Chicago Electric 44568 User manual

ARC WELDER WITHARC WELDER WITH
ARC WELDER WITHARC WELDER WITH
ARC WELDER WITH
THERMAL OVERLOADTHERMAL OVERLOAD
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
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
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
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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.
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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
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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)
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Electrical Schematic
REV 04/05