Chicago Electric 44567 User Manual

90 Amp flux wire

welDer

44567

ASSEMBLY AND OPERATING INSTRUCTIONS

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© 2000 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 and replacement parts, please call 1-800-444-3353.

Revised Cover Page 02/03; Manual revised 09/05

Contents

Speciﬁcations .............................................................................3

General Safety Rules ..................................................................3

Speciﬁc Safety Rules ........................................................................... 5

Grounding.............................................................................................. 8

Symbology ........................................................................................... 10

Unpacking ..................................................................................11

Assembly ....................................................................................11

Installing the Wire Reel ........................................................................ 12

Changing Wire feed roller ................................................................... 13

Trigger Switch Replacement ............................................................... 14

Operation ....................................................................................15

Before You Start Welding ..................................................................... 15

Duty Cycle (Duration of Use) .............................................................. 15

Setting Up The Weld ............................................................................. 16

Holding The Torch ................................................................................ 17

Weld Settings Chart ............................................................................. 18

Weld Diagnosis .................................................................................... 19

Maintenance ...............................................................................21

Nozzle Inspection, Cleaning, and Replacement ................................ 21

Contact Tip Inspection, Cleaning, and Replacement ........................ 21

Parts Lists and Diagrams .........................................................22

Wiring Schematic ................................................................................. 22

Parts List .............................................................................................. 23

Assembly Diagram ............................................................................... 24

Troubleshooting .........................................................................26

For technical questions, please call 1-800-444-3353;

Troubleshooting section at end of manual.

Page 2SKU 44567

SPECIFICATIONS

Welding Current 63 ~ 68 amps; High setting: 79 ~ 90 amps

Duty Cycle

Power Consumption

Heat Control 2 settings

Ground Cable 6 AWG, 6 foot

Torch Power Cable 8 AWG, 6 foot

Power Cord 3-wire, 14 AWG, UL listed

Welder Tip

Wire Size 0.030” ﬂux core wire

Wire Spool Size 4” diameter/ 2 lb. spool

Overall Dimensions 14-1/2 (L) x 8-1/2 (W) x 15-1/2 (H) inches

Weight 34.45 lb.

Accessories

10% at 80 amps; 18% at 60 amps

(See explanation of Duty Cycle on page 15.)

120 VAC, 24 amps peak, single phase Should be connected to a 20 amp minimum dedicated circuit

Included tips will accept 0.030” ﬂux core wire (0.9 mm tips, to account for thermal expansion of the wire)

Spare Welder Tip 0.9mm (for .030” wire) Welding Face Shield Wire Brush / Hammer combination

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.

GENERAL SAFETY RULES

WARNING!

READ AND UNDERSTAND ALL INSTRUCTIONS. Failure to follow all instructions listed below may result in electric shock, ﬁre, and/or serious injury.

SAVE THESE INSTRUCTIONS

Work Area

1. Keep your work area clean and well lit. Cluttered benches and dark areas invite accidents.

2. Do not operate power tools in explosive atmospheres, such as in the presence of ﬂammable liquids, gases, or dust. Power tools create sparks which may ignite the dust or fumes.

3. Keep bystanders, children, and visitors away while operating a power tool.

REV 10/03; 06/04; 02/05; 05/06

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Troubleshooting section at end of manual.

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Distractions can cause you to lose control. Protect others in the work area from debris such as chips and sparks. Provide barriers or shields as needed.

Electrical Safety

4. Avoid body contact with grounded surfaces such as pipes, radiators, ranges, and refrigerators. There is an increased risk of electric shock if your body is grounded.

5. Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock.

6. 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.

7. Do not abuse the Power Cord. Never use the Power Cord to carry the tools or pull

the Plug from an outlet. Keep the Power Cord away from heat, oil, sharp edges, or moving parts. Replace damaged Power Cords immediately. Damaged Power

Cords increase the risk of electric shock.

8. When operating a power tool outside, use an outdoor extension cord marked “W-A” or “W”. These extension cords are rated for outdoor use, and reduce the risk of electric shock.

