Chicago Electric 98233 Installation manual

TIG INVERTER WELDER

Model

98233

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 09j

SKU 98233 For technical questions, please call 1-800-444-3353. Page 2

CONTENTS

IMPORTANT SAFETY

INFORMATION ............................ 3

GENERAL POWER TOOL

SAFETY WARNINGS.......................3

TIG WELDER SAFETY WARNINGS..5

GROUNDING ................................. 9

GROUNDED TOOLS..........................9

EXTENSION CORDS .........................9

SYMBOLOGY...................................10

SPECIFICATIONS........................ 11

UNPACKING ................................ 11

LIST OF CONTENTS........................ 11

OPERATING INSTRUCTIONS .... 11

TOOL SET UP .................................. 11

WORK PIECE AND WORK AREA

SET UP .......................................... 11

GENERAL OPERATING

INSTRUCTIONS ........................ 13

MAINTENANCE AND

SERVICING ............................... 15

CLEANING, MAINTENANCE, AND

LUBRICATION...............................15

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

MAIN UNIT PARTS LIST ............. 17

MAIN UNIT DIAGRAM................. 17

TORCH PARTS LIST ................... 18

TORCH PARTS DIAGRAM.......... 18

ELECTRICAL DIAGRAM............. 19

LIMITED 1 YEAR / 90 DAY

WARRANTY .............................. 20

SKU 98233 For technical questions, please call 1-800-444-3353. Page 3

SAVE THIS MANUAL

Keep this manual for the safety warn-

ings and precautions, assembly, operat-

ing, 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 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 Power Tool Safety

Warnings

WARNING Read all safety

warnings and instructions.

Failure to follow the warnings and

instructions may result in electric

shock, re and/or serious injury.

Save all warnings and

instructions for future reference.

The term ″power tool″ in the

warnings refers to your mains-

operated (corded) power tool.

Work area safety1.

Keep work area clean and well lit.a.

Cluttered or dark areas invite acci-

dents.

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.

Electrical safety2.

Power tool plugs must match thea.

outlet. Never modify the plug in

any way. Do not use any adapter

plugs with grounded power tools.

SKU 98233 For technical questions, please call 1-800-444-3353. Page 4

Unmodied plugs and matching out-

lets will reduce risk of electric shock.

Avoid body contact with groundedb.

surfaces such as pipes, radiators,

ranges and refrigerators. There is

an increased risk of electric shock if

your body is grounded.

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 carrying, 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-e.

doors, use an extension cord suit-

able for outdoor use. Use of a cord

suitable for outdoor use reduces the

risk of electric shock.

If operating a power tool in a dampf.

location is unavoidable, use a

Ground Fault Circuit Interrupter

(GFCI) protected supply. Use of

a GFCI 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 inattention while operating power

tools may result in serious personal

injury.

Use safety equipment.b. Always

wear 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.

Prevent unintentional starting.c.

Ensure the switch is in the off-po-

sition before connecting to power

source or moving the tool. Carry-

ing power tools with your nger on

the switch or energizing power tools

that have the switch on invites acci-

dents.

Remove any adjusting key ord.

wrench before turning the power

tool on. A wrench or a key left at-

tached 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.

Dress properly. Do not wear loosef.

clothing or jewelry. Keep your

hair, clothing and gloves away

from moving parts. Loose clothes,

jewelry or long hair can be caught in

moving parts.

If devices are provided for the con-g.

nection of dust extraction and col-

lection facilities, ensure these are

connected and properly used. Use

of these devices can reduce dust-

related hazards.

Only use safety equipment thath.

has been approved by an appropri-

ate standards agency. Unapproved

safety equipment may not provide

adequate protection. Eye protection

must be ANSI-approved and breath-

ing protection must be NIOSH-ap-

SKU 98233 For technical questions, please call 1-800-444-3353. Page 5

proved for the specic hazards in the

work area.

Power tool use and care4.

Do not force the power tool. Usea.

the correct power tool for your ap-

plication. 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 thec.

power source from the power tool

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 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 dam-

aged, have the power tool repaired

before use. Many accidents are

caused by poorly maintained power

tools.

Keep cutting tools sharp andf.

clean. Properly maintained cutting

tools with sharp cutting edges are

less likely to bind and are easier to

control.

Use the power tool, accessoriesg.

and tool bits etc. in accordance

with these instructions, taking into

account the working conditions

and the work to be performed. Use

of the power tool for operations differ-

ent 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.

