Harbor Freight Tools 97503 Welder User Manual
Contents
1. DUAL WELDER 11197503 SET AND OPERATING INSTRUCTIONS Diagrams within this manual may not be drawn proportionally Due to continuing improvements actual product may differ slightly from the product described herein Distributed exclusively by Harbor Freight Tools 3491 Mission Oaks Blvd Camarillo CA 93011 Visit our website at http www harborfreight com Read this material before using this product Failure to do so can result in serious injury SAVE THIS MANUAL Copyright 2008 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 For technical questions or replacement parts please call 1 800 444 3353 CONTENTS IMPORTANT SAFETY 1 3 GENERAL SAFETY RULEGS 3 SPECIFIC SAFETY RULEGS 5 9 9 LIST OF 9 INITIAL SET UP INSTRUCTIONS 9 55 9 LOADING AND ADJUSTING THE WIRE TENSION 10 INSTALLING A GAS CYLINDER 11 OPERATING INSTRUCTIONS 12 TOOL SET 12 WORK PIECE AND WORK AREA SET UP 12 GENERAL OPERATING INSTRUCTIONS2. 13 MAINTENANCE AND SERVICING 16 CLEANING MAINTENANCE AND 16 NOZZLE 16 CONTACT 16 REPLACING THE WELDING TORCH 17 TROUBLESHOOTING 18 WIRE FEED MOTOR RUNS BUT WIRE DOES NOT FEED PROPERLY 18 WIRE CREATES A BIRD S NEST DURING OPERATION 18 WELDING ARC NOT STABLE 18 SKU 97503 For technical questions please call 1 800 444 3353 WELDER DOES NOT FUNCTION WHEN SWITCHED 18 WEAK ARC STRENGTH 18 WIRE FEEDS BUT ARC DOES NOT IGNITE 19 WIRE FEEDS BUT SHIELDING GAS DOES NOT FLOW 19 PLEASE READ THE FOLLOWING CAREFULLY sosisini 19 PARTS LIST AND ASSEMBLY 1 20 LIMITED 1 YEAR 90 DAY WARRANTY 21 2 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 IMPORTANT SAFETY INFORMATION In this manual on the la
3. a safe location 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 Do not weld or cut materials having a combustible coating or combustible internal structure as in walls or ceilings without an approved method for eliminating the hazard Do not dispose of hot slag in containers holding combustible materials Keep a fire extinguisher nearby and know how to use it After spot welding make a thorough examination for evidence of fire Be aware that easily visible smoke or flame may not be present for some time after the fire has started Do not weld or cut in atmospheres containing dangerously reactive or flammable 15 16 18 For technical questions please call 1 800 444 3353 gases vapors liquids and dust Provide adequate ventilation in work areas to prevent accumulation of flammable gases vapors and dust Do not apply heat to a container that has held an unknown substance or a combustible material whose contents when heated can produce flammable or explosive vapors Clean and purge containers before applying heat Vent closed containers including castings before preheating welding or cutting Do not touch live electrical parts Wear dry insulating gloves Do not touch electrode or conductor tong with bare hand Do not wear wet
4. or dirty If needed replace Contact Tip with proper size and type Wire Feeds but Shielding gas does not Flow Possible Causes and Solutions e Empty Gas Cylinder Check gas cylinder Nozzle Plugged Clean nozzle If damaged replace Regulator or cylinder valve closed Make sure both valves are adjusted properly Gas line blocked Check external hose and hose within Torch cable Gas solenoid broken or not connected properly Have a qualified technician check replace SKU 97503 For technical questions please call 1 800 444 3353 PLEASE READ THE FOLLOWING CAREFULLY THE MANUFACTURER AND OR DISTRIBUTOR HAS PROVIDED THE PARTS LISTANDASSEMBLY 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 OR SHE 15 QUALIFIED TO MAKE REPAIRS TO THE PRODUCT OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT IN FACT THE MANUFACTURER AND OR DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS AND NOT BY THE BUYER THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO Page 19 PARTS LIST AND ASSEMBLY DIAGRAM 7 0 Wire Feed Mechanism 81 Control Grout
