Chicago Electric 97719 Installation manual

ARC WELDER
135AC/105DC AMP
Model 97719
SET UP AND OPERATING INSTRUCTIONS
Visit our website at: http://www.harborfreight.com
Read this material before using this product.
Failure to do so can result in serious injury.
SAVE THIS MANUAL.
Copyright©2008 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 ex-
press written consent of Harbor Freight Tools. Diagrams within this manual may not be
drawn proportionally. Due to continuing improvements, actual product may differ slightly
from the product described herein. Tools required for assembly and service may not be
included.
For technical questions or replacement parts, please call 1-800-444-3353.
Revised Manual 09c, 09l

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CONTENTS
IMPORTANT SAFETY INFORMATION ........................................................................3
GENERAL SAFETY RULES....................................................................................3
SPECIFIC SAFETY RULES.....................................................................................5
SPECIFICATIONS.........................................................................................................9
UNPACKING .................................................................................................................9
INITIAL SET UP
INSTRUCTIONS............................................................................................................9
ASSEMBLY..............................................................................................................9
OPERATING INSTRUCTIONS....................................................................................10
WORK PIECE AND WORK AREA SET UP ..........................................................10
GENERAL OPERATING INSTRUCTIONS............................................................ 11
MAINTENANCE AND SERVICING.............................................................................13
TROUBLESHOOTING.................................................................................................14
PLEASE READ THE FOLLOWING CAREFULLY .....................................................14
PARTS LIST.................................................................................................................15
ASSEMBLY DIAGRAM ..............................................................................................16
LIMITED 1 YEAR / 90 DAY WARRANTY....................................................................17

Page 3SKU 97719 For technical questions, please call 1-800-444-3353.
SAVE THIS MANUAL
Keep this manual for the safety
warnings and precautions, assembly,
operating, inspection, maintenance and
cleaning procedures. Write the product’s
serial number in the back of the manual near
the assembly diagram (or month and year of
purchase if product has no number). Keep
this manual and the receipt in a safe and dry
place for future reference.
IMPORTANT SAFETY
INFORMATION
In this manual, on the labeling,
and all other information
provided with this product:
This is the safety alert
symbol. It is used to alert
you to potential personal
injury hazards. Obey all
safety messages that
follow this symbol to avoid
possible injury or death.
DANGER indicates
a hazardous
situation which, if not
avoided, will result in death or
serious injury.
WARNING
indicates a hazardous
situation which, if not
avoided, could result in death
or serious injury.
CAUTION, used
with the safety
alert symbol, indicates a
hazardous situation which, if
not avoided, could result in
minor or moderate injury.
NOTICE is used to
address practices
not related to personal injury.
CAUTION, without
the safety alert
symbol, is used to address
practices not related to
personal injury.
General Safety Rules
WARNING! Read all instructions
Failure to follow all instructions
listed below may result in
electric shock, re, and/or
serious injury. The term “power
tool” in all of the warnings listed
below refers to your line-operated
(corded) Arc Welder.
SAVE THESE INSTRUCTIONS
Work area safety1.
Keep work area clean and wella.
lit. Cluttered or dark areas invite
accidents.
Do not operate power tools inb.
explosive atmospheres, such as in
the presence of ammable liquids,
gases or dust. Power tools create
sparks which may ignite the dust or
fumes.
Keep children and bystandersc.
away while operating a power tool.
Distractions can cause you to lose
control.

Page 4SKU 97719 For technical questions, please call 1-800-444-3353.
Electrical safety2.
Avoid body contact with groundeda.
surfaces such as pipes, radiators,
ranges and refrigerators. There is
an increased risk of electric shock if
your body is grounded.
Do not touch exposed electricalb.
parts.
Do not expose power tools to rainc.
or wet conditions. Water entering a
power tool will increase the risk of
electric shock.
Do not abuse the cord. Never used.
the cord for pulling or unplugging the
power tool. Keep cord away from
heat, oil, sharp edges or moving
parts. Damaged or entangled cords
increase the risk of electric shock.
When operating a power toole.
outdoors, use an extension cord
suitable for outdoor use. Use of
a cord suitable for outdoor use
reduces the risk of electric shock.
Personal safety3.
Stay alert, watch what you area.
doing and use common sense
when operating a power tool. Do
not use a power tool while you are
tired or under the inuence of drugs,
alcohol or medication. A moment
of inattention while operating power
tools may result in serious personal
injury.
Use safety equipment. Always wearb.
ANSI-approved safety glasses and
arc shaded, impact safety full face
shield. Safety equipment such as
NIOSH-approved respirator, heavy-
duty work gloves, non-skid safety
shoes, or hearing protection used
for appropriate conditions will reduce
personal injuries.
Avoid accidental starting. Ensurec.
the switch is in the off-position
before plugging in.
Remove any adjusting key or wrenchd.
before turning the power tool on. A
wrench or a key left attached to a
rotating part of the power tool may
result in personal injury.
Do not overreach. Keep propere.
footing and balance at all times.
This enables better control of the
power tool in unexpected situations.
Power tool use and care4.
Do not force the power tool. Usea.
the correct power tool for your
application. The correct power tool
will do the job better and safer at the
rate for which it was designed.
Do not use the power tool if theb.
switch does not turn it on and
off. Any power tool that cannot
be controlled with the switch is
dangerous and must be repaired.
Disconnect the plug from thec.
power source before making any
adjustments, changing accessories,
or storing power tools. Such
preventive safety measures reduce
the risk of starting the power tool
accidentally.
Store idle power tools out of thed.
reach of children and do not allow
persons unfamiliar with the power
tool or these instructions to operate
the power tool. Power tools are
dangerous in the hands of untrained
users.
Maintain power tools. Check fore.
misalignment or binding of moving
parts, breakage of parts and any
other condition that may affect the
power tool’s operation. If damaged,

