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Chicago Electric MIG 200 93804 Assembly And Operating Instructions Manual

Welder dual mig 200
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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. 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, please call 1-800-444-3353.

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  • Page 1 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.

  • Page 2: Table Of Contents

    PRODUCT SPECIFICATIONS... 3 GENERAL SAFETY RULES ... 3 Specific Safety Rules ...6 Grounding... 9 Extension Cords ... 10 Symbology ... 10 UNPACKING... 10 ASSEMBLY INSTRUCTIONS ... 11 To Attach The Wheels ...11 To Install The Wire Spool ...11 To Route The Wire ...12 To Change Wire Settings ...

  • Page 3: Product Specifications

    PRODUCT SPECIFICATIONS y t i l l a 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.
  • Page 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.
  • Page 5 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. 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.

  • Page 6: Specific Safety Rules

    Avoid unintentional starting. Make sure you are prepared to begin work before turning on the Welder. Do not force the Welder. This tool will do the work better and safer at the speed and capacity for which it was designed.
  • Page 7 Prevent accidental fires. 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 fire resistant material. •...
  • Page 8 • 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.

  • Page 9: Grounding

    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.

  • Page 10: Extension Cords

    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”...

  • Page 11: Assembly Instructions

    Bolts, Lock Washers, and Washers provided. (See Assy. Diagram, page 28.) TO INSTALL THE WIRE SPOOL Use the Handle (5A) and lift the Door (6A) of the Welder to expose the Wire Feed Assembly. (See Figure D.) (1B) FIGURE D Unscrew and remove the two Nuts (1B) from the Threaded Shaft.

  • Page 12: 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. IMPORTANT: Securely hold onto the end of the Welding Wire and keep tension on it during the following steps.
  • Page 13 (4C) Lay the Torch Cable out in a straight line so that the Welding Wire moves through it easily. Leave the Door (6A) of the Welder open so that the Wire Feed Assembly can be observed. Remove the Gun Nozzle (1E) and Contact Tip (2E). (See Figure I.) For technical questions, please call 1-800-444-3353;...
  • Page 14 (4E) of the Torch Handle. Replace the Nozzle (1E), and cut off any excess Welding Wire over 1/2 inch. Then, close the Door (6A) of the Welder. (See Figure I.) REMINDER: 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.

  • Page 15: To Change Wire Settings

    WARNING! Make sure to turn off the Welder and unplug it from its electrical outlet prior to changing wire settings. Use the Handle (5A) and lift the Door (6A) of the Welder to expose the Wire Feed Assembly. (See Figure J.) Loosen, and lower the Handle (6.1C) on the Wire Feed Assembly.

  • Page 16: Setting The Gun Polarity For Wire Type

    Ground Clamp, using the Bolt, Lock Washer, and Nut provided. (See Figure L.) Insert the Connecting Plug of the Ground Cable (11D) into the Terminal Ground (10D) and twist the Connecting Plug to lock it in place. (See Figure L.) WELDER TORCH CABLE (SIDE VIEW) TERMINAL GROUND (10D) For technical questions, please call 1-800-444-3353;...

  • Page 17: To Install A Gas Cylinder

    Attach the Gas Hose from the Pressure Regulator/Flow Meter to the Gas Inlet Valve (17A) located on the Rear Panel (2A) of the Welder. (See Figure M.) Adjust the flow rate of the gas by turning the Flow Adjust. The typical flow rate is 20 cfh (cubic feet per hour).

  • Page 18: Operating Instructions

    Welder can safely produce a particular welding current. For example, this Welder, with a 15% duty cycle at 200 Amps, must be allowed to rest for at least eight minutes thirty seconds after every minute and thirty seconds of continuous weld at 200 Amps.

  • Page 19: Setting Up The Weld

    If using solid-core wire, connect and secure an Argon/ CO2 gas hose to the rear of the Welder. (If using flux core wire, protective gas is not required.) (See Figure M.) Securely clamp the Ground Cable Clamp (11D) as close as possible to the metal object to be welded, or to the metal workbench where the object is mounted and electrically connected.

  • Page 20: Holding The Welding Torch

    (2D). (See Figure P above, and Figure S, page 21.) Make sure the Power Switch (4D) is in its “OFF” position. Then plug Power Cord (1A) of the Welder into a dedicated, 220 VAC, 40 AMP line with delayed action type circuit breaker or fuse. (See Figure P.) While holding the Welding Torch (15E), with the Welding Wire clearly out of the way of any grounded objects, turn the Power Switch (4D) to its “ON”...

  • Page 21: 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.

  • Page 22: Volt-Ampere Curves

    Protector will activate. The Overload Indicator Light (7D) will illuminate and the Welder will automatically turn off. If this happens, turn the Power Switch (4D) to its “OFF” position and wait 3 to 5 minutes for the unit to cool down. (See Figure P.) After a few seconds, stop.

