Chicago Electric 3663 Installation manual

BANDSAW BLADE WELDER
Model 3663
SET UP 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.
Failure to do so can result in serious injury.
SAVE THIS MANUAL.
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 or replacement parts, please call 1-800-444-3353.
Revised 03d, 07k

Page 2SKU 3663 For technical questions, please call 1-800-444-3353.
SPECIFICATIONS
Power Requirements 220 V~, 1-Phase, 60 Hz, 6 A
( Only use on a 20 amp circuit)
Welding Current 280 A
Welding Blade Sizes 1/8” to 1/2”
Maximum Jaw Movement .137”
Note: Grinder not included.
Note: Performance of this tool (if powered by line voltage) may vary depending on variations
in local line voltage. Extension cord usage may also affect tool performance.
Save This Manual
You will need the manual for the safety warnings and precautions, assembly instructions, oper-
ating and maintenance procedures, parts list and diagram. Keep your invoice with this manual. Write
the invoice number on the inside of the front cover. Keep the manual and invoice in a safe and dry
place for future reference.
SAFETY WARNINGS AND PRECAUTIONS
WARNING: When using tool, basic safety precautions should always be followed to reduce
the risk of personal injury and damage to equipment.
Read all instructions before using this tool!
Keep work area clean1. . Cluttered areas invite injuries.
Observe work area conditions2. . Do not use the Welder in damp or wet locations. Don’t ex-
pose to rain. Keep work area well lighted. Do not use electrically powered tools in the presence
of ammable gases or liquids.
Keep children away3. . Children must never be allowed in the work area. Do not let them handle
machines, tools, or extension cords.
Store idle equipment4. . When not in use, tools must be stored in a dry location to inhibit rust.
Always lock up tools and keep out of reach of children.
Use the right tool for the job5. . Do not attempt to force a small tool or attachment to do the
work of a larger industrial tool. There are certain applications for which this tool was designed.
It will do the job better and more safely at the rate for which it was intended. Do not modify this
tool and do not use this tool for a purpose for which it was not intended.
Dress properly6. . Do not wear loose clothing or jewelry as they can be caught in moving parts.
Protective, electrically non-conductive clothes and non-skid footwear are recommended when
working. Wear restrictive hair covering to contain long hair. Always wear heavy-duty leather
gloves when handling bandsaw blades.
REV 07j

Page 3SKU 3663 For technical questions, please call 1-800-444-3353.
Inhalation Hazard
Welding/Plasma Cutting Produces TOXIC FUMES and GASSES.
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 • 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.
7. Use eye and ear protection. Always wear ANSI approved impact safety goggles. Wear a full
face shield if you are producing metal lings. Wear an ANSI approved dust mask or respirator
when working around metal and chemical dusts and mists.
Do not overreach8. . Keep proper footing and balance at all times. Do not reach over or across
running machines.
Maintain tools with care9. . Keep tools clean for better and safer performance. Follow instruc-
tions for lubricating and changing accessories. Inspect tool cords periodically and, if damaged,
have them repaired by an authorized technician. The handle must be kept clean, dry, and free
from oil and grease at all times.
Disconnect power10. . Unplug tool when not in use.
Avoid unintentional starting11. . Be sure the buttons are not depressed when not in use and
before plugging in.
Stay alert12. . Watch what you are doing, use common sense. Do not operate any tool when you
are tired.
Check for damaged parts13. . 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 xtures; and
any other condition that may affect proper operation. Any part that is damaged should be prop-
erly repaired or replaced by a qualied technician. Do not use the tool if any button does not
turn On and Off properly.
Guard against electric shock14. . Prevent body contact with grounded surfaces such as pipes,
radiators, ranges, and refrigerator enclosures.
Replacement parts and accessories15. . 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.
Donotoperatetoolisundertheinuenceofalcoholordrugs16. . Read warning labels if tak-
ing prescription medicine to determine if your judgement or reexes are impaired while taking
drugs. If there is any doubt, do not operate the Welder.

