Chicago Electric 98357 Installation manual

DENT REPAIR STUD WELDER

98357

SET UP AND OPERATING INSTRUCTIONS

Distributed exclusively by Harbor Freight Tools®.

3491 Mission Oaks Blvd., Camarillo, CA 93011

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.

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.

For technical questions or replacement parts, please call 1-800-444-3353.

SKU 98357 For technical questions, please call 1-800-444-3353. Page 2

SAVE THIS MANUAL

Keep this manual for the safety warn-

ings and precautions, assembly, operat-

ing, 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.

IMPORTANT SAFETY

INFORMATION

In this manual, on the labeling,

and all other information provid-

ed with this product:

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.

DANGER indicates

a hazardous

situation which, if not

avoided, will result in death or

serious injury.

WARNING

indicates a

hazardous situation which, if

not avoided, could result in

death or serious injury.

CAUTION, used

with the safety

alert symbol, indicates a

hazardous situation which, if

not avoided, could result in

minor or moderate injury.

NOTICE is used to

address practices

not related to personal injury.

CAUTION, without

the safety alert

symbol, is used to address

practices not related to

personal injury.

General Power Tool Safety

Warnings

WARNING Read all safety

warnings and instructions.

Failure to follow the warnings and

instructions may result in electric

shock, re and/or serious injury.

Save all warnings and

instructions for future reference.

The term ″power tool″ in the

warnings refers to your mains-

operated (corded) power tool or

battery-operated (cordless) power

tool.

Work area safety1.

Keep work area clean and well lit.a.

Cluttered or dark areas invite acci-

dents.

Do not operate power tools inb.

explosive atmospheres, such as in

the presence of ammable liquids,

gases or dust. Power tools create

sparks which may ignite the dust or

fumes.

Keep children and bystandersc.

away while operating a power tool.

Distractions can cause you to lose

control.

Electrical safety2.

Power tool plugs must match thea.

outlet. Never modify the plug in

any way. Do not use any adapter

SKU 98357 For technical questions, please call 1-800-444-3353. Page 3

plugs with grounded power tools.

Unmodied plugs and matching out-

lets will reduce risk of electric shock.

Avoid body contact with groundedb.

surfaces such as pipes, radiators,

ranges and refrigerators. There is

an increased risk of electric shock if

your body is grounded.

Do not expose power tools to rainc.

or wet conditions. Water entering

a power tool will increase the risk of

electric shock.

Do not abuse the cord. Never used.

the cord for carrying, pulling or

unplugging the power tool. Keep

cord away from heat, oil, sharp

edges or moving parts. Damaged

or entangled cords increase the risk

of electric shock.

When operating a power tool out-e.

doors, use an extension cord suit-

able for outdoor use. Use of a cord

suitable for outdoor use reduces the

risk of electric shock.

If operating a power tool in a dampf.

location is unavoidable, use a

Ground Fault Circuit Interrupter

(GFCI) protected supply. Use of

a GFCI reduces the risk of electric

shock.

Personal safety3.

Stay alert, watch what you are do-a.

ing and use common sense when

operating a power tool. Do not use

a power tool while you are tired

or under the inuence of drugs,

alcohol or medication. A moment

of inattention while operating power

tools may result in serious personal

injury.

Use personal protective equip-b.

ment. Always wear eye protection.

Safety equipment such as dust mask,

non-skid safety shoes, hard hat, or

hearing protection used for appropri-

ate conditions will reduce personal

injuries.

Prevent unintentional starting.c.

Ensure the switch is in the off-po-

sition before connecting to power

source and/or battery pack, pick-

ing up or carrying the tool. Carry-

ing power tools with your nger on

the switch or energizing power tools

that have the switch on invites acci-

dents.

Do not overreach. Keep properd.

footing and balance at all times.

This enables better control of the

power tool in unexpected situations.

Dress properly. Do not wear loosee.

clothing or jewelry. Keep your

hair, clothing and gloves away

from moving parts. Loose clothes,

jewelry or long hair can be caught in

moving parts.

Only use safety equipment thatf.

has been approved by an appropri-

ate standards agency. Unapproved

safety equipment may not provide

adequate protection. Eye protection

must be ANSI-approved and breath-

ing protection must be NIOSH-ap-

proved for the specic hazards in the

work area.

