WELDER DUAL MIG 200 Model 93804 ASSEMBLY AND OPERATING INSTRUCTIONS Due to continuing improvements, actual product may differ slightly from the product described herein. ® 3491 Mission Oaks Blvd., Camarillo, CA 93011 Visit our Web site at: http://www.harborfreight.com TO PREVENT SERIOUS INJURY, READ AND UNDERSTAND ALL WARNINGS AND INSTRUCTIONS BEFORE USE. Copyright© 2006 by Harbor Freight Tools®. All rights reserved.
Contents PRODUCT SPECIFICATIONS................................................... 3 GENERAL SAFETY RULES ..................................................... 3 Specific Safety Rules ........................................................................6 Grounding........................................................................................... 9 Extension Cords ............................................................................... 10 Symbology ..........................................
PRODUCT SPECIFICATIONS Welding Current 30 ~ 200 Amps Welding Capacity For welding 0.02" to 0.36" thickness Duty Cycle 100% @ 80 Amps / 15% @ 200 Amps (Welds 11/2 minutes out of 10 minutes @ full amperage) Power Consumption 230 Volt / 60 Hz / Single Phase / 38 Amps Open Voltage 16-34 Required Power Plug Type 3-Prong, 220 VAC, polarized, twist lock (not included) NEMA #L6-50 or equivalent Power Cord Rating 8 AWG x 3C Gas Inlet Size 1/4" Gas Flow Rate 10.5 ~ 31.
ELECTRICAL SAFETY 4. Grounded tools must be plugged into an outlet properly installed and grounded in accordance with all codes and ordinances. Never remove the grounding prong or modify the plug in any way. Do not use any adapter plugs. Check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded. If the tools should electrically malfunction or break down, grounding provides a low resistance path to carry electricity away from the user. 5.
15. Use clamps (not included) or other practical ways to secure and support the workpiece to a stable platform. Holding the work by hand or against your body is unstable and may lead to loss of control. 16. Do not force the tool. Use the correct tool for your application. The correct tool will do the job better and safer at the rate for which it is designed. 17. Do not use the power tool if the Power Switch does not turn it on or off.
SPECIFIC SAFETY RULES 1. Ground this product. This Welder requires the attachment and use of a UL®listed, 220 volt, grounded, 3-prong, electrical Power Cord Plug (not included). Only a qualified electrician should install the Power Cord Plug. Never remove the grounding prong or modify the Power Cord Plug in any way. Do not use adapter plugs with this product.
Prevent accidental fires. Remove any combustible material from the work area. 10. • • • • • • • 11. When possible, move the work to a location well away from combustible materials. If relocation is not possible, protect the combustibles with a cover made of fire resistant material. Remove or make safe all combustible materials for a radius of 35 feet (10 meters) around the work area. Use a fire resistant material to cover or block all open doorways, windows, cracks, and other openings.
• Have a recognized specialist in Industrial Hygiene or Environmental Services check the operation and air quality and make recommendations for the specific welding or cutting situation. Inhalation Hazard Welding Produces TOXIC FUMES and GASSES. Exposure to welding gasses can increase the risk of developing certain cancers, such as cancer of the larynx and lung cancer.
17. Use the right tool for the job. Do not attempt to force small equipment to do the work of larger industrial equipment. There are certain applications for which this Welder was designed. It will do the job better and more safely at the rate for which it was intended. Do not modify this Welder, and do not use this Welder for a purpose for which it was not intended. 18. WARNING! People with pacemakers should consult their physician(s) before using this product.
2. The grounding prong in the plug is connected through the green wire inside the cord to the grounding system in the tool. The green wire in the cord must be the only wire connected to the tool’s grounding system and must never be attached to an electrically “live” terminal. 3. Your tool must be plugged into an appropriate outlet, properly installed by a certified electrician and grounded in accordance with all codes and ordinances. EXTENSION CORDS AN EXTENSION CORD MUST NEVER BE USED WITH THIS ITEM.
ASSEMBLY INSTRUCTIONS WARNING! Always turn off the Welder and unplug the unit from its electrical outlet prior to performing any assembly, maintenance, or service. TO ATTACH THE WHEELS Attach the four Swivel Wheels (15A) at the front and at the rear of the Base (2A) of the unit, using the Bolts, Lock Washers, and Washers provided. (See Assy. Diagram, page 28.) TO INSTALL THE WIRE SPOOL 1. Use the Handle (5A) and lift the Door (6A) of the Welder to expose the Wire Feed Assembly. (See Figure D.
