Manual For The 63793 160A Spool Gun
User Manual: Manual for the 63793 160A Spool Gun 160A Spool Gun
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Owner’s Manual & Safety Instructions
Save This Manual%Keep this manual for the safety warnings and precautions, assembly,
operating, inspection, maintenance and cleaning procedures. Write the product’s serial number in the
back of the manual near the assembly diagram (or month and year of purchase if product has no number).
Keep this manual and the receipt in a safe and dry place for future reference.
When unpacking, make sure that the product is intact
and undamaged. If any parts are missing or broken,
please call 1-<?>-1-888-380-0318 as soon as possible.
Copyright© 2017 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 an d se rv ic e may n ot b e in cl uded.
;*,9%$."#%5,$*(",7%+*2&(*%'#"83%$."#%/(&9'4$1%
<,"7'(*%$&%9&%#&%4,8%(*#'7$%"8%#*("&'#%"8='(>1%
?@!6%ABC?%D@EF@G1
Owner’s Manual & Safety Instructions
Save This Manual%Keep this manual for the safety warnings and precautions, assembly,
operating, inspection, maintenance and cleaning procedures. Write the product’s serial number in the
back of the manual near the assembly diagram (or month and year of purchase if product has no number).
Keep this manual and the receipt in a safe and dry place for future reference.
When unpacking, make sure that the product is intact
and undamaged. If any parts are missing or broken,
please call 1-888-380-0318 as soon as possible.
Copyright© 2017 by Harbor Freight Tools®. All rights reserved.
No portion of this manual or any artwork contained herein may be reproduced in
any shape or form without the express written consent of Harbor Freight Tools.
Diagrams within this manual may not be drawn proportionally. Due to continuing
improvements, actual product may differ slightly from the product described herein.
Too ls r eq ui re d for a ss em bl y and s er vi ce m ay not be i nc lu de d.
;*,9%$."#%5,$*(",7%+*2&(*%'#"83%$."#%/(&9'4$1%
<,"7'(*%$&%9&%#&%4,8%(*#'7$%"8%#*("&'#%"8='(>1%
?@!6%ABC?%D@EF@G1
Owner’s Manual & Safety Instructions
Save This Manual%Keep this manual for the safety warnings and precautions, assembly,
operating, inspection, maintenance and cleaning procedures. Write the product’s serial number in the
back of the manual near the assembly diagram (or month and year of purchase if product has no number).
Keep this manual and the receipt in a safe and dry place for future reference.
When unpacking, make sure that the product is intact
and undamaged. If any parts are missing or broken,
please call 1-888-380-0318 as soon as possible.
Copyright© 2017 by Harbor Freight Tools®. All rights reserved.
No portion of this manual or any artwork contained herein may be reproduced in
any shape or form without the express written consent of Harbor Freight Tools.
Diagrams within this manual may not be drawn proportionally. Due to continuing
improvements, actual product may differ slightly from the product described herein.
Too ls r eq ui re d for a ss em bl y and s er vi ce m ay not be i nc lu de d.
;*,9%$."#%5,$*(",7%+*2&(*%'#"83%$."#%/(&9'4$1%
<,"7'(*%$&%9&%#&%4,8%(*#'7$%"8%#*("&'#%"8='(>1%
?@!6%ABC?%D@EF@G1
Owner’s Manual & Safety Instructions
Save This Manual%Keep this manual for the safety warnings and precautions, assembly,
operating, inspection, maintenance and cleaning procedures. Write the product’s serial number in the
back of the manual near the assembly diagram (or month and year of purchase if product has no number).
Keep this manual and the receipt in a safe and dry place for future reference.
When unpacking, make sure that the product is intact
and undamaged. If any parts are missing or broken,
please call 1-888-380-0318 as soon as possible.
Copyright© 2017 by Harbor Freight Tools®. All rights reserved.
No portion of this manual or any artwork contained herein may be reproduced in
any shape or form without the express written consent of Harbor Freight Tools.
Diagrams within this manual may not be drawn proportionally. Due to continuing
improvements, actual product may differ slightly from the product described herein.
Too ls r eq ui re d for a ss em bl y and s er vi ce m ay not be i nc lu de d.
;*,9%$."#%5,$*(",7%+*2&(*%'#"83%$."#%/(&9'4$1%
<,"7'(*%$&%9&%#&%4,8%(*#'7$%"8%#*("&'#%"8='(>1%
?@!6%ABC?%D@EF@G1
Owner’s Manual & Safety Instructions
Save This Manual%Keep this manual for the safety warnings and precautions, assembly,
operating, inspection, maintenance and cleaning procedures. Write the product’s serial number in the
back of the manual near the assembly diagram (or month and year of purchase if product has no number).
Keep this manual and the receipt in a safe and dry place for future reference. 17e
When unpacking, make sure that the product is intact
and undamaged. If any parts are missing or broken,
please call 1-888-380-0318 as soon as possible.
Copyright© 2017 by Harbor Freight Tools®. All rights reserved.
No portion of this manual or any artwork contained herein may be reproduced in
any shape or form without the express written consent of Harbor Freight Tools.
Diagrams within this manual may not be drawn proportionally. Due to continuing
improvements, actual product may differ slightly from the product described herein.
Too ls r eq ui re d for a ss em bl y and s er vi ce m ay not be i nc lu de d.
;*,9%$."#%5,$*(",7%+*2&(*%'#"83%$."#%/(&9'4$1%
<,"7'(*%$&%9&%#&%4,8%(*#'7$%"8%#*("&'#%"8='(>1%
?@!6%ABC?%D@EF@G1
Page 2 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1 Item 63793
?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?SETUP?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?SETUP
A,+7*%&2%P&8$*8$#
Safety ......................................................... 2
Specifications ............................................. 5
Setup .......................................................... 6
Maintenance and Service .......................... 17
Parts List and Diagram .............................. 19
Warranty .................................................... 20
R@;ECET%?ODQVG?%@ES%S6<CECACVE?
This is the Safety alert symbol. It is used to alert you to potential
personal injury hazards. Obey all Safety messages that
follow this symbol to avoid possible injury or death.
Indicates a hazardous situation which, if not avoided,
will result in death or serious injury.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
Addresses practices not related to personal injury.
CDUV;A@EA%?@<6AO%CE<V;D@ACVE
;*,9%,77%?,2*$>%),(8"83#%,89%"8#$('4$"&8#1%%
<,"7'(*%$&%2&77&)%$.*%),(8"83#%,89%"8#$('4$"&8#%5,>%(*#'7$%"8%*7*4$("4%#.&4WI%2"(*%,890&(%#*("&'#%"8='(>1%%%
?,X*%,77%),(8"83#%,89%"8#$('4$"&8#%2&(%2'$'(*%(*2*(*84*1
T*8*(,7%?,2*$>
U;VA6PA%>&'(#*72%,89%&$.*(#1%%;*,9%,89%'89*(#$,89%$."#%"82&(5,$"&81
1. Q*2&(*%'#*I%(*,9%,89%'89*(#$,89%
manufacturer′s instructions,
Material Safety Data Sheets (MSDS′s),
employer′s Safety practices, and ANSI Z49.1.
2. Y**/%&'$%&2%(*,4.%&2%4."79(*81%%%
Keep children and bystanders away while operating.
