Chicago Electric 98357 Installation manual

DENT REPAIR STUD WELDER
98357
SET UP AND OPERATING INSTRUCTIONS
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©2008 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.
For technical questions or replacement parts, please call 1-800-444-3353.

SKU 98357 For technical questions, please call 1-800-444-3353. Page 2
SAVE THIS MANUAL
Keep this manual for the safety warn-
ings and precautions, assembly, operat-
ing, 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.
IMPORTANT SAFETY
INFORMATION
In this manual, on the labeling,
and all other information provid-
ed with this product:
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.
DANGER indicates
a hazardous
situation which, if not
avoided, will result in death or
serious injury.
WARNING
indicates a
hazardous situation which, if
not avoided, could result in
death or serious injury.
CAUTION, used
with the safety
alert symbol, indicates a
hazardous situation which, if
not avoided, could result in
minor or moderate injury.
NOTICE is used to
address practices
not related to personal injury.
CAUTION, without
the safety alert
symbol, is used to address
practices not related to
personal injury.
General Power Tool Safety
Warnings
WARNING Read all safety
warnings and instructions.
Failure to follow the warnings and
instructions may result in electric
shock, re and/or serious injury.
Save all warnings and
instructions for future reference.
The term ″power tool″ in the
warnings refers to your mains-
operated (corded) power tool or
battery-operated (cordless) power
tool.
Work area safety1.
Keep work area clean and well lit.a.
Cluttered or dark areas invite acci-
dents.
Do not operate power tools inb.
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 children and bystandersc.
away while operating a power tool.
Distractions can cause you to lose
control.
Electrical safety2.
Power tool plugs must match thea.
outlet. Never modify the plug in
any way. Do not use any adapter

SKU 98357 For technical questions, please call 1-800-444-3353. Page 3
plugs with grounded power tools.
Unmodied plugs and matching out-
lets will reduce risk of electric shock.
Avoid body contact with groundedb.
surfaces such as pipes, radiators,
ranges and refrigerators. There is
an increased risk of electric shock if
your body is grounded.
Do not expose power tools to rainc.
or wet conditions. Water entering
a power tool will increase the risk of
electric shock.
Do not abuse the cord. Never used.
the cord for carrying, pulling or
unplugging the power tool. Keep
cord away from heat, oil, sharp
edges or moving parts. Damaged
or entangled cords increase the risk
of electric shock.
When operating a power tool out-e.
doors, use an extension cord suit-
able for outdoor use. Use of a cord
suitable for outdoor use reduces the
risk of electric shock.
If operating a power tool in a dampf.
location is unavoidable, use a
Ground Fault Circuit Interrupter
(GFCI) protected supply. Use of
a GFCI reduces the risk of electric
shock.
Personal safety3.
Stay alert, watch what you are do-a.
ing and use common sense when
operating a power tool. Do not use
a power tool while you are 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.
Use personal protective equip-b.
ment. Always wear eye protection.
Safety equipment such as dust mask,
non-skid safety shoes, hard hat, or
hearing protection used for appropri-
ate conditions will reduce personal
injuries.
Prevent unintentional starting.c.
Ensure the switch is in the off-po-
sition before connecting to power
source and/or battery pack, pick-
ing up or carrying the tool. Carry-
ing power tools with your nger on
the switch or energizing power tools
that have the switch on invites acci-
dents.
Do not overreach. Keep properd.
footing and balance at all times.
This enables better control of the
power tool in unexpected situations.
Dress properly. Do not wear loosee.
clothing or jewelry. Keep your
hair, clothing and gloves away
from moving parts. Loose clothes,
jewelry or long hair can be caught in
moving parts.
Only use safety equipment thatf.
has been approved by an appropri-
ate standards agency. Unapproved
safety equipment may not provide
adequate protection. Eye protection
must be ANSI-approved and breath-
ing protection must be NIOSH-ap-
proved for the specic hazards in the
work area.
Power tool use and care4.
Do not force the power tool. Usea.
the correct power tool for your ap-
plication. The correct power tool will
do the job better and safer at the rate
for which it was designed.
Do not use the power tool if theb.
switch does not turn it on and off.
Any power tool that cannot be con-

