Chicago Electric 93793 Installation manual

DUAL MIG WELDER

Model

93793

SET UP AND OPERATING INSTRUCTIONS

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.

contained herein may be reproduced in any shape or form without the express written consent of

Harbor Freight Tools. Diagrams within this manual may not be drawn proportionally. Due to continuing

improvements, actual product may differ slightly from the product described herein. Tools required for

assembly and service may not be included.

For technical questions or replacement parts, please call 1-800-444-3353.

Cover Revised 09l

Page 2For technical questions, please call 1-800-444-3353.SKU 93793

Contents

PRODUCT SPECIFICATIONS..............................................................3

GENERAL SAFETY RULES.................................................................3

Specic Safety Rules ....................................................................................... 6

Grounding ......................................................................................................... 9

Extension Cords .............................................................................................. 10

Symbology ....................................................................................................... 10

UNPACKING ........................................................................................10

ASSEMBLY INSTRUCTIONS..............................................................11

To Attach The Handle ...................................................................................... 11

To Install The Rear Wheels And Casters ....................................................... 11

To Install a 2 lb. Wire Spool ............................................................................ 12

To Install a 10 lb. Wire Spool .......................................................................... 12

To Route The Wire ........................................................................................... 13

To Change Wire Settings ................................................................................ 15

Setting The Gun Polarity For Wire Type........................................................ 16

To Attach The Ground Cable With Clamp ..................................................... 16

To Install A Gas Cylinder ................................................................................ 17

OPERATING INSTRUCTIONS ............................................................18

Before You Begin Welding.............................................................................. 18

Duty Cycle (Duration of Use).......................................................................... 18

Setting Up The Weld........................................................................................ 19

Holding The Welding Torch ............................................................................ 20

Weld Settings Chart ........................................................................................ 21

Weld Diagnosis................................................................................................ 23

When the Weld is Completed ......................................................................... 25

INSPECTION, MAINTENANCE, AND CLEANING .............................26

Nozzle Inspection, Cleaning, and Replacement ........................................... 26

Contact Tip Inspection, Cleaning, And Replacement .................................. 26

Replacing The Welding Torch Liner .............................................................. 27

Parts Lists and Diagrams ..................................................................28

Wiring Schematic ............................................................................................ 28

Parts List .......................................................................................................... 29

Assembly Diagram .......................................................................................... 30

TROUBLESHOOTING.........................................................................32

WARRANTY.........................................................................................34

Page 3For technical questions, please call 1-800-444-3353.SKU 93793

PRODUCT SPECIFICATIONS

Welding Current 35 ~ 140 A

Duty Cycle 18% @ 140 A / 100% @ 45 A

(Refer to chart and explanation on page 18)

Power Consumption 240 V~ / 60 Hz / 25 A

(Connect to a 25 A minimum dedicated circuit)

Open Voltage 15.5 - 20 V

Required Power Plug Type 3-Prong, 240 V~, polarized, twist lock (not included)

NEMA #L6-30 or equivalent

Power Cord Rating 12 AWG x 3C x 6’ Long

Gas Inlet Size 1/4”

Ground Cable 4 Gauge / 6’ Long

Torch Power Cable 8 Gauge / 6’ Long

Thermal Overload Protection (with Light) Automatic shutdown and restart after cool down

Wire Size 0.23” to 0.035”

Wire Spool Size 7-3/4” Diameter

Included Torch Tip Size 0.030”

Accessories Wheel Kit / Wire Spool / Torch Assy. / Grounding Clamp

Wire Brush & Hammer / Spare 1.0 & 0.8 Welding Tips

Hand-Held Face Shield

Net Weight 103 lb.

SAVE THIS MANUAL

You will need this manual for the safety warnings and precautions, assembly, operating,

inspection, maintenance and cleaning procedures, parts list and assembly diagram. Keep

your invoice with this manual. Write the invoice number on the inside of the front cover. Keep

this manual and invoice in a safe and dry place for future reference.