3. U7,4*%$.*%)*79*(%&8%,%#$,+7*%7&4,$"&8%+*2&(*%'#*1%%%
If it falls while plugged in, severe injury,
electric shock, or fire may result.
4. S&%8&$%&X*((*,4.1%%%
Y**/%/(&/*(%2&&$"83%,89%+,7,84*%,$%,77%$"5*#1
5. ?$,>%,7*($I%),$4.%).,$%>&'%,(*%9&"83%,89%'#*%
4&55&8%#*8#*%).*8%&/*(,$"83%,%)*79*(1%%
S&%8&$%'#*%,%)*79*(%)."7*%>&'%,(*%$"(*9%&(%'89*(%
$.*%"827'*84*%&2%9('3#I%,74&.&7%&(%5*9"4,$"&81
A moment of inattention while operating welders
may result in serious personal injury.
6. @X&"9%'8"8$*8$"&8,7%#$,($"831%%Make sure you are
prepared to begin work before turning on the Welder.
7. E*X*(%7*,X*%$.*%R*79*(%'8,$$*89*9%)."7*%
*8*(3"Z*91%Turn power off if you have to leave.
8. A.*%),(8"83#I%/(*4,'$"&8#I%,89%"8#$('4$"&8#%
9"#4'##*9%"8%$."#%"8#$('4$"&8%5,8',7%4,88&$%
4&X*(%,77%/&##"+7*%4&89"$"&8#%,89%#"$',$"&8#%
$.,$%5,>%&44'(1%%It must be understood by the
operator that common sense and caution are
factors which cannot be built into this product,
but must be supplied by the operator.
Page 3<&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1Item 63793
?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU? SETUP ?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU? SETUP
<'5*%,89%T,#%?,2*$>
INHALATION HAZARD:%
R*79"83%,89%U7,#5,%P'$$"83%/(&9'4*%$&["4%2'5*#1
1. 6[/&#'(*%$&%)*79"83%&(%4'$$"83%*[.,'#$%
2'5*#%4,8%"84(*,#*%$.*%("#W%&2%9*X*7&/"83%
4*($,"8%4,84*(#I%#'4.%,#%4,84*(%&2%$.*%
7,(>8[%,89%7'83%4,84*(1 Also, some diseases
that may be linked to exposure to welding
or plasma cutting exhaust fumes are:
• Early onset of Parkinson’s Disease
• Heart disease
• Ulcers
• Damage to the reproductive organs
• Inflammation of the small intestine or stomach
• Kidney damage
• Respiratory diseases such as
emphysema, bronchitis, or pneumonia
Use natural or forced air ventilation and wear
a respirator approved by NIOSH to protect
against the fumes produced to reduce the
risk of developing the above illnesses.
2. S&%8&$%'#*%8*,(%9*3(*,#"83%&(%
/,"8$"83%&/*(,$"&8#1
3. Y**/%.*,9%&'$%&2%2'5*#1%%
Do not breathe exhaust fumes.
4. F#*%*8&'3.%X*8$"7,$"&8I%*[.,'#$%,$%,(4I%&(%
+&$.I%$&%W**/%2'5*#%,89%3,#*#%2(&5%+(*,$."83%
Z&8*%,89%3*8*(,7%,(*,1%%If engineering controls
are not feasible, use an approved respirator.
5. R&(W%"8%,%4&82"8*9%,(*,%&87>%"2%"$%
"#%)*77KX*8$"7,$*9I%&(%)."7*%)*,("83%
,8%,"(K#'//7"*9%(*#/"(,$&(1
6. B,X*%,%(*4&38"Z*9%#/*4",7"#$%"8%
C89'#$(",7%B>3"*8*%&(%68X"(&85*8$,7%?*(X"4*#%
4.*4W%$.*%&/*(,$"&8%,89%,"(%H',7"$>%
,89%5,W*%(*4&55*89,$"&8#%
2&(%$.*%#/*4"2"4%)*79"83%#"$',$"&81%%
Follow OSHA guidelines for
Permissible Exposure Limits (PEL’s) and
the American Conference of Governmental
Industrial Hygienists recommendations for
Threshold Limit Values (TLV’s) for fumes and gases.
@(4%;,>%?,2*$>
@;P%;@O?%4,8%"8='(*%*>*#%,89%+'(8%#W"81
1. R*,(%@E?CK,//(&X*9%)*79"83%*>*%/(&$*4$"&8%
2*,$'("83%,$%7*,#$%,%8'5+*(%JN%#.,9*%7*8#%(,$"831
2. R*,(%7*,$.*(%7*33"83#I%2"(*%(*#"#$,8$%#.&*#%
&(%+&&$#%9'("83%'#*1%%Do not wear pants with
cuffs, shirts with open pockets, or any clothing
that can catch and hold molten metal or sparks.
3. Y**/%47&$."83%2(**%&2%3(*,#*I%&"7I%
#&7X*8$#I%&(%,8>%27,55,+7*%#'+#$,84*#1%%
Wear dry, insulating gloves and protective clothing.
4. R*,(%,8%,//(&X*9%.*,9%4&X*("83%$&%/(&$*4$%
$.*%.*,9%,89%8*4W1%Use aprons, cape, sleeves,
shoulder covers, and bibs designed and
approved for welding and cutting procedures.
5. R*,(%,8%,//(&X*9%)*79"83%=,4W*$%&(%7&83%#7**X*#%
$&%/(&$*4$%2&(*,(5#%2(&5%(,9",$"&8%+'(8#1%
6. R.*8%)*79"8304'$$"83%&X*(.*,9%&(%"8%4&82"8*9%
#/,4*#I%)*,(%27,5*%(*#"#$,8$%*,(%/7'3#%&(%
*,(%5'22#%$&%W**/%#/,(W#%&'$%&2%*,(#1
67*4$("4,7%?,2*$>
6G6PA;CP%?BVPY%4,8%YCGG1
1. A'(8%&22I%9"#4&88*4$%/&)*(I%,89%
9"#4.,(3*%67*4$(&9*%$&%3(&'89%+*2&(*%#*$$"83%
9&)8%$&(4.067*4$(&9*%.&79*(%,89%+*2&(*%#*(X"4*1
2. S&%8&$%$&'4.%*8*(3"Z*9%*7*4$("4,7%/,($#1%%
Wear dry, insulating gloves. Do not touch Electrode
holder, Electrode, welding torch, or welding wire with
bare hand. Do not wear wet or damaged gloves.
3. P&88*4$%$&%3(&'89*9I%T<PCK/(&$*4$*9%
/&)*(%#'//7>%&87>1
4. S&%8&$%'#*%8*,(%),$*(%&(%9,5/%&+=*4$#1
5. U*&/7*%)"$.%/,4*5,W*(#%#.&'79%4&8#'7$%$.*"(%
physician(s) before use. Electromagnetic fields
in close proximity to heart pacemaker could cause
pacemaker interference or pacemaker failure.
6. S&%8&$%*[/&#*%)*79*(#%$&%(,"8%&(%)*$%4&89"$"&8#1%%%
Water entering a welder will increase
the risk of electric shock.
