Harbor Freight Tools Stud Welder Dent Repair Kit Product manual
Contents
1. 14 CTP aaa hee aspa pasas T 9 WAITAMY L Is S E asaasa 16 Operation essen 10 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 A DANGER AWARNING 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 A CAUTION NOTICE CAUTION IMPORTANT SAFETY INFORMATION AWARNING 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 Addresses practices not related to personal injury General Safety Information PROTECT yourself and others Read and understand this information 5 Do not overreach Keep proper footing and balance at all times 1 Before use read and understand manufacturer s instructions Material Safety Data Sheets MSDS employer s safety practices and ANSI Z49 1 6 Avoid unintentional starting Make sure you are prepared to begin work before turning on the Welder 2 Keep out of reach of children Keep children and bystanders away w2. technical questions please call 1 800 444 3353 Page 13 m Z gt O m Parts List and Diagram Parts List Part Description Qty 6 Terminal 2 8 WireAssemby 1 9 GroundSleeve 1 12a 3mm Stud Electrode Tip not shown Cap Screw 1 4x20x 5 8 FRP Insulator Circuit Breaker Page 14 Part 16 3 7 2 For technical questions please call 1 800 444 3353 Description Qty Trigger Boot fr 1 Trigger 1 Power Cord 1 Left Housing 1 Hex Nut 10 32 Sn Insulator C 1 Transformer 1 Cap Screw 1 4x20x3 4 1 Flat Washer SAE 1 4 4 Screw 10 32x1 27 J 6 Braided Strap Ci 1 Screw 10 32 x 1 1 2 aw Hex Nut 1 4x20 02 Flat Washer 5 16 2 Item 61433 Assembly Diagram Tf RA o WS lv e VN Ni 2 MAINTENANCE N sede Item 61433 For technical questions please call 1 800 444 3353 Page 15 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 product 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 ind
3. Owner s Manual amp 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 ZEN DENT REPAIR STUD WELDER Visit our website at http www harborfreight com Email our technical support at tech harborfreight com ITEM 61433 When unpacking make sure that the product is intact and undamaged If any parts are missing or broken WARNING please call 1 800 444 3353 as soon as possible A Copyright 2013 by Harbor Freight Tools All rights reserved No portion Adi i Read this material before using this product 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 Failure to do so can result in serious injury Diagrams within this manual may not be drawn proportionally Due to continuing SAVE THIS MANUAL improvements actual product may differ slightly from the product described herein Tools required for assembly and service may not be included o gt e m e lt Table of Contents Safety ears n a R 2 Maintenan Geinin 12 SpeGIfICatlOrs iiit cete er 8 Parts List and Diagram
4. e 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 Item 61433 4 For technical questions please call 1 800 444 3353 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 confined spaces wear flame resistant ear plugs or ear muffs to keep sparks out of ears Page 3 o gt m m e lt Page 4 Electrical Safety Information ELECTRIC SHOCK can KILL Never leave the Stud Welder unattended while energized Turn off and disconnect power when leaving the work area 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 Connect to grounded GFCl protected power supply only Do not use near water or damp objects 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 Do not expose welders to rain or wet conditions Water entering a welder w
5. g Out the Dent 1 Slip the head of the Slide Hammer over the 3 To disengage the Slide Hammer head from the welded stud and tighten it on the exposed tip of stud gently tap the Center Handle forward against the stud by holding the Back Handle and turning the head of the Hammer until the stud is released the Head Roller away from the workpiece m 4 Cutthe stud off and grind it down so it 2 With one hand on the Center Handle and is flush with the metal surface one on the Back Handle apply a backward hammering motion hammering the Center Handle against the Back Handle away from the workpiece until the dent has popped out CAUTION Keep hands clear of pinch points Stud Hammer Head Center Handle Back Handle Workpiece Head Roller Figure D lt o lt nc Lu ou O CHICAGOG SEES WELDING Item 61433 For technical questions please call 1 800 444 3353 Page 11 Maintenance Procedures not specifically explained in this manual must be performed only by a qualified technician AWARNING TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION Release the Trigger and unplug the Stud Welder from its electrical outlet before performing any inspection maintenance or cleaning procedures TO PREVENT SERIOUS INJURY FROM WELDER FAILURE Do not use damaged equipment If abnormal noise or vibration occurs have the problem corrected before further use 1 BEFORE EACH USE inspect the general 2 AFTER USE wipe e
