Chicago Electric 97717 Welder User Manual
Contents
1. 011 ARC STICK WELDER 70 197717 SET UP AND OPERATING INSTRUCTIONS Diagrams within this manual may not be drawn proportionally Due to continuing improvements actual product may differ slightly from the product described herein Distributed exclusively by Harbor Freight Tools 3491 Mission Oaks Blvd Camarillo CA 93011 Visit our website at http www harborfreight com Read this material before using this product Failure to do so can result in serious injury SAVE THIS MANUAL Copyright 2008 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 CONTENTS IMPORTANT SAFETY 3 GENERAL SAFETY 3 SPECIFIC SAFETY 5 SPECIFICATIONS _ 9 UNPACKING 9 INITIAL SET UP INSTRUC IONS ee eee ea ene 9 e E E E E A E E E 9 OPERATING 2 10 WORK PIECE AND WORK AREA SET2. 10 GENERAL OPERATING 10 MAINTENANCE AND SERVICING 12 22 13 PLEASE READ THE FOLLOWING CAREFULLY 13 PARTS LIST AND ASSEMBLY 14 LIMITED 1 YEAR 90 DAY 15 SKU 97717 For technical questions please call 1 800 444 3353 Page 2 SAVE THIS MANUAL Keep this manual for the safety warnings and precautions assembly operating inspection maintenance and cleaning procedures Write the product s serial number in the back of the manual near the assembly diagram or month and year of purchase if product has no number Keep this manual and the receipt in a safe and dry place for future reference IMPORTANT SAFETY INFORMATION In this manual on the labeling and all other information provided with this product This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death DANGER indicates ADAN G ER a hazardous situation which if not avoided will result in death or serious injury AWARNING WARNING indicates a hazardous situation which if not avoided could result in death or serious injury
3. CAUTION used ACAUTION with the safety alert symbol indicates a hazardous situation which if not avoided could result in minor or moderate injury SKU 97717 NOTICE 1 CAUTION a a For technical questions please call 1 800 444 3353 NOTICE is used to address practices not related to personal injury CAUTION without the safety alert symbol is used to address practices not related to personal injury General Safety Rules WARNING Read all instructions Failure to follow all instructions listed below may result in electric shock fire and or serious injury The term power tool in all of the warnings listed below refers to your line operated corded Arc Welder SAVE THESE INSTRUCTIONS Work area safety Keep work area clean and well lit Cluttered or dark areas invite accidents 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 Keep children and bystanders away while operating a power tool Distractions can cause you to lose control Electrical safety 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 Page 3 SKU 97717 Do not touch exposed electrical parts Do not expose power tools to rain or wet conditions Water ent
4. prevent movement while working The work pieces should be held together firmly while welding The distance if any between the two workpieces must be controlled properly to allow the weld to hold both sides securely while allowing the weld to penetrate fully into the joint There must not be hazardous objects such as utility lines or foreign objects nearby that will present a hazard while working A barrier such as a welding curtain or welding shroud should be put up to protect others in the work area and limit the spray of sparks General Operating Instructions Protective gear ADANGER must be worn when using the Arc Welder ANSI approved arc shaded eye protection a full face shield welding gloves and welding apron NIOSH approved respirator and fire resistant work clothes without pockets should be worn when using this product Do not look at the ignited arc without eye protection Light from the arc can cause permanent damage to the eyes Light from the arc can burn the skin Do not breathe arc fumes The duty cycle defines the number of minutes within a 10 minute period during which a given Welder can safely produce a particular welding current For example at a 10 duty Page 10 SKU 97717 cycle at 70 Amps actual welding can occur for one minute and then the welder must cool for nine minutes At a 20 duty cycle at 50 Amps welding can occur for 2 minutes and then the welder must cool for
