Chicago Electric Welder 8878 User Manual

DENT REPAIR STUD WELDER  
Model 08878  
ASSEMbLy AND OPERATION INSTRUcTIONS  
Due to continuing improvements, actual product may differ slightly from the product described herein.  
®
3491 Mission Oaks Blvd., Camarillo, CA 93011  
Visit our website at: http://www.harborfreight.com  
TO PREVENT SERIOUS INjURy, READ AND UNDERSTAND  
ALL WARNINgS AND INSTRUcTIONS bEfORE USE.  
Copyright© 2003, 2007 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 or replacement parts, please call 1-800-444-3353.  
Manual revised 02/07  
 
with a qualified electrician if you are in doubt as to whether the outlet is  
properly grounded. If the tools should electrically malfunction or break down,  
grounding provides a low resistance path to carry electricity away from the user.  
2.  
3.  
Double insulated tools are equipped with a polarized plug (one blade is wider  
than the other). This plug will fit in a polarized outlet only one way. If the  
plug does not fit fully in the outlet, reverse the plug. If it still does not fit,  
contact a qualified electrician to install a polarized outlet. Do not change  
the plug in any way. Double insulation eliminates the need for the three wire  
grounded power cord and grounded power supply system.  
Avoid body contact with grounded surfaces such as pipes, radiators, ranges, and  
refrigerators. There is an increased risk of electric shock if your body is ground-  
ed.  
4.  
ꢀ.  
Do not expose power tools to rain or wet conditions. Water entering a power tool  
will increase the risk of electric shock.  
Do not abuse the Power Cord. Never use the Power cord to carry the tools  
or pull the Plug from an outlet. Keep the Power cord away from heat, oil,  
sharp edges, or moving parts. Replace damaged Power cords immediate-  
ly. Damaged Power Cords increase the risk of electric shock.  
6.  
1.  
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 operat-  
ing a power tool. Do not use a power tool while tired or under the influence  
of drugs, alcohol, or medication. A moment of inattention while operating  
power tools may result in serious personal injury.  
2.  
3.  
4.  
ꢀ.  
Dress properly. Do not wear loose clothing or jewelry. Contain long hair.  
Keep your hair, clothing, and gloves away from moving parts. Loose  
clothes, jewelry, or long hair can be caught in moving parts.  
Avoid accidental starting. be sure the Power Switch is off before plugging in.  
Carrying power tools with your finger on the Power Switch, or plugging in power  
tools with the Power Switch on, invites accidents.  
Remove adjusting keys or wrenches before turning the power tool on. A wrench  
or a key that is left attached to a rotating part of the power tool may result in per-  
sonal injury.  
Do not overreach. Keep proper footing and balance at all times. Proper foot-  
ing and balance enables better control of the power tool in unexpected situations.  
SKU 8878  
for technical questions, please call 1-800-444-3353.  
Page 3  
 
6.  
1.  
Use safety equipment. Always wear eye protection. Dust mask, nonskid safe-  
ty shoes, hard hat, or hearing protection must be used for appropriate conditions.  
TOOL USE AND cARE  
Use clamps (not included) or other practical ways to secure and support the  
workpiece to a stable platform. Holding the work by hand or against your body is  
unstable and may lead to loss of control.  
2.  
3.  
Do not force the tool. Use the correct tool for your application. The correct  
tool will do the job better and safer at the rate for which it is designed.  
Do not use the power tool if the Power Switch does not turn it on or off. Any tool  
that cannot be controlled with the Power Switch is dangerous and must be re-  
placed.  
4.  
Disconnect the Power Cord Plug from the power source before making any  
adjustments, changing accessories, or storing the tool. Such preventive safety  
measures reduce the risk of starting the tool accidentally.  
ꢀ.  
6.  
Store idle tools out of reach of children and other untrained persons. Tools are  
dangerous in the hands of untrained users.  
Maintain tools with care. Keep cutting tools sharp and clean. Properly main-  
tained tools with a sharp cutting edge are less likely to bind and are easier to  
control. Do not use a damaged tool. Tag damaged tools “Do not use” until re-  
paired.  
7.  
8.  
Check for misalignment or binding of moving parts, breakage of parts, and any  
other condition that may affect the tool’s operation. If damaged, have the tool  
serviced before using. Many accidents are caused by poorly maintained tools.  
Use only accessories that are recommended by the manufacturer for your model.  
Accessories that may be suitable for one tool may become hazardous when used  
on another tool.  
SERVIcE  
1.  
2.  
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 instruc-  
tions in the “Inspection, Maintenance, And Cleaning” section of this man-  
ual. Use of unauthorized parts or failure to follow maintenance instructions may  
create a risk of electric shock or injury.  
SKU 8878  
for technical questions, please call 1-800-444-3353.  
Page 4  
 
