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Harbor Freight Tools 94164 manual

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Table of contents for the manual

  • Page 1

    220 V AC * DUAL MIG WELDER 94164 SET UP AND OPERA TING 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 . SA VE THIS MANUAL. Copyright © 2006 by Harbor Freight T ools ® . All rights reserved. No portion of this manual or any artwork contain[...]

  • Page 2

    For technical questions, please call 1-800-444-3353; T roubleshooting section at end of manual. Page 2 SKU 94164 Contents PRODUCT SPECIFICA TIONS ..........................................................3 GENERAL SAFETY RULES ............................................................. 3 Specic Safety Rules ....................................[...]

  • Page 3

    For technical questions, please call 1-800-444-3353; T roubleshooting section at end of manual. Page 3 SKU 94164 PRODUCT SPECIFICA TIONS Welding Current 30 ~ 1 10 Amps Duty Cycle 15% @ 1 10 Amps / 100% @ 30 Amps (Refer to chart and explanation on page 18) Power Consumption 220 V olt / 60 Hz / Single Phase / 24.5 Amps (Should be connected to a 25 Am[...]

  • Page 4

    For technical questions, please call 1-800-444-3353; T roubleshooting section at end of manual. Page 4 SKU 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. ELECT[...]

  • Page 5

    For technical questions, please call 1-800-444-3353; T roubleshooting section at end of manual. Page 5 SKU 94164 Do not overreach. Keep proper footing and balan ce at all times. Proper footing and 5. balance enables better control of the power tool in unexpected situations. Always wear eye , hear ing, and breathing prote ction. For welding safety e[...]

  • Page 6

    For technical questions, please call 1-800-444-3353; T roubleshooting section at end of manual. Page 6 SKU 94164 SPECIFIC SAFETY RULES Ground this product. This W elder requires the attachment and use of a UL-listed, 1. 220 volt, grounded, 3-prong, electrical Power Cord Plug (not included). Only a qua li ed elect ric ian shou ld insta ll the Pow[...]

  • Page 7

    For technical questions, please call 1-800-444-3353; T roubleshooting section at end of manual. Page 7 SKU 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 [...]

  • Page 8

    For technical questions, please call 1-800-444-3353; T roubleshooting section at end of manual. Page 8 SKU 94164 Follow the American Conference of Governmental Industrial Hygienists • recommendations for Threshold Limit V alues (TL V’ s) for fumes and gases. Have a recognized specialist in Industrial Hygiene or Environmental Services • check [...]

  • Page 9

    For technical questions, please call 1-800-444-3353; T roubleshooting section at end of manual. Page 9 SKU 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,[...]

  • Page 10

    For technical questions, please call 1-800-444-3353; T roubleshooting section at end of manual. Page 10 SKU 94164 GROUNDED TOOLS: T OOLS WITH THREE PRONG PLUGS T ools marked with “Grounding Required” have a three wire cord and three prong 1. gr oun di ng plug . The plug mus t be conn ec te d to a prop er ly grou nd ed outl et . If the too l sho[...]

  • Page 11

    For technical questions, please call 1-800-444-3353; T roubleshooting section at end of manual. Page 1 1 SKU 94164 ASSEMBL Y INSTRUCTIONS W ARNING! Always turn off the W elder and unplug the unit from its elec- trical outlet prior to performing any assembly , maintenance, or service. T O A TT ACH THE HANDLE Insert the Handle (4) into the Handle Soc[...]

  • Page 12

    For technical questions, please call 1-800-444-3353; T roubleshooting section at end of manual. Page 12 SKU 94164 T O 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. IMPORT ANT : Securely hold onto the e[...]

  • Page 13

    For technical questions, please call 1-800-444-3353; T roubleshooting section at end of manual. Page 13 SKU 94164 W ARNING! EXERCISE EXTREME CAUTION - RISK OF FIRE AND/OR ELECTRIC SHOCK! Th e fo ll owi ng ste ps re qu ire app ly ing pow e r to the We l de r . Do no t to uc h an y th in g wit h the T orc h Han d le or W eld ing Wi re or an arc wil l[...]

  • Page 14

    For technical questions, please call 1-800-444-3353; T roubleshooting section at end of manual. Page 14 SKU 94164 T O CHANGE WIRE SETTINGS 1. W ARNING! 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 SWI[...]

  • Page 15

    For technical questions, please call 1-800-444-3353; T roubleshooting section at end of manual. Page 15 SKU 94164 SETTING THE GUN POLARITY FOR WIRE TYPE Set for Electrode Negative (DCEN) for 1. 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) for 2. [...]

  • Page 16

    For technical questions, please call 1-800-444-3353; T roubleshooting section at end of manual. Page 16 SKU 94164 T O INST ALL A GAS CYLINDER W ARNING: 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 regulato[...]

  • Page 17

    For technical questions, please call 1-800-444-3353; T roubleshooting section at end of manual. Page 17 SKU 94164 OPERA TING INSTRUCTIONS BEFORE YOU BEGIN WELDING Good welding requires a high degree of skill and experience. Y ou should practice a few sample welds on scrap metal before you begin welding your rst project. Additional practice perio[...]

  • Page 18

    For technical questions, please call 1-800-444-3353; T roubleshooting section at end of manual. Page 18 SKU 94164 SETTING UP THE WELD W ARNING! 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 W elder , the Ov[...]

