Chicago Electric 91811 User manual

130 AMP TIG / 90 AMP

ARC WELDER

ASSEMBLY AND OPERATING INSTRUCTIONS

3491 MISSION OAKS BLVD., CAMARILLO, CA 93011

VISIT OUR WEB SITE AT HTTP://WWW.HARBORFREIGHT.COM

this manual or any artwork contained herein may be reproduced in any shape or

form without the express written consent of Harbor Freight Tools.

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

91811

SKU 91811 For technical questions, please call 1-800-444-3353. Page 2

REV 10/04; 11/04; 09/05

SPECIFICATIONS

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SAVE THIS MANUAL

You will need the manual for the safety warnings and precautions, assembly instructions,

operating and maintenance procedures, parts list and diagram. Keep your invoice with this

manual. Write the invoice number on the inside of the front cover. Keep the manual and

invoice in a safe and dry place for future reference.

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 THESE INSTRUCTIONS

Work Area

1. Keep your work area clean and well lit. Cluttered benches and dark areas invite

accidents.

2. 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.

3. Keep bystanders, children, and visitors away while operating a power tool.

Distractions can cause you to lose control. Protect others in the work area from debris

such as chips and sparks. Provide barriers or shields as needed.

SKU 91811 For technical questions, please call 1-800-444-3353. Page 3

Electrical Safety

4. 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.

5. Do not expose power tools to rain or wet conditions. Water entering a power tool

will increase the risk of electric shock.

6. Grounded tools must be plugged into an outlet properly installed and grounded

in accordance with all codes and ordinances. Never remove the grounding

prong or modify the plug in any way. Do not use any adapter plugs. Check with

a qualified electrician if you are in doubt as to whether the outlet is properly

grounded. If the tools should electrically malfunction or break down, grounding

provides a low resistance path to carry electricity away from the user.

7. Double insulated tools are equipped with a polarized plug (one blade is wider

than the other). This plug will fit in a polarized outlet only one way. If the plug

does not fit fully in the outlet, reverse the plug. If it still does not fit, contact a

qualified electrician to install a polarized outlet. Do not change the plug in any

way. Double insulation eliminates the need for the three wire grounded power

cord and grounded power supply system.

8. Do not abuse the Power Cord. Never use the Power Cord to carry the tools or

pull the Plug from an outlet. Keep the Power Cord away from heat, oil, sharp

edges, or moving parts. Replace damaged Power Cords immediately. Damaged

Power Cords increase the risk of electric shock.

9. When operating a power tool outside, use an outdoor extension cord marked

“W-A” or “W”. These extension cords are rated for outdoor use, and reduce the risk of

electric shock.

Personal Safety

10. Stay alert. Watch what you are doing, and use common sense when operating a

power tool. Do not use a power tool while tired or under the influence of drugs,

alcohol, or medication. A moment of inattention while operating power tools may

result in serious personal injury.

11. Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep

your hair, clothing, and gloves away from moving parts. Loose clothes, jewelry, or

long hair can be caught in moving parts.

12. Avoid accidental starting. Be sure the Power Switch is off before plugging in.

Carrying power tools with your finger on the Power Switch, or plugging in power tools

with the Power Switch on, invites accidents.

13. Remove adjusting keys or wrenches before turning the power tool on. A wrench

or a key that is left attached to a rotating part of the power tool may result in personal

injury.

SKU 91811 For technical questions, please call 1-800-444-3353. Page 4

14. Do not overreach. Keep proper footing and balance at all times. Proper footing

and balance enables better control of the power tool in unexpected situations.

15. Use safety equipment. Always wear eye protection. Dust mask, nonskid safety

shoes, hard hat, or hearing protection must be used for appropriate conditions.

Tool Use and Care

16. Use clamps (not included) or other practical ways to secure and support the

workpiece to a stable platform. Holding the work by hand or against your body is

unstable and may lead to loss of control.

17. Do not force the tool. Use the correct tool for your application. The correct tool

will do the job better and safer at the rate for which it is designed.

18. Do not use the power tool if the Power Switch does not turn it on or off. Any tool

that cannot be controlled with the Power Switch is dangerous and must be replaced.

19. Disconnect the Power Cord Plug from the power source before making any

adjustments, changing accessories, or storing the tool. Such preventive safety

measures reduce the risk of starting the tool accidentally.

20. Store idle tools out of reach of children and other untrained persons. Tools are

dangerous in the hands of untrained users.

