Harbor Freight Tools 165 Amp_DC, 240 Volt, Inverter TIG/Stick Welder Product manual
Contents
1. 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 3 SKU 66787 For technical questions please call 1 800 442. 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 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 Ensure that the unit is placed on a 18 stable location before use If this unit falls while plugged in severe injury electric shock or fire may result Ground this product This Welder 19 requires the attachment and use of a ul listed 240 volt grounded 3 prong electrical power cord plug not included Only a quali fied 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 and 20 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 respirator Follow OSHA
3. 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 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 cut ting 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 pos sible protect the combustibles with a cover made of fire 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 fire resistant material to cover or block all open doorways win dows cracks and other openings Enclose the work area with por table 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 combus
4. into the nearest 240 volt dedicated grounded electrical outlet with delayed action type circuit break er or fuse See Figure c While gripping the Handle of the 8 Electrode Holder 8 with the Elec trode clear of grounded objects turn the Power Switch 16 oN See Figure c Hold the Electrode Holder 8 firmly 9 cautIoN The Electrode Holder is live See Figure a warNING 10 Never look at the ignited arc without ANSI approved arc shad ed eye protection in a full face shield Permanent eye damage or blindness can occur Skin burns can occur REV 09h Page 13 SKU 66787 For technical questions please call 1 800 444 3353 Wear a NIOSH approved respirator to avoid breathing arc fumes Stroke the area to be welded with the 11 Electrode to ignite the arc Never tap the Electrode into the welding sur face to ignite the arc This damages its external coating on the Electrode which prevents oxygen in the air from coming into contact with the molten metal causing it to oxidize Once the arc is ignited tilt the Elec 12 trode forward at an angle of approxi mately 30 and hold it at a distance from the welding object equal to the diameter of the Electrode NotE 13 If too much current is drawn from the Welder the internal Thermal Overload Protector will activate The Yellow Overheating Light 5 will illuminate and the Welder will auto matically shut off until it co
5. please call 1 800 444 3353 wEldEr partS lISt aNd aSSEMBlY dIaGraM part description Qty part description Qty 1 Housing 1 11 Transformer 1 2 Strap 1 12 Heat Sink 3 3 Potentiometer 1 13 Tapping Screw 4 2 x 9 5 14 4 Potentiometer Dial 1 14 Fan 2 5 LED Light 2 15 Cooling Vent 1 6 Quick Connector 2 16 Power Switch 1 7 Inductor 1 17 Power Cord 1 8 Electrode Holder 1 18 PCB Support 1 9 Ground Clamp 1 19 Cable Clip 1 10 Steel Base 1 20 PCB 1 REV 09h Page 17 SKU 66787 For technical questions please call 1 800 444 3353 part description Qty 1a Torch and Cable 1 2a Rod Holder 1 3a Ceramic Nozzle size 5 1 3b Ceramic Nozzle size 6 1 4a Collet Holder 1 6 mm 1 16 1 4b Collet Holder 2 4 mm 3 32 1 5a Collet 1 6 mm 1 16 1 5b Collet 2 4 mm 3 32 1 6a Plug 1 1a 2a 3a 3b 4a 4b 5a 5b 6a plEaSE rEad thE FollowING carEFullY THE MANUFACTURER AND OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY NEITHER THE MANUFACTURER OR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT IN FACT THE MANUFACTURER AND OR DISTRIBUTOR ExPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD B
6. 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 fire watch equipped with a fire 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 7 SKU 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 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 ven tilation 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 combus tible 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 weld ing or cutting Do not touch live electrical parts 16
7. SKU 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 torch 8 REV 09h Page 11 SKU 66787 For technical questions please call 1 800 444 3353 opEratING INStructIoNS read the ENtIrE IMportaNt SaFEtY INForMatIoN section at the beginning of this manual including all text
8. When the operator is not holding the Torch it must be sitting on a nonconductive nonflam mable surface Feed the filler 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 Arc 5 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 filter plate Move flammable and explosive mate 6 rial at least 35 feet from the welding arc to prevent welding sparks or mol ten 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 Avoid unintentional starting Prepare 7 to begin work before turning on the Welder Do not leave the Welder unattended 8 when it is plugged into an electrical outlet Turn off the tool and unplug it from its electrical outlet before
