Chicago Electric Welding System 67102 User Manual

80w plastic welding kit  
with iron  
Model 67102  
set up and operating instructions  
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 2008 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 improve-  
ments, 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.  
Revised Manual 10j  
 
b.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.  
This enables better control of the  
power tool in unexpected situations.  
4. power tool use and care  
a.do not force tool. use the correct  
tool for your application. The  
correct tool will do the job better  
and safer at the rate for which it was  
designed.  
c.do not expose power tools to rain  
or wet conditions. Water entering  
a power tool will increase the risk of  
electric shock.  
b.disconnect the plug from the  
power source and/or the battery  
pack from the tool before making  
any adjustments, changing  
d.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.  
accessories, or storing power  
tools. Such preventive safety  
measures reduce the risk of starting  
the power tool accidentally.  
e.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.  
c.store idle tools out of the reach of  
children and do not allow persons  
unfamiliar with the tool or these  
instructions to operate the power  
tool. Welding tools are dangerous in  
the hands of untrained users.  
f. if operating 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.  
d.Maintain welding tools. check for  
misalignment or binding of moving  
parts, breakage of parts and any  
other condition that may affect  
the tools operation. if damaged,  
have the tool repaired before use.  
Many accidents are caused by poorly  
maintained tools.  
3. personal safety  
a.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.  
e.keep cutting tools sharp and  
clean. Properly maintained cutting  
tools with sharp cutting edges are  
less likely to bind and are easier to  
control.  
f. use the tool and accessories  
in accordance with these  
b.use safety equipment. Always  
wear ANSI-approved safety goggles,  
heavy-duty work gloves and face  
shield during use.  
instructions, taking into account  
the working conditions and the  
work to be performed. Use of the  
tool for operations different from  
c.do not overreach. keep proper  
footing and balance at all times.  
SKU 67102  
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Page 3  
 
those intended could result in a  
hazardous situation.  
11. This product is not a toy. Keep it out  
of reach of children.  
5. service  
12. This product is designed for use only  
for plastic welding. This product  
is designed to be used only to weld  
plastic items.  
a.have your tool serviced by a  
qualified repair person using only  
identical replacement parts. This  
will ensure that the safety of the tool  
is maintained.  
13. When working with plastics, varnish,  
or similar materials, gases develop  
that are easily flammable and can  
lead to explosions. Be prepared for  
flames to develop and keep suitable  
fire extinguishing means at hand.  
welding kit safety warnings  
1. Do not use this Plastic Welding Kit  
near flammable materials.  
14. Do not point Welder at people or  
animals. The intense heat can injure  
them.  
2. Handle hot tip with care. Do not  
touch any metal parts on the Welder  
until they have completely cooled.  
15. Maintain labels and nameplates on  
the tool. These carry important safety  
information. If unreadable or missing,  
contact Harbor Freight Tools for a  
replacement.  
3. Use in well-ventilated areas only.  
4. Do not place the Welder in a vise to  
change heating elements.  
5. Always use Wire Brush (5) to clean  
the tip on the Welder.  
16. 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.  
6. Avoid electrical shock. Do not use in  
a damp or wet environment.  
7. Never rest the Welder on a flamma-  
ble surface.  
8. Avoid unintentional starting. Prepare  
to begin work before plugging in tool.  
• Properly maintain and inspect to  
avoid electrical shock.  
9. Do not leave the tool unattended  
when it is plugged into an electrical  
outlet. Unplug it from its electrical  
outlet and allow it to cool before  
leaving.  
• Any power cord must be properly  
grounded. Ground Fault Circuit  
Interrupter (GFCI) should also be  
implemented – it prevents sustained  
electrical shock.  
10. 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.  
17. Some dust created by power  
sanding, sawing, grinding, drilling,  
and other construction activities,  
contains chemicals known [to the  
State of California] to cause cancer,  
birth defects or other reproductive  
SKU 67102  
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Page 4  
 
