Chicago Electric 42802 User's Manual
Contents
1. Have a pair of vinyl gloves for use when handling the power and sprayed objects Use ANSI approved safety glasses If using an extension cord it must have a ground prong Control Box 1 8 Setup a dedicated electric oven with adequate ventilation for curing the coated objects with a temperature capability from 300 to 500 F WARNING Never use a gas oven the fumes from curing can be explo sive Never use a home oven that is also used for food Contamina tion of food will occur 9 Clean the object to be powder coated of any old coatings rust grease and oil OPERATION 1 Place or hang the cleaned object to be coated near the ventilation sys tem If the object has grooves or recesses position the object so that gravity as sists the powder mist to fall into the grooves or recesses 2 Connect the Disposable Moisture Separator 8 to the Spray Gun 2 For technical questions please call 1 800 444 3353 Page 5 Cup 4 Scatter Tip 12 J Regulating Screw 14 Trigger 7 Pressure Reducer Valve 18 3 Unscrew the Cup 4 from the Spray Gun 2 and fill with up to two inches of coating powder not supplied Turn the Cup upside down and place on a clean piece of paper Put on a pair of disposal vinyl gloves Open the powder coating container and using a piece of clean paper as a guide pour the powder into the Cup Turn the Spray Gun upside down and screw the Cup2. d ae ee th RUNNING OFF POWDER COATING SYSTEM HIGH CONTROL onp VOLTAGE SWITCH ____ 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 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 BUYERASSUMES 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 SKU 42802 For technical questions please call 1 800 444 3353 Page 9 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 prod uct is free from defects in materials and workmanship for 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 o
3. back into the Spray Gun Reseal powder container Note Only use the provided cups with this system Other cups will not seal properly 4 Connect the 1 4 inch air hose to the Disposable Moisture Separator 8 5 Attach the Ground Clip 10 to the metal object being coated Securely attach the Ground Clip to an area which is not being coated if possible This connection is abso lutely necessary to draw the electri cally charged power particles to the metal object SKU 42802 For technical questions please call 1 800 444 3353 Power Indicator Light 15 N Running Indicator Light 16 Rese roun SA eu PFPA ee ee Clip 10 FA i tpe jag Connection Power Switch 17 Pedal Switch Connection 11 Spray Gun 2 Connection 6 Turn ON the Power Switch 17 of the Control Box 1 7 Turn ON the compressor and adjust the air pressure to between 20 and 40 PSI This can be done at the compressor if it has a pressure value or on the Spray Gun by adjusting the Pressure Reducer Valve 18 Press the Spray Gun Trigger 7 and Pedal Switch 11 at the same time and test the spray pattern on a piece of scrap metal The Trigger controls the air and pow der flow The Pedal Switch controls the electrical charge If the pattern is too small or too large change the Scatter Tip 12 Remember that the pointed end of the Scatter Tip faces toward the Spray Gun and screws on The spray
4. cured coating Page 7 MAINTENANCE Wear disposable vinyl gloves Unplug the Control Box line cord from the electrical outlet Discharge the Conducting Pole 9 to the Ground Clip 10 Disconnect the air hose from the Spray Gun Remove the Cup and pour any re maining powder back into it s original container WARNING Powder clouds mist are explosive Before cleaning remove any possible ignition source in the area 6 Using compressed air blow out the Cup and all other parts that have col lected powder Uncontaminated powder residue can be stored and reused Store powder and Powder Coating System in a box located in a clean and dry location PARTS LIST Qt SprayGun Sd CY Spray GunPpe 7 Air Outlet Pipe Ee Air Input Pipe A SC Ground Clip tC Pedal Switch _ _ _ _ 1 Scatter Tip 1 Emitter tC Regulating Screw 1 Power Indicator Light 1 Running Indicator Light 1 Power Switch _ _ _ 1 Cups Disposable Moisture Separator reorder item 42980 Item 6e 9 Conducting Pole TS Note Replacement cups provided for other powder coating systems such as SKU 93306 94646 or 94244 may not seal properly Only use the cups provided Note Some parts are listed and shown for illustration purposes only and are not avail able individually as replacement parts SKU 42802 For technical questions please call 1 800 444 3353 REV 09d Page 8 ASSEMBLY DRAWING 7
