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Harbor Freight Tools 97503 manual

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Table of contents for the manual

  • Page 1

    DUAL MIG WELDER Model 97503 SET UP AND OPERA TING 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 T ools ® . 3491 Mission Oaks Blvd., Camarillo, CA 9301 1 Visit our website at: h[...]

  • Page 2

    Page 2 SKU 97503 For technical questions, please call 1-800-444-3353. CONTENTS IMPORT ANT SAFETY INFORMA TION ............................ 3 GENERAL SAFETY RULES .............. 3 SPECIFIC SAFETY RULES ............... 5 SPECIFICA TIONS .......................... 9 UNP ACKING .................................. 9 LIST OF CONTENTS .....................[...]

  • Page 3

    Page 3 SKU 97503 For technical questions, please call 1-800-444-3353. SA VE 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 ha[...]

  • Page 4

    Page 4 SKU 97503 For technical questions, please call 1-800-444-3353. Electrical safety 2. Avoid body contact with grounded a. 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 b. or wet conditions. W ater entering a power tool will i[...]

  • Page 5

    Page 5 SKU 97503 For technical questions, please call 1-800-444-3353. 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 f. tool bits etc., in accordance with these instructions and in the m[...]

  • Page 6

    Page 6 SKU 97503 For technical questions, please call 1-800-444-3353. • Avoid operating alone. • Do not use with power switch locked 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 electrica[...]

  • Page 7

    Page 7 SKU 97503 For technical questions, please call 1-800-444-3353. with a cover made of re resistant material. Remove or make safe all • combustible materials for a radius of 35 feet (10 meters) around the work area. Use a re resistant material to cover or block all open doorways, windows, cracks, and other openings. Enclose the work are[...]

  • Page 8

    Page 8 SKU 97503 For technical questions, please call 1-800-444-3353. way . Do not use adapter plugs with this product. Avoid overexposure to fumes and 19. 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 gases from your breathing zone and general area. Where vent[...]

  • Page 9

    Page 9 SKU 97503 For technical questions, please call 1-800-444-3353. SPECIFICA TIONS Welding Current 30 ~ 120 amps Duty Cycle 20% at 105 amps; 40% at 75 amps; 90% at 50 amps; 100% at 30 amps Input Power 230 V AC, 21 amps (Peak) at 60 Hz Open Circuit V oltage (max) 36 VDC Thermal Overload Protection with Light Automatic shutdown and restart after c[...]

  • Page 10

    Page 10 SKU 97503 For technical questions, please call 1-800-444-3353. 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[...]

  • Page 11

    Page 1 1 SKU 97503 For technical questions, please call 1-800-444-3353. on the T orch Handle until the Welding Wire feeds into the T orch Handle about 2 inches. If necessary , move the T orch Handle slightly in a circular motion to help feed the Welding Wire properly out of the Head T ube. If the Welding Wire does not feed 14. and the Spool is stat[...]

  • Page 12

    Page 12 SKU 97503 For technical questions, please call 1-800-444-3353. Inlet located on the Back Panel of the Welder . Adjust the ow rate of the gas by 27. turning the Flow Adjust. The typical ow rate is 10-30 CFH (cubic feet per hour). Check the Welding Wire manufacturer ’s recommended ow rate. Installation of a line-in, where 28. neces[...]

  • Page 13

    Page 13 SKU 97503 For technical questions, please call 1-800-444-3353. The duty cycle denes 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 aft[...]

  • Page 14

    Page 14 SKU 97503 For technical questions, please call 1-800-444-3353. welded with the electrode wire to ignite the arc. Never tap the electrode wire into the welding surface to ignite the arc. The Welding Wire should extend no 9. more than 1/2” past the Nozzle of the Welding T orch. The Welding Wire should be directed 10. straight into the joint[...]

  • Page 15

    Page 15 SKU 97503 For technical questions, please call 1-800-444-3353. T op gures are V oltage Settings. Bottom number is Wire Speed Setting. NOTE: The numbers within the spaces are the approximate wire feed/voltage settings recommended* for this wire size and material thickness. Material Thickness (Steel) .035”-.047” .047”-.075” .075”[...]

  • Page 16

    Page 16 SKU 97503 For technical questions, please call 1-800-444-3353. MAINTENANCE AND SER VICING Procedures not specically explained in this manual must be performed only by a qualied technician. TO PREVENT SERIOUS INJUR Y FROM ACCIDENT AL OPERA TION: T urn the Power Switch of the tool to its “OFF” position and unplug the tool from its e[...]

  • Page 17

    Page 17 SKU 97503 For technical questions, please call 1-800-444-3353. enlarges. A Contact T ip that measures 150% or more the original size* should be replaced. (*.045” or more for .030” T ips; .035” or more for .023 T ips.) If any problems are noted with a 5. Contact T ip, have it replaced. When inspection and maintenance is 6. completed, r[...]

  • Page 18

    Page 18 SKU 97503 For technical questions, please call 1-800-444-3353. TROUBLESHOOTING DANGER Important! Be CERT AIN to shut off the W elder , 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: Insufc[...]

  • Page 19

    Page 19 SKU 97503 For technical questions, please call 1-800-444-3353. Incorrect line voltage: • Check the line voltage and, if insufcient, 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 b[...]

  • Page 20

    Page 20 SKU 97503 For technical questions, please call 1-800-444-3353. P ARTS LIST AND ASSEMBL Y DIAGRAM P ARTS LIST Part Description 1 Side Panel B 2 Hinge 3 Handle Socket 4 Straight Handle 5 Fan 6 Back Panel 7 Rectifier Rack 8 Temperature Controller 9 10 1 1 12 13 14 15 16 17 18 19 20 21 Clap Panel Wire Spool Axle Wire Feed Mechanism Wire Feed Wh[...]

  • Page 21

    Page 21 SKU 97503 For technical questions, please call 1-800-444-3353. 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. LIMITED 1 YEAR / 90 DA Y W A[...]