Chicago Electric 44568 User manual

ARC WELDER WITHARC WELDER WITH

ARC WELDER WITH

THERMAL OVERLOADTHERMAL OVERLOAD

THERMAL OVERLOAD

ASSEMBLY AND OPERATING INSTRUCTIONS

3491 Mission Oaks Blvd., Camarillo, CA 93011

Visit our Web site at http://www.harborfreight.com

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

44568

Revised Cover Page 02/03

Page 2SKU 44568 For technical questions, please call 1-800-444-3353.

REV 03/01; 02/05; 03/05; REV 07/05

Note: ArcWelding AccessoryKit(SKU#35491)isavailablefromHarborFreightTools. Thiskit includes: 3M Cable

withElectrodeHolder,2MCablewithGroundClamp,Welding Mask and CombinationBrush/WeldingHammer.

Specifications

METINOITPIRCSED

egatloVnepO elbatsujdAV2.52/A031otV22/A84:noitarepoCA elbatsujdAV42/A99otV12/A52:noitarep

oCD

tnemeriuqeRrewoPzH06,esahpelgnis,CAV032

rewoPdebrosbAsttawoliK4.5

elcyCytuD)CD(SPMA001@%51,)CA(SPMA031@

%01

daolrevOlamrehT noitcetorP nokcabetunim4;nwodtuhssetunim02:gnittesCD nokcabetunim3;nwodtuhssetunim01:

gnittesCA

snoisnemiDsehcni)H(91x)W(2/1-31x)L(62

elbaCdnuorGtoof6,noitalusnielgnis,GWA4

elbaChcroTtoof6,noit

alusnielgnis,GWA4

droCrewoP devorppA.L.U,toof6,GWA41,detalusnielbuod,eroc-3

serutaeF rotacidnithgilneergh

tiwhctiwsrewoP rotacidnithgilrebmahtiwnoitcetorpdaolrevolamrehT bonktnemtsujdatnerruC

seirosseccA dleihSe

caF hsurBgalS/eriW eldnaHelbaCdnalluP

thgieWsbl53.85

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.

Page 3SKU 44568 For technical questions, please call 1-800-444-3353.

5. Do not force tool. It will do the job better and more safely at the rate for which it was

intended. Donotuseinappropriate attachments in an attempt toexceed the toolcapacity.

6. Use the right tool for the job. Donot attempttoforce a smalltoolorattachmenttodothe

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.

Followinstructionsforlubricatingandchanging accessories.Inspecttoolcords 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 youaredoing,usecommon sense.Do not operate anytoolwhen

you are tired.

15. Check for damaged parts. Beforeusing anytool, anypart 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;andanyothercondition thatmayaffectproperoperation.Anypartthatisdamaged

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

onprescriptionstodetermineifyour judgment or reflexes are impaired whiletakingdrugs.

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.

Page 4SKU 44568 For technical questions, please call 1-800-444-3353.

20. Use proper size and type extension cord.If an extension cord isrequired,itmustbe 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-

ductive 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.

Thisunitdrawsenoughcurrenttocauseseriousinjuryordeath.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.

REV 05/04

Page 5SKU 44568 For technical questions, please call 1-800-444-3353.

Unpacking

When unpacking, check to make sure the following parts are included.

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. 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 ArcWelder using the supplied hardware.

5. Snap in the Handle into the Face Shield (5).

Torch Cable

Clamp (2)

Ground Cable

Clamp (3)

Arc Welding Unit (1)

Wire Brush (4)

Face Shield and

Handle (5)

Line Cord (6) without

220VAC plug

Handle (7)

Handle Screws (8)

Wheel (9)

Wheel Hub (10)

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.

Page 6SKU 44568 For technical questions, please call 1-800-444-3353.

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) andTorch 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.

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.

edortcelE retemaiD tnerruCgnidleW spmAni

)mm6.1("4260.005~52

)mm2("870.008~04

)mm5.2("5790.0001~06

)mm51.3("582

21.0121~001

)mm4("651.0121~011

6. Verify that the Power Switch is in the OFF position, then plug the ArcWelder 220 VAC

plug into a dedicated, 40 amp line with delayed action type circuit breaker or fuses.

DC Operation:Torch Cable (2)

DC Operation:Ground Cable (3)

AC Operation:Torch Cable (2)

AC Operation:Ground Cable (3)

Power Switch

Thermal Overload Light

Power ON Light

Power Line Cord Torch

Cable (2)

Ground Cable (3)

Current Control Knob

Page 7SKU 44568 For technical questions, please call 1-800-444-3353.

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 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.

PLEASE READ THE FOLLOWING CAREFULLY

THEMANUFACTURERAND/ORDISTRIBUTOR HASPROVIDEDTHEPARTSDIAGRAMINTHIS MANUALASAREFERENCE

TOOLONLY. NEITHERTHEMANUFACTURERNOR DISTRIBUTORMAKESANYREPRESENTATIONORWARRANTYOFANY

KINDTOTHEBUYERTHAT HEORSHE ISQUALIFIEDTOMAKE ANYREPAIRSTOTHEPRODUCT ORTHAT HEOR SHEIS

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-

CENSEDTECHNICIANSANDNOTBYTHEBUYER.THEBUYERASSUMESALLRISKANDLIABILITYARISINGOUTOFHISOR

HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTSTHERETO, OR ARISING OUT OF HIS OR HER

INSTALLATION OFREPLACEMENTPARTSTHERETO.