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REV 04e, 04f, 07k
Use proper size and type extension cord17. . 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 re, or cause electrical damage to the tool. This tool re-
quires use of an extension cord of 20 amps capability (up to 50 feet), with wire size rated at 12
AWG. Longer extension cords require larger size wire. If you are using the tool outdoors, use an
extension cord rated for outdoor use (signied by “WA” on the jacket).
Maintenance18. . For your safety, maintenance should be performed regularly by a qualied tech-
nician.
This product, when used for welding and similar applications, produces chemicals known to the19.
State of California to cause cancer and birth defects (or other reproductive harm). (California
Health & Safety Code § 25249.5, et seq.)
The warnings, cautions, and instructions discussed in this instruction manual cannot cover all20.
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 sup-
plied by the operator.
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.
ASSEMBLY
This step should only be performed by a licensed electrician. Acquire an appropriate 220 V~,
1-Phase plug to t in the electrical outlet. Connect the plug, making sure that the black wire is the ener-
gized (hot) lead, the white wire is the other energized (hot) lead, and the green wire is the ground lead.
See the wiring diagram on page 8. FIGURE 1
Light
Annealing Button
Pressure Knob
Left Electrode
Left Hand Clamp
Power Cord
Light Switch
Welding Button
Right Electrode
Right Hand Clamp

Page 5SKU 3663 For technical questions, please call 1-800-444-3353.
REV 04f
OPERATION
This Bandsaw Blade Welder is used to weld saw blades between 1/8 and 1/2 inches in width.
Additional Warnings!
Make sure the Welding and Annealing Buttons are not depressed before plugging in the unit.1.
Never leave the welder unattended while running.2.
Always unplug before servicing. All internal maintenance should be performed by an authorized3.
service technician.
Sparksaregeneratedwhilewelding.Situatethewelderfarawayfromanyammable4.
materials. Work in a well-ventilated area.
Note: This unit does not have a grinder attachment.
WARNING! Handle blades with extreme care. They ex and twist easily, making them extremely dan-
gerous. Always wear heavy-duty leather gloves when handling bandsaw blades.
Saw blade preparation
Wearing heavy-duty leather gloves, use a metal table shear (not included) to trim 1/4” off each1.
end of the saw blade.
Note: The ends must be cut perfectly square to attain a full width weld. The cut should be made in an
area between the blade’s teeth (especially with larger blades). If hand shears (not included) are
used to cut the blade, it may be necessary to le the ends until they are square. Use a square
(tool, not included) to make sure the blade ends are 90°. There should be no taper on the very
end of the blade.
Using a ne emery cloth (not included), lightly clean both ends (and at surfaces near the ends) 2.
of the saw blade. Remove all burrs. Completely clean off all dirt, coatings, and oil.
Welding
Refer to FIGURES and the Assembly Drawing on page 9.
Verify that the plug is not plugged into the power outlet.1.
Turn the Pressure Knob (12) to zero. See2. FIGURE 2. When the Pressure Knob (12) is turned
to zero, the Right Electrode (5) will separate from the Left Electrode (13).
FIGURE 3
FIGURE 2

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REV 04f, 07k
Loosen both of the clamp handles (Left Hand Clamp (14) and Right Hand Clamp (6)). See3. FIG-
URE 3.
Place one end of the saw blade (not included) under the Left Electrode (13). See4. FIGURE 4
on page 6. Make sure it is aligned squarely and the teeth are facing back. The saw blade end
should protrude 1/4” out of the clamp, toward the center.
Tighten the Left Hand Clamp (14). See5. FIGURE 4.
Repeat steps 4 and 5 on the Right Electrode (5) and Right Hand Clamp (6) with the other end of6.
the saw blade. See FIGURE 5.
To butt up the ends of the blades, turn the Pressure Knob (12) to the setting based on the blade7.
width you are welding, i.e. if you are welding a 1/4” blade, adjust the knob to number 2. See
FIGURE 2 on page 5. The wider the saw blade, the higher the Pressure Knob (12) should be
set.
Verify that the saw blades align squarely, front to back, and that the two ends butt together with8.
no space in-between. If they do not, remove the saw blades and recut the ends to make them
more square.
Put on your safety glasses, respirator, and gloves approved for welding.9.
Plug the unit in.10.
Press and hold the green Welding Button (4) until the weld cycle is complete. If popping occurs,11.
or holes are created during the welding process, the blade ends were not butted together cor-
rectly. Unplug the Welder and prepare the saw blade ends again.
With the Welding Button (4) still pressed, loosen the Right Hand Clamp (6) and turn the Pres-12.
sure Knob (12) counterclockwise to zero. Then, release the Welding Button (4). See FIGURE 6.
FIGURE 4 FIGURE 5
FIGURE 6