Power tool use and care4.

Do not force the power tool. Usea.

the correct power tool for your ap-

plication. The correct power tool will

do the job better and safer at the rate

for which it was designed.

Do not use the power tool if theb.

switch does not turn it on and off.

Any power tool that cannot be con-

SKU 98357 For technical questions, please call 1-800-444-3353. Page 4

trolled with the switch is dangerous

and must be repaired.

Disconnect the plug from thec.

power source and/or the battery

pack from the power tool before

making any adjustments, chang-

ing accessories, or storing power

tools. Such preventive safety mea-

sures reduce the risk of starting the

power tool accidentally.

Store idle power tools out of thed.

reach of children and do not allow

persons unfamiliar with the power

tool or these instructions to oper-

ate the power tool. Power tools are

dangerous in the hands of untrained

users.

Maintain power tools. Check fore.

misalignment or binding of moving

parts, breakage of parts and any

other condition that may affect the

power tool’s operation. If dam-

aged, have the power tool repaired

before use. Many accidents are

caused by poorly maintained power

tools.

Use the power tool, accessoriesf.

and tool bits etc. in accordance

with these instructions, taking into

account the working conditions

and the work to be performed. Use

of the power tool for operations differ-

ent from those intended could result

in a hazardous situation.

Service5.

Have your power tool serviced bya.

a qualied repair person using

only identical replacement parts.

This will ensure that the safety of the

power tool is maintained.

Specic Safety Warnings

Maintain labels and nameplates on1.

the tool. These carry important safety

information. If unreadable or miss-

ing, contact Harbor Freight Tools for a

replacement.

Avoid unintentional starting. Prepare2.

to begin work before turning on the

tool.

Do not leave the tool unattended3.

when it is plugged into an electrical

outlet. Turn off the tool, and unplug it

from its electrical outlet before leav-

ing.

This product is not a toy. Keep it out4.

of reach of children.

People with pacemakers should5.

consult their physician(s) before use.

-

imity to heart pacemaker could cause

pacemaker interference or pacemak-

er failure. In addition, people with

pacemakers should:





on.



avoid electrical shock.



grounded. Ground Fault Circuit Inter-

rupter (GFCI) should also be imple-

mented – it prevents sustained elec-

trical shock.

SKU 98357 For technical questions, please call 1-800-444-3353. Page 5

Some dust created by power sand-6.

ing, sawing, grinding, drilling, and

other construction activities, contains

chemicals known [to the State of Cali-

fornia] to cause cancer, birth defects

or other reproductive harm. Some

examples of these chemicals are:



-

ment or other masonry products

-

cally treated lumber

Your risk from these exposures var-

ies, depending on how often you do

this type of work. To reduce your

exposure to these chemicals: work in

a well ventilated area, and work with

approved safety equipment, such as

those dust masks that are specially



particles. (California Health & Safety

Code § 25249.5, et seq.)

WARNING: Handling the cord on7.

this product will expose 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. (Califor-

nia Health & Safety Code § 25249.5,

et seq.)

The warnings, precautions, and8.

instructions discussed in this manual

cannot cover all possible conditions

and situations that may occur. It

must be understood by that common

sense and caution are factors which

cannot be built into this product, but

must be supplied by the operator.

SAVE THESE

INSTRUCTIONS.

Inhalation Hazard

Welding/Plasma Cutting

Produces TOXIC

FUMES and

GASSES.

Exposure to welding or

cutting gasses can

increase the risk of

d e v e l o p i n g c e r t a i n

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

• Heart Disease

• Damage to the

reproductive organs

• Ulcers

• Inammation of the small

intestine or stomach

• 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.

SKU 98357 For technical questions, please call 1-800-444-3353. Page 6

GROUNDING

TO PREVENT

ELECTRIC SHOCK

AND DEATH FROM

INCORRECT GROUNDING

WIRE CONNECTION:

Check with a qualied

electrician if you are in doubt

as to whether the outlet is

properly grounded. Do not

modify the power cord plug

provided with the tool. Never

remove the grounding prong

from the plug. Do not use the

tool if the power cord or plug

is damaged. If damaged, have

it repaired by a service facility

before use. If the plug will not

t the outlet, have a proper

outlet installed by a qualied

electrician.