SKU 98357 For technical questions, please call 1-800-444-3353. Page 4
trolled with the switch is dangerous
and must be repaired.
Disconnect the plug from thec.
power source and/or the battery
pack from the power tool before
making any adjustments, chang-
ing accessories, or storing power
tools. Such preventive safety mea-
sures reduce the risk of starting the
power tool accidentally.
Store idle power tools out of thed.
reach of children and do not allow
persons unfamiliar with the power
tool or these instructions to oper-
ate the power tool. Power tools are
dangerous in the hands of untrained
users.
Maintain power tools. Check fore.
misalignment or binding of moving
parts, breakage of parts and any
other condition that may affect the
power tool’s operation. If dam-
aged, have the power tool repaired
before use. Many accidents are
caused by poorly maintained power
tools.
Use the power tool, accessoriesf.
and tool bits etc. in accordance
with these instructions, taking into
account the working conditions
and the work to be performed. Use
of the power tool for operations differ-
ent from those intended could result
in a hazardous situation.
Service5.
Have your power tool serviced bya.
a qualied repair person using
only identical replacement parts.
This will ensure that the safety of the
power tool is maintained.
Specic Safety Warnings
Maintain labels and nameplates on1.
the tool. These carry important safety
information. If unreadable or miss-
ing, contact Harbor Freight Tools for a
replacement.
Avoid unintentional starting. Prepare2.
to begin work before turning on the
tool.
Do not leave the tool unattended3.
when it is plugged into an electrical
outlet. Turn off the tool, and unplug it
from its electrical outlet before leav-
ing.
This product is not a toy. Keep it out4.
of reach of children.
People with pacemakers should5.
consult their physician(s) before use.
-
imity to heart pacemaker could cause
pacemaker interference or pacemak-
er failure. In addition, people with
pacemakers should:


on.

avoid electrical shock.

grounded. Ground Fault Circuit Inter-
rupter (GFCI) should also be imple-
mented – it prevents sustained elec-
trical shock.

SKU 98357 For technical questions, please call 1-800-444-3353. Page 5
Some dust created by power sand-6.
ing, sawing, grinding, drilling, and
other construction activities, contains
chemicals known [to the State of Cali-
fornia] to cause cancer, birth defects
or other reproductive harm. Some
examples of these chemicals are:

-
ment or other masonry products
-
cally treated lumber
Your risk from these exposures var-
ies, depending on how often you do
this type of work. To reduce your
exposure to these chemicals: work in
a well ventilated area, and work with
approved safety equipment, such as
those dust masks that are specially

particles. (California Health & Safety
Code § 25249.5, et seq.)
WARNING: Handling the cord on7.
this product will expose you to lead,
a chemical known to the State of
California to cause cancer, and birth
defects or other reproductive harm.
Wash hands after handling. (Califor-
nia Health & Safety Code § 25249.5,
et seq.)
The warnings, precautions, and8.
instructions discussed in this manual
cannot cover all possible conditions
and situations that may occur. It
must be understood by that common
sense and caution are factors which
cannot be built into this product, but
must be supplied by the operator.
SAVE THESE
INSTRUCTIONS.
Inhalation Hazard
Welding/Plasma Cutting
Produces TOXIC
FUMES and
GASSES.
Exposure to welding or
cutting gasses can
increase the risk of
d e v e l o p i n g c e r t a i n
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.

SKU 98357 For technical questions, please call 1-800-444-3353. Page 6
GROUNDING
TO PREVENT
ELECTRIC SHOCK
AND DEATH FROM
INCORRECT GROUNDING
WIRE CONNECTION:
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 facility
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 Re-1.
quired” 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 is2.
connected through the green wire in-
side 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 attached to an electrically
“live” terminal. (See 3-Prong Plug
and Outlet.)
The tool must be plugged into an3.
appropriate outlet, properly installed
and grounded in accordance with all
codes and ordinances. The plug and
outlet should look like those in the
preceding illustration. (See 3-Prong
Plug and Outlet.)
Double Insulated Tools: Tools
with Two Prong Plugs
Tools marked “Double Insulated” do1.
not require grounding. They have
a special double insulation system

and complies with the applicable
-
tories, Inc., the Canadian Standard
Association, and the National Electri-
cal Code. (See Outlets for 2-Prong
Plug.)

SKU 98357 For technical questions, please call 1-800-444-3353. Page 7
Double insulated tools may be used2.
in either of the 120 volt outlets shown
in the preceding illustration. (See
Outlets for 2-Prong Plug.)
Extension Cords
Grounded1. 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 outlet2.
increases, you must use a heavier
gauge extension cord. Using exten-
sion cords with inadequately sized
wire causes a serious drop in voltage,
resulting in loss of power and pos-
sible tool damage.
(See Table A.)
The smaller the gauge number of the3.
wire, the greater the capacity of the
cord. For example, a 14 gauge cord
can carry a higher current than a 16
gauge cord. (See Table A.)
When using more than one exten-4.
sion cord to make up the total length,
make sure each cord contains at
least the minimum wire size required.
(See Table A.)
If you are using one extension cord5.
for more than one tool, add the
nameplate amperes and use the sum
to determine the required minimum
cord size. (See Table A.)
If you are using an extension cord6.
outdoors, make sure it is marked with

indicate it is acceptable for outdoor
use.
Make sure the extension cord is prop-7.
erly wired and in good electrical con-
dition. Always replace a damaged
extension cord or have it repaired by

