Chicago Electric 44568 Welder User Manual
Contents
1. CHICAGO B CTT ELECTRIC systems INDUSTRIAL ARC WELDER WITH THERM AL OVERLOAD ole 144568 ASSEMBLY AND OPERATING INSTRUCTIONS 3491 Mission Oaks Blvd Camarillo CA 93011 Visit our Web site at http www harborfreight com 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 Specifications ITEM DESCRIPTION Oban Volt de AC operation 48A 22V to 130A 25 2V Adjustable p g DC operation 25A 21V to 99A 24V Adjustable 230 VAC single phase 60 Hz Absorbed Power 5 4 Kilowatts Duty Cycle 10 130 AMPS AC 15 100 AMPS DC Thermal Overload DC setting 20 minutes shutdown 4 minute back on Protection AC setting 10 minutes shutdown 3 minute back on 26 L x 13 1 2 W x 19 H inches Ground Cable 4 AWG single insulation 6 foot Torch Cable 4 AWG single insulation 6 foot Power Cord 3 core double insulated 14 AWG 6 foot U L Approved Power switch with green light indicator Features Thermal overload protection with amber light indicator Current adjustment knob Face Shield Accessories Wire Slag Brush Pull and Cable Handle 58 35 Ibs Note Arc Welding Accessory Kit SKU 35491 is available from Harbor Freight Tools This kit includes 3M2. Item Description Qty e Line God no 220 VAG pua ea Te Wet z 13 Current Control Knob se Power Switch Knob NOTE Some parts are listed and shown for illustra tion purposes only and are not available individually as replacement parts a13 Cable Connection Knobs SKU 44568 For technical questions please call 1 800 444 3353 Page 8 REV 04 05
3. Cable with Electrode Holder 2M Cable with Ground Clamp Welding Mask and Combination Brush Welding Hammer 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 re duce 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 2 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 REV 03 01 02 05 03 05 REV 07 05 SKU 44568 For technical questions please call 1 800 444 3353 Page 2 10 11 12 13 14 15 16 17 18 19 Do not force tool It will do the job b
4. and adjusting wrenches are removed from the tool or machine work surface before plugging it in 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 Stay alert Watch what you are doing use common sense Do not operate any tool when you are tired 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 Guard against electric shock Prevent body contact with grounded surfaces such as pipes radiators ranges and refrigerator enclosures 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 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
5. doubt do not operate the tool Maintenance For your safety service and maintenance should be performed regularly by a qualified technician SKU 44568 For technical questions please call 1 800 444 3353 Page 3 20 Use proper size and type 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 fire 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 10 AWG Longer extension cords require larger size wire If you are using the tool outdoors use an extension cord rated for outdoor use signified by WA on the jacket Note Performance of this tool may vary depending on variations in local line voltage Exten sion cord usage may also affect tool performance Warning The warnings cautions and instructions discussed in this instruction manual cannot cover all possible conditions and situations that may occur It must be under stood by the operator that common sense and caution are factors which cannot be built into this product but must be supplied by the operator Arc Welding Safety Warnings and Precautions Warning This product when used for welding and similar applications produces chemi cals known to the State of California to cause cancer and birth defects or other repro ducti
6. 44 3353 REV 684 3 Avoid eye and body damage Arc 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 the provided Face Shield with arc shaded filter plate 4 Know proper arc welding practices Read and understand the manufacturer s instructions as well as your employer s safety practices for arc welding 5 Connect only to a code approved power source Connect only to a grounding power source conforming to the National Electrical Code and Local Codes 6 Avoid fire and explosion Remove flammable and explosive material from at least 35 feet from the welding arc to prevent welding sparks or molten metal from starting a fire Keep a type ABC fire extinguisher within easy reach Thoroughly clean the object being welded of any paint grease or other foreign material 7 Avoid being burned Always wear ANSI approved welding gear leather gloves leather apron and shoes Unpacking When unpacking check to make sure the following parts are included Handle Screws 8 Handle 7 Arc Welding Unit 1 Wheel 9 Line Cord 6 without 2 Wheel Hub 10 220 VAC plug Torch Cable _ F Shield and Gamo ee ace onield an Pp Wwe Handle 5 Ground Cable Clamp 3 Wire Brush 4 If any parts are missing or broken please call Harbor Freight Tools at the number on the cover of t
7. cted 4 Place the desired welding electrode rod securely into the jaws of the Torch Cable Clamp 2 5 While viewing the Current Setting Gauge below right turn the Current Control Knob to the correct current setting for the electrode rod being used Electrode Welding Current Diameter in Amps 0 0624 1 6 mm 25 50 0 078 2 mm 40 80 0 0975 2 5 mm 60 100 0 12285 3 15 mm 100 121 0 156 4 mm 110 121 6 Verify that the Power Switch is in the OFF position then plug the Arc Welder 220 VAC plug into a dedicated 40 amp line with delayed action type circuit breaker or fuses SKU 44568 For technical questions please call 1 800 444 3353 Page 6 If an extension cord is used it must have the following wire size up to 30 feet use 10 AWG size wire 30 to 50 feet use 8 AWG wire Over 50 feet use 6 AWG wire 7 While holding the Torch Cable Clamp with electrode clearly out of the way of any grounded objects turn the Power Switch to the ON position 8 Orient yourself on the area to be welded then place the Face Shield over your eyes Warning Never look at the ignited arc without ANSI approved arc shaded eye protec tion in a full face shield Permanent eye damage or blindness can occur Skin burns can occur Never breath arc fumes 9 Stroke the area to be welded with the electrode to ignite the arc Never tap the electrode into the welding surface to ignite the arc This damages its external coating on
