Chicago Electric 93457 User manual

AUTO BODY SPOT WELDER

WITH CART

93457

ASSEMBLY AND OPERATING INSTRUCTIONS

3491 Mission Oaks Blvd., Camarillo, CA 93011

Visit ourWeb site at: http://www.harborfreight.com

any artwork contained herein may be reproduced in any shape or form without the express

written consent of Harbor Freight Tools.

For technical questions, please call 1-800-444-3353.

TO PREVENT SERIOUS INJURY,

READ AND UNDERSTAND ALL WARNINGS

AND INSTRUCTIONS BEFORE USE.

Due to continuing improvements, actual product may differ slightly from the product described herein.

SKU 93457 For technical questions, please call 1-800-444-3353. Page 2

Contents

Product Specifications .............................................................. 3

General Safety Rules ................................................................. 3

Specific Safety Rules ................................................................. 6

Grounding ................................................................................. 10

Unpacking ................................................................................. 12

Assembly Instructions............................................................. 12

Welder Function Chart ............................................................. 13

Control Panel Features ............................................................ 14

Operating Instructions ............................................................. 15

Washer Spot Welding: ....................................................................... 15

Wiggle Wire Spot Welding: ................................................................ 17

Needle Spot Welding: ........................................................................ 18

Pin Welding: ........................................................................................ 19

Tempering:.......................................................................................... 19

Flat Shrink Tip Welding: .................................................................... 19

Patch Welding:.................................................................................... 20

Selecting The Proper Repair Accessory: ....................................... 21

Accessory Installation: ..................................................................... 21

Troubleshooting ....................................................................... 22

Inspection, Maintenance, and Cleaning ................................. 23

Parts List ................................................................................... 24

Assembly Diagram ................................................................... 25

Accessory List.......................................................................... 26

Electrical Schematic ................................................................ 27

SKU 93457 For technical questions, please call 1-800-444-3353. Page 3

PRODUCT SPECIFICATIONS

SAVE THIS MANUAL

You will need this manual for the safety warnings and precautions, assembly, oper-

ating, inspection, maintenance and cleaning procedures, parts list and assembly

diagram. Keep your invoice with this manual. Write the invoice number on the

inside of the front cover. Keep this manual and invoice in a safe and dry place for

future reference.

GENERAL SAFETY RULES

WARNING!

READ AND UNDERSTAND ALL INSTRUCTIONS

Failure to follow all instructions listed below may result in

electric shock, fire, and/or serious injury.

SAVE THESE INSTRUCTIONS

WORK AREA

1. Keep your work area clean and well lit. Cluttered benches and dark areas

invite accidents.

2. 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.

3. Keep bystanders,children, and visitors away while operating a power tool.

Distractions can cause you to lose control. Protect others in the work area from

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SKU 93457 For technical questions, please call 1-800-444-3353. Page 4

ELECTRICAL SAFETY

4. Grounded tools must be plugged into an outlet properly installed and

grounded in accordance with all codes and ordinances. Never remove the

grounding prong or modify the plug in any way. Do not use any adapter

plugs. Check with a qualified electrician if you are in doubt as to whether

the outlet is properly grounded. If the tools should electrically malfunction or

break down, grounding provides a low resistance path to carry electricity away

from the user.

5. 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.

6. Do not expose power tools to rain or wet conditions. Water entering a power

tool will increase the risk of electric shock.

7. Do not abuse the Power Cord. Never use the Power Cord to carry the tools

or pull the Plug from an outlet. Keep the Power Cord away from heat, oil,

sharp edges, or moving parts. Replace damaged Power Cords immedi-

ately. Damaged Power Cords increase the risk of electric shock.

8. When operating a power tool outside,use an outdoor extension cord

marked “W-A” or “W”. These extension cords are rated for outdoor use, and

reduce the risk of electric shock.

PERSONAL SAFETY

9. Stay alert. Watch what you are doing, and use common sense when oper-

ating a power tool. Do not use a power tool while tired or under the influ-

ence of drugs, alcohol, or medication. A moment of inattention while operat-

ing power tools may result in serious personal injury.

10. Dress properly. Do not wear loose clothing or jewelry. Contain long hair.

Keep your hair, clothing, and gloves away from moving parts. Loose

clothes, jewelry, or long hair can be caught in moving parts.

debris such as chips and sparks. Provide barriers or shields as needed.

11. Avoid accidental starting. Be sure the Power Switch is off before plugging

in. Carrying power tools with your finger on the Power Switch, or plugging in

power tools with the Power Switch on, invites accidents.