5. reach of children and unauthorized people 4 WARNING If the supply cord of this Arc Welder is damaged it must be replaced only by a qualified service technician For technical questions please call 1 800 444 3353 Page 12 TROUBLESHOOTING Welder does not hum 1 No power at electrical outlet 1 Check circuit fuse or circuit breaker when turned on 2 Broken or damaged Power Cord 2 Have Power Cord repaired or replaced by a qualified electrician Welder hums but does 1 Inadequate current at electrode and or poor 1 Check Ground Clamp Cable and not weld connections at Welder connection to workpiece 2 Check Welding Cable and Electrode Holder 3 Check all Welder external connections Arc difficult to strike 1 Electrode diameter too large 1 Use smaller diameter electrode 2 Workpiece not properly grounded 2 Verify proper grounding no paint varnish or corrosion 3 Heavy loads making power line voltage low 3 Run Arc Welder on dedicated 120 volt 20 Amp circuit Welder gives trickle shots 1 Accidental contact with workpiece 1 Avoid contact with workpiece 2 Current leakage caused by damp work area 2 Make sure clothing and work area are dry Welder overheats blows 1 Use of extension cord 1 Relocate Arc Welder to avoid use of fuses trips circuit breaker extension If relocation of Welder is not possible use thicker lower gauge number extension cord 2 Electrode diameter too l
6. the work area Do not use near degreasing or painting operations 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 extinguisher 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 hazard Page 6 20 21 22 SKU 97717 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 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 flammable 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 whe
7. 717 For technical questions please call 1 800 444 3353 Page 8 SPECIFICATIONS Electrical 120 V 60 Hz Requirements Power Plug 20 Amp 3 Prong Grounded Power Switch Rocker with Light Yellow Type Thermal Overload Light Red Settinas Minimum 50 Amp 9 70 Welding Up to 1 8 Thick Steel a Single Pass Capacity Recommended 1 16 Diameter for 15 Amp Circuits Electrode Size Up to 5 64 Diameter for 20 Amp Circuits Duty Cycle 10 70 Amps 20 50 Amps Welding Shield Qty 1 Hammer Brush Qty 1 Accessories Electrode Holder Qty 1 Ground Clamp Qty 1 UNPACKING When unpacking check to make sure that the item is intact and undamaged any parts are missing or broken please call Harbor Freight Tools at the number shown on the cover of this manual as soon as pos sible INITIAL SET UP INSTRUCTIONS Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before set up or use of this product A SKU 97717 For technical questions please call 1 800 444 3353 TO PREVENT INJURY FROM ACCIDENTAL OPERATION Turn the Power Switch of the tool to its OFF position and unplug the tool from its electrical outlet before assembling or making any adjustments to the tool Note For additional information regarding the parts listed in the following pages refer to the Assembly
8. 8 minutes Failure to carefully observe duty cycle limitations can stress a Welder s power generation system contributing to premature Welder failure This Welder is equipped with an internal thermal protection system to help prevent damage to the unit When the Arc Welder overheats a red light is illuminated on the control panel and the unit automatically shuts down Then the unit returns to service when it cools down and the red light turns off Once the unit returns to service follow a more conservative duty cycle routine to help prevent excess wear to the Welder Attach the Ground Cable with Clamp 10 as close as possible to the intended welding location See Assy Diagram Place the bare end of the electrode not included in the Electrode Holder 9 NOTE Always keep the jaws of the Electrode Holder clean to ensure proper electrical contact with the electrode See Assy Diagram Set the desired current 50 70 Amps for the type of metal being welded with the MIN MAX Switch 12 Thin metals use low current and heavy metals use high current See Assy Diagram 10 For technical questions please call 1 800 444 3353 Make sure the Power Switch 13 is off then plug the Arc Welder s Power Cord 8 into a dedicated 120 VAC 20 amp line with delayed action type circuit breaker or fuses See Assy Diagram While grasping the handle of the Electrode Holder 9 with the electrode clear
9. Diagram near the end of this manual Assembly 1 assemble the Welding Shield place the Shield on a flat surface Press the Handle into place Then insert the Filter Lens See Figure A FIGURE A 2 This Arc Welder is equipped with a 120 volt 20 Amp 3 prong grounded Power Plug 8 If this Plug does not fit your existing 120 volt electrical outlet have a qualified electrician Page 9 OPERATING INSTRUCTIONS install a 120 volt 20 Amp 3 hole grounded electrical outlet See Figure B FIGURE B SAFETY INFORMATION section Read the ENTIRE IMPORTANT at the beginning of this manual including all text under subheadings therein before set up or use of this product AWARNING TO PREVENT SERI OUS INJURY FROM ACCIDENTAL OPERATION Turn the switch to its off position before performing any inspection maintenance or cleaning procedures Workpiece and Work Area Set Up 1 SKU 97717 Designate a work area that is clean and well lit The work area must not allow access by children or pets to prevent injury and distraction Route the power cord along a safe route to reach the work area without creating a tripping hazard or exposing 1 the power cord to possible damage The power cord must reach the work area with enough extra length to allow free movement while working For technical questions please call 1 800 444 3353 Secure loose workpieces using a vise or clamps not included to
