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.)

Page 11Item 61792 For technical questions, please call 1-888-866-5797.
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.
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.
1. IMPORTANT: This Welder is
equipped with a 240 volt, grounded,
3-prong Power Cord Plug. Never
remove the grounding prong or
modify the Plug in any way. Do not
use adapter plugs with this Welder.
2. Connect the Ground Clamp Cable to
the NEGATIVE (-) terminal.
(See Figure A.)
3. Connect the Electrode Holder Cable
to the POSITIVE (+) terminal.
(See Figure A.)
Work Piece and Work Area Set Up
1. Designate a work area that is clean
and well-lit. The work area must not
allow access by children or pets to
prevent injury and distraction.
2. Route the Power Cord (28) along a
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.
3. Secure loose work pieces using
a vise or clamps (not included) to
prevent movement while working.
The work pieces should be firmly
held together 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.
4. There must not be hazardous
objects, such as utility lines or foreign
objects, nearby that will present a
hazard while working.
5. A barrier, such as a welding curtain
or welding shroud should be put up
to protect others in the work area and
limit the spray of sparks.
WARNING

Page 12Item 61792 For technical questions, please call 1-888-866-5797.
General Operating Instructions
Please Note: The
following
instructions are for Arc
Welding using the Electrode
Holder.
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.
1. The 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 MMA 40% duty cycle at 145
Amps (maximum setting), must be
allowed to rest for at least 6 minutes
after every 4 minutes of continuous
weld at 145 Amps.
• Failure to carefully observe duty
cycle limitations can stress a
Welder’s power generation system,
contributing 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
automatically shuts down, then
returns to service when it cools
down.
• Once the unit returns to service,
follow a more conservative duty
cycle routine to help prevent excess
wear to the Welder.
2. Mount the metal to be welded to
the metal work table. It should be
mounted so that the welding debris
falls to the cement floor.
3. Place the Welder no closer than six
feet from the workpiece to be welded
and attach the Tig Torch, if desired.
4. Securely attach the Ground Clamp to
a part of the workpiece or metal table.
(See Figure A.)
5. Place the bare end of an Electrode
(not included) in the Electrode Holder.
NOTE: Always keep the jaws of the
Electrode Holder clean to ensure
proper electrical contact with the
Electrode. (See Figure A.)
6. Set the desired current on the
Potentiometer Dial from 10 to145
amps for the type of metal being
welded. Thin metals use low current
and heavy metals use high current.
(See Figure B.)
7. Make sure the Power Switch is OFF.
Then plug the Welder’s Power Cord
into the nearest 240 volt, dedicated,
grounded electrical outlet with
delayed action type circuit breaker or
fuse. (See Figure C.)
8. While gripping the Handle of the
Electrode Holder, with the Electrode
clear of grounded objects, turn the
Power Switch ON. (See Figure C.)
DANGER

Page 13Item 61792 For technical questions, please call 1-888-866-5797.
9. Hold the Electrode Holder firmly.
CAUTION! The Electrode Holder is
“live”. (See Figure A.)
10. WARNING! Never look at the ignited
arc without ANSI-approved, arc
shaded, eye protection in a full face
shield. Permanent eye damage or
blindness can occur. Skin burns can
occur. Wear a NIOSH-approved
respirator to avoid breathing arc
fumes.
11. Stroke the area to be welded with the
Electrode to ignite the arc. Never tap
the Electrode into the welding surface
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.
12. Once the arc is ignited, tilt the
Electrode forward at an angle
of approximately 30° and hold it
at a distance from the welding
object equal to the diameter of the
Electrode.
13. NOTE: If too much current is drawn
from the Welder, the internal Thermal
Overload Protector will activate.
The Yellow “Overheating” Light
will illuminate, and the Welder will
automatically shut off until it cools
down. Please wait until the welder
automatically restarts after the yellow
“overheating” light turns off.
(See Figures B and C.)
14. When the weld is complete, lift the
Electrode clearly away from any
grounded object. Then turn the
Power Switch OFF. (See Figure C.)
15. Unplug the Power Cord from its
electrical outlet.
16. Remove the Ground Clamp from
the workpiece it is clamped onto.
Then remove the Electrode from the
Electrode Holder. (See Figure A.)
17. Allow all components of the Welder
to completely cool. Then clean and
store the Welder indoors out of reach
of children and other unauthorized
persons.
18. IMPORTANT: Refer to the included
“Weld Diagnoses” pamphlet for tips
and suggestions regarding proper
welding.

Page 14Item 61792 For technical questions, please call 1-888-866-5797.
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).
1. To use Tig Torch, first disconnect
Electrode Holder Cable.
2. Connect the Ground Clamp Cable to
the POSITIVE (+) terminal.
3. Connect the Tig Torch Cable to the
NEGATIVE (-) terminal.
4. Attach the welder’s Ground Clamp
to a clean uncoated metal part of the
workpiece near the welding location.
5. Close the Gas Flow Knob on the
torch completely, turning it clockwise
until it stops. Turn the argon gas
supply on.
6. Hold the torch in a safe direction,
plug the welder’s power cord into a
grounded,240 VAC,GFCI-protected
receptacle and turn the Welder on.
7. Turn the Gas Flow Knob on the
torch counterclockwise to allow the
shielding gas to flow.
8. Tilt the torch forward, towards the
workpiece. Keep a constant distance
between the torch and the workpiece
but do not contact it.
9. Feed the filler metal into the arc
with a properly insulated holder
(not included).
10. Turn Gas Flow Knob on TIG torch to
adjust the flow of shielding gas.
11. After welding, hold Torch in a
safe direction, turn off the welder,
close the Gas Flow Knob on the
torch (clockwise), and unplug the
welder. Then, place the torch on
a nonconductive, nonflammable
surface, and close the argon supply
at the argon bottle.
DANGER