5. pattern can also be adjust ed using the Regulating Screw 14 loosen to expand the pattern tighten to reduce the pattern size 9 When coating keep the Spray Gun approximately eight inches from the metal object Point the Spray Gun toward the ob ject at different angles to guarantee that all areas are coated REV 09d Page 6 When completed the object should be completely coated with a dull Opaque coat of powder 10 When finished spraying remove your foot from the Pedal Switch 11 press the Control Box Power Switch 17 to the OFF position unplug the Control Box power cord from the electrical outlet WARNING The Spray Gun is still elec trically charged Discharge Con ducting Pole before touching or you could be shocked 11 Touch the Conducting Pole 9 to the Ground Clip 10 to discharge any residual electricity 12 Wipe the Scatter Tip off with a clean cloth 13 Place the activated charcoal respira tor over your face mouth and hose WARNING The fumes produced dur ing curing are hazardous to your health Do not breathe the fumes 14 With the oven preheated to the de sired temperature 300 to 500 de grees F place the object on the oven rack close the door and turn the ventilation system ON Typical curing time is 15 minutes Check the Powder Coating container for recommended curing time and temperature If the object is large curing may take more time The powe
6. 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 properly repaired or re placed by a qualified technician Do not use the tool if any switch does not turn On and Off properly 15 Guard against electric shock Prevent body contact with grounded surfaces such as pipes radiators ranges and refrigerator enclosures Never touch the object being coated with one hand while spraying with the other SKU 42802 16 20 For technical questions please call 1 800 444 3353 Replacement parts and acces sories 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 accesso ries are available from Harbor Freight Tools Do not operate tool if under the in fluence of alcohol or drugs Read warning labels on prescriptions to determine if your judgment or reflex es are impaired while taking drugs If there is any doubt do not operate the tool 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 requires use of an extensi
7. CHICAGO Electric POWDER COATING SYSTEM Kere i 42802 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 2000 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 Tools required for assembly and service may not be included For technical questions or replacement parts please call 1 800 444 3353 Manual Revised 09d SPECIFICATIONS 20 V 60 Hz 20 to 40 PSI dry air Power Consumption Air Suppl Air Inlet 1 4 inch NPT thread Power Cord 16 AWG Note Performance of this tool 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 safe ty warnings and precautions assembly instructions operating 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 manua
8. e electrically non conductive clothes and non skid footwear are recom mended when working Wear restric tive hair covering to contain long hair Use eye and ear protection Always wear ANSI approved impact safety goggles Wear a full face shield if you are producing metal filings or wood chips Wear an ANSI approved dust mask or respirator when working around metal wood and chemical dusts and mists Do not overreach Keep proper footing and balance at all times Do not reach over or across running machines REV 09d For technical questions please call 1 800 444 3353 Page 2 10 Maintain tools with care Keep tools sharp and clean for better and safer performance Follow instruc tions for lubricating and changing accessories Inspect tool cords peri odically and if damaged have them repaired by an authorized technician The handles must be kept clean dry and free from oil and grease at all times 11 Disconnect power Unplug trans former when not in use 12 Avoid unintentional starting Be sure the switch is in the Off position when not in use and before plugging in Do not carry any tool with your finger on the trigger whether it is plugged in or not 13 Stay alert Watch what you are do ing use common sense Do not oper ate any tool when you are tired 14 Check for damaged parts Before using any tool any part that ap pears damaged should be carefully checked to determine that it will oper ate
9. f 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 EXPRESS LY 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 com plaint must accompany the merchandise If our inspection verifies the defect we will ei ther 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 re paired 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 SKU 42802 For technical questions please call 1 800 444 3353 Page 10
