Chicago Electric 60662 User manual

Page 2SKU 60662 For technical questions, please call 1-800-444-3353.
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.
IMPORTANT SAFETY
INFORMATION
In this manual, on the labeling,
and all other information
provided with this product:
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.
DANGER indicates
a hazardous
situation which, if not
avoided, will result in death or
serious injury.
WARNING
indicates a
hazardous situation which, if
not avoided, could result in
death or serious injury.
CAUTION, used
with the safety
alert symbol, indicates a
hazardous situation which, if
not avoided, could result in
minor or moderate injury.
NOTICE is used to
address practices
not related to personal injury.
CAUTION, without
the safety alert
symbol, is used to address
practices not related to
personal injury.
General Power Tool Safety
Warnings
WARNING Read all safety
warnings and instructions.
Failure to follow the warnings and
instructions may result in electric
shock, re 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.
1. Work area safety
a.Keep work area clean and well
lit. Cluttered or dark areas invite
accidents.
b.Do not operate power tools in
explosive atmospheres, such as in
the presence of ammable liquids,
gases or dust.
c. Keep children and bystanders
away while operating a power tool.
Distractions can cause you to lose
control.
2. Electrical safety
a.Power tool plugs must match the
outlet. Never modify the plug in
any way. Do not use any adapter
plugs with grounded power tools.
Unmodied plugs and matching
outlets will reduce risk of electric
shock.

Page 3SKU 60662 For technical questions, please call 1-800-444-3353.
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.
c. Do not expose power tools to rain
or wet conditions. Water entering
a power tool will increase the risk of
electric shock.
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.
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.
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.
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 inuence of
drugs, alcohol or medication. A
moment of inattention while operating
power tools may result in serious
personal injury.
b.Use safety equipment. Always
wear ANSI-approved safety goggles,
heavy-duty work gloves and face
shield during use.
c. Do not overreach. Keep proper
footing and balance at all times.
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.
b.Disconnect the plug from the
power source and/or the battery
pack from the tool before making
any adjustments, changing
accessories, or storing power
tools. Such preventive safety
measures reduce the risk of starting
the power tool accidentally.
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.
d.Maintain welding tools. Check for
misalignment or binding of moving
parts, breakage of parts and any
other condition that may affect
the tool’s operation. If damaged,
have the tool repaired before use.
Many accidents are caused by poorly
maintained tools.
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
instructions, taking into account
the working conditions and the
work to be performed. Use of the
tool for operations different from
those intended could result in a
hazardous situation.

Page 4SKU 60662 For technical questions, please call 1-800-444-3353.
5. Service
a.Have your tool serviced by a
qualied repair person using only
identical replacement parts. This
will ensure that the safety of the tool
is maintained.
Welding Kit Safety Warnings
1. Do not use this Plastic Welding Kit
near ammable materials.
2. Handle hot tip with care. Do not
touch any metal parts on the Welder
until they have completely cooled.
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.
6. Avoid electrical shock. Do not use in
a damp or wet environment.
7. Never rest the Welder on a amma-
ble surface.
8. Avoid unintentional starting. Prepare
to begin work before plugging in tool.
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.
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.
11. This product is not a toy. Keep it out
of reach of children.
12. This product is designed for use only
for plastic welding. This product
is designed to be used only to weld
plastic items.
13. When working with plastics, varnish,
or similar materials, gases develop
that are easily ammable and can
lead to explosions. Be prepared for
ames to develop and keep suitable
re extinguishing means at hand.
14. Do not point Welder at people or
animals. The intense heat can injure
them.
15. Maintain labels and nameplates on
the tool. These carry important safety
information. If unreadable or missing,
contact Harbor Freight Tools for a
replacement.
16. People with pacemakers should
consult their physician(s) before
use. Electromagnetic elds in close
proximity to heart pacemaker could
cause pacemaker interference or
pacemaker failure. In addition,
people with pacemakers should:
• Avoid operating alone.
• Properly maintain and inspect to
avoid electrical shock.
• Any power cord must be properly
grounded. Ground Fault Circuit
Interrupter (GFCI) should also be
implemented – it prevents sustained
electrical shock.
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
harm. Some examples of these
chemicals are:
• Lead from lead-based paints
• Crystalline silica from bricks and
cement or other masonry products
• Arsenic and chromium from
chemically treated lumber

