Chicago Welding 94164 Set Up And Operating Instructions Manual Download Page 27 | Manualshive

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For technical questions, please call 1-800-444-3353;

troubleshooting section at end of manual.

Page 27

SKU 94164

pARtS LIStS AnD DIAGRAMS

WIRInG SChEMAtIC

REV 01/07

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Summary of Contents for 94164

Page 1: ...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 proporti...

Page 2: ...ire 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 Holdin...

Page 3: ...sh 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 mai...

Page 4: ...not abuse the Power Cord Never use the Power Cord to carry the tools or pull 4 the Plug from an outlet Keep the Power Cord away from heat oil sharp edges or moving parts Replace damaged Power Cords im...

Page 5: ...ty measures reduce the risk of starting the tool accidentally Store idle tools out of reach of children and other untrained persons Tools are 5 dangerous in the hands of untrained users Maintain tools...

Page 6: ...trical 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 if 7 hot surfaces are accidently con...

Page 7: ...o not dispose of hot slag in containers holding combustible materials Keep a fire extinguisher nearby and know how to use it After spot welding make a thorough examination for evidence of fire Be awar...

Page 8: ...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...

Page 9: ...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...

Page 10: ...system and must never be attached to an electrically live terminal Your tool must be plugged into an appropriate outlet properly installed by a certified 3 electrician and grounded in accordance with...

Page 11: ...rresponding 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...

Page 12: ...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 in...

Page 13: ...ghtly 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...

Page 14: ...k 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 Inner 5 Panel 8 of the welder Replace the Feed Roller Bracket...

Page 15: ...ctrode Positive DCEP for 2 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 not 3...

Page 16: ...Stand to the side of the cylinder 4 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 turne...

Page 17: ...r 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 allowe...

Page 18: ...ol 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...

Page 19: ...ea to be welded then place a Face Shield over your 11 eyes 12 WARNING Never look at the ignited arc withoutANSI approved arc shaded eye protection in a full face shield Permanent eye damage or blindne...

Page 20: ...35 047 047 075 075 125 125 157 157 250 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...

Page 21: ...Welding Wire back and forth across the joint in a c 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 Overl...

Page 22: ...ch on page 19 Insufficient weld material 3 Increase wire feed speed Insufficient weld heat 4 Reduce Welding Speed Cross Sections Weld Not Adhering Properly Gaps present between weld and previous bead...

Page 23: ...e Fine spatter is normal Possible Causes and Solutions Wire feeding too fast 1 Reduce wire feed speed Stickout too long 2 Reduce stickout Dirty workpiece or welding wire 3 Make certain that workpiece...

Page 24: ...Welding Torch 15 on a nonflammable nonconductive surface NOTE The wire brush hammer can now be used to clean up the weld 23 CAUTION The weld may still be quite hot and sparks chips may fly when clean...

Page 25: ...even If the end is 3 uneven chipped melted cracked or otherwise damaged the Nozzle will adversely effect the weld and should be replaced Reinstall the Nozzle 15h after inspecting and cleaning the Cont...

Page 26: ...d Screws 10g Trim off the Liner that extends past the Clamp Make sure that all torch parts lay back into place properly including the Protective 10 Sleeve 15a Head Tube 15f and Trigger 15d See Assembl...

Page 27: ...For technical questions please call 1 800 444 3353 Troubleshooting section at end of manual Page 27 SKU 94164 Parts Lists and Diagrams Wiring Schematic REV 01 07...

Page 28: ...e 1 15b Locking Collar 1 15c Lower Housing 1 15d Trigger 1 15e Switch Body 1 15f Head Tube 1 Part Description Qty 15g Contact Tip 8 mm 1 15h Nozzle 1 15i Push lock Coupler 2 15j Gas Hose 1 15k Liner 1...

Page 29: ...ease call 1 800 444 3353 Troubleshooting 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 replaceme...

Page 30: ...echnical questions please call 1 800 444 3353 Troubleshooting section at end of manual Page 30 SKU 94164 Assembly Diagram continued 10d 10e 10c 10a 10f 11 10k 10l 10h 10g 10b 10i 10j Wire Feed Mechani...

Page 31: ...ates a bird s nest During operation Possible Causes and Solutions Excess wire feed pressure 1 Adjust wire feed pressure properly follow instructions on page 12 13 Incorrect contact tip size 2 Replace...

Page 32: ...2 Have a technician check and secure replace Switch Body 15e Internal fuse blown 3 Have a qualified technician check replace Troubleshooting continued Weak Arc strength Possible Cause and Solution Inc...

Page 33: ...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 This warranty does not apply to damage due dir...

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