TO ROUTE THE WIRE NOTE: When installing wire of a different size or composition, you will also need to change wire settings, set the gun polarity, and, possibly, install a gas cylinder. See pages 15-17. 1. IMPORTANT: Securely hold onto the end of the Welding Wire and keep tension on it during the following steps. If this is not done the Welding Wire will spring backward, creating a tangled “bird’s nest” and resulting in wasted wire. (See Figure E.) 2.
4. Keep tension on the Wire, and guide at least 12 inches of Wire into the Wire Inlet Guide (3C). (See Figure G.) WIRE INLET GUIDE (3C) WELDING WIRE 5. FIGURE G Lower the Lever (4C) on the Wire Feed Assembly. Raise and tighten the Handle (6.1C). Once the Wire is held in place, you may release it. (See Figure H.) HANDLE (6.1C) LEVER (4C) WELDING WIRE FIGURE H 6. Lay the Torch Cable out in a straight line so that the Welding Wire moves through it easily.
WARNING! EXERCISE EXTREME CAUTION - RISK OF FIRE AND/OR ELECTRIC SHOCK! The following steps require applying power to the Welder. Do not touch anything with the Torch Handle or Welding Wire or an arc will be ignited. Do not touch the internal components of the unit while it is plugged in. 8. Plug the Power Cord (1A) into its 220 volt, grounded, electrical outlet. Then, turn the Welder’s Power Switch (4D) to its “ON” position. 9. Point the Torch Handle away from all objects.
TO CHANGE WIRE SETTINGS 1. WARNING! Make sure to turn off the Welder and unplug it from its electrical outlet prior to changing wire settings. 2. Use the Handle (5A) and lift the Door (6A) of the Welder to expose the Wire Feed Assembly. (See Figure J.) 3. Loosen, and lower the Handle (6.1C) on the Wire Feed Assembly. Then, raise the Lever (4C). (See Figure J.) 4. Remove the Screw that secures the Roller (5C) in place. Then, remove the two Rollers. (See Figure J.) 5.
SETTING THE GUN POLARITY FOR WIRE TYPE 1. Set for Electrode Positive (DCEP) for gas welding with solid-core wire. Red Electrode Cable (C) to Positive Terminal (A); Black Ground Cable (D) to Negative Terminal (B). SHOWN IN ILLUSTRATION, INITIAL SETUP. (See Figure K.) 2. Set for Electrode Negative (DCEN) for gas-less flux core wire. Red Electrode Cable (C) to Negative Terminal (B); Black Ground Cable (D) to Positive Terminal (A). (See Figure K.) 3.
TO INSTALL A GAS CYLINDER 1. CAUTION! Do not use an Argon/Mixed pressure regulator/flow meter with CO2 shielding gas. To use CO2 shielding gas, you must install a CO2 gas pressure regulator/flow meter (neither one included). 2. With assistance, set the cylinder upright against a solid post or other stationary object and use a chain or a heavy duty strap (neither included) to secure the cylinder in place. (See Figure M.) 3. Remove the protective cap from the cylinder.
OPERATING INSTRUCTIONS BEFORE YOU BEGIN WELDING Good welding requires a high degree of skill and experience. You should practice a few sample welds on scrap metal before you begin welding your first project. Additional practice periods are recommended whenever you weld a different thickness of material, wire, or weld a different type of connection. DUTY CYCLE (DURATION OF USE) 1. CAUTION! Avoid damage to the Welder by not leaving the unit on for more than the prescribed duty cycle time. 2.
SETTING UP THE WELD WARNING! Before welding, make sure to read and understand all safety precautions and warnings discussed on pages 3 through 10. 1. Power Switch (4D): Always make sure the Power Switch is in its “OFF” position before plugging the Welder into a 220 volt, grounded, electrical outlet. (See Figure P.) 2. Overload Protector (7D): If too much current is drawn from the Welder, the Overload Protector will activate. The RED Overload Indicator will illuminate.
at hand. The distance (if any) between the two workpieces must be controlled properly to allow the weld to hold both sides securely while allowing the weld to penetrate fully into the joint. 8. Set the desired welding current (30 to 200 Amps) for the type/thickness of metal being welded, using the Wire Feed Speed Knob (3D) and Voltage Selector Knob (2D). (See Figure P above, and Figure S, page 21.) 9. Make sure the Power Switch (4D) is in its “OFF” position.