10. FACT THE MANUFACTURER AND OR DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS AND NOT BY THE BUYER THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO SKU 97717 For technical questions please call 1 800 444 3353 Page 13 PARTS LIST AND ASSEMBLY DIAGRAM vl L XYW NIIN 1 Oow Page 14 For technical questions please call 1 800 444 3353 SKU 97717 LIMITED 1 YEAR 90 DAY WARRANTY Harbor Freight Tools Co makes every effort to assure that its products meet high quality and durability standards and warrants to the original purchaser that for a period of ninety days from date of purchase that the torch liner wire feed mechanism if applicable welding clamps electrode holders cables and accessories packed with the welder are free of defects in materials and workmanship This Limited 90 Day 1 Year Warranty shall not apply to consumable parts such as tips welding wire and gas nozzles Harbor Freight Tools also warrants to the original purchaser for a period of one year from date of purchase that the transformer and rectifier are free from defects in materials and workmanship 90 days if used by a professional contr
11. actor or if used as rental equipment This warranty does not apply to damage due directly or indirectly to misuse abuse negligence or accidents repairs or alterations outside our facilities normal wear and tear or to lack of maintenance We shall in no event be liable for death injuries to persons or property or for incidental contingent special or consequential damages arising from the use of our product Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation of exclusion may not apply to you THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS To take advantage of this warranty the product or part must be returned to us with transportation charges prepaid Proof of purchase date and an explanation of the complaint must accompany the merchandise If our inspection verifies the defect we will either repair or replace the product at our election or we may elect to refund the purchase price if we cannot readily and quickly provide you with a replacement We will return repaired products at our expense but if we determine there is no defect or that the defect resulted from causes not within the scope of our warranty then you must bear the cost of returning the product This warranty gives you specific legal rights and you may also have other rights which vary from state to state 3491 Mission Oa
12. arge 2 Use smaller diameter electrode 3 Overloaded circuit 3 Run Arc Welder on dedicated 120 volt 20 Amp circuit Bead is intermittently too 1 Inconsistent travel speed 1 Decrease and maintain travel speed thin or too thick 2 Output Amp setting too low 2 Increase output Amp setting or change to smaller diameter electrode Electrode sticks to work 1 Arc length too short 1 Lift electrode to correct arc length as soon piece as arc is struck 2 Output Amp setting too low 2 Increase output Amp setting or change to smaller diameter electrode Electrodes sputter and 1 Damp electrodes 1 Use dry electrodes and store in a dry stick location Weld bead does not 1 Travel speed too fast 1 Decrease travel speed etrate base metal 2 Arc length too short 2 Increase arc length 3 Output Amp setting too low 3 Increase output Amp setting Ragged depressions at 1 Slow and or inconsistent travel speed 1 Increase and maintain travel speed edge of weld 2 Output Amp setting too high 2 Reduce output Amp setting PLEASE READ THE FOLLOWING CAREFULLY THE MANUFACTURER AND OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY NEITHER THE MANUFACTURER OR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT IN
