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.
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.

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.
9.
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)

Page 11SKU 97503 For technical questions, please call 1-800-444-3353.
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.
If the Welding Wire does not feed14.
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.
Feed the Welding Wire against scrap15.
wood that is 2 to 3 inches away. If
the Wire stops instead of bending,
turn the Welder OFF and unplug it.
Tighten the Tension Adjusting Knob
more.
Turn the Welder OFF, unplug it, and16.
discharge the electrode to ground.
Insert the contact tip onto the Welding
Wire and screw it rmly in place.
Replace the Nozzle and cut off any
excess Welding Wire over 1/2 inch.
Check that +/– cables to connection17.
Knobs (34) are correct. See photo
this page.
When using Non-ux wire and 18.
Protective gas, connect Ground cable
with clamp to the “-” terminal and the
Internal Power cable to “+” terminal.
Strap down the Argon / CO2 gas
cylinder and connect the hose to the
rear of the MIG Welder.
When using Flux-core wire (DO NOT19.
USE Protective gas), connect Ground
cable with clamp to “+” terminal,
and the internal Power cable to “-”
terminal.
Close the Side Panel B (1).20.
Installing a gas cylinder
Do not use an Argon/Mixed pressure21.
regulator/ow meter with CO2
shielding gas. To use CO2 shielding
gas, you must install a CO2 gas
pressure regulator/ow meter (neither
one included).
Thread the provided straps through22.
the slots on the back of the welder.
With assistance, set the cylinder onto
the shelf at the back of the welder.
Secure the cylinder in place with both23.
of the straps.
Remove the protective cap from the24.
cylinder. Stand to the side of the
cylinder valve, and open the valve
slightly to blow dust and dirt from the
valve. Close the valve.
Make sure the Flow Adjust on the25.
Pressure Regulator/Flow Meter
is turned off. Screw the Pressure
Regulator/Flow Meter (not included)
rmly onto the cylinder valve.
Attach the Gas Line to the Pressure26.
Regulator/Flow Meter from the Gas
Connections

Page 12SKU 97503 For technical questions, please call 1-800-444-3353.
Inlet located on the Back Panel of the
Welder.
Adjust the ow rate of the gas by 27.
turning the Flow Adjust. The typical
ow rate is 10-30 CFH (cubic feet
per hour). Check the Welding Wire
manufacturer’s recommended ow
rate.
Installation of a line-in, where28.
necessary, and connecting a
Twist-lock plug to the Power Cord
must be performed by a licensed
electrician.
OPERATING 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.
Tool Set Up
TO PREVENT
SERIOUS INJURY
FROM ACCIDENTAL
OPERATION:
Turn the switch to its off
position before performing
any inspection, maintenance,
or cleaning procedures.
Work Piece and Work Area Set Up
Designate a work area that is clean1.
and well-lit. The work area must not
allow access by children or pets to
prevent injury and distraction.
Route the power cord along a safe2.
route to reach the work area without
creating a tripping hazard or exposing
the power cord to possible damage.
The power cord must reach the work
area with enough extra length to
allow free movement while working.
Secure loose work pieces using3.
a vise or clamps (not included) to
prevent movement while working.
The work pieces should be rmly
held together and in position while
welding. The distance (if any)
between the two work pieces must
be controlled properly to allow the
weld to hold both sides securely while
allowing the weld to penetrate fully
into the joint.
There must not be hazardous4.
objects, such as utility lines or foreign
objects, nearby that will present a
hazard while working.
A barrier, such as a welding curtain5.
or welding shroud should be put up
to protect others in the work area and
limit the spray of sparks.
General Operating Instructions
Protective gear
must be worn
when using the MIG Welder;
ANSI-approved, arc shaded,
eye protection, a full face
shield, heavy-duty work
gloves, a welding apron,
respirator, and heavy-duty
work clothes without pockets
should be worn when using
this product. Do not look at
the ignited arc without eye
protection. Light from the arc
can cause permanent damage
to the eyes. Light from the
arc can burn the skin. Do not
breathe arc fumes.
WARNING
DANGER

