Chicago Electric 3663 Welder User Manual
Contents
1. nd JF NO Tig hand clamp and set pressure ined to number O beter releasing button ANNEALING 1 Retighten the right hand clamp Push Me annealing button until Pe blade becomes can rec repeat Pus operation several tmes but reduce this redness each time uniti no longer visible 3 Remove welded blade and grind away Pa weld fash Verify that the saw blades align squarely front to back and that the two ends butt together with 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 Plug the unit in Press and hold the green Welding Button 4 until the weld cycle is complete If popping occurs 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 sure Knob 12 counterclockwise to zero Then release the Welding Button 4 See FIGURE 6 FIGURE 6 Pa pae do a De REV 04f 07k SKU 3663 For technical questions please call 1 800 444 3353 Page 6 Annealing the Weld Note The annealing process tempers and toughens the blade reducing brittleness Retighten the Right Hand Clamp 6 See Figure 7 2 Press and hold the red Annealing Button 11 until the blade becomes dark red Release the Annealing Button 112. 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 1 Keep work area clean Cluttered areas invite injuries 2 Observe work area conditions 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 flammable gases or liquids di Keep children away Children must never be allowed in the work area Do not let them handle machines tools or extension cords 4 Store idle equipment 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 5 Use the right tool for the job 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 6 Dress properly 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 hai
3. ELECTRIC EALE BANDSAW BLADE WELDER 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 SPECIFICATIONS Power Requirements 220 V 1 Phase 60 Hz GA Only use on a 20 amp circuit Welding Current 280 A Welding Blade Sizes 1 8 to 1 2 Maximum Jaw Movement 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
4. after a few seconds FIGURE 7 3 Repeat pressing and releasing pulsating action the An nealing Button 11 while reducing the annealing time several times until the redness is no longer visible 4 Let the saw blade cool for at least five minutes then unplug the plug and remove the blade from the Welder Di Use an 8 inch mill bastard file not included to file off the welding flash If the flash is too hard and will not easily file off repeat the annealing process 6 File all of the flashing from around the weld being careful 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 REV 04f SKU 3663 For technical questions please call 1 800 444 3353 Page 7 MAINTENANCE WARNING Unplug welder before performing any maintenance 1 When not in use cover and store the Welder in a clean dry location 2 Perio
5. are not available individually as replacement parts REV 04f 07k SKU 3663 For technical questions please call 1 800 444 3353 Page 9 PARTS LIST 6 im o e Lamp shied o o o o i Doe TT SKU 3663 For technical questions please call 1 800 444 3353 Elo Connection Piece REV 04f 08a Page 10 ASSEMBLY DRAWING REV 04f 08a Page 11 For technical questions please call 1 800 444 3353 SKU 3663 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 rectifier 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 n
6. d Clamp 6 See FIG URE 3 Place one end of the saw blade not included under the Left Electrode 13 See 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 FIGURE 4 FIGURE 5 5 ic i PERATION OF WE TER JPERATION OF WELDER WELDING 1 Bult biade A and locale joint in center between the lectrodes Ciamp blade ends 2 Set the Toledo ip wider the saw blade is the higher the ni a 3 Pre DP and hold until complete weld cycle has WOT Ai hand clamp and set pressere knob to m we releasing button ANNEAL nG 1 Relighien the right hand clamp 2 Push the annealing bulion until the blade becomes dark red h reduce tus redness each time until no longer visible 3 Remove welded biade and grind away the weld fash Tighten the Left Hand Clamp 14 See FIGURE 4 Repeat steps 4 and 5 on the Right Electrode 5 and Right Hand Clamp 6 with the other end of 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 blade 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 An on and hold anti complete epid cycle has taten place WELDING a afl dher and icala joint in center between the two electrodes Clam ER ia
7. dically open and use fine grit sandpaper to clean the carbon residue from the inside sur faces of the terminal clamps 3 Always unplug before servicing All internal maintenance should be performed by a qualified service technician Wiring Diagram REV 04f SKU 3663 For technical questions please call 1 800 444 3353 Page 8 FRONT PANEL PARTS LIST AND DIAGRAM Part Part Part Description 6 Righi Hand Ciamp Case A P nnealing Button Line Cord without plug 4 Welding Button Right Electrode Left Electrode 1 10 Lt 12 13 14 15 0 6 4 6 6 16 Ca 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 ORARISING OUT OF HIS OR HER INSTAL LATION OF REPLACEMENT PARTS THERETO Note Some parts are listed and shown for illustration purposes only and
