Chicago Electric 40388 Installation manual

ARC WELDER - 120
Model 40388
SET UP AND OPERATING INSTRUCTIONS
Diagrams within this manual may not be drawn proportionally.
Due to continuing improvements, actual product may differ slightly from the product described herein.
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©1999 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 or replacement parts, please call 1-800-444-3353.
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SPECIFICATIONS
Input Power 115/230 V~ , 42 A
Maximum Amperage Output 120 A
Electrode Sizes
(Note: Electrodes not included)
1/16” to 5/64” (115V)
1/16” to 3/32” (230V)
Features
This is a high-quality hobby arc welder, delivering up to 140 Amps welding current. It
will hold electrodes sizes from 1/16” to 3/32” in diameter. It is thermally protected, and has
a high temperature warning light. Step-less variable Amperage is easily adjustable using a
control knob, with an easy-to-read gauge on top of the unit. This welder is easily portable,
using the attached carrying handle. This welder will use either 115 Volt or 230 Volt current.
Save This Manual
You will need the manual for the safety warnings and precautions, assembly instruc-
tions, 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!
Keep work area clean. Cluttered areas invite injuries.
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 elec-
trically powered tools in the presence of ammable gases or liquids.
Keep children away. Children must never be allowed in the work area. Do not let
them handle machines, tools, or extension cords.
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.
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.
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. Do not use a 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 non-conductive clothes and non-skid footwear
are recommended when working. Wear restrictive hair covering to contain long hair.
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Use eye and ear protection. Wear ANSI-approved impact safety goggles at all
times. Wear a full face shield if you are producing metal lings or wood chips. Wear
an ANSI approved dust mask or respirator when working around metal, wood, and
chemical dusts 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 perfor-
mance. 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 electrical equipment when not in use.
Remove adjusting keys and wrenches. Check that keys 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 nger 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 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 xtures, and any other condition that may affect proper opera-
tion. Any part that is damaged should be properly repaired or replaced by a qualied
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, clamps, vises, and metal enclosures.
Replacement parts and accessories. When servicing, use only identical replace-
ment parts. Use of any other parts will void the warranty. Only use accessories in-
tended for use with this tool. Approved accessories are available from Harbor Freight
Tools.
Do not operate tool if under the inuence of alcohol or drugs. Read warning
labels on prescriptions to determine if your judgment or reexes are impaired while
taking drugs. If there is any doubt, do not operate the tool.
People with pacemakers should consult their physician(s) before use. Electro-
magnetic elds in close proximity to heart pacemaker could cause pacemaker inter-
ference or pacemaker failure.
WARNING: This product, when used for welding 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.)
The warnings, precautions, and instructions discussed in this instruction man-
ual 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.
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Safety Warnings and Precautions for Arc Welding
WARNING! Arc Welding Can be Hazardous.
It is your responsibility to operate this equipment in a safe manner.
Fire or Explosion Precautions
Arc welding creates heat and sparks. These can cause re or explosion. Please follow
these safety considerations while using your spot welder.
Be aware of ying sparks. Only weld in an area that does not contain any materials
which can be ignited by ying sparks. Extinguish any signicant ying sparks before
continuing to weld.
Protect yourself and others around you from burns which can be caused by ying
sparks.
Never weld in an area which contains materials which can be ignited by ying
sparks.
Be sure that you have a re extinguisher nearby before using this welder.
Never weld enclosed containers. Sparks in an enclosed container can trigger an
explosion.
Never weld in an atmosphere which might contain ammable fumes.
Periodically during welding, and after completion of job, inspect your area for any
ignition that might have been caused by ying sparks.
Electric Shock Hazard Precautions
Be aware that your arc welder operates through high resistance electrical current. Exposure
to this current can cause injury or death. Please use safety precautions against electrical
shock while using your welder.
Always unplug your welder prior to making any adjustments or repairs.
Never leave your welder unattended while plugged in.
Never use your welder in a wet environment, or while you are wet or on a wet sur-
face.
Always wear electrical insulating clothing, gloves and shoes while using your welder.
Never use an extension cord which is not properly approved and rated for this equip-
ment.
Assure that you are drawing from an electrical supply which is protected by a 30
Amp fuse or breaker switch.
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Personal Safety Precautions
Flying Sparks can cause injury, and Hot Materials can cause burns. Please wear appropri-
ate safety clothing, and observe precautions to prevent burns or injury to yourself or others.
Wear ANSI approved safety goggles or glasses when using this equipment.
Wear protective clothing such as heavy gloves, apron, boots, mask or hood.
Do not look directly into the welding arc without appropriate protective eyeshields.
Do not allow others to look directly into the arc without appropriate eye protection.
Wear protective gloves while welding. Welding causes the metal to become very hot,
which can cause burns. Do not touch welded areas until you are certain they have
cooled.
Assure that hot welded materials are not placed where others can touch them, or
they can cause a re.
The electrode, and especially the welding rods become very hot during welding. Ex-
ercise extreme caution to prevent burns to yourself or others from these areas.
Inhalation Hazard
Welding/PlasmaCuttingProducesTOXIC FUMESandGASSES.
Exposure to welding or cutting 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 or plasma cutting gasses or fumes are:
• Early onset of Parkinson’s Disease • Heart Disease
• Damage to the reproductive organs • Ulcers
• Inammation 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.
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ARC WELDER ASSEMBLY
Installing the Handle
Locate the HANDLE (27) and SCREW (28).
Slide the HANDLE (27) onto the top of the
CASE (26), indexing the tabs on the underside
of the HANDLE onto the slots on top of the
CASE, as indicated by lines (A) in Figure 1.
Insert the SCREW (28) through the HANDLE
(27), as shown in Figure 1, and tighten secure-
ly with a screwdriver.
