Harbor Freight Tools 97503 User Manual
DUAL MIG WELDER
Model
97503
SET UP 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
INFORMATION ............................ 3
GENERAL SAFETY RULES .............. 3
SPECIFIC SAFETY RULES ............... 5
SPECIFICATIONS .......................... 9
WELDER DOES NOT
FUNCTION WHEN
SWITCHED ON ........................18
WEAK ARC STRENGTH ............ 18
WIRE FEEDS, BUT ARC DOES
NOT IGNITE .............................19
WIRE FEEDS, BUT SHIELDING
GAS DOES NOT FLOW ...........19
UNPACKING .................................. 9
LIST OF CONTENTS .......................... 9
INITIAL SET UP INSTRUCTIONS . 9
ASSEMBLY.........................................9
LOADING AND ADJUSTING
THE WIRE TENSION. ..............10
INSTALLING A GAS CYLINDER 11
OPERATING INSTRUCTIONS .... 12
TOOL SET UP .................................. 12
WORK PIECE AND WORK AREA
SET UP ..........................................12
GENERAL OPERATING
INSTRUCTIONS ............................13
MAINTENANCE AND
SERVICING ............................... 16
PLEASE READ THE FOLLOWING
CAREFULLY ..................................19
PARTS LIST AND ASSEMBLY
DIAGRAM .................................. 20
LIMITED 1 YEAR / 90 DAY
WARRANTY .............................. 21
CLEANING, MAINTENANCE, AND
LUBRICATION ...............................16
NOZZLE CARE ................................. 16
CONTACT TIP CARE .......................16
REPLACING THE WELDING
TORCH LINER ...............................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
Page 2SKU 97503 For technical questions, please call 1-800-444-3353.
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 labeling,
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.
CAUTION, used
CAUTION
alert symbol, indicates a
hazardous situation which, if
not avoided, could result in
minor or moderate injury.
NOTICE is used to
NOTICE
not related to personal injury.
CAUTION, without
CAUTION
symbol, is used to address
practices not related to
personal injury.
with the safety
address practices
the safety alert
General Safety Rules
WARNING! Read all instructions
Failure to follow all instructions
listed below may result in
electric shock, re, 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
DANGER indicates
DANGER
situation which, if not
avoided, will result in death or
serious injury.
WARNING
WARNING
hazardous situation which, if
not avoided, could result in
death or serious injury.
a hazardous
indicates a
Work area safety1.
Keep work area clean and well a.
lit. Cluttered or dark areas invite
accidents.
Do not operate power tools in b.
explosive atmospheres, such as in
the presence of ammable liquids,
gases or dust. Power tools create
sparks which may ignite the dust or
fumes.
Keep children and bystanders c.
away while operating a power
tool. Distractions can cause you
to lose control.
Page 3SKU 97503 For technical questions, please call 1-800-444-3353.
Electrical safety2.
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. Water entering a
power tool will increase the risk of
electric shock.
Do not abuse the cord. Never use c.
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 d.
outdoors, use an extension cord
suitable for outdoor use. Use of
a cord suitable for outdoor use
reduces the risk of electric shock.
Personal safety3.
Stay alert, watch what you are a.
doing and use common sense
when operating a power tool. Do
not use a power tool while you are
tired or under the inuence of drugs,
alcohol or medication. A moment
of inattention while operating power
tools may result in serious personal
injury.
Use safety equipment. Always b.
wear eye protection. Safety
equipment such as arc shaded,
impact safety full face shield,
dust mask or respirator, heavyduty work gloves, non-skid safety
shoes, or hearing protection used
for appropriate conditions will
reduce personal injuries.
Avoid accidental starting. Ensure c.
the switch is in the off-position
before plugging in. Carrying power
tools with your nger on the switch
or plugging in power tools that have
the switch on invites accidents.
Remove any adjusting key or wrench d.
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 e.
footing and balance at all times.
