Chicago Electric 61792 Assembly instructions

Revised Manual 09h, 09k, 09l

Owner’s Manual & Safety Instructions

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.

When unpacking, make sure that the product is intact

and undamaged. If any parts are missing or broken,

please call 1-888-866-5797 as soon as possible.

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.

Diagrams within this manual may not be drawn proportionally. Due to continuing

improvements, actual product may differ slightly from the product described herein.

Tools required for assembly and service may not be included.

Read this material before using this product.

Failure to do so can result in serious injury.

SAVE THIS MANUAL.

Visit our website at: http://www.harborfreight.com

Email our technical support at: [email protected]

REV 14e

Page 2Item 61792 For technical questions, please call 1-888-866-5797.

CONTENTS

IMPORTANT SAFETY INFORMATION............................................................................3

General Safety Rules...........................................................................................3

Specific Safety Rules...........................................................................................5

PRODUCT SPECIFICATIONS.........................................................................................9

UNPACKING....................................................................................................................9

TIG TORCH ASSEMBLY.................................................................................................9

WELDER FEATURES....................................................................................................10

OPERATING INSTRUCTIONS.......................................................................................11

Tool Set Up.........................................................................................................11

Work Piece and Work Area Set Up...................................................................11

General Operating Instructions.........................................................................12

TIG TORCH Operating Instructions...................................................................14

MAINTENANCE AND SERVICING................................................................................15

TROUBLESHOOTING...................................................................................................16

PLEASE READ THE FOLLOWING CAREFULLY.........................................................17

WELDER PARTS LIST AND ASSEMBLY DIAGRAM...................................................18

TIG TORCH PARTS LIST AND ASSEMBLY DIAGRAM...............................................19

PRODUCT WARRANTY INFORMATION......................................................................20

Page 3Item 61792 For technical questions, please call 1-888-866-5797.

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 (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.

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

a hazardous

situation which, if not

avoided, will result in death or

serious injury.

WARNING

indicates a

hazardous situation which, if

not avoided, could result in

death or serious injury.

CAUTION, used

with the safety

alert symbol, indicates a

hazardous situation which, if

not avoided, could result in

minor or moderate injury.

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/TIG Inverter Welder.

SAVE THESE INSTRUCTIONS

1. Work area safety

a. Keep work area clean and well

lit. Cluttered or dark areas invite

accidents.

b. 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.

c. Keep children and bystanders

away while operating a power tool.

Distractions can cause you to lose

control.

2. Electrical safety

a. 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.

IMPORTANT SAFETY

INFORMATION

Page 4Item 61792 For technical questions, please call 1-888-866-5797.

b. Do not expose power tools to rain

or wet conditions. Water entering a

power tool will increase the risk of

electric shock.

c. 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.

d. 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.

3. 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.

b. Use safety equipment. Always wear

eye protection. Safety equipment

such as arc shaded, impact safety

full face shield, dust mask or

respirator, heavy-duty work gloves,

non-skid safety shoes, or hearing

protection used for appropriate

conditions will reduce personal

injuries.

c. 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.

d. Do not overreach. Keep proper

footing and balance at all times.

This enables better control of the

power tool in unexpected situations.

4. Power tool use and care

a. 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.

b. 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.

c. 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.

d. 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.

e. 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.

f. Use the power tool and its

accessories in accordance with

these instructions and in the manner

intended for the particular type of

power tool, taking into account the

working conditions and the work to

be performed. Use of the power tool

Page 5Item 61792 For technical questions, please call 1-888-866-5797.

for operations different from those

intended could result in a hazardous

situation.

5. 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

1. Maintain labels and nameplates on

the tool. These carry important safety

information. If unreadable or missing,

contact Harbor Freight Tools for a

replacement.

2. Do not touch the tip of the Torch

when the welder is connected to

power. The Torch will immediately

activate when it is plugged in. The

operator must carefully direct

the torch whenever the welder is

connected to power. When the

operator is not holding the Torch, it

must be sitting on a nonconductive,

nonflammable surface.

3. Feed the filler metal being used into

the arc with a properly insulated

holder.

4. 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.

5. Avoid eye and body damage. Arc

rays and infrared radiation can

injure eyes and burn skin. Wear

ANSI approved eye and body

protection. Do not allow viewing by

visitors without proper eye and body

protection. Use a Face Shield with

arc shaded filter plate.

6. 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 fire extinguisher

within easy reach. Thoroughly clean

the object being welded of any paint,

grease, or other foreign material.

7. Avoid unintentional starting. Prepare

to begin work before turning on the

Welder.

8. Do not leave the Welder unattended

when it is plugged into an electrical

outlet. Turn off the tool, and unplug

it from its electrical outlet before

leaving.

9. 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.

10. This product is not a toy. Keep it out

of reach of children.

11. Industrial applications must follow

OSHA guidelines.

12. People with pacemakers should

consult their physician(s) before

use. Electromagnetic fields in close

proximity to heart pacemaker could

Page 6Item 61792 For technical questions, please call 1-888-866-5797.

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

avoid electrical shock.

• Any power cord must be properly

grounded. Ground Fault Circuit

Interrupter (GFCI) should also be

implemented – it prevents sustained

electrical shock.

13. WARNING: This product, when used

for welding, produces chemicals

known to the State of California to

cause cancer and birth defects (or

other reproductive harm). (California

Health & Safety Code § 25249.5, et

seq.)