WELD SETTINGS CHART This Chart is intended to show general guidelines for different wire sizes and for different thicknesses of material. The settings should only be used at the beginning of a weld and must be adjusted after stopping and carefully inspecting the weld. Proper welding takes good technique and practice. Flux Core / 1.2mm 1 2 3 4 5 6 7 8 Stainless Steel / 1.0mm Wire Type / Diameter Steel / 0.8mm Steel / 1.2mm 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 Aluminium / 1.
VOLT-AMPERE CURVES Volt-Ampere Curves show minimum and maximum voltage and amperage output capabilities of the Welder. Curves of other settings fall between the curves shown. (See Figure O.) 45 FIGURE O O u tpu t vo ltag e 40 35 30 25 20 15 10 5 0 ɯɯ 20 40 60 80 100 120 140 160 180 200 Weld am pe res 18. Squeeze (and hold) the Trigger Switch (13E) of the Welding Torch (15E) and stroke the area to be welded with the Welding Wire to ignite the arc. A.
WELD DIAGNOSIS WELD PENETRATION EXCESS OR BURN-THROUGH Weld droops on top and underneath, or falls through entirely, making a hole. PROPER Weld is visible underneath and bulges slightly on top. INADEQUATE Weld does not contact the joint fully, just on the surface. CROSS SECTIONS POSSIBLE CAUSES AND SOLUTIONS 1. Excessive material at weld: Reduce wire feed speed. 2. Overheating: Increase welding speed and ensure that welding speed is kept steady.
POROSITY CROOKED/WAVY BEAD Small cavities or holes in the bead. TOP VIEW TOP VIEW POSSIBLE CAUSES AND SOLUTIONS POSSIBLE CAUSES AND SOLUTIONS 1. Stickout too long: 1. Stickout too long: Reduce stickout. Reduce stickout. 2. Inaccurate welding: 2. Dirty workpiece or welding wire: Use two hands or rest hand on steady surMake certain that workpiece and wire are face. both clean and free from oil, coatings, and other residues. 3. Insufficient gas flow at weld: Increase flow of shielding gas. 4.
WHEN THE WELD IS COMPLETED 21. Lift the Welding Wire completely away from any grounded object. Set the face shield down. Then, turn the Power Switch (4D) to its “OFF” position. (See Figure P.) 22. Unplug the Power Cord (1A) from the electrical outlet. Then, make sure to set the Welding Torch (15E) on a nonflammable, nonconductive surface. 23. NOTE: A wire brush/hammer (not included) can now be used to clean up the weld. CAUTION! The weld may still be quite hot, and sparks/chips may fly when cleaning.
INSPECTION, MAINTENANCE, AND CLEANING WARNING! Before performing any maintenance on the Welder, unplug the Power Cord (1A) from its electrical outlet and allow all components of the Welder to completely cool. 1. Periodically remove the Side Panel (3A) and Door (6A) from the unit and, using compressed air, blow out all dust and debris from the interior. 2. Always store the Welder in a clean, dry, safe location out of reach of children and other unauthorized people. 3.
REPLACING THE WELDING TORCH LINER Remove NOZZLE, slip type (1E) Remove TIP (2E) 1. Remove FITTING (16C) 2.Untwist NUT holding GUIDE (14C) 3. Remove GUN CABLE 4.Remove BLOCK, CABLE with CAP Remove LINER. (10E) Without bending, insert a new LINER Pull LINER out the other end Cut LINER off 9 mm from head tube. Install TIP (2E), NOZZLE (1E). Install BLOCK, CABLE with CAP. Install GUN. Twist NUT holding GUIDE.
PARTS LISTS & ASSEMBLY DIAGRAMS Part # 1A 2A 3A 4A 5A 6A 7A 8A 8.1A 8.2A 8.3A 8.4A 9 10 11A Description Power Cord (8 AWGx3: 250V) Rear Panel/Base Side Panel Top Panel Handle Door Center Baffle Flat Cable (16) Terminal (IDC-16F) Terminal (OHU-4) Voltage Selector Switch Terminal (SG57648) Wire Drive Assy. Front Panel Flat Cable (10) Qty. 1 1 1 2 1 1 1 1 1 1 1 3 1 1 1 Part # 11.1A 11.2A 11.3A 11.4A 11.5A 11.