21. Maintain tools with care. Keep cutting tools sharp and clean. Properly maintained

tools with a sharp cutting edge are less likely to bind and are easier to control. Do not

use a damaged tool. Tag damaged tools “Do not use” until repaired.

22. 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. Many accidents are caused by poorly maintained tools.

23. Use only accessories that are recommended by the manufacturer for your

model. Accessories that may be suitable for one tool may become hazardous when

used on another tool.

Service

24. Tool service must be performed only by qualified repair personnel. Service or

maintenance performed by unqualified personnel could result in a risk of injury.

25. When servicing a tool, use only identical replacement parts. Follow instructions

in the

“Inspection, Maintenance, And Cleaning”

section of this manual. Use of

unauthorized parts or failure to follow maintenance instructions may create a risk of

electric shock or injury.

SKU 91811 For technical questions, please call 1-800-444-3353. Page 5

SPECIFIC SAFETY RULES FOR THIS PRODUCT

1. Maintain labels and nameplates on the welder. These carry important information.

If unreadable or missing, contact Harbor Freight Tools for a replacement.

2. Maintain a safe working environment. Keep the work area well lit. Make sure there

is adequate surrounding workspace. Always keep the work area free of obstructions,

grease, oil, trash, and other debris. Do not use a power tool in areas near flammable

chemicals, dusts, and vapors. Do not use this product in a damp or wet location.

3. Avoid unintentional starting. Make sure you are prepared to begin work before

turning on the Welder.

4. Unplug before performing maintenance. Always unplug the Welder from its

electrical outlet before performing and inspection, maintenance, or cleaning

procedures.

5. Never leave the Welder unattended while energized. Turn power off if you have to

leave the Welder.

6. Maintain a safe working environment. Keep the work area well lit. Make sure there

is adequate surrounding workspace. Always keep the work area free of obstructions,

grease, oil, trash, and other debris.

7. 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 goggles with a welding helmet

featuring at least a number 10 shade lens rating. Any additional safety

equipment worn on the head (such as a respirator or hearing protector) must fit

properly and safely underneath the welding helmet without decreasing the helmet’s

effectiveness.

• 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 or cutting overhead or in confined spaces, wear flame resistant ear

plugs or ear muffs to keep sparks out of ears.

8. 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.

SKU 91811 For technical questions, please call 1-800-444-3353. Page 6

•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 door-

ways, 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 welding process and for at least one half hour after the

welding is completed.

•Do not weld or cut on materials having a combustible coating or combustible inter-

nal 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 welding or cutting, 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.

9. 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 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 respi-

rator.

•Work in a confined area only if it is well ventilated, or while wearing an air-supplied

respirator.

•Follow OSHA guidelines for Permissible Exposure Limits (PEL’s) for various fumes

and gases.

•Follow the American Conference of Governmental Industrial Hygienists recommen-

dations 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.

SKU 91811 For technical questions, please call 1-800-444-3353. Page 7

10. Always keep the Welding Hoses away from welding spot. Examine the Welding

Hoses for cuts, burns, or worn areas before each use. If any damaged areas are found,

replace the Welding Hoses immediately.

11. Read and understand all instructions and safety precautions as outlined in the

manufacturer’s manual for the material you will weld.

12. Proper cylinder care. Secure cylinders to a cart, wall, or post, to prevent them

from falling. All cylinders should be used and stored in an upright position.

Never drop or strike a cylinder. Do not use cylinders that have been dented.

Cylinder caps should be used when moving or storing cylinders. Empty cylinders

should be kept in specified areas and clearly marked “empty.”

13. Never use oil or grease on any inlet connector, outlet connector, or cylinder

valves.

WARNING! This product, when used for welding and similar applications, contains

or produces a chemical known to the State of California to cause cancer and birth de-

fects (or other reproductive harm).

(California Health & Safety Code 25249.5 et seq.)

WARNING! The brass components of this product contain lead, a chemical known

to the State of California to cause birth defects (or other reproductive harm).

(California

Health & Safety Code 25249.5 et seq.)

WARNING! Pacemaker safety warning. People with pacemakers should consult

their physician(s) before using this product. Electromagnetic fields in close proximity

to a heart pacemaker could cause interference to, or failure of the pacemaker.

SKU 91811 For technical questions, please call 1-800-444-3353. Page 8

GROUNDING

This welder requires a 3-prong, 220 VAC, polarized, twistlock plug (not supplied). This

plug must be installed by a qualified electrician.