SKU 93457 For technical questions, please call 1-800-444-3353. Page 5

12. Remove adjusting keys or wrenches before turning the power tool on. A

wrench or a key that is left attached to a rotating part of the power tool may result

in personal injury.

13. Do not overreach. Keep proper footing and balance at all times. Proper

footing and balance enables better control of the power tool in unexpected

situations.

14. Always wear eye, hearing, and breathing protection. Wear ANSI ap-

proved safety impact goggles, ANSI approved hearing protectors, and

ANSI approved dust mask or respirator when using this product.

Nonskid safety shoes, hard hat, or hearing protection must be used for

appropriate conditions.

TOOL USE AND CARE

15. Use clamps (not included) or other practical ways to secure and support the

workpiece to a stable platform. Holding the work by hand or against your body

is unstable and may lead to loss of control, causing personal injury and/or prop-

erty damage.

16. Do not force the tool. Use the correct tool for your application. The correct

tool will do the job better and safer at the rate for which it is designed.

17. Do not use the power tool if the Power Switch does not turn it on or off. Any

tool that cannot be controlled with the Power Switch is dangerous and must be

replaced.

18. Disconnect the Power Cord Plug from the power source before making any

adjustments, changing accessories, or storing the tool. Such preventive

safety measures reduce the risk of starting the tool accidentally.

19. Store idle tools out of reach of children and other untrained persons. Tools

are dangerous in the hands of untrained users.

20. Maintain tools with care. Keep the welder clean. Properly maintained welders

with a are easier to control. Do not use a damaged welder. Tag damaged welders

“Do not use” until repaired.

21. Check for misalignment or binding of moving parts, breakage of parts, and

any other condition that may affect the tool’s operation. If damaged, have

the tool serviced before using. Many accidents are caused by poorly main-

tained tools.

SKU 93457 For technical questions, please call 1-800-444-3353. Page 6

22. Use only accessories that are recommended by the manufacturer for your

model. Accessories that may be suitable for one tool may become hazardous

when used on another tool.

SERVICE

23. Tool service must be performed only by qualified repair personnel. Service

or maintenance performed by unqualified personnel could result in a risk of injury.

24. When servicing a tool, use only identical replacement parts. Follow

instructions in the

“Inspection, Maintenance, And Cleaning”

section of this

manual. Use of unauthorized parts or failure to follow maintenance instructions

may create a risk of electric shock or injury.

SPECIFIC SAFETY RULES

1. Ground this product. This Welder requires the attachment and use of a UL

listed, 230 volt, grounded, 3-prong, electrical Power Cord Plug (not included).

Only a qualified 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. To comply with the National Electric Code, and to provide

additional protection from the risk of electrical shock, this product should only be

connected to a 230 volt, 3-hole outlet that is properly grounded and protected by a

Ground Fault Circuit Interrupter (GFCI). (See Figure A, page 10.)

2. Maintain labels and nameplates on the Welder. These carry important informa-

tion. If unreadable or missing, contact Harbor Freight Tools for a replacement.

3. Avoid unintentional starting. Make sure you are prepared to begin work before

turning on the Welder.

4. Do not force the Welder. This tool will do the work better and safer at the speed

and capacity for which it was designed.

5. Never leave the Welder unattended when it is plugged into an electrical

outlet. Turn off the tool, and unplug it from its electrical outlet before leaving.

6. Industrial applications must follow OSHA guidelines.

7. Never stand on the Welder. Serious injury could result if the Welder is tipped or

if hot surfaces are accidently contacted.

SKU 93457 For technical questions, please call 1-800-444-3353. Page 7

8. Maintain a safe working environment. Keep the work area well lit. Make sure

there is adequate surrounding workspace. Always keep the work area free of

obstructions, grease, oil, trash, and other debris. Do not use a power tool in areas

near flammable chemicals, dusts, and vapors. Do not use this product in a damp

or wet location.

9. 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 with a welding helmet with

protective lens.

• 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.

• 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.

• When welding/cutting overhead or in confined spaces, wear flame resistant ear

plugs or ear muffs to keep sparks out of ears.

10. Prevent accidental fires. Remove any combustible material from the

work area.

• When possible, move the work to a location well away from combustible materi-

als. If relocation is not possible, protect the combustibles with a cover made of

fire resistant material.

• 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.

• Enclose the work area with portable fire resistant screens. Protect combustible

walls, ceilings, floors, etc., from sparks and heat with fire 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 com-

bustibles 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.

• 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 elimi-

nating the hazard.

