Chicago Electric 8878 Parts list 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

SKU 8878 For technical questions, please call 1-800-444-3353. Page 2
SPECIFICATIONS
Welding Process Resistance Weld
Power Requirements 120 V, 60 Hz, ~40 A Peak
Circuit Requirement 20 A
Switch Push Button
Power Cord 14 AWG x 3C / 3 prong grounded plug
Features: High power low heat transformer with resettable safety breaker/ 2 lb.
Slide Hammer, 100 0.078” (2mm) copper studs
SAVE THIS MANUAL
You will need this manual for the safety warnings and precautions, assembly,
operating, inspection, maintenance and cleaning procedures, parts list and assembly
diagram. Keep your invoice with this manual. Write the invoice number on the inside
of the front cover. Keep this manual and invoice in a safe and dry place for future refer-
ence.
GENERAL SAFETY RULES
WARNING!
READ AND UNDERSTAND ALL INSTRUCTIONS
Failure to follow all instructions listed below may result in
electric shock, re, and/or serious injury.
SAVE THESE INSTRUCTIONS
WORK AREA
Keep your work area clean and well lit. Cluttered benches and dark areas invite
accidents.
Do not operate power tools in explosive atmospheres, such as in the presence
of ammable liquids, gases, or dust. Power tools create sparks which may ignite
the dust or fumes.
Keep bystanders, children, and visitors away while operating a power tool. Dis-
tractions can cause you to lose control. Protect others in the work area from
debris such as chips and sparks. Provide barriers or shields as needed.
ELECTRICAL SAFETY
Grounded tools must be plugged into an outlet properly installed and grounded
in accordance with all codes and ordinances. Never remove the grounding
prong or modify the plug in any way. Do not use any adapter plugs. Check
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SKU 8878 For technical questions, please call 1-800-444-3353. Page 3
with a qualied 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.
Double insulated tools are equipped with a polarized plug (one blade is wider
than the other). This plug will t in a polarized outlet only one way. If the
plug does not t fully in the outlet, reverse the plug. If it still does not t,
contact a qualied 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.
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.
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 inuence
of drugs, alcohol, or medication. A moment of inattention while operating
power tools may result in serious personal injury.
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 nger 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.
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SKU 8878 For technical questions, please call 1-800-444-3353. Page 4
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.
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.
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.
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.
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
Tool service must be performed only by qualied repair personnel. Service or
maintenance performed by unqualied 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.
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SPECIFIC SAFETY RULES
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 • 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.
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 ammable chemicals, dusts, and vapors. Do not use this product in a damp
or wet location.
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.
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.
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.
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Avoid accidental activation. Unplug the Stud Welder while inserting the stud
electrode into the Stud Welder.
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 § 25249.5,
et seq.)
People with pacemakers should consult their physician(s) before use. Electro-
magnetic elds 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 qualied 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 t the outlet, have a proper outlet installed by
a qualied electrician.
GROUNDED TOOLS: TOOLS WITH THREE PRONG PLUGS
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.)
Your tool must be plugged into an appropriate
outlet, properly installed and grounded in accor-
dance with all codes and ordinances. The plug
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3-Prong Plug and Outlet3-Prong Plug and Outlet

SKU 8878 For technical questions, please call 1-800-444-3353. Page 7
and outlet should look like those in the following illustration.
(See 3-Prong Plug and Outlet.)
EXTENSION CORDS
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 25’ - 50’ 10 gauge cord or a single 25’ 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.
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.
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-
x “W-A” (“W” in Canada) to indicate it is acceptable for outdoor use.
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 qualied elec-
trician before using it.
Protect your extension cords from sharp objects, excessive heat, and damp or
wet areas.
Symbology
Double Insulated V~ Volts Alternating Current
Canadian Standards Association AAmperes
Underwriters Laboratories, Inc. n0xxxx/min. No Load Revolutions per Minute
(RPM)
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.
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OPERATION
Note:
Stud Electrode
(23)
Electrode Assembly (26)
Trigger (17)
FIGURE 1
Circuit Breaker
Reset (20)
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
rst practice the procedure on a piece of scrap metal.
Welding the stud
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.
Insert a Stud (32) into the hole in the Stud Electrode (23). See FIGURE 2.
Plug the Cord (16) into an outlet ca-
pable of handling a 20 amp load.
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FIGURE 2
Stud (32)
Metal
Surface
FIGURE 2
Stud (32)
Metal
Surface

SKU 8878 For technical questions, please call 1-800-444-3353. Page 9
Holding the Stud Welder rmly with both hands and using a well-balanced
stance, rmly push the Stud (32) against
the metal surface until the Electrode
Assembly (26) is ush with the metal
surface. See FIGURE 3.
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.
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).
Pull the Stud Welder directly back, leaving the Stud (32) in place. You will notice
the tip of the stud remains exposed.
When done with the Stud Welder, unplug the tool and store it safely.
Pulling out the Dent
Metal
Surface
Roller
Back
Handle
Center Handle
FIGURE 4 - Slide Hammer (31)
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.
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 ush with the metal surface.
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Metal
Surface
FIGURE 3
Electrode
Assembly (26)
Metal
Surface
FIGURE 3
Electrode
Assembly (26)
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SKU 8878 For technical questions, please call 1-800-444-3353. Page 10
INSPECTION, MAINTENANCE, AND CLEANING
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.
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 ne steel
wool.
If necessary, use a ne metal le to keep the electrode at and clean.
TROUBLESHOOTING
Problem Cause Solution
Stud does not Weld, weld Area
is Cold
Insufcient/no contact to
metal surface with Electrode
Assembly
No power to line cord
Stud Welder Circuit Breaker
Open
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Clean metal surface for the
entire Electrode Assembly
(26) to contact fully, press
harder, and ensure Electrode
Assembly (26) contacts the
surface evenly
Check Power Source
Press Circuit Breaker Reset
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Weak weld, stud does not hold “On Time” Not long enough.
Electrode or Stud dirty
Weld surface not cleaned
down to bare metal
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Hold trigger longer
Clean or replace both
Clean surface to the metal
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Weld is burning through metal Weld time is too long
Using incorrect Stud
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Shorten weld time
Replace the Stud with the
correct size and clean the
electrode
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Circuit breaker continues to trip Circuit rating not large enough
Electrical fault in Welder
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Connect to 20 A dedicated
circuit
Have qualied technician
service welder
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