Harbor Freight Tools Welder 97719 User 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  
 
CAutiOn, used  
with the safety  
alert symbol, indicates a  
hazardous situation which, if  
not avoided, could result in  
minor or moderate injury.  
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.  
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  
general Safety Rules  
provided with this product:  
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 Welder.  
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.  
SAVE thESE inStRuCtiOnS  
1. Work area safety  
DAngER indicates  
a hazardous  
situation which, if not  
avoided, will result in death or  
serious injury.  
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.  
WARning  
indicates a hazardous  
situation which, if not  
avoided, could result in death  
or serious injury.  
c. Keep children and bystanders  
away while operating a power tool.  
Distractions can cause you to lose  
control.  
SKU 97719  
For technical questions, please call 1-800-444-3353.  
Page 3  
 
2. Electrical safety  
c. Avoid accidental starting. Ensure  
the switch is in the off-position  
before plugging in.  
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.  
d. Remove any adjusting key or wrench  
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.  
b. Do not touch exposed electrical  
parts.  
e. Do not overreach. Keep proper  
footing and balance at all times.  
This enables better control of the  
power tool in unexpected situations.  
c. Do not expose power tools to rain  
or wet conditions. Water entering a  
power tool will increase the risk of  
electric shock.  
d. 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.  
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.  
e. 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.  
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.  
3. personal safety  
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.  
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.  
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.  
b. Use safety equipment. Always wear  
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.  
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,  
SKU 97719  
For technical questions, please call 1-800-444-3353.  
Page 4  
 
have the power tool repaired before  
use. Many accidents are caused by  
poorly maintained power tools.  
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.  
f. Use the power tool, accessories and  
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.  
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.  
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.  
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.  
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.  
7. Avoid unintentional starting. Prepare  
to begin work before turning on the  
tool.  
8. Do not leave the tool unattended  
when it is plugged into an electrical  
outlet. Turn off the tool, and unplug  
it from its electrical outlet before  
leaving.  
2. NEVER connect one Cable (33, 34)  
to a DC Cable Connection Knob (22)  
and the other Cable to an AC Cable  
Connection Knob.  
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.  
3. ALWAYS unplug the Power Cord  
(32) from its electrical outlet before  
connecting Cables (33, 34).  
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  
10. This product is not a toy. Keep it out  
of reach of children.  
11. Industrial applications must follow  
OSHA guidelines.  
SKU 97719  
For technical questions, please call 1-800-444-3353.  
Page 5  
 
12. People with pacemakers should  
consult their physician(s) before  
use. Electromagnetic fields in close  
proximity to heart pacemaker could  
cause pacemaker interference or  
pacemaker failure. In addition,  
people with pacemakers should:  
• Avoid operating alone.  
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.  
• 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.  
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.  
13. WARNING: This product, when used  
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.)  
16. When possible, move the work to a  
location well away from combustible  
materials. If relocation is not pos-  
sible, protect the combustibles with a  
cover made of fire resistant material.  
17. 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.  
14.  
Prevent eye  
injury and  
burns. Wearing  
and using  
ANSI-approved  
personal safety clothing and safety  
devices reduce the risk for injury.  
18. Ground this product. This Welder  
requires the attachment and use  
of a UL-listed, 240 volt, grounded,  
3-prong, electrical Power Cord Plug  
(not included). Only a qualified  
Wear ANSI-approved safety impact  
eye goggles underneath welding  
eye protection featuring at least a  
Number 10 shade lens rating.  
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.  
• 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.  
19. Do not use near degreasing or  
painting operations.  
REV 09d  
SKU 97719  
For technical questions, please call 1-800-444-3353.  
Page 6  
 
20. Enclose the work area with portable  
fire resistant screens. Protect  
combustible walls, ceilings, floors,  
etc., from sparks and heat with fire  
resistant covers.  
containers, including castings, before  
preheating, welding, or cutting.  
25. 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.  
21. 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.  
26. 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 large enough to cover your  
full area of contact with the work or  
ground.  
22. 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.  
27. 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.  
23. Do not dispose of hot slag in  
containers holding combustible  
materials. Keep a fire extinguisher  
nearby and know how to use it.  
28. 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  
gases from your breathing zone and  
general area.  
24. 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  
29. 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.  
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  
30. Follow OSHA guidelines for  
Permissible Exposure Limits (PEL’s)  
for various fumes and gases.  
31. Follow the American Conference of  
Governmental Industrial Hygienists  
SKU 97719  
For technical questions, please call 1-800-444-3353.  
Page 7  
 
recommendations for Threshold Limit  
Values (TLV’s) for fumes and gases.  
WARning  
32. 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.  
inhALAtiOn hAzARD:  
Welding and plasma Cutting produce  
tOxiC FumES.  
33. 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.  
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  
• Inflammation 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.  
SKU 97719  
For technical questions, please call 1-800-444-3353.  
Page 8  
 
