Chicago Welding 94164 Set Up And Operating Instructions Manual
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Chicago Welding 94164 Set Up And Operating Instructions Manual

220 vac* dual mig welder
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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
©
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.
Revised Manual 10f
220 VAC
MIG WELDER
. All rights reserved. No portion of this manual or any artwork
®
*220 VAC refers to input voltage.
DUAL
*
94164

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Summary of Contents for Chicago Welding 94164

  • Page 1 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.

  • Page 2: Table Of Contents

    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; SKU 94164 troubleshooting section at end of manual. Contents Page 2...

  • Page 3: Product Specifications

    flammable liquids, gases, or dust. Power tools create sparks which may ignite the dust or fumes. For technical questions, please call 1-800-444-3353; SKU 94164 Troubleshooting section at end of manual. 30 ~ 110 Amps 15% @ 110 Amps / 100% @ 30 Amps (Refer to chart and explanation on page 18) 220 Volt / 60 Hz / Single Phase / 24.5 Amps...

  • Page 4: Electrical Safety

    Remove adjusting keys or wrenches before turning the power tool on. A wrench or 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; SKU 94164 troubleshooting section at end of manual. ELECtRICAL SAFEtY pERSOnAL SAFEtY...
  • Page 5 “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; SKU 94164 troubleshooting section at end of manual. tOOL USE AnD CARE SERVICE...

  • Page 6: Specific Safety Rules

    Avoid unintentional starting. Make sure you are prepared to begin work before turning on the Welder. Do not force the Welder. This tool will do the work better and safer at the speed and capacity for which it was designed.
  • Page 7 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. For technical questions, please call 1-800-444-3353; SKU 94164 troubleshooting section at end of manual. Always keep your head out of the Page 7...
  • Page 8 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; SKU 94164 troubleshooting section at end of manual. • heart Disease •...

  • Page 9: Grounding

    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.

  • Page 10: Extension Cords

    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.

  • Page 11: Assembly Instructions

    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. Unscrew and remove the Wing Nut (40) and Spool Knob (39). Install a 2 lb. Spool (not included) onto...

  • Page 12: To Route The Wire

    ADJUStInG KnOB 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. For technical questions, please call 1-800-444-3353;...
  • Page 13 COntACt (15g) Turn the Welder OFF, unplug it, and discharge the electrode to ground. Insert the Contact Tip (15g) onto the Welding Wire and screw it firmly into the Head Tube (15f) of the Torch Handle. Replace the Nozzle (15h), and cut off any excess Welding Wire over 1/2 inch.

  • Page 14: To Change Wire Settings

    ChAnGE WIRE SEttInGS 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. SCREW (10l) Loosen, and lower the Tension Adjusting Knob (10b) on the Wire Feed Assembly.

  • Page 15: Setting The Gun Polarity For Wire Type

    Changeover Label negative (–) Output terminal Ground Cable Electrode Cable For technical questions, please call 1-800-444-3353; SKU 94164 troubleshooting section at end of manual. gasless flux core wire. Negative electrode gas welding with solid-core wire. Positive FIGURE h REV 09a...

  • Page 16: To Install A Gas Cylinder

    To use CO regulator/flow meter (neither one included). Thread the provided strap through the slots on the back of the welder. With assistance, set the cylinder onto the shelf at the back of the welder. Secure the cylinder in place with the strap.

  • Page 17: Operating Instructions

    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.

  • Page 18: Setting Up The Weld

    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.

  • Page 19: Holding The Welding Torch

    (See Figure L.) Make sure the Power Switch is in its 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 way of any grounded objects, turn the Power Switch to its “On”...

  • Page 20: Weld Settings Chart

    Welding Instructions continued on next page. For technical questions, please call 1-800-444-3353; SKU 94164 Page 20 troubleshooting section at end of manual.
  • Page 21 For a wider weld, draw the Welding Wire back and forth across the joint in a curve. This is called a “weave bead”. note: If too much current is drawn from the Welder, the internal Thermal Overload Protector will activate. The Overload Indicator Light (28) will illuminate and the Welder will automatically turn off.