Installing the Ground Clamp
WARNING! Be sure to connect the Ground Clamp to the GROUND WIRE (4) ONLY. Check
the Parts Diagram to be sure you have selected the correct wire.
Figure 2.
Ground Clamp
Installation
Locate the Ground Clamp which is included in your welder kit, see Figure 2, step 1.
Slide the Handle Grip off the Ground Clamp, exposing the Wire Attachment area .
Slide the Handle Grip over the end of the GROUND WIRE (4), see Figure 2, Step 2.
Attach the GROUND WIRE (4) to the Ground Clamp, using a Bolt, Nut and Washer,
as shown in Figure 2, Step 3.
With the GROUND WIRE secure, slide the Handle Grip over the Ground Clamp,
covering the attachment of the Ground Wire to the Ground Clamp.
Your assembled Ground Clamp will look like Figure 2, Step 5.
WARNING! Welder produces powerful electric currents. Operator must remain insulated
from this current. Never use if any insulating Handle Grip is not in good repair.
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Figure 1. Handle InstallationFigure 1. Handle Installation
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Installing the Electrode Handle
Figure 3. Installing the
Electrode Handle
Locate the ELECTRODE CABLE (5), as shown in the parts diagram, and the Elec-
trode Handle as shown in gure 3, Step 1 above.
Slide the Handle Grip off the Electrode Handle, as shown in Step 2 above.
Insert the ELECTRODE CABLE (5) through the Handle Grip, and attach to the Elec-
trode Handle as shown in Step 3 above. Note: You must place bare end of ELEC-
TRODE CABLE wire into opening in end of Electrode Handle, then by tightening the
Screw, tighten the Clamping Plate onto the bare end of the ELECTRODE CABLE,
clamping it securely into place.
With the ELECTRODE CABLE secured into the Electrode Handle, slide the Handle
Grip over the wire connection, as shown in Step 4 above. Tighten the Handle Grip
securely in place by tightening the screw in the base of the Handle Grip, as shown.
WARNING! Never use your welder if the Insulating Handle Grips are not in good condition
and securely in place. Dangerous potentially fatal shocks can result from improper
handle insulation.
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Installing the Power Plug
Note: This Arc Welder is equipped to operate with either 115 or 230 Volt power supply.
Standard “household” current in the U.S. is 110-120 Volts. If you will be using a
“household” outlet, follow directions for 115 Volt wiring. Electric service for applianc-
es such as stoves in the U.S. are 220-240 Volts. If you will be using an “appliance”
outlet, follow directions for 230 Volt wiring. If you have ANY DOUBT, consult a quali-
ed electrician. Severe damage can result from improperly wiring this Arc Welder.
Determine which voltage you will be using, and secure a UL approved plug for the
selected voltage which will t your wall outlet.
Identify the correct wires you will be using for your voltage from the chart below.
115 Volt installation 230 Volt Installation
Ground Green Green
Neutral White
Hot Black L1 Black L1, Red L2
Tied Off Wire Red White
Prepare the wires by stripping approximately 1/2” of the insulation from the end of
each wire.
Depending on the plug design, insert the prepared cable ends into the plug from the
back.
Attach the Green wire to the Ground pole of the plug.
Wire the appropriate plug as shown in #2 above.
To tie off the wire shown in #2 above: Using a Wire Nut, cap the bare end of the un-
used wire, carefully insulating it from contact with any metal or conducting surface.
WARNING! Before operating this welder, make sure that the plug is properly wired for
the voltage to be used, AND that the SELECTOR SWITCH (1) is set for the proper
voltage. The Selector Switch must be set before the Arc Welder is plugged in and
turned on. Severe equipment failure and property damage can result from improper
wiring or switch selection.
WARNING! If Arc Welder is operated at 115 V~, be sure not to regulate the current over 70
A, or the 30 A breaker in your house line will trip.
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Wiring Diagram
115/230 V~ 115 V~: B - M 230 V~: M - N
B=White N=Red M=Black
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Preparing a Safe Workplace Environment to Avoid Hazardous Conditions
The primary hazards to be managed when using Arc Welding equipment include Electric
Shock, Fumes and Gasses, Sparks and Fire, Arc Light, and Tools and Equipment in the
Work Area.
Electrical Hazards
Work only in a dry environment. This includes dry clothing, shoes, oors and tools.
Maintain an insulation layer between yourself and the electrodes, the workpiece and
the oor. Keep the Electrode Insulated Handle Grips in good condition, wear insu-
lated gloves, and insulated shoes.
Do not plug in or turn on the welder until you are prepared to work, and are condent
that it is safe to do so. Do not allow the Welding Rod, or Electrode Holder to touch
anything that you do not intend to weld.
Fumes and Gasses
The Flux and alloying metals components of the welding rods gives off fumes as the
rod is used. Be sure to work in a well-ventilated are to avoid excessive inhalation of
these fumes.
The heat generated by welding, and the sparks and splatter that can y out can
ignite any ammable materials or gasses in the area. Be sure that there are no am-
mable materials in the are before beginning to weld.
Work piece coatings may burn or fume with Arc ignition. Be sure to provide for prop-
er ventilation.
Sparks and Fire
Arc welding creates considerable heat, both in the workpiece, and in sparks and
splatter that may y or drip from the workpiece.
Remove any combustibles from the area.
Always have a second person present to watch for res.
Keep a re extinguisher available at the worksite.
Remember that the workpiece becomes very hot, and can cause re or injury.
Arc Light
The light created by Arc Welding can damage your eyes and skin.
Always wear an ANSI approved welding face shield before striking an arc.
Never allow an onlooker to view the welding Arc.
Wear dark colored long sleeve clothing to protect your skin.
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