Chicago Electric 44567 Assembly and 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

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

TO PREVENT SERIOUS INJURY,

READ AND UNDERSTAND ALL WARNINGS

AND INSTRUCTIONS BEFORE USE.

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

Troubleshooting section at end of manual. Page 2SKU 44567

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 3

SKU 44567

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

SPECIFICATIONS

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

Duty Cycle 10% at 80 amps; 18% at 60 amps

(See explanation of Duty Cycle on page 15.)

Power Consumption 120 VAC, 24 amps peak, single phase

Should be connected to a 20 amp minimum dedicated circuit

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 Included tips will accept 0.030” ﬂux core wire

(0.9 mm tips, to account for thermal expansion of the wire)

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

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.

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

Troubleshooting section at end of manual. Page 4

SKU 44567

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

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

Troubleshooting section at end of manual. Page 5

SKU 44567

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.

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

Troubleshooting section at end of manual. Page 6

SKU 44567

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 extin-

guisher, 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 haz-

ard.

• 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

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

Troubleshooting section at end of manual. Page 7

SKU 44567

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 ﬂam-

mable 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 recommenda-

tions 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.

10.

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.

Read and understand all instructions and safety precautions as outlined in the

manufacturer’s manual for the material you will weld or cut.

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

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 8

SKU 44567

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 facil-

ity 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.)

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

Troubleshooting section at end of manual. Page 9

SKU 44567

REV 05/04

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

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

Troubleshooting section at end of manual. Page 10SKU 44567

cord contains at least the minimum wire size required. (See Figure C.)

5. If you are using one extension cord for more than one tool, add the nameplate amperes

and use the sum to determine the required minimum cord size. (See Figure C.)

6. If you are using an extension cord outdoors, make sure it is marked with the sufﬁx “W-

A” (“W” in Canada) to indicate it is acceptable for outdoor use.

7. Make sure your extension cord is properly wired and in good electrical condition. Always

replace a damaged extension cord or have it repaired by a qualiﬁed electrician before

using it.

8. Protect your extension cords from sharp objects, excessive heat, and damp or wet

areas.

RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS*

NAMEPLATE

AMPERES

(At Full Load)

EXTENSION CORD LENGTH

25 Feet 50 Feet 75 Feet 100 Feet 150 Feet

0 - 2.0 18 18 18 18 16

2.1 - 3.4 18 18 18 16 14

3.5 - 5.0 18 18 16 14 12

5.1 - 7.0 18 16 14 12 12

7.1 - 12.0 18 14 12 10 -

12.1 - 16.0 14 12 10 - -

16.1 - 20.0 12 10 - - -

FIGURE C * Based on limiting the line voltage drop to ﬁve

volts at 150% of the rated amperes.

SYMBOLOGY

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