Chicago Electric 94739 User Manual
Auto Body Stud Welding Kit
94739
ASSEMBLY AND OPERATING INSTRUCTIONS
Diagrams within this manual may not be drawn proportionally.
Due to continuing improvements, actual product may differ slightly from the product described herein.
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© 2006 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 or replacement parts, please call 1-800-444-3353.
SKU 94739 For technical questions, please call 1-800-444-3353 Page 1
Specifications
Power
Requirement
Secondary
No Load
Voltage
Timed Work
Mode
Included
Accessories
Dimensions 17”L x 11”W x 11”H Net Weight 63 Lbs.
230VAC, Single Phase, 60 Hz, 60
Amps
8.8V - 9.5V Max. Working
Timed Range: 0 - 1.2 sec. Required
(6) Electrode Tips, Slide-pull Ham-
mer, (2) Hook Tips, (3) Carbon Rods
Max Power
(Instant)
Current
(Instant)
Electrical
Plug
Duty Cycle 15% Spot Welding at Max. Output Power
10KVA
1300 A
3-Prong, 230 VAC, Polarized, Twist Lock, 60
Amps for maximum output (not included)
40% Carbon Warming at Min. Output Power
Save This Manual
You will need the manual for the safety warnings and precautions, assembly instructions, operating and
maintenance procedures, parts list and diagram. Keep your invoice with this manual. Write the invoice number on the inside of the front cover. Keep the manual and invoice in a safe and dry place for future reference.
General Safety Warnings and Precautions
WARNING: When using tool, basic safety precautions should always be followed to reduce the
risk of personal injury and damage to equipment.
Read all instructions before using this tool!
Work Area Safety
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 flam-
mable 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 debris such as chips and sparks.
Provide barriers or shields as needed.
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 whether the outlet is properly grounded. If the tool 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 refrigera-
tors. 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 tool or pull the Plug
from an outlet. Keep the Power Cord away from heat, oil, sharp edges, or moving parts.
Replace damaged Power Cords immediately. Damaged Power Cords increase the risk of electric
shock.
SKU 94739 For technical questions, please call 1-800-444-3353 Page 2
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 operating a power tool.
Do not use a power tool while tired or under the influence of drugs, alcohol, or medication. A
moment of inattention while operating 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.
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.
12. Remove adjusting keys or wrenches before turning the power tool on. A wrench or a key that
is left attached to an operational 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.
WARNING: This product, when used for welding, plasma cutting, soldering, or 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.)
Tool Use and Care
14. Use clamps (not included) or other practical ways to secure and support the work piece to a stable
platform. Holding the work by hand or against your body is unstable and may lead to loss of control.
15. 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.
16. 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.
17. 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.
18. Store idle tools out of reach of children and other untrained persons. Tools are dangerous in
the hands of untrained users.
19. Maintain tools with care. Keep the welder clean. Properly maintained tools function better and
are easier to control. Do not use a damaged tool. Tag damaged tools “Do not use” until repaired.
20. Check for misalignment or binding of moving parts, breakage of parts, and any other condi-
tion that may affect the tool’s operation. If damaged, have the tool serviced before using.
Many accidents are caused by poorly maintained tools.
SKU 94739 For technical questions, please call 1-800-444-3353 Page 3
Service
1. Tool service must be performed only by qualified repair personnel. Service or maintenance
performed by unqualified personnel could result in a risk of injury.
2. 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.
3. 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.
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).
2. Industrial applications must follow OSHA guidelines.
3. Have a designated safe place to set down the welding gun which is not flammable, will protect
the gun from being bumped or dropped and will not conduct electricity.
4. Never leave the welder unattended when it is plugged into an electrical outlet. Turn off the
welder, and unplug it from its electrical outlet before leaving.
5. 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.
SKU 94739 For technical questions, please call 1-800-444-3353 Page 4
6. 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.
7. 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, re 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 ammable 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 conned spaces, wear ame resistant ear plugs or ear muffs
to keep sparks out of ears.
8. Prevent accidental fires. Remove any combustible material from the work area.
• When possible, move the work to a location well away from combustible materials. 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 re 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 combustibles 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 eliminating the hazard.
• Do not dispose of hot slag in containers holding combustible materials. Keep a re extinguisher
nearby and know how to use it.
• After spot welding, make a thorough examination for evidence of re. 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 combustible material
whose contents, when heated, can produce flammable or explosive vapors. Clean and purge containers before applying heat. Vent closed containers, including castings, before preheating, welding,
or cutting.
9. 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.
SKU 94739 For technical questions, please call 1-800-444-3353 Page 5
• Where ventilation is questionable, have a qualied technician take an air sampling 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 conned 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 recommendations for
Threshold Limit Values (TLV’s) for fumes and gases.
• 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.
10. Read and understand all instructions and safety precautions as outlined in the manufacturer’s
manual for the material you will weld or cut.
11. 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.
12. 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.
13. 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.
14. 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.
SKU 94739 For technical questions, please call 1-800-444-3353 Page 6
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