KS Tools 150.1010 User manual

BEDIENUNGSANLEITUNG - OPERATING INSTRUCTIONS - NOTICE D‘UTILISATION
KS TOOLS Werkzeuge-Maschinen GmbH ●Seligenstädter Grund 10 - 12 ●D - 63150 Heusenstamm ●e-mail: [e-mail] ●www.kstools.com
KS TOOLS PDA Région de Brumath ●1 rue de Londres ●F - 67670 Mommenheim ●e-mail: [email protected] ●www.kstools.fr
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DE/MLA/HBA/07-08-2019
150.1010
Akku-Kunststoffreparatur-Satz, 134-tlg.
Battery-operated plastic repair set, 134 pcs
Kit de réparation plastique de batterie, 134 pièces

Introduction
Dear customer!
Thank you for buying one of our products. You can find all the information you need in these
operating instructions.
Please read the instructions completely with care and observe the advice given. The operating
instruction is part of the item and should be kept intact. The manufacturer is not liable for personal
injuries and material damages which result from improper use.
1. Provisions for use
Due to the high costs associated with the replacement of plastic panels (bumpers, inner wings,
headlamp bodies, engine covers, motorcycle bodywork, etc), this kit was developed to repair small
to medium sized damage that could render a panel unusable.
Thin plastic parts can be welded due to applied heat being contained in a small area. This plastic
welding tool is particularly convenient and versatile as it is cordless and powered by a lithium-ion
battery (2400mAh) which is rechargeable via a convenient USB port on a PC, laptop, power bank
or USB adaptor.
The kit is supplied with three attachments for the plastic welding tool: a standard plastic welding tip,
a hot staple attachment and a plastic welding tip fitted with a filler rod feeding tube. An LED torch
function is also included which also indicates that the welding tool heat control is switched ON.
The kit also comes with a range of consumables which makes it instantly ready for use: three sheets
of stainless steel wire mesh (50mm x 100mm); plastic welding filler rods (3 rods in each pack)
suitable for PE (polyethylene), ABS (acrylonitrile butadiene styrene), PP (polypropylene) and PS
(polystyrene) plastics; plus two sizes of alloy steel staples, 50 x 0.6mm and 50 x 0.8mm.
The manufacturer shall not be held liable for personal and/or material damage which can be traced
back to unintended use of the tool.
!
Pay heed to the vehicle manufacturer‘s specifications!
2. Technical data
Internal battery: Lithium-ion 2400mAh
Charging source: USB port 5V
Charging time: 3.5 hours
Running time on one charge: 35 minutes of use (plastic welding)
150-200 staples (hot stapling)
Internal charging board protects against overcharging, short circuit and electrostatic discharge.
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Note
Only use the staples provided with the kit. They are manufactured from a highly conductive grade
of none corroding alloy steel that heats up very quickly. When buying replacement staples only
purchase the part numbers listed below. Use of a different grade of stainless steel staple may cause
the instrument to overheat. Therefore, use of a different grade of stainless steel staple will invalidate
the warranty.
3. Components
Replacement welding filler rods, staples and reinforcing mesh are available under the following part
numbers:
Welding rods
ABS: 960.1125
PS: 960.1124
PE: 960.1122
PP: 960.1123
Staples
Flat staple 0.6mm (pack of 50): 150.1062
Flat staple 0.8mm (pack of 50): 150.1063
Stainless Steel reinforcing mesh 960.1121
LITHIUM
i0N PAT.
Material: PE
Material: PS
Material: ABS
Material: PP
ABD C
GE
P
H
I
M
L
K
J
N
O
Q
F
Fig 1
R
ST
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ABattery-operated soldering iron
BON / OFF switch
CHeat Control / LED torch button
DProtective cap for battery-operated soldering iron
EUSB input port
FCharging light
GWelding iron attachment for battery-operated soldering iron
HClamping attachment for battery-operated soldering iron
IWelding iron attachment with guide for battery-operated soldering iron
JPE (Polyethylene) repair sticks set, 6 pcs, black
KABS (Acrylnitril-Butadien-Styrol) repair stick set, 6 pcs, black
LPP (Polypropylen) repair sticks set, 6 pcs, black
MPS (Polystyrene) repair stick set, 6 pcs, black
NRepair clamp U-form, alloyed steel, Ø 0.8 mm, 50 pcs.
ORepair clamp U-form, alloyed steel, Ø 0.6 mm, 50 pcs.
PReinforcement mats set, 3 pcs, 100 x 55 mm
QCharging cable, 1 m USB to Micro-USB
RSafety stand
SAttachment twist-lock /bayonet fitting
TAttachment knurled grip
4. Safety and usage instructions
• Always wear heat resistant gloves when using the instrument and making repairs.
• Always wear eye protection when cutting staples.
• Failure to use the plastic welder correctly may result in fire, damage and /or personal injury.
• Keep hands and body clear of the welding tip when operating as it becomes very hot.
