Chicago Electric 61205 Montageanleitung

Read this material before using this product.

Failure to do so can result in serious injury.

SAVE THIS MANUAL.

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.

When unpacking, make sure that

the product is intact and undamaged.

If any parts are missing or broken, please call

1-888-866-5797 as soon as possible.

Save This Manual Keep this manual for the safety warnings and precautions, assembly, operating,

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.

Owner’s Manual & Safety Instructions

Visit our website at: http://www.harborfreight.com

Email our technical support at: [email protected]

61205

Owner’s Manual & Safety Instructions

Save This Manual Keep this manual for the safety warnings and precautions, assembly,

operating, 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. 22h

When unpacking, make sure that the product is intact

and undamaged. If any parts are missing or broken,

please call 1-888-866-5797 as soon as possible.

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.

Read this material before using this product.

Failure to do so can result in serious injury.

SAVE THIS MANUAL.

Page 2 For technical questions, please call 1-888-866-5797. Item 61205

Table of Contents

Safety................................................ 2

Specifications.................................... 7

Setup ................................................ 8

Operation ......................................... 10

Maintenance .................................... 12

Parts List and Diagrams .................. 14

Warranty .......................................... 16

WARNING SYMBOLS AND DEFINITIONS

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.

Indicates a hazardous situation which, if not avoided,

will result in death or serious injury.

Indicates a hazardous situation which, if not avoided,

could result in death or serious injury.

Indicates a hazardous situation which, if not avoided,

could result in minor or moderate injury.

Addresses practices not related to personal injury.

IMPORTANT SAFETY INFORMATION

Read all safety warnings and instructions.

Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.

Save all warnings and instructions for future reference.

General Safety Information

PROTECT yourself and others. Read and understand this information.

1. Before use, read and understand

manufacturer′s instructions,

Material Safety Data Sheets (MSDS),

employer′s safety practices, and ANSI Z49.1.

2. Keep out of reach of children.

Keep children and bystanders away while operating.

3. Hold the Welder securely during use.

If it falls while plugged in, severe injury,

electric shock, or fire may result.

4. Stay alert, watch what you are doing and use

common sense when operating a welder.

Do not use a welder while you are tired or under

the influence of drugs, alcohol or medication.

A moment of inattention while operating welders

may result in serious personal injury.

5. Do not overreach.

Keep proper footing and balance at all times.

6. Avoid unintentional starting. Make sure you are

prepared to begin work before turning on the Welder.

7. Never leave the Welder unattended while

energized. Turn power off if you have to leave.

8. The warnings, precautions, and instructions

discussed in this instruction 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.

SAFETY OPERATION MAINTENANCESETUP

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Fume and Gas Safety Information

FUMES AND GASES can be hazardous to your health.

1. Exposure to welding or cutting

exhaust fumes 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 or cutting exhaust fumes are:

• Early onset of Parkinson’s Disease

• Heart disease • Ulcers

• Damage to the reproductive organs

• Inflammation of the small intestine or

stomach • Kidney damage

• Respiratory diseases such as

emphysema, bronchitis, or pneumonia

2. Do not use near degreasing or

painting operations.

3. Keep head out of fumes.

Do not breathe exhaust fumes.

4. Use enough ventilation or exhaust, or both,

to keep fumes and gases from breathing

zone and general area. If engineering controls

are not feasible, use an approved respirator.

5. Work in a confined area only if it

is well-ventilated, or while wearing

an air-supplied respirator.

6. Have a recognized specialist in

Industrial Hygiene or Environmental Services

check the operation and air quality

and make recommendations

for the specific welding situation.

Follow OSHA guidelines for

Permissible Exposure Limits (PEL’s) and

the American Conference of Governmental

Industrial Hygienists recommendations for

Threshold Limit Values (TLV’s) for fumes and gases.

Arc Ray Safety Information

ARC RAYS can injure eyes and burn skin.

1. Wear ANSI-approved welding eye protection

featuring at least a number 10 shade lens rating.

2. Wear leather leggings, fire resistant shoes

or boots during use. Do not wear pants with

cuffs, shirts with open pockets, or any clothing

that can catch and hold molten metal or sparks.

3. Keep clothing free of grease, oil,

solvents, or any flammable substances.

Wear dry, insulating gloves and protective clothing.

4. 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.

5. When welding/cutting overhead or in confined

spaces, wear flame resistant ear plugs or

ear muffs to keep sparks out of ears.

SAFETYOPERATIONMAINTENANCE SETUP

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Electrical Safety Information

ELECTRIC SHOCK can KILL.

1. Never leave the Spot Welder unattended

while energized. Turn off and disconnect

power when leaving the work area.

2. Do not touch energized electrical parts.

Wear dry, insulating gloves. Do not touch

electrode or conductor tong with bare hand.

Do not wear wet or damaged gloves.

3. Connect to grounded, GFCI-protected

power supply only.

4. Do not use near water or damp objects.

5. People with pacemakers should consult their

physician(s) before use. Electromagnetic fields

in close proximity to heart pacemaker could cause

pacemaker interference or pacemaker failure.

