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.
Contents Important SAFETY Information ���������������������������� 3 General Safety Rules �������������� 3 Specific Safety Rules ��������������� 5 Specifications �������������������������� 9 Unpacking ���������������������������������� 9 List of contents �������������������������� 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 ���������
Save This Manual CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. Caution 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).
2. Electrical safety before plugging in. Carrying power tools with your finger on the switch or plugging in power tools that have the switch on invites accidents. a. 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. d. 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. b.
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. f. 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.
• 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. • Always use proper procedures to move cylinders. 13. • Wear ANSI-approved safety eye goggles underneath welding eye protection featuring at least a Number 10 shade lens rating. 11.
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 on a metal wall, ceiling, etc.
way. Do not use adapter plugs with this product. 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 gases from your breathing zone and general area. • Where ventilation is questionable, have a qualified technician take an air sampling to determine the need for corrective measures. Use mechanical ventilation to improve air quality.
Specifications Welding Current 30 ~ 120 amps Read the entire Important Safety Information section at the beginning of this manual including all text under subheadings therein before set up or use of this product.
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. 5. 6.
on the Torch Handle until the Welding Wire feeds into the Torch Handle 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. 20. Close the Side Panel B (1). Connections 14. 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. 15.
Inlet located on the Back Panel of the Welder. 27. 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. the power cord to possible damage. The power cord must reach the work area with enough extra length to allow free movement while working. 3. Secure loose work pieces using a vise or clamps (not included) to prevent movement while working.
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. Always read and follow wire manufacturer’s recommended polarity. If using non-flux core wire, secure the Argon/CO2 gas hose to the rear of the MIG Welder.
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 into 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.
Top figures are Voltage Settings. Bottom number is Wire Speed Setting. .030” .023” .030” .030” NOTE: The numbers within the spaces are the approximate wire feed/voltage settings recommended* for this wire size and material thickness. Wire Size (Flux Core, Mild Steel) Do Not Use Protective Gas Wire Size (Solid Core, Mild Steel) (Use with Protective Gas) .035” Material Thickness (Steel) .035”-.047” .047”-.075” .075”-.125” .125”-.157” .157”-.
Maintenance And Servicing Procedures not specifically explained in this manual must be performed only by a qualified technician. To prevent 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. WARNING To prevent serious injury from tool failure: Do not use damaged equipment.
enlarges. A Contact Tip that measures 150% or more the original size* should be replaced. (*.045” or more for .030” Tips; .035” or more for .023 Tips.) 5. If any problems are noted with a Contact Tip, have it replaced. 6. When inspection and maintenance is completed, reinstall the Contact Tip and Nozzle. Replacing the Welding Torch Liner 1. Switch welder off, disconnect power, and discharge electrode to ground before proceeding. 2.
Troubleshooting Danger 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: • Insufficient wire feed pressure: Increase wire feed pressure. • Incorrect wire feed roll size: Replace with the proper size. • Damaged torch, cable, or liner assembly: Have a qualified technician inspect these parts and replace as necessary.
• 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.
Parts list and assembly diagram PARTS LIST Description Part Part Description 1 Side Panel B 22 Filter Reactor 2 Hinge 23 Main Transformer 3 Handle Socket 24 Transformer Carriage 4 Straight Handle 25 Bottom Plate 5 Fan 26 Plastic Foot 6 Back Panel 27 Axle Bracket 7 28 Wheel, Plastic 8 Rectifier Rack Clap Panel 29 Axle 9 Wire Spool Axle 30 Temperature Controller 10 Wire Feed Mechanism 31 Control Circuit Board Bracket 11 Wire Feed Wheel 32 Control Circuit Board 12
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.
