Chicago Electric HOBBY ARC WELDER User manual

HOBBY ARC WELDER
Model 55594
ASSEMBLY AND OPERATING INSTRUCTIONS
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit our Web site at: http://www.harborfreight.com
Copyright 2005 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, please call 1-800-444-3353.
©
TO PREVENT SERIOUS INJURY,
READ AND UNDERSTAND ALL WARNINGS
AND INSTRUCTIONS BEFORE USE.
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®

SKU 55594 For technical questions, please call 1-800-444-3353. Page 2
PRODUCT SPECIFICATIONS
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 welding equipment in explosive atmospheres, such as in the
presence of flammable liquids, gases, or dust. Welding equipment creates
SAVE THIS MANUAL
You will need this manual for the safety warnings and precautions, assembly, operating,
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.
UNPACKING
When unpacking, check to make sure all the parts shown on the Parts List on page 20
are included. If any parts are missing or broken, please call Harbor Freight Tools at the
number shown on the cover of this manual as soon as possible.
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SKU 55594 For technical questions, please call 1-800-444-3353. Page 3
sparks which may ignite the dust or fumes.
3. Keep bystanders, children, and visitors away while operating welding equip-
ment. Distractions can cause you to lose control. Protect others in the work area
from arc rays, sparks, and slag. Provide barriers or shields as needed.
ELECTRICAL SAFETY
4. Grounded welding equipment 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 welding equipment should electrically
malfunction or break down, grounding provides a low resistance path to carry
electricity away from the user.
5. Double insulated tools are equipped with a polarized plug (one blade is
wider than the other). This plug will fit in a polarized outlet only one way. If
the plug does not fit fully in the outlet, reverse the plug. If it still does not
fit, contact a qualified electrician to install a polarized outlet. Do not
change the plug in any way. Double insulation eliminates the need for the
three wire grounded power cord and grounded power supply system.
6. 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.
7. Do not expose welding equipment to rain or wet conditions. Water entering
welding equipment will increase the risk of electric shock.
8. Do not abuse the Power Cord. Never use the Power Cord to carry welding
equipment 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.
9. When operating welding equipment 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
10. Stay alert. Watch what you are doing, and use common sense when
operating welding equipment. Do not use welding equipment while tired or
under the influence of drugs, alcohol, or medication. A moment of inattention
while operating welding equipment may result in serious personal injury.

SKU 55594 For technical questions, please call 1-800-444-3353. Page 4
11. Dress properly. Do not wear loose clothing or jewelry. Contain long hair.
Keep your hair, clothing, and gloves away from hot or moving parts. Loose
clothes, jewelry, or long hair can be caught in hot or moving parts. (See page 5,
number 3, for recommended safety clothing.)
12. Avoid accidental starting. Be sure the Power Switch is off before plugging
in. Plugging in welding equipment with the Power Switch on invites accidents.
13. Remove adjusting keys or wrenches before turning on the welding
equipment. A wrench or a key that is left attached to an electrically charged
part of the welding equipment may result in personal injury.
14. Do not overreach. Keep proper footing and balance at all times. Proper
footing and balance enables better control of the welding equipment in
unexpected situations.
15. Use safety equipment. Always wear eye protection. Dusk mask, non-skid
safety shoes, hard hat, or hearing protection must be used for appropriate
conditions.
TOOL USE AND CARE
16. 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.
17. Do not force the welding equipment. Use the correct equipment for your
application. The correct equipment will do the job better and safer at the rate for
which it is designed.
18. Do not use the power tool if the Power Switch does not turn it on or off.
Any equipment that cannot be controlled with the Power Switch is dangerous and
must be replaced.
19. Disconnect the Power Cord Plug from the power source before making any
adjustments, changing accessories, or storing the welding equipment.
Such preventive safety measures reduce the risk of starting the welding
equipment accidentally.
20. Store idle welding equipment out of reach of children and other untrained
persons. Welding equipment is dangerous in the hands of untrained users.