Page 13SKU 97503 For technical questions, please call 1-800-444-3353.
The duty cycle denes 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.
Failure to carefully observe duty•
cycle limitations can stress a
Welder’s power generation system,
contributing to premature Welder
failure.
This Welder is equipped with an •
internal thermal protection system
to help prevent damage to the
unit. When the unit overheats; it
automatically shuts down, then
returns to service when it cools
down.
Once the unit returns to service,•
follow a more conservative duty
cycle routine to help prevent excess
wear to the Welder.
Always read and follow wire1.
manufacturer’s recommended
polarity. If using non-ux core wire,
secure the Argon/CO2 gas hose to
the rear of the MIG Welder. (If using
ux core wire, protective gas is not
required.)
Attach the Ground Cable with Clamp2.
(14) as close as possible to the metal
object to be welded.
Set the desired current (30~1203.
amps) for the type of metal being
welded with the Temperature
Controller. Thin metals use low
current and heavy metals use high
current.
Set Switch Amps Duty
Cycle
Volts
Min. / 1 30 100% 15.2
Min. / 2 50 90% 16.5
Max. / 1 75 40% 17.7
Max. / 2 105 20% 19.2
Make sure the power switch is off,4.
then plug the MIG Welder Power
Cord into a dedicated, 230 VAC, 20
amp line with delayed action type
circuit breaker or fuses.
While holding the Welding Torch5.
handle, with the electrode wire clear
of grounded objects, turn the Power
Switch ON.
Momentarily press the Welding Torch6.
trigger switch to test the wire feed
speed. Adjust the speed by turning
the Wire Speed Knob.
Hold the Arc Shaded Face Shield7.
over your eyes.
Press (and hold) the Torch Trigger8.
Switch and stroke the area to be

Page 14SKU 97503 For technical questions, please call 1-800-444-3353.
welded with the electrode wire
to ignite the arc. Never tap the
electrode wire into the welding
surface to ignite the arc.
The Welding Wire should extend no9.
more than 1/2” past the Nozzle of the
Welding Torch.
The Welding Wire should be directed10.
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 llet
(T-shaped) welds.
The end of the Welding Torch should11.
be tilted so that the Welding Wire is
angled anywhere in between straight
on and 15 degrees in the direction of
the weld. The amount of tilt is called
the “drag angle”.
12. The wire feeds automatically, and
can be changed using the Wire
Speed Knob.
If too much current is drawn from13.
the MIG Welder, the overload
protection will activate, the red
overload indicator will light, and the
Arc Welder will shut down. If this
happens, turn the power Switch OFF
and wait about 3 ~ 5 minutes before
restarting.
When the weld is complete, lift the14.
Welding Torch handle away from any
grounded object, remove your Face
Shield, and turn the power Switch
OFF.
Unplug the power cord from the15.
electrical outlet.
Read the included weld diagnosis16.
pamphlet for tips and suggestions
concerning welding and proper
usage.
To prevent accidents, turn off the17.
tool and disconnect its power supply
after use. Clean, then store the
tool indoors out of children’s and
unauthorized people’s reach.

Page 15SKU 97503 For technical questions, please call 1-800-444-3353.
Top gures are Voltage Settings. Bottom number is Wire Speed Setting. NOTE: The numbers within the spaces are the approximate wire feed/voltage settings recommended* for this wire size and material thickness.
Material Thickness (Steel)
.035”-.047” .047”-.075” .075”-.125” .125”-.157” .157”-.187”
Wire Size
(Flux Core, Mild Steel)
Do Not Use Protective
Gas
.030”
MIN 1
1
MIN 2
3
MAX 1
4
MAX 1
6
MAX 2
6
.030”
MIN 1
1
MIN 2
2
MAX 1
3
MAX 1
5
MAX 2
5
Wire Size
(Solid Core, Mild Steel)
(Use with Protective
Gas)
.023”
MIN 2
4
MAX 1
7
MAX 2
5
MAX 2
8
.030”
MIN 2
2
MAX 1
5
MAX 1
6
MAX 2
5
MAX 2
7
.035”
MIN 2
1
MAX 1
2
MAX 1
3
MAX 2
4
MAX 2
5

