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.
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.

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.

SKU 98759 For technical questions, please call 1-800-444-3353. Page 11
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 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-


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-
-
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.

which vary from state to state.
3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • [phone]