DUAL MIG WELDER Model 93793 ASSEMBLY AND OPERATING INSTRUCTIONS 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 Web site at: http://www.harborfreight.com TO PREVENT SERIOUS INJURY, READ AND UNDERSTAND ALL WARNINGS AND INSTRUCTIONS BEFORE USE. Copyright© 2006 by Harbor Freight Tools®. All rights reserved.
Contents PRODUCT SPECIFICATIONS .......................................................... 3 GENERAL SAFETY RULES ............................................................. 3 Specific Safety Rules ................................................................................... 6 Grounding..................................................................................................... 9 Extension Cords ..........................................................................................
PRODUCT SPECIFICATIONS Item Welding Current Duty Cycle Power Consumption Open Voltage Required Power Plug Type Power Cord Rating Gas Inlet Size Ground Cable Torch Power Cable Thermal Overload Protection (with Light) Wire Size Wire Spool Size Included Torch Tip Size Accessories Net Weight Description 35 ~ 140 Amps 18% @ 140 Amps / 100% @ 45 Amps (Refer to chart and explanation on page 18) 230 Volt / 60 Hz / Single Phase / 25 Amps (Should be connected to a 25 Amp minimum dedicated circuit) 15.
ELECTRICAL SAFETY 4. Grounded tools must be plugged into an outlet properly installed and grounded in accordance with all codes and ordinances. Never remove the grounding prong or modify the plug in any way. Do not use any adapter plugs. Check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded. If the tools should electrically malfunction or break down, grounding provides a low resistance path to carry electricity away from the user. 5.
TOOL USE AND CARE 15. Use clamps (not included) or other practical ways to secure and support the workpiece to a stable platform. Holding the work by hand or against your body is unstable and may lead to loss of control. 16. Do not force the tool. Use the correct tool for your application. The correct tool will do the job better and safer at the rate for which it is designed. 17. Do not use the power tool if the Power Switch does not turn it on or off.
SPECIFIC SAFETY RULES 1. Ground this product. This Welder requires the attachment and use of a UL®listed, 220 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 way. Do not use adapter plugs with this product.
10. 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 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.
• Have a recognized specialist in Industrial Hygiene or Environmental Services check the operation and air quality and make recommendations for the specific welding or cutting situation. Inhalation Hazard Welding Produces TOXIC FUMES and GASSES. Exposure to welding gasses can increase the risk of developing certain cancers, such as cancer of the larynx and lung cancer.
17. Use the right tool for the job. Do not attempt to force small equipment to do the work of larger industrial equipment. There are certain applications for which this Welder was designed. It will do the job better and more safely at the rate for which it was intended. Do not modify this Welder, and do not use this Welder for a purpose for which it was not intended. 18. WARNING! People with pacemakers should consult their physician(s) before using this product.
2. The grounding prong in the plug is connected through the green wire inside the cord to the grounding system in the tool. The green wire in the cord must be the only wire connected to the tool’s grounding system and must never be attached to an electrically “live” terminal. 3. Your tool must be plugged into an appropriate outlet, properly installed by a certified electrician and grounded in accordance with all codes and ordinances. EXTENSION CORDS AN EXTENSION CORD MUST NEVER BE USED WITH THIS ITEM.
ASSEMBLY INSTRUCTIONS WARNING! Always turn off the Welder and unplug the unit from its electrical outlet prior to performing any assembly, maintenance, or service. TO ATTACH THE HANDLE HANDLE (45) Insert the Handle (45) into the Right Handle Socket (46) and Left Handle Socket (58). Then attach the Right and Left Handle Sockets to the Front Panel (57), using the four Bolts provided. (See Figure A.
TO INSTALL A 10 LB. WIRE SPOOL 1. Lift the Access Panel (31) of the Welder to expose the Wire Feed Assembly. 2. If the 10 lb. Spool Axle is not already installed: Unscrew and remove the Nut and Washer. Install the 10 lb. Spool Axle (13) onto the Shaft, using the spring underneath and the washer and nut above. (See Figure C.) 3. Remove the Spool Clip (14), if installed. Install a 10 lb.
TO ROUTE THE WIRE NOTE: When installing wire of a different size or composition, you will also need to change wire settings, set the gun polarity, and, possibly, install a gas cylinder. See pages 15-17. 1. IMPORTANT: Securely 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, creating a tangled “bird’s nest” and resulting in wasted wire. (See Figure D.) SPOOL WELDING WIRE 2.
