Harbor Freight Tools 1300 Watt Plastic Welding Kit with Air Motor and Temperature Adjustment Product manual
Contents
1. 2 2 ceeteeestegiegteeee deeds 7 Parts List and Diagram eeenee 11 SClUP eerie etn Ree 7 Warranty ccccccecceeeseeeeeeeeceeeeseeeeeteeeeseees 12 Operations eke eee 8 wn gt TI m j lt CHICAGO ca WELDING 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 A DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury AWARNING Indicates a hazardous situation which if not avoided could result in death or serious injury Indicates a hazardous situation which if not avoided ACAUTION could result in minor or moderate injury NOTICE CAUTION Addresses practices not related to personal injury IMPORTANT SAFETY INFORMATION General Power Tool Safety Warnings AWARNING Read all safety warnings and all 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 The term power tool in the warnings refers to your mains operated corded power tool Work Area Safety 1 Keep work area clean and well lit 3 Keep children and bystanders Cluttered or dark areas invite accidents away while operating a power tool Distractions can cause you to lose control 2 Do not opera2. BRUSH MAINTENANCE The carbon brushes may require maintenance when the motor performance of the tool decreases or stops working completely To maintain the brushes 1 BEFORE EACH USE inspect the general condition of the tool Check for loose hardware e misalignment or binding of moving parts sE a Remove the Carbon Brush Cover on damaged cord electrical wiring each side of the motor housing cracked or broken parts and b Remove the carbon brushes from the housing Keep track of which orientation the old carbon brushes were in to prevent needless wear if they will be reinstalled e any other condition that may affect its safe operation MAINTENANCE c If either carbon brush is worn down by more than 1 2 replace them both Item 96712 For technical questions please call 1 888 866 5797 Page 9 d To clean old carbon brushes before reusing 3 AFTER USE wipe external surfaces them rub the contact areas with a pencil eraser of the tool with clean cloth e Reinsert the old carbon brushes in the 4 Always store the tool in a clean dry same orientation to reduce wear safe location out of reach of children f When installing make sure the carbon portions and other unauthorized people of the brushes contact the motor armature and that the springs face away from the motor Also make sure the springs operate freely CAUTION All maintenance service and repairs not mentioned in this manual must only be
3. a hazard while working the work area without creating a tripping hazard or exposing the power cord to possible damage The power cord must reach the work area with enough extra length to allow free movement while working Page 8 For technical questions please call 1 888 866 5797 Item 96712 General Operating Instructions 1 Make sure that the Trigger is in the off position then plug in the tool NOTE Practice the welding procedure on scrap material before the work peice NOTE Rods or strips are not necessary for tack welding 2 Make sure the Nozzle is installed Allow air to run through the Nozzle to heat it up 3 While waiting for the Nozzle to heat up position the workpiece to be welded 4 Carefully apply the heated Nozzle to the area or seams of plastic to be joined Welding with Welding Rods With small pieces weld them just enough to hold the pieces together If the pieces are large you may need to weld along the entire seam or connection point Avoid overheating tack points as doing so will cause the plastic to warp burn or discolor Grind the tack points down to take off the edges When finished welding set the Potentiometer to 0 Rest the Plastic Welder on its Cradle to keep the hot Nozzle 1 21 22 from touching any surfaces Keep air flowing for five minutes after disconnecting the electricity To prevent accidents turn off the tool and unplug it after use Clean then store the tool
4. debris If any oil substance remains on the material use Methyl Ethyl Ketone 9 MEK not included to clean the material 7 l NOTE Make sure to read and understand all instructions and precautions as P outlined by the MEK manufacturer Bunce Nase 3 The heat generated by the Plastic Welding Kit can cause serious burns Observe all Safety P 2o Warnings and Precautions Inspect the Plastic Welder for signs of damage prior to each use 4 Screw on the correct welding Nozzle 7 NOTE When welding two plastic sheets together S at 90 use Nozzle 1 for the tack weld first Then use Nozzle 21 or 22 for the line weld BANGA oa Tor 5 Set the Potentiometer 20 at 0 Then ar ae Ee plug the Power Cord 19 into a 120 volt grounded electrical outlet 6 Turn on the Power Switch 14 Adjust the S j z Potentiometer 20 to reach the desired temperature see Figure A Allow the Plastic Welder to warm up for several minutes before starting to weld Output temperature readings taken at 90 surrounding temperature Figure A Workpiece and Work Area Set Up 1 Designate a work area that is clean and well lit 3 Secure loose workpieces using a vise or clamps The work area must not allow access by children not included to prevent movement while working or pets to prevent distraction and injury 4 There must not be objects such as utility lines 2 Route the power cord along a safe route to reach nearby that will present