Page 5SKU 97719 For technical questions, please call 1-800-444-3353.
have the power tool repaired before
use. Many accidents are caused by
poorly maintained power tools.
Use the power tool, accessories andf.
tool bits etc., in accordance with
these instructions and in the manner
intended for the particular type of
power tool, taking into account the
working conditions and the work to
be performed. Use of the power tool
for operations different from those
intended could result in a hazardous
situation.
Service5.
Have your power tool serviced bya.
a qualied repair person using only
identical replacement parts. This will
ensure that the safety of the power
tool is maintained.
Specic Safety Rules
Maintain labels and nameplates on1.
the tool. These carry important safety
information. If unreadable or missing,
contact Harbor Freight Tools for a
replacement.
NEVER connect one Cable (33, 34)2.
to a DC Cable Connection Knob (22)
and the other Cable to an AC Cable
Connection Knob.
ALWAYS unplug the Power Cord3.
(32) from its electrical outlet before
connecting Cables (33, 34).
Avoid electrical shock. Do not permit4.
electrically live parts, cables, or
electrodes to contact skin, clothing,
or gloves. Wear ANSI-approved
protective clothing. This unit draws
enough current to cause serious
injury or death. Before turning the
welder on, check the electrode
holder to be sure that there are no
protruding screw heads, and that
all insulation is secure. Do not weld
unless you are insulated from ground
and the work piece.
Avoid eye and body damage. Arc5.
rays and infrared radiation can
injure eyes and burn skin. Wear
ANSI-approved eye and body
protection. Do not allow viewing by
visitors without proper eye and body
protection. Use a Face Shield with
arc shaded lter plate.
Move ammable and explosive 6.
material at least 35 feet from the
welding arc to prevent welding sparks
or molten metal from starting a re.
Keep a type ABC re extinguisher
within easy reach. Thoroughly clean
the object being welded of any paint,
grease, or other foreign material.
Avoid unintentional starting. Prepare7.
to begin work before turning on the
tool.
Do not leave the tool unattended8.
when it is plugged into an electrical
outlet. Turn off the tool, and unplug
it from its electrical outlet before
leaving.
Use clamps (not included) or other9.
practical ways to secure and support
the work piece to a stable platform.
Holding the work by hand or against
your body is unstable and may lead
to loss of control.
This product is not a toy. Keep it out10.
of reach of children.
Industrial applications must follow11.
OSHA guidelines.