WARNING! EXERCISE EXTREME CAUTION - RISK OF FIRE AND/OR ELECTRIC SHOCK! 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 plugged in. 8. Plug the Power Cord (54) into its 220 volt, grounded, electrical outlet. Then, turn the Welder ON. 9. Point the Torch Handle away from all objects.
TO CHANGE WIRE SETTINGS 1. WARNING! Make sure to turn off the Welder and unplug it from its electrical outlet prior to changing wire settings. 2. Open the Access Panel (31) of the Welder to expose the Wire Feed Assembly. 3. Loosen, and lower the Tension Adjusting Knob (15b) on the Wire Feed Assembly. Then, raise the Swing Arm (15a). (See Figure G.) 4. Remove the two Screws (15j) that secures the Feed Roller Bracket (15i) in place. Then, remove the Feed Roller Bracket. (See Figure G.) 5.
SETTING THE GUN POLARITY FOR WIRE TYPE 1. Set for Electrode Positive (DCEP) for gas welding with solid-core wire. Positive electrode (C), negative ground (D). SHOWN IN ILLUSTRATION, INITIAL SETUP. (See Figure H.) 2. Set for Electrode Negative (DCEN) for gasless flux core wire. Negative electrode (C), positive ground (D). (See Figure H.) C E B 3. When connecting to the weld output terminals, do not place anything between the welding Cable Terminals (A and C) and their copper connections. (See Figure H.
TO INSTALL A GAS CYLINDER WARNING: Maximum cylinder height is 3 feet 3 inches (1m). Maximum cylinder weight is 88 lb., including gas. NEVER exceed either of these maximums. 1. CAUTION! Do not use an Argon/Mixed pressure regulator/flow meter with CO2 shielding gas. To use CO2 shielding gas, you must install a CO2 gas pressure regulator/flow meter (neither one included). 2. Thread the provided straps through the slots on the back of the welder.
OPERATING INSTRUCTIONS BEFORE YOU BEGIN WELDING Good welding requires a high degree of skill and experience. You should practice a few sample welds on scrap metal before you begin welding your first project. Additional practice periods are recommended whenever you weld a different thickness of material, wire, or weld a different type of connection. DUTY CYCLE (DURATION OF USE) 1. CAUTION! Avoid damage to the Welder by not leaving the unit on for more than the prescribed duty cycle time. 2.
SETTING UP THE WELD WARNING! Before welding, make sure to read and understand all safety precautions and warnings discussed on pages 3 through 10. 1. Overload Indicator Light (50): If too much current is drawn from the Welder, the Overload Protector will activate. The RED Overload Indicator Light will illuminate and the Welder will automatically turn off until it cools down. If this happens, turn the Power Switch to its “OFF” position and wait approximately 20 minutes. (See Figure L.) 2.
7. NOTE: The workpieces should be firmly held together and in position while welding. Use clamps (not included) to hold the workpieces so you can concentrate on the job at hand. 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. 8.
First number is Voltage Setting. Second number is Wire Speed Setting. WELD SETTINGS CHART FIGURE N Material Thickness (Steel) .030" .023" .035" .030" 2, 2 2, 3 1, 1 1, 1 3, 2 3, 3 3, 4 3, 2 2, 2 4, 3 4, 4 4, 6 4, 4 4, 5 5, 4 5, 5 5, 7 5, 5 5, 6 6, 5 6, 6 6, 6 6, 7 NOTE: The numbers within the spaces are the approximate wire feed/voltag e settings recom- .035"-.047" .047"-.075" .075"-.125" .125"-.157" .157"-.250" mended* for this wire size and material thickness.
18. Squeeze (and hold) the Trigger Switch (51e) of the Welding Torch (51) and stroke the area to be welded with the Welding Wire to ignite the arc. A. Never tap the Welding Wire into the welding surface to ignite the arc. This will cause the Welding Wire to stick to the workpiece. B. For a narrow weld, you can usually draw the Welding Wire in a steady straight line. This is called a “stringer bead”. C. For a wider weld, draw the Welding Wire back and forth across the joint in a curve.
