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Autobody dent RepAiR
ASSEMBLY AND OPERATING INSTRUCTIONS
Diagrams within this manual may not be drawn proportionally.
Due to continuing improvements, actual product may differ slightly from the product described herein.
Distributed exclusively by Harbor Freight Tools
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.
Copyright
©
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 or replacement parts, please call 1-800-444-3353.
SKU 94739
Welding Kit
3491 Mission Oaks Blvd., Camarillo, CA 93011
2006 by Harbor Freight Tools
For technical questions, please call 1-800-444-3353
94739
. All rights reserved. No portion of this
®
.
®
Page 1
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Table of Contents
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Summary of Contents for Chicago Electric 94739
- Page 1 Autobody dent RepAiR Welding Kit 94739 ASSEMBLY AND OPERATING INSTRUCTIONS Diagrams within this manual may not be drawn proportionally. Due to continuing improvements, actual product may differ slightly from the product described herein. 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.
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Page 2: Specifications
Specifications Power 230VAC, Single Phase, 60 Hz, 60 Max Power 10KVA Requirement Amps (Instant) Secondary 8.8V - 9.5V Max. Working 1300 A No Load Current Voltage (Instant) Timed Work Timed Range: 0 - 1.2 sec. Required 3-Prong, 230 VAC, Polarized, Twist Lock, 60 Mode Electrical Amps for maximum output (not included) -
Page 3: Personal Safety
When operating a power tool outside, use an outdoor extension cord marked “W-A” or “W”. These extension cords are rated for outdoor use, and reduce the risk of electric shock. Personal Safety Stay alert. Watch what you are doing, and use common sense when operating a power tool. Do not use a power tool while tired or under the influence of drugs, alcohol, or medication. -
Page 4: Specific Safety Rules
Service Tool service must be performed only by qualified repair personnel. Service or maintenance performed by unqualified personnel could result in a risk of injury. When servicing a tool, use only identical replacement parts. Follow instructions in the “Inspec- tion, Maintenance, And Cleaning” section of this manual. Use of unauthorized parts or failure to fol- low maintenance instructions may create a risk of electric shock or injury. - Page 5 Maintain a safe working environment. Keep the work area well lit. Make sure there is adequate surrounding workspace. Always keep the work area free of obstructions, grease, oil, trash, and other debris. Do not use a power tool in areas near flammable chemicals, dusts, and vapors. Do not use this product in a damp or wet location.
- Page 6 • Where ventilation is questionable, have a qualified technician take an air sampling to determine the need for corrective measures. Use mechanical ventilation to improve air quality. 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. •...
- Page 7 GROUNDING NOTE: This tool requires the installation of a 3-prong 230 VAC, polarized twistlock power cord plug (not included). The plug must be installed by a qualified electrician. See Figure A below. WARNING! Improperly connecting the grounding wire can result in the risk of electric shock. Check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded.
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Page 8: Extension Cords
EXTENSION CORDS Grounded, 230 VAC tools require a three wire extension cord. As the distance from the supply outlet increases, you must use a heavier gauge extension cord. Us- ing extension cords with inadequately sized wire causes a serious drop in voltage, resulting in loss of power and possible tool damage. - Page 9 Unpacking When unpacking, check to make sure that the product is intact and undamaged. Included Components and Accessories: Welding Unit Electrode with Magnet / Shrinking Electrode Puller Assembly (2) Pot Hooks (50) Washers (3) Carbon Electrodes (2) Spare Fuses If any parts are missing or broken, please call Harbor Freight Tools at the number on the cover of this manual.
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Page 10: Control Panel
Control Panel Function Selector (1): a) Continuous Operation is used for Carbon warming and tempering of work material. b) Timed Operation is used for washer or needle welding. c) OFF to turn off power supply to welder. Timer Control (2): Sets the duration of the pulse during timed welding operation. - Page 11 NOTE: Welding is a complex operation requiring training, skill and practice. We strongly recommend professional training before attempting any welding operation. This manual is intended only as basic information and cannot cover all aspects of the welding process. Preparing to use the welder Always clean both sides of the work material at and near the work place to remove paint, rust, dirt, grease and other contaminating material.
- Page 12 Using the Extractor Hook Thread the Extractor Hook (Pot Hook) onto the slide puller assembly. Fit the extractor hook onto the washer. Hold the Hand grip with one hand, and pull the Striker back sharply against the handle. This action will pull out the dent.
- Page 13 Using the Shrinking Electrode Insert the Magnetic / Shrinking Electrode in the Gun with the rounded Shrinking end protruding. Set the Ground Clamp as close as possible to the damaged area. Set the Function Selector to CONTINUOUS. Place the Electrode on the damaged area and squeeze the trigger. The electrode will heat up, as will the work material.
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Page 14: Maintenance And Troubleshooting
Cutting with the Carbon Electrodes: Using the Carbon Electrode, set the Function switch to “CONTINUOUS”. Attach the ground nearby the work location. Contact electrode to metal and squeeze the trigger. Hold trigger in ON position while the metal heats up. Eventually the metal will begin to melt. Move the Carbon Electrode along a path to cut the metal. WARNING: Plan ahead for the molten metal to fall onto a non-flammable surface, such as a concrete floor. - Page 15 Problem Possible Cause Possible Solution Power is OFF. Connect to power supply. Will not function. Power Light is Main Switch is not turned ON. Turn on switch. not on. Fuse is broken. Replace fuse. Power light and Thermostat light Automatic overheat interrupt protection. Allow welder to cool for at least 30 minutes.
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Page 16: Circuit Diagram
Welder Accessories Spot Weld Needle 3 pc 1 pc Extractor Main Wire Connection Circuit Diagram Diagram power work Microswitch FUSE S1-1 250V/3A Main Switch S1-2 Main Switch Control Board Thermostat REV 06l, 08b SKU 94739 For technical questions, please call 1-800-444-3353 Page 16... -
Page 17: Parts List
Parts List Part Description Part Description Transformer Grounding Clamp Cooling Fan Welding Gun Relay Cable Bushing Shift Switch Cable Bushing Front Panel Timer Knob Auxillary Transformer Function Selector Fuse Holder Top Cover Main Cable Handle Cable Bushing Power Light Fan Cover Thermostat Light Thermostat Working Light... - Page 18 Assembly Photo REV 06l, 08b SKU 94739 For technical questions, please call 1-800-444-3353 Page 18...
- Page 19 Assembly Photo NOTE: Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts. PLEASE READ THE FOLLOWING CAREFULLY THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY.
- Page 20 LIMITED 1 YEAR / 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 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 defects in materials and workmanship.