7. S&%8&$%,+'#*%$.*%4&(91%%E*X*(%'#*%$.*%4&(9%
2&(%4,((>"83I%/'77"83%&(%'8/7'33"83%$.*%)*79*(1%%
Y**/%4&(9%,),>%2(&5%.*,$I%&"7I%#.,(/%*93*#%
&(%5&X"83%/,($#1%%Damaged or entangled
cords increase the risk of electric shock.
8. S&%8&$%'#*%&'$9&&(#1
9. C8#'7,$*%>&'(#*72%2(&5%$.*%)&(W/"*4*%,89%
3(&'891%Use nonflammable, dry insulating
material if possible, or use dry rubber mats,
dry wood or plywood, or other dry insulating
material large enough to cover your full
area of contact with the work or ground.
Page 4 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1 Item 63793
?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?SETUP?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?SETUP
<"(*%?,2*$>
@;P%@ES%?G@T%4,8%4,'#*%2"(*1
1. P7*,(%,),>%&(%/(&$*4$%27,55,+7*%&+=*4$#1%%%
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.
2. Y**/%@QPK$>/*%2"(*%*[$"83'"#.*(%8*,(%
)&(W%,(*,%,89%W8&)%.&)%$&%'#*%"$1
3. D,"8$,"8%,%#,2*%)&(W"83%*8X"(&85*8$1%%%
Keep the work area well lit.
Make sure there is adequate
surrounding workspace. Keep the work area free
of obstructions, grease, oil, trash, and other debris.
4. S&%8&$%&/*(,$*%)*79*(#%"8%,$5&#/.*(*#%
4&8$,"8"83%9,83*(&'#7>%(*,4$"X*%&(%
27,55,+7*%7"H'"9#I%3,#*#I%X,/&(#I%&(%9'#$1%%
Provide adequate ventilation in work areas
to prevent accumulation of such substances.
Welders create sparks which may ignite flammable
substances or make reactive fumes toxic.
5. C2%)&(W"83%&8%,%5*$,7%),77I%4*"7"83I%*$41I%
/(*X*8$%"38"$"&8%&2%4&5+'#$"+7*#%&8%$.*%
&$.*(%#"9*%+>%5&X"83%$.*%4&5+'#$"+7*#%$&%,%
#,2*%7&4,$"&81 If relocation of combustibles is
not possible, designate someone to serve as
a fire watch, equipped with a fire extinguisher,
during the cutting process and for at least one
half hour after the cutting is completed.
6. S&%8&$%)*79%&(%4'$%&8%5,$*(",7#%.,X"83%
,%4&5+'#$"+7*%4&,$"83%&(%4&5+'#$"+7*%
"8$*(8,7%#$('4$'(*I%,#%"8%),77#%&(%4*"7"83#I%)"$.&'$%
,8%,//(&X*9%5*$.&9%2&(%*7"5"8,$"83%$.*%.,Z,(91
7. S&%8&$%9"#/&#*%&2%.&$%#7,3%"8%4&8$,"8*(#%
.&79"83%4&5+'#$"+7*%5,$*(",7#1
8. @2$*(%)*79"83I%5,W*%,%$.&(&'3.%*[,5"8,$"&8%
2&(%*X"9*84*%&2%2"(*1%%Be aware that easily
visible smoke or flame may not be present
for some time after the fire has started.
9. S&%8&$%,//7>%.*,$%$&%,%4&8$,"8*(%$.,$%.,#%.*79%
,8%'8W8&)8%#'+#$,84*%&(%,%4&5+'#$"+7*%
5,$*(",7%).&#*%4&8$*8$#I%).*8%.*,$*9I%
4,8%/(&9'4*%27,55,+7*%&(%*[/7&#"X*%X,/&(#1%%
Clean and purge containers before applying heat.
Vent closed containers, including castings,
before preheating, welding, or cutting.
R*79*(%F#*%,89%P,(*
1. S&%8&$%'#*%$.*%)*79*(%"2%$.*%#)"$4.%9&*#%8&$%$'(8%
"$%&8%,89%&221%%Any welder that cannot be controlled
with the switch is dangerous and must be repaired.
2. S"#4&88*4$%$.*%/7'3%2(&5%$.*%/&)*(%
#&'(4*%+*2&(*%5,W"83%,8>%,9='#$5*8$#I%
4.,83"83%,44*##&("*#I%&(%#$&("83%)*79*(#1%%
Such preventive Safety measures reduce the
risk of starting the welder accidentally.
3. U(*X*8$%'8"8$*8$"&8,7%#$,($"831%
68#'(*%$.*%#)"$4.%"#%"8%$.*%&22K
/&#"$"&8%+*2&(*%4&88*4$"83%$&%/&)*(%
#&'(4*%&(%5&X"83%$.*%)*79*(1 Carrying
or energizing welders that have the
switch on invites accidents.
4. ?$&(*%"97*%)*79*(#%&'$%&2%$.*%(*,4.%&2%
4."79(*8%,89%9&%8&$%,77&)%/*(#&8#%'82,5"7",(%
)"$.%$.*%)*79*(%&(%$.*#*%"8#$('4$"&8#%$&%
&/*(,$*%$.*%)*79*(1%%Welders are dangerous
in the hands of untrained users.
5. F#*%$.*%)*79*(%,89%,44*##&("*#%"8%
,44&(9,84*%)"$.%$.*#*%"8#$('4$"&8#I%$,W"83%
"8$&%,44&'8$%$.*%)&(W"83%4&89"$"&8#%,89%
$.*%)&(W%$&%+*%/*(2&(5*91 Use of the welder
for operations different from those intended
could result in a hazardous situation.
6. S&%8&$%'#*%$.*%)*79*(%2&(%/"/*%$.,)"831
D,"8$*8,84*
1. D,"8$,"8%)*79*(#1%%P.*4W%2&(%5"#,7"385*8$%&(%
+"89"83%&2%5&X"83%/,($#I%+(*,W,3*%&2%/,($#%
,89%,8>%&$.*(%4&89"$"&8%$.,$%5,>%,22*4$%$.*%
)*79*(\#%&/*(,$"&81%%C2%9,5,3*9I%.,X*%$.*%
)*79*(%(*/,"(*9%+*2&(*%'#*1 Many accidents
are caused by poorly maintained welders.
2. B,X*%>&'(%)*79*(%#*(X"4*9%+>%,%H',7"2"*9%
(*/,"(%/*(#&8%'#"83%&87>%"9*8$"4,7%
(*/7,4*5*8$%/,($#1%%This will ensure that
the Safety of the welder is maintained.
Page 5<&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1Item 63793
?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU? SETUP ?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU? SETUP
3. D,"8$,"8%7,+*7#%,89%8,5*/7,$*#%&8%$.*%R*79*(1%%%
These carry important information.
If unreadable or missing, contact
Harbor Freight Tools for a replacement.
4. F8/7'3%+*2&(*%5,"8$*8,84*1%Unplug the Welder
from its electrical outlet before any inspection,
maintenance, or cleaning procedures.
