Chicago Electric 61792 Assembly instructions

Revised Manual 09h, 09k, 09l
Owner’s Manual & Safety Instructions
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.
When unpacking, make sure that the product is intact
and undamaged. If any parts are missing or broken,
please call 1-888-866-5797 as soon as possible.
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.
Read this material before using this product.
Failure to do so can result in serious injury.
SAVE THIS MANUAL.
Visit our website at: http://www.harborfreight.com
Email our technical support at: [email protected]
REV 14e

Page 2Item 61792 For technical questions, please call 1-888-866-5797.
CONTENTS
IMPORTANT SAFETY INFORMATION............................................................................3
General Safety Rules...........................................................................................3
Specific Safety Rules...........................................................................................5
PRODUCT SPECIFICATIONS.........................................................................................9
UNPACKING....................................................................................................................9
TIG TORCH ASSEMBLY.................................................................................................9
WELDER FEATURES....................................................................................................10
OPERATING INSTRUCTIONS.......................................................................................11
Tool Set Up.........................................................................................................11
Work Piece and Work Area Set Up...................................................................11
General Operating Instructions.........................................................................12
TIG TORCH Operating Instructions...................................................................14
MAINTENANCE AND SERVICING................................................................................15
TROUBLESHOOTING...................................................................................................16
PLEASE READ THE FOLLOWING CAREFULLY.........................................................17
WELDER PARTS LIST AND ASSEMBLY DIAGRAM...................................................18
TIG TORCH PARTS LIST AND ASSEMBLY DIAGRAM...............................................19
PRODUCT WARRANTY INFORMATION......................................................................20

Page 3Item 61792 For technical questions, please call 1-888-866-5797.
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 (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.
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, fire, and/or
serious injury. The term “power
tool” in all of the warnings listed
below refers to your line-operated
(corded) ARC/TIG Inverter Welder.
SAVE THESE INSTRUCTIONS
1. Work area safety
a. Keep work area clean and well
lit. Cluttered or dark areas invite
accidents.
b. 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.
c. Keep children and bystanders
away while operating a power tool.
Distractions can cause you to lose
control.
2. Electrical safety
a. 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.
IMPORTANT SAFETY
INFORMATION

Page 4Item 61792 For technical questions, please call 1-888-866-5797.
b. Do not expose power tools to rain
or wet conditions. Water entering a
power tool will increase the risk of
electric shock.
c. Do not abuse the cord. Never use
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.
d. When operating a power tool
outdoors, use an extension cord
suitable for outdoor use. Use of
a cord suitable for outdoor use
reduces the risk of electric shock.
3. Personal safety
a. Stay alert, watch what you are
doing and use common sense
when operating a power tool. Do
not use a power tool while you are
tired or under the influence of drugs,
alcohol or medication. A moment
of inattention while operating power
tools may result in serious personal
injury.
b. Use safety equipment. Always wear
eye protection. Safety equipment
such as arc shaded, impact safety
full face shield, dust mask or
respirator, heavy-duty work gloves,
non-skid safety shoes, or hearing
protection used for appropriate
conditions will reduce personal
injuries.
c. Avoid accidental starting. Ensure
the switch is in the off-position
before plugging in. Carrying power
tools with your finger on the switch
or plugging in power tools that have
the switch on invites accidents.
d. Do not overreach. Keep proper
footing and balance at all times.
This enables better control of the
power tool in unexpected situations.
4. Power tool use and care
a. Do not force the power tool. Use
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.
b. Do not use the power tool if the
switch does not turn it on and
off. Any power tool that cannot
be controlled with the switch is
dangerous and must be repaired.
c. Disconnect the plug from the
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.
d. Store idle power tools out of the
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.
e. Maintain power tools. Check for
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.
f. Use the power tool and its
accessories 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

Page 5Item 61792 For technical questions, please call 1-888-866-5797.
for operations different from those
intended could result in a hazardous
situation.
5. Service
a. Have your power tool serviced by
a qualified repair person using only
identical replacement parts. This will
ensure that the safety of the power
tool is maintained.
Specific Safety Rules
1. Maintain labels and nameplates on
the tool. These carry important safety
information. If unreadable or missing,
contact Harbor Freight Tools for a
replacement.
2. 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.
3. Feed the filler metal being used into
the arc with a properly insulated
holder.
4. Avoid electrical shock. Do not permit
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.
5. Avoid eye and body damage. Arc
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 filter plate.
6. Move flammable and explosive
material at least 35 feet from the
welding arc to prevent welding sparks
or molten 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.
7. Avoid unintentional starting. Prepare
to begin work before turning on the
Welder.
8. Do not leave the Welder unattended
when it is plugged into an electrical
outlet. Turn off the tool, and unplug
it from its electrical outlet before
leaving.
9. Use clamps (not included) or other
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.
10. This product is not a toy. Keep it out
of reach of children.
11. Industrial applications must follow
OSHA guidelines.
12. People with pacemakers should
consult their physician(s) before
use. Electromagnetic fields in close
proximity to heart pacemaker could

Page 6Item 61792 For technical questions, please call 1-888-866-5797.
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.
13. WARNING: This product, when used
for welding, produces chemicals
known to the State of California to
cause cancer and birth defects (or
other reproductive harm). (California
Health & Safety Code § 25249.5, et
seq.)
14. Prevent eye injury and
burns. Wearing and using
ANSI-approved personal
safety clothing and safety
devices reduce the risk for
injury.
• Wear ANSI-approved safety impact
eye glasses underneath welding
eye protection featuring at least a
Number 10 shade lens rating.
• Leather leggings, 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/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
possible, protect the combustibles
with a cover made of fire resistant
material.
• 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
doorways, 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 cutting
process and for at least one half
hour after the cutting is completed.