5. please call 1 800 444 3353 Avoid eye and body damage Arc rays and infrared radiation can injure eyes and burn skin Wear ANSI approved eye and body protection Do not allow viewing by visitors without proper eye and body protection Use a Face Shield with arc shaded filter plate Move flammable and explosive material at least 35 feet from the welding arc to prevent welding sparks or molten metal from starting a fire Keep a type ABC fire extinguisher within easy reach Thoroughly clean the object being welded of any paint grease or other foreign material Avoid unintentional starting Prepare to begin work before turning on the tool Do not leave the tool unattended when it is plugged into an electrical outlet Turn off the tool and unplug it from its electrical outlet before leaving Use clamps not included or other practical ways to secure and support the work piece to a stable platform Holding the work by hand or against your body is unstable and may lead to loss of control This product is not a toy Keep it out of reach of children Industrial applications must follow OSHA guidelines People with pacemakers should consult their physician s before use Electromagnetic fields in close proximity to heart pacemaker could cause pacemaker interference or pacemaker failure addition people with pacemakers should Page 5 SKU 97503 Avoid operating alone Do not use with power switch locke
6. Board Bracket ooo o Overicad tight 40 2 20 caeno 2 Part SKU 97503 For technical questions please call 1 800 444 3353 Page 20 LIMITED 1 YEAR 90 DAY WARRANTY Harbor Freight Tools Co makes every effort to assure that its products meet high quality and durability standards and warrants to the original purchaser that for a period of ninety days from date of purchase that the torch liner wire feed mechanism if applicable welding clamps electrode holders cables and accessories packed with the welder are free of defects in materials and workmanship This Limited 90 Day 1 Year Warranty shall not apply to consumable parts such as tips welding wire and gas nozzles Harbor Freight Tools also warrants to the original purchaser for a period of one year from date of purchase that the transformer and rectifier are free from defects in materials and workmanship 90 days if used by a professional contractor or if used as rental equipment This warranty does not apply to damage due directly or indirectly to misuse abuse negligence or accidents repairs or alterations outside our facilities 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 c
7. 1 800 444 3353 Do not use an Argon Mixed pressure regulator flow meter with CO2 shielding gas To use 2 shielding gas you must install a CO2 gas pressure regulator flow meter neither one included Thread the provided straps through the slots on the back of the welder With assistance set the cylinder onto the shelf at the back of the welder Secure the cylinder in place with both of the straps Remove the protective cap from the cylinder Stand to the side of the cylinder valve and open the valve slightly to blow dust and dirt from the valve Close the valve Make sure the Flow Adjust on the Pressure Regulator Flow Meter is turned off Screw the Pressure Regulator Flow Meter not included firmly onto the cylinder valve Attach the Gas Line to the Pressure Regulator Flow Meter from the Gas Page 11 27 28 Inlet located on the Back Panel of the Welder Adjust the flow rate of the gas by turning the Flow Adjust The typical flow rate is 10 30 CFH cubic feet per hour Check the Welding Wire manufacturer s recommended flow rate Installation of a line in where necessary and connecting a Twist lock plug to the Power Cord must be performed by a licensed electrician OPERATING INSTRUCTIONS Read the ENTIRE IMPORTANT AWARNING SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before set up or use of this product Tool Set Up TO PREV
8. 10 shade lens rating Leather leggings fire resistant shoes or boots should be worn when using this product Do not wear pants with cuffs shirts with open pockets or any clothing that can catch and hold molten metal or sparks Keep clothing free of grease oil solvents or any flammable substances Wear dry insulating gloves and protective clothing Wear an approved head covering to protect the head and neck Use aprons cape sleeves shoulder covers and bibs designed and approved for welding and cutting procedures When welding cutting overhead or in confined spaces wear flame resistant ear plugs or ear muffs to keep sparks out of ears Prevent accidental fires Remove any combustible material from the work area When possible move the work to a location well away from combustible materials If relocation is not possible protect the combustibles Page 6 SKU 97503 with a cover made of fire resistant material 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 Enclose the work area with portable fire resistant screens Protect combustible walls ceilings floors etc from sparks and heat with fire resistant covers If working a metal wall ceiling etc prevent ignition of combustibles on the other side by moving the combustibles to
