VULCAN 63621 Owner's Manual & Safety Instructions

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. 19h

!"#"$%&'(%)*+#"$*%,$-%.$$/-00)))1.,(+&(2(*"3.$14&5

65,"7%&'(%$*4.8"4,7%#'//&($%,$-%/(&9'4$#'//&($:.,(+&(2(*"3.$14&5

When unpacking, make sure that the product is intact

and undamaged. If any parts are missing or broken,

please call 1-888-866-5797 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.

To ol s re q u ir e d fo r as s e mb l y a n d s e r vi c e m a y n o t b e in c l ud e d .

Read this material before using this product.
Failure to do so can result in serious injury.
SAVE THIS MANUAL.

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Safety ........................................................................2

Specifications ............................................................7

Controls .....................................................................8

MIG / Flux-Cored Wire Welding .................................10

TIG / Stick Welding ....................................................24

IFSMLMN%EHTURJE%FMK%K6;LMLGLRME

This is the Safety alert symbol. It is used to alert you to potential

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G,+7*%&2%P&8$*8$#

Welding Tips .............................................................34

Maintenance .............................................................41

Parts List and Diagram .............................................46

Warranty ...................................................................48

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.

LTORSGFMG%EF;6GH%LM;RSTFGLRM

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S*,9%,77%E,2*$V%),(8"83#%,89%"8#$('4$"&8#1%%
;,"7'(*%$&%2&77&)%$.*%),(8"83#%,89%"8#$('4$"&8#%5,V%(*#'7$%"8%*7*4$("4%#.&4W=%2"(*%,890&(%#*("&'#%"8X'(V1%%%
E,Y*%,77%),(8"83#%,89%"8#$('4$"&8#%2&(%2'$'(*%(*2*(*84*1

N*8*(,7%E,2*$V

OSRG6PG%V&'(#*72%,89%&$.*(#1%%S*,9%,89%'89*(#$,89%$."#%"82&(5,$"&81

1. U*2&(*%'#*=%(*,9%,89%'89*(#$,89%

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manufacturer′s instructions,
Material Safety Data Sheets (MSDS′s),
employer′s Safety practices, and ANSI Z49.1.

2. Q**/%&'$%&2%(*,4.%&2%4."79(*81%%%
Keep children and bystanders away while operating.

3. O7,4*%$.*%)*79*(%&8%,%#$,+7*%7&4,$"&8%+*2&(*%'#*1%%%
If it falls while plugged in, severe injury,
electric shock, or fire may result.

4. K&%8&$%&Y*((*,4.1%%%

Q**/%/(&/*(%2&&$"83%,89%+,7,84*%,$%,77%$"5*#1

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5. E$,V%,7*($=%),$4.%).,$%V&'%,(*%9&"83%,89%'#*%
4&55&8%#*8#*%).*8%&/*(,$"83%,%)*79*(1%%
K&%8&$%'#*%,%)*79*(%)."7*%V&'%,(*%$"(*9%&(%'89*(%
$.*%"827'*84*%&2%9('3#=%,74&.&7%&(%5*9"4,$"&81

A moment of inattention while operating welders
may result in serious personal injury.

6. FY&"9%'8"8$*8$"&8,7%#$,($"831%%Make sure you are
prepared to begin work before turning on the Welder.

7. M*Y*(%7*,Y*%$.*%I*79*(%'8,$$*89*9%)."7*%
*8*(3"Z*91%Turn power off if you have to leave.

8. G.*%),(8"83#=%/(*4,'$"&8#=%,89%"8#$('4$"&8#%

9"#4'##*9%"8%$."#%"8#$('4$"&8%5,8',7%4,88&$%
4&Y*(%,77%/&##"+7*%4&89"$"&8#%,89%#"$',$"&8#%
$.,$%5,V%&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 2 ;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1 Item 63621

;'5*%,89%N,#%E,2*$V

I*79"83%,89%O7,#5,%P'$$"83%/(&9'4*%$&["4%2'5*#1

INHALATION HAZARD:%

1. 6[/&#'(*%$&%)*79"83%&(%4'$$"83%*[.,'#$%
2'5*#%4,8%"84(*,#*%$.*%("#W%&2%9*Y*7&/"83%
4*($,"8%4,84*(#=%#'4.%,#%4,84*(%&2%$.*%
7,(V8[%,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. K&%8&$%'#*%8*,(%9*3(*,#"83%&(%

/,"8$"83%&/*(,$"&8#1

3. Q**/%.*,9%&'$%&2%2'5*#1%%
Do not breathe exhaust fumes.

4. \#*%*8&'3.%Y*8$"7,$"&8=%*[.,'#$%,$%,(4=%&(%

+&$.=%$&%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. I&(W%"8%,%4&82"8*9%,(*,%&87V%"2%"$%

"#%)*77?Y*8$"7,$*9=%&(%)."7*%)*,("83%
,8%,"(?#'//7"*9%(*#/"(,$&(1

6. ],Y*%,%(*4&38"Z*9%#/*4",7"#$%"8%
L89'#$(",7%]V3"*8*%&(%68Y"(&85*8$,7%E*(Y"4*#%

4.*4W%$.*%&/*(,$"&8%,89%,"(%<',7"$V%
,89%5,W*%(*4&55*89,$"&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.

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FSP%SFHE%4,8%"8X'(*%*V*#%,89%+'(8%#W"81

1. I*,(%FMEL?,//(&Y*9%)*79"83%*V*%/(&$*4$"&8%
2*,$'("83%,$%7*,#$%,%8'5+*(%>^%#.,9*%7*8#%(,$"831

2. I*,(%7*,$.*(%7*33"83#=%2"(*%(*#"#$,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. Q**/%47&$."83%2(**%&2%3(*,#*=%&"7=%

#&7Y*8$#=%&(%,8V%27,55,+7*%#'+#$,84*#1%%

Wear dry, insulating gloves and protective clothing.

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4. I*,(%,8%,//(&Y*9%.*,9%4&Y*("83%$&%/(&$*4$%
$.*%.*,9%,89%8*4W1%Use aprons, cape, sleeves,

shoulder covers, and bibs designed and
approved for welding and cutting procedures.

5. I*,(%,8%,//(&Y*9%)*79"83%X,4W*$%&(%7&83%#7**Y*#%

$&%/(&$*4$%2&(*,(5#%2(&5%(,9",$"&8%+'(8#1%

6. I.*8%)*79"8304'$$"83%&Y*(.*,9%&(%"8%4&82"8*9%
#/,4*#=%)*,(%27,5*%(*#"#$,8$%*,(%/7'3#%&(%
*,(%5'22#%$&%W**/%#/,(W#%&'$%&2%*,(#1

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Page 3;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1Item 63621

67*4$("4,7%E,2*$V

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1. G'(8%&22=%9"#4&88*4$%/&)*(=%,89%
9"#4.,(3*%*7*4$(&9*%$&%3(&'89%+*2&(*%#*$$"83%
9&)8%$&(4.0*7*4$(&9*%.&79*(%,89%+*2&(*%#*(Y"4*1

2. K&%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

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bare hand. Do not wear wet or damaged gloves.

3. P&88*4$%$&%3(&'89*9=%N;PL?/(&$*4$*9%

/&)*(%#'//7V%&87V1

4. K&%8&$%'#*%8*,(%),$*(%&(%9,5/%&+X*4$#1

5. O*&/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. K&%8&$%*[/&#*%)*79*(#%$&%(,"8%&(%)*$%4&89"$"&8#1%%%
Water entering a welder will increase
the risk of electric shock.

6J6PGSLP%E]RPQ%4,8%QLJJ1

7. K&%8&$%,+'#*%$.*%4&(91%%M*Y*(%'#*%$.*%4&(9%
2&(%4,((V"83=%/'77"83%&(%'8/7'33"83%$.*%)*79*(1%%
Q**/%4&(9%,),V%2(&5%.*,$=%&"7=%#.,(/%*93*#%
&(%5&Y"83%/,($#1%%Damaged or entangled

cords increase the risk of electric shock.

8. K&%8&$%'#*%&'$9&&(#1

9. L8#'7,$*%V&'(#*72%2(&5%$.*%)&(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.

10. G]LE%I6JKLMN%TFP]LM6%T\EG%U6%

PRMM6PG6K%GR%ORI6S%ER\SP6%LM%
FPPRSKFMP6%ILG]%FOOJLPFUJ6%
6J6PGSLPFJ%PRK6E1

;"(*%E,2*$V

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1. P7*,(%,),V%&(%/(&$*4$%27,55,+7*%&+X*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. Q**/%FUP?$V/*%2"(*%*[$"83'"#.*(%8*,(%

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)&(W%,(*,%,89%W8&)%.&)%$&%'#*%"$1

3. T,"8$,"8%,%#,2*%)&(W"83%*8Y"(&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. K&%8&$%&/*(,$*%)*79*(#%"8%,$5&#/.*(*#%

4&8$,"8"83%9,83*(&'#7V%(*,4$"Y*%&(%

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27,55,+7*%7"<'"9#=%3,#*#=%Y,/&(#=%&(%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.

FSP%FMK%EJFN%4,8%4,'#*%2"(*1

5. L2%)&(W"83%&8%,%5*$,7%),77=%4*"7"83=%*$41=%
/(*Y*8$%"38"$"&8%&2%4&5+'#$"+7*#%&8%$.*%
&$.*(%#"9*%+V%5&Y"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. K&%8&$%)*79%&(%4'$%&8%5,$*(",7#%.,Y"83%

,%4&5+'#$"+7*%4&,$"83%&(%4&5+'#$"+7*%
"8$*(8,7%#$('4$'(*=%,#%"8%),77#%&(%4*"7"83#=%)"$.&'$%
,8%,//(&Y*9%5*$.&9%2&(%*7"5"8,$"83%$.*%.,Z,(91

7. K&%8&$%9"#/&#*%&2%.&$%#7,3%"8%4&8$,"8*(#%
.&79"83%4&5+'#$"+7*%5,$*(",7#1

8. F2$*(%)*79"83=%5,W*%,%$.&(&'3.%*[,5"8,$"&8%
2&(%*Y"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. K&%8&$%,//7V%.*,$%$&%,%4&8$,"8*(%$.,$%.,#%.*79%

,8%'8W8&)8%#'+#$,84*%&(%,%4&5+'#$"+7*%
5,$*(",7%).&#*%4&8$*8$#=%).*8%.*,$*9=%
4,8%/(&9'4*%27,55,+7*%&(%*[/7&#"Y*%Y,/&(#1%%

Clean and purge containers before applying heat.
Vent closed containers, including castings,
before preheating, welding, or cutting.

Page 4 ;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1 Item 63621

I*79*(%\#*%,89%P,(*

1. K&%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. K"#4&88*4$%$.*%/7'3%2(&5%$.*%/&)*(%
#&'(4*%+*2&(*%5,W"83%,8V%,9X'#$5*8$#=%

4.,83"83%,44*##&("*#=%&(%#$&("83%)*79*(#1%%

Such preventive Safety measures reduce the
risk of starting the welder accidentally.

3. O(*Y*8$%'8"8$*8$"&8,7%#$,($"831%
68#'(*%$.*%#)"$4.%"#%"8%$.*%&22?
/&#"$"&8%+*2&(*%4&88*4$"83%$&%/&)*(%
#&'(4*%&(%5&Y"83%$.*%)*79*(1 Carrying

or energizing welders that have the
switch on invites accidents.

T,"8$*8,84*

1. T,"8$,"8%)*79*(#1%%P.*4W%2&(%5"#,7"385*8$%&(%
+"89"83%&2%5&Y"83%/,($#=%+(*,W,3*%&2%/,($#%
,89%,8V%&$.*(%4&89"$"&8%$.,$%5,V%,22*4$%$.*%
)*79*(_#%&/*(,$"&81%%L2%9,5,3*9=%.,Y*%$.*%
)*79*(%(*/,"(*9%+*2&(*%'#*1 Many accidents

are caused by poorly maintained welders.

2. ],Y*%V&'(%)*79*(%#*(Y"4*9%+V%,%<',7"2"*9%
(*/,"(%/*(#&8%'#"83%&87V%"9*8$"4,7%
(*/7,4*5*8$%/,($#1%%This will ensure that

the Safety of the welder is maintained.

4. E$&(*%"97*%)*79*(#%&'$%&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. \#*%$.*%)*79*(%,89%,44*##&("*#%"8%

,44&(9,84*%)"$.%$.*#*%"8#$('4$"&8#=%$,W"83%
"8$&%,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. K&%8&$%'#*%$.*%)*79*(%2&(%/"/*%$.,)"831

3. T,"8$,"8%7,+*7#%,89%8,5*/7,$*#%&8%$.*%I*79*(1%%%
These carry important information.
If unreadable or missing, contact
Harbor Freight Tools for a replacement.

4. \8/7'3%+*2&(*%5,"8$*8,84*1%Unplug the Welder
from its electrical outlet before any inspection,
maintenance, or cleaning procedures.

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N,#%E."*79*9%I*79"83%?%PV7"89*(%E,2*$V

PV7"89*(#%4,8%*[/7&9*%).*8%9,5,3*91

1. K&%8&$%)*79%&8%,%/(*##'("Z*9%&(%47&#*9%4V7"89*(1

2. K&%8&$%,77&)%,8%*7*4$(&9*%.&79*(=%

*7*4$(&9*=%)*79"83%$&(4.=%&(%)*79"83%
)"(*%$&%$&'4.%$.*%4V7"89*(1

3. Q**/%4V7"89*(#%,),V%2(&5%,8V%*7*4$("4,7%4"(4'"$#=%
"847'9"83%)*79"83%4"(4'"$#1

4. Q**/%/(&$*4$"Y*%4,/%"8%/7,4*%&Y*(%$.*%Y,7Y*%
*[4*/$%).*8%$.*%4V7"89*(%"#%"8%'#*1

5. \#*%&87V%4&((*4$%3,#%#."*79"83%*<'"/5*8$%
9*#"38*9%#/*4"2"4,77V%2&(%$.*%$V/*%&2%)*79"83%
V&'%)"77%9&1%%Maintain this equipment properly.

