Chicago Electric 3223 Welder User Manual
Contents
1. please call 1 800 444 3353 Page 8 LIMITED 1 YEAR 90 DAY WARRANTY Harbor Freight Tools Co makes every effort to assure that its products meet high qual ity and durability standards and warrants to the original purchaser that for a period of ninety days from date of purchase that the torch liner wire feed mechanism if applicable welding clamps electrode holders cables and accessories packed with the welder are free of de fects in materials and workmanship This Limited 90 Day 1 Year Warranty shall not apply to consumable parts such as tips welding wire and gas nozzles Harbor Freight Tools also warrants to the original purchaser for a period of one year from date of purchase that the transformer and rectifier are free from defects in materials and workmanship 90 days if used by a professional contractor or if used as rental equipment This warranty does not ap ply to damage due directly or indirectly to misuse abuse negligence or accidents repairs or alterations outside our facilities 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 spe cial 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 IMPL2. Lt Zz Lae 5 6 7 8 9 10 EN 12A 12B 12C 14 15 il sae 18 Replacement parts with asterisk are not available individually You must purchase 33 Transformer Assembly 1 4x20x3 4 NOTE Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts REV 08i SKU 3223 For technical questions please call 1 800 444 3353 Page 7 33 Transformer Assembly only sold as a replacement assembly oO lt n 14 15 16 17 18 20 21 22 23 24 25 26 27 28 29 30 31 32 33 Assembly Drawing 3 Bag of Studs not shown 4 Side Hammer not shown 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 SKU 3223 For technical questions
3. any broken parts or mounting fixtures and any other condition that may affect proper operation Any part that is damaged should be properly repaired or replaced by a qualified technician Do not use the tool if any switch does not turn On and Off properly Guard against electric shock Prevent body contact with grounded surfaces such as pipes radiators ranges and refrigerator enclosures Replacement parts and accessories When servicing use only identical replacement parts Use of any other parts will void the warranty Only use accessories intended for use with this tool Approved accessories are available from Harbor Freight Tools Do not operate tool if under the influence of alcohol or drugs Read warning labels if taking prescription medicine to determine if your judgment or reflexes are impaired while taking drugs If there is any doubt do not operate the tool Use proper size and type extension cord If an extension cord is required it must be of the proper size and type to supply the correct current to the tool without heating up Otherwise the extension cord could melt and catch fire or cause electrical damage to the tool This tool requires use of an extension cord with up to 20 amps capability up to 50 feet with wire size rated at 10 AWG Longer extension cords require larger size wire If you are using the tool outdoors use an extension cord rated for outdoor use signified by WA on the jacket Maintenance For you
4. IED INCLUDING THE WARRANTIES OF MERCHANT ABILITY 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 3491 Mission Oaks Blvd PO Box 6009 Camarillo CA 93011 800 444 3353 REV 08i SKU 3223 For technical questions please call 1 800 444 3353 Page 9
5. 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 1 Keep work area clean Cluttered areas invite injuries 2 Observe work area conditions Do not use machines or power tools in damp or wet locations Don t expose to rain Keep work area well lighted Do not use electrically powered tools in the presence of flammable gases or liquids 3 Keep children away Children must never be allowed in the work area Do not let them handle machines tools or extension cords 4 Store idle equipment When not in use tools must be stored in a dry location to inhibit rust Always lock up tools and keep out of reach of children 5 Use the right tool for the job Do not attempt to force a small tool or attachment to do the work of a larger industrial tool There are certain applications for which this tool was designed It will do the job better and more safely at the rate for which it was intended Do not modify this tool and do not use this tool for a purpose for which it was not intended 6 Dress properly Do not wear loose clothing or jewelry as they can be caught in moving parts Protective electrically non conductive clothes and non skid footwear are recommended when working Wear restrictive hair covering to contain long hair 7 Do not overreach Keep proper footing and balance at al
6. eing STUD WELDER DENT REPAIR KIT ASSEMBLY AND OPERATING INSTRUCTIONS Distributed exclusively by Harbor Freight Tools 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 2003 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 and replacement parts please call 1 800 444 3353 Cover Rev 06f 07e Specifications Welding Process Resistance Weld Power Requirement 120 V 60 Hz 40 A Peak Recommended Circuit 20 A dedicated Switch Pushbutton momentary Circuit Breaker Pushbutton reset Rating 125 250 VAC 60 Hz 10 amp Stud Weld Time 0 5 to 1 0 seconds Line Cord 6 foot 3 prong plug UL listed Weight 10 1 Ib Bag 100 each 2mm 3mm 4mm studs steel with copper coating Accessories 2 lb slide hammer dent puller One of each nozzle 2mm 3mm 4mm 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 Safety