Page 6SKU 97719 For technical questions, please call 1-800-444-3353.
People with pacemakers should12.
consult their physician(s) before
use. Electromagnetic elds in close
proximity to heart pacemaker could
cause pacemaker interference or
pacemaker failure. In addition,
people with pacemakers should:
• Avoid operating alone.
• Do not use with power switch locked
on.
• Properly maintain and inspect to
avoid electrical shock.
• Any power cord must be properly
grounded. Ground Fault Circuit
Interrupter (GFCI) should also be
implemented – it prevents sustained
electrical shock.
WARNING: This product, when used13.
for welding, plasma cutting, soldering,
or similar applications, produces
chemicals known to the State of
California to cause cancer and birth
defects (or other reproductive harm).
(California Health & Safety Code §
25249.5, et seq.)
14. Prevent eye
injury and
burns. Wearing
and using
ANSI-approved
personal safety clothing and safety
devices reduce the risk for injury.
Wear ANSI-approved safety impact•
eye goggles underneath welding
eye protection featuring at least a
Number 10 shade lens rating.
Leather leggings, re resistant •
shoes or boots should be worn
when using this product. Do not
wear pants with cuffs, shirts with
open pockets, or any clothing that
can catch and hold molten metal or
sparks.
Keep clothing free of grease,•
oil, solvents, or any ammable
substances. Wear dry, insulating
gloves and protective clothing.
Wear an approved head covering•
to protect the head and neck. Use
aprons, cape, sleeves, shoulder
covers, and bibs designed and
approved for welding and cutting
procedures.
When welding/cutting overhead•
or in conned spaces, wear ame
resistant ear plugs or ear muffs to
keep sparks out of ears.
15. Prevent accidental res.
Remove any combustible
material from the work
area.
When possible, move the work to a16.
location well away from combustible
materials. If relocation is not pos-
sible, protect the combustibles with a
cover made of re resistant material.
Remove or make safe all combustible17.
materials for a radius of 35 feet (10
meters) around the work area. Use
a re resistant material to cover or
block all open doorways, windows,
cracks, and other openings.
Ground this product. This Welder18.
requires the attachment and use
of a UL-listed, 240 volt, grounded,
3-prong, electrical Power Cord Plug
(not included). Only a qualied
electrician should install the Power
Cord Plug. Never remove the
grounding prong or modify the Power
Cord Plug in any way. Do not use
adapter plugs with this product.
Do not use near degreasing or19.
painting operations.
REV 09d

Page 7SKU 97719 For technical questions, please call 1-800-444-3353.
Enclose the work area with portable20.
re resistant screens. Protect
combustible walls, ceilings, oors,
etc., from sparks and heat with re
resistant covers.
If working on a metal wall, ceiling,21.
etc., prevent ignition of combustibles
on the other side by moving the
combustibles to a safe location. If
relocation of combustibles is not
possible, designate someone to
serve as a re watch, equipped with
a re extinguisher, during the cutting
process and for at least one half hour
after the cutting is completed.
Do not weld or cut on materials22.
having a combustible coating or
combustible internal structure, as in
walls or ceilings, without an approved
method for eliminating the hazard.
Do not dispose of hot slag in23.
containers holding combustible
materials. Keep a re extinguisher
nearby and know how to use it.
After spot welding, make a thorough24.
examination for evidence of re. Be
aware that easily-visible smoke or
ame may not be present for some
time after the re has started. Do
not weld or cut in atmospheres
containing dangerously reactive or
ammable gases, vapors, liquids, and
dust. Provide adequate ventilation in
work areas to prevent accumulation
of ammable gases, vapors, and
dust. Do not apply heat to a
container that has held an unknown
substance or a combustible material
whose contents, when heated, can
produce ammable or explosive
vapors. Clean and purge containers
before applying heat. Vent closed
containers, including castings, before
preheating, welding, or cutting.
Do not touch live electrical parts.25.
Wear dry, insulating gloves. Do not
touch electrode or conductor tong
with bare hand. Do not wear wet or
damaged gloves.
Protect yourself from electric shock.26.
Do not use outdoors. Insulate
yourself from the work piece and
ground. Use nonammable, dry
insulating material if possible, or
use dry rubber mats, dry wood or
plywood, or other dry insulating
material large enough to cover your
full area of contact with the work or
ground.
Ensure that the unit is placed on a27.
stable location before use. If this unit
falls while plugged in, severe injury,
electric shock, or re may result.
Avoid overexposure to fumes and28.
gases. Always keep your head out
of the fumes. Do not breathe the
fumes. Use enough ventilation or
exhaust, or both, to keep fumes and
gases from your breathing zone and
general area.
Where ventilation is questionable,29.
have a qualied technician take
an air sampling to determine the
need for corrective measures. Use
mechanical ventilation to improve
air quality. If engineering controls
are not feasible, use an approved
respirator.
Follow OSHA guidelines for30.
Permissible Exposure Limits (PEL’s)
for various fumes and gases.
Follow the American Conference of31.
Governmental Industrial Hygienists

Page 8SKU 97719 For technical questions, please call 1-800-444-3353.
recommendations for Threshold Limit
Values (TLV’s) for fumes and gases.
Have a recognized specialist in32.
Industrial Hygiene or Environmental
Services check the operation and air
quality and make recommendations
for the specic welding or cutting
situation.
The warnings, precautions,33.
and instructions discussed in
this instruction manual cannot
cover all possible conditions and
situations that may occur. It must
be understood by the operator that
common sense and caution are
factors which cannot be built into this
product, but must be supplied by the
operator.
WARNING
INHALATION HAZARD:
Welding and Plasma Cutting Produce
TOXIC FUMES.
Exposure to welding or cutting
exhaust fumes can increase the risk
of developing certain cancers, such as
cancer of the larynx and lung cancer.
Also, some diseases that may be linked
to exposure to welding or plasma cutting
exhaust fumes are:
• Early onset of Parkinson’s Disease
• Heart disease
• Ulcers
• Damage to the reproductive organs
• Inammation of the small intestine or
stomach
• Kidney damage
• Respiratory diseases such as
emphysema, bronchitis, or pneumonia
Use natural or forced air ventilation and
wear a respirator approved by NIOSH to
protect against the fumes produced to
reduce the risk of developing the above
illnesses.
SAVE THESE
INSTRUCTIONS.

