Chicago Electric 66787 Installation manual

240 VOLT ARC/TIG

INVERTER WELDER

AND TIG WELDING TORCH

Model

66787

SET UP AND OPERATING INSTRUCTIONS

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

Read this material before using this product.

Failure to do so can result in serious injury.

SAVE THIS MANUAL.

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.

For technical questions or replacement parts, please call 1-800-444-3353.

Revised Manual 09h, 09k, 09l

Page 2SKU 66787 For technical questions, please call 1-800-444-3353.

CONTENTS

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

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

 Specic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.........................................................................11

TIG TORCH Operating Instructions...................................................................13

MAINTENANCE AND SERVICING................................................................................14

TROUBLESHOOTING...................................................................................................15

WELDER PARTS LIST AND ASSEMBLY DIAGRAM...................................................16

TIG TORCH PARTS LIST AND ASSEMBLY DIAGRAM...............................................17

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

PRODUCT WARRANTY INFORMATION......................................................................18

Page 3SKU 66787 For technical questions, please call 1-800-444-3353.

SAVE THIS MANUAL

Keep this manual for the safety warn-

ings and precautions, assembly, operating,

inspection, maintenance and cleaning pro-

cedures. Write the product’s serial number

in the back of the manual (or month and

year of purchase if product has no num-

ber). 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 provid-

ed 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,re,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

Work area safety1.

Keep work area clean and well lit.a.

Cluttered or dark areas invite acci-

dents.

Do not operate power tools in ex-b.

plosive atmospheres, such as in

the presence of ammable liquids,

gases or dust. Power tools create

sparks which may ignite the dust or

fumes.

Keep children and bystanders awayc.

while operating a power tool. Dis-

tractions can cause you to lose

control.

Electrical safety2.

Avoid body contact with groundeda.

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 4SKU 66787 For technical questions, please call 1-800-444-3353.

Do not expose power tools to rainb.

or wet conditions. Water entering a

power tool will increase the risk of

electric shock.

Do not abuse the cord. Never usec.

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.

When operating a power tool out-d.

doors, use an extension cord suit-

able for outdoor use. Use of a cord

suitable for outdoor use reduces the

risk of electric shock.

Personal safety3.

Stay alert, watch what you are do-a.

ing and use common sense when

operating a power tool. Do not use

a power tool while you are tired or

under the inuence of drugs, alcohol

or medication. A moment of inatten-

tion while operating power tools may

result in serious personal injury.

Use safety equipment. Always wearb.

eye protection. Safety equipment

such as arc shaded, impact safety

full face shield, dust mask or respi-

rator, heavy-duty work gloves, non-

skid safety shoes, or hearing protec-

tion used for appropriate conditions

will reduce personal injuries.

Avoid accidental starting. Ensurec.

the switch is in the off-position be-

fore plugging in. Carrying power

tools with your nger on the switch

or plugging in power tools that have

the switch on invites accidents.

Do not overreach. Keep proper foot-d.

ing and balance at all times. This

enables better control of the power

tool in unexpected situations.

Power tool use and care4.

Do not force the power tool. Use thea.

correct power tool for your applica-

tion. The correct power tool will do

the job better and safer at the rate

for which it was designed.

Do not use the power tool if theb.

switch does not turn it on and off.

Any power tool that cannot be con-

trolled with the switch is dangerous

and must be repaired.

Disconnect the plug from the powerc.

source before making any adjust-

ments, changing accessories, or

storing power tools. Such preventive

safety measures reduce the risk of

starting the power tool accidentally.

Store idle power tools out of thed.

reach of children and do not allow

persons unfamiliar with the power

tool or these instructions to oper-

ate the power tool. Power tools are

dangerous in the hands of untrained

users.

Maintain power tools. Check fore.

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.

Use the power tool and its acces-f.

sories 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

for operations different from those

intended could result in a hazardous

situation.

Page 5SKU 66787 For technical questions, please call 1-800-444-3353.

Service5.

Have your power tool serviced bya.

a qualied repair person using only

identical replacement parts. This will

ensure that the safety of the power

tool is maintained.

SpecicSafetyRules

Maintain labels and nameplates on1.

the tool. These carry important safety

information. If unreadable or miss-

ing, contact Harbor Freight Tools for a

replacement.

Do not touch the tip of the Torch2.