GENERAL SAFETY RULES

WARNING!

READ AND UNDERSTAND ALL INSTRUCTIONS

Failure to follow all instructions listed below may result in

electric shock, re, and/or serious injury.

SAVE THESE INSTRUCTIONS

WORK AREA

Keep your work area clean and well lit.1. Cluttered benches and dark areas invite

accidents.

Do not operate power tools in explosive atmospheres, such as in the presence of2.

ammable liquids, gases, or dust. Power tools create sparks which may ignite the dust

or fumes.

Keep bystanders, children, and visitors away while operating a power tool.3.

Distractions can cause you to lose control. Protect others in the work area from debris

such as chips and sparks. Provide barriers or shields as needed.

Page 4For technical questions, please call 1-800-444-3353.SKU 93793

ELECTRICAL SAFETY

Grounded tools must be plugged1.

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 qualied

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.

Avoid body contact with grounded2.

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 or3.

wet conditions. Water entering a power

tool will increase the risk of electric

shock.

Do not abuse the Power Cord.4. Never

use the Power Cord to carry the tools

or pull the Plug from an outlet. Keep

the Power Cord away from heat,

oil, sharp edges, or moving parts.

Replace damaged Power Cords

immediately. Damaged Power Cords

increase the risk of electric shock.

When operating a power tool5.

outside, use an outdoor extension

cord marked “W-A” or “W”. These

extension cords are rated for outdoor

use, and reduce the risk of electric

shock.

PERSONAL SAFETY

Stay alert. Watch what you are1.

doing, and use common sense when

operating a power tool. Do not use

a power tool while tired or under

the inuence of drugs, alcohol, or

medication. A moment of inattention

while operating power tools may result in

serious personal injury.

Dress properly. Do not wear loose2.

clothing or jewelry. Contain long hair.

Keep your hair, clothing, and gloves

away from moving parts. Loose

clothes, jewelry, or long hair can be

caught in moving parts.

Avoid accidental starting.3. Be sure the

Power Switch is off before plugging

in. Carrying power tools with your nger

on the Power Switch, or plugging in

power tools with the Power Switch on,

invites accidents.

Remove adjusting keys or wrenches4.

before turning the power tool on. A

wrench or a key that is left attached to a

rotating part of the power tool may result

in personal injury.

Do not overreach. Keep proper5.

footing and balance at all times.

Proper footing and balance enables

better control of the power tool in

unexpected situations.

Always wear eye, hearing, and6.

breathing protection. For welding

safety equipment, refer to number 9on

page 6.

TOOL USE AND CARE

Use clamps (not included) or other1.

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.

Do not force the tool. Use the correct2.

tool for your application. The correct

Page 5For technical questions, please call 1-800-444-3353.SKU 93793

tool will do the job better and safer at the

rate for which it is designed.

Do not use the power tool if the Power3.

Switch does not turn it on or off. Any

tool that cannot be controlled with the

Power Switch is dangerous and must be

replaced.

Disconnect the Power Cord Plug from4.

the power source before making any

adjustments, changing accessories,

or storing the tool. Such preventive

safety measures reduce the risk of

starting the tool accidentally.

Store idle tools out of reach of5.

children and other untrained persons.

Tools are dangerous in the hands of

untrained users.

Maintain tools with care. Keep cutting6.

tools sharp and clean. Properly

maintained tools with a sharp cutting

edge are less likely to bind and are

easier to control. Do not use a damaged

tool. Tag damaged tools “Do not use”

until repaired.

Check for misalignment or binding of7.

moving parts, breakage of parts, and

any other condition that may affect

the tool’s operation. If damaged,

have the tool serviced before using.

Many accidents are caused by poorly

maintained tools.

Use only accessories that are8.

recommended by the manufacturer

for your model. Accessories that may

be suitable for one tool may become

hazardous when used on another tool.

SERVICE

Tool service must be performed only1.

by qualied repair personnel. Service

or maintenance performed by unqualied

personnel could result in a risk of injury.