Personal Safety

9. Stay alert. Watch what you are doing, and use common sense when operating a power tool. Do not use a power tool while tired or under the inﬂuence of drugs, alcohol, or medication. A moment of inattention while operating power tools may

result in serious personal injury.

10. Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep your hair, clothing, and gloves away from arc. Loose clothes, jewelry, or long hair can catch ﬁre.

11. Avoid accidental starting. Be sure the Power Switch is off before plugging in. Carrying power tools with your ﬁnger on the Power Switch, or plugging in power tools with the Power Switch on, invites accidents.

12. Remove adjusting keys or wrenches before turning the power tool on. A wrench or a key that is left attached to a rotating part of the power tool may result in personal injury.

13. Do not overreach. Keep proper footing and balance at all times. Proper footing and balance enables better control of the power tool in unexpected situations.

14. Use safety equipment. Always wear eye protection. For welding safety equipment, refer to number 7 on page 6.

Tool Use and Care

SKU 44567

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Page 4

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. Any tool that cannot be controlled with the Power Switch is dangerous and must be replaced.

18. Unless explicitly instructed otherwise, disconnect the Power Cord Plug from

the power source before making any adjustments, changing accessories, or storing the tool. Such preventive safety measures reduce the risk of starting the tool

accidentally.

19. Store idle tools out of reach of children and other untrained persons. Tools are dangerous in the hands of untrained users.

20. Maintain tools with care. Keep tools in good repair. Properly maintained tools will get the job done better. Do not use a damaged tool. Tag damaged tools “Do not use” until repaired.

21. Check for breakage of parts, and any other condition that may affect the tool’s operation. If damaged, have the tool serviced before using. Many accidents are caused by poorly maintained tools.

22. Use only accessories that are recommended by the manufacturer for your model. Accessories that may be suitable for one tool may become hazardous when used on another tool.

Service

23. Tool service must be performed only by qualiﬁed repair personnel. Service or maintenance performed by unqualiﬁed personnel could result in a risk of injury.

24. When servicing a tool, use only identical replacement parts. Follow instructions in the “Inspection, Maintenance, And Cleaning” section of this manual. Use of unauthorized parts or failure to follow maintenance instructions may create a risk of electric shock or injury.

SPECIFIC SAFETY RULES

1. Maintain labels and nameplates on the Welder. These carry important information. If unreadable or missing, contact Harbor Freight Tools for a replacement.

2. Maintain a safe working environment. Keep the work area well lit. Make sure there is adequate surrounding workspace. Always keep the work area free of obstructions, grease, oil, trash, and other debris. Do not use a power tool in areas near ﬂammable chemicals, dusts, and vapors. Do not use this product in a damp or wet location.

3. Avoid unintentional starting. Make sure you are prepared to begin work before turning on the Welder.

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Troubleshooting section at end of manual.

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4. Unplug before performing maintenance. Always unplug the Welder from its electrical outlet before performing any inspection, maintenance, or cleaning procedures.

5. Never leave the Welder unattended while energized. Turn power off if you have to leave the Welder.

6. Maintain a safe working environment. Keep the work area well lit. Make sure there is adequate surrounding workspace. Always keep the work area free of obstructions, grease, oil, trash, and other debris.

7. 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 impact eye goggles underneath welding eye protection featuring at least a number 10 shade lens rating, such as the one included.

• Leather leggings, ﬁre 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 ﬂammable 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 conﬁned spaces, wear ﬂame resistant ear plugs or ear muffs to keep sparks out of ears.

8. 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.

• 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.

• Enclose the work area with portable ﬁre resistant screens. Protect combustible walls, ceilings, ﬂoors, etc., from sparks and heat with ﬁre 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 ﬁre watch, equipped with a ﬁre extinguisher, during the cutting process and for at least one half hour after the cutting is completed.

• Do not weld or cut on 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 ﬁre extinguisher nearby and know how to use it.

• After spot welding, make a thorough examination for evidence of ﬁre. Be aware that

SKU 44567

For technical questions, please call 1-800-444-3353;

Troubleshooting section at end of manual.

