Chicago Electric 97719 Installation manual

ARC WELDER

135AC/105DC AMP

Model

97719

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.

or any artwork contained herein may be reproduced in any shape or form without the ex-

press 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 09c, 09l

Page 2SKU 97719 For technical questions, please call 1-800-444-3353.

CONTENTS

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

GENERAL SAFETY RULES....................................................................................3

SPECIFIC SAFETY RULES.....................................................................................5

SPECIFICATIONS.........................................................................................................9

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

INITIAL SET UP

INSTRUCTIONS............................................................................................................9

ASSEMBLY..............................................................................................................9

OPERATING INSTRUCTIONS....................................................................................10

WORK PIECE AND WORK AREA SET UP ..........................................................10

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

MAINTENANCE AND SERVICING.............................................................................13

TROUBLESHOOTING.................................................................................................14

PLEASE READ THE FOLLOWING CAREFULLY .....................................................14

PARTS LIST.................................................................................................................15

ASSEMBLY DIAGRAM ..............................................................................................16

LIMITED 1 YEAR / 90 DAY WARRANTY....................................................................17

Page 3SKU 97719 For technical questions, please call 1-800-444-3353.

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.

IMPORTANT SAFETY

INFORMATION

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, re, and/or

serious injury. The term “power

tool” in all of the warnings listed

below refers to your line-operated

(corded) Arc Welder.

SAVE THESE INSTRUCTIONS

Work area safety1.

Keep work area clean and wella.

lit. Cluttered or dark areas invite

accidents.

Do not operate power tools inb.

explosive 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 bystandersc.

away while operating a power tool.

Distractions can cause you to lose

control.

Page 4SKU 97719 For technical questions, please call 1-800-444-3353.

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.

Do not touch exposed electricalb.

parts.

Do not expose power tools to rainc.

or wet conditions. Water entering a

power tool will increase the risk of

electric shock.

Do not abuse the cord. Never used.

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 toole.

outdoors, use an extension cord

suitable for outdoor use. Use of

a cord suitable for outdoor use

reduces the risk of electric shock.

Personal safety3.

Stay alert, watch what you area.

doing 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 inattention while operating power

tools may result in serious personal

injury.

Use safety equipment. Always wearb.

ANSI-approved safety glasses and

arc shaded, impact safety full face

shield. Safety equipment such as

NIOSH-approved respirator, heavy-

duty work gloves, non-skid safety

shoes, or hearing protection used

for appropriate conditions will reduce

personal injuries.

Avoid accidental starting. Ensurec.

the switch is in the off-position

before plugging in.

Remove any adjusting key or wrenchd.

before turning the power tool on. A

wrench or a key left attached to a

rotating part of the power tool may

result in personal injury.

Do not overreach. Keep propere.

footing 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. Usea.

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.

Do not use the power tool if theb.

switch does not turn it on and

off. Any power tool that cannot

be controlled with the switch is

dangerous and must be repaired.

Disconnect the plug from thec.

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.

Store idle power tools out of thed.

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.

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,

Page 5SKU 97719 For technical questions, please call 1-800-444-3353.

have the power tool repaired before

use. Many accidents are caused by

poorly maintained power tools.

Use the power tool, accessories andf.

tool bits etc., 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.

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 missing,

contact Harbor Freight Tools for a

replacement.

NEVER connect one Cable (33, 34)2.

to a DC Cable Connection Knob (22)

and the other Cable to an AC Cable

Connection Knob.

ALWAYS unplug the Power Cord3.

(32) from its electrical outlet before

connecting Cables (33, 34).

Avoid electrical shock. Do not permit4.

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.

Avoid eye and body damage. Arc5.

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 lter plate.

Move ammable and explosive 6.

material at least 35 feet from the

welding arc to prevent welding sparks

or molten 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

tool.

Do not leave the tool unattended8.

when it is plugged into an electrical

outlet. Turn off the tool, and unplug

it from its electrical outlet before

leaving.

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.

Page 6SKU 97719 For technical questions, please call 1-800-444-3353.

People with pacemakers should12.

consult their physician(s) before

use. Electromagnetic elds in close

proximity to heart pacemaker could

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.

WARNING: This product, when used13.

for welding, plasma cutting, soldering,

or similar applications, 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 goggles 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

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 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 a16.

location well away from combustible

materials. If relocation is not pos-

sible, protect the combustibles with a

cover made of re resistant material.

Remove or make safe all combustible17.

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, windows,

cracks, and other openings.

Ground this product. This Welder18.

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

grounding prong or modify the Power

Cord Plug in any way. Do not use

adapter plugs with this product.

Do not use near degreasing or19.

painting operations.

REV 09d

Page 7SKU 97719 For technical questions, please call 1-800-444-3353.

Enclose the work area with portable20.

re resistant screens. Protect

combustible walls, ceilings, oors,

etc., from sparks and heat with re

resistant covers.