6. he switch is dangerous and must be repaired 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 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 Service Specific Safety Information 1 Item 61433 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 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 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 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 Maintain labels and nameplates on the Welder These carry important infor
7. hile operating 7 Never leave the Welder unattended while energized Turn power off if you have to leave 3 Hold the Welder securely during use If it falls while plugged in severe injury electric shock or fire may result 8 The warnings precautions and instructions discussed in this instruction manual cannot cover all possible conditions and situations Page 2 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 For technical questions please call 1 800 444 3353 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 Item 61433 9 This product when used for welding and similar applications contains or produces a chemical known to the State of California to cause cancer and birth defects or other reproductive harm California Health amp Safety Code S 25249 5 et seq 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 exhau
8. ill increase the risk of electric shock Fire Safety Information 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 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 large enough to cover your full area of contact with the work or ground Use care not to touch the welding tip to conductive material whenever the unit is plugged in Electric shock fire or burns may happen if appropriate precautions are not taken SPARKS AND HOT SLAG can cause fire 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 Keep ABC type fire extinguisher near work area and know how to use it 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 Do not operate welders in atmospheres containing dangerously reactive or flammable liquids gases vapors or dust Provide adequate ventila
9. irectly 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 EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS 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 complaint must accompany the merchandise If our inspection verifies the defect we will either 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 repaired 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 This warranty gives you specific legal rights and you may also have other rights which vary from state to state CHICAGOG i WELDING 3491 Mission Oaks Blvd PO Box 6009 Camari
10. llo CA 93011 800 444 3353
11. mation If unreadable or missing contact Harbor Freight Tools for a replacement Unplug before maintenance Unplug the Welder from its electrical outlet before any inspection maintenance or cleaning procedures A SAVE THESE INSTRUCTIONS For technical questions please call 1 800 444 3353 Page 5 SAFETY o gt Tl m e lt AWARNING 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 Extension Cords The Welder must be plugged into an appropriate outlet properly installed and grounded in accordance with all codes and ordinances 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 Asthe dista
12. nce 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 CHICAGOG ELECTRIC 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 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 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 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 Protect the extension cords from sharp objects excessive heat and damp or wet areas WELDING Page 6 For technical questions please call 1 800 444 3353 Item 61433 KVA SAFETY o Alternating Current CHICAGO G SEES WELDING Item 61433 For technical questions please call 1 800 444 3353 Page 7 Specifications Power Rating 120 VAC 60 Hz Circuit Requirement 20 A dedicated Weldable Materials Shee
13. rty Electrode Tip Clean Electrode Tip Circuit Breaker Circuit rating not Connect to 20 A dedicated circuit Continues to Trip large enough Electrical fault in Welder Have qualified technician service Welder Follow all safety precautions whenever diagnosing or servicing the tool Disconnect power supply before service AONVNALNIVIN Page 12 For technical questions please call 1 800 444 3353 Item 61433 PLEASE READ THE FOLLOWING CAREFULLY THE MANUFACTURER AND OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY NEITHER THE MANUFACTURER NOR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT IN FACT THE MANUFACTURER AND OR DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS AND NOT BY THE BUYER THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO Record Product s Serial Number Here Note If product has no serial number record month and year of purchase instead MAINTENANCE Note Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts Item 61433 For
