Operating instructions | Chicago Electric 44568 Welder User Manual

ARC WELDER WITH
THERMAL OVERLOAD
44568
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
Power Requirement
AC operation: 48A/22V to 130A/25.2V Adjustable
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
Protection
Dimensions
DC setting: 20 minutes shutdown; 4 minute back on
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
Thermal overload protection with amber light indicator
Current adjustment knob
Face Shield
Wire / Slag Brush
Pull and Cable Handle
58.35 lbs
Open Voltage
Features
Accessories
Weight
Note: Arc Welding Accessory Kit (SKU #35491) is available from Harbor Freight Tools. This kit includes: 3M 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 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.
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
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. 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.
7.
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.
8.
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.
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 tool when not in use.
12. 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
you are 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, radiators, ranges, and refrigerator 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. 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. Extension 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 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.
Arc Welding Safety Warnings and Precautions
Warning: This product, when used for welding and 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.
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.
SKU 44568
For technical questions, please call 1-800-444-3353.
4
REVPage
05/04
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
220 VAC plug
Wheel Hub (10)
Torch Cable
Clamp (2)
Ground Cable
Clamp (3)
Face Shield and
Handle (5)
Wire Brush (4)
If any parts are missing or broken, please call Harbor Freight Tools at the number on the
cover of this manual as soon as possible.
Assembly
1.
2.
3.
4.
5.
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.
Connect an appropriate 220 VAC electrical plug to the Line Cord (6).
This should only be done by a licensed electrician.
Place each Wheel (9) over the axle and insert the Wheel Hub (10).
Attach the Front Foot to the bottom of the Arc Welder using the supplied hardware.
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.
DC Operation: Torch Cable (2)
Thermal Overload Light
Power ON Light
Power Switch
DC Operation: Ground Cable (3)
AC Operation: Torch Cable (2)
Current Control Knob
AC Operation: Ground Cable (3)
Power Line Cord
Torch
Cable (2)
Ground Cable (3)
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
connected.
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
Diameter
6.
Welding Current
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
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 protection 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 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
Symptom
Welder does not
operate, or
continually blows
fuses
Probable Cause
1. Replace fuse, reset breaker, or use delayed
action breaker
2. Fuse blown or circuit breaker tripped 2. 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
4. Review recommended welding techniques
1. Improper fuse or circuit breaker
1. Low line voltage
Welding current
low or weak
2. Welding current setting too low
3. Poor cable connections
Will not hold an
arc
Suggested Remedy
1. Using a DC welding rod
2. Using a low hydrogen rod
1. Check power source for at least 220 VAC at 40
amps.
2. Turn the Current Control Knob to a higher
setting
3. Check and tighten all cable connections
1. Use a proper welding electrode
2. 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 EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSED 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
Parts List and Component Diagram
Item #
Description
(8)
Qty
1
Arc Welding Unit
1
2
Torch Cable Clamp
1
3
Ground Cable Clamp
1
4
Wire Brush
1
5
Face Shield and Handle
1
6
Line Cord (no 220 VAC plug)
1
7
Handle
1
8
Screws, Handle
2
9
Wheel
2
10
Hub, Wheel
2
11
Current Control Knob
1
12
Power Switch Knob
1
13
Cable Connection Knobs
4
(7)
(1)
(12)
(13)
(11)
(9)
(6)
(10)
(2)
(5)
(3)
(4)
NOTE: Some parts are listed and shown for illustration purposes only and are not available individually
as replacement parts.
REV 04/05
SKU 44568
For technical questions, please call 1-800-444-3353.
Page 8
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