• Do not leave a hot plastic welder unattended.
• Do not get the plastic welder wet or attempt to cool the welding head with water.
• Do not use with wet hands
• Make sure the tips are cold before leaving on any surface.
• Do not use for any purpose other than that it is intended for.
• Make sure all health and safety procedures are in place before commencing work.
• Keep out of reach of children.
• Let the plastic welder fully cool down before replacing in case.
Tools may in principle only be used for the purpose intended, under the conditions envisaged and
within the limitations as to their use.

5. Operation
1. Choose a suitable staple for repair and insert it into the tips (H).
2. Prepare plastic for repair by butting together.
3. Heat staple by pressing heat control button to heat the staple.
4. Press the staple gently against the plastic to be repaired, push staple until it is about half way
through material, then twist through about 10° to 15°.
5. Release the heat and hold the staple on the repair until it feels firm.
6. Slowly withdraw the tool, leaving the head of the staple in place and cut off the protruding ends
of the staple.
Charging
Refer to Figure 2:
• This plastic welding tool is powered by a lithium-ion
battery which is rechargeable via a convenient USB
port on a PC, laptop, power bank or USB adaptor.
Fully charge (3.5 hours) before first use.
• Plug the supplied USB charging lead (Q) into the
plastic welding tool input port (E) and then into the
USB power source. The charging light (F in Figure
1) will glow red to show that the unit is charging. The
charging light will glow green when the internal battery
is fully charged. Charging time is 3.5 hours.
• A full charge provides approximately 35 minutes of
use (plastic welding) or 150-200 staples (hot stapling).
Switching on
Refer to Figure 1:
• Push the ON / OFF switch (B) forward to the ON position.
• Now press the Heat Control / LED torch button (C) to provide heat to the welding tip or hot stapler.
The LED torch will also illuminate which also acts as an indicator that the heat is switched ON.
• The tip will heat very quickly, coming up to working temperature in 15-30 seconds.
• Use the Heat Control / LED torch button (C) to regulate the temperature of the attachment, by
pressing and releasing as necessary.
Shutting off
• Move the OFF / ON switch (B) to the OFF position.
• Place the plastic welder onto the supplied stand (R)
and let it fully cool down before replacing in case.
See “Storage” section below.
Storage
Refer to Figure 3:
• Once the plastic welding tool has cooled down, fit the
standard plastic welding tip (G), then fit the welding tip
cover / safety lock (D) over the welding tip and onto the
tool, lining up the LOCK tab with the ON / OFF switch.
• The LOCK tab on the cover (D) will ensure that tool cannot accidentally be switched on.
• Now store in the supplied case.
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Changing Attachments
The kit is supplied with three attachments for the plastic welding tool:
• Standard plastic welding tip (G) — used for general repairs with the stainless steel mesh and for
melting ribbon-type plastic fi ller strips.
• Hot staple attachment (H) — used to apply the supplied 0.6 and 0.8mm staples to stabilise and
reinforce repairs.
• Plastic welding tip fi tted with a fi ller rod feeding tube (I) — the supplied fi ller rods are fed
through the tube so that they melt directly onto the job. Used for deeper cracks that have been
V-ed out to take the fi ller. The attachments are connected to the tool via a twist-lock / bayonet
type fi tting (S in Figure 1). Holding the tool away from you, line up the attachment with the notch
on the housing, push in, and twist to the left to lock in position. Ensure that the attachment is fully
turned to the left and locked in place.
To remove, twist the attachment to the right, then lift off.
The orientation of the attachment can be adjusted by turning the knurled grip (T in Figure 1) to the
required position.
Using the Plastic Welder
With experience, many uses can be found for the plastic welding tool. But fi rst, it is important to
identify the type of plastic that is to be repaired. Look on the back of the panel or component; the
type of plastic PE, ABS, PP or PS, will be clearly marked. Use the correct fi ller rod for the type of
plastic being repaired.
With the hot staple attachment, it is worthwhile practicing on some scrap plastic components to
familiarise yourself with how much heat needs to be applied (length of time control button C is
depressed), to get a staple to a temperature where it will slide into the plastic being repaired, and
to get a feel of how much pressure is required to ensure that you don’t push straight through the
component.
Using the Plastic Welder:
With experience, many uses can be found for the plastic welding tool. But first, it is important to
identify the type of plastic that is to be repaired. Look on the back of the panel or component; the
type of plastic PE, ABS, PP or PS, will be clearly marked. Use the correct filler rod for the type of
plastic being repaired.
With the hot staple attachment, it is worthwhile practicing on some scrap plastic components to
familiarise yourself with how much heat needs to be applied (length of time control button C is
depressed), to get a staple to a temperature where it will slide into the plastic being repaired, and
to get a feel of how much pressure is required to ensure that you don’t push straight through the
component.
