Chicago Electric 40388 User Manual

5 (1)
Chicago Electric 40388 User Manual

Arc Welder - 120

Model 40388

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© 1999 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.

Revised Cover Page 03b; 04k; 07j

Specifications

Input Power

115/230 V~ , 42 A

Maximum Amperage Output

120 A

Electrode Sizes

1/16” to 5/64” (115V)

(Note: Electrodes not included)

1/16” to 3/32” (230V)

Features

This is a high-quality hobby arc welder, delivering up to 140 Amps welding current. It will hold electrodes sizes from 1/16” to 3/32” in diameter. It is thermally protected, and has a high temperature warning light. Step-less variable Amperage is easily adjustable using a control knob, with an easy-to-read gauge on top of the unit. This welder is easily portable, using the attached carrying handle. This welder will use either 115 Volt or 230 Volt current.

Save This Manual

You will need the manual for the safety warnings and precautions, assembly instructions, operating and maintenance procedures, parts list and diagram. Keep your invoice with this manual. Write the invoice number on the inside of the front cover. Keep the manual and invoice in a safe and dry place for future reference.

Safety Warnings and Precautions

WARNING: When using tool, basic safety precautions should always be followed to reduce the risk of personal injury and damage to equipment.

Read all instructions before using this tool!

1.Keep work area clean. Cluttered areas invite injuries.

. Observe work area conditions. Do not use machines or power tools in damp or wet locations. Don’t expose to rain. Keep work area well lighted. Do not use electrically powered tools in the presence of flammable gases or liquids.

3.Keep children away. Children must never be allowed in the work area. Do not let them handle machines, tools, or extension cords.

4.Store idle equipment. When not in use, tools must be stored in a dry location to inhibit rust. Always lock up tools and keep out of reach of children.

5.Do not force tool. It will do the job better and more safely at the rate for which it was intended. Do not use inappropriate attachments in an attempt to exceed the tool capacity.

6.Use the right tool for the job. Do not attempt to force a small tool or attachment to do the work of a larger industrial tool. Do not use a tool for a purpose for which it was not intended.

7.Dress properly. Do not wear loose clothing or jewelry as they can be caught in moving parts. Protective, electrically non-conductive clothes and non-skid footwear are recommended when working. Wear restrictive hair covering to contain long hair.

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Rev 00c,; 00k; 04k

8.Use eye and ear protection. Wear ANSI-approved impact safety goggles at all times. Wear a full face shield if you are producing metal filings or wood chips. Wear an ANSI approved dust mask or respirator when working around metal, wood, and chemical dusts and mists.

9.Do not overreach. Keep proper footing and balance at all times. Do not reach over or across running machines.

10.Maintain tools with care. Keep tools sharp and clean for better and safer performance. Follow instructions for lubricating and changing accessories. Inspect tool cords periodically and, if damaged, have them repaired by an authorized technician.

The handles must be kept clean, dry, and free from oil and grease at all times.

11.Disconnect power. Unplug electrical equipment when not in use.

1 . Remove adjusting keys and wrenches. Check that keys and adjusting wrenches are removed from the tool or machine work surface before plugging it in.

13.Avoid unintentional starting. Be sure the switch is in the Off position when not in use and before plugging in. Do not carry any tool with your finger on the trigger, whether it is plugged in or not.

14.Stay alert. Watch what you are doing, use common sense. Do not operate any tool when tired.

15.Check for damaged parts. Before using any tool, any part that appears damaged should be carefully checked to determine that it will operate properly and perform its intended function. Check for alignment and binding of moving parts, any broken parts or mounting fixtures, and any other condition that may affect proper operation. Any part that is damaged should be properly repaired or replaced by a qualified technician. Do not use the tool if any switch does not turn On and Off properly.

16.Guard against electric shock. Prevent body contact with grounded surfaces such as pipes, clamps, vises, and metal enclosures.

17.Replacement parts and accessories. When servicing, use only identical replacement parts. Use of any other parts will void the warranty. Only use accessories intended for use with this tool. Approved accessories are available from Harbor Freight Tools.

18.Do not operate tool if under the influence of alcohol or drugs. Read warning labels on prescriptions to determine if your judgment or reflexes are impaired while taking drugs. If there is any doubt, do not operate the tool.

19.People with pacemakers should consult their physician(s) before use. Electromagnetic fields in close proximity to heart pacemaker could cause pacemaker interference or pacemaker failure.

