Harbor Freight Tools 45689 User Manual

SPOT WELDER

Model

45689

SET UP AND OPERATING INSTRUCTIONS

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© 2001 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.

Manual Revised 10g

SPECIFICATIONS TABLE

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Electrical Input Requirements 115 Volt
Rated Output 1.5KVA @ 50% Duty Cycle
Output Amps+ / - 10 % 5,500
Material Capacity1/8” Thick, Mild Steel
Tong Length6”
Overall Dimensions 13” x 6” x 4.5”

.sbL 4.52thgieW

SAVE THIS MANUAL

You will need this manual for the safety warnings and precautions, assembly, operating,
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 WARNINGS AND PRECAUTIONS

1. KEEP WORK AREA CLEAN AND DRY. Cluttered, damp or wet work areas invite
injuries.

2. KEEP CHILDREN AWAY FROM WORK AREA. Do not allow children to handle this
product.

3. STORE IDLE EQUIPMENT. When not in use, tools and equipment should be stored in a
dry location to inhibit rust. Always lock up tools and equipment and keep out of reach of
children.

4. DO NOT USE THIS PRODUCT IF UNDER THE INFLUENCE OF ALCOHOL OR DRUGS.

Read warning labels on prescriptions to determine if your judgment or reexes are impaired

while taking drugs. If there is any doubt, do not attempt to use this product.

5. USE EYE, HEARING, BREATHING, AND HAND PROTECTION. Wear an ANSI approved
welding helmet/goggles with shaded lens, hearing protectors, breathing respirator, and
welding gloves when using this product. ANSI approved welding helmet/goggles with
shaded lens, hearing protectors, breathing respirators, and welding gloves are available
from Harbor Freight Tools.

6. DRESS SAFELY. Sparks and hot metal can injure. Always wear body protection. Non-
skid footwear or safety shoes should be used when working with this product. Do not wear
loose clothing or jewelry as they can become caught in moving parts. Wear a protective
hair covering to prevent long hair from becoming caught in moving parts. If wearing a long­sleeve shirt, roll sleeves up above elbows.

7. INDUSTRIAL APPLICATIONS MUST FOLLOW OSHA REQUIREMENTS.

Rev 02/02

Page 2For technical questions, please call 1-800-444-3353.SKU 45689

8. DO NOT OVERREACH. Keep proper footing and balance at all times to prevent tripping,
falling, back injury, etcetera.

9. STAY ALERT. Watch what you are doing at all times. Use common sense. Do not use this
product when you are tired or distracted from the job at hand.

10. CHECK FOR DAMAGED PARTS. Before using this product, carefully check that it will
operate properly and perform its intended function. Check for damaged parts and any other
conditions that may affect the operation of this product. Replace or repair damaged or worn
parts immediately.

11. REPLACEMENT PARTS AND ACCESSORIES. When servicing, use only identical
replacement parts. Only use accessories intended for use with this product. Approved
accessories are available from Harbor Freight Tools.

12. MAINTAIN THIS PRODUCT WITH CARE. Keep this tool clean and dry.

13. MAINTENANCE: For your safety, service and maintenance should be performed regularly

by a qualied technician.

14. USE THE RIGHT PRODUCT FOR THE RIGHT JOB. There are certain applications for
which this product was designed. Do not use small equipment, tools or attachments to do
the work of larger industrial equipment, tools or attachments. Do not use this product for a
purpose for which it was not intended.

SPECIFIC PRODUCT WARNINGS AND PRECAUTIONS

1. GROUND THIS PRODUCT. The supplied electrical Power Cord Plug for this product
is a grounded, 115 Volt, 3-Prong Plug. Never remove the grounding prong or modify the

Plug in any way. Do not use adapter plugs with this product. When in use, make sure this
product is always plugged into a grounded, 115 Volt, 3-hole electrical receptacle with an
appropriate breaker switch inline.

2. MAKE SURE THE CONTROL SWITCH (part #25) IS IN THE “OFF” POSITION BEFORE

PLUGGING IN THE POWER CORD. (See Figure D, and Assy. Diagram.)

3. DO NOT ABUSE THE POWER CORD. Do not use the Cord to pull the 3-Prong Plug from
a power outlet. Keep Cord away from heat, oil, sharp edges, and moving parts. Replace
damaged Cord immediately. Route the Power Cord safely. Protect it from being damaged
by other equipment in the shop. Do not route the Cord where it can be walked on or tripped
over.

