Chicago Electric 98759 Installation manual

SPOT WELDER

98759

SET UP AND OPERATING INSTRUCTIONS

Distributed exclusively by Harbor Freight Tools®.

3491 Mission Oaks Blvd., Camarillo, CA 93011

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.

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.

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

SKU 98759 For technical questions, please call 1-800-444-3353. Page 2

SAVE THIS MANUAL

Keep this manual for the safety warn-

ings and precautions, assembly, operat-

ing, 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.

IMPORTANT SAFETY

INFORMATION

In this manual, on the labeling,

and all other information provid-

ed 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.

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.

General Power Tool Safety

Warnings

WARNING Read all safety

warnings and instructions.

Failure to follow the warnings and

instructions may result in electric

shock, re and/or serious injury.

Save all warnings and

instructions for future reference.

The term ″power tool″ in the

warnings refers to your corded

power tool.

Work area safety1.

Keep work area clean and well lit.a.

Cluttered or dark areas invite acci-

dents.

Do not operate power tools inb.

explosive 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 bystandersc.away while operating a power tool.

Distractions can cause you to lose

control.

Electrical safety2.

Avoid body contact with groundeda.

surfaces such as pipes, radiators,

ranges and refrigerators. There is

an increased risk of electric shock if

your body is grounded.

SKU 98759 For technical questions, please call 1-800-444-3353. Page 3

Do not expose power tools to rainb.

or wet conditions. Water entering

a power tool will increase the risk of

electric shock.

Do not abuse the cord. Never usec.the cord for carrying, 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 suit-

able for outdoor use. Use of a cord

suitable for outdoor use reduces the

risk of electric shock.

If operating a power tool in a dampe.

location is unavoidable, use a

Ground Fault Circuit Interrupter

(GFCI) protected supply. Use of

a GFCI 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 inuence of drugs,

alcohol or medication. A moment

of inattention while operating power

tools may result in serious personal

injury.

Use personal protective equip-b.

ment. Always wear eye protection.

Safety equipment such as welding

mask, non-skid safety shoes, and

welding apron used for appropriate

conditions will reduce personal inju-

ries.

Prevent unintentional starting. En-c.sure the switch of the stick welder

is in the off-position before con-

necting to power source, picking

up or carrying the tool.

Do not overreach. Keep properd.

footing and balance at all times.

This enables better control of the

power tool in unexpected situations.

Dress properly. Do not wear loosee.

clothing or jewelry. Keep your

hair, clothing and gloves away

from moving parts. Loose clothes,

jewelry or long hair can be caught in

moving parts.

Only use safety equipment thatf. has been approved by an appropri-

ate standards agency. Unapproved

safety equipment may not provide

adequate protection. Eye protection

must be ANSI-approved and breath-

ing protection must be NIOSH-ap-

proved for the specic hazards in the

work area.

Power tool use and care4.

Do not force the power tool. Usea.

the correct power tool for your ap-

plication. The correct power tool will

do the job better and safer at the rate

for which it was designed.

Store idle power tools out of theb.

reach of children and do not allow

persons unfamiliar with the power

tool or these instructions to oper-

ate the power tool. Power tools are

dangerous in the hands of untrained

users.

Maintain power tools. Check forc.misalignment or binding of moving

parts, breakage of parts and any

other condition that may affect the

power tool’s operation. If dam-

aged, have the power tool repaired

before use. Many accidents are

SKU 98759 For technical questions, please call 1-800-444-3353. Page 4

caused by poorly maintained power

tools.

Use the power tool, accessoriesd.

and tool bits etc. in accordance

with these instructions, taking into

account the working conditions

and the work to be performed. Use

of the power tool for operations differ-

ent from those intended could result

in a hazardous situation.

Service5.

Have your power tool serviced bya.

a qualied repair person using

only identical replacement parts.

This will ensure that the safety of the

power tool is maintained.

Spot Welder Safety Warnings

Maintain labels and nameplates on1. the tool. These carry important safety

information. If unreadable or miss-

ing, contact Harbor Freight Tools for a

replacement.

Avoid unintentional starting. Prepare2. to begin work before turning on the

tool.

Rest the tool and connection to the3. electrode holder on a properly insu-

lated surface.

Do not leave the tool unattended4. when it is plugged into an electrical

outlet. Turn off the tool, and unplug it

from the welder before leaving.

This product is not a toy. Keep it out5. of reach of children.

People with pacemakers should6. consult their physician(s) before use.

-

imity to heart pacemaker could cause

pacemaker interference or pacemak-

er failure. In addition, people with

pacemakers should:





on.



avoid electrical shock.



grounded. Ground Fault Circuit Inter-

rupter (GFCI) should also be imple-

mented – it prevents sustained elec-

trical shock.

