Chicago Electric 55167 User manual

90 Amp flux wire
welDer
55167
ASSEMBLY AND OPERATING INSTRUCTIONS
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit our Web site at http://www.harborfreight.com
®
Copyright©2007 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.
TO PREVENT SERIOUS INJURY,
READ AND UNDERSTAND ALL WARNINGS
AND INSTRUCTIONS BEFORE USE.

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Troubleshooting section at end of manual. Page 2SKU 55167
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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Troubleshooting section at end of manual. Page 3SKU 55167
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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Troubleshooting section at end of manual. Page 4SKU 55167
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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Troubleshooting section at end of manual. Page 5SKU 55167
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.