9. ENT SERIOUS INJURY FROM ACCIDENTAL OPERATION Turn the switch to its off position before performing any inspection maintenance or cleaning procedures Work Piece and Work Area Set Up 1 Designate a work area that is clean and well lit The work area must not allow access by children or pets to prevent injury and distraction 2 Route the power cord along a safe route to reach the work area without creating a tripping hazard or exposing SKU 97503 For technical questions please call 1 800 444 3353 the power cord to possible damage The power cord must reach the work area with enough extra length to allow free movement while working Secure loose work pieces using a vise or clamps not included to prevent movement while working The work pieces should be firmly held together and in position while welding The distance if any between the two work pieces must be controlled properly to allow the weld to hold both sides securely while allowing the weld to penetrate fully into the joint There must not be hazardous objects such as utility lines or foreign objects nearby that will present a hazard while working A barrier such as a welding curtain or welding shroud should be put up to protect others in the work area and limit the spray of sparks General Operating Instructions Protective gear must worn when using the MIG Welder ANSIl approved arc shaded eye protection a full
10. FICATIONS SETUP 120amps INSTRUCTIONS 20 at 105 amps Read the ENTIRE IMPORTANT Suipeyele 40 at 75 amps SAFETY INFORMATION section 90 at 50 amps at the beginning of this manual 100 at 30 amps including all text under input Power 230 VAC 21 amps bheadi h in bef t p Peak at 60 Hz supneaqings therein before se max TO PREVENT Thermal Overload Automatic shutdown AWARNING SERIOUS INJURY i ae and restart after cool Protection with Light down FROM ACCIDENTAL 0 023 to 0 030 inch OPERATION steel and stainless Turn the Power Switch of the Wire Size steel 0 030 to 0 035 tool to its OFF position and core and unplug the tool from its aluminum electrical outlet before 22 gauge to 3 16 Welding Capacity Steel assembling or making any Wire Spool Size 2 Ib Spool adjustments to the tool 62 2 Ibs Note For additional information regarding the parts listed in the following pages refer to the Assembly Diagram near UNPACKING the end of this manual When unpacking check to make sure that the item is intact and undamaged If Assembly any parts are missing or broken please 4 Slide the Axle 29 through the holes call Harbor Freight Tools at the number at the rear of the unit shown on the cover of this manual as soon as possible 2 Secure both Wheels 28 to the Axle with the Locking Rings 42 List of contents 3 Lift up t
11. act Tip have it replaced When inspection and maintenance 10 completed reinstall the Contact Tip and Nozzle Replacing the Welding Torch Liner Switch welder off disconnect power and discharge electrode to ground before proceeding Secure welding wire to the spool cut 11 it near the spool and remove it from the torch and cable Gently twist and slide the Locking Collar off the torch and onto the Protective Sleeve Slide the Upper Housing forward and off the Lower Housing Remove the four Screws that hold the Cable Clamp in place Set aside the Cable Clamp Screws and the Liner Sleeve underneath the cable clamp Lay torch cable out straight to allow the cable to twist within the sleeve Press in on the Push lock Coupler and remove the Liner from the gun end Install a new Liner and Fitting from the gun end with the end without a Fitting first For technical questions please call 1 800 444 3353 Attach the Fitting at the end of the Liner to the Push lock Coupler on the Switch Body Slide the Liner Sleeve back onto the end of the liner Reinstall the Cable Clamp and Screws Trim off the Liner that extends past the Clamp Make sure that all torch parts lay back into place properly including the Protective Sleeve Head Tube and Trigger See Assembly Diagram While all parts are properly in place carefully put the Upper Housing back onto the Lower Housing and slide back to secure Slide the Lo
