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
®
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; Manual revised 09/05
TO PREVENT SERIOUS INJURY,
READ AND UNDERSTAND ALL WARNINGS
AND INSTRUCTIONS BEFORE USE.

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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

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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.

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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

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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.

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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

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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.

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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.)

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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

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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