Chicago Electric 94056 User Manual
90 AMP FLUX WIRE WELDER
94056
SET UP AND OPERATING INSTRUCTIONS
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© 2005 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.
For technical questions or replacement parts, please call 1-800-444-3353.
REV 06g, 09e, 09h
SPECIFICATIONS
.8 mm wire on 16 ga.
Welding Current
Duty Cycle
Power Consumption 120 V~, 24 A
Ground Cable 4 AWG, single insulation, 6’
Torch Power Cable 8 AWG, single insulation, 6’
Thermal Overload
Welder Tip
Wire Size 0.030” ux core wire (using 0.030” Welder Tip)
Wire Spool Size 4” diameter
Overall Dimensions 14-1/2” (L) x 7-7/8” (W) x 15-1/2” (H)
Weight 34.45 lb.
Accessories Spare Welder Tip (0.035”)
sheet steel
.8 mm wire on 1/4”
steel plate
10% @ 90 Amps (Max Setting) or
10% @ 80 Amps (Min Setting, actual 11%)
Both settings:
10 min. shutdown, 3 min. back on with Light
0.030”; Spare: Welder Tip 0.035”;
Will also accept a 0.023” welder tip (not included)
104.3/95.5 A
(Max/Min Setting)
103.7/103.1 A
(Max/Min Setting)
Note: Performance of this tool may vary depending on variations in local line voltage.
Extension cord usage may also affect tool performance.
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
REV 06l
tool!
Keep work area clean1. . Cluttered
areas invite injuries.
Observe work area conditions2. . 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 ammable gases
or liquids.
Keep children away3. . Children must
never be allowed in the work area.
Do not let them handle machines,
tools, or extension cords.
Store idle equipment4. . 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.
Do not force tool5. . It will do the job
better and more safely at the rate
Page 2For technical questions, please call 1-800-444-3353.SKU 94056
for which it was intended. Do not
use inappropriate attachments in an
attempt to exceed the tool capacity.
Use the right tool for the job6. . Do
not attempt to force a small tool or
attachment to do the work of a larger
industrial tool. There are certain
applications for which this tool was
designed. Do not modify this tool and
do not use this tool for a purpose for
which it was not intended.
Dress properly7. . Do not wear loose
clothing or jewelry as they can be
caught in moving parts. Protective,
electrically nonconductive clothes and
nonskid footwear are recommended
when working. Wear restrictive hair
covering to contain long hair.
Use eye and ear protection8. . Always
wear ANSI-approved, arc-shaded,
impact safety face shield. Always use
the full face shield when welding.
Wear a NIOSH-approved dust mask
or respirator when working around
metal, chemical dusts, fumes and
mists.
Do not overreach9. . Keep proper
footing and balance at all times. Do
not reach over or across running
machines.
Disconnect power11. . Unplug tool
when not in use.
Remove adjusting keys and 12.
wrenches. Check that keys and
adjusting wrenches are removed
from the tool or machine work surface
before plugging it in.
Avoid unintentional starting13. . Be
sure the switch is in the Off position
when not in use and before plugging
in. Do not carry any tool with your
nger on the trigger, whether it is
plugged in or not.
Stay alert14. . Watch what you are
doing, use common sense. Do not
operate any tool when you are tired.
Check for damaged parts15. . 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 xtures; and any
other condition that may affect proper
operation. Any part that is damaged
should be properly repaired or
replaced by a qualied technician. Do
not use the tool if any switch does not
turn On and Off properly.
Maintain tools with care10. . 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.
REV 06g
Guard against electric shock16. .
Prevent body contact with grounded
surfaces such as pipes, radiators,
ranges, and refrigerator enclosures.
Replacement parts and 17.
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.
Page 3For technical questions, please call 1-800-444-3353.SKU 94056
Approved accessories are available
INHALATION HAZARD:
Welding and Plasma Cutting Produce
TOXIC FUMES.
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 plasma cutting
exhaust fumes are:
• Early onset of Parkinson’s Disease
• Heart disease • Ulcers
• Damage to the reproductive organs
• Inammation of the small intestine or
stomach • Kidney damage
• Respiratory diseases such as
emphysema, bronchitis, or pneumonia
Use natural or forced air ventilation and
wear a respirator approved by NIOSH to
protect against the fumes produced to
reduce the risk of developing the above
illnesses.
from Harbor Freight Tools.
Do not operate tool if under the 18.
inuence of alcohol or drugs.
Read warning labels on prescriptions
to determine if your judgment or
reexes are impaired while taking
drugs. If there is any doubt, do not
operate the tool.
Maintenance19. . For your safety,
service and maintenance should be
performed regularly by a qualied
technician.
Use proper size and type 20.
extension cord. If an extension cord
is required, it must be of the proper
size and type to supply the correct
current to the tool without heating
up. Otherwise, the extension cord
could melt and catch re, or cause
electrical damage to the tool. This
tool requires use of an extension cord
of 20 amps minimum capability (up
to 30 feet), with wire size rated at 12
AWG. Longer extension cords require
larger size wire. If you are using the
tool outdoors, use an extension cord
rated for outdoor use (signied by
“WA” on the jacket).
Avoid electrical shock21. . Do not
permit electrically live parts, cables,
or electrodes to contact skin, clothing,
or gloves. Protective clothing should
be hole-free, dry, and ANSI-approved.
This unit draws enough current to
cause serious injury or death. Before
turning the welder on, check the
electrode holder to be sure that there
are no protruding screw heads, and
that all insulation is secure. Do not
weld unless you are insulated from
ground and the work piece.
WARNING
Avoid breathing fumes or gases22. .
They can cause serious health
problems. Use an active ventilation
system directly above the welding
area. Keep your head out of the
fumes.
Avoid eye and body damage23. .
Welding rays and infrared radiation
can injure eyes and burn skin.
Wear ANSI-approved eye and body
protection. Do not allow viewing by
visitors without proper eye and body
protection. Use a face shield with arc-
shaded lter plate.
Page 4For technical questions, please call 1-800-444-3353.SKU 94056
Know proper welding practices24. .
Read and understand the
manufacturer’s instructions, as well
as your employer’s safety practices
for welding.
Connect only to a code approved 25.
power source. Connect only to a
grounding power source conforming
to the National Electrical Code and
Local Codes.
UNPACKING
When unpacking, check to make sure
the item is intact and undamaged. If any
parts are missing or broken, please call
Harbor Freight Tools at 1-800-444-3353 as
soon as possible.
ASSEMBLY
Avoid re and explosion26. . Remove
ammable and explosive material
from at least 35 feet from the welding
site to prevent welding sparks or
molten metal from starting a re.
Keep a type ABC re extinguisher
within easy reach. Thoroughly clean
the object being welded of any paint,
grease, or other foreign material.
Avoid being burned27. . Always wear
ANSI-approved welding gear: leather
gloves, leather apron, and shoes.
WARNING: This product, when used 28.
for welding, plasma cutting, soldering,
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.)
Cover (31)
Handle (30)
Wire
Cover
Locking
Spring (8)
Reel (27)
1. Attach the Handle (30) to the Cover
(31) using screw (29) inserted from the
Handle top-rear.
Attach the Cover Locking Spring (8) to 2.
the front of the Base Frame (14) using
the supplied self-tapping screw.
The warnings, cautions, and 29.
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.
Page 5For technical questions, please call 1-800-444-3353.SKU 94056
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