Page 5SKU 60662 For technical questions, please call 1-800-444-3353.
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 lter 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.
SAVE THESE
INSTRUCTIONS.
GROUNDING
TO PREVENT
ELECTRIC SHOCK
AND DEATH FROM
INCORRECT GROUNDING
WIRE CONNECTION: Check
with a qualied 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 t
outlet, have a proper outlet
installed by a qualied
electrician.
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 satises OSHA requirements
and complies with the applicable
standards of Underwriters Labora-
tories, Inc., the Canadian Standard
Association, and the National Electri-
cal 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”.)
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 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.)

Page 6SKU 60662 For technical questions, please call 1-800-444-3353.
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.)
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.)
5. If using extension cord outdoors,
make sure it is marked with “W-
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 qualied
electrician before using it.
7. Protect extension cords from sharp
objects, high heat, and wet areas.
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 - - -
TABLE A
* Based on limiting the line
voltage drop to ve volts at
150% of the rated amperes.
Symbology
Double Insulated
Symbology
Canadian Standards Association
Underwriters Laboratories, Inc.
V~ Volts Alternating Current
AAmperes
n0xxxx/min. No Load Revolutions per Minute
(RPM)

Page 7SKU 60662 For technical questions, please call 1-800-444-3353.
SPECIFICATIONS
Electrical Requirements 120 V~ / 60 Hz
Max. Temperature 525° F
Power Cord 18-AWG x 2C
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.
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
TO PREVENT
SERIOUS INJURY
FROM ACCIDENTAL
OPERATION: Unplug the tool
from its electrical outlet and
allow it to cool before
performing any inspection,
maintenance, or cleaning
procedures.
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.
2. Route the power cord along a safe
path 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 hazardous
objects, such as utility lines or foreign
objects, nearby that will present a
hazard while working.
General Operating Instructions
1. Note: It is recommended that you
rst practice this procedure on scrap
material.
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.
4. To connect sections of non-exible
plastic or to repair or ll-in cracks,
apply the Welder’s tip to the end of
a Repair Stick (2) and melt the Stick
onto the work surface.
5. Melt and spread the Repair Stick over
cracked or damaged area. Use edge
of welding tip to melt off any excess
plastic.
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
surface with 80-grit sandpaper (not
included).

Page 8SKU 60662 For technical questions, please call 1-800-444-3353.
8. To repair exible plastic tabs or any
plastic that requires elasticity, sand
area with 25-40 grit sandpaper.
9. Cut an appropriate-sized piece of
the Reinforcing Mesh (3). Once the
Welder is heated, t mesh piece into
corner of tab. Applying the mesh will
reinforce the plastic tab.
10. Lightly scuff melted mesh with sand-
paper.
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.
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.
13. Melt Mesh into plastic gap, rell-
ing edge around hole or slot. Apply
melted plastic to Mesh and allow to
cool.
14. Remove aluminum tape from hole
and, if necessary, re-drill hole and
smooth with 80-grit sandpaper.
15. When welding is nished, unplug the
Power Cord and set the Welder onto
the Welder Stand (4) and allow to
cool down.
16. Once cool, clean off welding tip using
the Wire Brush (5) and then store Kit
indoors out of children’s reach.
MAINTENANCE AND
SERVICING
Procedures not specically
explained in this manual
must be performed only by a
qualied technician.
TO PREVENT
SERIOUS INJURY
FROM ACCIDENTAL
OPERATION: Unplug the tool
from its electrical outlet and
allow to cool before
performing any inspection,
maintenance, or cleaning
procedures.
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
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.
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 qualied
service technician.
4. Always store Welding Kit in a clean,
dry and safe location away from
children.

Page 9SKU 60662 For technical questions, please call 1-800-444-3353.
Part Description Qty.
1 Welder 1
2Repair Sticks 20
3Reinforcing Mesh 1
Part Description Qty.
4 Welder Stand 1
5 Wire Brush 1
6 Power Cord 1
PARTS LIST & DIAGRAM
16
3
4
5
2

Page 10SKU 60662 For technical questions, please call 1-800-444-3353.
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 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.