12. beling and all other information provided with this product This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death A DANGER indicates 4A DANGER a hazardous situation which if not avoided will result in death or serious injury AWARNING WARNING indicates a hazardous situation which if not avoided could result in death or serious injury SKU 97503 For technical questions please call 1 800 444 3353 CAUTION used ACAUTION with the safety alert symbol indicates a hazardous situation which if not avoided could result in minor or moderate injury NOTICE is used to address practices not related to personal injury CAUTION without CAUTION the safety alert symbol is used to address practices not related to personal injury General Safety Rules WARNING Read all instructions Failure to follow all instructions listed below may result in electric shock fire and or serious injury The term power tool in all of the warnings listed below refers to your line operated corded Dual MIG Welder SAVE THESE INSTRUCTIONS 1 Work area safety a Keep work area clean and well lit Cluttered or dark areas invite accidents b Do not operate power tools in explosive atmospheres such as in the presence of flammable liquids gases or dust Power tools create s
13. cking Collar back onto the Housings and twist to secure Check the Torch carefully for proper operation Route the Wire as instructed in the Loading and Adjusting the Wire Tension Section Page 17 TROUBLESHOOTING 4DAN GER Important Be CERTAIN to shut off the Welder disconnect it from power and discharge the torch to ground before adjusting cleaning or repairing the unit Wire feed motor runs but wire does not feed properly Possible Causes and Solutions e Insufficient wire feed pressure Increase wire feed pressure Incorrect wire feed roll size Replace with the proper size e Damaged torch cable or liner assembly Have a qualified technician inspect these parts and replace as necessary Wire creates bird s nest During operation Possible Causes and Solutions e Excess wire feed pressure Adjust wire feed pressure e Incorrect contact tip size Replace with the proper tip for the wire size used e Gun end not inserted into drive housing properly Loosen gun securing bolt and push gun end into housing just enough so that it does not touch wire feed mechanism e Damaged liner Have a qualified technician inspect and repair replace as necessary Welding arc not stable Possible Causes and Solutions e Wire not feeding properly See first Troubleshooting section above e Incorrect contact tip size Replace with the proper tip for the wire size used e Incorrect wire
14. d on Properly maintain and inspect to avoid electrical shock Any power cord must be properly grounded Ground Fault Circuit Interrupter GFCI should also be implemented it prevents sustained electrical shock WARNING This product when used for welding plasma cutting soldering or similar applications produces chemicals known to the State of California to cause cancer and birth defects or other reproductive harm California Health amp Safety Code 25249 5 et seq Cylinders can explode when damaged e Never weld a pressurized or a closed cylinder Never lay a welding torch on a cylinder Never allow a welding electrode to touch the cylinder Keep cylinders away from any electrical circuits including welding circuits Keep protective cap in place over the valve except when the cylinder is in use 14 Use only correct gas shielding equipment designed specifically for the type of welding you will do Maintain this equipment properly Protect gas cylinders from heat being struck physical damage slag flames sparks and arcs For technical questions please call 1 800 444 3353 Always use proper procedures to move cylinders Prevent eye injury and burns Wearing and using ANSI approved personal safety clothing and safety devices reduce the risk for injury e Wear ANSI approved safety eye goggles underneath welding eye protection featuring at least a Number
15. face shield heavy duty work gloves a welding apron respirator and heavy duty work clothes without pockets should be worn when using this product Do not look at the ignited arc without eye protection Light from the arc can cause permanent damage to the eyes Light from the arc can burn the skin Do not breathe arc fumes Page 12 Switch Settings _ 0 10 20 30 40 50 60 70 80 90 100 Duration of Use Amperage The duty cycle defines the number of minutes within a 10 minute period during which a given Welder can safely produce a particular welding current For example this Welder with a 20 duty cycle at 105 Amps setting Max 2 must be allowed to rest for at least 8 minutes after two minutes of continuous weld at 105 Amps 1 2 Power Level Switch Wire Feed Speed Control SKU 97503 Failure to carefully observe duty cycle limitations can stress a Welder s power generation system contributing to premature Welder failure This Welder is equipped with an internal thermal protection system to help prevent damage to the unit When the unit overheats it automatically shuts down then returns to service when it cools down Once the unit returns to service follow a more conservative duty cycle routine to help prevent excess wear to the Welder Controls and Indicators Overload shutdown Indicator Lamp Min Max Switch On O