SPEcIfIc SAfETy RULES  
1.  
Maintain labels and nameplates on the Stud Welder. These carry important infor-  
mation. If unreadable or missing, contact Harbor Freight Tools for a replacement.  
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.  
2.  
3.  
Always wear ANSI-approved safety impact glasses and a NIOSH-approved dust  
mask or respirator under a properly shaded welding face shield along with heavy-  
duty work gloves when using the Stud Welder. Using personal safety devices  
reduce the risk for injury.  
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 ob-  
structions, 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.  
4.  
ꢀ.  
Always keep the electrical cord away from hot and/or moving parts on the tool.  
Avoid unintentional starting. Make sure you are prepared to begin work before  
plugging in the Stud Welder.  
6.  
Never leave the Stud Welder unattended when it is plugged into an electrical  
outlet. Turn off the tool, and unplug it from its electrical outlet before leaving the  
work area.  
7.  
8.  
Always unplug the Stud Welder from its electrical outlet before performing and  
inspection, maintenance, or cleaning procedures.  
Avoid burns. Do not touch the welded stud electrode or work surface until it  
cools.  
REV 03/07  
SKU 8878  
for technical questions, please call 1-800-444-3353.  
Page ꢀ  
 
9.  
Avoid accidental activation. Unplug the Stud Welder while inserting the stud  
electrode into the Stud Welder.  
10.  
11.  
Avoid electrical shock. Do not operate the Stud Welder with its protective case  
removed. Do not touch grounded surfaces while operating  
WARNING! This product, when used for welding and similar applications, pro-  
duces chemicals known to the State of California to cause cancer and birth de-  
fects (or other reproductive harm). (California Health & Safety Code § 2ꢀ249.ꢀ,  
et seq.)  
12.  
People with pacemakers should consult their physician(s) before use. Electro-  
magnetic fields in close proximity to heart pacemaker could cause pacemaker  
interference or pacemaker failure.  
gROUNDINg  
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. 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 facil-  
ity before use. If the plug will not fit the outlet, have a proper outlet installed by  
a qualified electrician.  
gROUNDED TOOLS: TOOLS WITH THREE PRONg PLUgS  
1.  
2.  
Tools marked with “Grounding Required” 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 is connected  
through the green wire inside 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 at-  
tached to an electrically “live” terminal.  
(See 3-Prong Plug and Outlet.)  
3.  
Your tool must be plugged into an appropriate  
outlet, properly installed and grounded in accor-  
dance with all codes and ordinances. The plug  
3-Prong Plug and Outlet  
SKU 8878  
for technical questions, please call 1-800-444-3353. Page 6  
 
and outlet should look like those in the following illustration.  
(See 3-Prong Plug and Outlet.)  
ExTENSION cORDS  
1.  
2.  
Grounded 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 outlet increases, you must use a heavier gauge  
extension cord. Only use a single 2ꢀ’ - ꢀ0’ 10 gauge cord or a single 2ꢀ’ or less  
12 gauge cord with this tool. Using extension cords with inadequately sized wire  
causes a serious drop in voltage, resulting in loss of power and possible tool  
damage.  
3.  
The smaller the gauge number of the wire, the greater the capacity of the cord.  
For example, a 10 gauge cord can carry a higher current than a 12 gauge cord.  
Do not use extension cords with greater gauge numbers.  
4.  
ꢀ.  
Do not use the extension cord for more than one tool.  
If you are using an extension cord outdoors, make sure it is marked with the suf-  
fix “W-A” (“W” in Canada) to indicate it is acceptable for outdoor use.  
6.  
7.  
Make sure your extension cord is properly wired and in good electrical condition.  
Always replace a damaged extension cord or have it repaired by a qualified elec-  
trician before using it.  
Protect your extension cords from sharp objects, excessive heat, and damp or  
wet areas.  
Symbology  
Double Insulated  
Volts Alternating Current  
Amperes  
V~  
A
Canadian Standards Association  
Underwriters Laboratories, Inc.  
No Load Revolutions per Minute  
(RPM)  
n xxxx/min.  
0
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.  
SKU 8878  
for technical questions, please call 1-800-444-3353.  
Page 7  
 
OPERATION  
fIgURE 1  
Electrode Assembly (26)  
Stud Electrode  
(23)  
circuit breaker  
Reset (20)  
Trigger (17)  
Note: For additional information regarding the parts listed in the following pages, refer  
to the Assembly Diagram on page 12.  
caution: 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.  
Note: Before trying to pull a dent out of your own vehicle, it is recommended that you  
first practice the procedure on a piece of scrap metal.  
Welding the stud  
1.  
On the location you are going to weld, and in a area as large as the Electrode  
Assembly (26) surrounding it, clean the surface down to the metal (no paint).  
The entire Electrode Assembly (26) needs to evenly contact the surface without  
interference to weld properly.  
2.  
3.  
Insert a Stud (32) into the hole in the Stud Electrode (23). See fIgURE 2.  
Plug the cord (16) into an outlet ca-  
fIgURE 2  
pable of handling a 20 amp load.  
Stud (32)  
Metal  
Surface  
SKU 8878  
for technical questions, please call 1-800-444-3353.  
Page 8  
 