SKU 55594 For technical questions, please call 1-800-444-3353. Page 5
21. Maintain welding equipment with care. Keep equipment clean and dry.
Properly maintained equipment is less likely to malfunction and is easier to
control. Do not use damaged welding equipment. Tag damaged equipment “Do
not use” until repaired.
22. Check for misalignment or binding of moving parts, breakage of parts, and
any other condition that may affect the equipment’s operation. If damaged,
have the equipment serviced before using. Many accidents are caused by
poorly maintained equipment.
23. Use only accessories that are recommended by the manufacturer for your
model. Accessories that may be suitable for one type of welding equipment may
become hazardous when used on another type of equipment
SERVICE
24. Equipment service must be performed only by qualified repair personnel.
Service or maintenance performed by unqualified personnel could result in a risk
of injury.
25. When servicing welding equipment, 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, burns, or other injury.
SPECIFIC SAFETY RULES
1. 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 the Welder in areas
near flammable chemicals, dusts, and vapors.
2. Maintain labels and nameplates on the Welder. These carry important
information. If unreadable or missing, contact Harbor Freight Tools for a
replacement.
3. Prevent eye injury and burns. Wearing and using personal safety clothing and
safety devices reduce the risk of injury. Wear ANSI approved safety impact
eyeglasses with a welding helmet featuring at least a number 10 shade lens
rating. Leather leggings, rubber soled, fire resistant shoes or boots should be
worn when using this Welder. 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 other flammable substances. Wear
dry, insulating gloves and protective clothing. Wear an approved head covering

SKU 55594 For technical questions, please call 1-800-444-3353. Page 6
5. Do not perform welding or cutting operations near chlorinated hydrocarbon
vapors produced by degreasing or painting. The heat generated by arc rays
can react to form phosgene, a highly toxic gas.
6. Irritation of the eyes, nose, and throat are symptoms of inadequate
ventilation. Take immediate steps to improve ventilation. Do not continue
operations if symptoms persist.
7. When welding or cutting in small areas, the operator should be externally
accompanied by another person (standing near the enclosed work area) to
observe accident prevention procedures.
8. When welding or cutting, be aware that high frequency radiation may be
produced which can interfere with radio navigation, safety devices,
computers, and communications equipment. Before operating, have a
qualified technician check out that possibility.
9. Keep high frequency source doors and panels tightly shut. Keep spark
gaps at the correct settings. Use proper grounding and shielding to minimize the
possibility of interference. Keep all cables close together and close to the
ground. Locate the welding or cutting operation as far as possible from sensitive
electronic equipment, or have the electronic equipment shut down temporarily.
10. Prevent accidental fires. Remove any combustible material from the work
area. When possible, move the work to a location well away from combustible
to protect head and neck. Use aprons, cape, sleeves and shoulder covers, and
bibs designed and approved for welding procedures. When welding overhead or
in confined spaces, wear flame resistant ear plugs or ear muffs to keep sparks
out of ears.
4. 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 recommendations 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 situation.

SKU 55594 For technical questions, please call 1-800-444-3353. Page 7
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, floor, ceiling, etc., prevent ignition of
combustibles on the other side by moving the combustibles to a safe location. If
relocation of the combustibles is not possible, designate someone to serve as a
fire watch, equipped with a fire extinguisher, during the welding process and at
least one half hour after the welding is completed. Do not place the torch on any
material other than bare concrete until the torch is completely cooled. Do not
weld on materials having a combustible coating or combustible internal structure
such as walls or ceilings, without an approved method for eliminating the hazard.
Do not dispose of hot slag in containers holding combustible materials. Keep a
fire extinguisher nearby, and know how to use it. After welding, make a thorough
examination for evidence of fire. Be aware that easily visible smoke or flame
may not be present for some time after the fire has started. Do not weld in
atmospheres containing dangerously reactive or flammable gasses, vapors,
liquids, and dust. Provide adequate ventilation in work areas to prevent
accumulation of flammable gases, vapors, or 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 or welding.
11. Read and understand all instructions and safety precautions as outlined in
the manufacturer’s manual for the material you will weld.
12. Industrial applications must follow OSHA requirements.
13. Never plug the Power Cord of this product into an electrical outlet while
standing on a wet or damp surface.
14. Connect the earth ground as near as possible to the operating area. Earth
connections to structural parts of the building or other places distant to the
operating area will reduce their effectiveness and increase the danger of electric
shock.
15. In addition to grounding the workpiece with the Welder Grounding Clamp,
an earth grounding of the workpiece is recommended. Ground it directly to
an earth pipe or grounding rod with a separate cable of appropriate size.
IMPORTANT: Only a qualified, certified electrician should perform this
procedure.