TIG Welder Safety Warnings

Connection of a plug to this unit1.

must only be performed by a certi-

ed electrician.

Do not exceed 20 PSI for shielding2.

gas; 10 PSI is recommended.

Avoid electrical shock. Do not per-3.

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 screws,

and that all insulation is secure. Do

not weld unless you are insulated

from ground and the work piece.

Avoid eye and body damage. Arc4.

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.

SKU 98233 For technical questions, please call 1-800-444-3353. Page 6

Move ammable and explosive mate-5.

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.

If working on a wall or ceiling prevent6.

ignition of combustibles on the other

side by moving them to a safe loca-

tion.

Industrial applications must follow7.

OSHA guidelines.

8. Prevent eye

injury and

burns. Wearing

and using

ANSI-approved personal safety

clothing and safety devices reduce

the risk for injury.

Leather leggings, re resistant shoes 9.

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 and work surfaces free10.

of grease, oil, solvents, or any am-

mable substances. Wear dry, insulat-

ing gloves and protective clothing.

Wear an approved head covering11.

to protect the head and neck. Use

aprons, cape, sleeves, shoulder cov-

ers, and bibs designed and approved

for welding and cutting procedures.

When welding/cutting overhead or in12.

conned spaces, wear ame resistant

ear plugs or ear muffs to keep sparks

out of ears.

13. Prevent accidental res.

Remove any combustible

material from the work

area.

When possible, move the work to a14.

location well away from combustible

materials. If relocation is not pos-

sible, protect the combustibles with a

cover made of re resistant material.

Do not use near degreasing or paint-15.

ing operations.

Enclose the work area with portable16.

re resistant screens. Protect com-

bustible walls, ceilings, oors, etc.,

from sparks and heat with re resis-

tant covers.

Do not weld or cut on materials hav-17.

ing a combustible coating or combus-

tible internal structure, as in walls or

ceilings, without an approved method

for eliminating the hazard.

After spot welding, make a thorough18.

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. Pro-

vide 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 am-

mable or explosive vapors. Clean

and purge containers before applying

heat. Vent closed containers, includ-

ing castings, before preheating, weld-

ing, or cutting.

Do not touch live electrical parts.19.

Wear dry, insulating gloves. Do not

touch electrode or conductor tong

SKU 98233 For technical questions, please call 1-800-444-3353. Page 7

with bare hand. Do not wear wet or

damaged gloves.

Ensure that the unit is placed on a20.

stable location before use. If this unit

falls while plugged in, severe injury,

electric shock, or re 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.

Avoid overexposure to fumes and21.

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,22.

have a qualied technician take an air

sampling to determine the need for

corrective measures. Use mechani-

cal ventilation to improve air quality.

If engineering controls are not fea-

sible, use an approved respirator.

Follow OSHA guidelines for Permis-23.

sible Exposure Limits (PEL’s) for vari-

ous fumes and gases.

Follow the American Conference of24.

Governmental Industrial Hygienists

recommendations for Threshold Limit

Values (TLV’s) for fumes and gases.

Have a recognized specialist in25.

Industrial Hygiene or Environmental

Services check the operation and air

quality and make recommendations

for the specic welding or cutting situ-

ation.

Maintain labels and nameplates on26.

the tool. These carry important safety

information. If unreadable or miss-

ing, contact Harbor Freight Tools for a

replacement.

Avoid unintentional starting. Prepare27.

to begin work before turning on the

tool.

Do not leave the tool unattended28.

when it is plugged into an electrical

outlet. Turn off the tool, and unplug it

from its electrical outlet before leav-

ing.

Do not splice welding cables.29.

Do not weld sealed containers. All30.

containers should be considered un-

safe unless they have been rendered

safe or declared safe by a qualied

person.

SKU 98233 For technical questions, please call 1-800-444-3353. Page 8

This product is not a toy. Keep it out31.

of reach of children.

People with pacemakers should32.

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:

• 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.

A GFCI may provide protection from33.

the “wall to the welder”, but a GFCI

will not protect you from faults be-

tween the “welder and the work”.

Because a GFCI cannot protect

you from faults between the “welder

and the work” using proper welding

technique and personal protection

equipment while welding is crucial.

Ground the workpiece as well as the

welder.

Use a non-conductive safety mat on34.

the work surface to insulate the op-

erator from the work surface.