13. ering a power tool will increase the risk of electric shock Do not abuse the cord Never use the cord for pulling or unplugging the power tool Keep cord away from heat oil sharp edges or moving parts Damaged or entangled cords increase the risk of electric shock When operating a power tool outdoors use an extension cord suitable for outdoor use Use of a cord suitable for outdoor use reduces the risk of electric shock Personal safety a Stay alert watch what you are doing and use common sense when operating a power tool Do not use a power tool while you are tired or under the influence of drugs alcohol or medication A moment of inattention while operating power tools may result in serious personal injury Use safety equipment Always wear ANSI approved safety glasses and arc shaded impact safety full face shield Safety equipment such as NIOSH approved respirator heavy duty work gloves non skid safety shoes or hearing protection used for appropriate conditions will reduce personal injuries Avoid accidental starting Ensure the switch is in the off position before plugging in Carrying power tools with your finger on the switch or plugging in power tools that have the switch on invites accidents a For technical questions please call 1 800 444 3353 Remove any adjusting key or wrench before turning the power tool on A wrench or a key left attached to a rotating part of the power tool
14. fire extinguisher within easy reach Thoroughly clean the object being welded of any paint grease or other foreign material Avoid unintentional starting Prepare to begin work before turning on the tool Do not leave the tool unattended when it is plugged into an electrical outlet Turn off the tool and unplug it from its electrical outlet before leaving Use clamps not included or other practical ways to secure and support the work piece to a stable platform Holding the work by hand or against your body is unstable and may lead to loss of control This product is not a toy Keep it out of reach of children Industrial applications must follow OSHA guidelines People with pacemakers should consult their physician s before use Electromagnetic fields in close proximity to heart pacemaker could cause pacemaker interference or pacemaker failure In addition people with pacemakers should Avoid operating alone Do not use with power switch locked on Properly maintain and inspect to Page 5 11 12 SKU 97717 avoid electrical shock Any power cord must be properly grounded Ground Fault Circuit Interrupter GFCI should also be implemented it prevents sustained electrical shock WARNING This product when used for welding plasma cutting soldering or similar applications produces chemicals known to the State of California to cause cancer and birth defects or other reproduct
15. ive harm California Health amp Safety Code 25249 5 et seq Prevent eye injury and burns Wearing and using 5 personal safety clothing and safety devices reduce the risk for injury e Wear ANSI approved safety impact eye goggles underneath welding eye protection featuring at least a Number 10 shade lens rating 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 13 14 15 16 17 18 19 For technical questions please call 1 800 444 3353 When welding cutting overhead or in confined spaces wear flame resistant ear plugs or ear muffs to keep sparks out of ears 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
16. ks Blvd PO Box 6009 Camarillo CA 93011 800 444 3353 Record Product s Serial Number Here Note If product has no serial number record month and year of purchase instead Note Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts SKU 97717 For technical questions please call 1 800 444 3353 Page 15
17. may result in personal injury Do not overreach Keep proper footing and balance at all times This enables better control of the power tool in unexpected situations Power tool use and care Do not force the power tool Use the correct power tool for your application The correct power tool will do the job better and safer at the rate for which it was designed Do not use the power tool if the switch does not turn it on and off Any power tool that cannot be controlled with the switch is dangerous and must be repaired Disconnect the plug from the power source before making any adjustments changing accessories or storing power tools Such preventive safety measures reduce the risk of starting the power tool accidentally Store idle power tools out of the reach of children and do not allow persons unfamiliar with the power tool or these instructions to operate the power tool Power tools are dangerous in the hands of untrained users Maintain power tools Check for misalignment or binding of moving parts breakage of parts and any other condition that may affect the power tool s operation If damaged have the power tool repaired before use Many accidents are caused by poorly maintained power tools Page 4 SKU 97717 f Use the power tool accessories and tool bits etc in accordance with these instructions and in the manner intended for the particular type of power tool taking into acc