  • Page 22: Weld Diagnosis

    Keep arc on leading edge of weld puddle. Hold gun at proper angles as stated under Holding The Torch on page 19. For technical questions, please call 1-800-444-3353; SKU 94164 troubleshooting section at end of manual. WELD DIAGnOSIS Weld penetration pROpER Weld is visible underneath and bulges slightly on top.
  • Page 23 * this test WILL damage the weld it is performed on. this test is OnLY an indicator of weld technique and is not intended to test working welds. For technical questions, please call 1-800-444-3353; SKU 94164 troubleshooting section at end of manual. Crooked/wavy bead View pOSSIBLE CAUSES AnD SOLUtIOnS Stickout too long: Reduce stickout.

  • Page 24: When The Weld Is Completed

    Make sure not to damage the weld or material when striking it. The wire brush can then be used to help remove oxidation and some fine spatter. For technical questions, please call 1-800-444-3353; SKU 94164 troubleshooting section at end of manual. Page 24...

  • Page 25: Inspection, Maintenance, And Cleaning

    Periodically open the Access Panel (12) from the unit and, using compressed air, blow out all dust and debris from the interior. Always store the Welder in a clean, dry, safe location out of reach of children and other unauthorized people.

  • Page 26: Replacing The Welding Torch Liner

    REpLACInG thE WELDInG tORCh LInER Switch welder off, disconnect power, and discharge electrode to ground before proceeding. Secure welding wire to the spool, cut it near the spool, and remove it from the torch and cable. Gently twist and slide the Locking Collar (15b) off the torch and onto the Protective Sleeve (15a).

  • Page 27: Parts Lists And Diagrams

    LIStS AnD DIAGRAMS WIRInG SChEMAtIC REV 01/07 For technical questions, please call 1-800-444-3353; SKU 94164 Page 27 troubleshooting section at end of manual.

  • Page 28: Parts List

    Locking Collar Lower Housing Trigger Switch Body Head Tube *Wire feed mechanism includes parts 10a-10j, & 11 For technical questions, please call 1-800-444-3353; SKU 94164 troubleshooting section at end of manual. pARtS LISt qty. part Description Contact Tip (.8 mm)

  • Page 29: Assembly Diagram

    ASSEMBLY DIAGRAM For technical questions, please call 1-800-444-3353; SKU 94164 Page 29 troubleshooting section at end of manual.
  • Page 30 ASSEMBLY DIAGRAM (COntInUED) Wire Feed Mechanism (10) For technical questions, please call 1-800-444-3353; SKU 94164 Page 30 troubleshooting section at end of manual.

  • Page 31: Troubleshooting

    Be CERtAIn to shut off the Welder, disconnect it from power, and discharge the torch to ground before adjusting, cleaning, or repairing the unit. Wire feed motor runs but wire does not feed properly pOSSIBLE CAUSES AnD SOLUtIOnS Insufficient wire feed pressure: Increase wire feed pressure properly - follow instructions on page 12-13.

  • Page 32: Weak Arc Strength

    (continued) Be CERtAIn to shut off the Welder, disconnect it from power, and discharge the torch to ground before adjusting, cleaning, or repairing the unit. Welder does not function when switched on pOSSIBLE CAUSES AnD SOLUtIOnS tripped thermal protection device: Shut the welder’s switch to off and allow it to cool for at least 20 minutes.

  • Page 33: Warranty

    Limited 90 Day/1 Year Warranty shall not apply to consumable parts such as tips, welding wire, and gas nozzles. Harbor Freight Tools also warrants to the original purchaser, for a period of one year from date of purchase, that the transformer and rectifier are free from defects in materials and workmanship (90 days if used by a professional contractor or if used as rental equipment).

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