14. st 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 notuse near degreasing or painting operations 3 Keep head out of fumes Do not breathe exhaust fumes Arc Ray Safety Information 10 Handling the cord on this product will expose 4 you to lead a chemical known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling California Health amp Safety Code 25249 5 et seq SAFETY 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 Work in a confined area only if it is well ventilated or while wearing an air supplied respirator 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 RAYS can injure eyes and burn skin 1 Wear ANSI approved welding eye protection featuring at least a number 10 shad
15. t steel Stud Weld Time 0 5 to 1 0 seconds Duty Cycle Tool can weld one stud each 8 minute time interval CHICAGOG a WELDING Page 8 For technical questions please call 1 800 444 3353 Item 61433 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 Diagram on page 14 Components and Controls Trigger Ground Sleeve e e e LU o a e 2 mm Stud Electrode Tip Circuit Breaker Reset Button Slide Hammer 2mm Studs u 2 Studs V Additional 3mm Head Roller Stud Electrode Tip Figure A Item 61433 For technical questions please call 1 800 444 3353 Page 9 lo E m o A Welding the Stud Note It is recommended that the following procedures be practiced on a piece of scrap metal prior to actual use 1 Clean the surface where the stud is to be welded in an area as large as the Ground Sleeve down to the metal Ensure that the surface is free from scale oxides paint grease and oil The entire Ground Sleeve needs to evenly contact the surface without interference to weld properly 2 With the Welder unplugged insert a stud of the correct size into the hole in the Stud Electrode Tip Note Ensure that the size of stud being used ma
16. tches the size of the Stud Electrode Tip installed on the Stud Welder Ground Sleeve Workpiece Stud Electrode Tip Figure B 3 Plug the Power Cord into an electrical outlet on a circuit with a minimum 20 amp capacity Page 10 For technical questions please call 1 800 444 3353 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 4 Assume a well balanced stance and hold the Stud Welder firmly with both hands Push the Welder and stud against the workpiece until the Ground Sleeve is flush with the metal surface Ground Sleeve Workpiece I NN N wy osunos amp Figure C 5 With the Ground Sleeve PERFECTLY FLUSH against the surface hold the Stud Welder steady and press in on the Trigger momentarily for 0 5 to 1 second then immediately release the Trigger Note It is normal for approximately 1 4 of discoloration to show around the weld If the Trigger is held down for more than 1 second the metal skin of the vehicle will burn Note If the Stud Welder remains on too long approximately 6 seconds the circuit breaker will shut the unit down to protect it To reset the circuit breaker allow the unit to cool down and then push the Circuit Breaker Reset Button 6 Pullthe Stud Welder directly back leaving the welded stud in place with the tip of the stud exposed Item 61433 Pullin
17. tion in work areas to prevent accumulation of such substances Welders create sparks which may ignite flammable substances or make reactive fumes toxic For technical questions please call 1 800 444 3353 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 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 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 Item 61433 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 t
18. xternal surfaces condition of the Stud Welder Check for of the Welder with clean cloth loose hardware 3 Keep the Ground Sleeve free of oxidation misalignment or binding of moving parts by cleaning with fine steel wool cracked or broken parts 4 Periodically inspect Stud Electrode Tips Use a fine damaged electrical wiring metal file as needed to keep the Electrode Tip flat and clean to maintain a proper contact surface any other condition that may amie se sale Operation 5 AMWARNING If the supply cord of this Welder is damaged it must be replaced only by a qualified service technician Troubleshooting Possible Causes Likely Solutions Stud Does Not Weld Unit not plugged into Plug Power Cord into electrical outlet Weld Area Cold electrical outlet No power to Power Cord 2 Check power source Welder circuit Press Circuit Breaker Reset Button breaker tripped Ground Sleeve has Clean weld surface for the entire Ground poor no contact with Sleeve to contact fully press harder and ensure weld surface Ground Sleeve contacts the surface evenly Weak Weld Stud 1 Weld time too short Increase weld time Does Not Hold Electrode Tip or Clean or replace Electrode Tip and or stud stud dirty Weld surface not Clean surface down to bare metal cleaned sufficiently Weld Burning Weld time too long Shorten weld time Through Metal Using incorrect stud Replace stud with correct size Di
Download Pdf Manuals
Related Search