9. before performing any inspection maintenance or cleaning procedures to prEVENt SErIouS INjurY FroM tool FaIlurE do not use damaged equipment If abnormal noise or vibration occurs have the problem corrected before further use BEFORE EACH USE inspect the 1 general condition of the Welder Check for loose screws misalignment or binding of moving parts cracked electrode holder head or other broken parts damaged electrical wiring and any other condition that may affect its safe operation PERIODICALLY 2 clean out the cool ing Vent 15 and Fan 14 with com pressed air The Ceramic Nozzle 3a 3b on the 3 Tig Torch will occasionally need to be cleaned of spatter from welding Clean it with a metal brush When the nozzle deteriorates or can no longer be cleaned it will need to be replaced Unscrew the nozzle and replace it with a new one For welding quality and ability 4 maintain a point on the tip AFTER USE 5 clean external surfaces of the Welder with a clean cloth 6 warNING If the Power Cord 17 of this Welder is damaged it must be replaced only by a qualified service technician warNING REV 09h Page 15 SKU 66787 For technical questions please call 1 800 444 3353 trouBlEShootING problem possible cause s likely Solution s Welder will not turn on No power at electrical outlet 1 Power Cord not connected 2 Line voltage incorrect 3 Check p
10. work pieces should be firmly held to gether and in position while welding The distance if any between the two work pieces 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 ob 4 jects such as utility lines or foreign objects nearby that will present a hazard while working A barrier such as a welding curtain 5 or welding shroud should be put up to protect others in the work area and limit the spray of sparks General operating Instructions please Note the following instructions are for arc welding using the Electrode holder warNING daNGEr REV 09h Page 12 SKU 66787 For technical questions please call 1 800 444 3353 protective gear must be worn when using the welder aNSI approved arc shaded eye protection a full face shield heavy duty work gloves a welding apron respirator and heavy duty work clothes without pockets should be worn when using this product do not look at the ignited arc without eye protection light from the arc can cause permanent damage to the eyes light from the arc can burn the skin do not breathe arc fumes The 1 duty cycle defines the number of minutes within a 10 minute period during which a given Welder can safely produce a particular welding current For example this Welder with a 40 duty cycle at 130 Amps maximum setting must be al
11. 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 Copyright 2009 by Harbor Freight Tools All rights reserved 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 For technical questions or replacement parts please call 1 800 444 3353 Revised Manual 09h 09k 09l Page 2 SKU 66787 For technical questions please call 1 800 444 3353 coNtENtS IMportaNt SaFEtY INForMatIoN 3 General Safety rules 3 Specific Safety Rules 5 product SpEcIFIcatIoNS 9 uNpacKING
12. 4 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 fire and or serious injury The term power tool in all of the warnings listed below refers to your line operated corded ARC TIG In
13. E UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS AND NOT BY THE BUYER THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO REV 09h tIG torch partS lISt aNd aSSEMBlY dIaGraM Page 18 SKU 66787 For technical questions please call 1 800 444 3353 record product s Serial Number here Note If product has no serial number record month and year of purchase instead Note Some parts are listed and shown for illustration purposes only and are not avail able individually as replacement parts lIMItEd 90 daY warraNtY Harbor Freight Tools Co makes every effort to assure that its products meet high quality and durability standards and warrants to the original purchaser that this prod uct is free from defects in materials and workmanship for the period of 90 days from the date of purchase This warranty does not apply to damage due directly or indirectly to misuse abuse negligence or accidents repairs or alterations outside our facilities criminal activity improper installation normal wear and tear or to lack of maintenance We shall in no event be liable for death injuries to persons or property or for incidental contingent special or consequential damages arising from the use of our product Some states do not allow the exclusion or limitation of incidental or consequential d
14. amages so the above limitation of exclusion may not apply to you THIS WARRANTY IS ExPRESS LY IN LIEU OF ALL OTHER WARRANTIES ExPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS To take advantage of this warranty the product or part must be returned to us with transportation charges prepaid Proof of purchase date and an explanation of the com plaint must accompany the merchandise If our inspection verifies the defect we will ei ther repair or replace the product at our election or we may elect to refund the purchase price if we cannot readily and quickly provide you with a replacement We will return re paired products at our expense but if we determine there is no defect or that the defect resulted from causes not within the scope of our warranty then you must bear the cost of returning the product This warranty gives you specific legal rights and you may also have other rights which vary from state to state 3491 Mission Oaks Blvd PO Box 6009 Camarillo CA 93011 800 444 3353