18. n heated can produce flammable or explosive vapors Clean and purge containers before applying heat Vent closed containers including castings before preheating welding or cutting 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 Protect yourself from electric shock Do not use outdoors Insulate yourself from the work piece 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 Ensure that the unit is placed on a stable location before use If this unit 23 24 26 26 27 For technical questions please call 1 800 444 3353 falls while plugged in severe injury electric shock or fire may result 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 Follow OSHA guidelines for Permissible Exposure Limits PEL s for variou
19. of grounded objects turn the Power Switch 13 to its ON position See Assy Diagram Hold the Welding Shield in front of your eyes WARNING Never look at the ignited arc without ANSI approved arc shaded eye protection in a full face shield Permanent eye damage or blindness can occur Skin burns can occur Wear a NIOSH approved respirator to avoid breathing arc fumes 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 Once the arc is ignited tilt the electrode backward 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 red light on the Control Panel will illuminate and the Welder will automatically shut off until it cools down If this happens turn the Power Page 11 15 Switch 13 to its OFF position and wait about 10 minutes Then restart the Welder See Assy Diagram When the weld is complete lift the electrode clearly away from any grounded object Set the Welding Shield down and turn the power Switch 13 to its OFF position See Assy Diagram Unplug the Powe
20. ount the working conditions and the work to be performed Use of the power tool for operations different from those intended could result in a hazardous situation Service a Have your power tool serviced by a qualified repair person using only identical replacement parts This will ensure that the safety of the power tool is maintained Specific Safety Rules Maintain labels and nameplates on the tool These carry important safety information If unreadable or missing contact Harbor Freight Tools for a replacement Avoid electrical shock Do not permit electrically live parts cables or electrodes to contact skin clothing or gloves Wear ANSI approved protective clothing This unit draws enough current to cause serious injury or death 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 Avoid eye and body damage Arc rays and infrared radiation can injure eyes and burn skin Wear ANSI approved eye and body For technical questions please call 1 800 444 3353 protection Do not allow viewing by visitors without proper eye and body protection Use a Face Shield with arc shaded filter plate Move flammable and explosive material at least 35 feet from the welding arc to prevent welding sparks or molten metal from starting a fire Keep a type ABC
21. r Cord 8 from the electrical outlet See Assy Diagram Remove the clamped Ground Cable from the object it is clamped onto Then remove the electrode from the Electrode Holder 9 See Assy Diagram Clean and store the Arc Welder indoors out of reach of children and other unauthorized people IMPORTANT Please read the included Weld Diagnosis Pamphlet for tips and suggestions concerning welding and proper usage MAINTENANCE AND SERVICING Procedures not specifically explained in this manual SKU 97717 must be performed only by a qualified technician AWARNING TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION Turn the Power Switch of the tool to its OFF position and unplug the tool from its electrical outlet before performing any inspection maintenance cleaning or storage procedures 1 BEFORE EACH USE inspect the general condition of the Arc Welder Check for cracked or missing insulators damaged electrical wiring and any other condition that may affect its safe operation If abnormal noise or vibration occurs have the problem corrected before further use Do not use damaged equipment 2 AFTER USE clean external surfaces of the Arc Welder with a clean cloth Use compressed air to blow all dust and debris from the ventilation openings Do not hold the air nozzle too close to the ventilation openings 3 AFTER USE store the Arc Welder in a clean dry safe location out of
22. s 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 or cutting situation Page 7 INHALATION HAZARD Welding and Plasma Cutting Produce TOXIC FUMES Exposure to welding or cutting exhaust fumes 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 or plasma cutting exhaust fumes are Early onset of Parkinson s Disease Heart disease Ulcers Damage to the reproductive organs Inflammation of the small intestine or stomach Kidney damage Respiratory diseases such as emphysema bronchitis or pneumonia Use natural or forced air ventilation and wear a respirator approved by NIOSH to protect against the fumes produced to reduce the risk of developing the above illnesses 28 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 97
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