Page 16SKU 97503 For technical questions, please call 1-800-444-3353.
MAINTENANCE AND
SERVICING
Procedures not specically
explained in this manual
must be performed only by a
qualied 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.
TO PREVENT SERIOUS
INJURY FROM TOOL
FAILURE:
Do not use damaged
equipment. If abnormal noise
or vibration occurs, have the
problem corrected before
further use.
Cleaning, Maintenance, and
Lubrication
BEFORE EACH USE,1. inspect the
general condition of the tool. Check
for loose screws, misalignment or
binding of moving parts, cracked or
broken parts, damaged electrical
wiring, and any other condition that
may affect its safe operation.
AFTER USE,2. clean external surfaces
of the tool with clean cloth.
PERIODICALLY3. , open the Access
Panel (12) from the unit and, using
compressed air, blow out all dust and
debris from the interior.
4. WARNING! If the supply cord of
this power tool is damaged, it must
be replaced only by a qualied
service technician.
Nozzle Care
Turn the Nozzle counterclockwise1.
while pulling to remove.
Scrub the interior of the Nozzle clean2.
with a wire brush.
Examine the end of the Nozzle. The3.
end should be at and even. If the
end is uneven, chipped, melted,
cracked, or otherwise damaged, the
Nozzle will adversely effect the weld
and should be replaced.
Replace the Nozzle after inspecting4.
and cleaning the Contact Tip
Contact Tip Care
Make sure the entire Welding Torch is1.
completely cool before proceeding.
Remove the Nozzle, as explained2.
above, and the Contact Tip.
Scrub the exterior of the Contact Tip3.
clean with a wire brush. Check that
the Contact Tip is the proper type for
the wire size used.
Examine the hole at the end of4.
the Contact Tip for the following
problems:
Shape: The hole should be an even•
circle, and should not be oblong or
have any bulges in it.
Size: The Contact Tip will decrease•
in efciency as the center hole
WARNING

Page 17SKU 97503 For technical questions, please call 1-800-444-3353.
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.)
If any problems are noted with a5.
Contact Tip, have it replaced.
When inspection and maintenance is6.
completed, reinstall the Contact Tip
and Nozzle.
Replacing the Welding Torch
Liner
Switch welder off, disconnect power,1.
and discharge electrode to ground
before proceeding.
Secure welding wire to the spool, cut2.
it near the spool, and remove it from
the torch and cable.
Gently twist and slide the Locking3.
Collar off the torch and onto the
Protective Sleeve. Slide the Upper
Housing forward and off the Lower
Housing.
Remove the four Screws that hold the4.
Cable Clamp in place. Set aside the
Cable Clamp, Screws, and the Liner
Sleeve underneath the cable clamp.
Lay torch cable out straight to allow5.
the cable to twist within the sleeve.
Press in on the Push-lock Coupler6.
and remove the Liner from the gun
end.
Install a new Liner and Fitting from7.
the gun end with the end without a
Fitting rst.
Attach the Fitting at the end of the8.
Liner to the Push-lock Coupler on the
Switch Body.
Slide the Liner Sleeve back onto the9.
end of the liner. Reinstall the Cable
Clamp and Screws. Trim off the Liner
that extends past the Clamp.
Make sure that all torch parts lay10.
back into place properly including
the Protective Sleeve, Head Tube,
and Trigger. See Assembly Diagram.
While all parts are properly in place,
carefully put the Upper Housing back
onto the Lower Housing and slide
back to secure. Slide the Locking
Collar back onto the Housings and
twist to secure.
Check the Torch carefully for proper11.
operation.
Route the Wire as instructed in the12.
Loading and Adjusting the Wire
Tension Section.

