Chicago Electric 3663 Installationshandbuch

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.

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.

Page 4SKU 3663 For technical questions, please call 1-800-444-3353.

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

Page 6SKU 3663 For technical questions, please call 1-800-444-3353.

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

Page 7SKU 3663 For technical questions, please call 1-800-444-3353.

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

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