16. feed speed Adjust wire feed speed to achieve a more stable arc Loose torch cable or ground cable Check to ensure that all connections are tight e Damaged torch or loose connection within torch Have a qualified technician inspect and repair replace as necessary Welder does not function when switched on Possible Causes and Solutions e Tripped thermal protection device Shut the welder s switch to off and allow it to cool for at least 20 minutes Reduce duration or frequency of welding periods to help reduce wear on the welder Refer to Duty Cycle section Faulty or improperly connected Switch Body Have a technician check and secure replace Switch Body Internal fuse blown Have a qualified technician check replace Weak Arc strength Possible Cause and Solution SKU 97503 For technical questions please call 1 800 444 3353 Page 18 Incorrect line voltage Check the line voltage and if insufficient have a licensed electrician remedy the situation Wire Feeds but arc does not ignite Possible Causes and Solutions Improper ground connection Make certain that the work piece is contacted properly by the Ground Clamp and that the work piece is properly cleaned near the ground clamp and the welding location Improperly sized or excessively worn Contact Tip Verify that Contact Tip is the proper size for the welding wire used Check that the hole in the tip is not deformed enlarged
17. ff Switch Line Cord Ground Cable with Clamp Welding Torch Cable For technical questions please call 1 800 444 3353 Always read and follow wire manufacturer s recommended polarity If using non flux core wire secure the 2 gas hose to the rear of the MIG Welder If using flux core wire protective gas is not required Attach the Ground Cable with Clamp 14 as close as possible to the metal object to be welded Set the desired current 30 120 amps for the type of metal being welded with the Temperature Controller Thin metals use low current and heavy metals use high current Duty Volts Cycle Make sure the power switch is off then plug the MIG Welder Power Cord into a dedicated 230 VAC 20 amp line with delayed action type circuit breaker or fuses While holding the Welding Torch handle with the electrode wire clear of grounded objects turn the Power Switch ON Momentarily press the Welding Torch trigger switch to test the wire feed speed Adjust the speed by turning the Wire Speed Knob Hold the Arc Shaded Face Shield over your eyes Press and hold the Torch Trigger Switch and stroke the area to be Page 13 welded with the electrode wire to ignite the arc Never tap the electrode wire into the welding surface to ignite the arc 9 The Welding Wire should extend no more than 1 2 past the Nozzle of the Welding Torch 10 The Welding Wire should be directed straight i
18. for misalignment or binding of moving parts breakage of parts and any Page 4 SKU 97503 other condition that may affect the power tool s operation If damaged have the power tool repaired before use Many accidents are caused by poorly maintained power tools Use the power tool accessories and tool bits etc in accordance with these instructions and in the manner intended for the particular type of power tool taking into account the working conditions and the work to be performed Use of the power tool for operations different from those intended could result in a hazardous situation Service a Have your power tool serviced by a qualified repair person using only identical replacement parts This will ensure that the safety of the power tool is maintained Specific Safety Rules Maintain labels and nameplates on the tool These carry important safety information If unreadable or missing contact Harbor Freight Tools for a replacement Avoid electrical shock Do not permit electrically live parts cables or electrodes to contact skin clothing or gloves Wear ANSI approved protective clothing This unit draws enough current to cause serious injury or death Before turning the welder on check the electrode holder to be sure that there are no protruding screw heads and that all insulation is secure Do not weld unless you are insulated from ground and the work piece For technical questions
