Chicago Electric 68886 User Manual
Owner’s Manual & Safety Instructions
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.
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Email our technical support at: tech@harborfreight.com
When unpacking, make sure that the product is intact
and undamaged. If any parts are missing or broken,
please call 1-800-444-3353 as soon as possible.
Copyright© 2011 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. Diagrams
within this manual may not be drawn proportionally. Due to continuing
improvements, actual product may differ slightly from the product described
herein. Tools required for assembly and service may not be included.
Read this material before using this product.
Failure to do so can result in serious injury.
SAVE THIS MANUAL.
Table of Contents
Safety ......................................................... 2
Setup .......................................................... 7
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP
Specifications ............................................. 7
Basic Welding ............................................ 15
This is the safety alert symbol. It is used to alert you to potential personal injury hazards.
Welding Tips .............................................. 23
Maintenance .............................................. 27
Parts List and Diagrams ............................ 30
Warranty .................................................... 32
WARNING SYMBOLS AND DEFINITIONS
Obey all safety messages that follow this symbol to avoid possible injury or death.
Indicates a hazardous situation which, if not avoided,
will result in death or serious injury.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
Addresses practices not related to personal injury.
IMPORTANT SAFETY INFORMATION
Read all safety warnings and instructions.
Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.
Save all warnings and instructions for future reference.
General Safety
PROTECT yourself and others. Read and understand this information.
1. Before use, read and understand
manufacturer′s instructions,
Material Safety Data Sheets (MSDS′s),
employer′s safety practices, and ANSI Z49.1.
2. Keep out of reach of children.
Keep children and bystanders away while operating.
3. Place the welder on a stable location before use.
If it falls while plugged in, severe injury,
electric shock, or fire may result.
4. Do not overreach.
Keep proper footing and balance at all times.
5. Stay alert, watch what you are doing and use
common sense when operating a welder.
Do not use a welder while you are tired or under
the influence of drugs, alcohol or medication.
A moment of inattention while operating welders
may result in serious personal injury.
6. Avoid unintentional starting. Make sure you are
prepared to begin work before turning on the Welder.
7. Never leave the Welder unattended while
energized. Turn power off if you have to leave.
8. 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.
9. 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.)
10. Handling the cord on this product will expose
you to lead, a chemical known to the State of
California to cause cancer, and birth defects or
other reproductive harm.
Wash hands after handling.
(California Health & Safety Code § 25249.5, et seq.)
Page 2 For technical questions, please call 1-800-444-3353. SKU 68886
Fume and Gas Safety
FUMES AND GASES can be hazardous to your health.
1. 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 cutting exhaust fumes are:
• Early onset of Parkinson’s Disease
• Heart disease • Ulcers
• Damage to the reproductive organs
• Inflammation of the small intestine or
stomach • Kidney damage
• Respiratory diseases such as
emphysema, bronchitis, or pneumonia
2. Do not use near degreasing or
painting operations.
3. Keep head out of fumes.
Do not breathe exhaust fumes.
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP
4. Use enough ventilation, exhaust at arc, or
both, to keep fumes and gases from breathing
zone and general area. If engineering controls
are not feasible, use an approved respirator.
5. Work in a confined area only if it
is well-ventilated, or while wearing
an air-supplied respirator.
6. Have a recognized specialist in
Industrial Hygiene or Environmental Services
check the operation and air quality
and make recommendations
for the specific welding situation.
Follow OSHA guidelines for
Permissible Exposure Limits (PEL’s) and
the American Conference of Governmental
Industrial Hygienists recommendations for
Threshold Limit Values (TLV’s) for fumes and gases.
Arc Ray Safety
ARC RAYS can injure eyes and burn skin.
1. Wear ANSI-approved welding eye protection
featuring at least a number 10 shade lens rating.
2. Wear leather leggings, fire resistant shoes
or boots during use. Do not wear pants with
cuffs, shirts with open pockets, or any clothing
that can catch and hold molten metal or sparks.