7. l times Do not reach over or across running machines REV 04b 04e 07e SKU 3223 For technical questions please call 1 800 444 3353 Page 2 10 11 12 13 14 15 16 17 18 19 20 21 Use eye and ear protection Always wear ANSI approved impact safety goggles Wear a NIOSH approved dust mask or respirator when working around metal wood and chemical dusts and mists Maintain tools with care Keep tools sharp and clean for better and safer performance Follow instructions for lubricating and changing accessories Inspect tool cords periodically and if damaged have them repaired by a qualified technician The handles must be kept clean dry and free from oil and grease at all times Disconnect power Unplug tool when not in use Remove adjusting keys and wrenches Check that keys and adjusting wrenches are removed from the tool or machine work surface before plugging it in Avoid unintentional starting Be sure the switch is in the Off position when not in use and before plugging in Do not carry any tool with your finger on the trigger whether it is plugged in or not Stay alert Watch what you are doing use common sense Do not operate any tool when you are tired Check for damaged parts Before using any tool any part that appears damaged should be carefully checked to determine that it will operate properly and perform its intended function Check for alignment and binding of moving parts
8. oward the metal surface until the Electrode Assembly touches the metal surface 5 While holding the Stud Welder steady press in on the Trigger Switch momentarily from 0 5 to 1 second Release the Trigger Switch Trigger Switch Stud Electrode 7 i Electrode Assembly 6 Pull the Stud Welder directly back leaving the welded stud in place There should be less than 1 4 inch discoloration around the weld re Place and tighten the Slide Hammer head onto the welded stud by turning the head roller toward you to the top of its rotation and slide the tip over the stud to be pulled 8 With one hand on the center handle and the other hand on the back handle apply a backward hammering motion to the desired pressure until the dent has popped out B Back Handle Head Roller lt gt 9 Disengage the Slide Hammer head from the welded stud by tapping the center handle forward on the head until the Stud is released 10 Cut off stud and grind down the stud tip to the metal surface SKU 3223 For technical questions please call 1 800 444 3353 Page 5 Troubleshooting SYMPTOM POSSIBLE CAUSE SUGGESTED ACTION 1 No power to line cord 1 Check power source Stud does not weld 2 Stud Welder circuit breaker open 2 Press Circuit Breaker Reset button Weld area cold 3 Not making contact to metal surface 3 Press harder on the Stud Welder with Electrode Assy Clean metal area better Weld time is longer 1 Electrode or S
9. r safety service and maintenance should be performed regularly by a qualified technician 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 This Stud Welder requires the use of both hands when operating This helps maintain tool stability and keeps hands away from the working area of the tool SKU 3223 For technical questions please call 1 800 444 3353 Page 3 22 Avoid burns Do not touch the welded stud electrode or work surface until it cools 23 Avoid accidental activation Unplug the Stud Welder while inserting the stud electrode into the Stud Welder 24 Avoid electrical shock Do not operate the Stud Welder with its protective case removed Do not touch grounded surfaces while operating Inhalation Hazard Welding Plasma Cutting Produces TOXIC FUMES and GASSES Exposure to welding or cutting gasses 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 plasma cutting gasses or fumes are e Early onset of Parkinson s Disease e Heart Disease e Damage to the reproductive organs e Ulcers Inflammation of the small intestine or stomach Kidney damage e Respiratory diseases such as emphysema bronchitis or pneumonia Safety precautions such as using natural or forced air ventila
10. tion and wearing an ANSI approved respirator are ESSENTIAL to reduce the risk of developing the above illnesses Warning The warnings cautions and instructions discussed in this instruction manual cannot cover all possible conditions and situations that may occur It must be under stood by the operator that common sense and caution are factors which cannot be built into this product but must be supplied by the operator Note Performance of this tool may vary depending on variations in local line voltage Exten sion cord usage may also affect tool performance Unpacking When unpacking check to make sure the following parts are included Slide Hammer Dent Puller Package of 100 each 2mm 2 3mm 4mm Stud Electrodes If any parts are missing or broken please call Harbor Freight Tools at the number on the cover of this manual as soon as possible REV 04e SKU 3223 For technical questions please call 1 800 444 3353 Page 4 Operation Note Before trying to pull out a dent on your vehicle it is recommended that you first practice welding to a scrap of metal Also practice pulling out the dent with the Slide Hammer 1 Clean the surface down to the metal where the stud is to be welded 2 Insert the stud into the hole of the Stud Electrode 3 Plug the Line Cord into an electrical circuit outlet with at least a 20 amp capacity 4 With sure footing and both hands on the Stud Welder push the Stud Welder t
11. tud dirty 1 Clean or replace both than one second 2 Weld surface not cleaned to the metal 2 Clean surface again 1 On Time not long enough Hold trigger longer Weak weld stud 2 Electrode or Stud dirty Clean of replace both does not hold 3 Weld surface not cleaned down to Clean surface to metal bare metal 1 Circuit rating not large enough Connect to 20 A dedicated circuit 2 Electrical fault in Welder Have qualified technician service welder Circuit breaker continues to trip 1 Weld time is too long Shorten weld time 2 Using incorrect stud Replace stud with correct size 3 Dirty electrode Clean electrode Weld is burning through the metal Maintenance Warning Always unplug the line cord from the electrical outlet before performing any maintenance Repairs should only be performed by a qualified technician ie Periodically inspect line cord for cracks Replace if necessary 2 Clean the unit using a damp cloth Never use solvents 3 Keep the electrode assembly free of oxidation by cleaning with fine steel wool 4 If necessary use a fine metal file to keep the electrode flat and clean REV 07e SKU 3223 For technical questions please call 1 800 444 3353 Page 6 Parts List 1 Nut Brass 5 16 18 2 Insulator Sleeve 100 pcs 2mm studs 100 pcs 3mm studs 100 pcs 4mm studs Screw hex head cap 1 4x20x5 8 Insulator FRP 4 5 7 0 1 Circuit Breaker 120 VAC Part _
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