Chicago Electric 98759 Operating instructions

Spot welder
Set up and Operating Instructions
Distributed exclusively by Harbor Freight Tools®.
3491 Mission Oaks Blvd., Camarillo, CA 93011
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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 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.
NOTICE is used to
address practices
not related to personal injury.
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.
CAUTION, without
the safety alert
symbol, is used to address
practices not related to
personal injury.
General Power Tool Safety
Important SAFETY
WARNING 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.
The term ″power tool″ in the
warnings refers to your corded
power tool.
In this manual, on the labeling,
and all other information provided with this product:
This is the safety alert
symbol. It is used to alert
you to potential personal
injury hazards. Obey all
safety messages that
follow this symbol to avoid
possible injury or death.
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
DANGER 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.
with the safety
alert symbol, indicates a
hazardous situation which, if
not avoided, could result in
minor or moderate injury.
SKU 98759
Work area safety
c.Keep children and bystanders
away while operating a power tool.
Distractions can cause you to lose
Electrical safety
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.
For technical questions, please call 1-800-444-3353.
Page 2
b.Do not expose power tools to rain
or wet conditions. Water entering
a power tool will increase the risk of
electric shock.
necting to power source, picking
up or carrying the tool.
d.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 abuse the cord. Never use
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.
e.Dress properly. Do not wear loose
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.
d.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.
e.If operating a power tool in a damp
location is unavoidable, use a
Ground Fault Circuit Interrupter
(GFCI) protected supply. Use of
a GFCI reduces the risk of electric
Personal safety
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
b.Use personal protective equipment. Always wear eye protection.
Safety equipment such as welding
mask, non-skid safety shoes, and
welding apron used for appropriate
conditions will reduce personal injuries.
c.Prevent unintentional starting. Ensure the switch of the stick welder
is in the off-position before con-
SKU 98759
f. Only use safety equipment that
has been approved by an appropriate standards agency. Unapproved
safety equipment may not provide
adequate protection. Eye protection
must be ANSI-approved and breathing protection must be NIOSH-approved for the specific hazards in the
work area.
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.
b.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
c.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, have the power tool repaired
before use. Many accidents are
For technical questions, please call 1-800-444-3353.
Page 3
er failure. In addition, people with
pacemakers should:
• Avoid operating alone.
• Do not use with power switch locked
• Properly maintain and inspect to
avoid electrical shock.
• Any power cord must be properly
grounded. Ground Fault Circuit Inter­
rupter (GFCI) should also be imple­
mented – it prevents sustained elec­
trical shock.
caused by poorly maintained power
d.Use the power tool, accessories
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 different from those intended could result
in a hazardous situation.
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.
Spot Welder Safety Warnings
Maintain labels and nameplates on
the tool. These carry important safety
information. If unreadable or miss­
ing, contact Harbor Freight Tools for a
Avoid unintentional starting. Prepare
to begin work before turning on the
Rest the tool and connection to the
electrode holder on a properly insu­
lated surface.
Do not leave the tool unattended
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 out
of reach of children.
People with pacemakers should
consult their physician(s) before use.
Electromagnetic fields in close prox­
imity to heart pacemaker could cause
pacemaker interference or pacemak­
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WARNING: The brass components
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
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:
• Lead from lead-based paints
• Crystalline silica from bricks and ce­
ment or other masonry products
• Arsenic and chromium from chemi­
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
designed to filter out microscopic
particles. (California Health & Safety
Code § 25249.5, et seq.)
WARNING: Handling the cord on
this product will expose you to lead,
a chemical known to the State of
For technical questions, please call 1-800-444-3353.
Page 4
California to cause cancer, and birth
defects or other reproductive harm.
Wash hands after handling. (Califor­
nia Health & Safety Code § 25249.5,
et seq.)
Prevent accidental fires.
Remove any combustible
material from the work
area. 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.
If working on a wall or ceiling prevent
ignition of combustibles on the other
side by moving them to a safe loca­
Industrial applications must follow
OSHA guidelines. Follow OSHA
guidelines for Permis­sible Exposure
Limits (PEL’s) for vari­ous fumes and
Prevent eye injury and
burns. Wearing and using
ANSI-approved personal
safety clothing and safety
devices reduce the risk for injury.
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 and work surfaces free
of grease, oil, solvents, or any flam­
mable substances. Wear dry, insulat­
ing gloves and protective clothing.
Wear an approved head covering
to protect the head and neck. Use
aprons, cape, sleeves, shoulder cov­
ers, and bibs designed and approved
for welding and cutting procedures.
10. Do not exceed input amperage of 50
11. Follow all directions provided in the
manual of the ARC (stick) welder
used with this product.
12. The warnings, precautions, and in­
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
Electrical Safety
Avoid electrical shock. Do not per­
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. Arc
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
arc shaded filter plate.
SKU 98759
For technical questions, please call 1-800-444-3353.
Page 5
10. When welding/cutting overhead or in
confined spaces, wear flame resistant
ear plugs or ear muffs to keep sparks
out of ears.
11. Do not use near degreasing or paint­
ing operations.