Protect the extension cords from8.
sharp objects, excessive heat, and
damp or wet areas.
RECOMMENDED MINIMUM WIRE
GAUGE FOR EXTENSION CORDS*
(120/240 VOLT)
NAMEPLATE
AMPERES
(at full load)
EXTENSION CORD
LENGTH
25’ 50’ 75’
100’ 150’
0 – 2.0 18 18 18 18 16
2.1 – 3.4 18 18 18 16 14
3.5 – 5.0 18 18 16 14 12
5.1 – 7.0 18 16 14 12 12
7.1 – 12.0 18 14 12 10 -
12.1 – 16.0 14 12 10 - -
16.1 – 20.0 12 10 - - -
TABLE A
* Based on limiting the line
voltage drop to ve volts at
150% of the rated amperes.
Symbology
Double Insulated
Canadian Standards Association

V~ Volts Alternating Current
AAmperes
n0xxxx/min. 
(RPM)

SKU 98357 For technical questions, please call 1-800-444-3353. Page 8
SPECIFICATIONS
Welding Process Reistance 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
100.078” (2mm) copper
studs
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.
OPERATING INSTRUCTIONS
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.
Tool Set Up
TO PREVENT
SERIOUS INJURY
FROM ACCIDENTAL
OPERATION:
Turn the Power Switch of the
tool to its “OFF” position and
unplug the tool from its
electrical outlet before
performing any inspection,
maintenance, or cleaning
procedures.
Note: For additional information regarding
the parts listed in the following pages,
refer to the Assembly Diagram on
page 12.
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.
Stud Electrode
(23)
Electrode Assembly (26)
Trigger (17)
FIGURE 1
Circuit Breaker
Reset (20)

SKU 98357 For technical questions, please call 1-800-444-3353. Page 9
Note: Before trying to pull a dent out of
your own vehicle, it is recommended

on a piece of scrap metal.
Welding the stud
On the location you are going to weld,1.
and in a area as large as the Elec-
trode Assembly (26) surrounding it,
clean the surface down to the metal
(no paint). The entire Electrode As-
sembly (26) needs to evenly contact
the surface without interference to
weld properly.
Insert a2. Stud (32) into the hole in the
Stud Electrode (23). See FIGURE
2, below.
Plug the3. Cord (16) into an outlet ca-
pable of handling a 20 amp load.
4. 
both hands and using a well-bal-
Stud
(32) against the metal surface until
the Electrode Assembly (26)
with the metal surface. See FIGURE
3, above.
With the Electrode Assembly (26)5.
PERFECTLY SQUARE to the sur-
face, hold the Stud Welder very
steady and squeeze the Trigger (17)
for only 1/2 to 1 second. Immediately
release the Trigger (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,6.
leaving the Stud (32) in place. You
will notice the tip of the stud remains
exposed.
When done with the Stud Welder,7.
unplug the tool and store it safely.
Metal
Surface
FIGURE 3
Electrode
Assembly (26)
FIGURE 2
Stud (32)
Metal
Surface

SKU 98357 For technical questions, please call 1-800-444-3353. Page 10
Pulling Out the Dent
Slip the end roller of the1. Slide Ham-
mer (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, below.
With one hand on the Center Handle2.
and one on the Back Handle, apply a
backward hammering motion, ham-
mering the Center Handle against the
Back Handle (away from the metal
surface) until the dent has popped
out. See FIGURE 4.
To disengage the3. Slide Hammer (31)
from the Stud (32), gently tap the
Center Handle forward against the
Roller until the Stud (32) is released.
Cut the4. Stud off and grind it down so

MAINTENANCE AND
SERVICING
Procedures not specically
explained in this manual
must be performed only by a
qualied technician.
TO PREVENT
SERIOUS INJURY
FROM ACCIDENTAL
OPERATION:
Turn the Power Switch of the
tool to its “OFF” position and
unplug the tool from its
electrical outlet before
performing any inspection,
maintenance, or cleaning
procedures.
TO PREVENT SERIOUS
INJURY FROM TOOL
FAILURE:
Do not use damaged
equipment. If abnormal noise
or vibration occurs, have the
problem corrected before
further use.
Cleaning, Maintenance, and
Lubrication
BEFORE EACH USE,1. inspect the
general condition of the tool. Check
for loose screws, misalignment or
binding of moving parts, cracked or
broken parts, damaged electrical wir-
ing, and any other condition that may
affect its safe operation.
Periodically inspect the power cord2.
for cracks. Replace if necessary.
Clean the unit using a damp cloth.3.
Never use solvents.
Keep the4. Electrode Assembly (26)

steel wool.
5.

Metal
Surface
Roller
Back
Handle
Center Handle
FIGURE 4 - Slide Hammer