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Chicago Electric 68886 manual

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Table of contents for the manual

  • Page 1

    Visit our website at: http://www .harborfreight.com Email our technical support at: tech@harborfreight.com Read this material before using this product. Failure to do so can result in serious injury . SA VE THIS MANUAL. Copyright © 201 1 by Harbor Freight T ools ® . All rights reserved. No portion of this manual or any artwork contained herein ma[...]

  • Page 2

    Page 2 For technical questions, please call 1-800-444-3353. SKU 68886 T able of Contents Safety ......................................................... 2 Setup .......................................................... 7 Specifications ............................................. 7 Basic Welding ............................................ 15 We[...]

  • Page 3

    Page 3 For technical questions, please call 1-800-444-3353. SKU 68886 Fume and Gas Safety FUMES AND GASES can be hazardous to your health. 1. 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 o[...]

  • Page 4

    Page 4 For technical questions, please call 1-800-444-3353. SKU 68886 Electrical Safety ELECTRIC SHOCK can KILL. 1. T urn off, disconnect power , and discharge electrode to ground before setting down torch/electrode holder and before service. 2. Do not touch energized electrical parts. Wear dry , insulating gloves. Do not touch electrode holder , e[...]

  • Page 5

    Page 5 For technical questions, please call 1-800-444-3353. SKU 68886 W elder use and care 1. Do not use the welder if the switch does not turn it on and off. Any welder that cannot be controlled with the switch is dangerous and must be repaired. 2. Disconnect the plug from the power source before making any adjustments, changing accessories, or st[...]

  • Page 6

    Page 6 For technical questions, please call 1-800-444-3353. SKU 68886 Grounding TO PREVENT ELECTRIC SHOCK AND DEA TH FROM INCORRECT GROUNDING WIRE CONNECTION: Check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded. Have a plug installed by a certified electrician. Do not use the welder if the power cord[...]

  • Page 7

    Page 7 For technical questions, please call 1-800-444-3353. SKU 68886 Symbology Wire Feed (Speed) Workpiece Ground Cable T orch Cable Overheat Shutdown Indicator Cooling Fan Housing Ground Point V~ V olts Alternating Current A Amperes OCV Open Circuit V oltage K VA Kilovolt Amperes (V olts / 1000 * Amperes) IPM Inches Per Minute AW G American Wire [...]

  • Page 8

    Page 8 For technical questions, please call 1-800-444-3353. SKU 68886 1. Attach the handle to the Face Shield by lining up the two rectangular tabs on the handle with the corresponding holes in the face shield and A. press the tabs through the holes and then B. slide the tabs forward from the back, locking the round tab in place. 2. Wear heavy-duty[...]

  • Page 9

    Page 9 For technical questions, please call 1-800-444-3353. SKU 68886 Wire Spool Installation 1. T urn the welder OFF and unplug it before proceeding. 2. Pull up on the door latch, then open the Door . 3. Remove the Spool Knob, Spool Spring, and upper Spool Plate. If replacing a Spool, remove the old Spool and all remaining wire from the liners. 4.[...]

  • Page 10

    Page 10 For technical questions, please call 1-800-444-3353. SKU 68886 6a. Flux Core (Gas-less) Wire Setup: Remove the two Knobs securing the cables. Connect the Black Ground Cable to the rear , red, positive T erminal using the Knob. Connect the Red T orch Cable to the front, black, negative T erminal using the other Knob. This is the initial setu[...]

  • Page 11

    Page 1 1 For technical questions, please call 1-800-444-3353. SKU 68886 7. T urn the Feed T ensioner knob counterclockwise to loosen it enough to pull it down to remove tension. (Do not loosen the T ensioner knob too much, or the T ensioner will come apart.) Then, swing the Feed Swing Arm up. 8. Feed Roller Instructions: Check that the Feed Roller [...]

  • Page 12

    Page 12 For technical questions, please call 1-800-444-3353. SKU 68886 IMPORT ANT : Securely hold onto the end of the welding wire and keep tension on it during the following steps. If this is not done, the welding wire will unravel and create a tangled “bird’ s nest”, wasting wire. 9. Cut off all bent and crimped wire. The cut end must have [...]

  • Page 13

    Page 13 For technical questions, please call 1-800-444-3353. SKU 68886 W ARNING The following steps require applying power to the welder with the cover open. T o prevent serious injury from fire or electric shock: 1. Do not touch anything (especially not the Ground Clamp) with the T orch or welding wire, or an arc may be ignited. 2. Do not touch in[...]

  • Page 14

    Page 14 For technical questions, please call 1-800-444-3353. SKU 68886 17. T o 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, slightly tighten the feed tensioner clockwise, and try again. If the wire bends from the feed pressure[...]

  • Page 15

    Page 15 For technical questions, please call 1-800-444-3353. SKU 68886 Basic Welding Read the ENTIRE IMPORT ANT SAFETY INFORMA TION section at the beginning of this manual including all text under subheadings therein before welding. TO PREVENT SERIOUS INJUR Y : Protective gear must be worn when using the Welder; minimum shade number 10 full face sh[...]

  • Page 16

    Page 16 For technical questions, please call 1-800-444-3353. SKU 68886 Control Panel Layout Overload Indicator: This lights up if duty cycle work period is exceeded, resulting in overheating the welder . Rest the T orch on an electrically non-conductive, heat-resistant surface, such as a concrete slab, well clear of the ground clamp while allowing [...]

  • Page 17

    Page 17 For technical questions, please call 1-800-444-3353. SKU 68886 A void damage to the Welder by not welding for more than the prescribed duty cycle time. The Duty Cycle defines the number of minutes, within a 10 minute period, during which a given welder can produce a particular welding current without overheating. For example, this Welder wi[...]