6. Do not expose welders to rain or wet conditions.

Water entering a welder will increase

the risk of electric shock.

7. Do not abuse the cord. Never use the cord

for carrying, pulling or unplugging the Welder.

Keep cord away from heat, oil, sharp edges

or moving parts. Damaged or entangled

cords increase the risk of electric shock.

8. Do not use outdoors.

9. 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 large enough to cover your full

area of contact with the work or ground.

10. Use care not to touch the welding tip to

grounded material whenever the unit is

plugged in. Electric shock, fire, or burns may

happen if appropriate precautions are not taken.

Fire Safety Information

SPARKS AND HOT SLAG can cause fire.

1. Clear away or protect flammable objects.

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.

2. Keep ABC-type fire extinguisher near

work area and know how to use it.

3. Maintain a safe working environment.

Keep the work area well lit.

Make sure there is adequate

surrounding workspace. Keep the work area free

of obstructions, grease, oil, trash, and other debris.

4. Do not operate welders in atmospheres

containing dangerously reactive or

flammable liquids, gases, vapors, or dust.

Provide adequate ventilation in work areas

to prevent accumulation of such substances.

Welders create sparks which may ignite flammable

substances or make reactive fumes toxic.

5. 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.

6. 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.

7. Do not dispose of hot slag in containers

holding combustible materials.

8. After 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.

9. 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.

SAFETY OPERATION MAINTENANCESETUP

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Operation Specific Safety Information

1. Do not use the Welder if the switch does not turn

it on and off. Any welder that cannot be controlled

with the switch is dangerous and must be repaired.

2. Disconnect the plug from the power

source before making any adjustments,

changing accessories, or storing welders.

Such preventive safety measures reduce the

risk of starting the Welder accidentally.

3. Prevent unintentional starting.

Ensure the switch is in the off-position before

connecting to power source or moving

the Welder. Carrying or energizing welders

that have the switch on invites accidents.

4. Store idle Welder out of the reach of

children and do not allow persons unfamiliar

with the Welder or these instructions to

operate the Welder. Welders are dangerous

in the hands of untrained users.

5. Use the Welder and accessories in

accordance with these instructions, taking

into account the working conditions and

the work to be performed. Use of the Welder

for operations different from those intended

could result in a hazardous situation.

Service Specific Safety Information

1. Maintain welders. Check for misalignment or

binding of moving parts, breakage of parts

and any other condition that may affect the

Welder’s operation. If damaged, have the

Welder repaired before use. Many accidents

are caused by poorly maintained welders.

2. Have your Welder serviced by a qualified

repair person using only identical

replacement parts. This will ensure that

the safety of the Welder is maintained.

3. Maintain labels and nameplates on the Welder.

These carry important information.

If unreadable or missing, contact

Harbor Freight Tools for a replacement.

4. Unplug before maintenance. Unplug the Welder

from its electrical outlet before any inspection,

maintenance, or cleaning procedures.

SAVE THESE INSTRUCTIONS.

SAFETYOPERATIONMAINTENANCE SETUP

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Grounding

TO PREVENT ELECTRIC SHOCK AND DEATH FROM INCORRECT GROUNDING WIRE

CONNECTION:

Check with a qualified electrician if you are in doubt as to whether the outlet is properly

grounded. Have a plug installed by a certified electrician. Do not use the Welder 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 Welders

1. The grounding prong in the plug is connected

through the green wire inside the cord to the

grounding system in the Welder. The green wire

in the cord must be the only wire connected to

the Welder’s grounding system and must never

be attached to an electrically “live” terminal.

2. The Welder must be plugged into an appropriate

outlet, properly installed and grounded in

accordance with all codes and ordinances.

Extension Cords

1. If an extension cord is used, it must have

the following wire size: up to 30 feet, use

10 AWG size wire; 30 to 50 feet, use 8 AWG

wire; Over 50 feet, use 6 AWG wire.

2. As the distance from the supply outlet increases,

a heavier gauge extension cord must be used.

Using extension cords with inadequately sized

wire causes a serious drop in voltage, resulting

in loss of power and possible Welder damage.

3. The smaller the gauge number of the wire,

the greater the capacity of the cord. For

example, a 14 gauge cord can carry a

higher current than a 16 gauge cord.

4. When using more than one extension cord to

make up the total length, make sure each cord

contains at least the minimum wire size required.

5. If using one extension cord for more than one

welder, add the nameplate amperes and use the

sum to determine the required minimum cord size.

6. If using an extension cord outdoors, make sure it

is marked with the suffix “W-A” (“W” in Canada)

to indicate it is acceptable for outdoor use.

7. Make sure the extension cord is properly wired

and in good electrical condition. Always replace

a damaged extension cord or have it repaired

by a qualified electrician before using it.

8. Protect the extension cords from sharp objects,

excessive heat, and damp or wet areas.