Page 18SKU 97503 For technical questions, please call 1-800-444-3353.
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:
Insufcient 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 qualied technician
inspect these parts and replace as
necessary.
Wire creates a bird’s nest During
operation.
Possible Causes and Solutions:
Excess wire feed pressure:•
Adjust wire feed pressure.
Incorrect contact tip size:•
Replace with the proper tip for the
wire size used.
Gun end not inserted into drive•
housing properly:
Loosen gun securing bolt and push
gun end into housing just enough
so that it does not touch wire feed
mechanism.
Damaged liner:•
Have a qualied technician inspect
and repair/replace as necessary.
Welding arc not stable.
Possible Causes and Solutions:
Wire not feeding properly:•
See rst Troubleshooting section
above.
Incorrect contact tip size:•
Replace with the proper tip for the
wire size used.
Incorrect wire feed speed:•
Adjust wire feed speed to achieve a
more stable arc.
Loose torch cable or ground cable:•
Check to ensure that all
connections are tight.
Damaged torch or loose connection•
within torch:
Have a qualied technician inspect
and repair/replace as necessary.
Welder does not function when
switched on
Possible Causes and Solutions:
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.
Faulty or improperly connected•
Switch Body:
Have a technician check and
secure/replace Switch Body.
Internal fuse blown:•
Have a qualied technician check/
replace.
Weak Arc strength
Possible Cause and Solution:

Page 19SKU 97503 For technical questions, please call 1-800-444-3353.
Incorrect line voltage:•
Check the line voltage and, if
insufcient, 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.
Check that the hole in the tip is
not deformed, enlarged, or dirty. If
needed, replace Contact Tip with
proper size and type.
Wire Feeds, but Shielding gas does not
Flow
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.
Gas line blocked:•
Check external hose, and hose
within Torch cable.
Gas solenoid broken or not•
connected properly:
Have a qualied technician check/
replace.
PLEASE READ THE FOLLOWING
CAREFULLY
THE MANUFACTURER AND/OR DISTRIBUTOR
HAS PROVIDED THE PARTS LISTANDASSEMBLY
DIAGRAM IN THIS MANUAL AS A REFERENCE
TOOL ONLY. NEITHER THE MANUFACTURER OR
DISTRIBUTOR MAKES ANY REPRESENTATION
OR WARRANTY OF ANY KIND TO THE BUYER
THAT HE OR SHE IS QUALIFIED TO MAKE ANY
REPAIRS TO THE PRODUCT, OR THAT HE OR
SHE IS QUALIFIED TO REPLACE ANY PARTS OF
THE PRODUCT. IN FACT, THE MANUFACTURER
AND/OR DISTRIBUTOR EXPRESSLY STATES
THATALL REPAIRS AND PARTS REPLACEMENTS
SHOULD BE UNDERTAKEN BY CERTIFIED AND
LICENSED TECHNICIANS, AND NOT BY THE
BUYER. THE BUYER ASSUMES ALL RISK AND
LIABILITYARISING OUT OF HIS OR HER REPAIRS
TO THE ORIGINAL PRODUCT OR REPLACEMENT
PARTS THERETO, OR ARISING OUT OF HIS OR
HER INSTALLATION OF REPLACEMENT PARTS
THERETO.

Page 20SKU 97503 For technical questions, please call 1-800-444-3353.
PARTS LIST AND ASSEMBLY DIAGRAM
PARTS LIST
Part Description
1 Side Panel B
2 Hinge
3 Handle Socket
4 Straight Handle
5 Fan
6 Back Panel
7 Rectifier Rack
8
Temperature Controller
9
10
11
12
13
14
15
16
17
18
19
20
21
Clap Panel
Wire Spool Axle
Wire Feed Mechanism
Wire Feed Wheel
Side Panel A
Power Cord
Ground Cable With Clamp
Welding Torch / Cable
Cover
Wire Speed Knob
Switch
Overload Light
Cable Nib
Part Description
22
Front Panel
23
Filter Reactor
24
Main Transformer
25
Transformer Carriage
26
Bottom Plate
27
Plastic Foot
28
Axle Bracket
29
Wheel, Plastic
30
Axle
31 Control Circuit Board Bracket
32 Control Circuit Board
33 Potentiometer
34 Knob
35 Nut, Copper, M6
36 Washer, Spring, 6
37 Washer, Copper, Plain,6
38 Washer, Insulating, 1
39 Screw, Copper, M6X35
40 Washer, Insulating, 2
41 Brace
42 Rings, 8
1
2
3
4
6
5
7 8 9
10
11 12
13 14
15 16 17 18 19 20
22
23
24
25
26 2728 29
31 32 33
34
38
35
36
37
39
40
21
30
41
42