19. he Side Panel 1 to nti expose the wire spool and Wire Feed Mechanism 10 Pull back on the Feed Tensioner CC to free the Feed Tension Arm DD and lift it up Remove Wire Feed Wheel Cover 0 030 0 8mm Welding Tip AA screws pull out the cover and pull out the Wire Feed Wheel BB 2 Pounds 0 030 Flux Core Wire See photo page 10 4 Note the two parallel grooves one is wider on the circumference of the Wire Feed Wheel BB On the sides SKU 97503 For technical questions please call 1 800 444 3353 Page 9 Loading and adjusting the wire tension 7 SKU 97503 of the wheel reference markings 0 6 or 0 8 are stamped They corresponding with wire sizes 0 6 0 023 and 0 8 0 030 and 0 035 The groove facing to the inside of the Wire Feed Mechanism 10 should correspond with the size of wire used Align the axle key with the slot in the Wire Feed Wheel and slide on the Wire Feed Spool BB Replace Wire Feed Wheel Cover AA the two screws and tighten See photo on this page Lay the Welding Torch Cable 16 in a straight line perpendicular to the welder unit as much as possible This will prevent the wire from puncturing the Welding Torch Cable 16 when exiting the Wire Feed Housing Throat FF See photo on this page Remove the wing nut and the spool axle nut from the Wire Spool Axle 10 Make sure that the coil spring is inserted onto the Spool Axle and place a spool with wire o
20. le about 2 inches If necessary move the Torch Handle slightly in a circular motion to help feed the Welding Wire properly out of the Head Tube If the Welding Wire does not feed and the Spool is stationary turn the Welder off and unplug it Tighten the Tension Adjusting Knob on the Wire Feed Assembly and rewind the Welding Wire slightly before retrying Feed the Welding Wire against scrap wood that is 2 to 3 inches away If the Wire stops instead of bending turn the Welder OFF and unplug it Tighten the Tension Adjusting Knob more Turn the Welder OFF unplug it and discharge the electrode to ground Insert the contact tip onto the Welding Wire and screw it firmly in place Replace the Nozzle and cut off any excess Welding Wire over 1 2 inch Check that cables to connection Knobs 34 are correct See photo this page When using Non flux wire and Protective gas connect Ground cable with clamp to the terminal and the Internal Power cable to terminal Strap down the Argon CO2 gas cylinder and connect the hose to the rear of the MIG Welder When using Flux core wire DO NOT USE Protective gas connect Ground cable with clamp to terminal and the internal Power cable to terminal 20 Close the Side Panel 1 j Side Panel B Wire Spool Axle Wire Spool Installing a gas cylinder 21 22 23 24 25 26 For technical questions please call
21. nel 12 from the unit and using compressed air blow out all dust and debris from the interior AWARNING If the supply cord of this power tool is damaged it must be replaced only by a qualified service technician Nozzle Care Turn the Nozzle counterclockwise while pulling to remove Scrub the interior of the Nozzle clean with a wire brush 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 Replace the Nozzle after inspecting and cleaning the Contact Tip Contact Tip Care Make sure the entire Welding Torch is completely cool before proceeding Remove the Nozzle as explained above and the Contact Tip Scrub the exterior of the Contact Tip clean with a wire brush Check that the Contact Tip is the proper type for the wire size used Examine the hole at the end of the Contact Tip for the following problems Shape The hole should be an even circle and should not be oblong or have any bulges in it e Size The Contact Tip will decrease in efficiency as the center hole SKU 97503 For technical questions please call 1 800 444 3353 Page 16 SKU 97503 enlarges A Contact that 8 measures 150 or more the original size should be replaced 045 or more for 030 Tips 035 or more for 023 Tips If any problems are noted with a Cont
22. nto the joint This gives an angle of 90 degrees straight up and down for groove end to end welds and an angle of 45 degrees for fillet T shaped welds 11 end of the Welding Torch should be tilted so that the Welding Wire is angled anywhere in between straight on and 15 degrees in the direction of the weld The amount of tilt is called the drag angle Drag Angle Up to 15 Angle in Weld Direction Weld Direction 12 wire feeds automatically and can be changed using the Wire Speed Knob 13 If too much current is drawn from the MIG Welder the overload protection will activate the red overload indicator will light and the Arc Welder will shut down If this happens turn the power Switch OFF and wait about 3 5 minutes before restarting SKU 97503 14 15 16 17 For technical questions please call 1 800 444 3353 When the weld is complete lift the Welding Torch handle away from any grounded object remove your Face Shield and turn the power Switch OFF Unplug the power cord from the electrical outlet Read the included weld diagnosis pamphlet for tips and suggestions concerning welding and proper usage To prevent accidents turn off the tool and disconnect its power supply after use Clean then store the tool indoors out of children s and unauthorized people s reach Page 14 Top figures are Voltage Settings Bottom number is Wire Speed Se