  • Page 18

    Page 18 For technical questions, please call 1-800-444-3353. SKU 68886 Metal Thickness Flux W eld Settings DCEN Polarity NO GAS Material Being Welded Wire T ype Shielding Gas Wire Diameter Suggested Settings 22 Ga .030″ 0.8mm 18 Ga .048″ 1.2mm 16 Ga .060″ 1.5mm 14 Ga .075″ 2.0mm 1/8″ 3.2mm 3/16″ 4.8mm 1/4″ 6.4mm Mild Steel Flux-core ([...]

  • Page 19

    Page 19 For technical questions, please call 1-800-444-3353. SKU 68886 1. Make practice welds on pieces of scrap the same thickness as your intended workpiece to practice technique before welding anything of value. Clean the weld surfaces thoroughly with a wire brush or angle grinder; there must be no rust, paint, oil, or other materials on the wel[...]

  • Page 20

    Page 20 For technical questions, please call 1-800-444-3353. SKU 68886 DANGER! TO PREVENT DEA TH FROM ASPHYXIA TION: Do not open gas without proper ventilation. Fix gas leaks immediately . Shielding gas can displace air and cause rapid loss of consciousness and death. Shielding gas without carbon dioxide can be even more hazardous, because asphyxia[...]

  • Page 21

    Page 21 For technical questions, please call 1-800-444-3353. SKU 68886 1. Press (and hold) T rigger and contact area to be welded with electrode wire to ignite arc. 2. For a narrow weld, you can usually draw the wire in a steady straight line, this is called a stringer bead . For a wider weld, draw the wire back and forth across the joint, this is [...]

  • Page 22

    Page 22 For technical questions, please call 1-800-444-3353. SKU 68886 Note: If Welder is used too long, the amber Overload Indicator will light and the Welder T orch will shut off until the welder cools. If this happens, rest the T orch on an electrically non-conductive, heat-resistant surface, such as a concrete slab, well clear of the ground cla[...]

  • Page 23

    Page 23 For technical questions, please call 1-800-444-3353. SKU 68886 Welding T ips A good way to test welding technique is to examine a weld’s appearance after it has cooled and the slag has been removed. Then, better welding can be learned by adjusting your weld technique to remedy any problems found. A typical solid wire (GMA W) weld before c[...]

  • Page 24

    Page 24 For technical questions, please call 1-800-444-3353. SKU 68886 EXCESS PENETRA TION OR BURN-THROUGH PROPER PENETRA TION INADEQUA TE PENETRA TION Not hot enough T oo hot Ideal heat Weld Diagnosis W orkpiece Heat Control / W eld Penetration Good Weld Current T oo Low or Wire Feed T oo Slow Current T oo High or Wire Feed T oo Fast Weld Speed T [...]

  • Page 25

    Page 25 For technical questions, please call 1-800-444-3353. SKU 68886 EXCESS PENETRA TION OR BURN-THROUGH Weld droops on top and underneath, or falls through entirely , making a hole. PROPER PENETRA TION Weld is visible underneath and bulges slightly on top. INADEQUA TE PENETRA TION Weld does not contact the joint fully , just on the surface. POSS[...]

  • Page 26

    Page 26 For technical questions, please call 1-800-444-3353. SKU 68886 Burn-Through Base material melts away , leaving a hole in the weld. POSSIBLE CAUSES AND SOLUTIONS 1. Workpiece overheating: Reduce current and/or wire feed speed. 2. Welding speed too slow: Increase welding speed and ensure that welding speed is kept steady . 3. Excessive materi[...]

  • Page 27

    Page 27 For technical questions, please call 1-800-444-3353. SKU 68886 Maintenance TO PREVENT SERIOUS INJUR Y , FIRE AND BURNS: Unplug the welder , rest the T orch on a heat-proof, electrically non-conductive surface, and allow all parts of the Welder to cool thoroughly before service. 1. Periodically remove the Side Panel, and using compressed air[...]

  • Page 28

    Page 28 For technical questions, please call 1-800-444-3353. SKU 68886 T roubleshooting IMPORT ANT! Be CERT AIN to shut off the Welder , disconnect it from power , and discharge the T orch 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 w[...]

  • Page 29

    Page 29 For technical questions, please call 1-800-444-3353. SKU 68886 T roubleshooting (continued) IMPORT ANT! Be CERT AIN to shut off the Welder , disconnect it from power , and discharge the T orch to ground before adjusting, cleaning, or repairing the unit. Power switch lights, but welder does not function when switched on POSSIBLE CAUSES AND S[...]

  • Page 30

    Page 30 For technical questions, please call 1-800-444-3353. SKU 68886 Parts List and Diagrams Wiring Diagram Welding T orch Gas/Gasless Gasless Gas Ground Clamp Wire Feed Motor Thermal Relay Welding T orch Switch Parts List Record Serial Number Here: Note: If product has no serial number , record month and year of purchase instead. Note: Some part[...]

  • Page 31

    Page 31 For technical questions, please call 1-800-444-3353. SKU 68886 Assembly Diagram 12345678 9 10 11 12 13 14 32 31 30 29 28 27 26 25 15 16 17 18 19 20 21 22 23 24 33 35 36 37 34 SAFETY MAINTENANCE BASIC WELDING WELDING TIPS SETUP[...]

  • Page 32

    3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 9301 1 • (800) 444-3353 Limited 90 Day W arranty Harbor Freight T ools Co. makes every effort to assure that its products meet high quality and durability standards, and warrants to the original purchaser that this product is free from defects in materials and workmanship for the period of[...]