8. gs If there is any doubt do not operate the Welder SKU 3663 For technical questions please call 1 800 444 3353 Page 3 17 18 19 20 Use proper size and type extension cord 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 fire 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 signified by WA on the jacket Maintenance For your safety maintenance should be performed regularly by a qualified tech nician This product when used for welding and similar applications produces chemicals known to the State of California to cause cancer and birth defects or other reproductive harm California Health amp Safety Code 25249 5 et seq The warnings cautions 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 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 bro
9. 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 power Unplug tool when not in use Avoid unintentional starting Be sure the buttons are not depressed when not in use and before plugging in Stay alert Watch what you are doing use common sense Do not operate any tool when you are tired Check for damaged parts 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 fixtures and any other condition that may affect proper operation Any part that is damaged should be prop erly repaired or replaced by a qualified technician Do not use the tool if any button does not turn On and Off properly Guard against electric shock Prevent body contact with grounded surfaces such as pipes radiators ranges and refrigerator enclosures Replacement parts and accessories 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 influence of alcohol or drugs Read warning labels if tak ing prescription medicine to determine if your judgement or reflexes are impaired while taking dru
10. ing bandsaw blades Saw blade preparation Wearing heavy duty leather gloves use a metal table shear not included to trim 1 4 off each end of the saw blade 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 file 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 fine emery cloth not included lightly clean both ends and flat surfaces near the ends of the saw blade Remove all burrs Completely clean off all dirt coatings and oil Welding I 2 Refer to FIGURES and the Assembly Drawing on page 9 Verify that the plug is not plugged into the power outlet FIGURE 3 FIGURE 2 OPER HON OF WEI ER crodes Camp Made ends Pressure Knob Sec to mi oi sen Unc MM sor Bo soy DAN x pe Ar 12 7 perda releasing button PRESSURE KNOB Left Hand Clamp 14 Right Hand Clamp 6 Turn the Pressure Knob 12 to zero See FIGURE 2 When the Pressure Knob 12 is turned to zero the Right Electrode 5 will separate from the Left Electrode 13 REV 04f SKU 3663 For technical questions please call 1 800 444 3353 Page 5 10 Lil 12 Loosen both of the clamp handles Left Hand Clamp 14 and Right Han
11. ken 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 fit 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 Welding Button Pressure Knob Left Electrode Right Electrode Power Cord Left Hand Clamp Right Hand Clamp Light Switch REV 04e 04f 07k SKU 3663 For technical questions please call 1 800 444 3353 Page 4 OPERATION This Bandsaw Blade Welder is used to weld saw blades between 1 8 and 1 2 inches in width Additional Warnings 1 2 di Note Make sure the Welding and Annealing Buttons are not depressed before plugging in the unit Never leave the welder unattended while running Always unplug before servicing All internal maintenance should be performed by an authorized service technician Sparks are generated while welding Situate the welder far away from any flammable materials Work in a well ventilated area This unit does not have a grinder attachment WARNING Handle blades with extreme care They flex and twist easily making them extremely dan gerous Always wear heavy duty leather gloves when handl
12. o 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 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 07k SKU 3663 For technical questions please call 1 800 444 3353 Page 12
13. r Always wear heavy duty leather gloves when handling bandsaw blades REV 07 SKU 3663 For technical questions please call 1 800 444 3353 Page 2 10 11 12 13 14 15 16 Welding Plasma Cutting Produces TOXIC FUMES and GASSES Inhalation Hazard 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 e Early onset of Parkinson s Disease e Heart Disease e Damage to the reproductive organs e Ulcers e Inflammation of the small intestine or stomach Kidney damage e 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 Use eye and ear protection Always wear ANSI approved impact safety goggles Wear a full face shield if you are producing metal filings Wear an ANSI approved dust mask or respirator when working around metal and chemical dusts and mists Do not overreach Keep proper footing and balance at all times Do not reach over or across running machines Maintain tools with care Keep tools clean for better and safer performance Follow instruc tions for lubricating and changing accessories Inspect tool cords periodically and
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