6. O(&$*4$%3,#%4V7"89*(#%2(&5%.*,$=%+*"83%#$('4W=%
/.V#"4,7%9,5,3*=%#7,3=%27,5*#=%#/,(W#=%,89%,(4#1

7. \#*%/(&/*(%/(&4*9'(*#%$&%5&Y*%4V7"89*(#1

%EF!6%G]6E6%LMEGS\PGLRME1

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Page 5;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1Item 63621

N(&'89"83

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GR%OS6!6MG%6J6PGSLP%E]RPQ%FMK%K6FG]%%
;SRT%LMPRSS6PG%NSR\MKLMN%ILS6%PRMM6PGLRM-%
P.*4W%)"$.%,%<',7"2"*9%*7*4$("4",8%"2%V&'%,(*%"8%9&'+$%,#%$&%).*$.*(%$.*%&'$7*$%"#%

/(&/*(7V%3(&'89*91%%K&%8&$%'#*%$.*%)*79*(%"2%$.*%/&)*(%4&(9%&(%/7'3%"#%9,5,3*91%%L2%9,5,3*9=%
.,Y*%"$%(*/,"(*9%+V%,%#*(Y"4*%2,4"7"$V%+*2&(*%'#*1%%L2%$.*%/7'3%)"77%8&$%2"$%$.*%&'$7*$=%.,Y*%,%/(&/*(%&'$7*$%
"8#$,77*9%+V%,%<',7"2"*9%*7*4$("4",8=%9&%8&$%'#*%,9,/$*(%/7'3#1

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1. The green wire inside the cord is connected to

the grounding system in the Welder. The green
wire in the cord must be the only wire connected
to the Welder’s grounding system and must
never be attached to an electrically “live” terminal.
Never leave the grounding wire disconnected
or modify either Power Cord Plug in any way.

2. Make sure the tool is connected to an outlet having
the same configuration as the plug. If the tool must
be reconnected for use on a different type of electric
circuit, the reconnection should be made by qualified
service personnel; and after reconnection, the tool
should comply with all local codes and ordinances.

6[$*8#"&8%P&(9#

K&%8&$%'#*%,8%*[$*8#"&8%4&(9%&8%$."#%)*79*(1

ILS6

S*/7,4*5*8$%P&(9#

1. \#*%&87V%&8*%&2%$.*%#'//7"*9%/&)*(%4&(9#%2&(%
$."#%)*79*(%&(%,8%"9*8$"4,7%(*/7,4*5*8$%4&(91

2. K&%8&$%"8#$,77%,%$."88*(%&(%7&83*(%
4&(9%&8%$."#%)*79*(1

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EV5+&7&3V

Wire Feed (Speed)

Workpiece Ground Cable

Torch Cable

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Overheat Shutdown Indicator

Cooling Fan

Housing Ground Point

3. K&%8&$%/,$4.%4&(9#%&2%,8V%7*83$.%

$&3*$.*(%2&(%$."#%"$*5=%/,$4.*#%5,V%,77&)%
5&"#$'(*%$&%/*8*$(,$*%$.*%"8#'7,$"&8=%
(*#'7$"83%"8%*7*4$("4%#.&4W1

LOT

FIN

Inches Per Minute

American 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.

TFLMG6MFMP6

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F

RP!

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Page 6 ;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1 Item 63621

Volts Alternating Current

Amperes

Open Circuit Voltage

Kilovolt Amperes

(Volts / 1000 * Amperes)

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.

E/*4"2"4,$"&8#

TLN

Power Input 120 VAC%0%60 Hz 240 VAC / 60 Hz

Current Input at Output 20.8 A at 100 A 25.5 A at 200 A

Welding Current Range 30 –140 A 30 –220 A

Rated Duty Cycles

Maximum OCV 78 VDC

Weldable Materials

Welding Wire Capacity

Wire Speed 50 – 500 IPM

Wire Spool Capacity Up to 12 lb spool

Power Input 120 VAC / 60 Hz 240 VAC / 60 Hz

Current Input at Output 20.6 A at 125 A 15.6 A at 175 A

Welding Current Range 10 A –125 A 10 A –175 A

Rated Duty Cycles

Maximum OCV 78 VDC

Weldable Materials Mild Steel, Stainless Steel, Chrome Moly

40% @ 100 A
100% @ 75 A

Mild Steel, Stainless Steel

Aluminum (with optional Spool Gun)

Solid Core: 0.025" / 0.030" / 0.035"

Flux Cored: 0.030" / 0.035" / 0.045"

GLN

40% @ 125 A
100% @ 90 A

25% @ 200 A

100% @ 115 A

30% @ 175 A

100% @ 105 A

EF;6GH

E$"4W

Power Input 120 VAC / 60 Hz 240 VAC / 60 Hz

Current Input at Output 19.5 A at 80 A 23.7 A at 175 A

Welding Current Range 10 A – 80 A 10 A –175 A

Rated Duty Cycles

Maximum OCV 78 VDC

Weldable Materials Mild Steel, Stainless Steel

40% @ 80 A

100% @ 60 A

25% @ 175 A

100% @ 100 A

GLN%0%EGLPQ PRMGSRJEILS6

I6JKLMN%GLOE

TFLMG6MFMP6

Page 7;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1Item 63621

EF;6GH

P&8$(&7#

;(&8$%O,8*7%P&8$(&7#

PRMGSRJE

ILS6

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P,+7*%E&4W*$%

]&5*%

U'$$&8

P&8$(&7%

Q8&+

J*2$%

Q8&+

O&)*(%

E)"$4.

MIG Gun /

E/&&7%N'8%

E/&&7%N'8%
N,#%R'$7*$

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E&4W*$

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M*3,$"Y*%

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M&$*- When using an optional Spool Gun (sold separately), connect the

Spool Gun gas hose to the Spool Gun Gas Outlet.

Page 8 ;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1 Item 63621

I"(*%;**9%

O&)*(%P,+7*

L8$*("&(%P&8$(&7#

I"(*%E/&&7

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Page 9;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1Item 63621

EF;6GH

MIG / Flux-Cored Wire Welding

S*,9%$.*%6MGLS6%LTORSGFMG%EF;6GH%LM;RSTFGLRM%#*4$"&8%,$%$.*%+*3"88"83%&2%$."#%5,8',7%
"847'9"83%,77%$*[$%'89*(%#'+.*,9"83#%$.*(*"8%+*2&(*%#*$%'/%&(%'#*%&2%$."#%/(&9'4$1

GR%OS6!6MG%E6SLR\E%LMa\SH%;SRT%FPPLK6MGFJ%RO6SFGLRM-%
G'(8%$.*%O&)*(%E)"$4.%&22%,89%'8/7'3%$.*%I*79*(%+*2&(*%#*$'/1

M&$*-%Remove the protective foam and cardboard from the Welder before setup.

PRMGSRJE

Wire Spool Installation / Wire Setup

1. G'(8%$.*%O&)*(%E)"$4.%R;;%,89%'8/7'3%
$.*%I*79*(%+*2&(*%/(&4**9"831

ILS6

O&)*(%
E)"$4.

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2. Pull up on the Door Latch,
then open the Door.

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3. >?`%O&'89%I"(*%E/&&7%L8#$,77,$"&8-
Remove the Wingnut and Spacer. If
replacing a Spool, remove the old Spool
and all remaining wire from the liners.

4. Place the new Wire Spool over the Spool Spindle
and against the Spool Brake Pad as illustrated.

G&%/(*Y*8$%)"(*%2**9%/(&+7*5#=%#*$%$.*%

TFLMG6MFMP6

E/&&7%#&%$.,$%"$%)"77%'8)"89%47&4W)"#*1

5. Replace the Spacer over the
Spool Spindle and secure Spool
in place with the Wingnut.

M&$"4*- If Wire Spool can spin freely, Wingnut is too
loose. This will cause the welding wire to unravel and
unspool which can cause tangling and feeding problems.

K&&(

K&&(%

J,$4.

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E/,4*(

E/&&7%

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>?`%7+%%

I"(*%E/&&7

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Page 10 ;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1 Item 63621

6. >^?>`%O&'89%I"(*%E/&&7%L8#$,77,$"&8-%
Remove the Wingnut and Spacer. If
replacing a Spool, remove the old Spool
and all remaining wire from the liners.

7. Place the Spool Adapter over the Spool Spindle
and against the Spool Brake Pad as illustrated.

8. Place the new Wire Spool over the Adapter and
line up pin on Adapter with hole in Spool.

G&%/(*Y*8$%)"(*%2**9%/(&+7*5#=%#*$%$.*%
E/&&7%#&%$.,$%"$%)"77%'8)"89%47&4W)"#*1

9. Replace the Spacer over the Spool Spindle
and secure Spool in place with the Wingnut.

M&$"4*- If Wire Spool can spin freely, Wingnut
is too loose. This will cause the welding
wire to unravel and unspool which can
cause tangling and feeding problems.

10. Screw the Spool Knob into the Spool Adapter.

>^?>`%7+%%

E/&&7%

F9,/$*(

I"(*%

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"8%$."#%

9"(*4$"&8

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I,77

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GLN%0%EGLPQ PRMGSRJEILS6

11. Turn the Feed Tensioner knob counterclockwise to
loosen it enough to pull it down to remove tension.
The spring-loaded Idler Arm will move up as shown.

;**9%G*8#"&8*(

I6JKLMN%GLOE

L97*(%F(5

TFLMG6MFMP6

Page 11;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1Item 63621

EF;6GH

12. ;**9%S&77*(%L8#$('4$"&8#-%
Check that the Feed Roller is correct for the
type of wire being used (solid core or flux­cored) and that it is turned to properly match

PRMGSRJE

the wire size marked on the Wire Spool:

;**9%S&77*(%

Q8&+

F

ILS6

GLN%0%EGLPQ

I6JKLMN%GLOE

a. Unscrew the Feed Roller Knob

counterclockwise.

b. Remove the Feed Roller Knob

to expose the Feed Roller.

c. Flip or replace the Feed Roller as needed

and confirm that it is the correct Roller
for the type of wire being used and that

$.*%8'5+*(%#.&)"83%"#%$.*%#,5*%,#%
$.*%)"(*%9",5*$*(%&8%$.*%E/&&71

E&7"9%P&(*%

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3(&&Y*

^1^b^%0%^1^bB%

0.045%
3(&&Y*

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^1^b^%0%^1^bB%

3(&&Y*%

3(&&Y*

;**9%

S&77*(%

U

P

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K

d. Screw the Feed Roller Knob back into

place to secure the Feed Roller.

Page 12 ;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1 Item 63621

13. Loosen the Knob on the Wire Feed
mechanism, then insert the Gun Cable
Connector through the hole on the Welder
front and into the socket on the Wire Feed.

14. Ensure that the Gun Cable Connector
is fully inserted into the socket on
the Wire Feed mechanism as shown,
then tighten the Knob securely.
If Connector is not fully inserted, the gas
connection will leak, preventing shielding
gas from reaching the welding arc.

MRGLP6- To prevent damage, do
not overtighten the Knob.

I"(*%;**9%

T*4.,8"#5

Q8&+

Incorrect – Connector not fully inserted

N'8%P,+7*%
P&88*4$&(

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I"(*%

;**9%

P&8$(&7%

P,+7*

15. Insert the Wire Feed Control Cable through
the hole on the Welder front and connect it
to the Wire Feed Control Socket inside the
machine, then tighten the lock ring on the Cable
plug. Note that the plug on the Cable fits into
the Socket in one specific orientation only.

16. KP6M%K"(*4$%P'((*8$%67*4$(&9*%

M*3,$"Y*%I"(*%E*$'/%2&(%;7'[?P&(*9%

(gasless) welding:
Plug Ground Clamp Cable into Positive (c)
Socket. Plug Wire Feed Power Cable
into Negative (d) Socket. Twist cables
clockwise all the way to lock in place.

Correct – Connector fully inserted

GLN%0%EGLPQ PRMGSRJEILS6

KP6M%%

Flux-Cored (Gasless)

O&7,("$V%E*$'/

I"(*%;**9%

O&)*(%P,+7*%"8%

M*3,$"Y*%E&4W*$

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N(&'89%P7,5/%P,+7*%

"8%O&#"$"Y*%E&4W*$

TFLMG6MFMP6

Page 13;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1Item 63621

EF;6GH

Reset

Power Input

Gas Inlet

Serial:

Vulcan OMNIPRO 220

17. KP6O%K"(*4$%P'((*8$%67*4$(&9*%O&#"$"Y*%I"(*%

Setup for Solid Core (gas shielded) welding:

a. Plug Ground Clamp Cable into Negative (d)

Socket. Plug Wire Feed Power Cable
into Positive (c) Socket. Twist cables

PRMGSRJE

clockwise all the way to lock in place.

b. Determine which type of shielding

gas would be appropriate for
the welding you will do. Refer
to the Settings Chart on the
inside of the Welder door.

KP6O%%

Solid Core (Gas Shielded)

O&7,("$V%E*$'/

N(&'89%P7,5/%P,+7*%

"8%M*3,$"Y*%E&4W*$

I"(*%;**9%

O&)*(%P,+7*%"8%

O&#"$"Y*%E&4W*$

ILS6

c. With assistance, set the 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.

d. Remove the cylinder’s cap. Stand to the

side of the valve opening, then open the

GLN%0%EGLPQ

valve briefly to blow dust and dirt from the
valve opening. Close the cylinder valve.

e. Locate the Regulator (included) and close its

valve until it is loose, then thread Regulator
onto cylinder and wrench-tighten connection.

M&$*- When using C100 shielding gas, connect the

enclosed CGA 580/320 adapter to the inlet connection

I6JKLMN%GLOE

of the Regulator and wrench-tighten. Thread the
adapter onto the gas cylinder and wrench-tighten.

4

U("*27V%&/*8%Y,7Y*%

9

$&%47*,8=%%

$.*8%47&#*%%

Y,7Y*1

2

*

f. Attach the Gas Hose (included)

Conforms to UL Std. 60974-1

269317

to the Regulator’s outlet and
the Welder’s gas inlet. Wrench­tighten both connections.