T,#%?."*79*9%R*79"83%K%P>7"89*(%?,2*$>
P>7"89*(#%4,8%*[/7&9*%).*8%9,5,3*91
1. S&%8&$%)*79%&8%,%/(*##'("Z*9%&(%47&#*9%4>7"89*(1
2. S&%8&$%,77&)%,8%67*4$(&9*%.&79*(I%
67*4$(&9*I%)*79"83%$&(4.I%&(%)*79"83%
)"(*%$&%$&'4.%$.*%4>7"89*(1
3. Y**/%4>7"89*(#%,),>%2(&5%,8>%*7*4$("4,7%4"(4'"$#I%
"847'9"83%)*79"83%4"(4'"$#1
4. Y**/%/(&$*4$"X*%4,/%"8%/7,4*%&X*(%$.*%X,7X*%
*[4*/$%).*8%$.*%4>7"89*(%"#%"8%'#*1
5. F#*%&87>%4&((*4$%3,#%#."*79"83%*H'"/5*8$%
9*#"38*9%#/*4"2"4,77>%2&(%$.*%$>/*%&2%)*79"83%
>&'%)"77%9&1%%Maintain this equipment properly.
6. U(&$*4$%3,#%4>7"89*(#%2(&5%.*,$I%+*"83%#$('4WI%
/.>#"4,7%9,5,3*I%#7,3I%27,5*#I%#/,(W#I%,89%,(4#1
7. F#*%/(&/*(%/(&4*9'(*#%$&%5&X*%4>7"89*(#1
%?@!6%AB6?6%CE?A;FPACVE?1
Wire Feed (Speed)
Workpiece Ground Cable
Torch Cable
Overheat Shutdown Indicator
Cooling Fan
!@PVolts Alternating Current
@Amperes
VP! Open Circuit Voltage
CUD Inches Per Minute
@RTAmerican Wire Gauge
Electric Shock Hazard.
Do not touch energized parts.
Inhalation Hazard.
Keep head out of fumes
and use proper ventilation.
Read manual before
setup and/or use.
Fire Hazard.
Keep flammable materials
away during welding. Spatter
can cause accidental fires.
Arc Ray Hazard.
Wear welding helmet with
properly rated filter lens.
Pacemaker Hazard.
Welding processes may
interfere with pacemakers.
Consult doctor before use.
?/*4"2"4,$"&8#
Wire Types Aluminum and Steel alloys
Wire Capacity 4" Spool, - 1lb aluminum and 2lb steel, 0.030" / 0.035"diameter
Rated Duty Cycle 35% @ 160 A
Page 6 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1 Item 63793
?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?SETUP
?*$'/
% ;*,9%$.*%6EAC;6%CDUV;A@EA%?@<6AO%CE<V;D@ACVE%#*4$"&8%,$%$.*%+*3"88"83%&2%$."#%
5,8',7%"847'9"83%,77%$*[$%'89*(%#'+.*,9"83#%$.*(*"8%+*2&(*%#*$%'/%&(%'#*%&2%$."#%/(&9'4$1
AV%U;6!6EA%?6;CVF?%CE]F;O%<;VD%@PPCS6EA@G%VU6;@ACVE-%
A'(8%$.*%U&)*(%?)"$4.%&22%,89%'8/7'3%$.*%)*79*(%+*2&(*%#*$%'/1
Place the Welder on a level surface that can bear its weight near the work
area. Leave space around the Welder for proper air flow.
E&$*- A.*%2&77&)"83%"8#$('4$"&8#%,(*%2&(%)*79"83%)"$.%@7'5"8'5%)"(*1
P&88*4$%?."*79"83%T,#
1. With assistance, place an 100% Argon cylinder
(not included) onto a cabinet or cart near the
Welder and secure the cylinder in place with
two straps (not included) to prevent tipping.
2. Remove the cylinder’s cap. Stand to the
side of the valve opening, then open the
valve briefly to blow dust and dirt from the
valve opening. Close the cylinder valve.
3. Close the Regulator’s valve by backing off knob
until it is loose, then thread Regulator onto
cylinder and wrench tighten connection.
4. Attach the Gas Hose (included) to the
Regulator’s Outlet and the Welder’s Gas Inlet.
Wrench-tighten both connections.
Reset
Power Input
Gas Inlet
4M
Q("*27>%&/*8%X,7X*%
$&%47*,8I%%
$.*8%47&#*%%
X,7X*1
^
J
Page 7<&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1Item 63793
?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU? SETUP
?*$%F/%?/&&7%T'8
1. Pull the Nozzle to remove it.
2. Unscrew the Contact Tip
counterclockwise and remove.
E&ZZ7* P&8$,4$%
A"/
3. Press Spool Cover Release Button,
then open Spool Cover.
4. Remove Spool Lock Knob by turning clockwise.
5. Loosen Spool Tension Knob without removing.
E&$*- To prevent unraveling, leave
wire secured to Spool.
6. Install Spool so wire will feed over top of Spool.
7. Tighten Spool Tension Knob until
Spool cannot spin freely.
8. Replace Spool Lock Knob by
turning counterclockwise.
?/&&7%
G&4W%Y8&+
?/&&7%
A*8#"&8%
Y8&+
?/&&7%P&X*(%
;*7*,#*%Q'$$&8
9. Hold end of wire while releasing from
Spool. Cut off any bent wire.
10. Keeping tension on Spool, feed
Wire into Inlet Guide.
11. Loosen Tension Knob.
12. Push on Tension Knob enough to create a
space, between Driver Roller and Tension Roller,
large enough so that Wire will pass through.
13. Push Wire 1/4" into Inlet.
14. Tighten Tension Knob.
A*8#"&8%
Y8&+
A*8#"&8%
@(5
A*8#"&8%
;&77*(
R"(*
C87*$%
T'"9*
S("X*%
;&77*(
C87*$
A*8#"&8%
?/("83
15. Close Spool Cover.
16. Set Spool Gun down on nonconductive,
nonflammable surface away from
any grounded objects.
Page 8 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1 Item 63793
?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?SETUP
Connect to Vulcan MIGMAX 140
1. Turn Power Switch OFF and unplug welder.
2. Open Door on side of Welder.
3. Remove MIG Gun and Wire Spool, if present.
S&&(
4. Set Polarity to DCEP (Direct
Current Electrode Positive):
a. Connect Black Ground Cable
to Negative Terminal (-).
b. Connect Red Electrode Cable
to Positive Terminal (+).
c. Make sure Cables sit flush in grooves.
T(&&X*
5. P&88*4$%?/&&7%T'8-
a. Loosen Knob without removing.
b. Plug Spool Gun Connector
into Spool Gun Socket.
c. Tighten Knob, do not over tighten.
d. Pull on Spool Gun Connector to ensure tight
connection. Re-seat if connection is not tight.
E&$*- If connection is not tight, arc will not ignite.
Y8&+
?/&&7%T'8%
P&88*4$&(
?/&&7%T'8%
?&4W*$%
6. Plug Wire Feed Control Cable into
Wire Feed Control Socket. Secure by
turning collar clockwise until tight.
E&$*- Plug will only fit one way.
7. Plug Gas Cable into Gas Outlet.
Secure by wrench tightening.