WARNING!

Improperly connecting the grounding wire can result in the risk of electric shock.

Check with a qualified electrician if you are in doubt as to whether the outlet is

properly grounded. Do not modify the power cord provided with the tool or

product. Never remove the grounding prong from the plug. Do not use the tool if

the power cord or plug is damaged. If damaged, have it repaired by a service

facility before use. If the plug will not fit the outlet, have a proper outlet installed by

a qualified electrician.

EXTENSION CORDS

If an extension cord is to be used with this welder, it must be rated to handle 220 VAC,

single phase at 20 amps.

1. Grounded, 220 VAC tools require a three wire extension cord.

2. As the distance from the supply outlet increases, you must use a heavier gauge

extension cord. Using extension cords with inadequately sized wire causes a serious

drop in voltage, resulting in loss of power and possible tool damage.

3. The smaller the gauge number of the wire, the greater the capacity of the cord. For

example, a 14 gauge cord can carry a higher current than a 16 gauge cord.

4. When using more than one extension cord to make up the total length, make sure

each cord contains at least the minimum wire size required.

5. If you are using one extension cord for more than one tool, add the nameplate

amperes and use the sum to determine the required minimum cord size.

6. If you are using an extension cord outdoors, make sure it is marked with the suffix “W-

A” (“W” in Canada) to indicate it is acceptable for outdoor use.

7. Make sure your extension cord is properly wired and in good electrical condition.

Always replace a damaged extension cord or have it repaired by a qualified

electrician before using it.

8. Protect your extension cords from sharp objects, excessive heat, and damp or wet

areas.

SKU 91811 For technical questions, please call 1-800-444-3353. Page 9

SYMBOLOGY

Ta b l e B

UNPACKING

When unpacking, check to make sure that all the parts are included. Refer to the Assembly

section, and the Assembly Drawing and Parts List at the end of this manual.

If any parts are missing or broken, please call Harbor Freight Tools at the number on the

cover of this manual as soon as possible.

ASSEMBLY INSTRUCTIONS

Connect a 3-prong, 220 VAC, polarized, twistlock plug (not supplied) to the Line Cord. This

plug must be installed by a qualified electrician.

TIG/ARC DC Welder

Grounding Clamp/Cable (54)

Arc Welding Electrode Holder (53)

TIG Torch Assembly (52)

220 VAC

Line Cord

TIG Torch

Accessories

Collets Nozzle Covers

SKU 91811 For technical questions, please call 1-800-444-3353. Page 10

OPERATING INSTRUCTIONS

Controls and Indicators

TIG Welding

Before beginning, please read and understand the section “Specific Safety Rules” as

described on pages 5, 6, and 7.

1. Place the Welder near the workpiece to be welded.

2. Connect a hose and coupling from the Argon gas regulator on the Argon gas tank (not

supplied) to the Argon Gas Inlet (49) at the rear of the unit.

3. Connect the TIG Torch (52) cable plug and gas outlet

hose as shown above. Twist to lock in place.

4. Plug in the Grounding Clamp/Cable (54) into the Ground

Cable Quick Coupler (8). Twist to lock in place.

5. Securely place the clamping end of the Grounding

Clamp/Cable (54) to a part of the workpiece metal that is

clean of paint, oil, or dirt.

6. Assemble the desired accessories and rod to the tip of

the TIG Torch (52) handle. Welding rod types may vary

for welding different metals.

7. Verify that the Power Switch (3) is off, then plug the 220 VAC line cord plug into a 220

VAC, 20 amp (minimum) outlet.

8. Turn the Current Adjustment Potentiometer (4) to the desired current. Refer to the

Specifications on page 2 for the current ranges.

9. Open the Screw Valve on the TIG Torch handle to the desired gas flux value.

TIG Torch Handle

Screw Valve

Tip Accessories

REV 11/04; 09/05; REV 07/06

Power Indicator (5)

Welding Indicator (6)

Power Switch (3)

Overheat Indicator (7)

Argon Gas Outlet (10)

TIG Torch or Arc Electrode

Holder - Quick Coupler (8)

TIG Torch Cable Plug or Arc

Electrode Holder Cable Plug

Workpiece Ground

Cable Clamp -

Quick Coupler (8)

Grounding Clamp/Cable (54)

Current Adjustment

Potentiometer (4)

Gas Outlet Hose

Argon Gas Inlet (49) at

opposite end of unit.

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