14. Prevent eye injury and

burns. Wearing and using

ANSI-approved personal

safety clothing and safety

devices reduce the risk for

injury.

• Wear ANSI-approved safety impact

eye glasses 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.

• When welding/cutting overhead

or in confined spaces, wear flame

resistant ear plugs or ear muffs to

keep sparks out of ears.

15. 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 the

work area. Use a fire resistant

material to cover or block all open

doorways, windows, cracks, and

other openings.

• 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.

Page 7Item 61792 For technical questions, please call 1-888-866-5797.

• 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.

• 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, when

heated, can produce flammable or

explosive vapors. Clean and purge

containers before applying heat.

Vent closed containers, including

castings, before preheating,

welding, or cutting.

16. 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.

17. 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.

18. Ensure that the unit is placed on a

stable location before use. If this unit

falls while plugged in, severe injury,

electric shock, or fire may result.

WARNING

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

•Inammation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.

19. 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

Page 8Item 61792 For technical questions, please call 1-888-866-5797.

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 various 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.

20. Ground this product. This Welder is

equipped with a 240 volt, grounded,

3-prong Power Cord Plug. Never

remove the grounding prong or

modify the Power Cord Plug in any

way. Do not use adapter plugs with

this product.

21. WARNING: Handling the Power

Cord on this product will expose you

to lead, a chemical known to the

State of California to cause cancer,

birth defects, and other reproductive

harm. Wash hands after handling.

(California Health & Safety Code §

25249.5 et seq.)

22. 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.

Page 9Item 61792 For technical questions, please call 1-888-866-5797.

SPECIFICATIONS

Electrical

Requirements

240 VAC/60 Hz/25 AMax.

PowerCord:SJT12 AWGx3C

Power Plug: 6-50P, 3-Prong,

240 VAC

Welding

Current Range

MMA:10 – 145 A

TIG:15 – 165 A

Maximum

Open Circuit

Voltage

85V

Duty Cycle MMA: 40% @ 145 Amps

TIG: 40% @ 165 Amps

Material

Thickness

MMA: Up to 1/4"

TIG: 22 gauge to 1/8"

Weldable

Materials

Mild steel, low alloy steel, and

stainless steel

(not suitable for aluminum)

Electrode

Capacity

MMA: 1/16", 3/32", 1/8"

TIG: 1/16", 3/32"

Electrode

Holder Cable

Length

5'- 4"

Ground Cable

Length 4'- 8"

Torch Cable

Length 12'-7"

Gas Hose 8'- 6"L,3/16"ID

UNPACKING

When unpacking, check to make sure

that the item is intact and undamaged. If

any parts are missing or broken, please

call Harbor Freight Tools at the number

shown on the cover of this manual as soon

as possible.

Note: For TIG Welding Torch Parts

List and Diagram, refer to page 19.

1. When assembling Torch, make

sure Torch Cable is not connected

to Welder or argon gas supply.

Ceramic

Nozzle

Long

Back

Cap

Gas Flow

Knob

Handle

(Front) (Back)

Thread either Long Back Cap (1a)

or Short Back Cap (2a) securely into

back of Torch Body (4a).

3. Choose a matching set of Collet

andColletHousing,either1.6 mm

(6a – 7a)or2.4 mm(15a – 16a),

depending on the size Electrode to be

used. Insert the Collet, narrower end

first, into the Collet Housing, and then

thread the Collet Housing loosely into

the front of the Torch.

4. Place a prepared Tungsten Electrode

(9a, 18a) into Collet, using the correct

diameter for the Collet used. Tighten

Collet Housing in place.

5. Attach correct Ceramic Nozzle (8a

or 17a) onto Collet Housing. Do not

overtighten. Ceramic Nozzles of

larger sizes will contain shielding gas

in a larger area, but may require more

gas flow to be effective.

6. Connect the gas hose securely to the

regulator on the argon bottle. Set the

argon regulator to 18-22 PSI. Follow

the gas cylinder manufacturer’s

instructions for set-up and use.

7. Connect the cable to the Welder.

Twist to lock in place.

TORCH ASSEMBLY

Page 10Item 61792 For technical questions, please call 1-888-866-5797.

WELDER FEATURES

1. Electrode Holder (11): Connect

the Electrode Holder Cable to the

POSITIVE Terminal located at the front

of the Welder. (See Figure A.)

2. Ground Clamp (10): Connect the

Ground Clamp Cable to the NEGATIVE

Terminal located on the front of the

Welder. (See Figure A.)

3. Potentiometer Dial (9): Turn the

Dial clockwise or counterclockwise to

regulate the welding current (from 10 to

145 amps). (See Figure B.)

4. Green “Power On” Light: When

illuminated, indicates the Welder is

receiving electrical power and is ready

for use. (See Figure B.)

5. Yellow “Overheating” Light: When

illuminated, indicates overheating

caused by an excessively intense duty

cycle. In this case, stop welding and

wait until the welder has cooled down.

The welder will automatically restart

after the yellow “overheating” light turns

off. (See Figure B.)

6. Fan (20): The Fan must operate

continuously when operating the

Welder to prevent the unit from

overheating. (See Figure C.)

7. Power Switch (26): The Power

Switch must illuminate before welding

operations can begin.

(See Figure C.)

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