63621 17b

30A/15.5V to 220A/25V

X 25% 60% 100%

I2200A 130A 115A

U0  78V

U224V 20.5V 19.75V

10A/20.4V to 175A/27V

X 25% 60% 100%

I2175A 115A 100A

U0  78V

U227V 24.6V 24V

10A/10.4V to 175A/17V

X 30% 60% 100%

I2175A 125A 105A

U0  15V

17V 15V 14.2V

U

2

I

= 25.5A

I

 12.8A

1max

1eff

23.7A

11.9A

U1 = 240V

15.6A

8.5A

1~50/60Hz

30A/15.5V to 140A/21V

X 40% 60% 100%

I2100A 85A 75A

U0  78V

U219V 18.25V 17.75V

10A/20.4V to 80A/23.2V

X 40% 60% 100%

I280A 70A 60A

U0  78V

23.2V 22.8V 22.4V

U

2

10A/10.4V to 125A/15V

X 40% 60% 100%

I2125A 105A 90A

U0  15V

15V 14.2V 13.6V

U

2

I

= 20.8A

I

= 13.1A

1max

1eff

19.5A

12.3A

U1 = 120V

20.6A

13A

1~50/60Hz

1

f1

IP21S

S

f2

TFLMG6MFMP6

Page 14 ;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1 Item 63621

LTORSGFMG

E*4'(*7V%.&79%&8$&%$.*%*89%&2%$.*%)*79"83%)"(*%,89%W**/%

$*8#"&8%&8%"$%9'("83%$.*%2&77&)"83%#$*/#1

L2%$."#%"#%8&$%9&8*=%$.*%)*79"83%)"(*%)"77%'8(,Y*7%,89%'8#/&&7%

)."4.%4,8%4,'#*%$,837"83%,89%2**9"83%/(&+7*5#1

18. Cut off all bent and crimped wire.
The cut end must have no burrs or
sharp edges; cut again if needed.

19. Keep tension on the wire and guide at
least 12 inches of wire into the Wire
Inlet Liner and Feed Guide.

20. Make sure the welding wire is resting in the groove
of the Feed Roller, then push the wire Idler Arm
down, and swing the Feed Tensioner up to latch it
across the tip of the arm.
After the wire is held by the Tensioner,
you may release it.

I*79"83%

I"(*

I"(*%

E/&&7

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I"(*%L87*$%

J"8*(

L97*(%F(5

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;**9%

N'"9*

;**9%G*8#"&8*(

M&$*- The tension should be 3 – 5 for solid wire and

2 – 3 for flux-cored wire. Too much force on flux-cored

wire will crush it and may cause feeding issues.

21. Pull the Nozzle to remove it.

22. Unscrew the Contact Tip
counterclockwise and remove.

23. Lay the MIG Gun Cable out in a straight line
so that the welding wire moves through it
easily. Leave the cover open, so that the
feed mechanism can be observed.

LTORSGFMG

E$,"87*##%#$**7%)"(*%"#%7*##%27*["+7*%$.,8%

&$.*(%)*79"83%)"(*1%%G.*(*2&(*=%"$%"#%5&(*%

9"22"4'7$%$&%2**9%$.(&'3.%$.*%7"8*(%,89%3'81%%

L$%"#%*#/*4",77V%"5/&($,8$%$&%W**/%$.*%3'8%4,+7*%

#$(,"3.$%)."7*%2**9"83%#$,"87*##%#$**7%)"(*1

M&ZZ7*

GLN%0%EGLPQ PRMGSRJEILS6

TLN%N'8

P&8$,4$

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I6JKLMN%GLOE

TFLMG6MFMP6

Page 15;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1Item 63621

EF;6GH

Reset

Power Input

Gas Inlet

PRMGSRJE

24. Plug either 120 VAC or 240 VAC Power

Cord into Power Input Socket.

M&$*- Plug will only fit one way.

ILS6

KFMN6S

OFSGE%TFH%U6%FG%I6JKLMN%!RJGFN6%

GR%OS6!6MG%6J6PGSLP%E]RPQ%FMK%K6FG]-

1. Q**/%.,89#%,),V%2(&5%I"(*%;**9%5*4.,8"#51

2. P7&#*%9&&(%+*2&(*%/7'33"83%"8=%'87*##%'#"83%P&79%

I"(*%;**9%$&%2**9%)"(*%$.(&'3.%$&%3'81

3. K&%8&$%$&'4.%G("33*(%)."7*%2**9"83%)"(*%$.(&'3.%$&%3'81

Serial:

Vulcan OMNIPRO 220

Conforms to UL Std. 60974-1

269317

17b

O&)*(%

L8/'$

63621

30A/15.5V to 220A/25V

X 25% 60% 100%

I2200A 130A 115A

U0  78V

U224V 20.5V 19.75V

10A/20.4V to 175A/27V

X 25% 60% 100%

I2175A 115A 100A

U0  78V

27V 24.6V 24V

U

2

10A/10.4V to 175A/17V

X 30% 60% 100%

I2175A 125A 105A

U0  15V

17V 15V 14.2V

U

2

I

= 25.5A

I

 12.8A

1max

1eff

23.7A

11.9A

U1 = 240V

15.6A

8.5A

1~50/60Hz

30A/15.5V to 140A/21V

X 40% 60% 100%

I2100A 85A 75A

U0  78V

U219V 18.25V 17.75V

10A/20.4V to 80A/23.2V

X 40% 60% 100%

I280A 70A 60A

U0  78V

23.2V 22.8V 22.4V

U

2

10A/10.4V to 125A/15V

X 40% 60% 100%

I2125A 105A 90A

U0  15V

15V 14.2V 13.6V

U

2

I

= 20.8A

I

= 13.1A

1max

1eff

19.5A

12.3A

U1 = 120V

20.6A

13A

1~50/60Hz

1

f1

IP21S

S

f2

GLN%0%EGLPQ

25. Do not touch the Gun’s Trigger. Plug the Power
Cord into a properly grounded, GFCI protected

120 VAC (20 amp rated) or 240 VAC receptacle that

matches the plug and turn the Power Switch ON.
The circuit must be equipped with delayed
action-type circuit breaker or fuses.

I6JKLMN%GLOE

26. Point the Gun away from
all objects. Press and
hold the Cold Wire Feed
Switch until the wire feeds
through two inches.

G.*%)"(*%7"8*(%5,V%4&5*%
&'$%)"$.%$.*%)*79"83%
)"(*1%%G."#%"#%8&(5,7=%

TFLMG6MFMP6

X'#$%/'#.%$.*%)"(*%7"8*(%
+,4W%"8$&%$.*%N'81

If the wire does not feed
properly and the Spool
is stationary, turn OFF
and unplug the Welder
and slightly tighten the
Feed Tensioner clockwise
before retrying.

O&)*(%

E)"$4.

P&79%I"(*%

;**9%E)"$4.

TLN%N'8

`e

I*79"83%

I"(*

Page 16 ;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1 Item 63621

27. To check the wire’s drive tension, press and hold
Trigger to feed the wire against a piece of wood
from 2 to 3 inches away.

M&$*-%%F2$*(%/(*##"83%G("33*(=%)"(*%)"77%#$&/%
2**9"83%,2$*(%b%#*4&89#%"2%$.*(*%"#%8&%,(41%%
P.*4W%$*8#"&8%2&(%7*##%$.,8%b%#*4&89#1%%
%

If the wire stops instead of bending, unplug
the Welder, slightly tighten the Feed Tensioner
clockwise, and try again. If the wire bends
from the feed pressure, then the tension
is set properly. Before proceeding, turn
OFF the Power Switch and unplug the
Power Cord from its electrical outlet.

28. Turn OFF the Power Switch and unplug the
Power Cord from its electrical outlet.

29. Close the Door. Make sure
Door is securely latched.

30. Select a Contact Tip that is compatible with
the welding wire used. Slide the Contact
Tip over the wire and thread it clockwise into
the MIG Gun. Tighten the Contact Tip.

31. Replace the Nozzle and cut the wire

off at 1/2" from tip (1/2" stickout).

M&ZZ7*

L84(*5*8$,77V%%

"84(*,#*%$*8#"&8%%

'8$"7%%

)"(*%+*89#1

P&8$,4$

G"/

EF;6GH

`dbe

TLN%N'8

R/$"&8,7%E/&&7%N'8%E*$'/

1. To se t u p o pt i ona l S poo l G un (s o ld se p ara te l y), p l ug Gr o un d C la m p C abl e i nto N e gat iv e (d) Socket. Plug
Wire Feed Power Cable into Positive (c) Socket. Twist cables clockwise all the way to lock in place.

2. Loosen the Knob on the Wire Feed
mechanism, then insert the Spool
Gun Cable Connector through the
hole on the Welder front and into
the socket on the Wire Feed.

3. Ensure Cable Connector is fully
inserted and tighten the Knob
securely. If Connector is not fully
inserted, the gas connection will
leak, preventing shielding gas
from reaching the welding arc.

MRGLP6- To prevent damage, do
not overtighten the Knob.

4. Insert the Wire Feed Control Cable
through hole on Welder front and
connect to the Wire Feed Control Socket
inside the machine, then tighten lock
ring on the Cable plug. Note that the
plug on the Cable fits into the Socket
in one specific orientation only.

5. Connect Gas Hose on Spool Gun Cable
Connector to Spool Gun Gas Outlet on front
of Welder. Refer to paragraph 17 on page 14
for further shielding gas setup information.

E/&&7%N'8

E/&&7%N'8%%

P,+7*%P&88*4$&(

N,#%]&#*

I"(*%;**9%

P&8$(&7%

P,+7*

N(&'89%

P7,5/%P,+7*%

"8%M*3,$"Y*%

E&4W*$

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N,#%R'$7*$

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O&)*(%P,+7*%"8%

O&#"$"Y*%E&4W*$

GLN%0%EGLPQ PRMGSRJEILS6

I6JKLMN%GLOE

6. Refer to Spool Gun manual for
operational information.

TFLMG6MFMP6

Page 17;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1Item 63621

U,#"4%I"(*%I*79"83

EF;6GH

S*,9%$.*%6MGLS6%LTORSGFMG%EF;6GH%LM;RSTFGLRM%#*4$"&8%,$%$.*%+*3"88"83%&2%$."#%5,8',7%
"847'9"83%,77%$*[$%'89*(%#'+.*,9"83#%$.*(*"8%+*2&(*%)*79"831

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O(&$*4$"Y*%3*,(%5'#$%+*%)&(8%).*8%'#"83%$.*%I*79*(f%5"8"5'5%#.,9*%8'5+*(%>^%2'77%2,4*%#."*79%

(or welding mask), ear protection, welding gloves, sleeves and apron, NIOSH-approved respirator, and fire

(*#"#$,8$%)&(W%47&$.*#%)"$.&'$%/&4W*$#%#.&'79%+*%)&(8%).*8%)*79"831%%%

PRMGSRJE

J"3.$%2(&5%$.*%,(4%4,8%4,'#*%/*(5,8*8$%9,5,3*%$&%$.*%*V*#%,89%#W"81%%
K&%8&$%+(*,$.*%,(4%2'5*#1

Flux-cored wire welding is used to weld mild steel
and stainless steel without shielding gas.

MIG welding uses solid wire and shielding gas,
and is used to weld mild steel and stainless steel.
MIG welding can also be used to weld thinner
workpieces than flux-cored welding can.

Aluminum welding can be performed with an
optional Spool Gun (sold separately) using

ILS6

aluminum wire and shielding gas.

Good welding takes a degree of skill and experience.
Practice a few sample welds on scrap before
welding your first project. Additional practice
periods are recommended whenever you weld:

• a different thickness of material

• a different type of material

• a different type of connection

GLN%0%EGLPQ

• using a different process

T,W*%/(,4$"4*%)*79#%&8%/"*4*#%&2%#4(,/%$&%/(,4$"4*%
$*4.8"<'*%+*2&(*%)*79"83%,8V$."83%&2%Y,7'*1

TFLMG6MFMP6

I6JKLMN%GLOE

GR%OS6!6MG%E6SLR\E%LMa\SH=%%
;LS6%FMK%U\SME-%
Q**/%)*79"83%$"/%47*,(%&2%3(&'89*9%
&+X*4$#%).*8*Y*(%'8"$%"#%/7'33*9%
"8%,89%$'(8*9%&81

O(,4$"4*%V&'(%)*79"83%

$*4.8"<'*%&8%#4(,/%

/"*4*#%+*2&(*%)*79"83%

,8V$."83%&2%Y,7'*1

O&)*(%

E)"$4.

g

Page 18 ;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1 Item 63621

Duty Cycle (Duration of Use)

FY&"9%9,5,3*%$&%$.*%I*79*(%+V%8&$%)*79"83%2&(%5&(*%
$.,8%$.*%/(*#4("+*9%9'$V%4V47*%$"5*1%%The Duty Cycle

defines the number of minutes, within a 10 minute
period, during which a given welder can produce a
particular welding current without overheating.

For example, a welder with a 40% duty cycle at

100 A welding current must be allowed to rest for at least

6 minutes after every 4 minutes of continuous welding.

Failure to carefully observe duty cycle limitations
can easily over-stress a welder’s power generation
system contributing to premature welder failure.

This Welder has an internal thermal protection system
to help prevent this sort of over-stress. When the
Welder overheats, it automatically shuts down and a
warning screen appears in the LCD Display window.
The Welder automatically returns to service after
cooling off. Should this occur, rest the MIG Gun on an
electrically non-conductive, heat-proof surface, such
as a concrete slab, well clear of the ground clamp.

F77&)%$.*%I*79*(%$&%4&&7%)"$.%$.*%O&)*(%E)"$4.%&8=%
#&%$.,$%$.*%"8$*(8,7%;,8%)"77%.*7/%4&&7%$.*%I*79*(1

When normal operation resumes, use shorter welding
periods and longer rest periods to prevent needless wear.

40% Use at 100 A

;&(%>^%P&8$"8'&'#%T"8'$*#

4%
T"8'$*#%
I*79"83

A

T"8'$*#%

S*#$"83

>^^h%P&8$"8'&'#%\#*%,$%CB F

25% Use at 200 A

;&(%>^%P&8$"8'&'#%T"8'$*#

`?>0`%

T"8'$*#%

I*79"83

C?>0`

T"8'$*#%

S*#$"83

>^^h%P&8$"8'&'#%\#*%,$%>>B F

EF;6GH

E*$$"83%\/%G.*%I*79

47,5/#

)&(W/"*4*#

P7*,8%#'(2,4*#%

$&%+,(*%5*$,71

P.,52*(%$."4W%)&(W/"*4*#1

1. T,W*%/(,4$"4*%)*79#%&8%/"*4*#%&2%#4(,/%$.*%
#,5*%$."4W8*##%,#%V&'(%"8$*89*9%)&(W/"*4*%
$&%/(,4$"4*%$*4.8"<'*%+*2&(*%)*79"83%,8V$."83%
&2%Y,7'*1%%Clean the weld surfaces thoroughly

with a wire brush or angle grinder; there
must be no rust, paint, oil, or other materials
on the weld surfaces, only bare metal.

