Manual For The 63785 150A TIG Torch
User Manual: Manual for the 63785 150A TIG Torch 150A TIG Torch
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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. 17e
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© 2017 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 an d se rv ic e may n ot b e in cl uded.
Read this material before using this product.
Failure to do so can result in serious injury.
SAVE THIS MANUAL.
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5
WARNING SYMBOLS AND DEFINITIONS
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.
Indicates a hazardous situation which, if not avoided,
will result in death or serious injury.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
Addresses practices not related to personal injury.
IMPORTANT SAFETY INFORMATION
Read all Safety warnings and instructions.
Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.
Save all warnings and instructions for future reference.
General Safety
PROTECT yourself and others. Read and understand this information.
1. Before use, read and understand manufacturer′s
instructions, Material Safety Data Sheets
(MSDS′s), employer′s Safety practices,
ANSI Z49.1, and welder instructions.
2. Keep out of reach of children.
Keep children and bystanders away while operating.
3. Place the welder on a stable location before use.
If it falls while plugged in, severe injury,
electric shock, or fire may result.
4. Do not overreach.
Keep proper footing and balance at all times.
5. Stay alert, watch what you are doing and use
common sense when operating a welder.
Do not use a welder while you are tired or under
the influence of drugs, alcohol or medication.
A moment of inattention while operating welders
may result in serious personal injury.
6. Avoid unintentional starting. Make sure you are
prepared to begin work before turning on the Welder.
7. Never leave the Welder unattended while
energized. Turn power off if you have to leave.
8. 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.
9. 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.)
10. WARNING: The cord of this product contains
lead and/or di (2-ethylhexyl) phthalate (DEHP),
chemicals known to the State of California
to cause cancer, and birth defects or other
reproductive harm. Wash hands after handling.
(California Health & Safety Code § 25249.5, et seq.)
Page 3For technical questions, please call 1-888-866-5797.Item 63785
11. 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.
12. Do not use near degreasing or
painting operations.
13. Keep head out of fumes.
Do not breathe exhaust fumes.
14. Use enough ventilation, exhaust at arc, or
both, to keep fumes and gases from breathing
zone and general area. If engineering controls
are not feasible, use an approved respirator.
15. Work in a confined area only if it
is well-ventilated, or while wearing
an air-supplied respirator.
16. Have a recognized specialist in
Industrial Hygiene or Environmental Services
check the operation and air quality
and make recommendations
for the specific welding situation.
Follow OSHA guidelines for
Permissible Exposure Limits (PEL’s) and
the American Conference of Governmental
Industrial Hygienists recommendations for
Threshold Limit Values (TLV’s) for fumes and gases.
17. Wear ANSI-approved welding eye protection
featuring at least a number 10 shade lens rating.
18. Wear leather leggings, fire resistant shoes
or boots during use. Do not wear pants with
cuffs, shirts with open pockets, or any clothing
that can catch and hold molten metal or sparks.
19. Keep clothing free of grease, oil,
solvents, or any flammable substances.
Wear dry, insulating gloves and protective clothing.
20. 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.
21. Wear an approved welding jacket or long sleeves
to protect forearms from radiation burns.
22. When welding/cutting overhead or in confined
spaces, wear flame resistant ear plugs or
ear muffs to keep sparks out of ears.
23. Turn off, disconnect power, and
discharge electrode to ground before
setting down torch/electrode holder and
before installing TIG torch to welder.
24. Turn off, disconnect power, and
discharge electrode to ground before setting
down torch/electrode holder and before service.
25. Do not touch energized electrical parts.
Wear dry, insulating gloves. Do not touch electrode
holder, electrode, welding torch, or welding wire with
bare hand. Do not wear wet or damaged gloves.
26. Do not use near water or damp objects.
27. 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.
28. Do not expose welders to rain or wet conditions.
Water entering a welder will increase
the risk of electric shock.
29. Do not use outdoors.
30. Insulate yourself from the workpiece 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.
31. Clear away or protect flammable objects.
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.
32. Keep ABC-type fire extinguisher near
work area and know how to use it.
33. Maintain a safe working environment.
Keep the work area well lit.