When servicing a tool, use only2.

identical replacement parts. Follow

instructions in the “Inspection,

Maintenance, And Cleaning” section

of this manual. Use of unauthorized

parts or failure to follow maintenance

instructions may create a risk of electric

shock or injury.

Page 6For technical questions, please call 1-800-444-3353.SKU 93793

Specic Safety Rules

Ground this product.1. This Welder

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

way. Do not use adapter plugs with this

product. To comply with the National

Electric Code, and to provide additional

protection from the risk of electrical

shock, this product should only be

connected to a 240 volt, 3-hole outlet

that is properly grounded.

Maintain labels and nameplates on2.

the Welder. These carry important

information. If unreadable or missing,

contact Harbor Freight Tools for a

replacement.

Avoid unintentional starting.3. Make

sure you are prepared to begin work

before turning on the Welder.

Do not force the Welder.4. This tool will

do the work better and safer at the speed

and capacity for which it was designed.

Never leave the Welder unattended5.

when it is plugged into an electrical

outlet. Turn off the tool, and unplug it

from its electrical outlet before leaving.

Industrial applications must follow6.

OSHA guidelines.

Never stand on the Welder.7. Serious

injury could result if the Welder is

tipped or if hot surfaces are accidently

contacted.

Maintain a safe working environment.8.

Keep the work area well lit. Make

sure there is adequate surrounding

workspace. Always keep the work area

free of obstructions, grease, oil, trash,

and other debris. Do not use a power

tool in areas near ammable chemicals,

dusts, and vapors. Do not use this

product in a damp or wet location.

9. 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 impact•

eye goggles with a welding helmet with

protective lens.

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.

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 cutting procedures.

When welding/cutting overhead or in•

conned spaces, wear ame resistant

ear plugs or ear muffs to keep sparks

out of ears.

10. 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 with a cover

made of re resistant material.

Remove or make safe all combustible•

materials for a radius of 35 feet (10

Page 7For technical questions, please call 1-800-444-3353.SKU 93793

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 on 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 easily-visible 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.

WARNING

INHALATION HAZARD:

Welding and Plasma Cutting Produce

TOXIC FUMES.

Exposure to welding or cutting exhaust

fumes can increase the risk of developing

certain cancers, such as cancer of the

larynx and lung cancer. Also, some

diseases that may be linked to exposure to

welding or plasma cutting exhaust fumes

are:

• Early onset of Parkinson’s Disease

• Heart disease • Ulcers

• Damage to the reproductive organs

• Inammation of the small intestine or

stomach • Kidney damage

• Respiratory diseases such as

emphysema, bronchitis, or pneumonia

Use natural or forced air ventilation and

wear a respirator approved by NIOSH to

protect against the fumes produced to

reduce the risk of developing the above

illnesses.

Avoid overexposure to fumes and12.

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 qualied technician take an air

sampling to determine the need for

corrective measures. Use mechanical

ventilation to improve air quality. If

engineering controls are not feasible,

use an approved respirator.

Page 8For technical questions, please call 1-800-444-3353.SKU 93793

Work in a conned area only if it is well •

ventilated, or while wearing an air-

supplied respirator.

Follow OSHA guidelines for Permissible•

Exposure Limits (PEL’s) for various

fumes and gases.

Follow the American Conference of•

Governmental Industrial Hygienists

recommendations for Threshold Limit

Values (TLV’s) for fumes and gases.

Have a recognized specialist in•

Industrial Hygiene or Environmental

Services check the operation and air

quality and make recommendations for

the specic welding or cutting situation.

Read and understand all instructions13.

and safety precautions as outlined

in the manufacturer’s manual for the

material you will weld or cut.

Do not touch live electrical parts14. .

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.15.

Do not use outdoors. Insulate yourself

from the workpiece and ground. Use

nonammable, 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 a16.

stable location before use. If this unit

falls while plugged in, severe injury,

electric shock, or re may result.

17. 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 specically for the

type of welding you will do. Maintain

this equipment properly.

