Chicago Electric 55525 Parts list manual

220 VAC* DUAL
MIG WELDER
Model 55525
ASSEMBLY AND OPERATION INSTRUCTIONS
Due to continuing improvements, actual product may differ slightly from the product described herein.
®
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit our website at: http://www.harborfreight.com
TO PREVENT SERIOUS INJURY, READ AND UNDERSTAND
ALL WARNINGS AND INSTRUCTIONS BEFORE USE.
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 or replacement parts, please call 1-800-444-3353.
*220 VAC refers to input voltage.

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Troubleshooting section at end of manual. Page 2SKU 55525
Contents
PRODUCT SPECIFICATIONS ......................................................... 3
GENERAL SAFETY RULES............................................................ 3
Specific Safety Rules .................................................................................. 6
Grounding .................................................................................................... 9
Extension Cords ......................................................................................... 10
Symbology .................................................................................................. 10
UNPACKING ................................................................................... 10
ASSEMBLY INSTRUCTIONS ......................................................... 11
To Attach The Handle ................................................................................. 11
Face Shield Assembly................................................................................ 11
To Install a Wire Spool................................................................................ 11
To Route The Wire....................................................................................... 12
To Change Wire Settings............................................................................ 14
Setting The Gun Polarity For Wire Type .................................................... 15
To Install A Gas Cylinder ........................................................................... 16
OPERATING INSTRUCTIONS........................................................ 17
Before You Begin Welding.......................................................................... 17
Duty Cycle (Duration of Use)..................................................................... 17
Setting Up The Weld ................................................................................... 18
Holding The Welding Torch ........................................................................ 19
Weld Settings Chart ................................................................................... 20
Weld Diagnosis........................................................................................... 22
When the Weld is Completed..................................................................... 24
INSPECTION, MAINTENANCE, AND CLEANING......................... 25
Nozzle Inspection, Cleaning, and Replacement ...................................... 25
Contact Tip Inspection, Cleaning, And Replacement.............................. 25
Replacing The Welding Torch Liner........................................................... 26
Parts Lists and Diagrams ............................................................. 27
Wiring Schematic ....................................................................................... 27
Parts List ..................................................................................................... 28
Assembly Diagram ..................................................................................... 29
TROUBLESHOOTING .................................................................... 31
WARRANTY.................................................................................... 33

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Troubleshooting section at end of manual. Page 3SKU 55525
PRODUCT SPECIFICATIONS
Welding Current 35 ~ 110 Amps
Duty Cycle 15% @ 110 Amps / 100% @ 35 Amps
(Refer to chart and explanation on page 18)
Power Consumption 220 Volt / 60 Hz / Single Phase / 24.5 Amps
(Should be connected to a 25 Amp minimum dedicated circuit)
Open Circuit Voltage 40 Volts Maximum
Required Power Plug Type 3-Prong, 220 VAC, polarized, twist lock (not included)
NEMA #L6-30 or equivalent
Power Cord Rating 14 AWG x 3C x 6’ Long
Gas Inlet Size 1/4”
Cables Ground: 6 Gauge, 6’.................Torch: 8 Gauge, 6’
Welding Wire Size 0.23” to 0.035”
Wire Spool Size 4” Diameter
Included Torch Tip Size 0.030”
Accessories Wire Spool / Cylinder Strap / Wire Brush & Hammer /
Spare .8mm & 1.0mm Welding Tips / Hand-Held Face Shield
Net Weight 53.5 Pounds
SAVE THIS MANUAL
You will need this manual for the safety warnings and precautions, assembly, oper-
ating, inspection, maintenance and cleaning procedures, parts list and assembly diagram.
Keep your invoice with this manual. Write the invoice number on the inside of the front
cover. Keep this 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
Keep your work area clean and well lit. Cluttered benches and dark areas invite
accidents.
Do not operate power tools in explosive atmospheres, such as in the pres-
ence of flammable liquids, gases, or dust. Power tools create sparks which may
ignite the dust or fumes.
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Troubleshooting section at end of manual. Page 4SKU 55525
Keep bystanders, children, and visitors away while operating a power tool.
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
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.
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.
Do not expose power tools to rain or wet conditions. Water entering a power
tool will increase the risk of electric shock.
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. Dam-
aged Power Cords increase the risk of electric shock.
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
Stay alert. Watch what you are doing, and use common sense when operat-
ing 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.
Dress properly. Do not wear loose clothing or jewelry. Contain long hair.
Keep your hair, clothing, and gloves away from moving parts. Loose clothes,
jewelry, or long hair can be caught in moving parts.
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.
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.
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For technical questions, please call 1-800-444-3353;
Troubleshooting section at end of manual. Page 5SKU 55525
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.
Always wear eye, hearing, and breathing protection. For welding safety equip-
ment, refer to number 9on page 6.
TOOL USE AND CARE
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.
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.
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.
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.
Store idle tools out of reach of children and other untrained persons. Tools
are dangerous in the hands of untrained users.
Maintain tools with care. Keep cutting tools sharp and clean. Properly main-
tained tools with a sharp cutting edge are less likely to bind and are easier to control.
Do not use a damaged tool. Tag damaged tools “Do not use” until repaired.
Check for misalignment or binding of moving parts, 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.
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
Tool service must be performed only by qualified repair personnel. Service or
maintenance performed by unqualified personnel could result in a risk of injury.
When servicing a tool, use only identical replacement parts. Follow instruc-
tions 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.
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