Chicago Electric 61433 Assembly instructions

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61433
Owner’s Manual & Safety Instructions
Save This Manual Keep this manual for the safety warnings and precautions, assembly,
operating, 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. 19c
When unpacking, make sure that the product is intact
and undamaged. If any parts are missing or broken,
please call 1-888-866-5797 as soon as possible.
Copyright© 2013 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.
Diagrams within this manual may not be drawn proportionally. Due to continuing
improvements, actual product may differ slightly from the product described herein.
Tools required for assembly an d se rv ic e may n ot b e in cl uded.
Read this material before using this product.
Failure to do so can result in serious injury.
SAVE THIS MANUAL.

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Table of Contents
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.
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
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.
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.
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.
SAFETY OPERATION MAINTENANCESETUP

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Fume and Gas Safety Information
FUMES AND GASES can be hazardous to your health.
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
2. Do not use near degreasing or
painting operations.
3. Keep head out of fumes.
Do not breathe exhaust fumes.
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.
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.
Arc Ray Safety Information
ARC RAYS can injure eyes and burn skin.
1. Wear ANSI-approved welding eye protection
featuring at least a number 10 shade lens rating.
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.
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.
SAFETYOPERATIONMAINTENANCE SETUP

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Electrical Safety Information
ELECTRIC SHOCK can KILL.
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.
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 conduc
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.
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.
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.
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.
SAFETY OPERATION MAINTENANCESETUP

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Operation Specific Safety Information
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.
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
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.
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.
SAVE THESE INSTRUCTIONS.
SAFETYOPERATIONMAINTENANCE SETUP

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Grounding
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.
Double Insulated Tools: Tools with Two Prong Plugs
Figure A: Outlets for 2-Prong Plug
1. Tools marked “Double Insulated” do not
require grounding. They have a special
double insulation system which satisfies
OSHA requirements and complies with
the applicable standards of Underwriters
Laboratories, Inc., the Canadian Standard
Association, and the National Electrical Code.
2. Double insulated tools may be used in either of the
120 volt outlets shown in the preceding illustration.
(See Outlets for 2-Prong Plug.)
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.
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.
SAFETY OPERATION MAINTENANCESETUP

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Symbology
Housing Ground Point
VVolts
~Alternating Current
AAmperes
OCV Open Circuit Voltage
KVA Kilovolt Amperes
(Volts / 1000 * Amperes)
AWG American Wire Gauge
SAFETYOPERATIONMAINTENANCE SETUP

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Specifications
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
SAFETY OPERATION MAINTENANCESETUP

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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.
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
Ground Sleeve
2 mm Stud
Electrode
Tip
Circuit Breaker
Reset Button
Slide Hammer
Additional 3 mm
Stud Electrode Tip
Head Roller
2 mm Studs
3 mm Studs
SAFETYOPERATIONMAINTENANCE SETUP

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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.
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.
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
Workpiece
Stud Electrode Tip
Stud
Figure B
3. Plug the Power Cord into an electrical outlet on
a circuit with a minimum 20 amp capacity.
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
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.
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.
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.
SAFETY OPERATION MAINTENANCESETUP

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Pulling Out the Dent
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.
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.
CAUTION! Keep hands clear of pinch points.
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.
Back Handle
Center Handle
Workpiece
Stud Hammer Head
Head Roller
SAFETYOPERATIONMAINTENANCE SETUP

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Maintenance
Procedures not specifically explained in this manual must
be performed only by a qualified technician.
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
• 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 Possible Causes Likely Solutions
Stud Does Not Weld;
Weld Area Cold
1. Unit not plugged into
electrical outlet.
2. No power to Power Cord.
3. Welder circuit
breaker tripped.
4. Ground Sleeve has
poor/no contact with
weld surface.
1. Plug Power Cord into electrical outlet.
2. Check power source.
3. Press Circuit Breaker Reset Button.
4. Clean weld surface for the entire Ground
Sleeve to contact fully, press harder, and ensure
Ground Sleeve contacts the surface evenly.
Weak Weld, Stud
Does Not Hold
1. Weld time too short.
2. Electrode Tip or
stud dirty.
3. Weld surface not
cleaned sufficiently.
1. Increase weld time.
2. Clean or replace Electrode Tip and/or stud.
3. Clean surface down to bare metal.
Weld Burning
Through Metal
1. Weld time too long.
2. Using incorrect stud.
3. Dirty Electrode Tip.
1. Shorten weld time.
2. Replace stud with correct size.
3. Clean Electrode Tip.
Circuit Breaker
Continues to Trip
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.
SAFETY OPERATION MAINTENANCESETUP

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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
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.
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.
SAFETYOPERATIONMAINTENANCE SETUP

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Parts List and Diagram
Parts List
Part Description Qty
1 Nut 5/16-18 2
2 Insulator Sleeve 1
3a 2 mm Studs (100/bag, not shown) 1 bag
3b 3 mm Studs (100/bag, not shown) 1 bag
4 Slide Hammer (not shown) 1
5 Head Roller (not shown) 1
6 Terminal 2
7 Wire Assembly 1
8 Wire Assembly 1
9 Ground Sleeve 1
10 Spring 1
11 Sliding Electrode 1
12 2 mm Stud Electrode Tip 1
12a 3 mm Stud Electrode Tip (not shown)
13 Cap Screw 1/4 x 20 x 5/8" 1
14 FRP Insulator 1
15 Circuit Breaker 1
Part Description Qty
16 Screw 10-32 x 7/8 2
17 Trigger Boot 1
18 Trigger 1
19 Power Cord 1
20 Left Housing 1
21 Nut 10-32 11
22 Insulator 1
23 Transformer 1
24 Cap Screw 1/4 x 20 x 3/4" 1
25 Flat Washer SAE 1/4" 4
26 Right Housing 1
27 Screw 10-32 x 1/2" 6
28 Braided Strap 1
29 Screw 10-32 x 1-1/2" 3
30 Nut 1/4 x 20 2
31 Flat Washer 5/16 2
32 Nut 5/16 1
SAFETY OPERATION MAINTENANCESETUP

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Assembly Diagram
18
31
1
32
30 25
28
27
26
29
2
9
12
11
10 25
30
14
6
816
7
15
17
19
21
20
21
22
23
13
24
25
SAFETYOPERATIONMAINTENANCE SETUP

26541 Agoura Road • Calabasas, CA 91302 • 1-888-866-5797
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.