Chicago Electric 95629 - Manuals

Page 2 - troubleshooting section at end of manual.; Contents

for technical questions, please call 1-800-444-3353; troubleshooting section at end of manual. Page 2 SKU 95424, 95629 Contents spECIfICAtIOns ............................................................................ 3GEnERAL sAfEty RULEs .............................................................

Page 3 - pLEAsE nOtE; Models; ARC option mode available in the 95424 MIG/ARC Welder.; spECIfICAtIOns; sAVE tHIs MAnUAL

for technical questions, please call 1-800-444-3353; troubleshooting section at end of manual. Page 3 SKU 95424, 95629 pLEAsE nOtE Models 95424 MIG/ARC WELDER and 95629 DUAL MIG WELDER have identi- cal features except for the ARC option mode available in the 95424 MIG/ARC Welder. The other features ...

Page 4 - GEnERAL sAfEty RULEs; READ AnD UnDERstAnD ALL InstRUCtIOns; WORK AREA

for technical questions, please call 1-800-444-3353; troubleshooting section at end of manual. Page 4 SKU 95424, 95629 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 tH...

Page 5 - pERsOnAL sAfEty

for technical questions, please call 1-800-444-3353; troubleshooting section at end of manual. Page 5 SKU 95424, 95629 pERsOnAL sAfEty stay alert. Watch what you are doing, and use common sense when operat-ing a power tool. Do not use a power tool while tired or under the influence of drugs, alcohol...

Page 6 - sERVICE; section of this manual.; spECIfIC sAfEty RULEs; Industrial applications must follow OsHA guidelines.

for technical questions, please call 1-800-444-3353; troubleshooting section at end of manual. Page 6 SKU 95424, 95629 Check for misalignment or binding of moving parts, breakage of parts, and any other condition that may affect the tool’s operation. If damaged, have the tool serviced before using. ...

Page 8 - Inhalation Hazard; Welding produces tOxIC fUMEs and GAssEs.; Exposure to welding gasses can increase the risk of developing

for technical questions, please call 1-800-444-3353; troubleshooting section at end of manual. Page 8 SKU 95424, 95629 material whose contents, when heated, can produce flammable or explosive va-pors. Clean and purge containers before applying heat. Vent closed containers, including castings, before...

Page 10 - Grounding; be installed by a certified electrician.; GROUnDED tOOLs: tOOLs WItH tHREE pROnG pLUGs; an electrically “live” terminal.; Extension Cords

for technical questions, please call 1-800-444-3353; troubleshooting section at end of manual. Page 10 SKU 95424, 95629 Grounding nOtE: this Welder requires the installation of a 3-prong, 230 VAC, polarized, twistlock power Cord plug (not included). nEMA configuration # L6-40 or equivalent. the plug...

Page 11 - UnpACKInG; When unpacking, make sure all parts shown on the; parts Lists near the end of; AssEMbLy InstRUCtIOns; AttACHInG tHE WHEELs; stationary

for technical questions, please call 1-800-444-3353; troubleshooting section at end of manual. Page 11 SKU 95424, 95629 UnpACKInG When unpacking, make sure all parts shown on the parts Lists near the end of this manual are included. If any parts are missing or broken, call Harbor Freight Tools. AssE...

Page 12 - Washer and Bolt

for technical questions, please call 1-800-444-3353; troubleshooting section at end of manual. Page 12 SKU 95424, 95629 AssEMbLy InstRUCtIOns (COntInUED) stationary Mobile Set the Axle (36A) with the Back Wheels (37A) attached against the bottom of the case. Then, screw the Bolts through the Washers...

Page 13 - InstALLInG A WIRE spOOL; for use with a 7” spool:; TO INSTALL THE WIRE SPOOL; for use with a 11” spool:; TO INSTALL THE WIRE SPOOL

for technical questions, please call 1-800-444-3353; troubleshooting section at end of manual. Page 13 SKU 95424, 95629 InstALLInG A WIRE spOOL Assembling the Wire Spool depends on whether you are using a 7” Spool or an 11” Spool. for use with a 7” spool: MIG&ARC 250 AMP - SKU 95424 MIG DUAL 250...