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 con-

nected to power. When the operator

is not holding the Torch, it must be

sitting on a nonconductive, nonam-

mable surface.

Feed the ller metal being used into 3.

the arc with a properly insulated

holder.

Avoid electrical shock. Do not per-4.

mit electrically live parts, cables, or

electrodes to contact skin, clothing, or

gloves. Wear ANSI-approved protec-

tive 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 se-

cure. Do not weld unless you are

insulated from ground and the work

piece.

Avoid eye and body damage. Arc5.

rays and infrared radiation can injure

eyes and burn skin. Wear ANSI ap-

proved eye and body protection. Do

not allow viewing by visitors without

proper eye and body protection. Use

a Face Shield with arc shaded lter

plate.

Move ammable and explosive mate-6.

rial at least 35 feet from the welding

arc to prevent welding sparks or mol-

ten metal from starting a re. Keep a

type ABC re extinguisher within easy

reach. Thoroughly clean the object

being welded of any paint, grease, or

other foreign material.

Avoid unintentional starting. Prepare7.

to begin work before turning on the

Welder.

Do not leave the Welder unattended8.

when it is plugged into an electrical

outlet. Turn off the tool, and unplug it

from its electrical outlet before leav-

ing.

Use clamps (not included) or other9.

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.

This product is not a toy. Keep it out10.

of reach of children.

Industrial applications must follow11.

OSHA guidelines.

People with pacemakers should12.

consult their physician(s) before use.

Electromagnetic elds in close prox-

imity to heart pacemaker could cause

pacemaker interference or pacemak-

er failure. In addition, people with

pacemakers should: Rev 09h

Page 6SKU 66787 For technical questions, please call 1-800-444-3353.

• 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 Inter-

rupter (GFCI) should also be imple-

mented – it prevents sustained elec-

trical shock.

WARNING: This product, when used13.

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, re 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 ammable sub-

stances. 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 conned spaces, wear ame

resistant ear plugs or ear muffs to

keep sparks out of ears.

15. Prevent accidental res.

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 pos-

sible, protect the combustibles with

a cover made of re resistant mate-

rial.

Remove or make safe all combus-•

tible materials for a radius of 35 feet

(10 meters) around the work area.

Use a re resistant material to cover

or block all open doorways, win-

dows, cracks, and other openings.

Enclose the work area with por-•

table re resistant screens. Protect

combustible walls, ceilings, oors,

etc., from sparks and heat with re

resistant covers.

If working on a metal wall, ceiling,•

etc., prevent ignition of combus-

tibles on the other side by moving

the combustibles to a safe loca-

tion. If relocation of combustibles

is not possible, designate someone

to serve as a re watch, equipped

with a re extinguisher, during the

cutting process and for at least one

half hour after the cutting is com-

pleted.

Do not weld or cut on materials•

having a combustible coating or

combustible internal structure, as

in walls or ceilings, without an ap-

Rev 09h

Page 7SKU 66787 For technical questions, please call 1-800-444-3353.

proved method for eliminating the

hazard.

Do not dispose of hot slag in con-•

tainers holding combustible materi-

als. Keep a re extinguisher nearby

and know how to use it.

After spot welding, make a thorough•

examination for evidence of re. Be

aware that easily-visible smoke or

ame may not be present for some

time after the re has started. Do

not weld or cut in atmospheres

containing dangerously reactive or

ammable gases, vapors, liquids,

and dust. Provide adequate ven-

tilation in work areas to prevent

accumulation of ammable gases,

vapors, and dust. Do not apply

heat to a container that has held an

unknown substance or a combus-

tible material whose contents, when

heated, can produce ammable or

explosive vapors. Clean and purge

containers before applying heat.

Vent closed containers, including

castings, before preheating, weld-

ing, or cutting.

Do not touch live electrical parts.16.

Wear dry, insulating gloves. Do not

touch electrode or conductor tong

with bare hand. Do not wear wet or

damaged gloves.

Protect yourself from electric shock.17.

Do not use outdoors. Insulate your-

self from the work piece and ground.

Use nonammable, 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.

Ensure that the unit is placed on a18.

stable location before use. If this unit

falls while plugged in, severe injury,

electric shock, or re may result.

Ground this product. This Welder19.

requires the attachment and use of

a UL-listed, 240 volt, grounded,

3-prong, electrical Power Cord

Plug (not included). Only a quali ed

electrician should install the Power

Cord Plug. Never remove the ground-

ing prong or modify the Power Cord

Plug in any way. Do not use adapter

plugs with this product.