?/&&7%T'8%
?&4W*$%
R"(*%<**9%
P&8$(&7%
?&4W*$
T,#%
V'$7*$
R"(*%<**9%
P&8$(&7%
P,+7*
T,#%
P,+7*
Page 9<&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1Item 63793
?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU? ?6AFU
S@ET6;
U@;A?%D@O%Q6%@A%R6GSCET%!VGA@T6
AV%U;6!6EA%6G6PA;CP%?BVPY%@ES%S6@AB-
1. Y**/%.,89#%,),>%2(&5%R"(*%<**9%5*4.,8"#51
2. P7&#*%9&&(%+*2&(*%/7'33"83%"8I%
3. ?$,>%47*,(%&2%)"(*%)."7*%2**9"83%)"(*%$.(&'3.%3'81
AV%U;6!6EA%?6;CVF?%CE]F;O-%U(&$*4$"X*%3*,(%5'#$%+*%)&(8%).*8%'#"83%$.*%R*79*(_%5"8"5'5%
shade number 10 full face shield (or welding mask), ear protection, welding gloves, sleeves and apron,
ECV?BK,//(&X*9%(*#/"(,$&(I%,89%2"(*%(*#"#$,8$%)&(W%47&$.*#%)"$.&'$%/&4W*$#%#.&'79%+*%)&(8%).*8%)*79"831%%
G"3.$%2(&5%$.*%,(4%4,8%4,'#*%/*(5,8*8$%9,5,3*%$&%$.*%*>*#%,89%#W"81%%S&%8&$%+(*,$.*%,(4%2'5*#1
8. P7&#*%S&&(%&8%#"9*%&2%R*79*(I%
5,W"83%#'(*%"$%7,$4.*#1
9. Plug either 120 VAC or 240 VAC Power Cord
into Power Input Socket on back of welder.
E&$*- Plug will only fit one way.
10. Plug Welder into properly grounded, GFCI
protected, 120 VAC (20 amp rated) outlet or
240 V outlet. The circuit must be equipped with
delayed action-type circuit breaker or fuses.
11. Turn Power Switch ON.
12. On inside of welder,
toggle Spool Gun/MIG Gun switch
to ?/&&7%T'8.
Spool
Gun
MIG
Gun
Cold
Wire Feed
a. Turn Amperage to A and Voltage to 1.
13. P.*4W%R"(*%S("X*%A*8#"&8-
a. Hold Spool Gun and point it
away from all objects.
b. Press and hold Trigger until at least 2"
of wire sticks out of the Gun. Release
Trigger. Trim wire to 2" as needed.
c. Hold Gun 2 - 3" away from piece of wood.
d. Press Trigger. When Wire touches wood,
it should bend instead of stopping.
• If Wire stops instead of bending,
turn off and unplug welder.
• Slightly tighten Tension Knob.
• Plug welder in and turn power on.
• Repeat steps c. and d. until Wire bends instead
of stopping. Trim wire to 2" as needed.
^KM`
A*8#"&8%
Y8&+
R"(*%?.&'79%
Q*89
14. Turn Power Switch OFF and unplug welder.
15. Choose Contact Tip same size as
Wire. Slide Contact Tip over Wire.
16. Replace Nozzle, trim wire to 1/2".
17. Set Spool Gun down on nonconductive,
nonflammable surface away from
any grounded objects.
18. Go to V/*(,$"&8%&8%/,3*%141
Page 10 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1 Item 63793
?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?SETUP
P&88*4$%$&%!'74,8%DCTD@a%^Jb
1. Turn Power Switch OFF and unplug welder.
2. Open Door on side of welder.
3. Remove MIG Gun and Wire Spool, if present.
S&&(
4. Set Polarity to DCEP (Direct
Current Electrode Positive):
a. Connect Black Ground Cable
to Negative Terminal (-).
b. Connect Red Electrode Cable
to Positive Terminal (+).
c. Make sure Cables sit flush in grooves.
T(&&X*
5. P&88*4$%?/&&7%T'8-
a. Loosen Knob without removing.
b. Plug Spool Gun Connector
into Spool Gun Socket.
c. Tighten Knob, do not over tighten.
d. Pull on Spool Gun Connector to ensure tight
connection. Re-seat if connection is not tight.
E&$*- If connection is not tight, arc will not ignite.
Y8&+
?/&&7%T'8%
P&88*4$&(
?/&&7%T'8%
?&4W*$%
6. Plug Wire Feed Control Cable into
Wire Feed Control Socket. Secure by
turning collar clockwise until tight.
E&$*- Plug will only fit one way.
7. Plug Gas Cable into Gas Outlet.
Secure by wrench tightening.
?/&&7%T'8%
?&4W*$%
R"(*%<**9%
P&8$(&7%
?&4W*$
T,#%
V'$7*$
R"(*%<**9%
P&8$(&7%
P,+7*
T,#%
P,+7*
Page 11<&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1Item 63793
?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU? ?6AFU
S@ET6;
U@;A?%D@O%Q6%@A%R6GSCET%!VGA@T6
AV%U;6!6EA%6G6PA;CP%?BVPY%@ES%S6@AB-
1. Y**/%.,89#%,),>%2(&5%R"(*%<**9%5*4.,8"#51
2. P7&#*%9&&(%+*2&(*%/7'33"83%"8I%
3. ?$,>%47*,(%&2%)"(*%)."7*%2**9"83%)"(*%$.(&'3.%3'81
AV%U;6!6EA%?6;CVF?%CE]F;O-%U(&$*4$"X*%3*,(%5'#$%+*%)&(8%).*8%'#"83%$.*%R*79*(_%5"8"5'5%
shade number 10 full face shield (or welding mask), ear protection, welding gloves, sleeves and apron,
ECV?BK,//(&X*9%(*#/"(,$&(I%,89%2"(*%(*#"#$,8$%)&(W%47&$.*#%)"$.&'$%/&4W*$#%#.&'79%+*%)&(8%).*8%)*79"831%%
G"3.$%2(&5%$.*%,(4%4,8%4,'#*%/*(5,8*8$%9,5,3*%$&%$.*%*>*#%,89%#W"81%%S&%8&$%+(*,$.*%,(4%2'5*#1
8. P7&#*%S&&(%&8%#"9*%&2%R*79*(I%
5,W"83%#'(*%"$%7,$4.*#1
9. Plug either 120 VAC or 240 VAC Power Cord
into Power Input Socket on back of welder.
E&$*- Plug will only fit one way.
10. Plug welder into a properly grounded, GFCI
protected, 120 VAC (20 amp rated) outlet or
240 V outlet. The circuit must be equipped with
delayed action-type circuit breaker or fuses.
11. Turn Power Switch ON.
12. Turn Process Selection Knob to ?/&&7%T'81
13. Turn Voltage to 1, Amperage to A and
Wire Diameter to MANUAL.
U(&4*##%
?*7*4$"&8%Y8&+
14. P.*4W%R"(*%S("X*%A*8#"&8-
a. Hold Spool Gun and point it
away from all objects.
b. Press and hold Trigger until at least 2"
of wire sticks out of the Gun. Release
Trigger. Trim wire to 2" as needed.
c. Hold Gun 2 - 3" away from piece of wood.
d. Press Trigger. When Wire touches
wood, it should bend instead of
stopping. Release Trigger.
• If Wire stops instead of bending,
turn off and unplug welder.
• Slightly tighten Tension Knob.
• Plug welder in and turn power on.
• Repeat steps c. and d. until Wire bends instead
of stopping. Trim wire to 2" as needed.
^KM`
A*8#"&8%
Y8&+
R"(*%?.&'79%
Q*89
15. Turn Power Switch OFF and unplug welder.
16. Choose Contact Tip same size as
Wire. Slide Contact Tip over Wire.