0. WARNING: This product, when used for welding 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.)

1. The warnings, precautions, 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.

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REV 07i

Safety Warnings and Precautions for Arc Welding

Warning! Arc Welding Can be Hazardous.

It is your responsibility to operate this equipment in a safe manner.

Fire or Explosion Precautions

Arc welding creates heat and sparks. These can cause fire or explosion. Please follow these safety considerations while using your spot welder.

1.Be aware of flying sparks. Only weld in an area that does not contain any materials which can be ignited by flying sparks. Extinguish any significant flying sparks before continuing to weld.

. Protect yourself and others around you from burns which can be caused by flying sparks.

3.Never weld in an area which contains materials which can be ignited by flying sparks.

4.Be sure that you have a fire extinguisher nearby before using this welder.

5.Never weld enclosed containers. Sparks in an enclosed container can trigger an explosion.

6.Never weld in an atmosphere which might contain flammable fumes.

7.Periodically during welding, and after completion of job, inspect your area for any ignition that might have been caused by flying sparks.

Electric Shock Hazard Precautions

Be aware that your arc welder operates through high resistance electrical current. Exposure to this current can cause injury or death. Please use safety precautions against electrical shock while using your welder.

1.Always unplug your welder prior to making any adjustments or repairs.

.

Never leave your welder unattended while plugged in.

3.Never use your welder in a wet environment, or while you are wet or on a wet surface.

4.Always wear electrical insulating clothing, gloves and shoes while using your welder.

5.Never use an extension cord which is not properly approved and rated for this equipment.

6.Assure that you are drawing from an electrical supply which is protected by a 30 Amp fuse or breaker switch.

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REV 07i

Personal Safety Precautions

Flying Sparks can cause injury, and Hot Materials can cause burns. Please wear appropriate safety clothing, and observe precautions to prevent burns or injury to yourself or others.

1. Wear ANSI approved safety goggles or glasses when using this equipment.. Wear protective clothing such as heavy gloves, apron, boots, mask or hood.

3.Do not look directly into the welding arc without appropriate protective eyeshields.

Do not allow others to look directly into the arc without appropriate eye protection.

4.Wear protective gloves while welding. Welding causes the metal to become very hot, which can cause burns. Do not touch welded areas until you are certain they have cooled.

5.Assure that hot welded materials are not placed where others can touch them, or they can cause a fire.

6.The electrode, and especially the welding rods become very hot during welding. Exercise extreme caution to prevent burns to yourself or others from these areas.

Inhalation Hazard

Welding/PlasmaCuttingProducestoxicfumesandgasses.

Exposure to welding or cutting gasses 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 gasses or fumes are:

Early onset of Parkinson’s Disease

Heart Disease

Damage to the reproductive organs

Ulcers

Inflammation of the small intestine or stomach

Kidney damage

Respiratory diseases such as emphysema, bronchitis or pneumonia

Safety precautions, such as using natural or forced air ventilation and wearing an ANSI approved respirator, are essential to reduce the risk of developing the above illnesses.

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REV 04e; 07i

Arc Welder Assembly

Installing the Handle

1.Locate the HANDLE (27) and SCREW (28).

. Slide the HANDLE (27) onto the top of the

CASE (26), indexing the tabs on the underside of the HANDLE onto the slots on top of the

CASE, as indicated by lines (A) in Figure 1.

3. Insert the SCREW (28) through the HANDLE

(27), as shown in Figure 1, and tighten securely with a screwdriver.

Installing the Ground Clamp

Figure 1. Handle Installation

 

WARNING! Be sure to connect the Ground Clamp to the GROUND WIRE (4) ONLY. Check the Parts Diagram to be sure you have selected the correct wire.

Figure 2.

Ground Clamp

Installation

1.Locate the Ground Clamp which is included in your welder kit, see Figure 2, step 1.

.

Slide the Handle Grip off the Ground Clamp, exposing the Wire Attachment area .

 

Slide the Handle Grip over the end of the Ground Wire (4), see Figure 2, Step 2.

3.Attach the Ground Wire (4) to the Ground Clamp, using a Bolt, Nut and Washer, as shown in Figure 2, Step 3.

4.With the GROUND WIRE secure, slide the Handle Grip over the Ground Clamp, covering the attachment of the Ground Wire to the Ground Clamp.

5.Your assembled Ground Clamp will look like Figure 2, Step 5.

WARNING! Welder produces powerful electric currents. Operator must remain insulated from this current. Never use if any insulating Handle Grip is not in good repair.

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REV 07i

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