WELD DIAGNOSIS WELD PENETRATION EXCESS OR BURN-THROUGH Weld droops on top and underneath, or falls through entirely, making a hole. PROPER Weld is visible underneath and bulges slightly on top. INADEQUATE Weld does not contact the joint fully, just on the surface. CROSS SECTIONS POSSIBLE CAUSES AND SOLUTIONS 1. Excessive material at weld: Reduce wire feed speed. 2. Overheating: Increase welding speed and ensure that welding speed is kept steady. POSSIBLE CAUSES AND SOLUTIONS 1.
POROSITY CROOKED/WAVY BEAD Small cavities or holes in the bead. TOP VIEW TOP VIEW POSSIBLE CAUSES AND SOLUTIONS POSSIBLE CAUSES AND SOLUTIONS 1. Stickout too long: 1. Stickout too long: Reduce stickout. Reduce stickout. 2. Inaccurate welding: 2. Dirty workpiece or welding wire: Use two hands or rest hand on steady surMake certain that workpiece and wire are face. both clean and free from oil, coatings, and other residues. 3. Insufficient gas flow at weld: Increase flow of shielding gas. 4.
WHEN THE WELD IS COMPLETED 21. Lift the Welding Wire completely away from any grounded object. Set the face shield down. Then, turn the Power Switch to its “OFF” position. 22. Unplug the Power Cord (54) from the electrical outlet. Then, make sure to set the Welding Torch (51) on a nonflammable, nonconductive surface. 23. NOTE: A wire brush/hammer (not included) can now be used to clean up the weld. CAUTION! The weld may still be quite hot, and sparks/chips may fly when cleaning.
INSPECTION, MAINTENANCE, AND CLEANING WARNING! Before performing any maintenance on the Welder, unplug the Power Cord (54) from its electrical outlet and allow all components of the Welder to completely cool. 1. Periodically open the Access Panel (31) from the unit and, using compressed air, blow out all dust and debris from the interior. 2. Always store the Welder in a clean, dry, safe location out of reach of children and other unauthorized people. 3.
REPLACING THE WELDING TORCH LINER 1. Switch welder off, disconnect power, and discharge electrode to ground before proceeding. 2. Secure welding wire to the spool, cut it near the spool, and remove it from the torch and cable. 3. Remove the four Screws (51l) holding the Torch Housings (51j & 51k) together. Set Housings and Screws aside. 4. Remove the four Screws (15g) that hold the Cable Clamp (15h) in place.
PARTS LISTS AND DIAGRAMS WIRING SCHEMATIC SKU 93793 For technical questions, please call 1-800-444-3353; Troubleshooting section at end of manual.
PARTS LIST Part Description Part Description 1 Side Panel 32 Latch 2 Gas Line 33 Filter Reactor 3 Chain 34 Main Transformer 35 Transformer Carriage 4 Gas Bottle Suppor t 36 Bottom Panel 5 Back Panel 37 Caster 6 Rubber Suppor t 38 Thermal Switch Bracket 7 Top Panel 39 Thermal Switch 8 Hinge 40 Axle Bracket 9 Rubber Washer 41 Cotter Pin 10 Nut, M8 42 Washer 11 Inner Panel 43 Wheel 12 Fan 44 Axle 13 10 lb. Spool Axle 45 Handle 14 10 lb.
ASSEMBLY DIAGRAM NOTE: Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts. SKU 93793 For technical questions, please call 1-800-444-3353; Troubleshooting section at end of manual.
ASSEMBLY DIAGRAM (CONTINUED) Wire Feed Mechanism (15) 15c 15d 15b 15a 15e 15g 15f 16 15h 15j 15i SKU 93793 For technical questions, please call 1-800-444-3353; Troubleshooting section at end of manual.
TROUBLESHOOTING 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 1. Insufficient wire feed pressure: Increase wire feed pressure properly - follow instructions on page 13-14. 2. Incorrect wire feed roll size: Replace with the proper one - follow the Wire Spool instructions on page 12. 3.
TROUBLESHOOTING (continued) 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. WELDER DOES NOT FUNCTION WHEN SWITCHED ON POSSIBLE CAUSES AND SOLUTIONS 1. 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 on page 18. 2.
TROUBLESHOOTING (continued) 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 FEEDS, BUT SHIELDING GAS DOES NOT FLOW 1. 2. 3. 4. 5. POSSIBLE CAUSES AND SOLUTIONS 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.