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Chicago Electric 55167 Assembly And Operating Instructions Manual

90 amp flux wire welder
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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
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 and replacement parts, please call 1-800-444-3353.

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Summary of Contents for Chicago Electric 55167

  • Page 1 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.

  • Page 2: Table Of Contents

    Contact Tip Inspection, Cleaning, and Replacement ... 21 Parts Lists and Diagrams ...22 Wiring Schematic ... 22 Parts List ... 23 Assembly Diagram ... 24 Troubleshooting ...26 For technical questions, please call 1-800-444-3353; SKU 55167 Troubleshooting section at end of manual. Contents Page 2...

  • Page 3: Specifications

    Keep bystanders, children, and visitors away while operating a power tool. For technical questions, please call 1-800-444-3353; SKU 55167 Troubleshooting section at end of manual. SPECIFICATIONS 63 ~ 68 amps; High setting: 79 ~ 90 amps 10% at 80 amps;...

  • Page 4: Electrical Safety

    Use safety equipment. Always wear eye protection. For welding safety equipment, refer to number 7 on page 6. For technical questions, please call 1-800-444-3353; SKU 55167 Troubleshooting section at end of manual. Electrical Safety Personal Safety...

  • Page 5: Specific Safety Rules

    Maintain labels and nameplates on the Welder. These carry important information. If unreadable or missing, contact Harbor Freight Tools for a replacement. Maintain a safe working environment. Keep the work area well lit. Make sure there is adequate surrounding workspace.
  • Page 6 Unplug before performing maintenance. Always unplug the Welder from its electrical outlet before performing any inspection, maintenance, or cleaning procedures. Never leave the Welder unattended while energized. Turn power off if you have to leave the Welder. Maintain a safe working environment. Keep the work area well lit. Make sure there is adequate surrounding workspace.
  • Page 7 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. For technical questions, please call 1-800-444-3353; SKU 55167 Troubleshooting section at end of manual. •...

  • Page 8: Grounding

    Use care not to touch the welding tip to grounded material whenever the unit is plugged in. This unit is what is referred to as a “hot tip” welder, meaning that current is available to the wire at all times that the power Switch (7a) is in the ON position.

  • Page 9: Extension Cords

    Protect your extension cords from sharp objects, excessive heat, and damp or wet For technical questions, please call 1-800-444-3353; SKU 55167 Troubleshooting section at end of manual. Outlets for 2-Prong Plug ExTENSION CORDS...

  • Page 10: Symbology

    12.1 - 16.0 16.1 - 20.0 FIGURE C n 0 xxxx/min. For technical questions, please call 1-800-444-3353; SKU 55167 Troubleshooting section at end of manual. ExTENSION CORD LENGTH 50 Feet 75 Feet * Based on limiting the line voltage drop to five volts at 150% of the rated amperes.

  • Page 11: Unpacking

    This unit is packed with a protective light film of oil, wipe the unit of with a clean rag prior to assembly. 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.

  • Page 12: Installing The Wire Reel

    Screw (37) Spring (36) INSTALLING THE WIRE REEL WARNING! Turn the welder OFF and unplug it before proceeding. Press on the Cover Locking Spring (8), then lift the Cover (31) using Handle (30), to expose the Wire Feed Unit (23).

  • Page 13: Changing Wire Feed Roller

    To check the wire’s drive tension, feed the wire against a piece of wood from 2 to 3 inches away. If the wire stops instead of bending, turn the welder OFF, unplug it, and slightly tighten the Wire Tension Adjusting Screw (37).

  • Page 14: Trigger Switch Replacement

    Torch with the Wrench (43). Test and adjust the drive tension as explained in steps 12-14 on the previous page. Close the welder’s cover and switch the Welder OFF. Unplug the Welder if it is not to be used at this time.

  • Page 15: Operation

    For example, this Welder with a 10% duty cycle at 80 amps must be allowed to rest for at least 9 minutes after every minute of continuous weld at 80 amps. Failure to carefully observe duty cycle limitations can easily over stress a welder’s power generation system contributing to premature welder...

  • Page 16: Setting Up The Weld

    18 of this manual. DO NOT SWITCH THE CURRENT WHILE WELDING. Verify that the Power Switch is in the OFF position, then plug the Flux Wire Welder plug into a dedicated, 110 VAC, 20 amp line with delayed action type circuit breaker or fuses.

  • Page 17: Holding The Torch

    Note: If too much current is drawn from the Flux Wire 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 3 ~ 5 minutes.

  • Page 18: Weld Settings Chart

    For technical questions, please call 1-800-444-3353; SKU 55167 Page 18 Troubleshooting section at end of manual.

  • Page 19: Weld Diagnosis

    Keep arc on leading edge of weld puddle. Hold gun at proper angles as stated under Holding The Torch on page 17. For technical questions, please call 1-800-444-3353; SKU 55167 Troubleshooting section at end of manual. WELD DIAGNOSIS WELD PENETRATION PROPER Weld is visible underneath and bulges slightly on top.
  • Page 20 When the weld is complete, lift the electrode wire clearly away from any grounded object, set the Face Shield down, turn toward the Flux Wire Welder, and turn the Power Switch to the OFF position.

  • Page 21: Maintenance

    Warning: Before performing any maintenance on the Welder, unplug the Power Cord from the electrical outlet and allow all parts of the welder to cool thoroughly. Periodically remove the Right and Left side panels (12 and 13), and using compressed air, blow out all dust from the interior.

  • Page 22: Parts Lists And Diagrams

    PARTS LISTS AND DIAGRAMS WIRING SCHEMATIC For technical questions, please call 1-800-444-3353; SKU 55167 Page 22 Troubleshooting section at end of manual.

  • Page 23: Parts List

    ITY 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. For technical questions, please call 1-800-444-3353; SKU 55167 Troubleshooting section at end of manual. PARTS LIST q’ty...

  • Page 24: Assembly Diagram

    ASSEMBLY DIAGRAM NOTE: Some parts are listed and shown for illustration purposes only and are not avail- able individually as replacement parts. For technical questions, please call 1-800-444-3353; SKU 55167 Page 24 Troubleshooting section at end of manual.
  • Page 25 For technical questions, please call 1-800-444-3353; SKU 55167 Page 25 Troubleshooting section at end of manual.

  • Page 26: Troubleshooting

    Be CERTAIN to shut off the Welder, disconnect it from power, and discharge the torch to ground before adjusting, cleaning, or repairing the unit. WIRE FEED MOTOR RUNS BUT WIRE DOES NOT FEED PROPERLY POSSIBLE CAUSES AND SOLUTIONS 1. Insufficient wire feed pressure: Increase wire feed pressure properly - follow steps 12-15 on page 13.
  • Page 27 TROUBLESHOOTING (continued) Be CERTAIN to shut off the Welder, disconnect it from power, and discharge the torch to ground before adjusting, cleaning, or repairing the unit. POWER SWITCH (7A) DOES NOT LIGHT WHEN SWITCHED ON POSSIBLE CAUSES AND SOLUTIONS 1. Unit is not connected to outlet properly or outlet is unpowered: Verify the voltage at the outlet and the connection to the outlet.

  • Page 28: Weak Arc Strength

    TROUBLESHOOTING (continued) Be CERTAIN to shut off the Welder, disconnect it from power, and discharge the torch to ground before adjusting, cleaning, or repairing the unit. WIRE FEEDS, BUT ARC DOES NOT IGNITE POSSIBLE CAUSES AND SOLUTIONS 1. Improper ground connection: Make certain that the workpiece is contacted properly by the Ground Clamp and that the workpiece is properly cleaned near the ground clamp and the welding location.

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