15. er s Ground Clamp 2 to a clean uncoated metal part of the workpiece near the welding location Close the Gas Flow Knob on the 3 torch completely turning it clockwise until it stops Turn the argon gas sup ply on hold the torch in a safe direction 4 plug the welder s power cord into a daNGEr REV 09h Page 14 SKU 66787 For technical questions please call 1 800 444 3353 grounded 240 V GFCI protected receptacle and turn the Welder on Turn the Gas Flow Knob on the torch 5 counterclockwise to allow the shield ing gas to flow Tilt the torch forward towards the 6 workpiece Keep a constant distance between the torch and the workpiece but do not contact it Feed the filler metal into the arc 7 with a properly insulated holder not included Turn Gas Flow Knob on TIG torch to 8 adjust the flow of shielding gas After welding hold Torch in a safe di 9 rection turn off the welder close the Gas Flow Knob on the torch clock wise and unplug the welder Then place the torch on a nonconductive nonflammable surface and close the argon supply at the argon bottle MaINtENaNcE aNd SErVIcING Procedures not specifically explained in this manual must be performed only by a qualified technician to prEVENt SErIouS INjurY FroM accIdENtal opEratIoN turn the power Switch 16 of the welder to its oFF position and unplug the tool from its electrical outlet
16. 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 8 SKU 66787 For technical questions please call 1 800 444 3353 tions for the specific welding or cut ting situation WARNING Handling the Power 21 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 amp 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 Inflammation 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 b
17. influence of drugs alcohol or medication A moment of inatten tion while operating power tools may result in serious personal injury Use safety equipment Always wear b 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 Ensure c the switch is in the off position be fore plugging in Carrying power tools with your finger 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 care 4 Do not force the power tool Use the a 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 the b 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 power c 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 the d reach of children and do
18. leav ing Use clamps not included or other 9 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 out 10 of reach of children Industrial applications must follow 11 OSHA guidelines People with pacemakers should 12 consult their physician s before use Electromagnetic fields in close prox imity to heart pacemaker could cause pacemaker interference or pacemak er failure In addition people with pacemakers should Rev 09h Page 6 SKU 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 used 13 for welding produces chemicals known to the State of California to cause cancer and birth defects or other reproductive harm California Health amp 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
19. lowed to rest for at least 6 minutes after every 4 minutes of continuous weld at 130 Amps Failure to carefully observe duty cy cle limitations can stress a Welder s power generation system contribut ing to premature Welder failure This Welder is equipped with an internal thermal protection system to help prevent damage to the unit When the unit overheats it auto matically shuts down then returns to service when it cools down Once the unit returns to service fol low a more conservative duty cycle routine to help prevent excess wear to the Welder Mount the metal to be welded to the 2 metal work table It should be mount ed so that the welding debris falls to the cement floor Place the Welder no closer than six 3 feet from the workpiece to be welded and attach the Tig Torch if desired Securely attach the Ground Clamp 4 9 to a part of the workpiece or metal table See Figure a Place the bare end of an Electrode 5 not included in the Electrode Holder 8 NOTE Always keep the jaws of the Electrode Holder clean to ensure proper electrical contact with the Electrode See Figure a Set the desired current on the Poten 6 tiometer Dial 4 from 10 to130 amps for the type of metal being welded Thin metals use low current and heavy metals use high current See Figure B Make sure the Power Switch 16 is 7 oFF Then plug the Welder s Power Cord 17
20. 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 for e 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 5 SKU 66787 For technical questions please call 1 800 444 3353 Service 5 Have your power tool serviced by a a qualified repair person using only identical replacement parts This will ensure that the safety of the power tool is maintained Specific Safety Rules Maintain labels and nameplates on 1 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 Torch 2 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