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.  
SpECiFiCAtiOnS  
240 V~ / 60 Hz / Single Phase  
Power Plug Type:  
Electrical  
Requirements  
240 Volt, 3-Prong, Grounded  
(Not Included)  
AC 55 - 135A  
DC 30 - 105A  
Output Current  
Max. Input  
Current  
40 Amps Operating  
Power On Light (Green)  
Thermal Overload Light (Orange)  
Indicators  
Welding  
Capacity  
Thickness  
Up to 1/4” (using 1/16”, 3/32” or 1/8”  
diameter electrodes)  
note: For additional information regarding  
the parts listed in the following pages,  
refer to the Assembly Diagram near  
the end of this manual.  
10% @ 130 Amps AC  
15% @ 100 Amps DC  
Duty Cycle  
25.2V (AC operation)  
24.2V (DC operation)  
Load Voltage  
Assembly  
Open Circuit  
Voltage  
68V (AC operation)  
60V (DC operation)  
1. To assemble the Welding Shield,  
place the Shield on a flat surface.  
Press the Handle into place. Then  
insert the Filter Lens.  
Welding Shield (Qty. 1)  
Hammer/Brush (Qty. 1)  
Electrode Holder (Qty. 1)  
Ground Clamp (Qty. 1)  
Accessories  
(See Figure A.)  
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  
FiguRE A  
subheadings therein before set  
up or use of this product.  
2. This Welder requires the attachment  
and use of a UL-listed, 240 volt,  
grounded, 3-prong, electrical Power  
Cord Plug (not included). Only a  
qualified electrician should install the  
REV 09d; 09l  
SKU 97719  
For technical questions, please call 1-800-444-3353.  
Page 9  
 
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.  
allow access by children or pets to  
prevent injury and distraction.  
2. Route the Power Cord (32) 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. To assemble the two Wheels (9),  
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.)  
3. Secure loose workpieces 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  
workpieces must be controlled  
4. To attach the Handle (30), align the  
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.)  
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.  
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.  
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.  
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  
1. Designate a work area that is clean  
and well-lit. The work area must not  
SKU 97719  
For technical questions, please call 1-800-444-3353.  
Page 10  
 
At a 15% duty cycle (at 100 Amps  
DC), welding can occur for 1.5  
minutes and then the welder must  
cool for 8.5 minutes.  
general Operating instructions  
protective gear  
must be worn when using the  
Arc Welder; AnSi-approved,  
arc shaded, eye protection,  
a full face shield, heavy-duty  
work gloves, a welding apron,  
niOSh-approved 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.  
Failure to carefully observe duty cy-  
cle limitations can stress a Welder’s  
power generation system, contribut-  
ing to premature Welder failure.  
2. This Welder is equipped with an inter-  
nal thermal protection system to help  
prevent damage to the unit. When  
the Arc Welder overheats the Yellow  
Lamp (24) is illuminated on the con-  
trol panel and the unit automatically  
shuts down. Then the unit returns to  
service when it cools down and the  
Yellow Lamp turns off automatically.  
(See Figure b.)  
Once the unit returns to service,  
follow a more conservative duty  
cycle routine to help prevent excess  
wear to the Welder.  
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:  
3. Determine whether AC or DC welding  
is to be used.  
At a 10% duty cycle (at 130 Amps  
AC), actual welding can occur for  
one minute and then the welder  
must cool for nine minutes.  
4. Connect the Grounding Cable with  
Clamp (34) and Welding Cable with  
Electrode Holder (33) for either AC or  
DC operation. (See Figure b.)  
FiguRE b  
pOWER On gREEn LAmp  
(23)  
DC CAbLE COnnECtiOn knOb  
(22)  
COnnECt WELDing CAbLE (33) hERE  
thERmAL OVERLOAD YELLOW LAmp  
(24)  
pOWER SWitCh knOb  
(25)  
DC CAbLE COnnECtiOn knOb  
(22)  
COnnECt gROunD CAbLE (34) hERE  
AmpERAgE COntROL knOb  
AC CAbLE COnnECtiOn knOb  
(22)  
(26)  
COnnECt WELDing CAbLE (33) hERE  
AC CAbLE COnnECtiOn knOb  
(22)  
COnnECt gROunD CAbLE (34) hERE  
SKU 97719  
For technical questions, please call 1-800-444-3353.  
Page 11  
 