WARNING: The brass components7. of this product contain lead, a chemi-

cal known to the State of California

to cause birth defects (or other repro-

ductive harm). (California Health &

Safety code § 25249.5, et seq.)

Some dust created by power sand-8. ing, sawing, grinding, drilling, and

other construction activities, contains

chemicals known [to the State of Cali-

fornia] to cause cancer, birth defects

or other reproductive harm. Some

examples of these chemicals are:



-

ment or other masonry products

-

cally treated lumber

Your risk from these exposures var-

ies, depending on how often you do

this type of work. To reduce your

exposure to these chemicals: work in

a well ventilated area, and work with

approved safety equipment, such as

those dust masks that are specially



particles. (California Health & Safety

Code § 25249.5, et seq.)

WARNING: Handling the cord on9. this product will expose you to lead,

a chemical known to the State of

SKU 98759 For technical questions, please call 1-800-444-3353. Page 5

California to cause cancer, and birth

defects or other reproductive harm.

Wash hands after handling. (Califor-

nia Health & Safety Code § 25249.5,

et seq.)

Do not exceed input amperage of 5010. Amps.

Follow all directions provided in the11. manual of the ARC (stick) welder

used with this product.

The warnings, precautions, and in-12. structions discussed in this instruction

manual cannot cover all possible con-

ditions 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.

Electrical Safety

Avoid electrical shock. Do not per-1. mit electrically live parts, cables, or

electrodes to contact skin, clothing, or

gloves. Wear ANSI-approved protec-

tive 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 screws,

and that all insulation is secure. Do

not weld unless you are insulated

from ground and the work piece.

Avoid eye and body damage. Arc2. rays and infrared radiation can in-

jure eyes and burn skin. Wear ANSI

approved and body protection. Do

not allow viewing by visitors without

proper eye and body protection. Use

a welding helmet with #11 lens and



3. 

Remove any combustible

material from the work



and explosive material at

least 35 feet from the welding arc to

prevent welding sparks or molten





reach. Thoroughly clean the object

being welded of any paint, grease, or

other foreign material.

If working on a wall or ceiling prevent4. ignition of combustibles on the other

side by moving them to a safe loca-

tion.

Industrial applications must follow5. OSHA guidelines. Follow OSHA

guidelines for Permissible Exposure



gases.

6. Prevent eye injury and

burns. Wearing and using

ANSI-approved personal

safety clothing and safety

devices reduce the risk for injury.

7. 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 and work surfaces free8.



mable substances. Wear dry, insulat-

ing gloves and protective clothing.

Wear an approved head covering9. to protect the head and neck. Use

aprons, cape, sleeves, shoulder cov-

ers, and bibs designed and approved

for welding and cutting procedures.

SKU 98759 For technical questions, please call 1-800-444-3353. Page 6

When welding/cutting overhead or in10.



ear plugs or ear muffs to keep sparks

out of ears.

Do not use near degreasing or paint-11. ing operations.

Enclose the work area with portable12.







tant covers.

Do not weld sealed containers. All13. containers should be considered un-

safe unless they have been declared



Use a non-conductive safety mat on14. the work surface to insulate the op-

erator from the work surface.

Read the directions for the stick15. welder that the Spot Welder will be

connected to.

SAVE THESE

INSTRUCTIONS.

SKU 98759 For technical questions, please call 1-800-444-3353. Page 7

SPECIFICATIONS

Input 35 to 50 Amps

Material Range 18 Gauge Maximum

Electrode Size 

Weld Time 2 to 3 Seconds

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

1-800-444-3353 as soon as possible.

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.

Tool Set Up

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 performing any

inspection, maintenance, or

cleaning procedures.

Work Piece and Work Area Set Up

Designate a work area that is clean1. and well-lit. The work area must not

allow access by children or pets to

prevent injury and distraction.

Route the power cord along a safe2. 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 al-

low free movement while working.

Secure loose work pieces using a3. vise or clamps (not included) to pre-

vent movement while working.

There must not be hazardous ob-4. jects, such as utility lines or foreign

objects, nearby that will present a

hazard while working.

General Operating Instructions

TO PREVENT

DEATH OR

SERIOUS INJURY:

Do not touch any metal part of

the Spot welder when it is

powered.

Read the manual for the ARC (stick)1. welder that is being used to power

the Spot Welder.

If welding on a vehicle; disconnect2. the vehicle’s battery.

Clean the work thoroughly before3. beginning operation. Remove all

grease, paint, and oil from the work-

piece.

Wear protective gear whenever weld-4. ing.