harm. Some examples of these  
chemicals are:  
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 plug  
provided with tool. never  
remove grounding prong from  
plug. do not use tool if power  
cord or plug is damaged. if  
damaged, have it repaired by  
a service facility before use. if  
plug will not fit outlet, have a  
proper outlet installed by a  
qualified electrician.  
• Lead from lead-based paints  
• Crystalline silica from bricks and  
cement or other masonry products  
• Arsenic and chromium from  
chemically treated lumber  
Your risk from these exposures  
varies, depending on how often you  
do this type of work. To reduce your  
exposure to these chemicals: work in  
a well ventilated area, and work with  
approved safety equipment, such as  
those dust masks that are specially  
designed to filter out microscopic  
particles. (California Health & Safety  
Code § 25249.5, et seq.)  
18. 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.  
grounded tools: tools with three  
prong plugs  
saVe these  
instructions.  
1. Tools marked with “Grounding  
Required” have a three wire cord and  
three prong grounding plug. Plug  
must be connected to a properly  
grounded outlet. If tool should  
electrically malfunction or break  
down, grounding provides a low  
resistance path to carry electricity  
away from user, reducing risk of  
electric shock. (see 3-prong plug  
and outlet.)  
SKU 67102  
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Page 5  
 
2. Grounding prong in plug is connected  
through green wire inside cord to  
grounding system in tool. Green wire  
in cord must be only wire connected  
to tool’s grounding system and must  
never be attached to “live” terminal.  
(see 3-prong plug and outlet.)  
A” (“W” in Canada) to indicate it is  
acceptable for outdoor use.  
6. Make sure extension cord is properly  
wired and in good electrical condition.  
Always replace damaged extension  
cord or have it repaired by a qualified  
electrician before using it.  
3. Tool must be plugged into appropriate  
outlet, properly installed and  
7. Protect extension cords from sharp  
objects, high heat, and wet areas.  
grounded in accordance with codes  
and ordinances. Plug and outlet  
should look like preceding illustration.  
(see 3-prong plug and outlet.)  
recoMMended MiniMuM wire  
gauge For eXtension cords*  
(120/240 Volt)  
eXtension cord  
naMeplate  
extension cords  
length  
aMperes  
(at full load)  
1. Grounded tools require a three wire  
extension cord. Double Insulated  
tools can use either a two or three  
wire extension cord.  
0 – 2.0  
2.1 – 3.4  
18  
18  
18  
18  
18  
14  
12  
18  
18  
18  
16  
14  
12  
10  
18  
18  
16  
14  
12  
10  
-
18  
16  
14  
12  
10  
-
16  
14  
12  
12  
-
3.5 – 5.0  
2. As distance from supply outlet  
increases, use a heavier gauge  
extension cord. Using extension  
cords with inadequately sized wire  
causes a drop in voltage, resulting  
in loss of power and possible tool  
damage. The smaller the gauge  
number of wire, the greater capacity  
of cord. For example, a 14 gauge  
cord can carry a higher current than a  
16 gauge cord. (see table a.)  
5.1 – 7.0  
7.1 – 12.0  
12.1 – 16.0  
16.1 – 20.0  
-
-
-
* Based on limiting the line  
voltage drop to five volts at  
150% of the rated amperes.  
taBle a  
symbology  
Double Insulated  
3. 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.)  
Canadian Standards Association  
Underwriters Laboratories, Inc.  
Volts Alternating Current  
Amperes  
V~  
a
4. If using extension cord for more than  
one tool, add nameplate amperes  
and use sum to determine required  
minimum cord size. (see table a.)  
No Load Revolutions per Minute  
(RPM)  
n xxxx/min.  
0
5. If using extension cord outdoors,  
make sure it is marked with “W-  
SKU 67102  
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Page 6  
 