  • Page 19

    For technical questions, please call 1-800-444-3353; T roubleshooting section at end of manual. Page 19 SKU 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 weldi ng cur rent (30 to [...]

  • Page 20

    For technical questions, please call 1-800-444-3353; T roubleshooting section at end of manual. Page 20 SKU 94164 WELD SETTINGS CHART FIGURE N Welding Instructions continued on next page. T op gures are V oltage Settings. Bottom number is Wire Speed Setting. NOTE: The numbers within the spaces are the approximate wire feed/voltage settings recom[...]

  • Page 21

    For technical questions, please call 1-800-444-3353; T roubleshooting section at end of manual. Page 21 SKU 94164 Squeeze (and hold) the T rigger Switch (15d) of the Welding T orch (15) and stroke 18. the area to be welded with the Welding Wire to ignite the arc. Never tap the Welding Wire into the welding surface to ignite the arc. This will a. ca[...]

  • Page 22

    For technical questions, please call 1-800-444-3353; T roubleshooting section at end of manual. Page 22 SKU 94164 WELD DIAGNOSIS EXCESS OR BURN-THROUGH Weld droops on top and underneath, or falls through entirely , making a hole. PROPER Weld is visible underneath and bulges slightly on top. INADEQUA TE Weld does not contact the joint fully , just o[...]

  • Page 23

    For technical questions, please call 1-800-444-3353; T roubleshooting section at end of manual. Page 23 SKU 94164 Crooked/wavy bead POSSIBLE CAUSES AND SOLUTIONS Stickout too long: 1. Reduce stickout. Inaccurate welding: 2. Us e t wo h and s or re st ha nd on s tea dy surface. TOP VIEW Porosity Small cavities or holes in the bead. POSSIBLE CAUSES A[...]

  • Page 24

    For technical questions, please call 1-800-444-3353; T roubleshooting section at end of manual. Page 24 SKU 94164 WHEN THE WELD IS COMPLETED Lift the Welding Wire completely away from any grounded object. Set the face 21. shield down. Then, turn the Power Switch to its “OFF” position. Unplug the Power Cord (13) from the electrical outlet. Then,[...]

  • Page 25

    For technical questions, please call 1-800-444-3353; T roubleshooting section at end of manual. Page 25 SKU 94164 INSPECTION, MAINTENANCE, AND CLEANING W ARNING! Before performing any maintenance on the Welder , unplug the Power Cord (13) from its electrical outlet and allow all components of the Welder to completely cool. 1. Periodically open the [...]

  • Page 26

    For technical questions, please call 1-800-444-3353; T roubleshooting section at end of manual. Page 26 SKU 94164 REPLACING THE WELDING T ORCH LINER Switch welder off, disconnect power , and discharge electrode to ground before 1. proceeding. Secure welding wire to the spool, cut it near the spool, and remove it from the torch 2. and cable. Gently [...]

  • Page 27

    For technical questions, please call 1-800-444-3353; T roubleshooting section at end of manual. Page 27 SKU 94164 P ARTS LISTS AND DIAGRAMS WIRING SCHEMA TIC REV 01/07[...]

  • Page 28

    For technical questions, please call 1-800-444-3353; T roubleshooting section at end of manual. Page 28 SKU 94164 P ARTS LIST Part Description Qty . 1 Side Panel 1 2 Hinge 2 3 Handle Socket 2 4 Handle 1 5 Fan 1 6 Back Panel 1 7 Rectier 1 8 Inner Panel 1 9 Wire Spool Axle 1 10 Wire Feed Mechanism* 1 10a Swing Arm 1 10b T ension Adjusting Knob 1 1[...]

  • Page 29

    For technical questions, please call 1-800-444-3353; T roubleshooting section at end of manual. Page 29 SKU 94164 NOTE : Some parts are listed and shown for illustration purposes only and are not avail- able individually as replacement parts. ASSEMBL Y DIAGRAM[...]

  • Page 30

    For technical questions, please call 1-800-444-3353; T roubleshooting section at end of manual. Page 30 SKU 94164 ASSEMBL Y DIAGRAM (CONTINUED) 10d 10e 10c 10a 10f 11 10k 10l 10h 10g 10b 10i 10j Wire Feed Mechanism (10)[...]

  • Page 31

    IMPORT ANT! Be CERT AIN to shut off the Welder , disconnect it from power , and discharge the torch to ground before adjusting, cleaning, or repairing the unit. SKU 94164 For technical questions, please call 1-800-444-3353. Page 31 If the steps above do not solve the problem or if the repairs involved are too complex, contact a qualied technicia[...]

  • Page 32

    IMPORT ANT! Be CERT AIN to shut off the Welder , disconnect it from power , and discharge the torch to ground before adjusting, cleaning, or repairing the unit. SKU 94164 For technical questions, please call 1-800-444-3353. Page 32 If the steps above do not solve the problem or if the repairs involved are too complex, contact a qualied technicia[...]

  • Page 33

    IMPORT ANT! Be CERT AIN to shut off the Welder , disconnect it from power , and discharge the torch to ground before adjusting, cleaning, or repairing the unit. SKU 94164 For technical questions, please call 1-800-444-3353. Page 33 If the steps above do not solve the problem or if the repairs involved are too complex, contact a qualied technicia[...]