23. onsequential 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 3491 Mission Oaks Blvd PO Box 6009 Camarillo CA 93011 800 444 3353 Record Product s Serial Number Here Note If product has no serial number record month and year of purchase instead Note Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts SKU 97503 For technical questions please call 1 800 444 3353 Page 21
24. or damaged gloves Protect yourself from electric shock Do not use outdoors Insulate yourself from the work piece and ground Use nonflammable dry insulating material if possible or use dry rubber mats dry wood or plywood or other dry insulating material big enough to cover your full area of contact with the work or ground Ensure that the unit is placed on a stable location before use If this unit falls while plugged in severe injury electric shock or fire may result Ground this product This Welder requires the attachment and use of a UL listed 240 volt grounded 3 prong electrical Power Cord Plug not included Only a qualified electrician should install the Power Cord Plug Never remove the grounding prong or modify the Power Cord Plug in any Page 7 way Do not use adapter plugs with this product AWARNING 19 Avoid overexposure to fumes and gases Always keep your head out of the fumes Do not breathe the fumes Use enough ventilation or exhaust or both to keep fumes and INHALATION HAZARD gases from your breathing zone and Welding and Plasma Cutting Produce general area TOXIC FUMES Where ventilation is questionable Exposure to welding or cutting have a qualified technician take exhaust fumes can increase the risk an air sampling to determine the of developing certain cancers such as need for corrective measures Use of the larynx and lung cancer mechanical ventilation to imp
25. parks which may ignite the dust or fumes c Keep children and bystanders away while operating a power tool Distractions can cause you to lose control Page 3 2 SKU 97503 Electrical safety Avoid body contact with grounded surfaces such as pipes radiators ranges and refrigerators There is an increased risk of electric shock if your body is grounded Do not expose power tools to rain or wet conditions Water entering a power tool will increase the risk of electric shock Do not abuse the cord Never use the cord for pulling or unplugging the power tool Keep cord away from heat oil sharp edges or moving parts Damaged or entangled cords increase the risk of electric shock When operating a power tool outdoors use an extension cord suitable for outdoor use Use of a cord suitable for outdoor use reduces the risk of electric shock Personal safety Stay alert watch what you are doing and use common sense when operating a power tool Do not use a power tool while you are tired or under the influence of drugs alcohol or medication A moment of inattention while operating power tools may result in serious personal injury Use safety equipment Always wear eye protection Safety equipment such as arc shaded impact safety full face shield dust mask or respirator heavy duty work gloves non skid safety shoes or hearing protection used for appropriate conditions will red
26. rove Also some diseases that may be linked air quality If engineering controls to exposure to welding or plasma cutting are not feasible use an approved exhaust fumes are respirator e Early onset of Parkinson s Disease Follow OSHA guidelines for Heart disease e Ulcers Permissible Exposure Limits PEL s Damage to the reproductive organs for various fumes and gases Inflammation of the small intestine or stomach Kidney damage Respiratory diseases such as emphysema bronchitis or pneumonia Follow the American Conference of Governmental Industrial Hygienists recommendations for Threshold Limit Values TLV s for fumes and Use natural or forced air ventilation and gases wear a respirator approved by NIOSH to protect against the fumes produced to reduce the risk of developing the above illnesses Have a recognized specialist in Industrial Hygiene or Environmental Services check the operation and air quality and make recommendations for the specific 20 The warnings precautions welding or cutting situation and instructions discussed in this instruction manual cannot cover all possible conditions and situations that may occur It must be understood by the operator that common sense and caution are factors which cannot be built into this product but must be supplied by the operator SAVE THESE INSTRUCTIONS SKU 97503 For technical questions please call 1 800 444 3353 Page 8 SPECI