3. Clamp Ground Cable to bare metal on the
workpiece near the weld area, or to metal work
bench where the workpiece is clamped.

2. Use clamps (not included) to hold the workpieces
in position so that you can concentrate on proper
welding technique. 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. The edges
of thicker workpieces may need to be chamfered
(or beveled) to allow proper weld penetration.

M&$"4*- When welding equipment on a vehicle,
disconnect the vehicle battery power from both the
positive connection and the ground before welding.
This prevents damage to some vehicle electrical
systems and electronics due to the high voltage
and high frequency bursts common in welding.

I&(W/"*4*

P7*,8%

#'(2,4*%$&%

N(&'89%

+,(*%5*$,71

P7,5/

GLN%0%EGLPQ PRMGSRJEILS6

I6JKLMN%GLOE

N(&'89%4&88*4$"&8%9*/*89#%

&8%9*#"(*9%)*79"83%/&7,("$V

TFLMG6MFMP6

Page 19;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1Item 63621

4. Turn the Power Switch to the OFF position,

EF;6GH

PRMGSRJE

then plug the Power Cord into a properly

grounded, GFCI protected 120 VAC (20 amp
rated) or 240 VAC receptacle that matches

the plug. The circuit must be equipped with
delayed action-type circuit breaker or fuses.

5. Set MIG Gun down on nonconductive, nonflammable
surface away from any grounded objects.

6. Turn the Power Switch ON.

E*$$"83#

ILS6

O&)*(%

E)"$4.

b. Set Wire Diameter and Material Thickness:

• Turn Left Knob to set wire diameter.

• Turn Right Knob to set material thickness.

J*2$%

Q8&+

GLN%0%EGLPQ

1. Press Home Button on Control Panel.

2. Turn Main Control Knob until desired
process appears on LCD display screen.

3. Press Main Control Knob to select process.

M&$*- Press Main Control Knob to go to next screen.
Press Back Button to return to the previous screen.

I6JKLMN%GLOE

4. Adjust settings for the selected process.

a. Polarity and Gas Settings:

• Plug cables in according to screen.

• Connect gas according to screen.

• Set SCFH between 20-30.

T,"8%

P&8$(&7%

Q8&+

S"3.$%
Q8&+

1^`Be 24Ga

c. Auto Weld Settings:

• Turn Left Knob to adjust Wire
Feed Speed (Amperage).

• Turn Right Knob to adjust Voltage.

>`> >b1@

^

O(&4*##

N,#%GV/*

S'8?L8%I;E

M&$*- If the Wire Feed Speed or Voltage settings are

adjusted manually, the white mark on the line shows

the recommended setting for your wire/electrode

diameter and workpiece thickness.

`B B

L89'4$,84*

^1^

1^b^e

24Ga

E/&$%G"5*(

^1^

K",5*$*(

G."4W8*##

I"(*%

T,$*(",7%

TFLMG6MFMP6

Page 20 ;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1 Item 63621

d. Optional Settings:

• Press Main Control Knob to
enter Optional Settings.

• Turn Main Control Knob until desired
setting appears on screen.

• Press Main Control Knob to
select desired setting.

• Turn Main Control Knob to adjust setting.

Available Optional Settings:

• Run-In WFS – Adjust wire speed before it
contacts workpiece. This setting represents
a % of the pre-set wire feed speed (WFS).

• Inductance – Adjust length of arc.
Increase for more fluid puddle and flatter
bead. Decrease for colder puddle.

• Spot Timer – Set timer for spot welding.

• Recall Setting – Retrieve saved settings.

• Save Setting – Program up to 5 different
configurations. Turn Main Control Knob to
scroll between 5 available slots. Press Main
Control Knob to access OVERWRITE MEMORY
SETTING screen and turn Main Control Knob
to choose YES selection. Press Main Control
Knob to save current Welder settings.

EF;6GH

M&$*- The initial settings may need to be

adjusted after stopping and carefully inspecting
the weld. Proper welding takes experience.

N,#%E."*79*9=%E&7"9?P&(*%I"(*%R87V

KFMN6Si%%GR%OS6!6MG%K6FG]%%
;SRT%FEO]HjLFGLRM-%
K&%8&$%&/*8%3,#%)"$.&'$%/(&/*(%Y*8$"7,$"&81%%;"[%3,#%
7*,W#%"55*9",$*7V1

Shielding gas can displace air and cause rapid loss of
consciousness and death.

E."*79"83%3,#%)"$.&'$%4,(+&8%9"&["9*%4,8%+*%
*Y*8%5&(*%.,Z,(9&'#%+*4,'#*%,#/.V[",$"&8%
4,8%#$,($%)"$.&'$%2**7"83%#.&($8*##%&2%+(*,$.1

1. Open gas cylinder valve all the way.

2. Set Flow Gauge to SCFH value
indicated on Settings Chart.

GLN%0%EGLPQ PRMGSRJEILS6

I6JKLMN%GLOE

TFLMG6MFMP6

Page 21;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1Item 63621

U,#"4%I"(*%I*79"83%G*4.8"<'*

EF;6GH

1.

Press (and hold) Trigger and contact the area
to be welded with electrode wire to ignite arc.

2. For a narrow weld, you can usually draw the wire
in a steady straight line.
This is called a stringer bead.

For a wider weld, draw the wire back and forth

PRMGSRJE

ILS6

across the joint.
This is called a weave bead and takes
practice to perform properly.

3. Direct the welding wire straight into the joint.
This gives an angle of 90° (straight up and
down) for butt (end to end) welds, and an
angle of 45° for fillet (T-shaped) welds.

#$("83*(%+*,9 )*,Y*%+*,9

I*79%TLN%N'8%,837*#=%%

Y"*)*9%2(&5%2(&8$%&2%)*79%X&"8$1

GLN%0%EGLPQ

4. For MIG welding using solid wire and
shielding gas, the end of the MIG Gun should
be tilted so that wire is angled anywhere
in-between straight on and 15° away

I6JKLMN%GLOE

from the direction you are welding. The
amount of tilt is called the push angle.

5. When using flux-cored wire without
shielding gas, the end of the MIG Gun
should be tilted so that wire is angled
anywhere in-between straight on and
15° in the direction you are welding. The
amount of tilt is called the drag angle.

45°

2"77*$%)*79%X&"8$

O'#.%F837*

0-15°

I*79%

K"(*4$"&8

E&7"9%I"(*%)"$.%E."*79"83%N,# ;7'[?P&(*9%I"(*%)"$.&'$%N,#

+'$$%)*79%X&"8$

K(,3%F837*

0-15°

90°

I*79%

K"(*4$"&8

TFLMG6MFMP6

6. The Contact Tip should remain within 1/2″
of the work surface. This distance is called
CTWD - Contact Tip to Work Distance.

Page 22 ;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1 Item 63621

PGIK%%

(up to 1/2")

M&$*-%%If Welder is used too long, a
warning screen appears in the LCD
Display window and the unit automatically
shuts down. The Welder automatically
returns to service after cooling off.
Should this occur, rest the MIG Gun
on an electrically non-conductive,
heat-proof surface, such as a concrete
slab, away from the ground clamp.

F77&)%$.*%I*79*(%$&%4&&7%)"$.%$.*%
O&)*(%E)"$4.%&8=%#&%$.,$%$.*%"8$*(8,7%
;,8%)"77%.*7/%4&&7%$.*%I*79*(1%%

When normal operation resumes, use
shorter welding periods and longer rest
periods to help prevent needless wear.

7. After welding the test weld on a piece
of scrap for a few seconds, stop, and
check your progress. Clean, then compare
your weld’s appearance with the diagrams
and descriptions in the I*79"83%G"/# section
starting on the next page. After making any
necessary adjustments, continue to weld

while carefully following the DUTY CYCLE
guidelines as explained on page 19.

PF\GLRMi%%I*79%)"77%+*%.&$=%9&%8&$%$&'4.1

JPK%

K"#/7,V

I,(8"83%

E4(**8

O&)*(%

E)"$4.

F2$*(%/(,4$"4*%)*79"83%2&(%,%2*)%#*4&89#=%

EGRO%,89%*[,5"8*%V&'(%)*79%'#"83%$.*%

3'"9*7"8*#%#$,($"83%&8%$.*%8*[$%/,3*1

;RJJRI%K\GH%PHPJ6i

120 VAC

40% Use at 100 A

;&(%>^%P&8$"8'&'#%T"8'$*#

4%

T"8'$*#%

I*79"83

100% Continuous Use at 75 A

A%
T"8'$*#%
S*#$"83

;&(%>^%P&8$"8'&'#%T"8'$*#

`?>0`%
T"8'$*#%
I*79"83

100% Continuous Use at 115 A

240 VAC

25% Use at 200 A

C?>0`%
T"8'$*#%
S*#$"83

EF;6GH

8. I.*8%)*79"83%"#%4&5/7*$*= #*$%$.*%TLN%
N'8%9&)8%&8%,%.*,$?/(&&2=%*7*4$("4,77V%
8&8?4&89'4$"Y*%#'(2,4*1

Turn the Power Switch OFF.

9. Allow Welder to cool down, then
unplug the Power Cord.

10. Remove Ground Clamp from workpiece
or table and disconnect MIG Gun.

11. Respool wire by clipping wire, removing gas

nozzle/contact tip on MIG gun, releasing Idler

Arm on Wire Feed mechanism, and rotating
the Wire Spool counterclockwise. Be sure
to securely hold wire as it is being respooled
because the end of wire has a tendency to
quickly unravel once it clears the wire feeder.

12. TLN%RMJH-%

P7&#*%#."*79"83%3,#%4V7"89*(%Y,7Y*%
#*4'(*7V1%%Remove Regulator and

replace cap. Disconnect Gas Hose from
Welder. Store and secure gas cylinder.

TLN%N'8

GLN%0%EGLPQ PRMGSRJEILS6

4&84(*$*%#7,+%

k&(%&$.*(%.*,$?/(&&2=%

non-conductive surface)

O&)*(%

E)"$4.

I6JKLMN%GLOE

TFLMG6MFMP6

Page 23;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1Item 63621

EF;6GH

TIG / Stick Welding

S*,9%$.*%6MGLS6%LTORSGFMG%EF;6GH%LM;RSTFGLRM%#*4$"&8%,$%$.*%+*3"88"83%&2%$."#%5,8',7%
"847'9"83%,77%$*[$%'89*(%#'+.*,9"83#%$.*(*"8%+*2&(*%#*$%'/%&(%'#*%&2%$."#%/(&9'4$1

GR%OS6!6MG%E6SLR\E%LMa\SH%;SRT%FPPLK6MGFJ%RO6SFGLRM-%
G'(8%$.*%O&)*(%E)"$4.%&22%,89%'8/7'3%$.*%I*79*(%+*2&(*%#*$'/1

M&$*-%Remove the protective foam and cardboard from the Welder before setup. 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.

PRMGSRJE

GLN%E*$'/

P&88*4$%P,+7*#

ILS6

GLN%0%EGLPQ

I6JKLMN%GLOE

;&&$%O*9,7%

(sold separately)

E."*79"83%
N,#%]&#*

;&&$%O*9,7%E&4W*$%

(inside Welder)

;&&$%O*9,7%

P,+7*

GLN%G&(4.%

P,+7*%"8%

M*3,$"Y*%

E&4W*$

N(&'89%P7,5/%P,+7*%

"8%O&#"$"Y*%E&4W*$

GLN%G&(4.%

(sold separately)

1. Plug Ground Clamp Cable into Positive Socket.
Twist clockwise all the way to lock in place.

TFLMG6MFMP6

2. Plug TIG Torch Cable (TIG Torch sold
separately) into Negative Socket. Twist
clockwise all the way to lock in place.

Page 24 ;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1 Item 63621

N(&'89%

P7,5/

3. Insert the Foot Pedal Cable (Foot Pedal
sold separately) through hole on Welder
front and connect to the Foot Pedal
Socket inside the machine. Secure by
turning collar clockwise until tight.

4. For connecting Shielding Gas Hose, refer to
Connect Shielding Gas section on next page.

P&88*4$%E."*79"83%N,#

Reset

Power Input

Gas Inlet

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. Locate the Regulator (included) and close its
valve until it is loose, then thread Regulator
onto cylinder and wrench-tighten connection.

4. Connect Shielding Gas Hose on TIG
Torch Cable Connector to the Regulator’s
Outlet and wrench-tighten connection.

>

EF;6GH

U("*27V%&/*8%Y,7Y*%

`

$&%47*,8=%%

$.*8%47&#*%%

Y,7Y*1

4

b

P&88*4$%O&)*(%P&(9

Plug either 120 VAC or 240 VAC Power

Cord into Power Input Socket.

M&$*- Plug will only fit one way.

IFSMLMNi GR%OS6!6MG%E6SLR\E%LMa\SH%
;SRT%FPPLK6MGFJ%RO6SFGLRM-%Do not

plug cord into wall outlet at this time.

O&)*(%

L8/'$

GLN%0%EGLPQ PRMGSRJEILS6

Serial:

Vulcan OMNIPRO 220

Conforms to UL Std. 60974-1

269317

17b

63621

30A/15.5V to 220A/25V

X 25% 60% 100%

I2200A 130A 115A

U0  78V

24V 20.5V 19.75V

U

2

10A/20.4V to 175A/27V

X 25% 60% 100%

I2175A 115A 100A

U0  78V

27V 24.6V 24V

U

2

10A/10.4V to 175A/17V

X 30% 60% 100%

I2175A 125A 105A

U0  15V

17V 15V 14.2V

U

2

I

= 25.5A

I

 12.8A

1max

1eff

23.7A

11.9A

U1 = 240V

15.6A

8.5A

1~50/60Hz

30A/15.5V to 140A/21V

X 40% 60% 100%

I2100A 85A 75A

U0  78V

19V 18.25V 17.75V

U

2

10A/20.4V to 80A/23.2V

X 40% 60% 100%

I280A 70A 60A

U0  78V

23.2V 22.8V 22.4V

U

2

10A/10.4V to 125A/15V

X 40% 60% 100%

I2125A 105A 90A

U0  15V

15V 14.2V 13.6V

U

2

I

= 20.8A

I

= 13.1A

1max

1eff

19.5A

12.3A

U1 = 120V

20.6A

13A

1~50/60Hz

1

f1

IP21S

S

f2

I6JKLMN%GLOE

TFLMG6MFMP6

Page 25;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1Item 63621

Sharpen Tungsten Electrode (sold separately)

N("89"83%

EF;6GH

To avoid Electrode contamination, dedicate a fine grit grinding wheel exclusively to Electrode grinding.