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REV 04f
Annealing the Weld
Note: The annealing process tempers and toughens the blade, reducing brittleness.
Retighten the Right Hand Clamp (6). See Figure 7.1.
Press and hold the red Annealing Button (11) until the blade2.
becomes dark red. Release the Annealing Button (11) after
a few seconds.
Repeat pressing and releasing (pulsating action) the An-3.
nealing Button (11) (while reducing the annealing time)
several times until the redness is no longer visible.
Let the saw blade cool for at least ve minutes, then unplug 4.
the plug and remove the blade from the Welder.
Use an 8 inch mill bastard le (not included) to le off the 5.
welding ash. If the ash is too hard and will not easily le
off, repeat the annealing process.
File all of the ashing from around the weld, being careful 6.
not to undercut the weld surface in comparison to the rest of
the blade.
Test the weld by carefully bending the blade to a 4 inch radius to see if it breaks.7.
Note: Test the repaired saw blade. After repairing the blade, carefully install it on the bandsaw fol-
lowing the instructions and safety warnings provided in the instruction manual of the bandsaw.
Once the blade is installed, make sure the guards and any cabinet doors on the tool are in the
closed/safe position. Run the saw for 2-3 minutes. Then, stop the saw, unplug it, and check the
weld visually before you begin cutting an actual workpiece. Do not continue if the weld shows
signs of cracking or breaking.
FIGURE 7

Page 8SKU 3663 For technical questions, please call 1-800-444-3353.
REV 04f
MAINTENANCE
WARNING! Unplug welder before performing any maintenance.
When not in use, cover and store the Welder in a clean, dry location.1.
Periodically, open and use ne grit sandpaper to clean the carbon residue from the inside sur-2.
faces of the terminal clamps.
Always unplug before servicing. All internal maintenance should be performed by a qualied 3.
service technician.
Wiring Diagram

Page 9SKU 3663 For technical questions, please call 1-800-444-3353.
REV 04f, 07k
FRONT PANEL PARTS LIST AND DIAGRAM
Part Description
1 Handle
2 Light Mantle
3 Base Frame
4 Welding Button
5 Right Electrode
Part Description
6 Right Hand Clamp
10 Case
11 Annealing Button
12 Pressure Knob
13 Left Electrode
Part Description
14 Left Hand Clamp
15 Light Switch
16 Line Cord (without plug)
PLEASE READ THE FOLLOWING CAREFULLY
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 REPRESENTA-
TION 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 INSTAL-
LATION OF REPLACEMENT PARTS THERETO.
Note: Some parts are listed and shown for illustration purposes only and are not available individually
as replacement parts.

Page 10SKU 3663 For technical questions, please call 1-800-444-3353.
PARTS LIST
REV 04f; 08a
Part Description
1 Ringent Circle
2 Defection Axes
3Cover of Deection Axes
4 Left Electrode
5 Right Electrode
6 Lamp
7 Lamp Holder
8 Lamp Shield
9 Nut
10 Knob
11 Bolt
12 Nameplate
13 Panel
14 Red Button
15 Green Button
16 Base of Deection Wheel
17 Bolt
18 Deection Wheel
19 Washer
20 Axes
21 Spring Washer
22 Nut
23 Batten
24 Bolt
25 Short Spring
26 Long Spring
Part Description
27 Bolt
28 Spring Washer
29 Washer
30 Base of Spring
31 Base of Spot Switch
32 Spot Switch
33 Connection
34 Base of Connection
35 Main Transformer
36 Nut
37 Spring Washer
38 Washer
39 Support Shelf of Transformer
40 Bolt
41 Base of Sliding Block
42 Inner-Hexagonal Bolt
43 Iron Wedge
44 Copper Block
46 Bolt
47 Label
48 Button Switch
49 Nail
50 Connection Piece
51 Copper Pressure Block
52 Handle

Page 11SKU 3663 For technical questions, please call 1-800-444-3353.
ASSEMBLY DRAWING
REV 04f; 08a

Page 12SKU 3663 For technical questions, please call 1-800-444-3353.
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. 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 rectier are free from defects in materials and work-
manship (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 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, special or conse-
quential damages arising from the use of our product. Some states do not allow the exclusion or limita-
tion 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 transporta-
tion charges prepaid. Proof of purchase date and an explanation of the complaint must accompany
the merchandise. If our inspection veries 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 specic 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 • [phone]
07k