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
Copyright©2005 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.
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.)