SAFETY OPERATION MAINTENANCESETUP

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Symbology

Housing Ground Point

VVolts

~Alternating Current

AAmperes

OCV Open Circuit Voltage

KVA Kilovolt Amperes

(Volts / 1000 * Amperes)

AWG American Wire Gauge

Specifications

Electrical Rating 120 V~ / 13.5 A

Rated Output 1.5 kVA @ 50% Duty Cycle

Output Amps ± 10% 5500

Weldable Materials Uncoated mild, galvanized, or stainless sheet steel

Not for welding aluminum, copper or copper alloys

Capacity Mild Steel: up to a combined thickness of 1/8" sheet steel

Galvanized Steel: two pieces of 20 gauge (0.039") sheet steel

Duty Cycle 50% @ 1.5 kVA, based on 10 second time period – unit can

weld for 5 seconds out of each 10 second time interval

SAFETYOPERATIONMAINTENANCE SETUP

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Setup

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.

Note: For additional information regarding the parts listed in the following pages,

refer to Parts List and Diagrams on page 14.

Components

Power Switch

Front Jam Nut

Rear Jam Nut

Wooden Handle Operating Lever

Electrode

Tips

Fixed Handle

Upper Tong

Lower Tong

Spatter

Guard

Figure A

SAFETY OPERATION MAINTENANCESETUP

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Dressing Electrode Tips

1. Electrode Tips (24) deform during use. For

optimal weld quality, inspect Electrode Tips before

use and clean, dress (resurface), or replace as

needed to maintain a proper contact surface.

2. Use a file or tip dresser tool (both not included) to

dress Electrode Tips and restore the spot diameter

and face angle to a condition approximately

the same as a new tip. See Figure B.

Note: When welding thinner materials a smaller tip

diameter is required than when welding thicker materials.

3. Used Electrode Tips that cannot be restored

to a suitable condition by dressing will

need to be replaced. Refer to Replacing

Electrode Tips on page 12.

Figure B

< 1/8"

Diameter

New

Electrode Tip

Used Electrode Tip

Needing Dressing

Restore Diameter

to Same as New Tip

Tong and Electrode Tip Alignment

1. Correct Tong/Electrode Tip alignment is necessary

to create a proper weld. Check to make sure

the Upper Tong (19) is aligned correctly with

the Lower Tong (19a) and that the Electrode

Tips (24) are centered and touch each other

exactly prior to welding operation. See Figure C.

2. To adjust the Upper Tong, loosen the four Cap

Screws (15) located at the top/front of the tool.

Refer to Assembly Diagram on page 15.

3. To adjust the Lower Tong, loosen the four Cap

Screws (30) located at the bottom/front of the

tool. Refer to Assembly Diagram on page 15.

4. Align the Upper and Lower Tongs and

Electrode Tips as shown in Figure C.

5. When alignment is complete

retighten the Cap Screws.

Electrode

Tips (24)

Upper Tong (19)

Side View

Lower Tong (19a)

Front View

Figure C

SAFETYOPERATIONMAINTENANCE SETUP

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Operation

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.

Adjusting Tong and Operating Lever Pressure

WARNING! TO PREVENT SERIOUS INJURY AND

ELECTRIC SHOCK: Prior to adjusting the Tong and

Operating Lever pressure, make sure the Spot Welder

is disconnected from its electrical supply source.

NOTICE: Excessive Tong pressure can damage the

Electrode Tips. Do not attempt to hold the workpieces

together by using the Tongs under high pressure as

a clamp or vise. To avoid damage, use separate

clamps to hold workpieces together if needed to

make good contact at the intended weld point.

1. The amount of pressure applied by the Tongs

is adjustable, and should be checked and/or

set before operation. Correct Tong pressure

is necessary to create a proper weld and to

prevent damage to the Electrode Tips.

2. If the Tong pressure is too weak, and the

workpieces are loose when the Tongs close, severe

arcing will occur between the workpieces when

current is applied and no weld will be produced.

To increase the Tong pressure, loosen the front

Jam Nut. The more the front Jam Nut is loosened,

the greater the pressure on the Electrode Tips

when the Operating Lever is pushed down to

close the Tongs. When the desired pressure is

achieved, turn the rear Jam Nut toward the Upper

Tong Holder to lock in position. See Figure D.

3. If the Tong pressure is too strong, the weld

nugget will dimple, and molten material will be

forced out around the weld point. To decrease the

Tong pressure, loosen the rear Jam Nut and turn

the front Jam Nut toward the Upper Tong Holder to

lock the desired pressure in position. See Figure D.

4. Adjusting the Cap Screw at the rear of the Fixed

Handle will determine how firmly the Tongs apply

pressure to the workpiece. The farther down

the Cap Screw is turned, the farther down the

Operating Lever will close and the more Tong

pressure will be applied. Adjust the Cap Screw to

allow the Operating Lever to be raised easily after

completion of the welding process. See Figure E.

5. The pressure required to push down the

Operating Lever may be adjusted by turning the

nuts located on each side of the Front Housing

clockwise or counterclockwise to loosen or

tighten the Lever action. See Figure D.

Front Jam

Nut

nut

Rear Jam

Nut

Operating

Lever

Front

Housing

Upper Tong

Holder

Figure D

SAFETY OPERATION MAINTENANCESETUP

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