If working on a metal wall, ceiling,21.

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 re watch, equipped with

a re extinguisher, during the cutting

process and for at least one half hour

after the cutting is completed.

Do not weld or cut on materials22.

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 in23.

containers holding combustible

materials. Keep a re extinguisher

nearby and know how to use it.

After spot welding, make a thorough24.

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 ventilation 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 combustible 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, welding, or cutting.

Do not touch live electrical parts.25.

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.26.

Do not use outdoors. Insulate

yourself 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 large enough to cover your

full area of contact with the work or

ground.

Ensure that the unit is placed on a27.

stable location before use. If this unit

falls while plugged in, severe injury,

electric shock, or re may result.

Avoid overexposure to fumes and28.

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,29.

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 for30.

Permissible Exposure Limits (PEL’s)

for various fumes and gases.

Follow the American Conference of31.

Governmental Industrial Hygienists

Page 8SKU 97719 For technical questions, please call 1-800-444-3353.

recommendations for Threshold Limit

Values (TLV’s) for fumes and gases.

Have a recognized specialist in32.

Industrial Hygiene or Environmental

Services check the operation and air

quality and make recommendations

for the specic welding or cutting

situation.

The warnings, precautions,33.

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.

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.

SAVE THESE

INSTRUCTIONS.

Page 9SKU 97719 For technical questions, please call 1-800-444-3353.

SPECIFICATIONS

Electrical

Requirements

240 V~ / 60 Hz / Single Phase

Power Plug Type:

240 Volt, 3-Prong, Grounded

(Not Included)

Output Current AC 55 - 135A

DC 30 - 105A

Max. Input

Current 40 Amps Operating

Indicators Power On Light (Green)

Thermal Overload Light (Orange)

Welding

Capacity

Thickness

Up to 1/4” (using 1/16”, 3/32” or 1/8”

diameter electrodes)

Duty Cycle 10% @ 130 Amps AC

15% @ 100 Amps DC

Load Voltage 25.2V (AC operation)

24.2V (DC operation)

Open Circuit

Voltage

68V (AC operation)

60V (DC operation)

Accessories

Welding Shield (Qty. 1)

Hammer/Brush (Qty. 1)

Electrode Holder (Qty. 1)

Ground Clamp (Qty. 1)

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.

INITIAL SET UP

INSTRUCTIONS

Read the ENTIRE IMPORTANT

SAFETY INFORMATION section

at the beginning of this manual

including all text under

subheadings therein before set

up or use of this product.

TO PREVENT

SERIOUS

INJURY FROM ACCIDENTAL

OPERATION:

Turn the Power Switch of

the Arc Welder to its “OFF”

position and unplug the

tool from its electrical outlet

before assembling or making

any adjustments.

Note: For additional information regarding

the parts listed in the following pages,

refer to the Assembly Diagram near

the end of this manual.

Assembly

To assemble the Welding Shield,1.

place the Shield on a at surface.

Press the Handle into place. Then

insert the Filter Lens.

(See Figure A.)

This Welder requires the attachment2.

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

FIGURE A

REV 09d; 09l

Page 10SKU 97719 For technical questions, please call 1-800-444-3353.

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.

To assemble the two Wheels (9),3.

insert the Axle (8) through the two

holes located at the bottom/rear of the

Base Frame (3). Place the Wheels

onto the protruding ends of the Axle.

Then secrure the Wheels in place,

using one Bolt (10) for each end of

the Axle. (See Assy. Diagram.)

To attach the Handle (30), align the4.

two holes in the Handle with the two

threaded mounting holes located

at the top of the Case (28). Secure

the Handle to the Case, using two

Screws (31). (See Assy. Diagram.)

OPERATING INSTRUCTIONS

Read the ENTIRE IMPORTANT

SAFETY INFORMATION section

at the beginning of this manual

including all text under

subheadings therein before set

up or use of this product.

TO PREVENT

SERIOUS

INJURY FROM ACCIDENTAL

OPERATION:

Turn the switch to its off

position before performing

any inspection, maintenance,

or cleaning procedures.

Workpiece and Work Area Set Up

Designate a work area that is clean1.

and well-lit. The work area must not

allow access by children or pets to

prevent injury and distraction.

Route the Power Cord (32) along a2.

safe route to reach the work area

without creating a tripping hazard or

exposing the power cord to possible

damage. The power cord must reach

the work area with enough extra

length to allow free movement while

working.

Secure loose workpieces using a vise3.

or clamps (not included) to prevent

movement while working. The work-

pieces should be rmly held together

and in position while welding. The

distance (if any) between the two

workpieces must be controlled

properly to allow the weld to hold both

sides securely while allowing the weld

to penetrate fully into the joint.

There must not be hazardous objects,4.

such as utility lines or foreign objects,

nearby that will present a hazard

while working.

A barrier, such as a welding curtain5.

or welding shroud, should be put up

to protect others in the work area and

limit the spray of sparks.

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