Always protect gas cylinders from heat,•

being struck, physical damage, slag,

ames, sparks, and arcs.

Always use proper procedures to move•

cylinders.

Use the right tool for the job.18. 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.

People with pacemakers should consult19.

their physician(s) before using this

product. Electromagnetic elds in close

proximity to a heart pacemaker could

cause interference to or failure of the

pacemaker.

The warnings and cautions discussed20.

in this 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.

WARNING!21. This product, when used

for welding and similar applications,

Page 9For technical questions, please call 1-800-444-3353.SKU 93793

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.)

SAVE THESE INSTRUCTIONS

Grounding

NOTE:

This Welder requires the installation of a

3-Prong, 240 V~, polarized,

twistlock Power Cord Plug (not included).

NEMA conguration # L6-30 or equivalent

The Plug must be installed by a certied

electrician.

WARNING!

Improperly connecting the grounding

wire can result in the risk of electric shock.

Check with a qualied electrician if you are

in doubt as to whether the outlet is properly

grounded. Do not modify the power cord

plug used with the tool. Never remove the

grounding prong from the plug. Do not use

the tool if the power cord or plug is damaged.

If damaged, have it repaired by a service

facility before use. If the plug will not t the

outlet, have a proper outlet installed by a

qualied electrician.

GROUNDED TOOLS: TOOLS WITH

THREE PRONG PLUGS

Tools marked with “Grounding Required”1.

have a three wire cord and three prong

grounding plug. The plug must be

connected to a properly grounded outlet.

If the tool should electrically malfunction

or break down, grounding provides a

low resistance path to carry electricity

away from the user, reducing the risk of

electric shock.

The grounding prong in the plug is2.

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.

Your tool must be plugged into an3.

appropriate outlet, properly installed by

a certied electrician and grounded

in accordance with all codes and

ordinances.

Extension Cords

AN EXTENSION CORD MUST NEVER

BE USED WITH THIS ITEM. Use of

an extension cord could result in

damage to the item or re.

Symbology

Double Insulated

Canadian Standards Association

Underwriters Laboratories, Inc.

V~ Volts Alternating Current

AAmperes

n0xxxx/min. No Load Revolutions per Minute

(RPM)

UNPACKING

When unpacking both boxes, make

sure all the parts shown on the Parts Lists

on pages 29 through 31 are included. If

any parts are missing or broken, please call

Harbor Freight Tools at 1-800-444-3353 as

soon as possible.

Page 10For technical questions, please call 1-800-444-3353.SKU 93793

AXLE BRACKET (40)

AXLE (44)

WASHER (42)

COTTER PIN

(41)

AXLE BRACKET (40)

COTTER PIN

(41)

WASHER (42)

WHEEL (43)

CASTER (37)

BOTTOM PANEL (36)

BOLT

BOTTOM

VIEW

FIGURE B

ASSEMBLY INSTRUCTIONS

WARNING! Always turn off the Welder and unplug the unit from its electri-

cal outlet prior to performing any assembly, maintenance, or service.

To Attach The Handle

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.)

BOLT

HANDLE (45)

RIGHT HAN-

DLE SOCKET

(46)

LEFT HAN-

DLE SOCKET

(46)

FIGURE A

To Install The Rear Wheels And Casters

Insert the two Axle Brackets (40) into the slots located at the rear of the Bottom Panel1.

(36). Secure the Axle Brackets to the Bottom Panel, using the two Screws provided.

Insert the Axle (44) through the openings (located on the underside of the Bottom Panel)

in the Axle Brackets. Insert one Wheel (43) on each end of the Axle. Insert one Washer

(42) on each end of the Axle. Then secure the two Wheels to the Axle, using one Cotter

Pin (41) on each end of the Axle. (See Figure B.)

Align the four mounting holes in each of the two Casters (37) with the threaded mounting2.

holes located at the front of the Bottom Panel (36). Then secure the two Casters to the

Bottom Panel, using the eight Bolts provided. (See Figure B.)

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