F.)
Note: When installing wire of a different size or composition, you will also need to change
wire settings, set the gun polarity, and, possibly, install a gas cylinder. See pages
14-16.
REV 08j

For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual. Page 14SKU 94164
TO CHANGE WIRE SETTINGS
1. WARNING! Make sure to turn off the Welder and unplug it from its electrical
outlet prior to changing wire settings.
Open the Access Panel (12) of the Welder to expose the Wire Feed Assembly.2.
FIGURE G
SWING ARM
(10a)
TENSION
ADJUSTING
KNOB
(10b)
SCREW
(10l)
FEED
ROLLER
BRACKET
(10k)
3. Loosen, and lower the Tension Adjusting Knob (10b) on the Wire Feed Assembly.
Then, raise the Swing Arm (10a). (See Figure G.)
Remove the two Screws (10l) that secure the Feed Roller Bracket (10k) in place.4.
Then, remove the Feed Roller Bracket. (See Figure G.)
Install a Wire Feed Roller (11) with the proper groove size facing towards the Inner5.
Panel (8) of the welder.
Replace the Feed Roller Bracket (10k), and secure in place with the Screws.6.
(See Figure G.)
Lower the Swing Arm (10a) on the Wire Feed Assembly. Then, lower and tighten7.
the Tension Adjusting Knob (10b). (See Figure G.)
Remove the Gun Nozzle (15h) and Contact Tip (15g). Install a Contact Tip that is8.
one size larger* than the diameter of Welding Wire used. Then, replace the Gun
Nozzle. (See Figure F, previous page.)
*This accommodates thermal expansion of the wire.
Install the Spool of Welding Wire, and route the Wire to the Torch Gun. Then, test9.
and, if necessary, adjust the Wire Feed Assembly as discussed in the previous
pages of this manual.

For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual. Page 15SKU 94164
SETTING THE GUN POLARITY FOR WIRE TYPE
Set for Electrode Negative (DCEN) for1. gasless ux core wire. Negative electrode
(E to C), positive ground (D to A). SHOWN IN FIGURE H, INITIAL SETUP.
Set for Electrode Positive (DCEP) for2. gas welding with solid-core wire. Positive
electrode (E to A), negative ground (D to C).
Connections the opposite of Figure H.
When connecting to the weld output terminals, do not3.
place anything between the welding Cable Terminals
(A and C) and their copper connections.
Always read and follow wire manufacturer’s4.
recommended polarity.
KEY:5.
Positive (+) Output TerminalA.
Polarity Changeover LabelB.
Negative (–) Output TerminalC.
Ground CableD.
Electrode CableE.
FIGURE H
A
B
C
D
E
REV 09a

For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual. Page 16SKU 94164
TO INSTALL A GAS CYLINDER
WARNING: Maximum cylinder height is 1 feet 7 inches (0.5m). Maximum cyl-
inder weight is 22 lb., including gas. NEVER exceed either of these maximums.
CAUTION!1. Do not use an Argon/Mixed pressure regulator/ow meter with CO2
shielding gas. To use CO2shielding gas, you must install a CO2gas pressure
regulator/ow meter (neither one included).
Thread the provided strap through the slots on the back of the welder. With2.
assistance, set the cylinder onto the shelf at the back of the welder.
Secure the cylinder in place with the strap.3.
Remove the protective cap from the cylinder. Stand to the side of the cylinder4.
valve, and open the valve slightly to blow dust and dirt from the valve. Then, close
the valve.
Make sure the Flow Adjust on the Pressure Regulator/Flow Meter is turned off.5.
Then, screw the Pressure Regulator/Flow Meter (not included) rmly onto the
cylinder valve.
Attach the Gas Line (41) to the Pressure Regulator/Flow Meter from the Gas Inlet6.
located on the Back Panel (6) of the Welder.
Adjust the ow rate of the gas by turning the Flow Adjust. The typical ow rate 7.
is 10-30 CFH (cubic feet per hour). Make sure to check the Welding Wire
manufacturer’s recommended ow rate.
WARNING
RISK OF EXPLOSION!
While the Gas Cylinder is attached, this unit must only
be transported using an appropriate welding cart (not
included).
Transporting this welder any other way could result in the
cylinder being damaged or ruptured, causing an explosion
and, potentially, SEVERE PERSONAL INJURY.

For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual. Page 17SKU 94164
OPERATING INSTRUCTIONS
BEFORE YOU BEGIN WELDING
Good welding requires a high degree of skill and experience. You should practice
a few sample welds on scrap metal before you begin welding your rst project.
Additional practice periods are recommended whenever you weld a different
thickness of material, wire, or weld a different type of connection.
DUTY CYCLE (DURATION OF USE)
CAUTION! Avoid damage to the Welder by not leaving the unit on for more than1.
the prescribed duty cycle time.
FIGURE K
2. The duty cycle denes the number of minutes, within a 10 minute period, during
which a given Welder can safely produce a particular welding current. For example,
this Welder, with a 15% duty cycle at 110 Amps (setting Max 2), must be allowed
to rest for at least 8 minutes and 30 seconds after every minute and 30 seconds of
continuous weld at 110 Amps.
(See Figure K.)
Failure to carefully observe duty cycle limitations can easily over stress a Welder’s3.
power generation system, contributing to premature Welder failure.
This Welder is equipped with an internal thermal protection system to help prevent4.
over stressing the unit. When the unit overheats, it automatically shuts down, then
automatically returns to service when it cools down.
Note: Once the unit returns to service, follow a more conservative duty cycle routine to
help prevent excess wear to the Welder. (See Figure K.)