27. tting Material Thickness Steel NOTE The numbers within the spaces are the approximate wire feed voltage settings recommended for this wire size and material 035 047 047 075 075 125 125 157 157 187 thickness Wire Size Flux Core Mild Steel Do Not Use Protective Gas Wire Size Solid Core Mild Steel Use with Protective Gas Page 15 For technical questions please call 1 800 444 3353 SKU 97503 MAINTENANCE AND SERVICING Procedures not specifically explained in this manual must be performed only by a qualified technician TO PREVENT AWARNING SERIOUS INJURY FROM ACCIDENTAL OPERATION Turn the Power Switch of the tool to its OFF position and unplug the tool from its electrical outlet before performing any inspection maintenance or cleaning procedures TO PREVENT SERIOUS INJURY FROM TOOL FAILURE Do not use damaged equipment If abnormal noise or vibration occurs have the problem corrected before further use Cleaning Maintenance and Lubrication 1 BEFORE EACH USE inspect the general condition of the tool Check for loose screws misalignment or binding of moving parts cracked or broken parts damaged electrical wiring and any other condition that may affect its safe operation 2 AFTER USE clean external surfaces of the tool with clean cloth 3 PERIODICALLY open the Access Pa
28. uce personal injuries Avoid accidental starting Ensure the switch is in the off position a For technical questions please call 1 800 444 3353 before plugging in Carrying power tools with your finger on the switch or plugging in power tools that have the switch on invites accidents Remove any adjusting key or wrench before turning the power tool on A wrench or a key left attached to a rotating part of the power tool may result in personal injury Do not overreach Keep proper footing and balance at all times This enables better control of the power tool in unexpected situations Power tool use and care Do not force the power tool Use the correct power tool for your application The correct power tool will do the job better and safer at the rate for which it was designed Do not use the power tool if the switch does not turn it on and off Any power tool that cannot be controlled with the switch is dangerous and must be repaired Disconnect the plug from the power source before making any adjustments changing accessories or storing power tools Such preventive safety measures reduce the risk of starting the power tool accidentally Store idle power tools out of the reach of children and do not allow persons unfamiliar with the power tool or these instructions to operate the power tool Power tools are dangerous in the hands of untrained users Maintain power tools Check
29. ver the axle noting that the wire winding must be in a counterclockwise direction Replace the Spool Axle Nut 10 the wing nut and tighten Verify free rotation of the spool over the axle CAUTION Hold onto the end of the Welding Wire and keep tension on it during the following steps If this is not done the Welding Wire will spring backward and tangle The end of the wire should be straight and have no burrs 8 10 11 A DANGER 12 13 For technical questions please call 1 800 444 3353 Twist off and pull to remove the Nozzle and unscrew the Contact tip of the Welder Wire Feed Mechanism Guide the tip through the feed tube until it protrudes the Wire Feed Wheel opening Direct and feed at least an inch of wire into the Wire Feed Housing Throat FF Close Wire Feed Mechanism 10 over the wire and adjust Feed Tension Knob D until there is a slight resistance on the wire Remove the nozzle and contact tip of the Welder The following steps require applying power to the Welder Do not touch anything with the Torch Handle or Welding Wire or an arc will be ignited Do not touch the internal components of the unit while it is powered Plug the Power Cord into a grounded 230 volt electrical outlet and turn the Welder ON Point the Torch Handle away from all objects Squeeze the Trigger Switch Page 10 SKU 97503 on the Torch Handle until the Welding Wire feeds into the Torch Hand
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