IFSMLMNi Some Electrodes may have
materials added to them that are hazardous to
breathe. Wear a respirator and ANSI-approved
Safety goggles when grinding an Electrode.

1. Shut off the welder and wait until Electrode
and Torch have cooled enough to handle.

PRMGSRJE

2. Remove Back Cap. Pull Electrode from front
of Torch. (Pulling it from rear will damage
Collet and create burrs on Electrode).

3. If Electrode has dulled or been otherwise
contaminated, use pliers or a suitable tool to
grip the Electrode above the contaminated
section and snap off the end of the Electrode.

Assemble TIG Torch (sold separately)

ILS6

1. Consult Settings Chart, on top of Welder, to
determine proper Tungsten Electrode size to be
used with thickness of material to be welded.

2. Match Collet and Collet Body sizes
to Tungsten Electrode size.

4. Lightly press Electrode tip
against the surface of
the grinding wheel at an angle.
Rotate Electrode tip until a
blunt point is formed.

M&$*- Grinding direction must be
parallel to length of Electrode.

5. The conical portion of the ideal

tip will be 2-1/2 times as long

as the Electrode diameter.

6. Re-insert Electrode into Collet with tip

protruding 1/8"-1/4" beyond the Ceramic

Nozzle, then re-tighten the Back Cap.

8. Lock Electrode in place with Back Cap.

Electrode should protrude 1/8" to 1/4"

beyond the Ceramic Nozzle.

67*4$(&9*

U,4W%P,/

I.**7

3. Thread Collet Body into the front of the Torch.

4. Make sure Ceramic Nozzle size is

GLN%0%EGLPQ

appropriate for application.

5. Thread Ceramic Nozzle onto Collet Body.

6. Insert Collet into back of Torch and into Collet Body.

7. Insert Tungsten Electrode into
Collet on front of Torch.

I6JKLMN%GLOE

TFLMG6MFMP6

L8#*($%$'83#$*8%
67*4$(&9*%.*(*1

P&77*$

P&77*$%
U&9V

P*(,5"4%
M&ZZ7*

Page 26 ;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1 Item 63621

E$"4W%E*$'/

Reset

Power Input

Gas Inlet

P&88*4$%P,+7*#

EF;6GH

N(&'89%P7,5/%P,+7*%

"8%M*3,$"Y*%E&4W*$

N(&'89%

P7,5/

1. Plug Ground Clamp Cable into Negative Socket.
Twist clockwise all the way to lock in place.

P&88*4$%O&)*(%P&(9

Plug either 120 VAC or 240 VAC Power

Cord into Power Input Socket.

M&$*- Plug will only fit one way.

IFSMLMNi GR%OS6!6MG%E6SLR\E%LMa\SH%
;SRT%FPPLK6MGFJ%RO6SFGLRM-%Do not

plug cord into wall outlet at this time.

67*4$(&9*%]&79*(%%

P,+7*%"8%O&#"$"Y*%E&4W*$

67*4$(&9*%

]&79*(

2. Plug Electrode Holder Cable into Positive Socket.
Twist clockwise all the way to lock in place.

Serial:

Vulcan OMNIPRO 220

Conforms to UL Std. 60974-1

269317

17b

O&)*(%

L8/'$

63621

30A/15.5V to 220A/25V

X 25% 60% 100%

I2200A 130A 115A

U0  78V

U224V 20.5V 19.75V

10A/20.4V to 175A/27V

X 25% 60% 100%

I2175A 115A 100A

U0  78V

27V 24.6V 24V

U

2

10A/10.4V to 175A/17V

X 30% 60% 100%

I2175A 125A 105A

U0  15V

17V 15V 14.2V

U

2

I

= 25.5A

I

 12.8A

1max

1eff

23.7A

11.9A

U1 = 240V

15.6A

8.5A

1~50/60Hz

30A/15.5V to 140A/21V

X 40% 60% 100%

I2100A 85A 75A

U0  78V

U219V 18.25V 17.75V

10A/20.4V to 80A/23.2V

X 40% 60% 100%

I280A 70A 60A

U0  78V

23.2V 22.8V 22.4V

U

2

10A/10.4V to 125A/15V

X 40% 60% 100%

I2125A 105A 90A

U0  15V

15V 14.2V 13.6V

U

2

I

= 20.8A

I

= 13.1A

1max

1eff

19.5A

12.3A

U1 = 120V

20.6A

13A

1~50/60Hz

1

f1

IP21S

S

f2

GLN%0%EGLPQ PRMGSRJEILS6

I6JKLMN%GLOE

TFLMG6MFMP6

Page 27;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1Item 63621

Basic TIG / Stick Welding

EF;6GH

% S*,9%$.*%6MGLS6%LTORSGFMG%EF;6GH%LM;RSTFGLRM%#*4$"&8%,$%$.*%+*3"88"83%&2%$."#%

5,8',7%"847'9"83%,77%$*[$%'89*(%#'+.*,9"83#%$.*(*"8%+*2&(*%#*$%'/%&(%'#*%&2%$."#%/(&9'4$1

%

GR%OS6!6MG%E6SLR\E%LMa\SH-%
O(&$*4$"Y*%3*,(%5'#$%+*%)&(8%).*8%'#"83%$.*%I*79*(f%5"8"5'5%#.,9*%8'5+*(%>^%2'77%2,4*%#."*79%

(or welding mask), ear protection, welding gloves, sleeves and apron, NIOSH-approved respirator, and fire

(*#"#$,8$%)&(W%47&$.*#%)"$.&'$%/&4W*$#%#.&'79%+*%)&(8%).*8%)*79"831%%%

PRMGSRJE

J"3.$%2(&5%$.*%,(4%4,8%4,'#*%/*(5,8*8$%9,5,3*%$&%$.*%*V*#%,89%#W"81%%
K&%8&$%+(*,$.*%,(4%2'5*#1

• DC TIG Welding is used to weld
mild steel and stainless steel using
a TIG Rod and shielding gas.

• AC TIG Welding is used to weld aluminum
using a TIG Rod and shielding gas.

• Stick Welding is used to weld mild
steel and stainless steel using a

ILS6

Good welding takes a degree of skill and experience.
Practice a few sample welds on scrap before
welding your first project. Additional practice
periods are recommended whenever you weld:

GLN%0%EGLPQ

T,W*%/(,4$"4*%)*79#%&8%/"*4*#%&2%#4(,/%$&%/(,4$"4*%
$*4.8"<'*%+*2&(*%)*79"83%,8V$."83%&2%Y,7'*1

Stick Electrode without shielding gas.

• a different thickness of material

• a different type of material

• a different type of connection

• using a different process

I6JKLMN%GLOE

TFLMG6MFMP6

GR%OS6!6MG%E6SLR\E%LMa\SH=%%
;LS6%FMK%U\SME-%
Q**/%)*79"83%$"/%47*,(%&2%3(&'89*9%
&+X*4$#%).*8*Y*(%'8"$%"#%/7'33*9%
"8%,89%$'(8*9%&81

O(,4$"4*%V&'(%)*79"83%

$*4.8"<'*%&8%#4(,/%

/"*4*#%+*2&(*%)*79"83%

,8V$."83%&2%Y,7'*1

O&)*(%

R8

g

Page 28 ;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1 Item 63621

Duty Cycle (Duration of Use)

FY&"9%9,5,3*%$&%$.*%I*79*(%+V%8&$%)*79"83%2&(%5&(*%
$.,8%$.*%/(*#4("+*9%9'$V%4V47*%$"5*1%%The Duty Cycle

defines the number of minutes, within a 10 minute
period, during which a given welder can produce a
particular welding current without overheating.

For example, a welder with a 40% duty

cycle at 125 A welding current must be

allowed to rest for at least 6 minutes after
every 4 minutes of continuous welding.

Failure to carefully observe duty cycle limitations
can easily over-stress a welder’s power generation
system contributing to premature welder failure.

GLN%S,$*9%K'$V%PV47*#

240 VAC

30% Use at 175 A

;&(%>^%P&8$"8'&'#%T"8'$*#

b

T"8'$*#%

I*79"83

100% Continuous Use at 105 A

C
T"8'$*#%
S*#$"83

;&(%>^%P&8$"8'&'#%T"8'$*#

T"8'$*#%
I*79"83

100% Continuous Use at 90 A

120 VAC

40% Use at 125 A

4

A
T"8'$*#%
S*#$"83

This Welder has an internal thermal protection system to
help prevent this sort of over-stress. When the Welder
overheats, it automatically shuts down and a warning
screen appears in the LCD Display window. The Welder
automatically returns to service after cooling off. Should
this occur, rest the Tig Torch or Electrode Holder on an
electrically non-conductive, heat-proof surface, such
as a concrete slab, well clear of the ground clamp.

F77&)%$.*%I*79*(%$&%4&&7%)"$.%$.*%O&)*(%E)"$4.%&8=%
#&%$.,$%$.*%"8$*(8,7%;,8%)"77%.*7/%4&&7%$.*%I*79*(1

When normal operation resumes, use
shorter welding periods and longer rest
periods to prevent needless wear.

E$"4W%S,$*9%K'$V%PV47*#

240 VAC

25% Use at 175 A

;&(%>^%P&8$"8'&'#%T"8'$*#

`?>0`
T"8'$*#%
I*79"83

100% Continuous Use at 100 A

C?>0`

T"8'$*#%

S*#$"83

;&(%>^%P&8$"8'&'#%T"8'$*#

T"8'$*#%

I*79"83

100% Continuous Use at 60 A

120 VAC

40% Use at 80 A

4

A
T"8'$*#%
S*#$"83

EF;6GH

E*$$"83%'/%$.*%I*79

47,5/#

)&(W/"*4*#

P7*,8%#'(2,4*#%

$&%+,(*%5*$,71

P.,52*(%$."4W%)&(W/"*4*#1

1. T,W*%/(,4$"4*%)*79#%&8%/"*4*#%&2%#4(,/%$.*%
#,5*%$."4W8*##%,#%V&'(%"8$*89*9%)&(W/"*4*%
$&%/(,4$"4*%$*4.8"<'*%+*2&(*%)*79"83%,8V$."83%
&2%Y,7'*1%%Clean the weld surfaces thoroughly

with a wire brush or angle grinder; there
must be no rust, paint, oil, or other materials
on the weld surfaces, only bare metal.

2. Use clamps (not included) to hold the workpieces
in position so that you can concentrate on
proper welding technique. 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. The edges of
thicker workpieces may need to be chamfered
(or beveled) to allow proper weld penetration.

MRGLP6- When welding equipment on a vehicle,
disconnect the vehicle battery power from both the
positive connection and the ground before welding.
This prevents damage to some vehicle electrical
systems and electronics due to the high voltage
and high frequency bursts common in welding.

I&(W/"*4*

GLN%0%EGLPQ PRMGSRJEILS6

I6JKLMN%GLOE

3. Clamp Ground Cable to bare metal on the
workpiece near the weld area, or to metal work
bench where the workpiece is clamped.

N(&'89%4&88*4$"&8%9*/*89#%

&8%9*#"(*9%)*79"83%/&7,("$V

N(&'89%

P7,5/

P7*,8%

#'(2,4*%$&%

+,(*%5*$,71

TFLMG6MFMP6

Page 29;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1Item 63621

GLN%I*79"83

EF;6GH

GR%OS6!6MG%E6SLR\E%LMa\SH%FMK%K6FG]-%%%
K&%8&$%)*79%)"$.&'$%N(&'89"83%P7,5/1%%
I.*8%$.*%&/*(,$&(%"#%8&$%.&79"83%$.*%G&(4.=%"$%5'#$%+*%#"$$"83%&8%,%8&84&89'4$"Y*=%8&827,55,+7*%#'(2,4*1%
R87V%.&79%GLN%S&9%)"$.%,8%*7*4$("4,77V%"8#'7,$*9%)*79"83%37&Y*1

%%%

GR%OS6!6MG%K6FG]%;SRT%FEO]HjLFGLRM-%

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K&%8&$%&/*8%3,#%)"$.&'$%/(&/*(%Y*8$"7,$"&81%%;"[%3,#%7*,W#%"55*9",$*7V1 Shielding gas can displace
air and cause rapid loss of consciousness and death. E."*79"83%3,#%)"$.&'$%4,(+&8%9"&["9*%4,8%+*%
*Y*8%5&(*%.,Z,(9&'#%+*4,'#*%,#/.V[",$"&8%4,8%#$,($%)"$.&'$%2**7"83%#.&($8*##%&2%+(*,$.1

MRGLP6-% TIG welding is a complicated process,

requiring experience and skill to achieve
successful results. Training beyond the scope of
this manual is required to TIG weld properly.

1. Open gas cylinder’s valve all the way.

2. Set Flow Gauge to SCFH value indicated on the

ILS6

Settings Chart on the inside of the Welder door.

9. Adjust settings for the TIG process.

a. Polarity and Gas Settings:

• Plug cables in according to screen.

• Connect gas according to screen.

• Set SCFH between 10-25.

3. Turn the Power Switch to the OFF position, then
plug the 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.

4. Set TIG Torch down on nonconductive,

GLN%0%EGLPQ

I6JKLMN%GLOE

nonflammable surface away from
any grounded objects.

5. Turn the Power Switch ON.

6. Press Home Button on Control Panel.

7. Turn Main Control Knob until TIG process
appears on LCD display screen.

8. Press Main Control Knob to select TIG process.

M&$*- Press Main Control Knob to go to next screen.
Press Back Button to return to the previous screen.

GLN

TFLMG6MFMP6

b. Set Rod Diameter and Material Thickness:

• Turn Left Knob to set rod diameter.

• Turn Right Knob to set material thickness.

c. Auto Weld Settings:

• Turn Left Knob to adjust output amperage.

• Turn Right Knob to ON to energize TIG Torch.