Make sure there is adequate surrounding workspace.
Keep the work area free of obstructions,
grease, oil, trash, and other debris.
34. Do not operate welders in atmospheres
containing dangerously reactive or
flammable liquids, gases, vapors, or dust.
Provide adequate ventilation in work areas
to prevent accumulation of such substances.
Welders create sparks which may ignite flammable
substances or make reactive fumes toxic.
Page 4 For technical questions, please call 1-888-866-5797. Item 63785
35. 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.
36. 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.
37. Do not dispose of hot slag in containers
holding combustible materials.
38. After 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.
39. 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.
40. Unplug before maintenance. Unplug the Welder
from its electrical outlet before any inspection,
maintenance, or cleaning procedures.
Gas Shielded Welding - Cylinder Safety
Cylinders can explode when damaged.
1. Do not weld on a pressurized or closed cylinder.
2. Do not allow an electrode holder,
electrode, welding torch, or welding
wire to touch the cylinder.
3. Keep cylinders away from any electrical circuits,
including welding circuits.
4. Keep protective cap in place over the valve
except when the cylinder is in use.
5. Use only correct gas shielding equipment
designed specifically for the type of welding
you will do. Maintain this equipment properly.
6. Protect gas cylinders from heat, being struck,
physical damage, slag, flames, sparks, and arcs.
7. Use proper procedures to move cylinders.
SAVE THESE INSTRUCTIONS.
Specifications
Cable Length 12 - 1/2’
Duty Cycle 150 A @ 60 % duty cycle (DC)
115 A @ 60 % duty cycle (AC)
Tungsten Range 0.020″ - 5/32″ (0.5 - 4.0 mm)
Weight 5.5 lbs.
Cooling Air cooled
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1. Determine which DINSE Connector is appropriate
for your welding system. For OMNIPRO 220 and
PROTIG 200 welders, use the 35-50 Connector. For
PROTIG 165 welders, use the 10-25 Connector.
2. Slide rubber sleeve on TIG Torch hose
back to expose threaded tip.
3. Screw DINSE Connector onto
threaded tip of TIG Torch hose.
4. Position rubber sleeve so that ridges align
with grooves on DINSE Connector.
5. Slide rubber sleeve over DINSE Connector
leaving only the end exposed. Apply enough
force to lock rubber sleeve onto Connector.
10-25 DINSE
Connector
35-50 DINSE
Connector
TIG Setup
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 off and unplug the Welder before setup.
TIG Setup
Connect DINSE
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Connect Cables
Ground Clamp Cable
in Positive Socket
Ground
Clamp
TIG Torch
Cable in
Negative
Socket
TIG Torch
Foot Pedal Socket
(inside Welder)
Foot Pedal
(sold separately)
Foot Pedal
Cable
1. OMNIPRO 220:
a. Plug TIG Torch Cable into Torch Adapter. Twist
clockwise all the way to lock into place.
b. Plug Torch Adapter into Negative Socket.
Twist clockwise all the way to lock in place.
c. Insert the Foot Pedal Cable, through hole
on Welder front and connect to the Foot
Pedal Socket inside the machine. Secure
by turning collar clockwise until tight.
d. Plug Ground Clamp cable into Positive Socket.
Twist clockwise all the way to lock in place.
2. PROTIG 165 and 200:
a. Plug Ground Clamp cable into Positive Socket.
Twist clockwise all the way to lock in place.
b. Plug TIG Torch cable into Negative Socket.
Twist clockwise all the way to lock in place.
c. Plug Foot Pedal cable into Foot Pedal Socket.
Secure by turning collar clockwise until tight.
OMNIPRO 220
Torch
Adapter
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PROTIG 165 TIG
Torch
Ground
Clamp
Negative
Socket Foot Pedal
Socket
Positive
Socket
Foot
Pedal
TIG
Torch
Ground
Clamp
Negative
Socket
Foot Pedal
Socket
Positive
Socket
Foot
Pedal
3. For connecting Shielding Gas Hose, refer to Connect Shielding Gas section on next page.
PROTIG 200
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Connect Shielding Gas
1. With assistance, place an 100% Argon cylinder
(not included) onto a cabinet or cart near the
Welder and secure the cylinder in place with
two straps (not included) to prevent tipping.