Page 6

easily visible smoke or ﬂame may not be present for some time after the ﬁre has started. Do not weld or cut in atmospheres containing dangerously reactive or ﬂammable gases, vapors, liquids, and dust. Provide adequate ventilation in work areas to prevent accumulation of ﬂammable 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 ﬂammable or explosive vapors. Clean and purge containers before applying heat. Vent closed containers, including castings, before preheating, welding, or cutting.

9. Avoid overexposure to fumes and 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 qualiﬁed 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.

• Work in a conﬁned area only if it is well-ventilated, or while wearing an air-supplied 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 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.

Also, some diseases that may be linked to exposure to welding 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.

10.

11. Do not touch live electrical parts. Wear dry, insulating gloves. Do not touch electrode

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Read and understand all instructions and safety precautions as outlined in the manufacturer’s manual for the material you will weld or cut.

or conductor tong with bare hand. Do not wear wet or damaged gloves.

For technical questions, please call 1-800-444-3353;

Troubleshooting section at end of manual.

Page 7

12. Protect yourself from electric shock. Do not use outdoors. Insulate yourself from the workpiece and ground. Use nonﬂammable, 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.

13. WARNING! People with pacemakers should consult their physician(s) before using this product. Electromagnetic ﬁelds in close proximity to a heart pacemaker could cause interference to, or failure of the pacemaker.

14. Use care not to touch the welding tip to grounded material whenever the unit is

plugged in. This unit is what is referred to as a “hot tip” welder, meaning that current is available to the wire at all times that the power Switch (7a) is in the ON position. Electric shock, ﬁre, or burns may happen if appropriate precautions are not

taken.

15. Ensure that the unit is placed on a stable location before use. If this unit falls while plugged in, severe injury, electric shock, or ﬁre may result.

16. WARNING! This product, when used for welding and similar applications, contains or produces a chemical known to the State of California to cause cancer and birth defects (or other reproductive harm). (California Health & Safety Code § 25249.5, et seq.)

GROUNDING

WARNING!

Improperly connecting the grounding wire can result in the risk of electric shock. Check with a qualiﬁed electrician if you are in doubt as to whether the outlet is properly grounded. Do not modify the power cord plug provided with the tool. Never remove the grounding prong from the plug. Do not use the tool if the power cord or plug is damaged. If damaged, have it repaired by a service facility before use. If the plug will not ﬁt the outlet, have a proper outlet installed by a qualiﬁed electrician.

GROUNDED TOOLS: TOOLS WITH THREE PRONG PLUGS

1. Tools marked with “Grounding Required” have a three wire cord and three prong grounding plug. The plug must be connected to a properly grounded outlet. If the tool should electrically malfunction or break down, grounding provides a low resistance path to carry electricity away from the user, reducing the risk of electric shock. (See Figure

A.)

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. (See Figure A.)

SKU 44567

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Troubleshooting section at end of manual.

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3. Your tool must be plugged into an appropriate outlet, properly installed and grounded in accordance with all codes and ordinances. The plug and outlet should look like those in the following illustration. (See Figure A.)

FIGURE A

DOUBLE INSULATED TOOLS: TOOLS WITH TWO PRONG PLUGS

4. Tools marked “Double Insulated” do not require grounding. They have a special double insulation system which satisﬁes OSHA requirements and complies with the applicable standards of Underwriters Laboratories, Inc., the Canadian Standard Association, and the National Electrical Code. (See Figure B.)

5. Double insulated tools may be used in either of the 120 volt outlets shown in the following illustration. (See Figure B.)

FIGURE B

EXTENSION CORDS

1. Grounded tools require a three wire extension cord. Double Insulated tools can use either a two or three wire extension cord.

2. As the distance from the supply outlet increases, you must use a heavier gauge extension cord. Using extension cords with inadequately sized wire causes a serious drop in voltage, resulting in loss of power and possible tool damage.

(See Figure C, next page.)

3. The smaller the gauge number of the wire, the greater the capacity of the cord. For example, a 14 gauge cord can carry a higher current than a 16 gauge cord.

(See Figure C.)

4. When using more than one extension cord to make up the total length, make sure each

REV 05/04

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Troubleshooting section at end of manual.

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