• Do not dispose of hot slag in containers holding combustible materials. Keep a

fire extinguisher nearby and know how to use it.

SKU 93457 For technical questions, please call 1-800-444-3353. Page 8

• 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 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 combus-

tible material whose contents, when heated, can produce flammable or explo-

sive vapors. Clean and purge containers before applying heat. Vent closed

containers, including castings, before preheating, welding, or cutting.

11. 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.

• Where ventilation is questionable, have a qualified technician take an air sam-

pling to determine the need for corrective measures. Use mechanical ventilation

to improve air quality. If engineering controls are not feasible, use an approved

respirator.

• Work in a confined area only if it is well ventilated, or while wearing an air-

supplied respirator.

• Follow OSHA guidelines for Permissible Exposure Limits (PEL’s) for various

fumes and gases.

• Follow the American Conference of Governmental Industrial Hygienists recom-

mendations for Threshold Limit Values (TLV’s) for fumes and gases.

Inhalation Hazard

Welding Produces TOXIC FUMES and GASSES.

Exposure to welding gasses 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 gasses

or fumes are:

•Early onset of Parkinson’s Disease •Heart Disease

•Damage to the reproductive organs •Ulcers

•Inflammation of the small intestine or stomach •Kidney damage

•Respiratory diseases such as emphysema, bronchitis or pneumonia

Safety precautions, such as using natural or forced air ventilation

and wearing an ANSI approved respirator, are ESSENTIAL to reduce

the risk of developing the above illnesses.

SKU 93457 For technical questions, please call 1-800-444-3353. Page 9

• 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.

12. Read and understand all instructions and safety precautions as outlined in

the manufacturer’s manual for the material you will weld or cut.

13. 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.

14. Protect yourself from electric shock. Do not use outdoors. 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 big

enough to cover your full area of contact with the work or ground.

15. Use caution when pulling out a dent. A weld or panel may unexpectedly give

way, possibly causing personal injury if caution is not exercised. Always pull in

such a way that you will not lose balance, strike yourself, or otherwise injure

yourself if the weld breaks. When using a Slide Hammer, make sure your body will

not be in the way of the impacting weight.

16. Use the right tool for the job. Do not attempt to force small equipment to do the

work of larger industrial equipment. There are certain applications for which this

Welder was designed. It will do the job better and more safely at the rate for which

it was intended. Do not modify this Welder, and do not use this Welder for a

purpose for which it was not intended.

17. WARNING! People with pacemakers should consult their physician(s) before

using this product. Electromagnetic fields in close proximity to a heart pacemaker

could cause interference to or failure of the pacemaker.

18. WARNING! The warnings and cautions discussed in this 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.

19. WARNING! This product, when used for welding and 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.

)

SAVE THESE INSTRUCTIONS

SKU 93457 For technical questions, please call 1-800-444-3353. Page 10

WARNING!

Improperly connecting the grounding wire can result in the risk of electric

shock. Check with a qualified electrician if you are in doubt as to whether the

outlet is properly grounded. Do not modify the power cord plug used with

the tool. Never remove the grounding prong from the plug. Do not use the

tool if the power cord or plug is damaged. If damaged, have it repaired by

a service facility before use. If the plug will not fit the outlet, have a proper

outlet installed by a qualified electrician.

GROUNDED TOOLS: TOOLS WITH THREE PRONG PLUGS

1. Tools marked with “Grounding Required” have a three wire cord and three prong

grounding plug. The plug must be connected to a properly grounded outlet. If the

tool should electrically malfunction or break down, grounding provides a low

resistance path to carry electricity away from the user, reducing the risk of electric

shock. (See Figure A.)

2. The grounding prong in the plug is connected through the green wire inside the

cord to the grounding system in the tool. The green wire in the cord must be the

only wire connected to the tool’s grounding system and must never be attached

to an electrically “live” terminal. (See Figure A.)

3. Your tool must be plugged into an appropriate outlet, properly installed

by a

certified electrician

and grounded in accordance with all codes and ordinances.

The plug and outlet should look like that in the following illustration.

(See Figure A.)

230 VOLT, GROUNDED,

3-PRONG,

POWER CORD PLUG

230 VOLT, GROUNDED,

ELECTRICAL OUTLET

FIGURE A

GROUNDING

NOTE:

This Welder requires the installation of a 3-Prong, 230 VAC, polarized,

twistlock Power Cord Plug (not included).

The Plug must be installed by a certified electrician.

(See Figure A,

and

Electrical Schematic, page 27.)

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