17. Replace Nozzle, trim wire to 1/2".
18. Set Spool Gun down on nonconductive,
nonflammable surface away from
any grounded objects.
19. Go to V/*(,$"&8%&8%/,3*%141
Page 12 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1 Item 63793
?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?SETUP
P&88*4$%$&%!'74,8%VDECU;V%^^N
1. Turn Power Switch OFF and unplug Welder.
2. Open Door on side of Welder.
S&&(
3. P&88*4$%?/&&7%T'8-
a. Loosen Knob without removing.
b. Plug Spool Gun Connector
into Spool Gun Socket.
c. Tighten Knob, do not over tighten.
d. Pull on Spool Gun Connector to ensure tight
connection. Re-seat if connection is not tight.
E&$*- If connection is not tight, arc will not ignite.
4. Plug Wire Feed Control Cable into
Wire Feed Control Socket. Secure by
turning collar clockwise until tight.
E&$*- Plug will only fit one way.
5. Plug Gas Cable into Gas Outlet.
Secure by wrench tightening.
Y8&+
?/&&7%T'8%
P&88*4$&(
T,#%
P,+7*
?/&&7%T'8%
?&4W*$%
R"(*%<**9%
P&8$(&7%
?&4W*$
R"(*%<**9%
P&8$(&7%
P,+7*
T,#%
V'$7*$
6. Plug Ground Clamp Cable into Negative Socket.
Twist clockwise all the way to lock in place.
7. Plug Wire Feed Power Cable into Positive Socket.
Twist clockwise all the way to lock in place.
T(&'89%
P7,5/%
P,+7* R"(*%<**9%
U&)*(%P,+7*
Page 13<&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1Item 63793
?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU? ?6AFU
S@ET6;
U@;A?%D@O%Q6%@A%R6GSCET%!VGA@T6
AV%U;6!6EA%6G6PA;CP%?BVPY%@ES%S6@AB-
1. Y**/%.,89#%,),>%2(&5%R"(*%<**9%5*4.,8"#51
2. P7&#*%9&&(%+*2&(*%/7'33"83%"8I%
3. ?$,>%47*,(%&2%)"(*%)."7*%2**9"83%)"(*%$.(&'3.%3'81
AV%U;6!6EA%?6;CVF?%CE]F;O-%U(&$*4$"X*%3*,(%5'#$%+*%)&(8%).*8%'#"83%$.*%R*79*(_%5"8"5'5%
shade number 10 full face shield (or welding mask), ear protection, welding gloves, sleeves and apron,
ECV?BK,//(&X*9%(*#/"(,$&(I%,89%2"(*%(*#"#$,8$%)&(W%47&$.*#%)"$.&'$%/&4W*$#%#.&'79%+*%)&(8%).*8%)*79"831%%
G"3.$%2(&5%$.*%,(4%4,8%4,'#*%/*(5,8*8$%9,5,3*%$&%$.*%*>*#%,89%#W"81%%S&%8&$%+(*,$.*%,(4%2'5*#1
8. P7&#*%S&&(%&8%#"9*%&2%R*79*(I%
5,W"83%#'(*%"$%7,$4.*#1
9. Plug either 120 VAC or 240 VAC Power Cord
into Power Input Socket on back of welder.
E&$*- Plug will only fit one way.
10. Plug Welder into properly grounded, GFCI
protected, 120 VAC (20 amp rated) outlet or
240 V outlet. The circuit must be equipped with
delayed action-type circuit breaker or fuses.
11. Turn Power Switch ON.
12. Push Home button.
13. Turn Main Knob until desired
Spool Gun/Wire Type process
appears on screen.
14. Press Main Knob. Confirm correct
Gas is connected to welder.
15. Press Main Knob. Make sure Diameter
and Thickness are set to lowest settings
by turning Left and Right Knobs.
1NMN` JcT,
Spool Gun 4043 Al
16. Press Main Knob. Ready to
check Wire Drive Tension.
348 Jb1b
N1N
N
1NMN`
N1N
^b b
JcT,
Spool Gun 4043 Al
JNNd%@(
17. P.*4W%R"(*%S("X*%A*8#"&8-
a. Hold Spool Gun and point it
away from all objects.
b. Press and hold Trigger until at least 2" of wire
sticks out of the Gun. Trim wire to 2" as needed.
c. Hold Gun 2 - 3" away from piece of wood.
d. Press Trigger. When Wire touches wood,
it should bend instead of stopping.
• If Wire stops instead of bending,
turn off and unplug welder.
• Slightly tighten Tension Knob.
• Plug welder in and turn power on.
• Reset Welder to desired process
and check settings.
• Repeat steps c. and d. until Wire bends instead
of stopping. Trim wire to 2" as needed.
^KM`
A*8#"&8%
Y8&+
R"(*%?.&'79%
Q*89
18. Turn Power Switch OFF and unplug welder.
19. Choose Contact Tip same size as
Wire. Slide Contact Tip over Wire.
20. Replace Nozzle, trim wire to 1/2".
21. Set Spool Gun down on nonconductive,
nonflammable surface away from
any grounded objects.
Page 14 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1 Item 63793
?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?SETUP
V/*(,$"&8
% ;*,9%$.*%6EAC;6%CDUV;A@EA%?@<6AO%CE<V;D@ACVE%#*4$"&8%,$%$.*%+*3"88"83%&2%$."#%
5,8',7%"847'9"83%,77%$*[$%'89*(%#'+.*,9"83#%$.*(*"8%+*2&(*%#*$%'/%&(%'#*%&2%$."#%/(&9'4$1
AV%U;6!6EA%?6;CVF?%CE]F;O%@ES%S6@AB-%%%
S&%8&$%)*79%)"$.&'$%T(&'89"83%P7,5/1%%
R.*8%$.*%&/*(,$&(%"#%8&$%.&79"83%$.*%?/&&7%T'8I%"$%5'#$%+*%#"$$"83%&8%,%8&84&89'4$"X*I%8&827,55,+7*%
#'(2,4*1%
V87>%.&79%?/&&7%T'8%)"$.%,8%*7*4$("4,77>%"8#'7,$*9%)*79"83%37&X*1%
AV%U;6!6EA%?6;CVF?%CE]F;O-%
U(&$*4$"X*%3*,(%5'#$%+*%)&(8%).*8%'#"83%$.*%R*79*(_%5"8"5'5%#.,9*%8'5+*(%JN%2'77%2,4*%
shield (or welding mask), ear protection, welding gloves, sleeves and apron, NIOSH-approved
(*#/"(,$&(I%,89%2"(*%(*#"#$,8$%)&(W%47&$.*#%)"$.&'$%/&4W*$#%#.&'79%+*%)&(8%).*8%)*79"831%%
%%%
AV%U;6!6EA%S6@AB%<;VD%@?UBOaC@ACVE-%
S&%8&$%&/*8%3,#%)"$.&'$%/(&/*(%X*8$"7,$"&81%%<"[%3,#%7*,W#%"55*9",$*7>1 Shielding gas can displace
air and cause rapid loss of consciousness and death. ?."*79"83%3,#%)"$.&'$%4,(+&8%9"&["9*%4,8%+*%
*X*8%5&(*%.,Z,(9&'#%+*4,'#*%,#/.>[",$"&8%4,8%#$,($%)"$.&'$%2**7"83%#.&($8*##%&2%+(*,$.1
;*2*(%$&%Q,#"4%R*79"83%#*4$"&8%"8%>&'(%!'74,8%)*79*(\#%5,8',7%
2&(%DCT%S'$>%P>47*I%?*$$"83%F/%A.*%R*79I%T(&'89"83%R&(W/"*4*I%
?*$$"83#I%?."*79"83%T,#%F#*%,89%Q,#"4%R*79"83%A*4.8"H'*1
?'+#$"$'$*%"8#$('4$"&8#%+*7&)%2&(%Q,#"4%R*79"83%A*4.8"H'*%"8%)*79*(\#%5,8',71%%
Q,#"4%R*79"83%A*4.8"H'*
1. Press (and hold) Spool Gun Trigger and contact
the area to be welded with wire to ignite arc.
