Harbor Freight Tools 66787 User Manual
240 VOLT ARC/TIG
Model
66787
INVERTER WELDER
AND TIG WELDING TORCH
SET UP AND OPERATING INSTRUCTIONS
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.
Revised Manual 09h, 09k, 09l
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.
For technical questions or replacement parts, please call 1-800-444-3353.
CONTENTS
IMPORTANT SAFETY INFORMATION............................................................................3
General Safety Rules...........................................................................................3
SpecicSafetyRules...........................................................................................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.........................................................................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 2SKU 66787 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 (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.
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.
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.
General Safety Rules
WARNING! Read all instructions
Failure to follow all instructions
listed below may result in
electricshock,re,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
Work area safety1.
Keep work area clean and well lit. a.
Cluttered or dark areas invite accidents.
Do not operate power tools in ex-b.
plosive 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 bystanders away c.
while operating a power tool. Distractions can cause you to lose
control.
Electrical safety2.
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.
Page 3SKU 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 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 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 inuence of drugs, alcohol
or medication. A moment of inattention 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 respirator, heavy-duty work gloves, nonskid safety shoes, or hearing protection used for appropriate conditions
will reduce personal injuries.
Avoid accidental starting. Ensure c.
the switch is in the off-position before plugging in. Carrying power
tools with your nger 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 care4.
Do not force the power tool. Use the a.
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 the b.
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 the power c.
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 the d.
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 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 4SKU 66787 For technical questions, please call 1-800-444-3353.
Service5.
Have your power tool serviced by a.
a qualied repair person using only
identical replacement parts. This will
ensure that the safety of the power
tool is maintained.
Avoid eye and body damage. Arc 5.
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.
SpecicSafetyRules
Maintain labels and nameplates on 1.
the tool. These carry important safety
information. If unreadable or missing, 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 connected to power. When the operator
is not holding the Torch, it must be
sitting on a nonconductive, nonammable surface.
Feed the ller 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 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.
Move ammable and explosive mate-6.
rial at least 35 feet from the welding
arc to prevent welding sparks or mol-
ten 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. 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 leaving.
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 elds in close proximity to heart pacemaker could cause
pacemaker interference or pacemaker failure. In addition, people with
pacemakers should:
Rev 09h
Page 5SKU 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 Interrupter (GFCI) should also be implemented – it prevents sustained electrical 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 & 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, 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.
approved for welding and cut ting
procedures.
When welding/cutting overhead •
or in conned 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 a •
location well away from combustible
materials. If relocation is not possible, protect the combustibles with
a cover made of re resistant material.
Remove or make safe all combus-•
tible 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.
Enclose the work area with por-•
table re resistant screens. Protect
combustible walls, ceilings, oors,
etc., from sparks and heat with re
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 re watch, equipped
with a re extinguisher, during the
cutting process and for at least one
half hour after the cutting is completed.
Wear an approved head covering •
to protect the head and neck. Use
aprons, cape, sleeves, shoulder
covers, and bibs designed and
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 6SKU 66787 For technical questions, please call 1-800-444-3353.
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