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  
speciFications  
Electrical Requirements 120 V~ / 60 Hz  
Max. Temperature  
Power Cord  
525° F  
allow free movement while working.  
18-AWG x 2C  
3. Secure loose workpieces using a vise  
or clamps (not included) to prevent  
movement while working.  
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 1-800-444-  
3353 as soon as possible.  
4. There must not be hazardous  
objects, such as utility lines or foreign  
objects, nearby that will present a  
hazard while working.  
general operating instructions  
operating instructions  
1. note: It is recommended that you  
first practice this procedure on scrap  
material.  
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.  
2. Plug the Power Cord (6) of the tool  
into a 120 volt, grounded, electrical  
outlet.  
3. Allow Welder (1) to pre-heat for 5  
to 10 minutes before use. Prep the  
surface by sanding off excess paint,  
or, if necessary, grinding surface to  
add texture.  
tool set up  
to preVent  
serious injurY  
FroM accidental  
4. To connect sections of non-flexible  
plastic or to repair or fill-in cracks,  
apply the Welder’s tip to the end of  
a Repair Stick (2) and melt the Stick  
onto the work surface.  
operation: unplug the tool  
from its electrical outlet and  
allow it to cool before  
performing any inspection,  
maintenance, or cleaning  
procedures.  
5. Melt and spread the Repair Stick over  
cracked or damaged area. Use edge  
of welding tip to melt off any excess  
plastic.  
work piece 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.  
6. warning! Be careful to not melt  
base material area during use.  
7. Once the melted area cools (apply  
cold water to speed up cooling), sand  
2. Route the power cord along a safe  
path to reach the work area without  
REV10j  
SKU 67102  
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Page 7  
 
surface with 80-grit sandpaper (not  
included).  
Maintenance and  
serVicing  
8. To repair flexible plastic tabs or any  
plastic that requires elasticity, sand  
area with 25-40 grit sandpaper.  
Procedures not specifically  
explained in this manual  
must be performed only by a  
qualified technician.  
9. Cut an appropriate-sized piece of  
the Reinforcing Mesh (3). Once the  
Welder is heated, fit mesh piece into  
corner of tab. Applying the mesh will  
reinforce the plastic tab.  
to preVent  
serious injurY  
FroM accidental  
operation: unplug the tool  
from its electrical outlet and  
allow to cool before  
10. Lightly scuff melted mesh with sand-  
paper.  
performing any inspection,  
maintenance, or cleaning  
procedures.  
11. Melt appropriate-sized piece of Plas-  
tic Stick into Mesh and use Welder  
to spread plastic into cracks and  
damaged area. Doing so will help  
strengthen plastic.  
to preVent serious  
injurY FroM tool  
Failure: do not use  
12. To repair damaged plastic bolt hole  
or slot, use sandpaper to taper and  
smooth broken edges. Apply alumi-  
num tape (not included) to surround-  
ing surface if desired.  
damaged equipment. if  
abnormal noise or vibration  
occurs, have the problem  
corrected before further use.  
cleaning, Maintenance, and  
lubrication  
13. Melt Mesh into plastic gap, refill-  
ing edge around hole or slot. Apply  
melted plastic to Mesh and allow to  
cool.  
1. BeFore each use, inspect the  
general condition of the tool. Check  
for loose screws, cracked or broken  
parts, damaged electrical wiring, and  
any other condition that may affect its  
safe operation.  
14. Remove aluminum tape from hole  
and, if necessary, re-drill hole and  
smooth with 80-grit sandpaper.  
15. When welding is finished, unplug the  
Power Cord and set the Welder onto  
the Welder Stand (4) and allow to  
cool down.  
2. aFter use, clean external surfaces  
of the tool with clean cloth.  
3.  
warning! if the supply cord of  
this power tool is damaged, it must  
be replaced only by a qualified  
service technician.  
16. Once cool, clean off welding tip using  
the Wire Brush (5) and then store Kit  
indoors out of children’s reach.  
4. Always store Welding Kit in a clean,  
dry and safe location away from  
children.  
SKU 67102  
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Page 8  
 
parts list & diagraM  
part  
description  
Qty.  
1
20  
1
part  
description  
Qty.  
1
2
3
Welder  
4
5
6
Welder Stand  
1
1
1
Repair Sticks  
Reinforcing Mesh  
Wire Brush  
Power Cord  
6
1
2
3
4
5
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.  
record products 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.  
SKU 67102  
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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 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 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 67102  
For technical questions, please call 1-800-444-3353.  
Page 10  
 

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