PARTS LISTS & ASSEMBLY DIAGRAMS (CONT.) Part # 1B 2B 3B 4B 5B 6B 7B Description Nut (M8) Retaining Spool Ring Spring Spool Brake Washer Cable w/Cap (Black) Nut (M8) Qty. 2 2 1 1 1 1 2 Part # 8B 9B 10B 11B 12B 13B 14B Description Power Terminal (Positive Output-Short) Cable w/Cap (Red) Power Terminal (Positive Output-Long) Nut (M12) Controller Connection Block Support 1B 2B 11B 9B 7B Qty.
PARTS LISTS & ASSEMBLY DIAGRAMS (CONT.) Part # 1C 2C 3C 4C 5C 6C 6.1C 6.2C 6.3C 6.4C Description Gear Motor Base Wire Inlet Guide Lever Roller Drive Handle Handle Spring Axle Washer (Semi-Spherical) Qty. 1 1 1 1 2 1 1 1 1 1 Part # 7C 8C 9C 10C 11C 12C 13C 14C 15C 16C Description Top Isolator Bottom Isolator Wire Adapter Guide Cable w/Cap (Red) Nut (M10) Gun (SB 150) Gun Terminal (OHU-2) Terminal (Flat Cable-10 WF-2) Connector Gun Block Fitting (Hose BRS Barbed Nipple) Qty.
PARTS LISTS & ASSEMBLY DIAGRAMS (CONT.) Part # 1D 1.1D 1.2D 1.3D 1.4D 1.5D 2D 3D Description Gun (SB 150) Nozzle (Slip Type) Contact Tip (0.8mm Wire) Head Tube Trigger Switch Feeder Connector Voltage Selector Knob Wire Feed Speed Knob Qty. 1 1 1 1 1 1 1 1 Part # 4D 5D 6D 7D 8D 9D 10D 11D Description Power Switch Nameplate Label Front Panel Overload Indicator Potentiometer (16K1-B 10KKC20) Switch Selector (8-Position) Terminal Ground (TEB-10-25) Ground Cable w/Clamp (TCB-10-25) Qty.
PARTS LISTS & ASSEMBLY DIAGRAMS (CONT.) Part # 1E* 2E* 3E* 4E* 5E* 6E* 7E 8E Description Nozzle (Slip Type) Contact Tip (0.8mm Wire) Spring Head Tube Sealant Spring Terminal Feeder Connector Qty. Part # Description 1 9E Nut (M12) 1 10E Liner 1 11E Liner Terminal 1 12E Switch Trigger Terminal 1 13E* Trigger Switch 1 14E* Base 2 15E* Complete Torch Assembly 1 *NOTE: Parts #1E*, 2E*, 3E*, 4E*, 5E*, 6E*, 13E*, and 14E* must be ordered as a Complete Torch Assembly: #15E*. Qty.
ELECTRICAL SCHEMATIC SKU 93804 For technical questions, please call 1-800-444-3353; Troubleshooting section at end of manual.
TROUBLESHOOTING IMPORTANT! Be CERTAIN to shut off the Welder, disconnect it from power, and discharge the torch to ground before adjusting, cleaning, or repairing the unit. WIRE FEED MOTOR RUNS BUT WIRE DOES NOT FEED PROPERLY POSSIBLE CAUSES AND SOLUTIONS 1. Insufficient wire feed pressure: Increase wire feed pressure properly - follow instructions on page 12-13. 2. Incorrect wire feed roll size: Replace with the proper one - follow the Installing The Wire Spool instructions, starting on page 11. 3.
TROUBLESHOOTING (continued) IMPORTANT! Be CERTAIN to shut off the Welder, disconnect it from power, and discharge the torch to ground before adjusting, cleaning, or repairing the unit. WELDER DOES NOT FUNCTION WHEN SWITCHED ON POSSIBLE CAUSES AND SOLUTIONS 1. Tripped thermal protection device: Shut the welder’s switch to off and allow it to cool for at least 20 minutes. Reduce duration or frequency of welding periods to help reduce wear on the welder. Refer to Duty Cycle section on page 18. 2.
TROUBLESHOOTING (continued) IMPORTANT! Be CERTAIN to shut off the Welder, disconnect it from power, and discharge the torch to ground before adjusting, cleaning, or repairing the unit. WIRE FEEDS, BUT SHIELDING GAS DOES NOT FLOW 1. 2. 3. 4. 5. POSSIBLE CAUSES AND SOLUTIONS Empty Gas Cylinder: Check gas cylinder. Nozzle Plugged: Clean nozzle. If damaged, replace. Regulator or cylinder valve closed: Make sure both valves are adjusted properly.