IFSMLMNi I*79*(%"#%8&)%*8*(3"Z*9%,89%
R/*8%P"(4'"$%!&7$,3*%"#%/(*#*8$1

J*2$%

Q8&+

Page 30 ;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1 Item 63621

T,"8%

P&8$(&7%

Q8&+

S"3.$%
Q8&+

O(&4*##

N,#%GV/*

S&9%

K",5*$*(

T,$*(",7%

G."4W8*##

d. Optional Settings:

• Press Main Control Knob to

enter Optional Settings.

• Turn Main Control Knob until desired

setting appears on screen.

• Press Main Control Knob to

select desired setting.

• Turn Main Control Knob to adjust setting.

Available Optional Settings:

• Recall Setting – Retrieve saved settings.

• Save Setting – Program up to

5 different configurations.

10. Hold TIG Torch in one gloved hand and the TIG
Rod (sold separately) in other gloved hand.

MRG6- Maintain a constant distance between the
Tungsten Electrode and the workpiece: between
1 and 1.5 times the diameter of the Electrode.

11. Open valve on TIG Torch to start gas flow.

12. To initiate welding arc, push Foot Pedal and touch
Electrode to work piece and lift. If not using Foot
Pedal, touch Electrode to work piece and lift.

13. When welding puddle is hot enough, tilt Torch
backward about 10-15 degrees from vertical and
move it back slightly. Add TIG Rod material as
needed to the front end of the weld puddle.

14. Alternate between pushing the torch/weld
puddle and adding the TIG Rod material.

MRG6- Remove the TIG Rod each time the Electrode
is advanced, but do not remove it from the gas shield.
This prevents oxidation from contaminating the weld.

15. When finished welding, release the Foot Pedal but
keep Torch on weld puddle until weld solidifies.
If not using Foot Pedal, pull Torch away from
work piece until welding arc is broken, then
return the gas coverage until weld solidifies.

EF;6GH

M&$*- The initial settings may need to be

adjusted after stopping and carefully inspecting
the weld. Proper welding takes experience.

IFSMLMNi%%GR%OS6!6MG%E6SLR\E%LMa\SH-%%
O(&$*4$"Y*%3*,(%5'#$%+*%)&(8%).*8%'#"83%$.*%
I*79*(f%5"8"5'5%#.,9*%8'5+*(%>^%2'77%2,4*%#."*79%

(or welding mask), ear protection, welding gloves,

#7**Y*#%,89%,/(&8=%MLRE]?,//(&Y*9%(*#/"(,$&(=%
,89%2"(*%(*#"#$,8$%)&(W%47&$.*#%)"$.&'$%/&4W*$#%
#.&'79%+*%)&(8%).*8%)*79"831%%J"3.$%2(&5%$.*%
,(4%4,8%4,'#*%/*(5,8*8$%9,5,3*%$&%$.*%*V*#%
,89%#W"81%%K&%8&$%+(*,$.*%,(4%2'5*#1

After practice welding on scrap, stop,

and check your progress. Perform

Strike Test according to E$("W*%G*#$%&8%

page 34. After making any necessary

adjustments, continue to weld while

carefully following the DUTY CYCLE
guidelines as explained on page 29.

16. Close valve on TIG Torch and turn Right Knob
to OFF to turn off power to TIG Torch.

17. Set TIG Torch down on nonconductive,
nonflammable surface away from
any grounded objects.

18. Turn the Power Switch OFF.

19. To prevent accidents, after use:

• Allow Welder to cool down.

• Unplug Welder’s power cord from outlet.

• Remove Ground Clamp from workpiece or table.

• Disconnect TIG Torch, Ground
and Foot Pedal Cables.

• Close gas cylinder’s valve securely,
remove regulator and replace cap.

• Disconnect Gas Hose from Welder.

• Store and secure gas cylinder.

• Clean, then store Welder and its accessories
indoors out of children’s reach.

GLN%0%EGLPQ PRMGSRJEILS6

I6JKLMN%GLOE

IFSMLMNi T*$,7%)&(W%+*84.%5'#$%
+*%3(&'89*9%).*8%GLN%)*79"831

TFLMG6MFMP6

Page 31;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1Item 63621

E$"4W%I*79"83

EF;6GH

GR%OS6!6MG%E6SLR\E%LMa\SH%FMK%K6FG]-%%%
K&%8&$%)*79%)"$.&'$%N(&'89"83%P7,5/1%%
I.*8%$.*%&/*(,$&(%"#%8&$%.&79"83%$.*%67*4$(&9*%]&79*(=%"$%5'#$%+*%
#"$$"83%&8%,%8&84&89'4$"Y*=%8&827,55,+7*%#'(2,4*1

1. Turn the Power Switch to the OFF position, then
plug the Welder into a properly grounded, GFCI

PRMGSRJE

ILS6

protected, 120 VAC (20 amp rated) outlet or
240 V outlet. The circuit must be equipped with

delayed action-type circuit breaker or fuses.

2. Set Electrode Holder down on
nonconductive, nonflammable surface
away from any grounded objects.

3. Turn the Power Switch ON.

4. Press Home Button on Control Panel.

5. Turn Main Control Knob until Stick process
appears on LCD display screen.

6. Press Main Control Knob to select STICK process.

M&$*- Press Main Control Knob to go to next screen.
Press Back Button to return to the previous screen.

E$"4W

GLN%0%EGLPQ

b. Set Electrode type:

• Turn Main Control Knob to set electrode type.

c. Set Electrode Diameter and Material Thickness:

• Turn Left Knob to set electrode diameter.

• Turn Right Knob to set material thickness.

I6JKLMN%GLOE

J*2$%

Q8&+

T,"8%

P&8$(&7%

Q8&+

7. Adjust settings for the STICK process.

a. Polarity Setting:

• Plug cables in according to screen.

TFLMG6MFMP6

S"3.$%
Q8&+

d. Auto Weld Settings:

• Turn Left Knob to adjust output amperage.

• Turn Right Knob to ON to
energize Electrode Holder.

IFSMLMNi I*79*(%"#%8&)%*8*(3"Z*9%,89%
R/*8%P"(4'"$%!&7$,3*%"#%/(*#*8$1

O(&4*##

67*4$(&9*%

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K",5*$*(

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Page 32 ;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1 Item 63621

e. Optional Settings: 

• Press Main Control Knob to
enter Optional Settings.

• Turn Main Control Knob until desired
setting appears on screen.

• Press Main Control Knob to
select desired setting.

• Turn Main Control Knob to adjust setting.

Available Optional Settings:

• Hot Start – Adjust amperage at start of weld.

• Arc Force – Adjust weld penetration
and smoothness.

• Recall Setting – Retrieve saved settings.

• Save Setting – Program up to
5 different configurations.

IFSMLMNi%%GR%OS6!6MG%E6SLR\E%LMa\SH-%%
O(&$*4$"Y*%3*,(%5'#$%+*%)&(8%).*8%'#"83%$.*%
I*79*(f%5"8"5'5%#.,9*%8'5+*(%>^%2'77%2,4*%#."*79%

(or welding mask), ear protection, welding gloves,

#7**Y*#%,89%,/(&8=%MLRE]?,//(&Y*9%(*#/"(,$&(=%
,89%2"(*%(*#"#$,8$%)&(W%47&$.*#%)"$.&'$%/&4W*$#%
#.&'79%+*%)&(8%).*8%)*79"831%%J"3.$%2(&5%$.*%
,(4%4,8%4,'#*%/*(5,8*8$%9,5,3*%$&%$.*%*V*#%
,89%#W"81%%K&%8&$%+(*,$.*%,(4%2'5*#1

After practice welding on scrap, stop,

and check your progress. Perform

Strike Test according to E$("W*%G*#$%&8%

page 34. After making any necessary

adjustments, continue to weld while

carefully following the DUTY CYCLE

guidelines as explained on page 29.

8. Place the bare metal end of the Stick Electrode (sold
separately) inside the jaws of the Electrode Holder.

9. Stroke the workpiece lightly to ignite the arc.
Tips for igniting the arc:

a. Tap the surface with the Electrode.

b. Stroke the surface with the Electrode.

c. Strike the surface like a match with the Electrode.

EF;6GH

10. After the arc ignites:

a. Lift the Electrode off workpiece the same

distance as the diameter of the bare metal end.

b. Tilt Electrode back 10 to 20 degrees.

c. Drag Electrode to the back end of the weld

puddle to deposit material as needed.

11. When finished welding; lift the Electrode from
the workpiece, then set Electrode Holder
down on nonconductive, nonflammable
surface away from any grounded objects.

12. Turn the Power Switch OFF.

13. To prevent accidents, after use:

• Allow Welder to cool down.

• Unplug Welder’s power cord from outlet.

• Remove Ground Clamp.

• Disconnect Electrode Holder
and Ground Cables.

14. Clean, then store Welder and its accessories
indoors out of children’s reach.

GLN%0%EGLPQ PRMGSRJEILS6

I6JKLMN%GLOE

M&$*- The initial settings may need to be

adjusted after stopping and carefully inspecting
the weld. Proper welding takes experience.

TFLMG6MFMP6

Page 33;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1Item 63621

EF;6GH

I*79"83%G"/#

A good way to test welding technique is to examine a weld’s appearance after it has cooled and the slag has been
removed. Then, better welding can be learned by adjusting your weld technique to remedy any problems found.

NOTICE: TIG welding is a complicated process, requiring experience and skill to achieve successful
results. Training beyond the scope of this manual is required to TIG weld properly.

F2$*(%/(,4$"4*%)*79"83%,%4&'/7*%

&2%)*79"83%+*,9#=%EGRO%,89%

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$.*%2&77&)"83%3'"9*7"8*#1

E$("W*%G*#$

F%$*#$%)*79%&8%,%OL6P6%R;%EPSFO%4,8%+*%

$*#$*9%+V%'#"83%$.*%2&77&)"83%/(&4*9'(*1

I6FS%FMEL?FOOSR!6K%EF;6GH%NRNNJ6E%

K\SLMN%G]LE%OSRP6K\S61

IFSMLMNi G."#%$*#$%ILJJ%9,5,3*%$.*%)*79%"$%"#%

ILS6

/*(2&(5*9%&81%%G."#%$*#$%"#%RMJH%,8%"89"4,$&(%&2%)*79%
$*4.8"<'*%,89%"#%8&$%"8$*89*9%$&%$*#$%)&(W"83%)*79#1

1. After two scraps have been welded together and the
weld has cooled, clamp one scrap in a sturdy vise.

2. Stay clear from underneath while you strike
the opposite scrap with a heavy hammer,
preferably a dead-blow hammer.

3. A NRRK%I6JK will deform but not break, as shown

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on top.
A ORRS%I6JK will be brittle and snap at the
weld, as shown on bottom.

P7*,8"83%$.*%I*79

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9*,9?+7&)%.,55*(

9*,9?+7&)%.,55*(

47,5/

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)&(W/"*4*

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+*89#%,89%"#%8&$%+("$$7*

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)&(W/"*4*

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#8,/#%&(%4(,4W#

GR%OS6!6MG%E6SLR\E%LMa\SH-%
P&8$"8'*%$&%)*,(%FMEL?,//(&Y*9%
#,2*$V%3&337*#%,89%/(&$*4$"Y*%)*,(%
).*8%47*,8"83%,%)*791%%
E/,(W#%&(%4."/#%5,V%27V%).*8%47*,8"831

1. A weld from flux-cored wire welding or stick
welding will be covered by slag. Use a chipping

TFLMG6MFMP6

hammer to knock this off. U*%4,(*2'7%8&$%
$&%9,5,3*%$.*%)*79%&(%+,#*%5,$*(",71

2. Use a wire brush to further clean the weld
or use an angle grinder (sold separately) to
shape the weld.

Page 34 ;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1 Item 63621

P."//"83%

],55*(

I"(*%U('#.

Wire Weld Diagnosis – Workpiece Heat Control / Weld Penetration

OSRO6S%O6M6GSFGLRMLMFK6l\FG6%O6M6GSFGLRM

M&$%.&$%*8&'3. G&&%.&$L9*,7%.*,$

]&)%$&%"84(*,#*%)&(W/"*4*%.*,$%%

,89%"84(*,#*%/*8*$(,$"&8-%%

k$&%)*79%G]LPQ6S workpieces properly)

a. L84(*,#*%)*79%4'((*8$

b. K*4(*,#*%$(,Y*7%#/**9

c. \#*%2,#$*(%)"(*%2**9

d. \#*%#.&($*(%PGIK

6[,5/7*%I"(*%I*79%K",3(,5#

6jP6EE%O6M6GSFGLRM%RS%

U\SM?G]SR\N]

]&)%$&%(*9'4*%)&(W/"*4*%.*,$%%

,89%7"5"$%/*8*$(,$"&8-%%

k$&%)*79%G]LMM6S workpieces properly)

e. K*4(*,#*%)*79%4'((*8$

f. L84(*,#*%$(,Y*7%#/**9

g. \#*%#7&)*(%)"(*%2**9

h. \#*%7&83*(%PGIK

EF;6GH

N&&9%%

I*79

!&7$,3*%%

G&&%J&)%&(%

I"(*%;**9%

G&&%E7&)

L84(*,#*%

R'$/'$%!&7$,3*

&(

L84(*,#*%I"(*%

;**9%E/**9

!&7$,3*%%

G&&%]"3.%&(%

I"(*%;**9%%

G&&%;,#$

GR%PRSS6PG-GR%PRSS6PG-

K*4(*,#*%

R'$/'$%!&7$,3*

&(

K*4(*,#*%I"(*%

;**9%E/**9

G(,Y*7%E/**9%

G&&%;,#$

GR%PRSS6PG-

$(,Y*7%

#7&)*(

G(,Y*7%E/**9%

G&&%E7&)

GR%PRSS6PG-

$(,Y*7%

2,#$*(

PGIK%

G&&%J&83%%

&(%

I(&83%O&7,("$V

GR%PRSS6PG-

P.*4W%O&7,("$V%%

,89

5,"8$,"8%

7*##%

$.,8%>0`e%

PGIK

GLN%0%EGLPQ PRMGSRJEILS6

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TFLMG6MFMP6

Page 35;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1Item 63621

Wire Weld Penetration (Workpiece Heat Control)

EF;6GH

6jP6EE%O6M6GSFGLRM%RS%

I*79%9(&&/#%&8%$&/%,89%

'89*(8*,$.=%&(%2,77#%$.(&'3.%

PRMGSRJE

1. I&(W/"*4*%&Y*(.*,$"83-%
Reduce wire feed speed.
Decrease weld current.

2. G(,Y*7%#/**9%$&&%#7&)-

ILS6

Increase travel speed and ensure
that travel speed is kept steady.