Page 14 - ROUtInG tHE WIRE; Welding Wire; Attach a Spool with the help of latch.

for technical questions, please call 1-800-444-3353; troubleshooting section at end of manual. Page 14 SKU 95424, 95629 ROUtInG tHE WIRE note: When installing wire of different size or composition, you will also need to change wire settings, set gun polarity, and, possibly, install gas cylinder. (se...

Page 17 - CHAnGInG WIRE sEttInGs; outlet prior to changing wire settings.; TO CHANGE WIRE SETTINGS; prior to changing wire settings.; TO ATTACH THE GROUND CABLE WITH CLAMP; and twist the Connecting Plug to lock it in place.; FIGURE F; Flip each Roller 180 degrees.; AttACHInG tHE GROUnD CAbLE WItH CLAMp

for technical questions, please call 1-800-444-3353; troubleshooting section at end of manual. Page 17 SKU 95424, 95629 CHAnGInG WIRE sEttInGs WARnInG! Make sure to turn off the Welder and unplug it from its electrical outlet prior to changing wire settings. Lift the Door (14A) of the Welder to expo...

Page 18 - sEttInG pOLARIty fOR WELDInG typE; Always read and follow wire manufacturer’s rec-; SETTING THE GUN & ELECTRODE POLARITY FOR WELDING TYPE

for technical questions, please call 1-800-444-3353; troubleshooting section at end of manual. Page 18 SKU 95424, 95629 sEttInG pOLARIty fOR WELDInG typE WARnInG! Always turn welder off and disconnect it from it’s electrical supply before opening the case or performing any adjustment, including the ...

Page 19 - InstALLInG A GAs CyLInDER; WARnInG: Using an oversized gas cylinder can cause tipping, result-; TO INSTALL A GAS CYLINDER; shielding gas. To use CO; Make sure to check the Welding Wire manufacturer’s recom-; FIGURE G; Make sure to check the Welding Wire manufacturer’s

for technical questions, please call 1-800-444-3353; troubleshooting section at end of manual. Page 19 SKU 95424, 95629 InstALLInG A GAs CyLInDER WARnInG: Using an oversized gas cylinder can cause tipping, result- ing in cylinder and equipment damage and personal injury. nEVER exceed maximum cylinde...

Page 20 - OpERAtInG InstRUCtIOns; bEfORE yOU bEGIn WELDInG; Continuous; Other settings fall between these two ranges.; help prevent excess wear to the Welder.

for technical questions, please call 1-800-444-3353; troubleshooting section at end of manual. Page 20 SKU 95424, 95629 OpERAtInG InstRUCtIOns bEfORE yOU bEGIn WELDInG Good welding requires a high degree of skill and experience. You should practice a few sample welds on scrap metal before you begin ...

Page 21 - sEttInG Up tHE WELD; Selector Knob based on thickness of the metal being welded.

for technical questions, please call 1-800-444-3353; troubleshooting section at end of manual. Page 21 SKU 95424, 95629 sEttInG Up tHE WELD WARnInG! before welding, make sure to read and understand all safety precautions and warnings discussed on pages 4 through 10. power switch (1C): Always make su...

Page 22 - MIG WELDInG sEt Up; gas hose to the rear of; Make sure the Power Switch (1C) is in its; NOTE: Welder MIG DUAL 250 AMP has no about the WIRE FEED SPEED KNOB; FIGURE; Turn the; Wire feed speed Knob (3C) to the appropriate sector. The RED; Electrode Indicator (4C) will light up and the wire will not move.

for technical questions, please call 1-800-444-3353; troubleshooting section at end of manual. Page 22 SKU 95424, 95629 MIG WELDInG sEt Up If using solid-core wire, connect and secure an Argon/ CO 2 gas hose to the rear of the Welder. (If using flux core wire, protective gas is not required.) 9. Mak...