For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual. Page 18SKU 94164
SETTING UP THE WELD
WARNING!
Before welding, make sure to read and understand all safety
precautions and warnings discussed on pages 3 through 10.
1. Overload Indicator Light (28): If too much current is drawn from the Welder, the
Overload Protector will activate. The RED Overload Indicator Light will illuminate
and the Welder will automatically turn off until it cools down. If this happens, turn
the Power Switch to its “OFF” position and wait approximately 20 minutes.
(See Figure L.)
Wire Speed Control Knob (17):2. The Scale surrounding the Knob is relative value,
not wire feed speed. (See Figure L.)
Voltage Controls (18, 19):3. Adjust the Voltage Controls based on thickness of metal
being welded. (See Figure L.)
If using solid-core wire, connect and secure an Argon/ CO4. 2gas hose to the rear of
the Welder. (If using ux core wire, protective gas is not required.)
VOLTAGE CONTROLS
(18, 19)
WIRE SPEED
CONTROL KNOB
(17)
OVERLOAD INDICATOR
LIGHT (28)
FIGURE L
POWER SWITCH
(19)
5. Securely clamp the Ground Clamp (14) as close as possible to the metal object to
be welded, or to the metal workbench where the object is mounted and electrically
connected. (See Figure L.)
NOTE:6. The workpieces should be rmly held together and in position while welding.
Use clamps (not included) to hold the workpieces so you can concentrate on the

For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual. Page 19SKU 94164
job at hand. The distance (if any) between the two workpieces must be controlled
properly to allow the weld to hold both sides securely while allowing the weld to
penetrate fully into the joint.
Set the desired welding current (30 to 140 amps) for the type of metal being welded,7.
using the Wire Speed Control Knob (17) and Voltage Controls (18, 19).
(See Figure L.)
Make sure the Power Switch is in its8. “OFF” position. Then plug Power Cord of
the Welder into a dedicated, 220 VAC, 25 amp line with delayed action type circuit
breaker or fuse.
While holding the Welding Torch (15), with the Welding Wire clearly out of the way9.
of any grounded objects, turn the Power Switch to its “ON” position.
Momentarily squeeze the Trigger (15d) of the Welding Torch (15) to test the wire10.
feed speed. If necessary, adjust the speed by turning the Wire Speed Control Knob
(17). (See Figure L.)
Orient yourself on the area to be welded, then place a Face Shield over your11.
eyes.
12. WARNING! Never look at the ignited arc without ANSI-approved,
arc-shaded, eye protection in a full face shield. Permanent eye
damage or blindness can occur. Skin burns can occur. Never
breathe arc fumes. (See page 8.)
HOLDING THE WELDING TORCH
Hold the Welding Torch (15) in one hand and the face shield in the other. If a hands-13.
free welding shield is used, then both hands can be used to control the Welding
Torch.
The Welding Wire should be directed straight into the joint.14.
This gives an angle of 90 degrees (straight up and down) for
groove (end to end) welds, and an angle of 45 degrees for
llet (T-shaped) welds.
The end of the Welding Torch should be tilted so that the15.
Welding Wire is angled anywhere in between straight on and
15 degrees in the direction of the weld. The amount of tilt is
called the “drag angle”. (See Figure M.)
The Welding Wire should extend no more than 1/2” past the16.
Nozzle (15h) of the Welding Torch (15). This distance is
called “stickout”. (See Figure M.)
Set the Wire Speed and Voltage Controls (17, 18, 19) to the recommended start17.
settings as shown in the Weld Settings Chart on the next page. (See Figure N.)
FIGURE M

For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual. Page 20SKU 94164
WELD SETTINGS CHART
FIGURE N
Welding Instructions continued on next page.
Top gures are Voltage Settings. Bottom number is Wire Speed Setting. NOTE: The numbers within the spaces are the approximate wire feed/voltage settings recom- mended* for this wire size and material thickness.
Material Thickness (Steel)
.035”-.047” .047”-.075” .075”-.125” .125”-.157” .157”-.250”
Wire Size
(Flux Core, Mild Steel)
.023”
MIN 1
1
MIN 2
3
MAX 1
4
MAX 1
6
MAX 2
6
.030”
MIN 1
1
MIN 2
2
MAX 1
3
MAX 1
5
MAX 2
5
Wire Size
(Solid Core, Mild Steel)
.023”
MIN 2
4
MAX 1
7
MAX 2
5
MAX 2
8
.030”
MIN 2
2
MAX 1
5
MAX 1
6
MAX 2
5
MAX 2
7
.035”
MIN 2
1
MAX 1
2
MAX 1
3
MAX 2
4
MAX 2
5
*This chart is only intended to show general guidelines for different wire sizes and for different thicknesses of material. The settings should only be used at the beginning of a weld and must be adjusted after stopping and carefully inspecting the weld. Proper welding takes good technique and practice.