REV 04/05

motpmySesuaCelbaborPydemeRdetsegguS

tonseodredleW ro,etarepo swolbyllaunitnoc sesuf

rekaerbtiucricroesufrepo

rpmI.1

deppirtrekaerbtiucricronwolbesuF.2 detavitcanoitcetorpdaolrevolamrehT.3 seuqinhcetgnidlewtcerrocn

ignisU.4

deyaledesuro,rekaerbteser,esufecalpeR.1 rekaerbnoitca rekaerbteserroesufecalpeR.2 .niagayrtdnanw

odslooctinuehtlitnutiaW.3 seuqinhcetgnidlewdednemmocerweiveR.4

tnerrucgnidleW kaewrowol

egatlovenilwoL.1

olootgnittestnerrucgnidleW.2

snoitcennocelbacrooP.3

04taCAV022tsaeltarofecruosrewopkcehC.1 .spma rehgihaotbonKlortnoCtnerruCehtnruT.2 gnittes snoitcennocelbacllanethgitdnakcehC.3

nadlohtonlliWcra

dorgnidlewCDag

nisU.1 dornegordyhwolagnisU.2 edortcelegnidlewreporpaesU.1 roretemaid.xam)mm2("870.0fodoraesU.2 .egnarpma

06~03norellams

Troubleshooting

Page 8SKU 44568 For technical questions, please call 1-800-444-3353.

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.

Parts List and Component Diagram

NOTE:Some parts are listed and shown for illustra-

tionpurposes only and are not availableindividually

as replacement parts.

(11)

(12)

(2) (3)

(1)

(4)

(5)

(6)

(7)

(8)

(9)

(10)

(13)

#metInoitpircseDytQ

1tinUgnidleWcrA1

2pmalCelbaChcroT1

3pmalCelbaCdnuorG1

4hsurBeriW1

5eldnaHdnadleihSecaF1

6)gulpCAV022

on(droCeniL1

7eldnaH1

8eldnaH,swercS2

9leehW2

01leehW,buH2

11bonKlortnoCtnerruC1

21bonKhctiwSrewoP1

31sbonKnoitcennoCelbaC4

Electrical Schematic

REV 04/05

Table of contents

Other Chicago Electric Welding System manuals

Chicago Electric

Chicago Electric 61433 Assembly instructions

Chicago Electric

Chicago Electric 97503 Installation manual

Chicago Electric

Chicago Electric 58605 Assembly instructions

Chicago Electric

Chicago Electric 63583 User manual

Chicago Electric

Chicago Electric 97719 Installation manual

Chicago Electric

Chicago Electric 68887 Instruction Manual

Chicago Electric

Chicago Electric 45949 User manual

Chicago Electric

Chicago Electric 98357 Installation manual

Chicago Electric

Chicago Electric 61205 Assembly instructions

Chicago Electric

Chicago Electric 62719 Assembly instructions

Chicago Electric

Chicago Electric 68888 Assembly instructions

Chicago Electric

Chicago Electric 91814 User manual

Chicago Electric

Chicago Electric 40388 Installation manual

Chicago Electric

Chicago Electric 97717 Installation manual

Chicago Electric

Chicago Electric 44567 Assembly and User manual

Chicago Electric

Chicago Electric Chicago Electric Welding Torch Mini-Kit... User manual

Chicago Electric

Chicago Electric 45690 User manual

Chicago Electric

Chicago Electric Dual Mig 151T-1 36692 Operating instructions

Chicago Electric

Chicago Electric MIG 170 Assembly instructions

Chicago Electric

Chicago Electric MIG 180 User manual

Chicago Electric

Chicago Electric 91220 User manual

Chicago Electric

Chicago Electric 98870 Installation manual

Chicago Electric

Chicago Electric 55525 Parts list manual

Chicago Electric

Chicago Electric 68888 User manual

Popular Welding System manuals by other brands

Berner

Berner PLASMACUT 54 instruction manual

Pro Spot

Pro Spot PR-155 Assembly instructions

Forney

Forney 210 operating manual

Thermal Arc

Thermal Arc 400S operating manual

Lincoln Electric

Lincoln Electric HANDYMIG 170I Operator's manual

GYS

GYS PROTIG 201 AC/DC Original instructions

TAFA

TAFA 30*8B35 owner's manual

Lincoln Electric

Lincoln Electric INVERTEC V350-PRO CE Technical specifications

ESAB

ESAB Buddy Arc 145 instruction manual

CIGWELD

CIGWELD 636804 use instructions

Red-D-Arc

Red-D-Arc DC-400 Operator's manual

Hobart Welding Products

Hobart Welding Products Spool Gun DP 3035-10 owner's manual

Elettro

Elettro HI-MIG 3000 SYNERGIC instruction manual

WIA

WIA Weldmatic 270 CP132-2 Operator's manual

Sonics

Sonics H520T instruction manual

Miller

Miller Big Blue 400D owner's manual

NewArc

NewArc RT2000 Operational manual

Hypertherm

Hypertherm powermax1000 Operator's manual