3. Keep clothing free of grease, oil,
solvents, or any flammable substances.
Wear dry, insulating gloves and protective clothing.
4. 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.
5. When welding/cutting overhead or in confined
spaces, wear flame resistant ear plugs or
ear muffs to keep sparks out of ears.
Page 3For technical questions, please call 1-800-444-3353.SKU 68886
Electrical Safety
ELECTRIC SHOCK can KILL.
1. Turn off, disconnect power, and
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP
discharge electrode to ground before setting
down torch/electrode holder and before service.
2. Do not touch energized electrical parts.
Wear dry, insulating gloves. Do not touch electrode
holder, electrode, welding torch, or welding wire with
bare hand. Do not wear wet or damaged gloves.
3. Connect to grounded, GFCI-protected
power supply only.
4. Do not use near water or damp objects.
5. 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.
6. Do not expose welders to rain or wet conditions.
Water entering a welder will increase
the risk of electric shock.
7. Do not abuse the cord. Never use the cord
for carrying, pulling or unplugging the welder.
Keep cord away from heat, oil, sharp edges
or moving parts. Damaged or entangled
cords increase the risk of electric shock.
8. Do not use outdoors.
9. 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 large enough to cover
your full area of contact with the work or ground.
Fire Safety
ARC AND HOT SLAG can cause fire.
1. Clear away or protect flammable objects.
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.
2. Keep ABC-type fire extinguisher near
work area and know how to use it.
3. Maintain a safe working environment.
Keep the work area well lit.
Make sure there is adequate surrounding workspace.
Keep the work area free of obstructions,
grease, oil, trash, and other debris.
4. Do not operate welders in atmospheres
containing dangerously reactive or
flammable liquids, gases, vapors, or dust.
Provide adequate ventilation in work areas
to prevent accumulation of such substances.
Welders create sparks which may ignite flammable
substances or make reactive fumes toxic.
5. 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.
6. 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.
7. Do not dispose of hot slag in containers
holding combustible materials.
8. After welding, make a thorough examination
for evidence of fire. Be aware that easily
visible smoke or flame may not be present
for some time after the fire has started.
9. 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.
Page 4 For technical questions, please call 1-800-444-3353. SKU 68886
Welder use and care
1. Do not use the welder if the switch does not turn
it on and off. Any welder that cannot be controlled
with the switch is dangerous and must be repaired.
2. Disconnect the plug from the power
source before making any adjustments,
changing accessories, or storing welders.
Such preventive safety measures reduce the
risk of starting the welder accidentally.
3. Prevent unintentional starting.
Ensure the switch is in the off-position before
connecting to power source or moving the welder.
Carrying or energizing welders that have
the switch on invites accidents.
Maintenance
1. Maintain welders. Check for misalignment or
binding of moving parts, breakage of parts
and any other condition that may affect the
welder’s operation. If damaged, have the
welder repaired before use. Many accidents
are caused by poorly maintained welders.
2. Have your welder serviced by a qualified
repair person using only identical
replacement parts. This will ensure that
the safety of the welder is maintained.
4. Store idle welders out of the reach of children and
do not allow persons unfamiliar with the welder or
these instructions to operate the welder. Welders
are dangerous in the hands of untrained users.
5. Use the welder and accessories in accordance
with these instructions, taking into account the
working conditions and the work to be performed.
Use of the welder for operations different from those
intended could result in a hazardous situation.
3. Maintain labels and nameplates on the Welder.
These carry important information.
If unreadable or missing, contact
Harbor Freight Tools for a replacement.
4. Unplug before maintenance. Unplug the Welder
from its electrical outlet before any inspection,
maintenance, or cleaning procedures.
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP
Gas Shielded Welding - Cylinder safety
Cylinders can explode when damaged.
1. Never weld on a pressurized or a closed cylinder.
2. Never allow an electrode holder,
electrode, welding torch, or welding
wire to touch the cylinder.
3. Keep cylinders away from any electrical circuits,
including welding circuits.
