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Chicago Electric 68887 manual

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Table of contents for the manual

  • Page 1

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  • Page 2

    Page 2 For technical questions, please call 1-800-444-3353. SKU 68887 T able of Contents Safety ......................................................... 2 Specifications ............................................. 7 Setup .......................................................... 7 Basic Welding ............................................ 12 We[...]

  • Page 3

    Page 3 For technical questions, please call 1-800-444-3353. SKU 68887 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 68887 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 68887 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 68887 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 68887 Specifications Electrical Rating 120V~ / 20A Welding Output 60 ~ 120 A, AC Capacity 18 gauge (0.048″) to 3/16″ (0.19″) mild steel only Not for welding aluminum or stainless steel Duty Cycle 20% @ 90A (See explanation on page 14) Open Circuit V oltage 27 K VA 2.38 Welder T i[...]

  • Page 8

    Page 8 For technical questions, please call 1-800-444-3353. SKU 68887 1. T urn the Welder to OFF and unplug it before proceeding. 2. Press in the pin at the top center of the control panel and open the cover . 3. Remove the Knob, Spring and the T op Plate. If replacing a Spool, remove the old Spool and all remaining wire from the liners. 4. Place t[...]

  • Page 9

    Page 9 For technical questions, please call 1-800-444-3353. SKU 68887 6. T urn the Feed T ensioner counterclockwise to loosen it enough to pull it up, releasing tension. Swing the Feed Swing Arm out. (Note: Do not loosen the Feed T ensioner too much, or it will come apart.) 7. Loosen and remove the Feed Knob. Compare the wire diameter marked on the[...]

  • Page 10

    Page 10 For technical questions, please call 1-800-444-3353. SKU 68887 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 Gun or welding wire or an arc will be ignited. 2. Do not touch inter[...]

  • Page 11

    Page 1 1 For technical questions, please call 1-800-444-3353. SKU 68887 16. 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 to OFF , unplug it, slightly tighten the Feed T ensioner clockwise , and try again. If the wire bends from the feed te[...]

  • Page 12

    Page 12 For technical questions, please call 1-800-444-3353. SKU 68887 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 13

    Page 13 For technical questions, please call 1-800-444-3353. SKU 68887 Control Panel Layout ON MIN OFF MAX WIRE FEED SPEED GUN GROUND 120V~ 60Hz 20A 90 AMP FLUX WIRE WELDER I T EM 68887 Wire .030″-.035″ Flux-core Capacity XX Ga. – X / X ″ Steel Plate Cables Electrode – X ′ Ground Clamp – X ′ Wire Speed Dial Gun Cable Ground Cable Cu[...]

  • Page 14

    Page 14 For technical questions, please call 1-800-444-3353. SKU 68887 W eld Settings Chart NOTE: The numbers within the spaces are the approximate wire feed settings recommended* for this wire size and material thickness. Material Thickness (Steel) 18 Gauge 16 Gauge 14 Gauge 1 / 8 ″ 3 / 16 ″ MIN current MAX current .030″ Wire Size (Flux Core[...]

  • Page 15

    Page 15 For technical questions, please call 1-800-444-3353. SKU 68887 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 16

    Page 16 For technical questions, please call 1-800-444-3353. SKU 68887 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 17

    Page 17 For technical questions, please call 1-800-444-3353. SKU 68887 Note: If Welder is used too long, the amber Overload Indicator will light and the Welder Gun will shut of f until the welder cools. If this happens, rest the Gun on an electrically non-conductive, heat-resistant surface, such as a concrete slab, well clear of the ground clamp. W[...]

  • Page 18

    Page 18 For technical questions, please call 1-800-444-3353. SKU 68887 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. Cleaning the W eld TO PREVENT SERIOUS INJUR Y : Continue[...]

  • Page 19

    Page 19 For technical questions, please call 1-800-444-3353. SKU 68887 Weld Diagnosis W orkpiece Heat Control / W eld Penetration EXCESS PENETRA TION OR BURN-THROUGH PROPER PENETRA TION INADEQUA TE PENETRA TION Not hot enough T oo hot Ideal heat How to increase workpiece heat and increase penetration: (to weld THICKER workpieces properly) How to re[...]

  • Page 20

    Page 20 For technical questions, please call 1-800-444-3353. SKU 68887 W eld Not Adhering Properly Gaps present between weld and previous bead or between weld and workpiece. See areas below . POSSIBLE CAUSES AND SOLUTIONS 1. Incorrect welding technique: Place stringer bead at correct place in joint. Adjust workpiece position or weld angle to permit[...]

  • Page 21

    Page 21 For technical questions, please call 1-800-444-3353. SKU 68887 Coat of Slag Over W eld Slag is a necessary part of a flux- core wire weld. It shields the weld from impurities. Clean off the slag with the Chipping Hammer and Wire Brush after welding. TO P VIEW P ARTIALL Y CHIPPED A W A Y TO SHOW WELD Burn-Through Base material melts away , l[...]

  • Page 22

    Page 22 For technical questions, please call 1-800-444-3353. SKU 68887 Maintenance TO PREVENT SERIOUS INJUR Y , FIRE AND BURNS: Unplug the Welder , rest the Gun on a heat-proof, electrically non-conductive surface, and allow all parts of the Welder to cool thoroughly before service. 1. Periodically remove the Right and Left side panels, and using c[...]

  • Page 23

    Page 23 For technical questions, please call 1-800-444-3353. SKU 68887 Contact T ip Inspection, Cleaning, and Replacement 1. Make sure that the entire Gun is completely cool and that the Power Cord is unplugged from the electrical outlet before proceeding. 2. Remove the Nozzle as explained in the previous subheading. Using the third oval hole on th[...]

  • Page 24

    Page 24 For technical questions, please call 1-800-444-3353. SKU 68887 T roubleshooting IMPORT ANT! Be CERT AIN to shut off the Welder , disconnect it from power , and discharge the Gun to ground before adjusting, cleaning, or repairing the unit. Wire Feed Motor Runs But W ire Does Not Feed Properly POSSIBLE CAUSES AND SOLUTIONS 1. Insufficient wir[...]

  • Page 25

    Page 25 For technical questions, please call 1-800-444-3353. SKU 68887 TROUBLESHOOTING (continued) IMPORT ANT! Be CERT AIN to shut off the Welder , disconnect it from power , and discharge the Gun to ground before adjusting, cleaning, or repairing the unit. Power Switch Lights, But W elder Does Not Function When Switched On POSSIBLE CAUSES AND SOLU[...]

  • Page 26

    Page 26 For technical questions, please call 1-800-444-3353. SKU 68887 Parts Lists and Diagrams Wiring Schematic R MAX S2 S1 T1 MIN B b Q A C 1 1 2 3 2 3 4 J G 1 2 3 4 24V Parts List 1 Grounding Cable 1 2 MIG T orch 1 3 Potentiometer Knob 1 4 Indicator 1 5 MIG T orch Holder 1 6 Font Panel 1 7 Left Panel 1 8 Middle Panel 1 9 Wire Feeder 1 10 Pin Lat[...]

  • Page 27

    Page 27 For technical questions, please call 1-800-444-3353. SKU 68887 Part 9 Detail .030″ 9a 9d 9f (hidden by part 9e) 9e 9b 9c 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 ind[...]

  • Page 28

    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[...]