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59646
PLASTIC WELDING KIT
WITH AIR MOTOR AND TEMPERATURE ADJUSTMENT
1600 WATT
Owner’s Manual & 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 Date Code 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. 25d
When unpacking, make sure that the product is intact
and undamaged. If any parts are missing or broken,
please call 1-800-444-3353 as soon as possible.
Copyright
©
2024 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.
read this material before using this product.
Failure to do so can result in serious injury.
SaVe tHiS ManuaL.
Page 2 For technical questions, please call 1-800-444-3353. 59646
SaFety OperatiOn MaintenanceSetup
table of contents
Safety ......................................................... 2
Specifications ............................................. 7
Setup .......................................................... 7
Operation .................................................... 8
Maintenance ............................................... 9
Parts List and Diagram .............................. 11
Warranty .................................................... 12
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.
Indicates a hazardous situation which, if not avoided,
will result in death or serious injury.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
Addresses practices not related to personal injury.
iMpOrtant SaFety inFOrMatiOn
General power tool Safety Warnings
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.
Cluttered or dark areas invite accidents.
2. Do not operate 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.
3. Keep children and bystanders
away while operating a power tool.
Distractions can cause you to lose control.
Page 3For technical questions, please call 1-800-444-3353.59646
SaFetyOperatiOnMaintenance Setup
electrical Safety
1. power tool plugs must match the outlet.
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
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
conditions. Water entering a power tool
will increase the risk of electric shock.
4. 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.
5. 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.
6. if operating a power tool in a damp location
is unavoidable, use a Ground Fault circuit
interrupter (GFci) protected supply.
Use of a GFCI reduces the risk of electric shock.
personal Safety
1. Stay alert, watch what you are doing
and use common sense when operating
a power tool. Do not use a power
tool while you are tired or under the
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.
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 power Switch is in the off-position
before connecting to power source, picking up
or carrying the tool.
Carrying power tools with your finger on the
Power Switch or energizing power tools that
have the Power Switch on invites accidents.
4. Do not overreach. Keep proper footing and
balance at all times. This enables better control
of the power tool in unexpected situations.
5. 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.
6. 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.
7. 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.
power tool use and care
1. Do not force the power tool. use the
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 power Switch
does not turn it on and off.
Any power tool that cannot be controlled with the
Power Switch is dangerous and must be repaired.
3. Disconnect the plug from the power source
before making any adjustments, changing
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.
5. 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.
6. Keep cutting tools sharp and clean. Properly
maintained cutting tools with sharp cutting edges
are less likely to bind and are easier to control.
7. use the power tool, accessories 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 different from those
intended could result in a hazardous situation.
Page 4 For technical questions, please call 1-800-444-3353. 59646
SaFety OperatiOn MaintenanceSetup
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. Do not use near flammable materials.
2. Do not touch barrel or tip when using. Do
not touch any metal parts on Welder
until they have completely cooled.
3. Do not place the Welder in a vise
to change heating elements.
4. Always use pliers to change the tip on the Welder.
5. Avoid electrical shock. Do not use in
a damp or wet environment.
6. Do not rest Welder on flammable surface.
7. This product is designed for use only for
plastic welding. This product is designed
to be used only to weld plastic items.
8. Maintain labels and nameplates on the tool.
These carry important safety information.
If unreadable or missing, contact
Harbor Freight Tools for a replacement.
9. Avoid unintentional starting.
Prepare to begin work before turning on the tool.
10. 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.
11. Use clamps (not included) or other practical ways
to secure and support the workpiece to a stable
platform. Holding the work by hand or against your
body is unstable and may lead to loss of control.
12. This product is not a toy.
Keep it out of reach of children.
13. For household use only.
14. 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:
• Avoid operating alone.
• Do not use with Power Switch locked on.
• Properly maintain and inspect to avoid
electrical shock.
• Properly ground power cord. Ground Fault Circuit
Interrupter (GFCI) should also be implemented
– it prevents sustained electrical shock.
15. 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.
SaVe tHeSe inStructiOnS.
Page 5For technical questions, please call 1-800-444-3353.59646
SaFetyOperatiOnMaintenance Setup
Grounding
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. 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 fit the outlet, have a proper outlet installed by
a qualified electrician.
Grounded tools: tools with three prong plugs
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.)
2. 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.)
3. The tool must be plugged into an 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
Outlets for 2-prong plug
1. 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.
2. 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 6 For technical questions, please call 1-800-444-3353. 59646
SaFety OperatiOn MaintenanceSetup
extension cords
1. Grounded tools require a three wire extension cord.
Double Insulated tools can use either
a two or three wire extension cord.
2. As the distance from the supply outlet increases,
you must use a heavier gauge extension cord.
Using extension cords with inadequately sized wire
causes a serious drop in voltage, resulting in loss of
power and possible tool damage. (See table a.)
3. The smaller the gauge number of the 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.)
4. When using more than one extension cord
to make up the total length, make sure
each cord contains at least the minimum
wire size required. (See table a.)