Page 7Item 61792 For technical questions, please call 1-888-866-5797.
• Do not weld or cut on materials
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 in
containers holding combustible
materials. 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 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.
16. Do not touch live electrical parts.
Wear dry, insulating gloves. Do not
touch electrode or conductor tong
with bare hand. Do not wear wet or
damaged gloves.
17. Protect yourself from electric shock.
Do not use outdoors. Insulate
yourself 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.
18. Ensure that the unit is placed on a
stable location before use. If this unit
falls while plugged in, severe injury,
electric shock, or fire 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.
19. 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

Page 8Item 61792 For technical questions, please call 1-888-866-5797.
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 guidelines for
Permissible Exposure Limits (PEL’s)
for various fumes and gases.
• Follow the American Conference of
Governmental Industrial Hygienists
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
recommendations for the specific
welding or cutting situation.
20. Ground this product. This Welder is
equipped with a 240 volt, grounded,
3-prong 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.
21. WARNING: Handling the Power
Cord on this product will expose you
to lead, a chemical known to the
State of California to cause cancer,
birth defects, and other reproductive
harm. Wash hands after handling.
(California Health & Safety Code §
25249.5 et seq.)
22. The warnings, precautions,
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.
SAVE THESE
INSTRUCTIONS.

Page 9Item 61792 For technical questions, please call 1-888-866-5797.
SPECIFICATIONS
Electrical
Requirements
240 VAC/60 Hz/25 AMax.
PowerCord:SJT12 AWGx3C
Power Plug: 6-50P, 3-Prong,
240 VAC
Welding
Current Range
MMA:10 – 145 A
TIG:15 – 165 A
Maximum
Open Circuit
Voltage
85V
Duty Cycle MMA: 40% @ 145 Amps
TIG: 40% @ 165 Amps
Material
Thickness
MMA: Up to 1/4"
TIG: 22 gauge to 1/8"
Weldable
Materials
Mild steel, low alloy steel, and
stainless steel
(not suitable for aluminum)
Electrode
Capacity
MMA: 1/16", 3/32", 1/8"
TIG: 1/16", 3/32"
Electrode
Holder Cable
Length
5'- 4"
Ground Cable
Length 4'- 8"
Torch Cable
Length 12'-7"
Gas Hose 8'- 6"L,3/16"ID
UNPACKING
When unpacking, check to make sure
that the item is intact and undamaged. If
any parts are missing or broken, please
call Harbor Freight Tools at the number
shown on the cover of this manual as soon
as possible.
Note: For TIG Welding Torch Parts
List and Diagram, refer to page 19.
1. When assembling Torch, make
sure Torch Cable is not connected
to Welder or argon gas supply.
2.
Ceramic
Nozzle
Long
Back
Cap
Gas Flow
Knob
Handle
(Front) (Back)
Thread either Long Back Cap (1a)
or Short Back Cap (2a) securely into
back of Torch Body (4a).
3. Choose a matching set of Collet
andColletHousing,either1.6 mm
(6a – 7a)or2.4 mm(15a – 16a),
depending on the size Electrode to be
used. Insert the Collet, narrower end
first, into the Collet Housing, and then
thread the Collet Housing loosely into
the front of the Torch.
4. Place a prepared Tungsten Electrode
(9a, 18a) into Collet, using the correct
diameter for the Collet used. Tighten
Collet Housing in place.
5. Attach correct Ceramic Nozzle (8a
or 17a) onto Collet Housing. Do not
overtighten. Ceramic Nozzles of
larger sizes will contain shielding gas
in a larger area, but may require more
gas flow to be effective.
6. Connect the gas hose securely to the
regulator on the argon bottle. Set the
argon regulator to 18-22 PSI. Follow
the gas cylinder manufacturer’s
instructions for set-up and use.
7. Connect the cable to the Welder.
Twist to lock in place.
TORCH ASSEMBLY

Page 10Item 61792 For technical questions, please call 1-888-866-5797.
WELDER FEATURES
1. Electrode Holder (11): Connect
the Electrode Holder Cable to the
POSITIVE Terminal located at the front
of the Welder. (See Figure A.)
2. Ground Clamp (10): Connect the
Ground Clamp Cable to the NEGATIVE
Terminal located on the front of the
Welder. (See Figure A.)
3. Potentiometer Dial (9): Turn the
Dial clockwise or counterclockwise to
regulate the welding current (from 10 to
145 amps). (See Figure B.)
4. Green “Power On” Light: When
illuminated, indicates the Welder is
receiving electrical power and is ready
for use. (See Figure B.)
5. Yellow “Overheating” Light: When
illuminated, indicates overheating
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.)
6. Fan (20): The Fan must operate
continuously when operating the
Welder to prevent the unit from
overheating. (See Figure C.)
7. Power Switch (26): The Power
Switch must illuminate before welding
operations can begin.
(See Figure C.)