Page 9SKU 97719 For technical questions, please call 1-800-444-3353.
SPECIFICATIONS
Electrical
Requirements
240 V~ / 60 Hz / Single Phase
Power Plug Type:
240 Volt, 3-Prong, Grounded
(Not Included)
Output Current AC 55 - 135A
DC 30 - 105A
Max. Input
Current 40 Amps Operating
Indicators Power On Light (Green)
Thermal Overload Light (Orange)
Welding
Capacity
Thickness
Up to 1/4” (using 1/16”, 3/32” or 1/8”
diameter electrodes)
Duty Cycle 10% @ 130 Amps AC
15% @ 100 Amps DC
Load Voltage 25.2V (AC operation)
24.2V (DC operation)
Open Circuit
Voltage
68V (AC operation)
60V (DC operation)
Accessories
Welding Shield (Qty. 1)
Hammer/Brush (Qty. 1)
Electrode Holder (Qty. 1)
Ground Clamp (Qty. 1)
UNPACKING
When unpacking, check to make sure
that the item is intact and undamaged. If
any parts are missing or broken, please call
Harbor Freight Tools at the number shown
on the cover of this manual as soon as
possible.
INITIAL SET UP
INSTRUCTIONS
Read the ENTIRE IMPORTANT
SAFETY INFORMATION section
at the beginning of this manual
including all text under
subheadings therein before set
up or use of this product.
TO PREVENT
SERIOUS
INJURY FROM ACCIDENTAL
OPERATION:
Turn the Power Switch of
the Arc Welder to its “OFF”
position and unplug the
tool from its electrical outlet
before assembling or making
any adjustments.
Note: For additional information regarding
the parts listed in the following pages,
refer to the Assembly Diagram near
the end of this manual.
Assembly
To assemble the Welding Shield,1.
place the Shield on a at surface.
Press the Handle into place. Then
insert the Filter Lens.
(See Figure A.)
This Welder requires the attachment2.
and use of a UL-listed, 240 volt,
grounded, 3-prong, electrical Power
Cord Plug (not included). Only a
quali ed electrician should install the
FIGURE A
REV 09d; 09l

Page 10SKU 97719 For technical questions, please call 1-800-444-3353.
Power Cord Plug. Never remove the
grounding prong or modify the Power
Cord Plug in any way. Do not use
adapter plugs with this product.
To assemble the two Wheels (9),3.
insert the Axle (8) through the two
holes located at the bottom/rear of the
Base Frame (3). Place the Wheels
onto the protruding ends of the Axle.
Then secrure the Wheels in place,
using one Bolt (10) for each end of
the Axle. (See Assy. Diagram.)
To attach the Handle (30), align the4.
two holes in the Handle with the two
threaded mounting holes located
at the top of the Case (28). Secure
the Handle to the Case, using two
Screws (31). (See Assy. Diagram.)
OPERATING INSTRUCTIONS
Read the ENTIRE IMPORTANT
SAFETY INFORMATION section
at the beginning of this manual
including all text under
subheadings therein before set
up or use of this product.
TO PREVENT
SERIOUS
INJURY FROM ACCIDENTAL
OPERATION:
Turn the switch to its off
position before performing
any inspection, maintenance,
or cleaning procedures.
Workpiece and Work Area Set Up
Designate a work area that is clean1.
and well-lit. The work area must not
allow access by children or pets to
prevent injury and distraction.
Route the Power Cord (32) along a2.
safe route to reach the work area
without creating a tripping hazard or
exposing the power cord to possible
damage. The power cord must reach
the work area with enough extra
length to allow free movement while
working.
Secure loose workpieces using a vise3.
or clamps (not included) to prevent
movement while working. The work-
pieces should be rmly held together
and in position while welding. The
distance (if any) between the two
workpieces must be controlled
properly to allow the weld to hold both
sides securely while allowing the weld
to penetrate fully into the joint.
There must not be hazardous objects,4.
such as utility lines or foreign objects,
nearby that will present a hazard
while working.
A barrier, such as a welding curtain5.
or welding shroud, should be put up
to protect others in the work area and
limit the spray of sparks.