21. ols down Please wait until the welder automati cally restarts after the yellow over heating light turns off See Figures B and c When the weld is complete lift the 14 Electrode clearly away from any grounded object Then turn the Power Switch 16 oFF See Figure c Unplug the Power Cord 17 from its 15 electrical outlet Remove the Ground Clamp 9 from 16 the workpiece it is clamped onto Then remove the Electrode from the Electrode Holder 8 See Figure a Allow all components of the Welder 17 to completely cool Then clean and store the Welder indoors out of reach of children and other unauthorized persons IMPORTANT Refer to the included 18 Weld Diagnoses pamphlet for tips and suggestions regarding proper welding tIG torch operating Instructions please Note the following instructions are for tig welding using the tig torch to prEVENt SErIouS INjurY aNd dEath 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 Feed the filler metal being used into the arc with a properly insulated holder not included To use Tig Torch first disconnect 1 Electrode Holder 8 Attach the weld
22. ower at electrical outlet 1 Check that Power Cord is plugged 2 in Make sure the Welder is plugged 3 into a 240VAC electrical outlet No weld output with ready light on Weld Cable loose 1 Improper Ground Clamp to 2 workpiece connection Tighten Weld Cable connection at 1 Welder Make sure the area where the 2 Ground Clamp is attached is clean exposed metal and free of dirt paint and oil No weld output with high temperature light on Welder overheated 1 Duty cycle or amps too high 2 Airflow is blocked 3 Allow unit to cool with Fan on 1 Reduce duty cycle or amps 2 Clean Vents and Fan out with 3 compressed air Erratic or improper arc or welding output Bad connections 1 Polarity incorrect 2 Workpiece painted or dirty 3 Clean and tighten all connections 1 Connect polarity correctly 2 Clean workpiece thoroughly 3 Fan not operating Fan blocked 1 Fan dirty 2 Fan burnt out 3 Remove obstruction 1 Clean out Fan with compressed 2 air Have the Fan replaced by a 3 qualified service technician Main supply fuse shuts off frequently Circuit Breaker is too low 1 amperage Install a dedicated 25 amp Circuit 1 Breaker Follow all safety precautions whenever diagnosing or servicing the welder disconnect power supply before servicing REV 09h Page 16 SKU 66787 For technical questions
23. 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 make 1 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 and 3 Collet Holder either 1 16 4a amp 5a or 3 32 4b amp 5b depending on the rod to be used Insert the Collet nar rower end first into the Collet Holder and then thread the Collet Holder loosely into the front of the Torch Place a prepared tungsten welding 4 rod the correct diameter for the Col let used into Collet Tighten Collet Holder in place Attach desired Ceramic Nozzle 3a or 5 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 flow to be effective Connect the gas hose securely to the 6 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 10
24. under subheadings therein before set up or use of this product Note For additional information regarding the parts listed in the following pages refer to the Assembly Diagram near the end of this manual tool Set up to prEVENt SErIouS INjurY FroM accIdENtal opEratIoN turn the switch to its off position before performing any inspection maintenance or cleaning procedures IMPORTANT This Welder requires 1 the attachment and use of a ul listed 240 volt grounded 3 prong electrical power cord plug not included Only a qualified electrician should install the Power Cord Plug Never remove the grounding prong or modify the Plug in any way Do not use adapter plugs with this Welder Connect the Ground Clamp 9 Cable 2 to the NEGATIVE terminal See Figure a Connect the Electrode Holder 8 3 Cable to the POSITIVE terminal See Figure a work piece and work area Set up Designate a work area that is clean 1 and well lit The work area must not allow access by children or pets to prevent injury and distraction Route the Power Cord 17 along a 2 safe route to reach the work area without creating a tripping hazard or exposing the Power Cord to pos sible damage The Power Cord must reach the work area with enough extra length to allow free movement while working Secure loose work pieces using a 3 vise or clamps not included to pre vent movement while working The
25. verter Welder SaVE thESE INStructIoNS work area safety 1 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 flammable liquids gases or dust Power tools create sparks which may ignite the dust or fumes Keep children and bystanders away c while operating a power tool Dis tractions can cause you to lose control Electrical safety 2 Avoid body contact with grounded a 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 4 SKU 66787 For technical questions please call 1 800 444 3353 Do not expose power tools to rain b or wet conditions Water entering a power tool will increase the risk of electric shock Do not abuse the cord Never use c 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 safety 3 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
26. y 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 9 SKU 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
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