4. Keep protective cap in place over the valve
except when the cylinder is in use.
5. Use only correct gas shielding equipment
designed specifically for the type of welding
you will do. Maintain this equipment properly.
6. Protect gas cylinders from heat, being struck,
physical damage, slag, flames, sparks, and arcs.
7. Always use proper procedures to move cylinders.
SAVE THESE INSTRUCTIONS.
Page 5For technical questions, please call 1-800-444-3353.SKU 68886
Grounding
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP
TO PREVENT ELECTRIC SHOCK AND DEATH
FROM INCORRECT GROUNDING WIRE CONNECTION:
Check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded.
Have a plug installed by a certified electrician.
Do not use the welder 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,
do not use adapter plugs.
1. The green wire inside the cord is connected to
the grounding system in the welder. The green
wire in the cord must be the only wire connected
to the welder’s grounding system and must never
be attached to an electrically “live” terminal.
Never leave the grounding wire disconnected
or modify the Power Cord Plug in any way.
2. Make sure the tool is connected to an outlet having
the same configuration as the plug. If the tool must
be reconnected for use on a different type of electric
circuit, the reconnection should be made by qualified
service personnel; and after reconnection, the tool
should comply with all local codes and ordinances.
3. A 250 V~ plug will need to be installed
by a certified electrician before use.
4. The plug shown (NEMA 6-50p) is for use on a
50 A circuit. A different 250 V~ plug and outlet
combination may be used, provided it is rated
to handle the electrical requirements of the tool
and is installed by a certified electrician.
250 V~ 3-Prong Plug (6-50p) and Outlet (6-50r)
(for up to 250 V~ and up to 50 A)
DO NOT USE
125 V~ PLUG.
NOTE SIZE
DIFFERENCE.
Extension Cords
Do not use an extension cord on this welder.
Replacement Cords
1. A qualified electrician can install either of the
following UL-listed, 3 wire cords as a replacement
cord for this welder:
12 AWG up to 6 feet long,
10 AWG up to 75 feet long, or
6 AWG up to 175 feet long.
Page 6 For technical questions, please call 1-800-444-3353. SKU 68886
2. Do not install a thinner or longer
cord on this welder.
3. Do not patch cords of any length together for this
item, patches may allow moisture to penetrate
the insulation, resulting in electric shock.
Symbology
Wire Feed (Speed)
Workpiece Ground Cable
Torch Cable
Overheat Shutdown Indicator
Cooling Fan
Housing Ground Point
V~
A
OCV
KVA
IPM
AWG
Volts Alternating Current
Amperes
Open Circuit Voltage
Kilovolt Amperes
(Volts / 1000 * Amperes)
Inches Per Minute
American Wire Gauge
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP
Specifications
Power Input 240 V~, 24 A
Welding Output
Capacity
Rated Duty Cycle
Open Circuit Voltage 34
KVA 5.75
Wire Speed 30 – 700 IPM
Cable Sizes
Wire Spool Capacity
Accessories
DCEN/DCEP
30-180 A
18 gauge (0.048″) to 1/4″ (0.25″) mild or stainless steel
Not for welding aluminum
20% at 140A
(See explanation on page 16)
Ground: 6′, 7 AWG
Torch: 6′, 7 AWG
Power: 3-wire, 6′ 5″, 12 AWG
6-50P NEMA plug type
up to 10 lb. spool
(one 1 lb. spool of flux-core wire included)
Spare Welder Tips (one each for .023″ and .030″– .035″ wire)
Welding Face Shield
Combination Wire Brush / Chipping Hammer
Page 7For technical questions, please call 1-800-444-3353.SKU 68886
Setup
Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP
Note: Remove the protective foam and cardboard from the welder before setup.
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 off and unplug the welder before assembly.
Face Shield Assembly
1. Attach the handle to the Face Shield by lining
up the two rectangular tabs on the handle with
the corresponding holes in the face shield and
A. press the tabs through the holes and then
B. slide the tabs forward from the back,
locking the round tab in place.