Grounded Tools: Tools with Three

Prong Plugs

Tools marked with “Grounding Re-1.

quired” have a three wire cord and

three prong grounding plug. The

plug must be connected to a properly

grounded outlet. If the tool should

electrically malfunction or break

down, grounding provides a low

resistance path to carry electricity

away from the user, reducing the risk

of electric shock. (See 3-Prong Plug

and Outlet.)

The grounding prong in the plug is2.

connected through the green wire in-

side the cord to the grounding system

in the tool. The green wire in the cord

must be the only wire connected to

the tool’s grounding system and must

never be attached to an electrically

“live” terminal. (See 3-Prong Plug

and Outlet.)

The tool must be plugged into an3.

appropriate outlet, properly installed

and grounded in accordance with all

codes and ordinances. The plug and

outlet should look like those in the

preceding illustration. (See 3-Prong

Plug and Outlet.)

Double Insulated Tools: Tools

with Two Prong Plugs

Tools marked “Double Insulated” do1.

not require grounding. They have

a special double insulation system



and complies with the applicable

-

tories, Inc., the Canadian Standard

Association, and the National Electri-

cal Code. (See Outlets for 2-Prong

Plug.)

SKU 98357 For technical questions, please call 1-800-444-3353. Page 7

Double insulated tools may be used2.

in either of the 120 volt outlets shown

in the preceding illustration. (See

Outlets for 2-Prong Plug.)

Extension Cords

Grounded1. tools require a three wire

extension cord. Double Insulated

tools can use either a two or three

wire extension cord.

As the distance from the supply outlet2.

increases, you must use a heavier

gauge extension cord. Using exten-

sion cords with inadequately sized

wire causes a serious drop in voltage,

resulting in loss of power and pos-

sible tool damage.

(See Table A.)

The smaller the gauge number of the3.

wire, the greater the capacity of the

cord. For example, a 14 gauge cord

can carry a higher current than a 16

gauge cord. (See Table A.)

When using more than one exten-4.

sion cord to make up the total length,

make sure each cord contains at

least the minimum wire size required.

(See Table A.)

If you are using one extension cord5.

for more than one tool, add the

nameplate amperes and use the sum

to determine the required minimum

cord size. (See Table A.)

If you are using an extension cord6.

outdoors, make sure it is marked with



indicate it is acceptable for outdoor

use.

Make sure the extension cord is prop-7.

erly wired and in good electrical con-

dition. Always replace a damaged

extension cord or have it repaired by



Protect the extension cords from8.

sharp objects, excessive heat, and

damp or wet areas.

RECOMMENDED MINIMUM WIRE

GAUGE FOR EXTENSION CORDS*

(120/240 VOLT)

NAMEPLATE

AMPERES

(at full load)

EXTENSION CORD

LENGTH

25’

50’

75’

100’

150’

0 – 2.0 18 18 18 18 16

2.1 – 3.4 18 18 18 16 14

3.5 – 5.0 18 18 16 14 12

5.1 – 7.0 18 16 14 12 12

7.1 – 12.0 18 14 12 10 -

12.1 – 16.0 14 12 10 - -

16.1 – 20.0 12 10 - - -

TABLE A

* Based on limiting the line

voltage drop to ve volts at

150% of the rated amperes.

Symbology

Double Insulated

Canadian Standards Association



V~ Volts Alternating Current

AAmperes

n0xxxx/min. 

(RPM)

SKU 98357 For technical questions, please call 1-800-444-3353. Page 8

SPECIFICATIONS

Welding Process Reistance Weld

Power

Requirements 120 V~ / 60 Hz / ~40 A Peak

Circuit

Requirement 20 A

Switch Push Button

Power Cord 14 AWG x 3C / 3-prong

grounded plug

Features

High-power low-heat

transformer with resettable

safety breaker

2 lb. Slide Hammer

100.078” (2mm) copper

studs

UNPACKING

When unpacking, check to make sure

that the item is intact and undamaged. 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.