SKU 55594 For technical questions, please call 1-800-444-3353. Page 8
16. Do not touch the welding wire if you are in contact with the workpiece,
ground, or another welding wire from a different machine.
17. Do not allow the welding wire to touch earth ground. Accidental earth
discharges may cause overheating and fire hazards.
18. Do not pass equipment cables through or near lifting chains, crane cables,
or any electrical lines.
19. Never use the Welder near water. Ensure that the surrounding area and cutting
objects are dry. Do not spray water or other liquids on or near the Welder.
20. Avoid all direct contact between the skin and wet garments and metal parts
under electrical power. Check that gloves and protective clothing are dry.
21. Never leave the Welder unattended when it is plugged into an electrical
outlet. Make sure to unplug it from its electrical outlet before leaving the area.
22. Do not unplug the Welder by pulling on the Power Cord. Keep the Power
Cord away from heated surfaces.
23. Always turn off the Welder in the event of a power failure.
24. Significant DC electrical voltage exists after turning off and unplugging the
Welder. Discharge the electrode to ground before handling.
25. Performance of this Welder may vary depending on variations in local line
voltage. Extension cord usage may also affect tool performance.
26. Always turn off the Welder and unplug the unit from its electrical outlet
before performing any inspection, maintenance, or cleaning procedures.
27. Use the right tool or attachment for the right job. Do not attempt to force a
small tool or attachment to do the work of a larger industrial tool or attachment.
There are certain applications for which this product was designed. It will do the
job better and more safely at the rate for which it was intended. Do not modify
this product, and do not use this product for a purpose for which it was not
intended.
28. WARNING! The brass components of this product contain lead, a
chemical known to the State of California to cause birth defects (or other
reproductive harm). (California Health & Safety code 25249.5, et seq.)

SKU 55594 For technical questions, please call 1-800-444-3353. Page 9
29. WARNING! This product, when used for welding, cutting, and 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.)
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 facility 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, next page.)
2. The grounding prong in the Plug is connected to the green wire inside the Cord to
the grounding system in the welding equipment. The green wire in the Cord
GROUNDING
WARNING!
30. WARNING! People with pacemakers should consult with their physician(s)
before using this product. Operation of electrical equipment in close proximity to
a heart pacemaker could cause interference or failure of the pacemaker.
31. WARNING! Welding and cutting fumes and gases may be hazardous if
inhaled for long periods of time.
32. WARNING! The warnings, precautions, and instructions discussed in this
instruction manual 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.
SAVE THESE INSTRUCTIONS

SKU 55594 For technical questions, please call 1-800-444-3353. Page 10
must be the only wire connected to the equipment’s grounding system and must
never be attached to an electrically “live” terminal. (See Figure A.)
3. Your welding equipment 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
THREE PRONG
PLUG
120 VOLT
GROUNDED
ELECTRICAL OUTLET
THIS PRODUCT
USES A
THREE PRONG PLUG
DOUBLE INSULATED TOOLS: TOOLS WITH TWO PRONG PLUGS
1. 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.)
2. Double insulated tools may be used in either of the 120 volt outlets shown in the
following illustration. (See Figure B.)
FIGURE B