4. MAINTAIN A SAFE WORK ENVIRONMENT. Do not use this product in or near damp or
wet areas. Do not expose this product to rain. Keep work area well lit. Make sure there is
adequate surrounding work space. Use this product in a well ventilated area. (Read Material
Safety Data Sheets/MSDS for metals, coatings, and cleaners.) Do not operate this product

Rev 02/02

Page 3For technical questions, please call 1-800-444-3353.SKU 45689

in the presence of ammable liquids, gases, or dust. To avoid accidental electric shock, do

not let your body come in contact with grounded surfaces such as pipes, radiators, ranges
and refrigerators. Always keep a re extinguisher nearby.

5. DO NOT FORCE THE EQUIPMENT. This Spot Welder will do the work better and safer at
the speed and capacity for which it was designed.

6. AVOID UNINTENTIONAL STARTING. Make sure you are prepared to begin work before
turning the Control Switch (part #25) “ON”.

7. Caution: Never touch the Upper and Lower Tongs (parts #46, #47) when welding a
workpiece. Allow the Tong Tips (part #48) and the workpiece to cool before handling. (See

Figures A, B, E, and Assy. Diagram.)

8. MAKE SURE THE WORKPIECE IS SECURED AT ALL TIMES DURING OPERATION.
Use a vise, clamps, etcetera (not provided).

9. OVERUSE CAN CAUSE OVERHEATING. After continuous use, allow the Spot Welder
adequate time to cool before the next use.

10. BEFORE TRYING NEW OR COMPLICATED TECHNIQUES, STUDY THE PROCEDURE,

AND PRACTICE WITH SCRAP METAL.

11. ALWAYS DISCONNECT THE SPOT WELDER FROM ITS ELECTRICAL SUPPLY SOURCE
BEFORE ASSEMBLING, PERFORMING ANY SERVICES OR MAINTENANCE always

disconnect the electrical cord before leaving the work area, moving the tool from one location
to another, handing the tool to another person, changing Tong Tips (part #48), cleaning the
unit, etcetera.

12. 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.)

13. WARNING: Operation of equipment in close proximity to a heart pacemaker could cause
interference or failure of the pacemaker.

REV 05/04

Page 4For technical questions, please call 1-800-444-3353.SKU 45689

UNPACKING

When unpacking, check to make sure all parts shown on the Parts List (page 12) are included.
If any parts are missing or broken, please call Harbor Freight Tools at the number shown on
the cover of this manual as soon as possible.

ASSEMBLY INSTRUCTIONS

NOTE: For additional references to the parts listed below, refer to the Assembly Dia­gram on page 13 of this manual.

To Attach The Upper And Lower Tongs:

1. Caution: Prior to attaching the Upper and Lower Tongs (parts #46, #47), make sure the

Spot Welder is disconnected from its electrical power source.

2. NOTE: Make sure the Upper and Lower Tongs (parts #46, #47) are clean and not cor-

roded before installing. If necessary, clean the Tongs with steel wool.

3. To attach the Lower Tong (part #47) to the Spot Welder, loosen the four Cap Screws

(part #3) located at the bottom/front of the tool. (See Figure A, and Assy. Diagram.)

4. Slide the Lower Tong (part #47) between the Tong Insulator (part #33) and Lower Tong

Clamp (part #35), and position the Lower Tong so that the Tong Tip (part #48) faces up.

5. NOTE: Check to make sure the Lower Tong (part #47) will align with the Upper Tong

(part #46) when fully assembled. (See Figure B, and Assy. Diagram.)

6. Retighten the four Cap Screws (part #3).

7. To attach the Upper Tong (part #46) to the Spot Welder, loosen the four Cap Screws

(parts #3, #11) located at the top/front of the tool. (See Figure A, and Assy. Diagram.)

8. Slide the Upper Tong (part #46) between the Tong Top Holder (part #12) and Upper

Tong Clamp (part #13), and position the Upper Tong so that the Tong Tip (part #48)
faces down.

9. NOTE: Check to make sure the Upper Tong (part #46) will align with the Lower Tong

(part #47) when fully assembled. (See Figure B, and Assy. Diagram.)

Page 5For technical questions, please call 1-800-444-3353.SKU 45689