• E,((&)%R*79- Push the wire in a steady
straight line. This is called a stringer bead.
?$("83*(%Q*,9
• R"9*%R*79: Push the wire back and forth
across the joint. This is called a weave bead
and takes practice to perform properly.
R*,X*%Q*,9
2. Direct the welding wire straight into the join:.
• 45° angle for fillet welds.
• 90° angle for butt welds,
R*79%DCT%T'8%,837*#I%%
X"*)*9%2(&5%2(&8$%&2%)*79%=&"8$1
45°
2"77*$%)*79%=&"8$
90°
+'$$%)*79%=&"8$
Page 15<&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1Item 63793
?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU? SETUP
3. The Spool Gun should be tilted so that wire
is angled anywhere from straight on and 15°
away from the direction you are welding. The
amount of tilt is called the push angle.
R*79%
S"(*4$"&8
U'#.%@837*
0-15°
4. The Contact Tip should remain within 1/2"
of the work surface. This distance is called
CTWD - Contact Tip to Work Distance.
PARS%%
(up to 1/2")
;*2*(%$&%Q,#"4%R*79"83%#*4$"&8%"8%>&'(%!'74,8%)*79*(\#%
5,8',7%2&(%(*5,"8"83%)*79"83%"8#$('4$"&8#1
Page 16 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1 Item 63793
?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?SETUP
Q'(8KA.(&'3.
Q,#*%5,$*(",7%5*7$#%,),>I%%
7*,X"83%,%.&7*%"8%$.*%)*791
UV??CQG6%P@F?6?%@ES%?VGFACVE?
1. R&(W/"*4*%&X*(.*,$"83-%
Reduce current and/or wire feed speed.
2. A(,X*7%#/**9%$&&%#7&)-
Increase travel speed and ensure
that travel speed is kept steady.
3. 6[4*##"X*%5,$*(",7%,$%)*79-%
Reduce wire feed speed.
TOP
VIEW
P(&&W*90R,X>%Q*,9
UV??CQG6%P@F?6?%@ES%?VGFACVE?
1. C8,44'(,$*%)*79"83-
Use two hands or rest hand on steady surface.
2. C84&8#"#$*8$%$(,X*7%#/**9-%
Maintain steady travel speed.
3. PARS%$&&%7&83-
Reduce CTWD.
TOP
VIEW
U&(&#"$>
?5,77%4,X"$"*#%&(%.&7*#%"8%$.*%+*,91
UV??CQG6%P@F?6?%@ES%?VGFACVE?
1. C84&((*4$%/&7,("$>-
Check that polarity is set correctly
for type of welding.
2. Insufficient shielding gas (MIG only):
Increase flow of gas.
Clean nozzle.
Maintain proper CTWD.
3. Incorrect shielding gas (MIG only):
Use shielding gas recommended by wire supplier.
4. S"($>%)&(W/"*4*%&(%)*79"83%)"(*-
Clean workpiece down to bare metal.
Make certain that wire is clean and free
from oil, coatings, and other residues.
5. C84&8#"#$*8$%$(,X*7%#/**9-%
Maintain steady travel speed.
6. PARS%$&&%7&83-
Reduce CTWD.
TOP
VIEW
6[4*##"X*%?/,$$*(
<"8*%#/,$$*(%"#%8&(5,71%
?/,$$*(%$.,$%"#%3(,"8>%,89%7,(3*%"#%,%/(&+7*51
UV??CQG6%P@F?6?%@ES%?VGFACVE?
1. S"($>%)&(W/"*4*%&(%)*79"83%)"(*-
Clean workpiece down to bare metal.
Make certain that wire is clean and free
from oil, coatings, and other residues.
2. C84&((*4$%/&7,("$>-
Check that polarity is set correctly
for type of welding.
3. Insufficient shielding gas (MIG only):
Increase flow of gas.
Clean nozzle.
Maintain proper CTWD.
4. R"(*%2**9"83%$&&%2,#$-%
Reduce wire feed speed.
5. PARS%$&&%7&83-
Reduce CTWD.
TOP
VIEW
R*79%U(&+7*5#
Page 17<&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1Item 63793
?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU? SETUP
D,"8$*8,84*%,89%?*(X"4*
AV%U;6!6EA%?6;CVF?%CE]F;OI%<C;6%@ES%QF;E?-%
F8/7'3%$.*%)*79*(I%(*#$%$.*%?/&&7%T'8%&8%,%.*,$K/(&&2I%*7*4$("4,77>%8&8K4&89'4$"X*%#'(2,4*I%
,89%,77&)%,77%/,($#%&2%$.*%R*79*(%$&%4&&7%$.&(&'3.7>%+*2&(*%#*(X"4*1%
1. Q6<V;6%6@PB%F?6I inspect the general
condition of the Spool Gun. Check for:
• loose hardware,
• misalignment or binding of moving parts,
• damaged cord/electrical wiring,
• frayed or damaged cables,
• cracked or broken parts, and
• any other condition that may
affect its safe operation.
2. @<A6;%6!6;O%F?6I%inspect and
clean Nozzle and Contact Tip.%%
3. @<A6;%6!6;O%F?6I Store in a
clean and dry location.
4. U6;CVSCP@GGOI clean Barrel, replace Inlet Guide
E&ZZ7*%,89%P&8$,4$%A"/%C8#/*4$"&8%,89%P7*,8"83
1. D,W*%#'(*%$.,$%$.*%?/&&7%T'8%"#%4&5/7*$*7>%
4&&7%,89%$.,$%$.*%U&)*(%P&(9%"#%'8/7'33*9%
2(&5%$.*%*7*4$("4,7%&'$7*$%+*2&(*%/(&4**9"831
2. Pull the Nozzle to remove it.
3. Scrub the interior of the Nozzle
clean with a wire brush.
4. Examine the end of the Nozzle. The end should be
flat and even. If the end is uneven, chipped, melted,
cracked, or otherwise damaged, replace Nozzle.
5. Unscrew the Contact Tip counterclockwise
and slide it off the welding wire to remove.
6. Scrub the outside of the Tip clean
with a wire brush. Clean out the inside of the
tip with a tip cleaner (sold separately).
7. Examine the shape of the hole at the end of the
Contact Tip. It should be an even circle; if it is
oblong or has any bulges in it, replace Contact Tip.