12. Enclose the work area with portable
fire resistant screens. Protect com­
bustible walls, ceilings, floors, etc.,
from sparks and heat with fire resis­
tant covers.
13. Do not weld sealed containers. All
containers should be considered un­
safe unless they have been declared
safe by a qualified person.
14. Use a non-conductive safety mat on
the work surface to insulate the op­
erator from the work surface.
15. Read the directions for the stick
welder that the Spot Welder will be
connected to.
Save these
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For technical questions, please call 1-800-444-3353.
Page 6
35 to 50 Amps
Material Range
18 Gauge Maximum
Electrode Size
5-7/8” L x 0.279” D (2 included)
Weld Time
2 to 3 Seconds
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
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 clean
and well-lit. The work area must not
allow access by children or pets to
prevent injury and distraction.
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Route the power cord 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 al­
low free movement while working.
Secure loose work pieces using a
vise or clamps (not included) to pre­
vent movement while working.
There must not be hazardous ob­
jects, such as utility lines or foreign
objects, nearby that will present a
hazard while working.
General Operating Instructions
Do not touch any metal part of
the Spot welder when it is
Read the manual for the ARC (stick)
welder that is being used to power
the Spot Welder.
If welding on a vehicle; disconnect
the vehicle’s battery.
Clean the work thoroughly before
beginning operation. Remove all
grease, paint, and oil from the work­
Wear protective gear whenever weld­
Choose the Welding Head that suits
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)
is best suited for welding on flat sur­
faces. Twist the correct welding head
For technical questions, please call 1-800-444-3353.
Page 7
for the job onto the end of the Spot
Welder firmly.
11. Pull the Trigger all the way back and
touch the prongs to the workpiece.
Insert one of the included electrodes
(16) and tighten the Lock Screw (12)
to fix the electrode in place.
Clamp the electrode holder of the
ARC welder onto the Connection (15)
of the Spot Welder.
12. Release the trigger slowly until it
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.
Adjust the output to no greater than
50 Amps.
DANGER! To prevent serious
injury and death. If the operator
is not holding the Spot Welder, it
must be sitting on a nonconductive, nonflammable surface. The
Spot Welder will immediately
turn on when the power button
is turned on. The connection between the Spot Welder and the
electrode clamp of the ARC welder
must also be must be sitting on
a nonconductive, nonflammable
10. Turn on the ARC welder.
13. Pull the trigger all the way back to
break the arc.
14. Allow the Spot Welder to cool down
after ten welds.
15. When finished welding; lift the elec­
trode from the workpiece, discharge
the electrode to ground and turn the
Welder off. Disconnect the Spot
Welder from its power source.
16. Place the Spot Welder down on a
nonflammable, nonconductive sur­
face to cool.
17. To prevent accidents, disconnect the
Spot Welder from the ARC welder
after use. Clean, then store the tool
indoors out of children’s reach.
Weld does not occur.
Weld not strong/deep
Longer than normal
weld time required.
Burn through at weld
1. Unit not plugged in.
2. Blown fuse or circuit breaker.
1. Electrode dirty or oxidized.
2. Poor contact with metals.
3. Electrode holder dirty or oxidized.
1. Plug Power Cord into electrical outlet.
2. Replace fuse or reset circuit breaker.
1. Clean or replace Electrode.
2. Press harder against workpiece/.
3. Clean area with copper cleaner and
fine wet-dry sandpaper.
1. Metals to be welded are dirty.
1. Clean metals with fine wet-dry
2. Electrode dirty, oxidized, or pitted. 2. Clean, resurface, or replace Electrode.
3. Nuts on Conductors loose.
3. Tighten nuts.
4. Facility line voltage low.
4. Check line voltage with voltmeter.
1. Weld time too long.
1. Shorten weld time.
2. Electrode dirty, oxidized, or pitted. 2. Clean, resurface, or replace Electrode.
REV 09c
SKU 98759
For technical questions, please call 1-800-444-3353.
Page 8
Maintenance And
Procedures not specifically
explained in this manual
must be performed only by a
qualified technician.
To prevent
serious injury
from accidental
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
Do not use damaged
equipment. If abnormal noise
or vibration occurs, have the
problem corrected before
further use.
be replaced only by a qualified
service technician.
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 certified
and 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.
Cleaning, Maintenance, and
BEFORE EACH USE, 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, clean external surfaces
of the tool with clean cloth.
WARNING! If the supply cord of
this power tool is damaged, it must
SKU 98759
For technical questions, please call 1-800-444-3353.
Page 9
Parts List
Welding Head - Two Prong
Welding Head - Four Prong
Axis Assembly
Parts List
Frame Handle
Screw M4x22
Lock Screw M5x10
Screw M4x12
Nut M4
Electrode (not shown)
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.
SKU 98759
For technical questions, please call 1-800-444-3353.
Page 10
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 prod­
uct 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 express­
ly 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 com­
plaint must accompany the merchandise. If our inspection verifies the defect, we will ei­
ther 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 re­
paired 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
SKU 98759
For technical questions, please call 1-800-444-3353.
Page 11