Plastic Welding Repair:
1. Standard plastic welding tip (G) attachment. An example of a repair is outlined below:
Repairing a split or crack in a plastic bumper:
• Using a mini-sander or belt-sander fitted with a 120-180 grit disc, remove paint and primer from
the surrounding area and bring the level of the surface down around the area to be repaired.
Then feather off with a DA sander.
• Fit the standard plastic welding tip (G) to the plastic welding tool.
• If the split goes to the edge of the panel, it is recommended to reinforce with a hot staple inserted
at the top edge of the split. The edge is held straight and flush as the staple is applied.
• If necessary, stainless steel reinforcing mesh (P) can be cut to size. For a split it will be cut to
strips about 12-25 millimetres wide.

• Heat welding tip by pressing and holding the control button (C) for 4-10 seconds.
• Be aware that the tip gets very hot in use and can cause serious burns if handled. Take care to
keep the tips away from flammable objects.
• When the tip has come up to temperature initially tack the mesh onto the end of the repair. The
hot melting knife is used to heat the mesh and soften the plastic of the panel as the mesh is
pressed into the plastic. As the melted plastic comes through the mesh it can be smoothed over
with the tip.
• If the crack or damaged area follows a curve, the stainless steel mesh can be formed to also
follow the curve. The intention is to bury the mesh below the surface of the plastic, smoothing off
with the welding tip as you proceed.
• If required, to bring the level of surface back up and to add strength, welding filler rods can be
used to add material. Use the correct type of welding rod for the plastic substrate being repaired.
• Remember that you can stop repair and then recommence at any time. This is a heatbased
process. You are not dependant on any chemical curing so you can stop and start when
convenient.
• The repair is then sanded down to continue with the preparation and painting.
2. Plastic Welding tip c/w filler rod feeding tube (I):
• Use in a similar method to the standard plastic welding tip (outlined above); the supplied filler
rods are fed through the tube so that they melt directly onto the job. Used for deeper cracks that
have been V-ed out to take the filler.
• Used to add filler rod material to reinforce the repair and bring the repair to surface level.
• Run the tip along the crack as you also feed the filler rod down through the tip. Move slowly
and carefully making sure the material is of a sufficient temperature to weld successfully to the
substrate.
3. Hot Staple (H) attachment. An example of a repair is outlined below:
Hot Staple Repair:
• Clean the plastic surface to be repaired of any contaminants prior to repair.
• Choose suitable staple for type of repair and insert it into the tips of the hot staple attachment (H).
• Staple arms can be bent if required to achieve access.
• Prepare plastic for repair by butting together
• Heat staple by pressing and holding the control button (C) for 4-8 seconds. Press the staple
gently against the plastic to be repaired; push staple until it is about half way through material,
then twist through about 10-15°.
• Release control button (C) and hold the staple on the repair until the plastic cools and it feels
fi r m .
• Slowly withdraw the tool, leaving the head of the staple in place.
• Cut of the protruding ends of the staple with side cutters or similar. Hold on to protruding ends
during the cutting operation. (Wear eye protection).
• When repairing large areas or long cracks, repeat the procedure at 1-3cm intervals.
• Remove the remaining ends of the staple with sander. Continue with repair in the normal way.
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6. Maintenance
Incorrect or defective replacement parts can lead to damage.
7. Checks
All tools are to be checked for damage.
8. Disposal
The tool is to be disposed of or recycled in accordance with the legislation of the respective country.
9. Guarantee
The KS Tools Werkzeuge-Maschinen GmbH guarantee applies for all tools that are used under
normal usage conditions.
The following are excluded from the guarantee:
• Consumables e.g. any type of cutting tools, cutting inserts and disks, cutting and scraping tools,
brooms, brushes, files, batteries, bits or bit sockets, rotor blades in pneumatic devices, isolators
on heating coils, any type of fuses, carbon brushes, etc.
• Faulty functioning of parts that show usage-related or other natural wear and tear, as well as
tool defects that can be traced back to usage-related or other natural wear and tear.
• Defects in the tool that can be traced back to a failure to observe the operating instructions,
improper use, use under abnormal environmental conditions or unsuitable operating conditions,
overloading or improper maintenance.
Also defects in tools caused by the use of accessory parts or other parts that are not KS Tools
original parts.
• Tools which have been modified or equipped with additions.
• Minor deviations from the intended quality that are however insignificant for the value and
suitability for use of the tool.
The guarantee period is 12 months in cases of industrial or equal use.
The guarantee period starts on the date of purchase by the commercial end customer. The date of
the original purchase receipt is decisive. For technical products with limited guarantee types A, B
and C, the user must principally submit the purchase receipt in addition to the serial number of the
device, if present.
The guarantee applies under consideration of the guarantee type for the duration specified in the
price list valid on the day the product was purchase.
If no guarantee claim exists for the product (expiration of the guarantee time, guarantee exclusion
for the reasons listed in Sec. 2) but the repair is still possible, this will only be carried our following
approval of the cost estimate by the user.