4.  
ꢀ.  
Holding the Stud Welder firmly with both hands and using a well-balanced  
stance, firmly push the Stud (32) against  
fIgURE 3  
Assembly (26)  
the metal surface until the Electrode  
Assembly (26) is flush with the metal  
surface. See fIgURE 3.  
Electrode  
With the Electrode Assembly (26)  
perfeCtly squAre to the surface,  
hold the Stud Welder very steady and  
squeeze the Trigger (17) for only 1/2 to  
1 second. Immediately release the Trig-  
ger (17) after 1/2 to 1 seconds.  
Metal  
Surface  
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).  
6.  
Pull the Stud Welder directly back, leaving the Stud (32) in place. You will notice  
the tip of the stud remains exposed.  
7.  
When done with the Stud Welder, unplug the tool and store it safely.  
Pulling out the Dent  
fIgURE 4 - Slide Hammer (31)  
center Handle  
Roller  
Metal  
Surface  
back  
Handle  
1.  
2.  
Slip the end roller of the Slide Hammer (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.  
With one hand on the Center Handle and one on the Back Handle, apply a back-  
ward hammering motion, hammering the Center Handle against the Back Handle  
(away from the metal surface) until the dent has popped out. See fIgURE 4.  
3.  
4.  
To disengage the Slide Hammer (31) from the Stud (32), gently tap the Center  
Handle forward against the Roller until the Stud (32) is released.  
Cut the Stud off and grind it down so it is flush with the metal surface.  
REV 03/07  
SKU 8878  
for technical questions, please call 1-800-444-3353.  
Page 9  
 
INSPEcTION, MAINTENANcE, AND cLEANINg  
1.  
2.  
WARNINg! Make sure the tool is unplugged from its electrical outlet before  
performing any inspection, maintenance, or cleaning procedures.  
bEfORE EAcH USE, inspect the general condition of the Stud Welder. Check  
for loose screws, misalignment or binding of moving parts, cracked or broken  
parts, damaged electrical wiring, and any other condition that may affect its safe  
operation. If abnormal noise or vibration occurs, have the problem corrected  
before further use.  
Do not use damaged equipment.  
3.  
4.  
ꢀ.  
Periodically inspect the power cord for cracks. Replace if necessary.  
Clean the unit using a damp cloth. Never use solvents.  
Keep the Electrode Assembly (26) free of oxidation by cleaning with fine steel  
wool.  
6.  
If necessary, use a fine metal file to keep the electrode flat and clean.  
TROUbLESHOOTINg  
Problem  
cause  
Solution  
Stud does not Weld, weld Area  
is Cold  
1. Insufficient/no contact to  
metal surface with Electrode  
Assembly  
1. Clean metal surface for the  
entire Electrode Assembly  
(26) to contact fully, press  
harder, and ensure Electrode  
Assembly (26) contacts the  
surface evenly  
2. No power to line cord  
3. Stud Welder Circuit Breaker  
Open  
2. Check Power Source  
3. Press Circuit Breaker Reset  
1. Hold trigger longer  
Weak weld, stud does not hold  
1. “On Time” Not long enough.  
2. Electrode or Stud dirty  
2. Clean or replace both  
3. Clean surface to the metal  
3. Weld surface not cleaned  
down to bare metal  
Weld is burning through metal  
Circuit breaker continues to trip  
1. Weld time is too long  
2. Using incorrect Stud  
1. Shorten weld time  
2. Replace the Stud with the  
correct size and clean the  
electrode  
1. Circuit rating not large enough 1. Connect to 20 A dedicated  
circuit  
2. Electrical fault in Welder  
2. Have qualified technician  
service welder  
SKU 8878  
for technical questions, please call 1-800-444-3353.  
Page 10  
 
PARTS LIST  
Part  
1
2
3
4
6
7
8
Description  
Q’ty  
1
2
2
2
2
1
6
1
4
1
1
1
8
1
1
1
Part  
17  
18  
19  
20  
21  
22  
23  
24  
2ꢀ  
26  
27  
28  
29  
30  
31  
32  
Description  
Q’ty  
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
Insulator Sleeve  
Nut  
Washer  
Nut  
Trigger  
Trigger Boot  
Screw  
Circuit Breaker Reset  
Insulator F.R.P.  
Screw  
Stud Electrode  
Sliding Electrode  
Spring  
Electrode Assembly  
Wire Assembly  
Wire Assembly  
Terminal  
Split Washer  
Slide Hammer  
2mm Studs (100/Bag)  
Split Lock Washer  
Braided Strap  
Screw  
Case (right)  
Washer  
Screw  
Transformer  
Insulator  
Nut  
Case (left)  
Label  
9
10  
11  
12  
13  
14  
1ꢀ  
16  
Cord  
ASSEMbLy DIAgRAM  
SKU 8878  
for technical questions, please call 1-800-444-3353.  
Page 11  
 
PLEASE READ THE fOLLOWINg cAREfULLy  
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEM-  
BLY DIAGRAM IN THIS MANUALAS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER  
OR 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 LIABILITYARISING 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.  
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 avail-  
able individually as replacement parts.  
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 materi-  
als 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 apply to damage due directly  
or indirectly to misuse, abuse, negligence or accidents, repairs or alterations outside our facili-  
ties, 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 trans-  
portation 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 07k  
SKU 8878  
for technical questions, please call 1-800-444-3353.  
Page 12  
 

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