Harbor Freight Tools Stud Welder Dent Repair Kit Product manual

Table of Contents
SAFETY
Safety.......................................................... 2
Specifications.............................................. 8
Setup........................................................... 9
Operation.................................................... 10
Maintenance............................................... 12
Parts List and Diagram............................... 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.
SETUP
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
OPERATION
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.
MAINTENANCE
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.
Page 2
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.
For technical questions, please call 1-800-444-3353.
Item 61433
10. Handling the cord on 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.
(California Health & Safety Code § 25249.5, et seq.)
SAFETY
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 & Safety Code § 25249.5, et seq.)
Fume and Gas Safety Information
FUMES AND GASES can be hazardous to your health.
2. Do not use near degreasing or
painting operations.
3. Keep head out of fumes.
Do not breathe exhaust fumes.
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.
SETUP
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.
OPERATION
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
Arc Ray Safety Information
ARC RAYS can injure eyes and burn skin.
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. 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.
For technical questions, please call 1-800-444-3353.
Page 3
MAINTENANCE
1. Wear ANSI-approved welding eye protection
featuring at least a number 10 shade lens rating.
Electrical Safety Information
ELECTRIC SHOCK can KILL.
SAFETY
1. Never leave the Stud 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.
SETUP
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
conductive 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.
OPERATION
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.
MAINTENANCE
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.
Page 4
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.
For technical questions, please call 1-800-444-3353.
Item 61433
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
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.
OPERATION
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.
SETUP
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.
SAFETY
Operation Specific Safety Information
MAINTENANCE
SAVE THESE INSTRUCTIONS.
Item 61433
For technical questions, please call 1-800-444-3353.
Page 5
Grounding
SAFETY
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.
SETUP
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.
OPERATION
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.
MAINTENANCE
Page 6
For technical questions, please call 1-800-444-3353.
Item 61433
Symbology
Underwriters Laboratories, Inc.
Housing Ground Point
Volts
Amperes
Open Circuit Voltage
Kilovolt Amperes
(Volts / 1000 * Amperes)
American Wire Gauge
Alternating Current
MAINTENANCE
OPERATION
SETUP
V
~
A
OCV
KVA
AWG
SAFETY
Canadian Standards Association
Item 61433
For technical questions, please call 1-800-444-3353.
Page 7
Specifications
SAFETY
Power Rating
120 VAC, 60 Hz
Circuit Requirement
20 A (dedicated)
Weldable Materials
Sheet steel
Stud Weld Time
0.5 to 1.0 seconds
Duty Cycle
Tool can weld one stud each 8 minute time interval
SETUP
OPERATION
MAINTENANCE
Page 8
For technical questions, please call 1-800-444-3353.
Item 61433
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.
SAFETY
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
SETUP
Ground Sleeve
2 mm Stud
Electrode
Tip
OPERATION
Circuit Breaker
Reset Button
Slide Hammer
MAINTENANCE
2 mm Studs
3 mm Studs
Additional 3 mm
Stud Electrode Tip
Head Roller
Figure A
Item 61433
For technical questions, please call 1-800-444-3353.
Page 9
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.
SAFETY
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.
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
SETUP
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 matches the size of the Stud Electrode
Tip installed on the Stud Welder.
Ground Sleeve
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.
Stud
Workpiece
OPERATION
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.
Stud Electrode Tip
Figure B
3. Plug the Power Cord into an electrical outlet on
a circuit with a minimum 20 amp capacity.
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. Pull the Stud Welder directly back,
leaving the welded stud in place with
the tip of the stud exposed.
MAINTENANCE
Page 10
For technical questions, please call 1-800-444-3353.
Item 61433
Pulling Out the Dent
2. With one hand on the Center Handle and
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.
3. To disengage the Slide Hammer head from the
stud, gently tap the Center Handle forward against
the head of the Hammer until the stud is released.
4. Cut the stud off and grind it down so it
is flush with the metal surface.
SAFETY
1. Slip the head of the Slide Hammer over the
welded stud and tighten it on the exposed tip of
the stud by holding the Back Handle and turning
the Head Roller away from the workpiece.
CAUTION! Keep hands clear of pinch points.
Hammer Head
Center Handle
Back Handle
SETUP
Stud
Workpiece
Head Roller
MAINTENANCE
OPERATION
Figure D
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.