Choose the Welding Head that suits5. the needs of the job best. The Two

Prong Head (1) is best suited for

welding inside corners and on curved

surfaces. The Four Prong Head (2)

-

faces. Twist the correct welding head

SKU 98759 For technical questions, please call 1-800-444-3353. Page 8

for the job onto the end of the Spot



Insert one of the included electrodes6.





Clamp the electrode holder of the7. ARC welder onto the Connection (15)

of the Spot Welder.

Adjust the output to no greater than8. 50 Amps.

9. DANGER! To prevent serious

injury and death. If the operator

is not holding the Spot Welder, it

must be sitting on a nonconduc-

tive, nonammable surface. The

Spot Welder will immediately

turn on when the power button

is turned on. The connection be-

tween the Spot Welder and the

electrode clamp of the ARC welder

must also be must be sitting on

a nonconductive, nonammable

surface.

Turn on the ARC welder.10.

Pull the Trigger all the way back and11. touch the prongs to the workpiece.

Release the trigger slowly until it12. connects the workpiece, then pull the

trigger back about 1/16”. The arc will

be ignited. The weld should take two

to three seconds to complete.

Pull the trigger all the way back to13. break the arc.

Allow the Spot Welder to cool down14. after ten welds.

15. trode from the workpiece, discharge

the electrode to ground and turn the

Welder off. Disconnect the Spot

Welder from its power source.

Place the Spot Welder down on a16.

-

face to cool.

To prevent accidents, disconnect the17. Spot Welder from the ARC welder

after use. Clean, then store the tool

indoors out of children’s reach.

TROUBLESHOOTING

Symptom Cause Solution

Weld does not occur. Unit not plugged in.1.

Blown fuse or circuit breaker.2.

Plug Power Cord into electrical outlet.1.

Replace fuse or reset circuit breaker.2.

Weld not strong/deep

enough. Electrode dirty or oxidized.1.

Poor contact with metals.2.

Electrode holder dirty or oxidized.3.

Clean or replace Electrode.1.

Press harder against workpiece/.2.

Clean area with copper cleaner and3.





weld time required. Metals to be welded are dirty.1.

Electrode dirty, oxidized, or pitted.2.

Nuts on Conductors loose.3.

Facility line voltage low.4.

1. sandpaper.

Clean, resurface, or replace Electrode.2.

Tighten nuts.3.

Check line voltage with voltmeter.4.

Burn through at weld

point. Weld time too long.1.

Electrode dirty, oxidized, or pitted.2.

Shorten weld time.1.

Clean, resurface, or replace Electrode.2.

REV 09c

SKU 98759 For technical questions, please call 1-800-444-3353. Page 9

MAINTENANCE AND

SERVICING

Procedures not specically

explained in this manual

must be performed only by a

qualied technician.

TO PREVENT

SERIOUS INJURY

FROM ACCIDENTAL

OPERATION:

Turn the Power Switch of the

ARC welder to its “OFF”

position and unplug the tool

from the electrode clamp

before performing any

inspection, maintenance, or

cleaning procedures.

TO PREVENT SERIOUS

INJURY FROM TOOL

FAILURE:

Do not use damaged

equipment. If abnormal noise

or vibration occurs, have the

problem corrected before

further use.

Cleaning, Maintenance, and

Lubrication

BEFORE EACH USE,1. inspect the

general condition of the tool. Check

for loose screws, misalignment or

binding of moving parts, cracked or

broken parts, damaged electrical wir-

ing, and any other condition that may

affect its safe operation.

AFTER USE,2. clean external surfaces

of the tool with clean cloth.

3. WARNING! If the supply cord of

this power tool is damaged, it must

be replaced only by a qualied

service technician.

PLEASE READ THE FOLLOWING

CAREFULLY

THE MANUFACTURER AND/OR DISTRIBUTOR







MANUFACTURER OR DISTRIBUTOR MAKES

ANY REPRESENTATION OR WARRANTY OF

ANY KIND TO THE BUYER THAT HE OR SHE







IN FACT, THE MANUFACTURER AND/OR





















SKU 98759 For technical questions, please call 1-800-444-3353. Page 10

PARTS LIST

Part Description Qty.

1 Welding Head - Two Prong 1

2 Welding Head - Four Prong 1

3 Washer 1

4 Case 1

5 Washer 1

6 Tube 1

7 Piston 1

8 Axis Assembly 1

PARTS LIST

Part Description Qty.

9 Spring 1

10 Frame Handle 1

11 Screw M4x22 1

12  1

13 Screw M4x12 4

14 Nut M4 1

15 Connection 1

16 Electrode (not shown) 2

DIAGRAM

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 avail-

able individually as replacement parts.

Table of contents

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