2. Wear heavy-duty work gloves, the edges of the
filter lens may be sharp. Remove any protective
film from both sides of the filter lens. Slide the
filter lens into the helmet behind the holding tabs.
Make sure that the filter lens fits securely and
that light cannot leak around its edges.
BB
AA
Face Shield
(viewed from front)
(viewed from back)
Round
Tab
Handle
Filter Lens
Face Shield
Plug Attachment
1. A 250 V~ plug will need to be installed
by a certified electrician before use.
2. The plug shown is for use on a 50 A circuit. A
different 250 V~ plug and outlet combination
may be used, provided it is rated to handle
the electrical requirements of the tool and
is installed by a certified electrician.
Note: Although 125 V~ plugs may look similar,
the required plug is much larger, see illustration.
250 V~ 3-Prong Plug (6-50p) and Outlet (6-50r)
(for up to 250 V~ and up to 50 A)
Page 8 For technical questions, please call 1-800-444-3353. SKU 68886
DO NOT USE
125 V~ PLUG.
NOTE SIZE
DIFFERENCE.
Wire Spool Installation
1. Turn the welder OFF and unplug
it before proceeding.
2. Pull up on the door latch,
then open the Door.
3. Remove the Spool Knob, Spool Spring, and upper
Spool Plate. If replacing a Spool, remove the old
Spool and all remaining wire from the liners.
I
O
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP
Door
door
latch
Spool Knob
4. Place the new Wire Spool over the Spool Spindle
and on top of the lower Spool Plate as illustrated.
To prevent wire feed problems, set the
Spool so that it will unwind clockwise.
5. Secure Spool in place with the upper Spool Plate
(narrower end against the Spool),
then the Spool Spring and Spool Knob.
Spool Spring
Upper
Spool Plate
Wire Spool
Lower
Spool Plate
Spool Spindle
wire must
unwind this
direction
Page 9For technical questions, please call 1-800-444-3353.SKU 68886
6a. Flux Core (Gas-less) Wire Setup:
Remove the two Knobs securing the cables.
Connect the Black Ground Cable to the rear, red,
positive Terminal using the Knob.
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP
Connect the Red Torch Cable to the front, black,
negative Terminal using the other Knob.
This is the initial setup, called
Direct Current Electrode Negative (DCEN).
6b. Solid Core (Gas Shielded) Wire Setup:
a. Remove the two Knobs securing the cables.
Connect the Black Ground Cable to the front,
black, negative Terminal using the Knob.
Connect the Red Torch Cable to the rear, red,
positive Terminal using the other Knob.
This is called Direct Current Electrode Positive
(DCEP).
Flux Core (Gas-less) Polarity Setup
DCEN
Knobs
+
Ground
(Black)
–
Torch
(Red)
Torch Polarity:
Ground Polarity: +
Solid Core (Gas Shielded) Polarity Setup
DCEP
Knobs
+
Torch
(Red)
–
Ground
(Black)
Torch Polarity:
Ground Polarity: –
–
+
b. Determine which type of shielding gas
would be appropriate for the welding
you will do - see chart on welder.
c. With assistance, set the cylinder
(not included) onto a shelf or cart near
the welder and secure the cylinder in
place with two straps (not included).
d. Remove the protective cap from the cylinder (if
present). Stand to the side of the valve opening,
and open the valve briefly to blow dust and dirt
from the valve opening. Close the cylinder valve.
e. Obtain an appropriate Regulator/Flowmeter
(not included) and close its valve completely.
Thread its inlet connector onto the
cylinder and wrench tighten.
c
Briefly open valve
d
f
e
to clean,
then close
valve.
Note: If the threads do not match, then the Regulator/
Flowmeter is likely for a different type of cylinder/gas.
f. Attach the Gas Hose securely to the
outlet of the Regulator/Flowmeter
using a hose clamp (sold separately).
Page 10 For technical questions, please call 1-800-444-3353. SKU 68886
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