Chicago Electric Welder 3223 User Manual

STUD WELDER DENT REPAIR KIT  
03223  
ASSEMBLY AND OPERATING INSTRUCTIONS  
Distributed exclusively by  
Harbor Freight Tools®.  
3491 Mission Oaks Blvd., Camarillo, CA 93011  
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  
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8.  
9.  
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.  
10. Disconnect power. Unplug tool when not in use.  
11. Remove adjusting keys and wrenches. Check that keys and adjusting wrenches are  
removed from the tool or machine work surface before plugging it in.  
12. 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.  
13. Stay alert. Watch what you are doing, use common sense. Do not operate any tool  
when you are tired.  
14. 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; 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.  
15. Guard against electric shock. Prevent body contact with grounded surfaces such as  
pipes, radiators, ranges, and refrigerator enclosures.  
16. 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.  
17. 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.  
18. 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).  
19. Maintenance. For your safety, service and maintenance should be performed regularly  
by a qualified technician.  
20. 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.  
21. This StudWelder 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  
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Page 3  
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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 StudWelder with its protective case removed.  
Do not touch grounded surfaces while operating.  
Inhalation Hazard  
Welding/PlasmaCuttingProducestoxICfumesandgasses.  
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:  
early onset of Parkinson’s Disease  
Damage to the reproductive organs  
Inflammation of the small intestine or stomach  
Heart Disease  
ulcers  
Kidney damage  
Respiratory diseases such as emphysema, bronchitis or pneumonia  
safety precautions, such as using natural or forced air ventilation 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.  
Stud Welder  
Slide Hammer Dent Puller  
Package of 100 each: 2mm,  
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  
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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.  
2.  
3.  
Clean the surface down to the metal where the stud is to be welded.  
Insert the stud into the hole of the Stud Electrode.  
Plug the Line Cord into an electrical circuit outlet with at least a 20 amp capacity.  
4.  
5.  
With sure footing, and both hands on the Stud Welder, push the Stud Welder toward  
the metal surface until the Electrode Assembly touches the metal surface.  
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  
Electrode Assembly  
Circuit Breaker Reset  
6.  
7.  
8.  
Pull the Stud Welder directly back, leaving the welded stud in place. There should be  
less than 1/4 inch discoloration around the weld.  
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.  
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.  
Back Handle  
Head Roller  
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.  
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Troubleshooting  
SYMPTOM  
POSSIBLE CAUSE  
SUGGESTED ACTION  
1. No power to line cord  
Stud does not weld; 2. Stud Welder circuit breaker open  
1. Check power source  
2. Press Circuit Breaker Reset button  
Weld area cold  
3. Not making contact to metal surface  
with Electrode Assy.  
3. Press harder on the Stud Welder;  
Clean metal area better.  
1. Electrode or Stud dirty  
1. Clean or replace both  
Weld time is longer  
than one second  
2. Weld surface not cleaned to the metal 2. Clean surface again  
1. “On Time” not long enough  
2. Electrode or Stud dirty  
1. Hold trigger longer  
Weak weld, stud  
does not hold  
2. Clean of replace both  
3. Clean surface to metal  
3. Weld surface not cleaned down to  
bare metal  
1. Circuit rating not large enough  
2. Electrical fault in Welder  
1. Connect to 20 A dedicated circuit  
Circuit breaker  
continues to trip  
2. Have qualified technician service  
welder  
1. Weld time is too long  
2. Using incorrect stud  
3. Dirty electrode  
1. Shorten weld time  
2. Replace stud with correct size  
3. 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.  
1.  
2.  
3.  
4.  
Periodically inspect line cord for cracks. Replace if necessary.  
Clean the unit using a damp cloth. Never use solvents.  
Keep the electrode assembly free of oxidation by cleaning with fine steel wool.  
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  
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Parts List  
Part  
1
Description  
Qty  
2
Nut, Brass, 5/16-18  
2
Insulator Sleeve  
1
100 pcs. 2mm studs  
100 pcs. 3mm studs  
100 pcs. 4mm studs  
3
bags  
3
4
5
Slide Hammer  
1
1
2
1
1
1
1
1
1
1
1
Washer, Split Lock, 5/16”  
Terminal, Closed End  
Wire Assembly, ag / spade  
Wire Assembly, ag / bare  
Electrode Assembly  
6
7
8
9
10  
11  
Spring, Sliding Electrode  
Sliding Electrode  
12A 2mm electrode  
12B 3mm electrode  
12C 4mm electrode  
Screw, hex head cap,  
1/4x20x5/8”  
13  
1
14  
15  
Insulator, FRP  
1
1
2
1
1
1
1
8
1
1
Circuit Breaker, 120 VAC  
Screw, Roundhead, 10-32x7/8”  
Trigger Boot  
16  
17  
18  
Trigger Switch  
19*  
20  
Line Cord, 120 VAC  
Case, Left  
21  
Nut, hex, 10-32  
22*  
23*  
Insulator, Nomex  
Transformer, 120 VAC  
Screw, hex head cap,  
1/4x20x3/4”  
24  
1
Replacement parts with  
asterisk are not available  
individually. You must  
purchase #33 Transformer  
Assembly.  
25  
26  
27  
28  
29  
30  
31  
32  
33  
Washer, flat SAE 1/4”  
Case, right  
4
1
6
1
2
2
2
1
Screw, round head, 10-32x1-3/4”  
Strap, Braided  
* #33Transformer Assembly  
only sold as a replacement  
assembly.  
Washer, Split Lock, 1/4”  
Nut, hex, 1/4x20  
Washer, Flat brass, 5/16”  
Nut  
Transformer Assembly  
1
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.  
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Assembly Drawing  
PLEASE READ THE FOLLOWING CAREFULLY  
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDEDTHE PARTS DIAGRAM INTHIS 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  
OFTHE PRODUCT. IN FACT, THE MANUFACTURER AND/OR DISTRIBUTOR EXPRESSLY STATESTHAT  
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  
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LIMITED 1YEAR / 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 IMPLIED, 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.  
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