SAFETY
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
condition of the Stud Welder. Check for:
• loose hardware
• misalignment or binding of moving parts
SETUP
• cracked or broken parts
• damaged electrical wiring
• any other condition that may
affect its safe operation.
2. AFTER USE, wipe external surfaces
of the Welder with clean cloth.
3. Keep the Ground Sleeve free of oxidation
by cleaning with fine steel wool.
4. Periodically inspect Stud Electrode Tips. Use a fine
metal file as needed to keep the Electrode Tip flat
and clean to maintain a proper contact surface.
5.
WARNING! If the supply cord of this
Welder is damaged, it must be replaced
only by a qualified service technician.
Troubleshooting
Problem
OPERATION
Stud Does Not Weld;
Weld Area Cold
Possible Causes
1. Unit not plugged into
electrical outlet.
Likely Solutions
1. Plug Power Cord into electrical outlet.
2. No power to Power Cord. 2. Check power source.
Weak Weld, Stud
Does Not Hold
MAINTENANCE
Weld Burning
Through Metal
Circuit Breaker
Continues to Trip
3. Welder circuit
breaker tripped.
3. Press Circuit Breaker Reset Button.
4. Ground Sleeve has
poor/no contact with
weld surface.
4. Clean weld surface for the entire Ground
Sleeve to contact fully, press harder, and ensure
Ground Sleeve contacts the surface evenly.
1. Weld time too short.
1. Increase weld time.
2. Electrode Tip or
stud dirty.
2. Clean or replace Electrode Tip and/or stud.
3. Weld surface not
cleaned sufficiently.
3. Clean surface down to bare metal.
1. Weld time too long.
1. Shorten weld time.
2. Using incorrect stud.
2. Replace stud with correct size.
3. Dirty Electrode Tip.
3. Clean Electrode Tip.
1. Circuit rating not
large enough.
2. Electrical fault in Welder.
1. Connect to 20 A dedicated circuit.
2. Have qualified technician service Welder.
Follow all safety precautions whenever diagnosing or servicing
the tool. Disconnect power supply before service.
Page 12
For technical questions, please call 1-800-444-3353.
Item 61433
MAINTENANCE
OPERATION
SETUP
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.
SAFETY
PLEASE READ THE FOLLOWING CAREFULLY
Record Product’s Serial Number Here:
Note: If product has no serial number, record month and year of purchase instead.
Note: Some parts are listed and shown for illustration purposes only,
and are not available individually as replacement parts.
Item 61433
For technical questions, please call 1-800-444-3353.
Page 13
Parts List and Diagram
Parts List
SAFETY
Part
SETUP
1
2
3a
3b
4
5
6
7
8
9
10
11
12
12a
13
14
15
Description
Nut 5/16-18
Insulator Sleeve
2 mm Studs (100/bag, not shown)
3 mm Studs (100/bag, not shown)
Slide Hammer (not shown)
Head Roller (not shown)
Terminal
Wire Assembly
Wire Assembly
Ground Sleeve
Spring
Sliding Electrode
2 mm Stud Electrode Tip
3 mm Stud Electrode Tip (not shown)
Cap Screw 1/4 x 20 x 5/8"
FRP Insulator
Circuit Breaker
Qty
2
1
1 bag
1 bag
1
1
2
1
1
1
1
1
1
1
1
1
Part
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Description
Screw 10-32 x 7/8
Trigger Boot
Trigger
Power Cord
Left Housing
Hex Nut 10-32
Insulator
Transformer
Cap Screw 1/4 x 20 x 3/4"
Flat Washer SAE 1/4"
Right Housing
Screw 10-32 x 1/2"
Braided Strap
Screw 10-32 x 1-1/2"
Hex Nut 1/4 x 20
Flat Washer 5/16
Nut 5/16
Qty
2
1
1
1
1
11
1
1
1
4
1
6
1
3
2
2
1
OPERATION
MAINTENANCE
Page 14
For technical questions, please call 1-800-444-3353.
Item 61433
12
Item 61433
9
10
MAINTENANCE
11
2
30
32
6
25
31
14
30
25
1
For technical questions, please call 1-800-444-3353.
8
15
16
OPERATION
28
27
26
7
29
17
19
SETUP
18
25
24
13
23
21
SAFETY
22
20
21
Assembly Diagram
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 indirectly,
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.
3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-3353