5. performed by a qualified service technician 5 Awarninc If the supply cord of this power tool is damaged it must be replaced Note New carbon brushes tend to only by a qualified service technician spark when first used until they wear and conform to the motor s armature g Replace the Carbon Brush Covers Do not overtighten Troubleshooting Possible Causes Likely Solutions Tool will not start 1 Cord not connected Check that cord is plugged in 2 No power at outlet Check power at outlet If outlet is unpowered turn off tool and check circuit breaker If breaker is tripped make sure circuit is right capacity for tool and circuit has no other loads Tool s thermal reset breaker Turn off tool and allow to cool tripped if equipped Press reset button on tool Internal damage or wear Have technician service tool Carbon brushes or Trigger for example Tool operates slowly 1 Forcing tool to work too fast Allow tool to work at its own rate Extension cord too long or cord Eliminate use of extension cord If an extension diameter too small cord is needed use one with the proper diameter for its length and load See Extension Cords in Grounding section on page 5 Performance Carbon brushes worn or damaged Have qualified technician replace brushes decreases over time Excessive noise Internal damage or wear Carbon Have technician service tool or rattling brushes or bearings for ex
6. CTIONS For technical questions please call 1 888 866 5797 Item 96712 AWARNING 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 Do not modify the power cord plug provided with the tool grounding prong from the plug Do not use the tool if the power cord or plug is damaged it repaired by a service facility before use a qualified electrician Grounded Tools Tools with Three eee ee wiih Three Prong Muas _ Plugs EOR 3 Prong Plug and Outlet 1 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 If the plug will not fit the outlet have a proper outlet installed by Never remove the If damaged have SAFETY 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 attached to an electrically live terminal See 3 Prong Plug and Outlet The tool must be plugged into an appropriate outlet properly in
7. MANUFACTURER OR 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 Parts List Part Description Qty 6 Circuit Board Cover __ 1 e Fan o o Tr el 9 Control CircuitBoard 1 10 Fan Cover _ _ 1 11 Seal Rubber Ring 1 Assembly Diagram Part Description Qty Ma miy L MAINTENANCE 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 Item 96712 For technical questions please call 1 888 866 5797 Page 11 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
8. Owner s Manual amp 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 CHICAGOS eierne WELDING 1300 WAIT PLASTIC WELDING KIT with AIR MOTOR ano TEMPERATURE ADJUSTMENT Visit our website at http www harborfreight com Email our technical support at productsupport harborfreight com ITEM 96712 REV 14h When unpacking make sure that the product is intact and undamaged If any parts are missing or broken AWARNING please call 1 888 866 5797 as soon as possible Copyright 2007 by Harbor Freight Tools All rights reserved A No portion of this manual or any artwork contained herein may be reproduced in Read this material before using this product any shape or form without the express written consent of Harbor Freight Tools Failure to do so can result in serious injury Diagrams within this manual may not be drawn proportionally Due to continuing SAVE THIS MANUAL improvements actual product may differ slightly from the product described herein Tools required for assembly and service may not be included Table of Contents Safely e ea AA 2 Maintenance ciennes 9 SPeCifiCatiOnS
9. ample Overheating 1 Forcing tool to work too fast 1 Allow tool to work at its own rate 2 Blocked motor housing vents 2 Wear ANSI approved safety goggles and NIOSH approved dust mask respirator while blowing dust out of motor using compressed air Motor being strained by long or Eliminate use of extension cord If an extension small diameter extension cord cord is needed use one with the proper diameter for its length and load See Extension Cords in Grounding section on page 5 Weld does not Insufficient weld heat Increase potentiometer setting slightly penetrate joint 2 Incorrect fill material 2 Make sure that fill material is appropriate for material being welded Plastic starts Too much weld heat Make sure to have adequate ventilation to break down Decrease potentiometer setting slightly smoke or burn Unsatisfactory weld Potentiometer not properly adjusted Refer to the plastic material manufacturer s manual to determine the proper heat required Then set the Potentiometer to the proper heat setting AONVNALNIVIN Follow all safety precautions whenever diagnosing or servicing the tool Disconnect power supply before service Page 10 For technical questions please call 1 888 866 5797 Item 96712 Parts List and Diagram PLEASE READ THE FOLLOWING CAREFULLY THE MANUFACTURER AND OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY NEITHER THE