Page 15Item 61792 For technical questions, please call 1-888-866-5797.
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 of the Welder to its
“OFF” position and unplug
the tool from its electrical
outlet 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.
1. BEFORE EACH USE, inspect the
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.
2. PERIODICALLY, clean out the cooling
Vent and Fan with compressed air.
3. The Ceramic Nozzle on the 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.
4. For welding quality and ability,
maintain a point on the tip.
5. AFTER USE, clean external surfaces
of the Welder with a clean cloth.
6. WARNING! If the Power Cord of
this Welder is damaged, it must be
replaced only by a qualified service
technician.
WARNING

Page 16Item 61792 For technical questions, please call 1-888-866-5797.
TROUBLESHOOTING
Problem Possible Cause(s) Likely Solution(s)
Welder will not turn on. 1. No power at electrical outlet.
2. Power Cord not connected.
3. Line voltage incorrect.
1. Check power at electrical outlet.
2. Check that Power Cord is plugged
in.
3. Make sure the Welder is plugged
intoa240 VACelectricaloutlet.
No weld output with
ready light on.
1. Weld Cable loose.
2. Improper Ground Clamp-to-
workpiece connection.
1. Tighten Weld Cable connection at
Welder.
2. Make sure the area where the
Ground Clamp is attached is
clean, exposed metal, and free of
dirt, paint, and oil.
No weld output with high
temperature light on.
1. Welder overheated.
2. Duty cycle or amps too high.
3. Airowisblocked.
1. Allow unit to cool with Fan on.
2. Reduce duty cycle or amps.
3. Clean Vents and Fan out with
compressed air.
Erratic or improper arc or
welding output.
1. Bad connections.
2. Polarity incorrect.
3. Workpiece painted or dirty.
1. Clean and tighten all connections.
2. Connect polarity correctly.
3. Clean workpiece thoroughly.
Fan not operating. 1. Fan blocked.
2. Fan dirty.
3. Fan burnt out.
1. Remove obstruction.
2. Clean out Fan with compressed
air.
3. Have the Fan replaced by a
qualiedservicetechnician.
Main supply fuse shuts
off frequently.
1. Circuit Breaker is too low
amperage.
1. Install a dedicated 25 amp Circuit
Breaker.
Follow all safety precautions whenever diagnosing or servicing the
Welder. Disconnect power supply before servicing.

Page 17Item 61792 For technical questions, please call 1-888-866-5797.
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 BE
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.
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
available individually as replacement parts.

Page 18Item 61792 For technical questions, please call 1-888-866-5797.
WELDER PARTS LIST AND ASSEMBLY DIAGRAM
Part Description Qty
1 Belt 1
2 Cover 1
3 PCB Support 1
4 PCB 1
5 Control PCB 1
6 Potentiometer 1
7 Green LED 1
8 Yellow LED 1
9 Potentiometer Knob 1
10 Ground Clamp 1
11 Electrode Holder 1
12 Temperature Controller 1
13 RectierTubeSTTH6003CW 3
14 RectierTubeHeatSink 1
15 Quick Connector 2
Part Description Qty
16 Inductor 1
17 Transformer 1
18 Base 1
19 Fan Support PCB 1
20 Fan 2
21 Tapping Screw 4.2×9.5 15
22 IGBT K30N60HS 4
23 IGBT Heat Sink 2
24 Fan Cover 1
25 Capacitor 2
26 Power Switch 1
27 Power Cord Clip 1
28 Power Cord 1
29 Relay Heat Sink 1
30 Relay 1
22
28
27
1
2
3
4
5
6
7
8
9
10
11
12
24
14
15
1617
18 13
20
21
23
19
25
30
26
29

Page 19Item 61792 For technical questions, please call 1-888-866-5797.
Part Description Qty
1a Long Back Cap 1
2a Short Back Cap 1
3a Cup Gasket 1
4a Torch Body with Gasket 1
5a Cup Gasket 1
6a Collet1.6 mm 1
7a ColletHousing1.6 mm 1
8a Ceramic Nozzle size 5 1
9a TungstenElectrode1.6 mm 1
10a Gas Flow Knob 1
Part Description Qty
11a Torch Handle 1
12a Torch Cable 1
13a Air Hose 1
14a Quick Plug 1
15a Collet2.4 mm 1
16a ColletHousing2.4 mm 1
17a Ceramic Nozzle size 6 1
18a TungstenElectrode2.4 mm 1
19a Hose Clip 1
TIG TORCH PARTS LIST AND ASSEMBLY DIAGRAM
6a
15a
17a
1a
2a
3a
4a
5a
7a
16a
8a
9a
10a
11a
18a
12a 13a 14a
19a

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 product
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
damages, so the above limitation of exclusion may not apply to you. THIS WARRANTY
IS EXPRESSLY 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
complaint must accompany the merchandise. If our inspection verifies the defect, we
will either 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 repaired 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 • 1-888-866-5797