5. Attach the Grounding Cable with  
Clamp (34) as close as possible to  
the intended welding location.  
(See Assy. Diagram.)  
external coating on the electrode  
which prevents oxygen in the air from  
coming into contact with the molten  
metal, causing it to oxidize.  
6. Place the bare end of the electrode  
(not included) in the Electrode Holder  
(33). nOtE: Always keep the jaws  
of the Electrode Holder clean to  
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.  
ensure proper electrical contact with  
the electrode. (See Assy. Diagram.)  
7. Set the desired current (up to 135  
Amps AC - up to 105 Amps DC) for  
the type of metal being welded with  
the Amperage Control Knob (26).  
Thin metals use lower current and  
heavy metals use higher current.  
(See Figure b.)  
13. nOtE: If too much current is drawn  
from the Arc Welder, the Thermal  
Overload Protector will activate. The  
Yellow Lamp (24) on the Control  
Panel will illuminate, and the Welder  
will automatically shut off until it  
cools down. If this happens, turn the  
Power Switch Knob (25) to its “OFF”  
position and wait about 10 minutes.  
Then restart the Welder.  
8. Make sure the Power Switch Knob  
(25) is off, then plug the Arc Welder’s  
Power Cord (32) into a dedicated,  
240 VAC, with delayed action type  
circuit breaker or fuses.  
(See Figure b.)  
14. When the weld is complete, lift the  
electrode clearly away from any  
grounded object. Set the Welding  
Shield down, and turn the power  
Switch Knob (25) to its “OFF”  
position. (See Figure b.)  
(See Figure b.)  
9. While grasping the handle of the  
Electrode Holder (33), with the  
electrode clear of grounded objects,  
turn the Power Switch Knob (25) to  
its “On” position. (See Figure b.)  
15. Unplug the Power Cord (32) from the  
electrical outlet.(See Assy. Diagram.)  
10. Hold the Welding Shield in front  
of your eyes. WARning! Never  
look at the ignited arc without ANSI-  
approved arc shaded eye protection  
as in a full face shield. Permanent  
eye damage or blindness can occur.  
Skin burns can occur. Wear a  
16. Remove the Grounding Cable with  
Clamp (34) from the object it is  
clamped onto. Then remove the  
electrode from the Electrode Holder  
(33). (See Assy. Diagram.)  
17. Clean and store the Arc Welder  
indoors out of reach of children and  
other unauthorized people.  
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  
18. impORtAnt: Please read the in-  
cluded “Weld Diagnosis Pamphlet”  
for tips and suggestions concerning  
welding and proper usage.  
REV 09d  
SKU 97719  
For technical questions, please call 1-800-444-3353.  
Page 12  
 
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 tool to its “OFF” position and unplug  
the tool from its electrical outlet before performing any inspection,  
maintenance, cleaning, or storage procedures.  
1. bEFORE EACh uSE, inspect the general condition of the Arc Welder. Check for  
cracked or missing insulators, damaged electrical wiring, and any other condition  
that may affect its safe operation. If abnormal noise or vibration occurs, have the  
problem corrected before further use. Do not use damaged equipment.  
2. AFtER uSE, clean external surfaces of the Arc Welder with a clean cloth. Use  
compressed air to blow all dust and debris from the ventilation openings.  
3. AFtER uSE, store the Arc Welder in a clean, dry, safe location out of reach of  
children and other unauthorized people.  
note: When not in use, always keep the grounding cable and its Clamp (34)  
disconnected from any metal object.  
SKU 97719  
For technical questions, please call 1-800-444-3353.  
Page 13  
 