10. d to appropriate outlet Page 6 For technical questions please call 1 888 866 5797 Item 96712 Specifications 120VAC 60Hz 1300W 6 3 CFM 105 to 850 A Angle Tip 1 3 4 L B Curved Rounded Tip 2 1 8 L C Bent Tip 1 1 2 L Setup Before Use 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 11 Functions SETUP Cradle On Off Switch Handle Nozzle A Nozzle C Nozzle A CHICAGOS an WELDING Item 96712 For technical questions please call 1 888 866 5797 Page 7 e m S e zZ 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 AWARNING TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION Make sure that the Trigger is in the off position and unplug the tool from its electrical outlet before performing any procedure in this section 1 Determine if the finished product you are welding is in need of a beveled edge If so 2 use a grinder or table saw not included See to bevel any edges to a 60 angle H 2 All materials to be welded must be cleaned of any dirt dust or
11. d or against your body is unstable and may lead to loss of control 12 13 16 This product is not a toy Keep it out of reach of children 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 In addition people with pacemakers should e Avoid operating alone e Do not use with Trigger locked on e Properly maintain and inspect to avoid electrical shock e Properly ground power cord Ground Fault Circuit Interrupter GFCI should also be implemented it prevents sustained electrical shock WARNING The cord of this product contains lead a chemical known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling California Health amp Safety Code 25249 5 et seq WARNING The brass components of this product contain lead a chemical 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 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 A SAVE THESE INSTRU
12. indoors out of children s reach NOTE When welding with welding rods use the correct welding rod for the material being welded If welding vinyl use a vinyl welding rod If welding PVC use a PVC welding rod CAUTION Never place a welding rod inside the Nozzle 1 21 22 1 Material up to 1 2 thick can be welded As different types of plastic material will melt at different temperatures the Potentiometer must be properly adjusted Hold the Welder with one hand With the other hand hold the welding rod Hold the welding rod close to the Nozzle about 1 4 to 3 8 away You are now ready to begin the welding operation When finished welding set the Potentiometer to 0 Rest the Plastic Welder on its Cradle to keep the hot Nozzle from touching any surfaces IMPORTANT Keep the air flowing for several minutes to allow the Welder to cool Then close the air supply Maintenance and Servicing Procedures not specifically explained in this manual must be performed only by a qualified technician AWARNING TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION Make sure that the Trigger is in the off position and unplug the tool from its electrical outlet before performing any procedure in this section 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 2 CARBON
13. ng in loss of lt power and possible tool damage See Table A TABLE A RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS 120 240 VOLT 3 The smaller the gauge number of the wire the NAMEPLATE EXTENSION CORD greater the capacity of the cord For example AMPERES LENGTH a 14 gauge cord can carry a higher current than a 16 gauge cord See Table A at full load 25 50 75 100 150 4 When using more than one extension cord to make up the total length make sure 2 1 3 4 each cord S S n eo 3 5 5 0 5 If you are using one extension cord for more 7 1 12 0 18 14 12 10 than one tool add the nameplate amperes 12 1 16 0 14 12 10 and use the sum to determine the required minimum cord size See Table A 16 1 20 0 Bee ee ee ea Based on limiting the line voltage drop to five volts at 6 If you are using an extension cord outdoors make 150 of the rated amperes sure it is marked with the suffix W A W in Canada to indicate it is acceptable for outdoor use Symbology o Double Insulated No Load Revolutions per Minute RPM bow WARNING marking concerning Risk e Canadian Standards Association of Eye Injury Wear ANSI approved safety goggles with side shields Underwriters Laboratories Inc Read theman al Beles set up and or use WARNING marking concerning Risk of Fire Keep flammable objects away Risk of Electric Shock Properly connect power cor
14. ool Carrying power tools with your finger on the Trigger or energizing power tools that have the Trigger on invites accidents Power Tool Use and Care 1 Do not force the power tool Use the 5 correct power tool for your application The correct power tool will do the job better and safer at the rate for which it was designed 2 Do not use the power tool if the Trigger does not turn it on and off Any power tool that cannot be controlled with the 6 Trigger is dangerous and must be repaired 3 Disconnect the plug from the power source before making any adjustments changing 7 accessories or storing power tools Such preventive safety measures reduce the risk of starting the power tool accidentally 4 Store idle power tools out of the reach of children and do not allow persons unfamiliar with the power tool or these instructions to operate the power tool Power tools are dangerous in the hands of untrained users Item 96712 For technical questions please call 1 888 866 5797 Do not abuse the cord Never use 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 outdoors use an extension cord suitable for outdoor use Use of a cord suitable for outdoor use reduces the risk of electric shock SAFETY If operating a power tool in a damp location is