OPERATING INSTRUCTIONS

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.

Tool Set Up

TO PREVENT

SERIOUS INJURY

FROM ACCIDENTAL

OPERATION:

Turn the Power Switch of the

tool to its “OFF” position and

unplug the tool from its

electrical outlet before

performing any inspection,

maintenance, or cleaning

procedures.

Note: For additional information regarding

the parts listed in the following pages,

refer to the Assembly Diagram on

page 12.

Always make sure

the power cord to

the Stud Welder is unplugged

from its electrical outlet prior

to assembling or making any

adjustments to the tool.

Stud Electrode

(23)

Electrode Assembly (26)

Trigger (17)

FIGURE 1

Circuit Breaker

Reset (20)

SKU 98357 For technical questions, please call 1-800-444-3353. Page 9

Note: Before trying to pull a dent out of

your own vehicle, it is recommended



on a piece of scrap metal.

Welding the stud

On the location you are going to weld,1.

and in a area as large as the Elec-

trode Assembly (26) surrounding it,

clean the surface down to the metal

(no paint). The entire Electrode As-

sembly (26) needs to evenly contact

the surface without interference to

weld properly.

Insert a2. Stud (32) into the hole in the

Stud Electrode (23). See FIGURE

2, below.

Plug the3. Cord (16) into an outlet ca-

pable of handling a 20 amp load.

4. 

both hands and using a well-bal-

Stud

(32) against the metal surface until

the Electrode Assembly (26)

with the metal surface. See FIGURE

3, above.

With the Electrode Assembly (26)5.

PERFECTLY SQUARE to the sur-

face, hold the Stud Welder very

steady and squeeze the Trigger (17)

for only 1/2 to 1 second. Immediately

release the Trigger (17) after 1/2 to 1

seconds.

Note: It is normal for approximately 1/4”

of discoloration to show around the

weld. If you hold the trigger down

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 Breaker,

allow the unit to cool down and then

push the Circuit Breaker Reset (20).

Pull the Stud Welder directly back,6.

leaving the Stud (32) in place. You

will notice the tip of the stud remains

exposed.

When done with the Stud Welder,7.

unplug the tool and store it safely.

Metal

Surface

FIGURE 3

Electrode

Assembly (26)

FIGURE 2

Stud (32)

Metal

Surface

SKU 98357 For technical questions, please call 1-800-444-3353. Page 10

Pulling Out the Dent

Slip the end roller of the1. Slide Ham-

mer (31) over the Stud (32) and

tighten it on the exposed tip of the

stud by holding the Back Handle and

turning the Roller counterclockwise.

See FIGURE 4, below.

With one hand on the Center Handle2.

and one on the Back Handle, apply a

backward hammering motion, ham-

mering the Center Handle against the

Back Handle (away from the metal

surface) until the dent has popped

out. See FIGURE 4.

To disengage the3. Slide Hammer (31)

from the Stud (32), gently tap the

Center Handle forward against the

Roller until the Stud (32) is released.

Cut the4. Stud off and grind it down so



MAINTENANCE AND

SERVICING

Procedures not specically

explained in this manual

must be performed only by a

qualied technician.

TO PREVENT

SERIOUS INJURY

FROM ACCIDENTAL

OPERATION:

Turn the Power Switch of the

tool to its “OFF” position and

unplug the tool from its

electrical outlet before

performing any inspection,

maintenance, or cleaning

procedures.

TO PREVENT SERIOUS

INJURY FROM TOOL

FAILURE:

Do not use damaged

equipment. If abnormal noise

or vibration occurs, have the

problem corrected before

further use.

Cleaning, Maintenance, and

Lubrication

BEFORE EACH USE,1. inspect the

general condition of the tool. Check

for loose screws, misalignment or

binding of moving parts, cracked or

broken parts, damaged electrical wir-

ing, and any other condition that may

affect its safe operation.

Periodically inspect the power cord2.

for cracks. Replace if necessary.

Clean the unit using a damp cloth.3.

Never use solvents.

Keep the4. Electrode Assembly (26)



steel wool.

5.



Metal

Surface

Roller

Back

Handle

Center Handle

FIGURE 4 - Slide Hammer

Table of contents

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