10. l 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 machines or power tools in damp or wet locations Don t expose to rain Keep work area well lighted Do not use electrically powered tools in the presence of flammable gases or liquids SKU 42802 Keep children away Children must never be allowed in the work area Do not let them handle machines tools or extension cords 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 Do not force tool It will do the job better and more safely at the rate for which it was intended Do not use inappropriate attachments in an at tempt to exceed the tool capacity 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 Do not modify this tool and do not use this tool for a purpose for which it was not intended Dress properly Do not wear loose clothing or jewelry as they can be caught in moving parts Protectiv
11. on cord of 0 to 10 amps capability up to 50 feet with wire size rated at 18 AWG Longer exten sion 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 service and maintenance should be performed regularly by a qualified technician The warnings cautions and instruc tions discussed in this instruction manual cannot cover all possible con ditions 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 Page 3 product but must be supplied by the operator Additional Safety Warnings for the Powder Coating System 1 The powder dust is flammable when floating in the air Ventilate the area well Verify that there are no flames or ignition source nearby Control excess dust by cleaning up after each use Never vacuum up the dust using a non explosion proof vacuum cleaner Never cure coated object in a gas oven as the fumes recreated can be flammable only use an electric oven Never smoke while using the Pow der Coating System 2 Avoid electrical shock Never touch the emitter metal tip of the Spray Gun After use and turned OFF touch the emitter to the Ground Clip to discharge it Do not use the Spray Gun if you carry and use any electronic medical devices Never touch the me
12. r coating should melt to a smooth gloss finish all over the object Check the curing object often to prevent over curing which can cause roughness to the surface SKU 42802 15 D For technical questions please call 1 800 444 3353 When cured turn the oven OFF and open the oven door slightly to allow the object to cool gradually before removing When the object is cooled too rapidly a dull finish may result Process Tips To remove an orange peel effect after curing wet sand the object with 400 grit sandpaper dry and repeat the coating process Over powder coat ing can cause this effect Polish with traditional paint polishes Lightly buff with a loose wheel and white rouge compound to remove imperfections Thoroughly clean the Cup before changing powders Some powders are made from poly ester while others are made from polyurethane A mixture of both can cause pitting of the coated object Porous metal objects may need a thorough cleaning with a brush and pre painting cleaning solutions If the powder starts to buildup in one place blow off with light air pressure Moisture in the air will cause pow der buildup Replace the Disposable Moisture Separator 8 Poor disbursement can be caused by low air pressure Adjust the air pres sure or replace the Disposable Mois ture Separator The Cup should have at least one inch of powder during coating Use automotive paint remover to remove a
13. tal object during coating 3 Avoid powder contamination Protect your lungs by using an ap proved dust mask Never cure objects in an electric oven that is used for food also Ventilate the area well Wear an activated charcoal respi rator when oven curing the coated object SKU 42802 For technical questions please call 1 800 444 3353 Unpacking When unpacking check to make sure the following parts are included Refer to the Parts List and Assembly Drawing at the end of this manual Foot Switch In line Filters Ground Clip Cable Spray Gun Transformer two Powder Cups three Scatter Tips If any parts are missing or broken please call Harbor Freight Tools at the number on the cover of this manual as soon as possible Page 4 SKU 42802 MAIN COMPONENTS Scatter Tip ma Regulating Screw 14 Disposable Moisture Separator 8 Connect Air Hose PREPARATION Setup an air supply with an air pres sure regulator and moisture trap do not use an inline air oiler The air compressor must provide an air pres sure of 20 to 40 PSI Select a safe location for spraying and curing with adequate lighting active ventilation no flame or ignition source an area dry clean and covered free of flammable material Have an activated charcoal filter respirator availability for use when curing Have disposable dust masks avail able for use when powder spraying
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