  • Page 23: Weld Diagnosis

    EXCESS OR BURN-THROUGH Weld droops on top and underneath, or falls through entirely, making a hole. 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. WELD NOT ADHERING PROPERLY Gaps present between weld and previous bead or between weld and workpiece.
  • Page 24 POROSITY Small cavities or holes in the bead. VIEW POSSIBLE CAUSES AND SOLUTIONS 1. Stickout too long: Reduce stickout. 2. Dirty workpiece or welding wire: Make certain that workpiece and wire are both clean and free from oil, coatings, and other residues.

  • Page 25: When The Weld Is Completed

    WHEN THE WELD IS COMPLETED 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.) Unplug the Power Cord (1A) from the electrical outlet. Then, make sure to set the Welding Torch (15E) on a nonflammable, nonconductive surface.

  • Page 26: Inspection, Maintenance, And Cleaning

    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. Always store the Welder in a clean, dry, safe location out of reach of children and other unauthorized people.

  • Page 27: Replacing The Welding Torch Liner

    REPLACING THE WELDING TORCH LINER Remove NOZZLE, slip type (1E) Remove TIP (2E) Remove LINER. (10E) Cut LINER off 9 mm from head tube. Install TIP (2E), NOZZLE (1E). PLEASE READ THE FOLLOWING CAREFULLY THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY.

  • Page 28: Parts Lists & Assembly Diagrams

    PARTS LISTS & ASSEMBLY DIAGRAMS Part # Description Power Cord (8 AWGx3: 250V) Rear Panel/Base Side Panel Top Panel Handle Door Center Baffle Flat Cable (16) 8.1A Terminal (IDC-16F) 8.2A Terminal (OHU-4) 8.3A Voltage Selector Switch 8.4A Terminal (SG57648) Wire Drive Assy. Front Panel Flat Cable (10) Refer to serial number (location shown below) when ordering parts for this item.
  • Page 29 PARTS LISTS & ASSEMBLY DIAGRAMS (CONT.) Part # Description Nut (M8) Retaining Spool Ring Spring Spool Brake Washer Cable w/Cap (Black) Nut (M8) For technical questions, please call 1-800-444-3353; SKU 93804 Troubleshooting section at end of manual. Qty. Part # Description Power Terminal (Positive Output-Short) Cable w/Cap (Red)
  • Page 30 PARTS LISTS & ASSEMBLY DIAGRAMS (CONT.) Part # Description Gear Motor Base Wire Inlet Guide Lever Roller Drive Handle 6.1C Handle 6.2C Spring 6.3C Axle 6.4C Washer (Semi-Spherical) For technical questions, please call 1-800-444-3353; SKU 93804 Troubleshooting section at end of manual. Qty.
  • Page 31 PARTS LISTS & ASSEMBLY DIAGRAMS (CONT.) Part # Description Gun (SB 150) 1.1D Nozzle (Slip Type) 1.2D Contact Tip (0.8mm Wire) 1.3D Head Tube 1.4D Trigger Switch 1.5D Feeder Connector Voltage Selector Knob Wire Feed Speed Knob 1.1D 1.2D 1.3D 1.4D For technical questions, please call 1-800-444-3353;...
  • Page 32 PARTS LISTS & ASSEMBLY DIAGRAMS (CONT.) Part # Description Nozzle (Slip Type) Contact Tip (0.8mm Wire) Spring Head Tube Sealant Spring Terminal Feeder Connector Parts #1E*, 2E*, 3E*, 4E*, 5E*, 6E*, 13E*, and 14E* must be ordered as a For technical questions, please call 1-800-444-3353; SKU 93804 Troubleshooting section at end of manual.

  • Page 33: Electrical Schematic

    ELECTRICAL SCHEMATIC For technical questions, please call 1-800-444-3353; SKU 93804 Page 33 Troubleshooting section at end of manual.

  • Page 34: Troubleshooting

    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 POSSIBLE CAUSES AND SOLUTIONS 1. Insufficient wire feed pressure: Increase wire feed pressure properly - follow instructions on page 12-13.

  • Page 35: Weak Arc Strength

    TROUBLESHOOTING (continued) 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.

  • Page 36: Warranty

    (if applicable), welding clamps, electrode holders, cables and accessories packed with the welder are free of defects in materials and workmanship. This Limited 1 Year/90 Day Warranty shall not apply to consumable parts such as tips, welding wire, and gas nozzles. Harbor Freight Tools also warrants to the original purchaser, for a period of one year from date of purchase, that the transformer and rectifier are free from defects in materials and workmanship.

This manual is also suitable for:

93804Mig 200

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