3. 6[4*##"Y*%5,$*(",7%,$%)*79-%
Reduce wire feed speed.

U*89%,$%a&"8$

OSRO6S%O6M6GSFGLRM

U\SM?G]SR\N]

*8$"(*7V=%5,W"83%,%.&7*1

OREELUJ6%PF\E6E%FMK%ERJ\GLRME

I*79%"#%Y"#"+7*%'89*(8*,$.%,89%

+'73*#%#7"3.$7V%&8%$&/1

LMFK6l\FG6%O6M6GSFGLRM

I*79%9&*#%8&$%/*8*$(,$*%$.*%

X&"8$%2'77V=%X'#$%&8%$.*%#'(2,4*1

PROFILE VIEWS

OREELUJ6%PF\E6E%FMK%ERJ\GLRME

4. L84&((*4$%)*79"83%$*4.8"<'*-

Maintain 1/2" or less CTWD.
Keep arc on leading edge of weld puddle.
Hold MIG Gun at proper angles.

5. L8#'22"4"*8$%)*79%.*,$-%
Reduce travel speed.
Increase weld current.

6. I&(W/"*4*#%$&&%$."4W047&#*-
Bevel thick workpieces, allow slight
gap, and weld in several passes.

7. L8#'22"4"*8$%)*79%5,$*(",7-%
Increase wire feed speed.

PROFILE

GLN%0%EGLPQ

I6JKLMN%GLOE

VIEW

OREELUJ6%PF\E6E%FMK%ERJ\GLRME

1. L5/(&/*(%47,5/"83-
Clamp workpieces securely.
Make tack welds to hold workpieces.

2. 6[4*##"Y*%.*,$-
Weld a small portion and allow to cool before
proceeding.
Increase travel speed.
Reduce wire feed speed.

P&,$%&2%E7,3%RY*(%I*79

TOP

VIEW

TFLMG6MFMP6

PARTIALLY CHIPPED AWAY TO SHOW WELD

E7,3%"#%,%8*4*##,(V%/,($%&2%,%27'[?4&(*9%)"(*%
)*791%%L$%#."*79#%$.*%)*79%2(&5%"5/'("$"*#1%%
P7*,8%&22%$.*%#7,3%)"$.%,%P."//"83%],55*(%
,89%I"(*%U('#.%,2$*(%)*79"831

N,#?#."*79*9%TLN%)*79#%,(*%/(&$*4$*9%+V%$.*%
#."*79"83%3,#%,89%9&%8&$%8**9%#7,3%$&%/(&$*4$%$.*51

I*79%M&$%F9.*("83%O(&/*(7V

N,/#%/(*#*8$%+*$)**8%)*79%,89%/(*Y"&'#%+*,9%&(%

+*$)**8%)*79%,89%)&(W/"*4*1%%E**%,(*,#%+*7&)1

PROFILE

VIEW

OREELUJ6%PF\E6E%FMK%ERJ\GLRME

1. L84&((*4$%)*79"83%$*4.8"<'*-
Place stringer bead at correct place in joint.
Adjust workpiece position or weld angle to permit
proper welding to bottom of piece.
Pause briefly at sides during weave bead.
Keep arc on leading edge of weld puddle.
Hold MIG Gun at proper angles.

2. L8#'22"4"*8$%)*79%.*,$-%
Increase current.
Increase wire feed speed.

3. K"($V%)&(W/"*4*-
Clean workpiece down to bare metal.

4. L8#'22"4"*8$%)*79%5,$*(",7-%
Increase wire feed speed.

5. I&(W/"*4*%3,/%$&&%8,((&)-%
Widen groove or increase bevel.

Page 36 ;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1 Item 63621

Wire Weld – Porosity

Wire Weld – Excessive Spatter

E5,77%4,Y"$"*#%&(%.&7*#%"8%$.*%+*,91

TOP

VIEW

OREELUJ6%PF\E6E%FMK%ERJ\GLRME

1. L84&((*4$%/&7,("$V-
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. K"($V%)&(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. L84&8#"#$*8$%$(,Y*7%#/**9-%
Maintain steady travel speed.

6. PGIK%$&&%7&83-
Reduce CTWD.

;"8*%#/,$$*(%"#%8&(5,71%

E/,$$*(%$.,$%"#%3(,"8V%,89%7,(3*%"#%,%/(&+7*51

TOP

VIEW

OREELUJ6%PF\E6E%FMK%ERJ\GLRME

1. K"($V%)&(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. L84&((*4$%/&7,("$V-
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. I"(*%2**9"83%$&&%2,#$-%
Reduce wire feed speed.

5. PGIK%$&&%7&83-
Reduce CTWD.

EF;6GH

Wire Weld – Crooked/Wavy Bead

TOP

VIEW

OREELUJ6%PF\E6E%FMK%ERJ\GLRME

1. L8,44'(,$*%)*79"83-
Use two hands or rest hand on steady surface.

2. L84&8#"#$*8$%$(,Y*7%#/**9-%
Maintain steady travel speed.

3. PGIK%$&&%7&83-
Reduce CTWD.

Wire Weld – Burn-Through

U,#*%5,$*(",7%5*7$#%,),V=%%
7*,Y"83%,%.&7*%"8%$.*%)*791

TOP

VIEW

OREELUJ6%PF\E6E%FMK%ERJ\GLRME

1. I&(W/"*4*%&Y*(.*,$"83-%

Reduce current and/or wire feed speed.

2. G(,Y*7%#/**9%$&&%#7&)-
Increase travel speed and ensure
that travel speed is kept steady.

3. 6[4*##"Y*%5,$*(",7%,$%)*79-%
Reduce wire feed speed.

GLN%0%EGLPQ PRMGSRJEILS6

I6JKLMN%GLOE

TFLMG6MFMP6

Page 37;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1Item 63621

Stick Weld Diagnosis – Workpiece Heat Control / Weld Penetration

EF;6GH

OSRO6S%O6M6GSFGLRMLMFK6l\FG6%O6M6GSFGLRM

6jP6EE%O6M6GSFGLRM%RS%

U\SM?G]SR\N]

PRMGSRJE

M&$%.&$%*8&'3. G&&%.&$L9*,7%.*,$

]&)%$&%"84(*,#*%)&(W/"*4*%.*,$%%

,89%"84(*,#*%/*8*$(,$"&8-%%

k$&%)*79%G]LPQ6S workpieces properly)

a. Increase current. b. Weld more slowly.

6[,5/7*%E$"4W%I*79%K",3(,5#

ILS6

E$"4W%)*79#%)"77%.,Y*%,%4&,$%&2%#7,3%&Y*(%$.*5%'8$"7%47*,8*91

GLN%0%EGLPQ

]&)%$&%(*9'4*%)&(W/"*4*%.*,$%%

,89%7"5"$%/*8*$(,$"&8-%%

k$&%)*79%G]LMM6S workpieces properly)

c. Decrease current. d. Weld more quickly.

PJ6FM%I6JKE%;LSEGi

TFLMG6MFMP6

N&&9%

I6JKLMN%GLOE

I*79

Page 38 ;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1 Item 63621

P'((*8$%%

G&&%J&)%

GR%PRSS6PG-%

Increase the

current

P'((*8$%%

G&&%]"3.

GR%PRSS6PG-%

Decrease

the current

I*79%E/**9%

G&&%;,#$

GR%PRSS6PG-

Weld slower

I*79%E/**9%

G&&%E7&)

GR%PRSS6PG-

Weld faster

F(4%J*83$.%%

G&&%E.&($%

GR%PRSS6PG-

Increase
distance

F(4%J*83$.%%

G&&%J&83%

GR%PRSS6PG-

Decrease

distance

Stick Weld Penetration (Workpiece Heat Control)

6jP6EE%O6M6GSFGLRM%RS%

U\SM?G]SR\N]

I*79%9(&&/#%&8%$&/%,89%

'89*(8*,$.%&(%2,77#%$.(&'3.%

*8$"(*7V=%5,W"83%,%.&7*1

OREELUJ6%PF\E6E%FMK%ERJ\GLRME%;RS%

6jP6EE%O6M6GSFGLRM%RS%U\SM?G]SR\N]

1. I&(W/"*4*%&Y*(.*,$"83-%
Reduce current.

2. I*79"83%#/**9%$&&%#7&)-
Increase welding speed and ensure
that welding speed is kept steady.

I*79%"#%Y"#"+7*%'89*(8*,$.%,89%

OSRO6S%O6M6GSFGLRM

+'73*#%#7"3.$7V%&8%$&/1

PROFILE VIEWS

OREELUJ6%PF\E6E%FMK%ERJ\GLRME%;RS

1. L84&((*4$%)*79"83%$*4.8"<'*-
Keep arc on leading edge of weld puddle.
Hold torch at proper angles.

2. L8#'22"4"*8$%)*79%.*,$-%
Slow down so fill material has time to melt
into the weld location. Increase current.

3. I&(W/"*4*#%$&&%$."4W047&#*-
Bevel thick workpieces, allow slight
gap, and weld in several passes.

4. L8#'22"4"*8$%)*79%5,$*(",7-%
Increase amount of fill material.

LMFK6l\FG6%O6M6GSFGLRM

I*79%9&*#%8&$%4&8$,4$%$.*%X&"8$%

2'77V=%X'#$%&8%$.*%#'(2,4*1

EF;6GH

LMFK6l\FG6%O6M6GSFGLRM

Stick Weld – Weld Not Adhering Properly

N,/#%/(*#*8$%+*$)**8%)*79%,89%/(*Y"&'#%+*,9%&(%+*$)**8%)*79%,89%)&(W/"*4*1%%E**%,(*,#%+*7&)1

OREELUJ6%PF\E6E%FMK%ERJ\GLRME

PROFILE

VIEW

1. L84&((*4$%)*79"83%$*4.8"<'*-
Place stringer bead at correct place in joint.
Adjust workpiece position or weld angle to permit
proper welding to bottom of piece.
Keep arc on leading edge of weld puddle.
Hold Electrode and fill material at proper angles.

2. L8#'22"4"*8$%)*79%.*,$-%
Increase current.

3. K"($V%)&(W/"*4*-
Clean workpiece down to bare metal.

4. L8#'22"4"*8$%)*79%5,$*(",7-%
Increase amount of fill material.

5. K"#$,84*%+*$)**8%)&(W/"*4*#%$&%7,(3*-%
Decrease distance and increase bevel.

Stick Weld – Bend at Joint

OREELUJ6%PF\E6E%FMK%ERJ\GLRME

PROFILE

VIEW

1. L5/(&/*(%47,5/"83-
Clamp workpieces securely.
Make tack welds to hold workpieces.

2. 6[4*##"Y*%.*,$-
Weld a small portion and allow to cool before
proceeding.
Increase weld speed.

GLN%0%EGLPQ PRMGSRJEILS6

I6JKLMN%GLOE

TFLMG6MFMP6

Page 39;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1Item 63621

Stick Weld – Coat of Slag Over Weld

EF;6GH

E7,3%"#%,%8*4*##,(V%/,($%&2%,%#$"4W%)*791%%L$%#."*79#%

TOP

VIEW

PARTIALLY CHIPPED AWAY TO SHOW WELD

Stick Weld – Porosity m%E5,77%4,Y"$"*#%&(%.&7*#%"8%$.*%+*,91

PRMGSRJE

$.*%)*79%2(&5%"5/'("$"*#1%%P7*,8%&22%$.*%#7,3%)"$.%$.*%
P."//"83%],55*(%,89%I"(*%U('#.%,2$*(%)*79"831

OREELUJ6%PF\E6E%FMK%ERJ\GLRME

TOP

VIEW

Stick Weld – Crooked/Wavy Bead

ILS6

OREELUJ6%PF\E6E%FMK%ERJ\GLRME

TOP

VIEW

GLN%0%EGLPQ

Stick Weld – Excessive Spatter

OREELUJ6%PF\E6E%FMK%ERJ\GLRME

1. K"($V%)&(W/"*4*%&(%2"77%5,$*(",7-
Clean workpiece down to bare metal.
Make certain that fill material and Electrode are
clean and free from oil, coatings, and other residues.

2. L84&8#"#$*8$%)*79"83%#/**9-%
Maintain steady weld speed.

1. L8,44'(,$*%)*79"83-
Use two hands or rest hand on steady surface.

2. L84&8#"#$*8$%)*79"83%#/**9-%
Maintain steady weld speed.

;"8*%#/,$$*(%"#%8&(5,71%E/,$$*(%$.,$%"#%
3(,"8V%,89%7,(3*%"#%,%/(&+7*51%

TOP

VIEW

I6JKLMN%GLOE

K"($V%)&(W/"*4*%&(%2"77%5,$*(",7-

Clean workpiece down to bare metal.
Make certain that fill material and Electrode are
clean and free from oil, coatings, and other residues.

Stick Weld – Burn-Through m%U,#*%5,$*(",7%5*7$#%,),V=%7*,Y"83%,%.&7*%"8%$.*%)*791

TFLMG6MFMP6

OREELUJ6%PF\E6E%FMK%ERJ\GLRME

TOP

VIEW

1. I&(W/"*4*%&Y*(.*,$"83-%
Reduce current.

2. I*79"83%#/**9%$&&%#7&)-
Increase welding speed and ensure
that welding speed is kept steady.

3. 6[4*##"Y*%5,$*(",7%,$%)*79-%
Reduce amount of fill material.

Page 40 ;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1 Item 63621

T,"8$*8,84*

GR%OS6!6MG%E6SLR\E%LMa\SH=%;LS6%FMK%U\SME-%
\8/7'3%$.*%I*79*(=%(*#$%$.*%$&&7%&8%,%.*,$?/(&&2=%*7*4$("4,77V%8&8?4&89'4$"Y*%#'(2,4*=%,89%,77&)%
,77%/,($#%&2%$.*%I*79*(%$&%4&&7%$.&(&'3.7V%+*2&(*%#*(Y"4*1%

1. U6;RS6%6FP]%\E6= inspect the general
condition of the Welder. Check for:

• loose hardware

• misalignment or binding of moving parts

• damaged cord / electrical wiring

• frayed or damaged cables

• cracked or broken parts

• any other condition that may

affect its safe operation.