15. stalled 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 Double Insulated Tools Tools with Two Prong Plugs Plugs Outlets for 2 Prong Plug Item 96712 For technical questions please call 1 888 866 5797 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 Double insulated tools may be used in either of the 120 volt outlets shown in the preceding illustration See Outlets for 2 Prong Plug Page 5 Extension Cords 1 Grounded tools require a three wire extension cord 7 Make sure the extension cord is properly wired Double Insulated tools can use either and in good electrical condition Always replace a two or three wire extension cord a damaged extension cord or have it repaired by a qualified electrician before using it JPE 2 As the distance from the supply outlet increases gt you must use a heavier gauge extension cord 8 Protect the extension cords from sharp objects aL Using extension cords with inadequately sized wire excessive heat and damp or wet areas j causes a serious drop in voltage resulti
16. te power tools in explosive atmospheres such as in the presence of flammable liquids gases or dust Power tools create sparks which may ignite the dust or fumes Page 2 For technical questions please call 1 888 866 5797 Item 96712 Electrical Safety 1 Power tool plugs must match the outlet 4 Never modify the plug in any way Do not use any adapter plugs with grounded power tools Unmodified plugs and matching outlets will reduce risk of electric shock 2 Avoid body contact with grounded surfaces 5 such as pipes radiators ranges and refrigerators There is an increased risk of electric shock if your body is grounded 3 Do not expose power tools to rain or wet 6 conditions Water entering a power tool will increase the risk of electric shock Personal Safety 1 Stay alert watch what you are doing 4 and use common sense when operating a power tool Do not use a power tool while you are tired or under the 5 influence of drugs alcohol or medication A moment of inattention while operating power tools may result in serious personal injury 2 Use personal protective equipment 6 Always wear eye protection Protective equipment such as dust mask non skid safety shoes hard hat or hearing protection used for appropriate conditions will reduce personal injuries 3 Prevent unintentional starting Ensure the Trigger is in the off position before connecting to power source picking up or carrying the t
17. 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 righ
18. ts which vary from state to state CHICAGOS aca WELDING 3491 Mission Oaks Blvd PO Box 6009 Camarillo CA 93011 1 888 866 5797
19. unavoidable use a Ground Fault Circuit Interrupter GFCI protected supply Use of a GFCI reduces the risk of electric shock Do not overreach Keep proper footing and balance at all times This enables better control of the power tool in unexpected situations Dress properly Do not wear loose 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 If devices are provided for the connection of dust extraction and collection facilities ensure these are connected and properly used Use of dust collection can reduce dust related hazards Only use safety equipment that has been approved by an appropriate standards agency Unapproved safety equipment may not provide adequate protection Eye protection must be ANSI approved and breathing protection must be NIOSH approved for the specific hazards in the work area Maintain power tools Check for misalignment or binding of moving parts breakage of parts and any other condition that may affect the power tool s operation If damaged have the power tool repaired before use Many accidents are caused by poorly maintained power tools Keep cutting tools sharp and clean Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control Use the power tool accessories and tool bits etc in accordance with these instructions taking into account the
20. working conditions and the work to be performed Use of the power tool for operations different from those intended could result in a hazardous situation Page 3 wn gt mn m j lt Service Have your power tool serviced by a qualified repair person using only identical replacement parts This will ensure that the safety of the power tool is maintained Welder Safety Warnings 1 2 Page 4 Do not use near flammable materials Do not touch barrel or tip when using Do not touch any metal parts on Welder until they have completely cooled Do not place the Welder in a vise to change heating elements Always use pliers to change the tip on the Welder Avoid electrical shock Do not use in a damp or wet environment Never rest Welder on flammable surface This product is designed for use only for plastic welding This product is designed to be used only to weld plastic items Maintain labels and nameplates on the tool These carry important safety information If unreadable or missing contact Harbor Freight Tools for a replacement Avoid unintentional starting Prepare to begin work before turning on the tool Do not leave the tool unattended when it is plugged into an electrical outlet Turn off the tool and unplug it from its electrical outlet before leaving Use clamps not included or other practical ways to secure and support the workpiece to a stable platform Holding the work by han
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