Page 23 - WELD SETTINGS CHART; This Chart is intended to show; general; guidelines for different wire sizes and for dif-; MIG WELD sEttInGs CHARt; fIGURE j

for technical questions, please call 1-800-444-3353; troubleshooting section at end of manual. Page 23 SKU 95424, 95629 MIG&ARC 250 AMP - SKU 95424 MIG DUAL 250 AMP – SKU For technical questions, please call 1-800-444-3353; Troubleshooting section at end of manual. Page 25 WELD SETTINGS CHART Th...

Page 24 - HOLDInG tHE WELDInG tORCH/ELECtRODE HOLDER; WARnInG! never look at the ignited arc without AnsI-approved,

for technical questions, please call 1-800-444-3353; troubleshooting section at end of manual. Page 24 SKU 95424, 95629 Turn the Power Switch (1C) to its “Off” position. Clamp the bare end of the selected electrode in the electrode holder. Electrode Penetration Attributes NI-CL Shallow For cast Iron...

Page 25 - width must not be more than 2.5 times the electrode diameter.; “Off” position; and wait 3 to 5 minutes for the unit to cool down.; WHEn tHE WELD Is COMpLEtED; fIGURE L

for technical questions, please call 1-800-444-3353; troubleshooting section at end of manual. Page 25 SKU 95424, 95629 If the electrode fuses to the workpiece, quickly twist to release it and lift it slightly farther on your next attempt. The Welding Wire/Electrode should be directed straight into ...

Page 26 - Turn the Nozzle (1E) counterclockwise while pulling to remove.

for technical questions, please call 1-800-444-3353; troubleshooting section at end of manual. Page 26 SKU 95424, 95629 InspECtIOn, MAIntEnAnCE, AnD CLEAnInG WARnInG! before performing any maintenance on the Welder, unplug the power Cord (1A) from its electrical outlet and allow all components of th...

Page 27 - REpLACInG tHE WELDInG tORCH LInER (MIG OnLy); REPLACING THE WELDING TORCH LINER; WARRAnty; LIMIted 90 dAy/1 yeAr wArrAnty

for technical questions, please call 1-800-444-3353; troubleshooting section at end of manual. Page 27 SKU 95424, 95629 REpLACInG tHE WELDInG tORCH LInER (MIG OnLy) REPLACING THE WELDING TORCH LINER Remove NOZZLE, slip type. Remove TIP. 1.Disconnect GUN TERMINAL (11D) & TERMI NAL (12D). 2.Untwis...

Page 28 - pARts LIsts AnD DIAGRAMs; pARts LIst A; pLEAsE READ tHE fOLLOWInG CAREfULLy

for technical questions, please call 1-800-444-3353; troubleshooting section at end of manual. Page 28 SKU 95424, 95629 pARts LIsts AnD DIAGRAMs pARts LIst A part Description Qty. 1A Power Cord (8 AWG x 3C: 250V)l 1 2A Power Cord Clip 1 3A Chain 1 4A Hose Connector 1 5A Arm 1 6A Rear Panel/Base 1 7A...

Page 29 - AssEMbLy DIAGRAMs; figure L

for technical questions, please call 1-800-444-3353; troubleshooting section at end of manual. Page 29 SKU 95424, 95629 n O t E : Some par ts are listed and sho wn f or illustr ation pur poses only and are not a vailab le individually as replacement par ts . AssEMbLy DIAGRAMs MIG&ARC 250 AMP - S...

Page 30 - figure M; PARTS LISTS & ASSEMBLY DIAGRAMS

for technical questions, please call 1-800-444-3353; troubleshooting section at end of manual. Page 30 SKU 95424, 95629 AssEMbLy DIAGRAMs (COntInUED) part Description Qty. 1B Main Transformer 1 2B Rectifier 2 3B Fixing Corner 1 4B Hose Connector 1 part Description Qty. 5B Filter Reactor w/ Thermo Re...