2. O6SLRKLPFJJH= have a qualified
technician remove the Rear Panel
and use compressed air to blow
out all dust from the interior.

3. F;G6S%6!6SH%\E6, store in
a clean and dry location.

4. For optimal MIG / Flux-Cored wire weld

<',7"$V=%47*,8%,89%"8#/*4$%$.*%TLN%
N'8%P&8$,4$%G"/%,89%M&ZZ7*%+*2&(*%
*,4.%'#*=%,#%*[/7,"8*9%+*7&)1

TLN%N'8%M&ZZ7*%,89%P&8$,4$%G"/%L8#/*4$"&8%,89%P7*,8"83

1. T,W*%#'(*%$.,$%$.*%*8$"(*%TLN%N'8%"#%4&5/7*$*7V%
4&&7%,89%$.,$%$.*%O&)*(%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, the Nozzle will
adversely effect the weld and should be replaced.

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). Check that the Tip
is the proper type for the wire size used.

7. Examine the shape of the hole at the end of
the Contact Tip. It should be an even circle; it
should not be oblong or have any bulges in it.

8. If any problems are noted, replace the
Contact Tip. Select a new Tip of the
correct size for the welding wire used.

9. Reinstall the Tip and securely
reinstall the Nozzle as well.

P

M

&ZZ7*

&8$,4$

G

"/

EF;6GH

GLN%0%EGLPQ PRMGSRJEILS6

S*/7,4"83%$.*%JPK%E4(**8%P&Y*(

1. Carefully pry frame off of Display (17)
by inserting flathead screwdriver (sold
separately) into one of the side slots.

K

"#/7,V

2. Insert a new Screen Cover (18) into Screen
Frame (19) with the gap facing downward.

E4(**8%

;(,5*

E4(**8%

P

&Y*(

3. Insert frame back into slot on Display with
the top end being placed in first.

I6JKLMN%GLOE

TFLMG6MFMP6

Page 41;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1Item 63621

Troubleshooting – MIG / Flux-Cored Welding

EF;6GH

LTORSGFMGi

U*%P6SGFLM%$&%#.'$%&22%$.*%I*79*(=%9"#4&88*4$%"$% 2(&5% /&)*(=%,89%9"#4.,(3*% $.*% TLN% N'8%$&%

3(&'89%+*2&(*%,9X'#$"83=%47*,8"83=%&(%(*/,"("83%$.*%'8"$1

O(&+7*5 O&##"+7*%P,'#*# J"W*7V%E&7'$"&8#

1. Insufficient wire feed pressure.

2. Incorrect wire feed roller size.

Wire Feed Motor

PRMGSRJE

Runs but Wire Does
Not Feed Properly

Wire Creates a
Bird’s Nest During
Operation

ILS6

Wire Stops
During Welding

GLN%0%EGLPQ

I6JKLMN%GLOE

Welding Arc
Not Stable

TFLMG6MFMP6

Weak Arc Strength

3. Damaged MIG Gun, cable, or liner assembly.

4. Feed Tensioner is too tight.

1. Excess wire feed pressure.

2. Incorrect Contact Tip size.

3. MIG Gun Cable Connector not fully
inserted into Wire Feed mechanism.

4. Damaged liner.

1. Gun cable is severely bent and Wire
Feed mechanism cannot feed wire.

2. Gun liner is clogged or worn.

3. Gun liner is too small for
welding wire being used.

4. Wire is tangled on the spool.

5. Wire is not making contact with Feed Rollers.

6. Feed Roller is not making enough contact
with wire or is crushing flux-cored wire.

1. Wire not feeding properly.

2. Incorrect Contact Tip or liner
size or excessive wear.

3. Incorrect wire feed speed.

4. Loose MIG Gun cable or ground cable.

5. Damaged MIG Gun or loose
connection within Gun.

6. Incorrect polarity for process being run.

7. Gas coverage may be insufficient or too high.

8. Poor connection with workpiece.

1. Incorrect line voltage.

2. Improper gauge or length of cord.

3. Not enough current.

1. Increase wire feed pressure properly.
Follow step 27 on page 17.

2. Flip roll to correct size. Follow the Feed
Roller instructions on page 12.

3. Have a qualified technician inspect these
parts and replace as necessary.

4. Loosen Feed Tensioner so it applies only
enough pressure to prevent continued
spinning after the Gun Trigger is released.

1. Adjust wire feed pressure properly.
Follow step 27 on page 17.

2. Replace with the proper tip for wire used.

3. Insert Gun Cable Connector properly.
Follow steps 13 and 14 on page 13.

4. Have a qualified technician inspect

and repair/replace as necessary.

1. Straighten Gun cable.

2. Check gun liner for obstruction.
Replace if necessary.

3. Check that gun liner is correct size for wire.

4. Check wire for cross winding or tangled spool.

5. Check Feed Rollers and ensure correct
groove for wire diameter is being used.

6. Check Feed Tensioner and ensure it is set properly.

1. See first Troubleshooting section above.

2. Replace with the proper tip or
liner size for wire used.

3. Adjust wire feed speed to achieve
a more stable arc.

4. Check to ensure that all connections are tight.

5. Have a qualified technician inspect

and repair/replace as necessary.

6. Ensure polarity is correct for operation:
DCEP for MIG welding and DCEN for
Flux-Cored self-shielded welding.

7. Ensure gas flow rate is set according to
Settings Chart. Make sure MIG Gun Cable
Connector is fully inserted into Wire Feed
mechanism with no O-Rings exposed.

8. Check the ground clamp connection to
the workpiece and machine. Ensure
the MIG Gun is properly secured.

1. Check the line voltage and, if insufficient, have
a licensed electrician remedy the situation.

2. Do not use an extension cord on this Welder.
Use only one of the supplied power cords for
this Welder or an identical replacement cord.

3. Switch current to proper setting for metal thickness.

;&77&)%,77%#,2*$V%/(*4,'$"&8#%).*8*Y*(%9",38&#"83%&(%#*(Y"4"83%$.*%*<'"/5*8$1

Page 42 ;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1 Item 63621

O(&+7*5 O&##"+7*%P,'#*# J"W*7V%E&7'$"&8#

Welder Does Not
Function When
Switched On

LCD Display
Does Not Light
When Welder is
Switched On

Wire Feeds, but Arc
Does Not Ignite

Porosity in the
Weld Metal

1. Tripped thermal protection device.

2. Circuit supplies insufficient input voltage or
amperage.

3. Faulty or improperly connected Trigger.

4. Machine is in low- or
over-voltage protection.

5. Machine is in the incorrect mode.

1. Unit is not connected to outlet properly.

2. Outlet is unpowered.

3. Plug does not have correct rating.

4. Circuit breaker has tripped due
to high input amperage.

5. Input Power Cord is not seated properly.

1. Improper ground connection.

2. Improperly sized Contact Tip.

3. Excessively worn Contact Tip.

4. Dirty Contact Tip.

1. Shielding gas bottle is empty.

2. Not enough or too much shielding gas.

3. Dirty workpiece.

4. Gun is being used too far
away from workpiece.

5. Polarity is incorrect for the application.

6. Dirty welding wire is introducing
contamination into the weld.

1. If a warning screen appears in the LCD Display
window, Welder may have overheated and shut
down. Stop and wait with the Power Switch ON
for the Welder to cool. The Welder automatically
returns to service after cooling off. Reduce
duration or frequency of welding periods to
help reduce wear on the Welder. Refer to
Duty Cycle (Duration of Use) on page 19.

2. Verify that the circuit is designed to supply the
required input voltage and amperage as detailed
on the Specifications table. If a warning screen
appears in the LCD Display window, check the
input voltage to ensure it is within specified range.

3. Ensure the gun connection is properly
seated on machine. Qualified technician

must check and secure/replace Trigger.

4. Check input voltage and ensure it falls within
the specified range. If input voltage is correct,
press Reset Button on back of machine.

5. Ensure the correct process has been selected.

1. Verify the voltage at the outlet and
the connection to the outlet.

2. Check circuit breaker/GFCI devices;
if any are tripped, determine and
remedy cause before resetting.

3. Make sure installed plug is correct rating.
See Specifications on page 7.

4. Press Reset Button on back of
machine to reset circuit breaker.

5. Ensure the twist lock input Power
Cord is fully secured.

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.

1. Check gas bottle and replenish as necessary.

2. Check gas regulator to ensure proper flow.

3. Clean workpiece down to bare metal.

4. Check CTWD (contact tip to work
distance) for the proper procedure.

5. Check the polarity and ensure it is DCEP
for MIG and DCEN for Flux-Cored.

6. Make certain that welding wire is clean
and free of rust and residues.

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Page 43;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1Item 63621

Troubleshooting – TIG / Stick Welding

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Welder Does Not
Function When
Switched On

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LCD Display Does Not
Light When Welder
is Switched On

Weak Arc Strength 1. Incorrect line voltage.

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Welding Arc
Not Stable.

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1. Tripped thermal protection device.

2. Faulty or improperly
connected Trigger.

3. Ground Clamp not attached
to workpiece.

4. Shielding Gas not connected.

1. Unit is not connected
to outlet properly.

2. Outlet is unpowered.

2. Improper gauge or length of cord.

1. Loose electrode cable
or ground cable.

2. Damaged electrode holder or loose
connection within electrode holder.

3. Adjust current setting.

4. Shielding gas getting low.

LTORSGFMGi

1. Reduce duration or frequency of welding periods
to help reduce wear on the welder. Refer to
Duty Cycle (Duration of Use) on page 29.

2. Qualified technician must check and

secure/replace Trigger.

3. Attach Ground Clamp to workpiece.

4. Connect shielding gas to Welder.

1. Verify the voltage at the outlet and
the connection to the outlet.

2. Check circuit breaker/GFCI devices; if any are tripped,
determine and remedy cause before resetting. Verify
that the circuit is designed to supply the required input
amperage as detailed in Specifications on page 7.

1. Check the line voltage and, if insufficient, have
a licensed electrician remedy the situation.

2. Do not use an extension cord on this Welder. Use
only one of the supplied power cords for this
Welder or an identical replacement cord.

1. Check to ensure that all connections are tight.

2. Have a qualified technician inspect and

repair/replace as necessary.

3. Make sure setting matches
recommended setting on chart.

4. Replace shielding gas cylinder.

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Page 44 ;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1 Item 63621

I"("83%E4.*5,$"4

-

Drawing Wire MotorWire Feed Motor

OUT+

*

OUT

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Hall Sensor

1
2
3

M

CN7

1
2
3

CN4

4

M

5

Gas valve 2

Gas valve 1

Gas Valve 1 Gas Valve 2

Touch Switch

1
2
3

CN3

4

4

1
2

3

CN6

3

2

1

4127

8

19

20

Main Board

IGBT

2

4

-

+

〜

〜

1

3

2

4

-

+

〜

〜

RECITIFIER

3

1

v

4
3
2
1

CN1

Gun switch

34

Remote control plug

1

2

CN3

7
6
5

4

1

9

6

5

11 10

4
3

CN8

2
1

1
2
3
4
5
6
7

CN1

12345

6

CN2

Remote Control Board

34

15V

PFC

-t

34

J

33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17

CN5

16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1

2
1

FAN1

2
1

2 1

FAN2

12345

678

M4

1
2
3
4
5

control panel

6
7
8
9

10
11
12
13
14
15
16
17

M3

18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34

678

Operation panel

234

1

CN1

S1

CN1

5

123

4

567

11

8910

10

11

4

56789

VR3A

21

123

3

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VR1A

3

21

LCD screen

VR2A

3

21

S2

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FAN2

Switch

AC1

Fuse

F

AC2

G

FAN1

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Page 45;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1Item 63621

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OJ6FE6%S6FK%G]6%;RJJRILMN%PFS6;\JJH

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

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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.

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1 Housing 1
2 Handle Base 1
3 Handle Cover 1
4 Hinge 2
5 Hinge Pin 2
6 Door 1
7 Latch 1
8 Panel 1
9 PFC Inductor 1

10 Spool 1

11 Remote Control PCB 1
12 Wire Feed Mechanism 1
13 Foot Pedal Connector 1
14 Air Connector 1
15 Cover 1
16 Display PCB 1
17 Display 1
18 Screen Cover 1
19 Screen Frame 1
20 MIG Welding Gun 1
21 Front Handle Cover 1
22 Front Panel 1
23 Control Panel 1
24 Side Knob 2
25 Knob 1
26 Storage Door 1
27 Switch 1
28 Air Connector 1
29 Air Fitting 1
30 Quick Connector 2
31 Ground Clamp 1
32 Electrode Holder 1

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33 Wire Feed Connector 1
34 Air Connector 1
35 Output Inductor 1
36 Air Connector 3
37 Solenoid Valve 2
38 Base 1
39 Insulating Board 1
40 Main PCB 1
41 Control PCB 1
42 Fast Recovery Diode 6
43 Air Duct 1
44 Rectifier Radiator Bracket 1
45 Rectifier Radiator 1
46 Fan 1
47 Transformer 1
48 IGBT 2
49 Heatsink 1
50 Fast Recovery Diode 2
51 IGBT Radiator Bracket 1
52 IGBT Radiator 1
53 Bridge Rectifier 2
54 IGBT 4
55 IGBT Radiator 2
56 Fan 1
57 Threaded Y-connector 1
58 120 VAC Power Cord 1
59 Rear Panel 1
60 Rear Handle Cover 1
61 Power Connector 1
62 Overload Protector 1
63 Rear Panel 1
64 240 VAC Power Cord 1

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S*4&(9%O(&9'4$_#%E*(",7%M'5+*(%]*(*-%

M&$*- If product has no serial number, record month and year of purchase instead.

M&$*- Some parts are listed and shown for illustration purposes only,

and are not available individually as replacement parts.

Page 46 ;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1 Item 63621

F##*5+7V%K",3(,5

27

28

29 30

262425

23

22

21

20

19

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18

3231

33

3534 36 37

38 44 45

13

10 912 11 815 141617

7

6

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2345

63

62

1

4239 40 41

43

46

47

48

49

50

51

52

53

56

54

57

55

58

61

60

59

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64

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Page 47;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?@AA?BCDC1Item 63621

J"5"$*9%D^%K,V%I,((,8$V

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.

26541 Agoura Road • Calabasas, CA 91302 • 1-888-866-5797