Turn off, unplug, and discharge elec-35.

trodes after use and before service.

Do not attempt to cool the welding tip36.

with uids. Allow the tip to cool down

gradually.

Secure cylinders upright to prevent37.

them from falling. All cylinders should

be used and stored in an upright po-

sition. 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

specied areas and clearly marked

“empty.”

Some dust created by power sand-38.

ing, sawing, grinding, drilling, and

other construction activities, contains

chemicals known [to the State of Cali-

fornia] to cause cancer, birth defects

or other reproductive harm. Some

examples of these chemicals are:

• Lead from lead-based paints

• Crystalline silica from bricks and ce-

ment or other masonry products

• Arsenic and chromium from chemi-

cally treated lumber

Your risk from these exposures var-

ies, depending on how often you do

this type of work. To reduce your

exposure to these chemicals: work in

a well ventilated area, and work with

approved safety equipment, such as

those dust masks that are specially

designed to lter out microscopic

particles. (California Health & Safety

Code § 25249.5, et seq.)

WARNING: Handling the cord on39.

this product will expose you to lead,

a chemical known to the State of

California to cause cancer, and birth

defects or other reproductive harm.

Wash hands after handling. (Califor-

nia Health & Safety Code § 25249.5,

et seq.)

The warnings, precautions, and in-40.

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

SKU 98233 For technical questions, please call 1-800-444-3353. Page 9

factors which cannot be built into this

product, but must be supplied by the

operator.

SAVE THESE

INSTRUCTIONS.

GROUNDING

TO PREVENT

ELECTRIC SHOCK

AND DEATH FROM

INCORRECT GROUNDING

WIRE CONNECTION:

Check with a qualied

electrician if you are in doubt

as to whether the outlet is

properly grounded. Have a

plug installed by a certied

electrician. 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

t the outlet, have a proper

outlet installed by a qualied

electrician.

Grounded Tools

The grounding prong in the plug is1.

connected through the green wire in-

side the cord to the grounding system

in the tool. The green wire in the cord

must be the only wire connected to

the tool’s grounding system and must

never be attached to an electrically

“live” terminal.

The tool must be plugged into an2.

appropriate outlet, properly installed

and grounded in accordance with all

codes and ordinances.

Extension Cords

As the distance from the supply outlet1.

increases, you must use a heavier

gauge extension cord. Using exten-

sion cords with inadequately sized

wire causes a serious drop in voltage,

resulting in loss of power and pos-

sible tool damage.

(See Table A.)

The smaller the gauge number of the2.

wire, the greater the capacity of the

cord. For example, a 14 gauge cord

can carry a higher current than a 16

gauge cord. (See Table A.)

When using more than one exten-3.

sion cord to make up the total length,

make sure each cord contains at

least the minimum wire size required.

(See Table A.)

If you are using one extension cord4.

for more than one tool, add the

nameplate amperes and use the sum

to determine the required minimum

cord size. (See Table A.)

If you are using an extension cord5.

outdoors, make sure it is marked with

the sufx “W-A” (“W” in Canada) to

indicate it is acceptable for outdoor

use.

Make sure the extension cord is prop-6.

erly wired and in good electrical con-

dition. Always replace a damaged

extension cord or have it repaired by

a qualied electrician before using it.

Protect the extension cords from7.

sharp objects, excessive heat, and

damp or wet areas.

SKU 98233 For technical questions, please call 1-800-444-3353. Page 10

RECOMMENDED MINIMUM WIRE

GAUGE FOR EXTENSION CORDS*

(120/240 VOLT)

NAMEPLATE

AMPERES

(at full load)

EXTENSION CORD

LENGTH

25’

50’

75’

100’

150’

0 – 2.0 18 18 18 18 16

2.1 – 3.4 18 18 18 16 14

3.5 – 5.0 18 18 16 14 12

5.1 – 7.0 18 16 14 12 12

7.1 – 12.0 18 14 12 10 -

12.1 – 16.0 14 12 10 - -

16.1 – 20.0 12 10 - - -

TABLE A

* Based on limiting the line

voltage drop to ve volts at

150% of the rated amperes.

Symbology

Double Insulated

Canadian Standards Association

Underwriters Laboratories, Inc.

V~ Volts Alternating Current

AAmperes

n0xxxx/min. No Load Revolutions per Minute

(RPM)

Table of contents

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