Page 31 - figure n; Figure N

for technical questions, please call 1-800-444-3353; troubleshooting section at end of manual. Page 31 SKU 95424, 95629 AssEMbLy DIAGRAMs (COntInUED) front panel #23A part Description Qty. 1C Power Switch 1 2C Overload Indicator 1 3C Wire Feed Speed Knob 1 4C Electrode Welding Indicator (only for 95...

Page 32 - Figure O; figure O

for technical questions, please call 1-800-444-3353; troubleshooting section at end of manual. Page 32 SKU 95424, 95629 AssEMbLy DIAGRAMs (COntInUED) Wire Drive Assembly #16A part Description Qty. 1D Gear Motor 1 2D Base 1 3D Lever 1 4D Drive Handle (4D) 1 4.1D Handle (4D) 1 4.2D Spring 1 4.3D Axle ...

Page 33 - figure p

for technical questions, please call 1-800-444-3353; troubleshooting section at end of manual. Page 33 SKU 95424, 95629 AssEMbLy DIAGRAMs (COntInUED) Gun (sb 25) #20A part Description Qty. 1E Nozzle (Slip Type) 1 2E Contact Tip 1 3E Spring 1 4E Head Tube 1 5E Sealant 1 6E Spring 1 7E Terminal; 1 8E ...

Page 34 - ELECTRICAL SCHEMATIC

for technical questions, please call 1-800-444-3353; troubleshooting section at end of manual. Page 34 SKU 95424, 95629 MIG/ARC WELDER (95424) – ELECtRICAL sCHEMAtIC MIG&ARC 250 AMP - SKU 95424 MIG DUAL 250 AMP – SKU For technical questions, please call 1-800-444-3353; Troubleshooting section at...

Page 35 - MIG DUAL WELDER (95629) – ELECtRICAL sCHEMAtIC

for technical questions, please call 1-800-444-3353; troubleshooting section at end of manual. Page 35 SKU 95424, 95629 MIG DUAL WELDER (95629) – ELECtRICAL sCHEMAtIC MIG&ARC 250 AMP - SKU 95424 MIG DUAL 250 AMP – SKU For technical questions, please call 1-800-444-3353; Troubleshooting section a...

Page 36 - COnnECtIOn sCHEMAtIC; CONNECTION SCHEMATIC

for technical questions, please call 1-800-444-3353; troubleshooting section at end of manual. Page 36 SKU 95424, 95629 pOWER CORD, COnnECtIOn bLOCK bC-4 & tRAnsfORMERs COnnECtIOn sCHEMAtIC MIG&ARC 250 AMP - SKU 95424 MIG DUAL 250 AMP – SKU For technical questions, please call 1-800-444-3353...

Page 37 - See first; Welder does not function when switched on; pOssIbLE CAUsEs AnD sOLUtIOns; Refer to; Weak arc strength; pOssIbLE CAUsE AnD sOLUtIOn

IMpORtAnt! be CERtAIn to shut off the Welder, disconnect it from power, and discharge the torch to ground before adjusting, cleaning, or repairing the unit. SKU 95424, 95629 for technical questions, please call 1-800-444-3353. Page 37 If the steps above do not solve the problem or if the repairs inv...

Page 38 - Wire feed motor runs but wire does not feed (MIG welding only); Replace with the proper one - follow the; Wire creates a bird’s nest during operation (MIG welding only)

IMpORtAnt! be CERtAIn to shut off the Welder, disconnect it from power, and discharge the torch to ground before adjusting, cleaning, or repairing the unit. SKU 95424, 95629 for technical questions, please call 1-800-444-3353. Page 38 If the steps above do not solve the problem or if the repairs inv...

Page 39 - Wire feeds, but shielding gas does not flow (MIG welding only); Have a qualified technician check/replace.; Use dry electrodes that have been stored correctly.; Wire feed motor does not run (MIG welding only); Change knob setting to proper speed.

IMpORtAnt! be CERtAIn to shut off the Welder, disconnect it from power, and discharge the torch to ground before adjusting, cleaning, or repairing the unit. SKU 95424, 95629 for technical questions, please call 1-800-444-3353. Page 39 If the steps above do not solve the problem or if the repairs inv...