This enables better control of the
power tool in unexpected situations.
Power tool use and care4.
Do not force the power tool. Use a.
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 b.
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 c.
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 d.
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 for e.
misalignment or binding of moving
parts, breakage of parts and any
Page 4SKU 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 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.
Service5.
Avoid eye and body damage. Arc 3.
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 lter plate.
Move ammable and explosive 4.
material at least 35 feet from the
welding arc to prevent welding sparks
or molten metal from starting a re.
Keep a type ABC re extinguisher
within easy reach. Thoroughly clean
the object being welded of any paint,
grease, or other foreign material.
Have your power tool serviced by a.
a qualied repair person using only
identical replacement parts. This will
ensure that the safety of the power
tool is maintained.
Specic Safety Rules
Maintain labels and nameplates on 1.
the tool. These carry important safety
information. If unreadable or missing,
contact Harbor Freight Tools for a
replacement.
Avoid electrical shock. Do not permit 2.
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.
Avoid unintentional starting. Prepare 5.
to begin work before turning on the
tool.
Do not leave the tool unattended 6.
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 7.
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 8.
of reach of children.
Industrial applications must follow 9.
OSHA guidelines.
People with pacemakers should 10.
consult their physician(s) before
use. Electromagnetic elds in close
proximity to heart pacemaker could
cause pacemaker interference or
pacemaker failure. In addition,
people with pacemakers should:
Page 5SKU 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
electrical shock.
WARNING: This product, when used 11.
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 & Safety Code §
25249.5, et seq.)
Always use proper procedures to •
move cylinders.
13. Prevent eye injury and
burns. Wearing and using
ANSI-approved personal
safety clothing and safety
devices reduce the risk for
injury.
Wear ANSI-approved safety eye •
goggles underneath welding eye
protection featuring at least a
Number 10 shade lens rating.
Leather leggings, re 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.
12. Cylinders can explode
when damaged:
Never weld on 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.
Use only correct gas shielding •
equipment designed specically
for the type of welding you will do.
Maintain this equipment properly.
Protect gas cylinders from heat, •
being struck, physical damage,
slag, ames, sparks, and arcs.
Keep clothing free of grease, •
oil, solvents, or any ammable
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 cut ting
procedures.
When welding/cutting overhead •
or in conned spaces, wear ame
resistant ear plugs or ear muffs to
keep sparks out of ears.
14. Prevent accidental res.
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 6SKU 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 area with portable •
re resistant screens. Protect
combustible walls, ceilings, oors,
etc., from sparks and heat with re
resistant covers.
If working on a metal wall, •
ceiling, etc., prevent ignition of
combustibles on the other side
by moving the combustibles to
a safe location. If relocation of
combustibles is not possible,
designate someone to serve as
a re watch, equipped with a re
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 re extinguisher
nearby and know how to use it.
After spot welding, make a •
thorough examination for evidence
of re. Be aware that easilyvisible smoke or ame may not
be present for some time after
the re has started. Do not weld
or cut in atmospheres containing
dangerously reactive or ammable
gases, vapors, liquids, and dust.
Provide adequate ventilation in
work areas to prevent accumulation
of ammable 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 ammable 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. 15.
Wear dry, insulating gloves. Do not
touch electrode or conductor tong
with bare hand. Do not wear wet or
damaged gloves.
Protect yourself from electric shock. 16.
Do not use outdoors. Insulate
yourself from the work piece and
ground. Use nonammable, 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 17.
stable location before use. If this unit
falls while plugged in, severe injury,
electric shock, or re may result.
Ground this product. This Welder 18.
requires the attachment and use of a
UL-listed, 240 volt grounded, 3-prong,
electrical Power Cord Plug (not
included). Only a quali ed electrician
should install the Power Cord Plug.
Never remove the grounding prong
or modify the Power Cord Plug in any
Page 7SKU 97503 For technical questions, please call 1-800-444-3353.
Loading...