Chicago Electric 93457 Assembly And Operating Instructions Manual
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Chicago Electric 93457 Assembly And Operating Instructions Manual

Chicago Electric 93457 Assembly And Operating Instructions Manual

Auto body spot welder with cart
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AUTO BODY SPOT WELDER
WITH CART
93457
ASSEMBLY AND OPERATING INSTRUCTIONS
Due to continuing improvements, actual product may differ slightly from the product described herein.
®
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit our Web site at: http://www.harborfreight.com
TO PREVENT SERIOUS INJURY,
READ AND UNDERSTAND ALL WARNINGS
AND INSTRUCTIONS BEFORE USE.
©
®
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.

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Summary of Contents for Chicago Electric 93457

  • Page 1 AUTO BODY SPOT WELDER WITH CART 93457 ASSEMBLY AND OPERATING INSTRUCTIONS Due to continuing improvements, actual product may differ slightly from the product described herein. ® 3491 Mission Oaks Blvd., Camarillo, CA 93011 Visit our Web site at: http://www.harborfreight.com TO PREVENT SERIOUS INJURY, READ AND UNDERSTAND ALL WARNINGS AND INSTRUCTIONS BEFORE USE.

  • Page 2: Table Of Contents

    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 2...

  • Page 3: Product Specifications

    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 SKU 93457 For technical questions, please call 1-800-444-3353. Page 3...
  • Page 4 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 4...
  • Page 5 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 5...

  • Page 6: Specific Safety Rules

    Turn off the tool, and unplug it from its electrical outlet before leaving. Industrial applications must follow OSHA guidelines. 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 6...
  • Page 7 • 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 7...
  • Page 8 • 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. SKU 93457 For technical questions, please call 1-800-444-3353. Page 8...
  • Page 9 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 9...

  • Page 10: Grounding

    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 SKU 93457 For technical questions, please call 1-800-444-3353. Page 10...
  • Page 11 Recommended Minimum Wire Gauge For Extension Cords* (230 Volt) * Based on limiting the line voltage drop FIGURE B to five volts at 150% of the rated amperes. SKU 93457 For technical questions, please call 1-800-444-3353. Page 11...

  • Page 12: Unpacking

    (See Figure D, next page.) To Attach The Accessory Tray: Use the four Bolts provided to attach the Accessory Tray (5) to the side of the Cart (39). (See Figure D, next page.) SKU 93457 For technical questions, please call 1-800-444-3353. Page 12...

  • Page 13: Welder Function Chart

    SWIVEL WHEEL (16) FIGURE D WELDER FUNCTION CHART The Welder is designed to provide a variety of welding functions, as shown in the illustration below. (See Figure E.) Continuous FIGURE E SKU 93457 For technical questions, please call 1-800-444-3353. Page 13...

  • Page 14: Control Panel Features

    Reduce amperage, voltage, or duty cycle before continuing to weld. Then, re- sume work. (See Figure F, next page.) Working Light (46): When illuminated, indicates improper grounding. (See Figure F, next page.) SKU 93457 For technical questions, please call 1-800-444-3353. Page 14...

  • Page 15: Operating Instructions

    (1.5mm) thick Washer (2A) securely into the Washer Electrode Socket (1A). (See Assy. Diagram.) Plug the electrical plug of the Welder’s Power Cord (35) into the nearest 230 volt, grounded, electrical outlet. SKU 93457 For technical questions, please call 1-800-444-3353. Page 15...
  • Page 16 Pothook with all of the Washers to pull out the dent. (See Figure G.) WELDING SURFACE ADAPTER (16A) WASHER (2A) POTHOOK (7A) STRIKER (17A) (6A) FIGURE G SKU 93457 For technical questions, please call 1-800-444-3353. Page 16...

  • Page 17: Wiggle Wire Spot Welding

    Gun). Weld at three places on the Wiggle Wire (one at each end and at the middle). NOTE: Wiggle Wire is typically used for welding large dents. (See Figure H.) WIGGLE WIRE ELECTRODE (3A) WIGGLE WIRE (10A) WORK SURFACE FIGURE H SKU 93457 For technical questions, please call 1-800-444-3353. Page 17...

  • Page 18: Needle Spot Welding

    Weld the dented area as desired. Then, pull the Striker (6A) towards the handle of the Extractor (4) to pull out the dent. (See Figure I.) WORK SURFACE WELDING EXTRACTOR ADAPTER (16A) NEEDLE STRIKER EXTRACTOR (17A) (4A) (6A) HANDLE FIGURE I SKU 93457 For technical questions, please call 1-800-444-3353. Page 18...

  • Page 19: Pin Welding

    NOTE: The shrinking time required is determined by the thickness of the metal and the type of metal. If the unit does not shrink properly on the first attempt, a slightly longer time may be needed. SKU 93457 For technical questions, please call 1-800-444-3353. Page 19...

  • Page 20: Patch Welding

    (See Figure K.) 0.5mm 0.8mm 1.0mm FIGURE J PROPER METHOD IMPROPER METHOD DOTTED LINE MUST BE CLEANED VEHICLE BODY SPOT WELD PATCH PIECE PATCH PIECE GROUND CLAMP (14) WELDING GUN FIGURE K SKU 93457 For technical questions, please call 1-800-444-3353. Page 20...

  • Page 21: Selecting The Proper Repair Accessory

    Refer to the illustration below to determine the proper accessories to use for specific welding procedures. (See Figure L.) For welding Washer (1A) For shrinking (1A) For spot welding (5A) (3A) (3A) (5A) (7A) (4A) FIGURE L (8A) SKU 93457 For technical questions, please call 1-800-444-3353. Page 21...

  • Page 22: Troubleshooting

    Wrong welding mode. Select the proper welding mode. Pre-selected welding time is too Select a suitable welding time. short. SKU 93457 For technical questions, please call 1-800-444-3353. Page 22...

  • Page 23: Inspection, Maintenance, And Cleaning

    Then, restart the Welder. (See Figure F.) WARNING! All maintenance, service, or repairs not mentioned in this manual must only be performed by a qualified service technician. FUSE (11A) FUSE HOLDER (37) FIGURE M SKU 93457 For technical questions, please call 1-800-444-3353. Page 23...

  • Page 24: Parts List

    NOTE: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts. SKU 93457 For technical questions, please call 1-800-444-3353. Page 24...

  • Page 25: Assembly Diagram

    ASSEMBLY DIAGRAM NOTE: Parts ending in A are shown in the Accessory List on the next page. SKU 93457 For technical questions, please call 1-800-444-3353. Page 25...

  • Page 26: Accessory List

    Spot Weld Electrode 2 pc Fuse 1 pc Adapter 5 pc NOTE: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts. SKU 93457 For technical questions, please call 1-800-444-3353. Page 26...

  • Page 27: Electrical Schematic

    ELECTRICAL SCHEMATIC BLACK WIRE Input: 230VAC, GROUND CLAMP GROUND WHITE WIRE GREEN WIRE REV 11/05 SKU 93457 For technical questions, please call 1-800-444-3353. Page 27...

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