tROubLEShOOting  
problem  
possible Causes  
possible Solutions  
Welder does not “hum”  
when turned on.  
1. No power at electrical outlet.  
1. Check circuit fuse or circuit breaker.  
2. Broken or damaged Power Cord.  
2. Have Power Cord repaired or replaced by  
a qualified electrician.  
Welder “hums” but does  
not weld.  
1. Inadequate current at electrode and/or poor  
connections at Welder.  
1. Check Ground Clamp, Cable, and  
connection to workpiece.  
2. Check Welding Cable and Electrode  
Holder.  
3. Check all Welder external connections.  
1. Use smaller diameter electrode.  
Arc difficult to strike.  
1. Electrode diameter too large.  
2. Workpiece not properly grounded.  
2. Verify proper grounding (no paint, varnish,  
or corrosion).  
3. Heavy loads, making power line voltage low.  
3. Run Arc Welder on dedicated 230 volt  
circuit.  
Welder gives trickle shots. 1. Accidental contact with workpiece.  
1. Avoid contact with workpiece.  
2. Current leakage caused by moist clothing or  
work area.  
2. Make sure clothing and work area are dry.  
Welder overheats, blows  
1. Use of extension cord.  
1. Relocate Arc Welder to avoid use of  
extension cord. If relocation of Welder  
is not possible, use thicker (lower gauge  
number) extension cord.  
fuses, trips circuit breaker.  
2. Electrode diameter too large.  
3. Overloaded circuit.  
2. Use smaller diameter electrode.  
3. Run Arc Welder on dedicated 230 volt  
circuit.  
Bead is intermittently too  
thin or too thick.  
1. Inconsistent travel speed.  
2. Output Amp setting too low.  
1. Decrease and maintain travel speed.  
2. Increase output Amp setting or change to  
smaller diameter electrode.  
Electrode sticks to work-  
piece.  
1. Arc length too short.  
1. Lift electrode to correct arc length as soon  
as arc is struck.  
2. Increase output Amp setting or change to  
smaller diameter electrode.  
2. Output Amp setting too low.  
1. Damp electrodes.  
Electrodes sputter and  
stick.  
1. Use dry electrodes and store in a dry  
location.  
Weld bead does not pen-  
etrate base metal.  
1. Travel speed too fast.  
2. Arc length too short.  
1. Decrease travel speed.  
2. Increase arc length.  
3. Output Amp setting too high.  
3. Reduce output Amp setting.  
Ragged depressions at  
edge of weld.  
1. Slow and/or inconsistent travel speed.  
2. Output Amp setting too high.  
1. Increase and maintain travel speed.  
2. Reduce output Amp setting.  
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 CERTIFIEDAND 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.  
SKU 97719  
For technical questions, please call 1-800-444-3353.  
Page 14  
 
pARtS LiSt  
part #  
1
Description  
Kickstand, Plastic  
Screw (ST4.2x13)  
Base Frame  
Qty.  
part #  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
44  
Description  
Qty.  
1
1
1
1
4
4
1
1
1
2
2
2
1
2
1
2
2
4
4
4
1
4
4
Green Lamp  
Yellow Lamp  
2
1
3
Power Switch Knob  
Amperage Control Knob  
Relief Strain  
1
4
Screw (M6x25)  
Foot, Plastic  
1
5
1
6
Screw (M4x12)  
Rectifier  
Case  
1
7
Clear Cover  
1
8
Axle  
Handle  
1
9
Wheel, Plastic  
Bolt (M6x12)  
Screw (M4x8)  
Fan Support Shelf  
Locating Collar  
Fan  
Screw (M5x30)  
Power Cord  
2
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
1
Welding Cable with Electrode Holder  
Grounding Cable with Clamp  
Movable Iron Core Frame  
Movable Iron Core  
Indicator  
1
1
1
2
Screw (M4x40)  
Nut (M4)  
1
Clamp Ring  
2
Bolt (M8x16)  
Bolt (M8x37)  
Insulation Washer (1)  
Switch  
Filter Reactor  
1
Thermostat  
1
Baffle  
1
Transformer  
1
Insulation Washer (2)  
Cable Connecting Knob  
Transformer Carriage  
Rubber Ring  
2
1
SKU 97719  
For technical questions, please call 1-800-444-3353.  
Page 15  
 
ASSEmbLY DiAgRAm  
SKU 97719  
For technical questions, please call 1-800-444-3353.  
Page 16  
 
LimitED 1 YEAR / 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 for a period of  
ninety days from date of purchase that the torch, liner, wire feed mechanism (if applicable),  
welding clamps, electrode holders, cables and accessories packed with the welder are  
free of defects in materials and workmanship. this Limited 90 Day/1 Year Warranty  
shall not apply to consumable parts such as tips, welding wire, and gas nozzles.  
Harbor Freight Tools also warrants to the original purchaser, for a period of one year from  
date of purchase, that the transformer and rectifier are free from defects in materials and  
workmanship (90 days if used by a professional contractor or if used as rental equipment).  
This warranty does not apply to damage due directly or indirectly to misuse, abuse,  
negligence or accidents, repairs or alterations outside our facilities, 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 • (800) 444-3353  
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.  
SKU 97719  
For technical questions, please call 1-800-444-3353.  
Page 17  
 

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