P7*,8"83%Q,((*7
1. Remove Nozzle and Contact Tip.
2. Remove Hex Bolt, then pull Barrel out.
3. Using compressed air, blow out Barrel.
4. Replace Barrel, Contact Tip and Nozzle.
B*[%
Q&7$
Q,((*7
;*/7,4"83%C87*$%T'"9*
1. Remove Hex Set Screw.
2. Pull out Inlet Guide.
3. Replace Inlet Guide.
4. Replace Hex Set Screw.
SV%EVA%&X*($"3.$*81%%68#'(*%C87*$%T'"9*%
"#%#8'31%%VX*($"3.$*8"83%)"77%4,'#*%
/*(5,8*8$%9,5,3*%$&%C87*$%T'"9*1
B*[%?*$%
?4(*)
C87*$%
T'"9*
Page 18 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1 Item 63793
?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?SETUP
A(&'+7*#.&&$"83
U(&+7*5 U&##"+7*%P,'#*# G"W*7>%?&7'$"&8#
Wire feed motor
runs but wire does
not feed properly
1. Tension Knob is too tight.
2. Damaged Gun, cable, or liner assembly.
3. Tension Knob is too tight.
1. Tighten Tension Knob so it applies only
enough pressure to prevent continued
spinning after the Gun Trigger is released.
2. Have a qualified technician inspect these
parts and replace as necessary.
3. Loosen Tension Knob so it applies only
enough pressure to prevent continued
spinning after the Gun Trigger is released.
Wire creates a bird’s
nest during operation
1. Tension Knob is too tight.
2. Incorrect Contact Tip size.
3. Damaged liner.
1. Loosen Tension Knob
2. Replace with the proper tip for wire used.
3. Have a qualified technician inspect
and repair/replace as necessary.
Wire stops
during welding
1. Gun liner is clogged or worn.
2. Wire is tangled on the spool.
3. Tension Roller is not making
enough contact with wire.
1. Check gun liner for obstruction, blow out with
compressed air. Have liner replaced if necessary.
2. Check wire for cross winding or tangled spool.
3. Check Tension Knob and ensure it is set properly.
Wire feeds, but arc
does not ignite
1. Improper ground connection.
2. Improperly sized Contact Tip.
3. Excessively worn Contact Tip.
4. Dirty Contact Tip.
1. Make certain that the workpiece is contacted
properly by the Ground Clamp and that
the workpiece is properly cleaned near the
ground clamp and the welding location.
2. Verify that Contact Tip is the proper size
for welding wire. If needed, replace
Contact Tip with proper size and type.
3. Check that the hole in the tip is not
deformed or enlarged. If needed, replace
Contact Tip with proper size and type.
4. Properly clean Contact Tip.
Porosity in the
weld metal
1. Gun is being used too far away from workpiece.
2. Dirty welding wire is introducing
contamination into the weld.
1. Check CTWD (contact tip to work distance).
2. Make certain that welding wire is clean
and free of rust and residues.
Welding arc
not stable
1. Wire not feeding properly.
2. Incorrect or damaged Contact Tip.
3. Loose Gun cable or ground cable.
4. Damaged Gun or loose connection within Gun.
5. Gas coverage may be insufficient or too high.
6. Poor connection with workpiece.
1. See first Troubleshooting section above.
2. Replace Contact Tip.
3. Check to ensure that all connections are tight.
4. Have a qualified technician inspect
and repair/replace as necessary.
5. Ensure gas flow rate is set according to Settings Chart.
Make sure Gun Cable Connector is fully inserted into
Wire Feed mechanism with no O-Rings exposed.
6. Check the ground clamp connection to the workpiece
and machine. Ensure the Gun is properly secured.
<&77&)%,77%#,2*$>%/(*4,'$"&8#%).*8*X*(%9",38&#"83%&(%#*(X"4"83%$.*%*H'"/5*8$1
Page 19<&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1Item 63793
?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU? SETUP
U,($#%G"#$%,89%S",3(,5
U,($ S*#4("/$"&8 e$>
1 Handle 1
2 Trigger 1
3 Block 1
4 Cover 1
5 Hanger Hook 1
6 Spool Shaft 1
7 Spool Tensioner 1
8 Spacer 1
9 Spool Tension Knob 1
10 Spool Lock Knob 1
11 Latch 1
12 Spool Cover Release Button 1
14 Drive Roller 1
15 Tension Spring 1
16 Bushing 1
17 Tension Roller 1
18 Tension Knob 1
19 Inlet Guide 1
20 Tension Arm 1
21 Tension Arm Shaft 1
22 Bracket 1
U,($ S*#4("/$"&8 e$>
23 Motor And Gear Box 1
24 Gas Connector 1
25 Wire Feeder Assembly 1
26 Conducting Bar 1
27 Liner Assembly 1
28 O-Ring 7.65X1.78 2
29 Barrel 1
30 Insulator 1
31 Gas Diffuser 1
32 Contact Tip 4
33 Nozzle 12mm 1
35 Internal Gas Hose 1
36 Front Spring Cable Support 1
37 Cable Assembly 1
38 Back Spring Cable Support 1
39 Connector 1
40 Connector Insulator 1
41 Connector 1
42 Gas Hose Plug 1
43 Wire Feed Plug 1
33
31
30
32
29
28
27
26
23
22
14
21
20
19
18
16
17
15
2
1
3
4
1
5
9
8
7
6
10
11
12
35
36
37
38
39
41
43
24
25
40
42
;*4&(9%U(&9'4$\#%?*(",7%E'5+*(%B*(*-%
E&$*- If product has no serial number, record month and year of purchase instead.
E&$*- Some parts are listed and shown for illustration purposes only,
and are not available individually as replacement parts.
3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • 1-888-380-0318
Limited 90 Day Warranty
Harbor Freight Tools Co. makes every effort to assure that its products meet high quality and durability standards,
and warrants to the original purchaser that this product is free from defects in materials and workmanship for the
period of 90 days from the date of purchase. This warranty does not apply to damage due directly or indirectly,
to misuse, abuse, negligence or accidents, repairs or alterations outside our facilities, criminal activity, improper
installation, normal wear and tear, or to lack of maintenance. We shall in no event be liable for death, injuries
to persons or property, or for incidental, contingent, special or consequential damages arising from the use of
our product. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the
above limitation of exclusion may not apply to you. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS.
To take advantage of this warranty, the product or part must be returned to us with transportation charges
prepaid. Proof of purchase date and an explanation of the complaint must accompany the merchandise.
If our inspection verifies the defect, we will either repair or replace the product at our election or we may
elect to refund the purchase price if we cannot readily and quickly provide you with a replacement. We will
return repaired products at our expense, but if we determine there is no defect, or that the defect resulted
from causes not within the scope of our warranty, then you must bear the cost of returning the product.
This warranty gives you specific legal rights and you may also have other rights which vary from state to state.
UG6@?6%;6@S%AB6%<VGGVRCET%P@;6<FGGO
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM
IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER OR DISTRIBUTOR
MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS
QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT, OR THAT HE OR SHE IS QUALIFIED TO REPLACE
ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER AND/OR DISTRIBUTOR EXPRESSLY
STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND
LICENSED TECHNICIANS, AND NOT BY THE BUYER. THE BUYER ASSUMES ALL RISK AND LIABILITY
ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS
THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO.