5. If you are using one extension cord for more
than one tool, add the nameplate amperes
and use the sum to determine the required
minimum cord size. (See table a.)
6. If you are using an extension cord outdoors, make
sure it is marked with the suffix “W-A” (“W” in
Canada) to indicate it is acceptable for outdoor use.
7. Make sure the extension cord is properly wired
and in good electrical condition. Always replace
a damaged extension cord or have it repaired
by a qualified electrician before using it.
8. Protect the extension cords from sharp objects,
excessive heat, and damp or wet areas.
taBLe a: 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 - - -
* Based on limiting the line voltage drop to five volts at
150% of the rated amperes.
Symbology
Double Insulated
V
Volts
~
Alternating Current
a
Amperes
n
0
xxxx/min.
No Load Revolutions per Minute (RPM)
WARNING marking concerning Risk
of Eye Injury. Wear ANSI-approved
safety goggles with side shields.
Read the manual before
set-up and/or use.
WARNING marking
concerning Risk of Fire.
Do not cover ventilation ducts.
Keep flammable objects away.
WARNING marking concerning
Risk of Electric Shock.
Properly connect power cord
to appropriate outlet.
Page 7For technical questions, please call 1-800-444-3353.59646
SaFetyOperatiOnMaintenance Setup
Specifications
Electrical Rating 120VAC / 60Hz / 1600W
Air Requirement 6.3 CFM
Temperature Range 120° to 1080°
Maximum Material
Thickness
1/2"
Nozzle Sizes
A. Bent Tip (1-1/2″ L)
B. Angle Tip (1-3/4″L)
C. Curved/Rounded Tip (2-1/8″ L)
D Speed Welding Tip
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
Barrel
a.
Bent tip
nozzle
cradle
power
Switch
Handle
c.
curved/
rounded
nozzle
B.
angle tip
nozzle
D.
Speed Welding
nozzle
Heating
element
temperature
control Knob
Page 8 For technical questions, please call 1-800-444-3353. 59646
SaFety OperatiOn MaintenanceSetup
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.
Set up
tO preVent SeriOuS inJury FrOM acciDentaL OperatiOn:
Make sure that the power Switch is in the off-position and unplug the tool from
its electrical outlet before performing any procedure in this section.
1. If workpieces require beveled edge,
cut edges to a 60° angle.
2. Clean workpieces with acetone (not included).
cautiOn! tO preVent inJury: Follow
acetone manufacturer’s instructions.
3. Thread Nozzle onto tool, tighten using
a wrench (sold separately).
nOte: When welding two plastic sheets together
at 90°, use Bent Nozzle for the tack weld first. Then
use Angled Nozzle or Curved Nozzle for the line weld.
Nozzle Type Heat Setting Output
Angled Nozzle 1 170°F
2 440°F
3 690°F
4 800°F
5 880°F
6 920°F
7 980°F
8 1030°F
9 1040°F
10 1080°F
Curved Nozzle 1 190°F
2 300°F
3 480°F
4 600°F
5 680°F
6 780°F
7 860°F
8 910°F
9 950°F
10 980°F
Bent Nozzle 1 170°F
2 200°F
3 490°F
4 730°F
5 780°F
6 800°F
7 860°F
8 900°F
9 910°F
10 920°F
Speed Welding Nozzle
Page 9For technical questions, please call 1-800-444-3353.59646
SaFetyOperatiOnMaintenance Setup
Workpiece and Work area Set up
1. Designate a work area that is clean and well lit.
The work area must not allow access by children
or pets to prevent distraction and injury.
2. Route the power cord along a safe route to reach
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.
3. Secure loose workpieces using a vise or clamps
(not included) to prevent movement while working.
4. There must not be objects, such as utility lines,
nearby that will present a hazard while working.
General Operating instructions
WarninG!: tO preVent SeriOuS
inJury FrOM BurnS: Inspect tool before
each use. Do not use if damaged.
WarninG!: The heat generated by the Plastic
Welding Kit can cause serious burns. Observe all
Safety Warnings and Precautions. Inspect the Plastic
Welder for signs of damage prior to each use.
1. Set the Temperature Control Knob to “0”.
Make sure the Power Switch is in the
off-position then plug the Power Cord into
a 120 volt, grounded, electrical outlet.
2. Turn on the Power Switch. Adjust the
Temperature Control Knob to reach the desired
temperature. Allow the Plastic Welder to warm
up for several minutes before starting to weld.
3. Allow air to run through the Nozzle to heat it up.
4. Carefully apply the Nozzle to the area to be joined.
5. 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.
6. 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.
7. When finished welding, set the Temperature Control
Knob to “0”. Rest the Plastic Welder on its Cradle
to keep the hot Nozzle from touching any surfaces.
8. IMPORTANT! Keep the air flowing for several
minutes to allow the Welder to cool.