Avoid overexposure to fumes and20.

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

gases from your breathing zone and

general area.

Where ventilation is questionable,•

have a qualied 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 Permis-•

sible Exposure Limits (PEL’s) for

various fumes and gases.

Follow the American Conference•

of Governmental Industrial Hygien-

ists 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 recommenda-

Rev 09h

Page 8SKU 66787 For technical questions, please call 1-800-444-3353.

tions for the specic welding or cut-

ting situation.

WARNING: Handling the Power21.

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.)

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.

23. The warnings, precautions, and in-

structions discussed in this instruction

manual cannot cover all possible con-

ditions 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.

REV 09e; 09h

Page 9SKU 66787 For technical questions, please call 1-800-444-3353.

SPECIFICATIONS

Electrical

Requirements

240V~ / 60 Hz / 25A max.

Power Cord: SJT 12AWG x 3C

Power Plug: 3-Prong, 240 VAC

(Not Included)

Output

Amperage

Range

10-130 Amps

Maximum

Open Circuit

Voltage

61V

Duty Cycle

40% @ 130 Amps

60% @ 120 Amps

100% @ 80 Amps

Maximum

Welding

Capacity

1/4” - For Welding Steel Only

Electrode

Diameter

Capacity

For Use With

1/16”, 3/32” and 1/8” Diameter

Rods

Electrode

Holder Head

Ground Cable

75”

65”

Torch Cable

Length 12’ 9”

Gas Hose 8’ 6” L, 0.34” OD, .19” ID

Additional

Features

May be used for both arc and tig

welding.

Quick starting with high open

voltage.

Anti-Stick circuit works with

rutile, basic steel, stainless

steel, and cast iron electrodes.

Additional amperage during

short arc length conditions

increases electrode penetration.

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 17.

REV 09h, 09l

When assembling Torch, make1.

sure Torch Cable is not connected

to Welder or argon gas supply.

Ceramic

Nozzle

(3a/3b)

Rod

Holder

(2a)

Gas Flow

Knob

Handle

(Front) (Back)

2. Thread either Rod Holder (2a) or Plug

(6a) securely into back of Torch (1a).

Choose a matching set of Collet and3.

Collet Holder, either 1/16” (4a & 5a)

or 3/32” (4b & 5b), depending on the

rod to be used. Insert the Collet, nar-

rower end rst, into the Collet Holder,

and then thread the Collet Holder

loosely into the front of the Torch.

Place a prepared tungsten welding4.

rod (the correct diameter for the Col-

let used) into Collet. Tighten Collet

Holder in place.

Attach desired Ceramic Nozzle (3a or5.

3b) onto Collet Holder. Do not over-

tighten. Ceramic Nozzles of larger

sizes will contain shielding gas in a

larger area, but may require more gas

ow to be effective.

Connect the gas hose securely to the6.

regulator on the argon bottle. Set the

argon regulator to 18-22 PSI. Fol-

low the gas cylinder manufacturer’s

instructions for set-up and use.

Connect the cable to the Welder.7.

Twist to lock in place.

TORCH ASSEMBLY

Page 10SKU 66787 For technical questions, please call 1-800-444-3353.

WELDER FEATURES

Electrode Holder (8):1. Connect the

Electrode Holder Cable to the POSI-

TIVE Terminal located at the front of

the Welder. (See Figure A.)

Ground Clamp (9):2. Connect the

Ground Clamp Cable to the NEGATIVE

Terminal located on the front of the

Welder. (See Figure A.)

Potentiometer Dial (4):3. Turn the Dial

clockwise or counterclockwise to regu-

late the welding current (from 10 to 130

amps). (See Figure B.)

Green “Power On” Light (5):4. When

illuminated, indicates the Welder is

receiving electrical power and is ready

for use. (See Figure B.)

Yellow “Overheating” Light (5):5.

When illuminated, indicates overheat-

ing 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.)

Fan (14):6. The Fan must operate con-

tinuously when operating the Welder to

prevent the unit from overheating.

(See Figure C.)

Power Switch (16):7. The Power Switch

must illuminate before welding opera-

tions can begin.

(See Figure C.)

Tig Welder Torch8.

REV 09h

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