2. Remove the cylinder’s cap. Stand to the
side of the valve opening, then open the
valve briefly to blow dust and dirt from the
valve opening. Close the cylinder valve.
3. Locate the Regulator (included) and close its
valve until it is loose, then thread Regulator
onto cylinder and wrench-tighten connection.
4. Connect Gas Hose.
a. OMNIPRO 220: Connect Shielding Gas
Hose on TIG Torch Cable Connector to the
Regulator’s Outlet and wrench-tighten connection.
b. PROTIG 165 and 200: Attach the Gas Hose to
the Regulator’s Outlet and the Welder’s Gas Inlet.
Wrench-tighten both connections.
5. Open Gas Flow Valve on Torch.
Note: When using TIG Torch with OMNIPRO 220,
gas flow is continuous. Close Gas Flow Valve
on TIG Torch when welding is complete.
4 a 3
1
Briefly open valve
to clean,
then close
valve.
2
4b
Power Input
Gas Inlet
Reset
Power Input
Gas Inlet
4b
PROTIG 165 PROTIG 200
5
Gas Flow
Valve
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Sharpen Tungsten Electrode
To avoid Electrode contamination, dedicate a fine grit grinding wheel exclusively to Electrode grinding.
WARNING! Some Electrodes may have
materials added to them that are hazardous to
breathe. Wear a respirator and ANSI-approved
Safety goggles when grinding an Electrode.
1. Shut off the welder and wait until Electrode
and Torch have cooled enough to handle.
2. Remove Back Cap. Pull Electrode from front
of Torch. (Pulling it from rear will damage
Collet and create burrs on Electrode).
3. If Electrode has dulled or been otherwise
contaminated, use pliers or a suitable tool to
grip the Electrode above the contaminated
section and snap off the end of the Electrode.
4. Lightly press Electrode tip
against the surface of
the grinding wheel at an angle.
Rotate Electrode tip until a blunt
point is formed.
Note: Grinding direction must be
parallel to length of Electrode.
5. The conical portion of the ideal
tip will be 2-1/2 times as long
as the Electrode diameter.
6. Re-insert Electrode into Collet with tip
protruding 1/8"-1/4" beyond the Ceramic
Nozzle, then re-tighten the Back Cap.
Grinding
Wheel
Electrode
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Assemble TIG Torch
1. Consult Settings Chart, on top of Welder, to
determine proper Tungsten Electrode size to be
used with thickness of material to be welded.
2. Match Collet and Collet Body sizes
to Tungsten Electrode size.
3. Thread Collet Body into the front of the Torch.
4. Make sure Ceramic Nozzle size is
appropriate for application.
5. Thread Ceramic Nozzle onto Collet Body.
6. Insert Collet into back of Torch and into Collet Body.
7. Insert Tungsten Electrode into Collet on front of Torch.
8. Lock Electrode in place with Back Cap.
Electrode should protrude 1/8" to 1/4"
beyond the Ceramic Nozzle.
Collet
Body
Ceramic
Nozzle
Collet
Back Cap
Insert tungsten
Electrode here.
9. Refer to welder manual for instruction
on basic TIG/Stick welding techniques
and safety practices.
Page 11For technical questions, please call 1-888-866-5797.Item 63785
Maintenance
TO PREVENT SERIOUS INJURY, FIRE AND BURNS:
Unplug the Welder, rest the tool on a heat-proof, electrically non-conductive surface, and allow
all parts of the Welder to cool thoroughly before service.
1. BEFORE EACH USE, inspect the general
condition of the Torch. Check for:
• loose hardware
• misalignment or binding of moving parts
• damaged cord / electrical wiring
• frayed or damaged cables
• cracked or broken parts
• any other condition that may
affect its safe operation.
2. AFTER EVERY USE, store in
a clean and dry location.
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Record Product’s Serial Number Here:
Note: If product has no serial number, record month and year of purchase instead.
Note: Other than consumables, replacement parts are not available for this item.
3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • 1-888-866-5797
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.
