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240 Volt arc/tIG
INVErtEr wEldEr
aNd tIG wEldING t orch
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.
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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.
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coNtENtS IMportaNt SaFEtY INForMatIoN............................................................................3 General Safety rules...........................................................................................3 Specific Safety Rules...........................................................................................5 product SpEcIFIcatIoNS.........................................................................................9 uNpacKING.................................
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NotIcE is used to SaVE thIS MaNual address practices Keep this manual for the safety warn- not related to personal injury. ings and precautions, assembly, operating, cautIoN, without inspection, maintenance and cleaning pro- the safety alert cedures. Write the product’s serial number symbol, is used to address in the back of the manual (or month and practices not related to year of purchase if product has no num- personal injury. ber). Keep this manual and the receipt in a safe and
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b. Do not expose power tools to rain 4. power tool use and care or wet conditions. Water entering a a. Do not force the power tool. Use the power tool will increase the risk of correct power tool for your applica- electric shock. tion. The correct power tool will do c. Do not abuse the cord. Never use the job better and safer at the rate the cord for pulling or unplugging the for which it was designed. power tool. Keep cord away from b. Do not use the power tool if the heat, oil, sha
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5. Service 5. Avoid eye and body damage. Arc rays and infrared radiation can injure a. Have your power tool serviced by eyes and burn skin. Wear ANSI ap- a qualified repair person using only proved eye and body protection. Do identical replacement parts. This will not allow viewing by visitors without ensure that the safety of the power proper eye and body protection. Use tool is maintained. a Face Shield with arc shaded filter plate. Specific Safety Rules 6. Move flammable and explo
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• Avoid operating alone. approved for welding and cut ting • Do not use with power switch locked procedures. on. • When welding/cutting overhead • Properly maintain and inspect to or in confined spaces, wear flame avoid electrical shock. resistant ear plugs or ear muffs to • Any power cord must be properly keep sparks out of ears. grounded. Ground Fault Circuit Inter- 15. Prevent accidental fires. rupter (GFCI) should also be imple- mented – it prevents sustained elec- Remove any com
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proved method for eliminating the 18. Ensure that the unit is placed on a hazard. stable location before use. If this unit falls while plugged in, severe injury, • Do not dispose of hot slag in con- electric shock, or fire may result. tainers holding combustible materi- als. Keep a fire extinguisher nearby 19. Ground this product. This Welder and know how to use it. requires the attachment and use of • After spot welding, make a thorough a ul-listed, 240 volt, grounded, examination for
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tions for the specific welding or cut- 23. The warnings, precautions, and in- ting situation. structions discussed in this instruction manual cannot cover all possible con- 21. WARNING: Handling the Power ditions and situations that may occur. Cord on this product will expose you It must be understood by the operator to lead, a chemical known to the that common sense and caution are State of California to cause cancer, factors which cannot be built into this birth defects, and other r
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SpEcIFIcatIoNS t orch aSSEMBl Y 240V~ / 60 Hz / 25A max. 1. when assembling t orch, make Electrical Power Cord: SJT 12AWG x 3C sure t orch cable is not connected Requirements Power Plug: 3-Prong, 240 VAC to w elder or argon gas supply. (Not Included) Output (Back) (Front) Amperage 10-130 Amps Range rod Maximum ceramic holder Open Circuit 61V Nozzle (2a) Voltage (3a/3b) 40% @ 130 Amps Duty Cycle 60% @ 120 Amps Gas Flow 100% @ 80 Amps Knob Maximum handle Welding 1/4”
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wEldEr FEaturES 1. Electrode holder (8): Connect the Electrode Holder Cable to the POSI- TIVE Terminal located at the front of the Welder. (See Figure a.) 2. Ground clamp (9): Connect the Ground Clamp Cable to the NEGATIVE Terminal located on the front of the Welder. (See Figure a.) 3. potentiometer dial (4): Turn the Dial clockwise or counterclockwise to regu- late the welding current (from 10 to 130 amps). (See Figure B.) 4. Green “power on” light (5): When illuminated, indica
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w ork piece and w ork area Set up opEratING INStructIoNS 1. Designate a work area that is clean read the ENtIrE IMportaNt and well-lit. The work area must not SaFEtY INForMatIoN section allow access by children or pets to at the beginning of this manual prevent injury and distraction. including all text under subheadings therein before set 2. Route the Power Cord (17) along a up or use of this product. safe route to reach the work area without creating a tripping hazard Note: For add
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protective gear must be worn ed so that the welding debris falls to when using the w elder; aNSI- the cement floor. approved, arc shaded, eye 3. Place the Welder no closer than six protection, a full face shield, feet from the workpiece to be welded heavy duty work gloves, a and attach the Tig Torch, if desired. welding apron, respirator, and heavy-duty work clothes 4. Securely attach the Ground Clamp without pockets should be (9) to a part of the workpiece or metal worn when using th
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Wear a NIOSH-approved respirator of children and other unauthorized to avoid breathing arc fumes. persons. 11. Stroke the area to be welded with the 18. IMPORTANT: Refer to the included Electrode to ignite the arc. Never tap “Weld Diagnoses” pamphlet for tips the Electrode into the welding sur- and suggestions regarding proper face to ignite the arc. This damages welding. its external coating on the Electrode which prevents oxygen in the air from tIG t orch operating Instructions coming
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grounded, 240 V~, GFCI-protected t o prEVENt SErIouS receptacle and turn the Welder on. INjur Y FroM tool FaIlurE: do not use 5. Turn the Gas Flow Knob on the torch damaged equipment. If counterclockwise to allow the shield- abnormal noise or vibration ing gas to flow. occurs, have the problem corrected before further use. 6. Tilt the torch forward, towards the workpiece. Keep a constant distance 1. BEFORE EACH USE, inspect the between the torch and the workpiece general condition o
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trouBlEShootING problem possible cause(s) likely Solution(s) Welder will not turn on. 1. No power at electrical outlet. 1. Check power at electrical outlet. 2. Power Cord not connected. 2. Check that Power Cord is plugged in. 3. Line voltage incorrect. 3. Make sure the Welder is plugged into a 240VAC electrical outlet. No weld output with 1. Weld Cable loose. 1. Tighten Weld Cable connection at ready light on. Welder. 2. Improper Ground Clamp-to- 2. Make sure the area where the workpiece con
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wEldEr p artS lISt aNd aSSEMBl Y 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 SKU 66787 For technical questions, please call 1-800-444-3353. Page 16
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tIG torch p artS lISt aNd aSSEMBl Y dIaGraM 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 3a 4a 5a 2a 3b 4b 5b 6a plEaSE rEad thE FollowING carEFull Y THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFAC
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lIMItEd 90 da Y 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 installa