8. ent 2 Welding current setting too low low or weak 3 Poor cable connections 1 Using a DC welding rod Will not hold an 2 Using a low hydrogen rod arc Check and tighten all cable connections Use a proper welding electrode Use a rod of 0 078 2 mm max diameter or smaller on 30 60 amp range PLEASE READ THE FOLLOWING CAREFULLY THE MANUFACTURER AND OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY NEITHER THE MANUFACTURER NOR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT IN FACT THE MANUFACTURER AND OR DISTRIBUTOR EX PRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND LI CENSED TECHNICIANS AND NOT BY THE BUYER THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO REV 04 05 SKU 44568 For technical questions please call 1 800 444 3353 Page 7 Maintenance 1 Periodically tighten all cable connection screws on the cable clamps 2 Periodically clean both cable clamps of all grease dirt welding slag and carbon deposits 3 Store the Arc Welder and cable clamps in a clean and dry location Electrical Schematic
9. etter and more safely at the rate for which it was intended Do not use inappropriate attachments in an attempt to exceed the tool capacity 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 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 properly 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 protection Always wear ANSI approved arc shaded impact safety face shield Always use the full face shield provided when arc welding Wear an ANSI approved dust mask or respirator when working around metal chemical dusts fumes and mists Do not overreach Keep proper footing and balance at all times Do not reach over or across running machines 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 Disconnect power Unplug tool when not in use Remove adjusting keys and wrenches Check that keys
10. his manual as soon as possible Assembly 1 Attach the Handle 7 to the top of the Arc Welding Unit 1 using Handle Screws 8 The long portion of the Handle should be facing forward 2 Connect an appropriate 220 VAC electrical plug to the Line Cord 6 This should only be done by a licensed electrician 3 Place each Wheel 9 over the axle and insert the Wheel Hub 10 4 Attach the Front Foot to the bottom of the Arc Welder using the supplied hardware 5 Snap in the Handle into the Face Shield 5 SKU 44568 For technical questions please call 1 800 444 3353 Page 5 Operation Caution Before arc welding read and understand all safety precautions and warnings listed on pages 2 through 5 1 Determine whether AC or DC welding is to be used 2 Connect the Ground Cable 3 and Torch Cable 2 to the Arc Welder as shown in the photo on the next page for either AC or DC operation Remove the connector knob and place the cable over each terminal and tighten the connector knob completely Thermal Overload Light Power ON Light Power Switch DC Operation Torch Cable 2 DC Operation Ground Cable 3 AC Operation Torch Cable 2 Current Control Knob AC Operation Ground Cable 3 Power Line Cord Torch Ground Cable 3 Cable 2 3 Securely clamp the Ground Cable Clamp 3 as close as possible to the metal object to be welded or to the metal work bench where the object is mounted and electrically conne
11. the electrode which prevents oxygen in the air from coming into contact with the molten metal causing it to oxidize 10 Once the arc is ignited tilt the electrode forward at an angle of approximately 30 and hold it at a distance from the welding object equal to the diameter of the electrode Note If too much current is drawn from the Arc Welder the Thermal Overload protector will activate the amber indicator will light and the Arc Welder will turn off until it cools down If this happens turn the Power Switch to the OFF position and wait about 20 minutes 11 When the weld is complete lift the electrode clearly away from any grounded object set the Face Shield down and turn toward the Arc Welder and turn the Power Switch to the OFF position 12 Remove the electrode from the Torch Cable Clamp 13 Unplug the Power Cord from the electrical outlet Troubleshooting Probable Cause Suggested Remedy 1 Improper fuse or circuit breaker Replace fuse reset breaker or use delayed action breaker 2 Fuse blown or circuit breaker tripped Replace fuse or reset breaker 3 Thermal overload protection activated 3 Wait until the unit cools down and try again 4 Using incorrect welding techniques Review recommended welding techniques 1 Low line voltage Check power source for at least 220 VAC at 40 amps Turn the Current Control Knob to a higher setting Welder does not operate or continually blows fuses Welding curr
12. ve harm California Health amp Safety Code 25249 5 et seq 1 Avoid electrical shock 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 2 Avoid breathing fumes or gases They can cause serious health problems Use an active ventilation system directly above the welding area Keep your head out of the fumes 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 e Heart Disease e Damage to the reproductive organs e Ulcers Inflammation of the small intestine or stomach Kidney damage e 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 SKU 44568 For technical questions please call 1 800 4
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