9. To prevent accidents, turn off the tool and
unplug it after use. Clean, then store the
tool indoors out of children’s reach.
using Welding rods
nOte: Use the same type of welding
rod as the material being joined.
cautiOn! Never place a welding rod inside the Nozzle.
1. Material up to 1/2" thick can be welded. As
different types of plastic material will melt
at different temperatures, the Temperature
Control must be properly adjusted.
2. Hold the Welder with one hand. With the other
hand, hold the welding rod. Hold the welding
rod close to the Nozzle (1/4" to 3/8" away).
3. Proceed with welding operation.
4. When finished welding, set the Temperature Control
Knob to “0”. Rest the Plastic Welder on its Cradle
to keep the hot Nozzle from touching any surfaces.
5. IMPORTANT! Keep the air flowing for several
minutes to allow the Welder to cool.
6. To prevent accidents, turn off the tool and
unplug it after use. Clean, then store the
tool indoors out of children’s reach.
Maintenance and Servicing
procedures not specifically explained in this manual must
be performed only by a qualified technician.
tO preVent SeriOuS inJury FrOM acciDentaL OperatiOn:
Make sure that the power Switch 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.
Page 10 For technical questions, please call 1-800-444-3353. 59646
SaFety OperatiOn MaintenanceSetup
cleaning, Maintenance, and Lubrication
1. BeFOre eacH uSe, inspect the general
condition of the tool. Check for:
• loose hardware,
• misalignment or binding of moving parts,
• damaged cord/electrical wiring,
• cracked or broken parts, and
• any other condition that may
affect its safe operation.
2. aFter uSe, wipe external surfaces
of the tool with clean cloth.
3. Always store the tool in a clean, dry,
safe location out of reach of children
and other unauthorized people.
cautiOn! All maintenance, service, and repairs
not mentioned in this manual must only be
performed by a qualified service technician.
4. WarninG! tO preVent SeriOuS inJury:
if power cord is damaged, it must be replaced
only by a qualified service technician.
troubleshooting
problem possible causes Likely Solutions
Tool will not start. 1. Cord not connected.
2. No power at outlet.
3. Tool’s thermal reset breaker
tripped (if equipped).
4. Internal damage or wear.
(Carbon brushes or
Power Switch, for example.)
1. Check that cord is plugged in.
2. 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.
3. Turn off tool and allow to cool.
Press reset button on tool.
4. Have technician service tool.
Tool operates slowly. 1. Forcing tool to work too fast.
2. Extension cord too long or cord
diameter too small.
1. Allow tool to work at its own rate.
2. Eliminate use of extension cord. If an extension
cord is needed, use one with the proper diameter
for its length and load. See Extension Cords
in Grounding section on page 5.
Performance
decreases over time.
Carbon brushes worn or damaged. Have qualified technician replace brushes.
Excessive noise
or rattling.
Internal damage or wear. (Carbon
brushes or bearings, for example.)
Have technician service tool.
Overheating. 1. Forcing tool to work too fast.
2. Blocked motor housing vents.
3. Motor being strained by long or
small diameter extension cord.
1. Allow tool to work at its own rate.
2. Wear ANSI-approved safety goggles and
NIOSH-approved dust mask/respirator while
blowing dust out of motor using compressed air.
3. Eliminate use of extension cord. If an extension
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
penetrate joint.
1. Insufficient weld heat.
2. Incorrect fill material.
1. Increase potentiometer setting slightly.
2. Make sure that fill material is appropriate
for material being welded.
Plastic starts
to break down,
smoke, or burn.
Too much weld heat. Make sure to have adequate ventilation.
Decrease potentiometer setting slightly.
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.
Follow all safety precautions whenever diagnosing or servicing the tool.
Disconnect power supply before service.
Page 11For technical questions, please call 1-800-444-3353.59646
SaFetyOperatiOnMaintenance Setup
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 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
1 Power Cord 1
2 Power Cord Sheath 1
3 Mesh Sheet 1
4 Temperature Control Knob 1
5 Power Switch/Cover Assembly 1
6 Control Circuit Board 1
7 Motor Housing 2
8 Carbon Brush Cap 1
9 Carbon Brush holder 1
10 Carbon Brush 1
11 Motor Assembly 1
12 Rubber Ring 1
13 Cradle 1
part Description Qty
14 Fan Volute 1
15 Fan Cover 2
16 Fan Head Housing 1
17 Heat Protector 1
18 Insulation Washer 2
19 Temperature Sensor 1
20 Heating Element 2
21 Insulating Tube 1
22 Barrel 1
23 Bent Nozzle 1
24 Angled Nozzle 1
25 Speed Welding Nozzle 1
26 Curved Nozzle 1
assembly Diagram
record product’s Date code Here:
note: if product has no Date code, 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. Specify UPC 193175477682 when ordering parts.
26677 agoura road • calabasas, ca 91302 • 1-800-444-3353
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 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 rights which vary from state to state.
