Chicago Electric 97503 Installation 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.

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.

Page 2SKU 97503 For technical questions, please call 1-800-444-3353.

CONTENTS

IMPORTANT SAFETY

INFORMATION ............................ 3

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

SPECIFIC SAFETY RULES ...............5

SPECIFICATIONS.......................... 9

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

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

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

PLEASE READ THE FOLLOWING

CAREFULLY .................................. 19

PARTS LIST AND ASSEMBLY

DIAGRAM .................................. 20

LIMITED 1 YEAR / 90 DAY

WARRANTY .............................. 21

Page 3SKU 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.

DANGER indicates

a hazardous

situation which, if not

avoided, will result in death or

serious injury.

WARNING

indicates a

hazardous situation which, if

not avoided, could result in

death or serious injury.

CAUTION, used

with the safety

alert symbol, indicates a

hazardous situation which, if

not avoided, could result in

minor or moderate injury.

NOTICE is used to

address practices

not related to personal injury.

CAUTION, without

the safety alert

symbol, is used to address

practices not related to

personal injury.

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

Work area safety1.

Keep work area clean and wella.

lit. Cluttered or dark areas invite

accidents.

Do not operate power tools inb.

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 bystandersc.

away while operating a power

tool. Distractions can cause you

to lose control.

DANGER

WARNING

CAUTION

NOTICE

CAUTION

Page 4SKU 97503 For technical questions, please call 1-800-444-3353.

Electrical safety2.

Avoid body contact with groundeda.

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 rainb.

or wet conditions. Water entering a

power tool will increase the risk of

electric shock.

Do not abuse the cord. Never usec.

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 toold.

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 area.

doing and use common sense

when operating a power tool. Do

not use a power tool while you are

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.

Use safety equipment. Alwaysb.

wear eye protection. Safety

equipment such as arc shaded,

impact safety full face shield,

dust mask or respirator, heavy-

duty work gloves, non-skid safety

shoes, or hearing protection used

for appropriate conditions will

reduce personal injuries.

Avoid accidental starting. Ensurec.

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 wrenchd.

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 propere.

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. Usea.

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 theb.

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 thec.

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 ofd.

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 fore.

misalignment or binding of moving

parts, breakage of parts and any

Page 5SKU 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 andf.

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.

Have your power tool serviced bya.

a qualied repair person using only

identical replacement parts. This will

ensure that the safety of the power

tool is maintained.

Specic Safety Rules

Maintain labels and nameplates on1.

the tool. These carry important safety

information. If unreadable or missing,

contact Harbor Freight Tools for a

replacement.

Avoid electrical shock. Do not permit2.

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 eye and body damage. Arc3.

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.

Avoid unintentional starting. Prepare5.

to begin work before turning on the

tool.

Do not leave the tool unattended6.

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 other7.

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 out8.

of reach of children.

Industrial applications must follow9.

OSHA guidelines.

People with pacemakers should10.

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 6SKU 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 used11.

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.)

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 specically

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.

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.

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.

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 7SKU 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 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.

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 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 a17.

stable location before use. If this unit

falls while plugged in, severe injury,

electric shock, or re may result.

Ground this product. This Welder18.

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 8SKU 97503 For technical questions, please call 1-800-444-3353.

way. Do not use adapter plugs with

this product.

Avoid overexposure to fumes and19.

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.

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.

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.

The warnings, precautions,20.

and instructions discussed in

this instruction 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.

SAVE THESE

INSTRUCTIONS.

Page 9SKU 97503 For technical questions, please call 1-800-444-3353.

SPECIFICATIONS

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 VAC, 21 amps

(Peak) at 60 Hz

Open Circuit Voltage

(max) 36 VDC

Thermal Overload

Protection with Light

Automatic shutdown

and restart after cool

down

Wire Size

0.023 to 0.030 inch

steel and stainless

steel; 0.030 to 0.035

inch ux core and

aluminum

Welding Capacity 22 gauge to 3/16”

Steel

Wire Spool Size 2 lb. Spool

Weight 62.2 lbs.

UNPACKING

When unpacking, check to make sure

that the item is intact and undamaged. If

any parts are missing or broken, please

call Harbor Freight Tools at the number

shown on the cover of this manual as soon

as possible.

List of contents

Description Qty

Dual MIG Welder 1

Wheel 2

Axle 1

0.030” (0.8mm) Welding Tip 1

0.040 (1.0mm) Welding Tip 1

2 Pounds (0.030”) Flux Core Wire 1

Hand Held Shaded Face Shield 1

Brush Hammer 1

Welder Tip Close End Wrench 1

24” Strap For Gas Bottle 2

INITIAL SET UP

INSTRUCTIONS

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.

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

assembling or making any

adjustments to the tool.

Note: For additional information regarding

the parts listed in the following pages,

refer to the Assembly Diagram near

the end of this manual.

Assembly

Slide the Axle (29) through the holes1.

at the rear of the unit.

Secure both Wheels (28) to the Axle2.

with the Locking Rings (42).

Lift up the Side Panel B (1) to3.

expose the wire spool and Wire

Feed Mechanism (10). Pull back on

the Feed Tensioner (CC) to free the

Feed Tension Arm (DD) and lift it up.

Remove Wire Feed Wheel Cover

(AA) screws, pull out the cover, and

pull out the Wire Feed Wheel (BB).

See photo page 10.

Note the two parallel grooves (one4.

is wider) on the circumference of the

Wire Feed Wheel (BB). On the sides

WARNING

Page 10SKU 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 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.

Lay the Welding Torch Cable (16) in5.

a straight line, perpendicular to the

welder unit, as much as possible.

This will prevent the wire from

puncturing the Welding Torch Cable

(16) when exiting the Wire Feed

Housing Throat (FF). See photo on

this page.

Remove the wing nut and the spool6.

axle nut from the Wire Spool Axle

(10). Make sure that the coil spring

is inserted onto the Spool Axle, and

place a spool with wire over the axle,

noting that the wire winding must

be in a counterclockwise direction.

Replace the Spool Axle Nut (10),

the wing nut, and tighten. Verify free

rotation of the spool over the axle.

Loading and adjusting the wire tension.

CAUTION:7. 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 and tangle. The end of the

wire should be straight and have no

burrs.

Twist off and pull to remove the8.

Nozzle and unscrew the Contact tip

of the Welder.

Guide the tip through the feed tube

until it protrudes the Wire Feed

Wheel opening. Direct and feed at

least an inch of wire into the Wire

Feed Housing Throat (FF).

Close Wire Feed Mechanism (10)10.

over the wire, and adjust Feed

Tension Knob (D) until there is a

slight resistance on the wire.

Remove the nozzle and contact tip of11.

the Welder.

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 powered.

Plug the Power Cord into a grounded12.

230 volt electrical outlet and turn the

Welder ON.

Point the Torch Handle away from all13.

objects. Squeeze the Trigger Switch

DANGER

(EE)

(FF)

(AA) (BB)

(CC)

(DD)

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