Harbor Freight Tools Soldering Gun 04328 User Manual

SOLDERING GUN KIT  
180 WATT WITH LIGHT  
Model 04328  
ASSEMBLY AND OPERATING INSTRUCTIONS  
®
3491 Mission Oaks Blvd., Camarillo, CA 93011  
Copyright 2003 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.  
For technical questions, please call 1-800-444-3353.  
 
ELECTRICAL SAFETY  
4.  
Grounded tools must be plugged into an outlet properly installed and  
grounded in accordance with all codes and ordinances. Never remove the  
grounding prong or modify the plug in any way. Do not use any adapter  
plugs. Check with a qualified electrician if you are in doubt as to whether  
the outlet is properly grounded. If the tools should electrically malfunction or  
break down, grounding provides a low resistance path to carry electricity away  
from the user.  
5.  
6.  
Double insulated tools are equipped with a polarized plug (one blade is  
wider than the other). This plug will fit in a polarized outlet only one way. If  
the plug does not fit fully in the outlet, reverse the plug. If it still does not  
fit, contact a qualified electrician to install a polarized outlet. Do not  
change the plug in any way. Double insulation eliminates the need for the  
three wire grounded power cord and grounded power supply system.  
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.  
7.  
8.  
Do not expose power tools to rain or wet conditions. Water entering a power  
tool will increase the risk of electric shock.  
Do not abuse the Power Cord. Never use the Power Cord to carry the tools  
or pull the Plug from an outlet. Keep the Power Cord away from heat, oil,  
sharp edges, or moving parts. Replace damaged Power Cords immedi-  
ately. Damaged Power Cords increase the risk of electric shock.  
9.  
When operating a power tool outside, use an outdoor extension cord  
marked “W-A” or “W”. These extension cords are rated for outdoor use, and  
reduce the risk of electric shock.  
PERSONAL SAFETY  
10.  
11.  
Stay alert. Watch what you are doing, and use common sense when oper-  
ating a power tool. Do not use a power tool while tired or under the influ-  
ence of drugs, alcohol, or medication. A moment of inattention while operat-  
ing power tools may result in serious personal injury.  
Dress properly. Do not wear loose clothing or jewelry. Contain long hair.  
Keep your hair, clothing, and gloves away from moving parts. Loose  
clothes, jewelry, or long hair can be caught in moving parts.  
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12.  
13.  
14.  
15.  
Avoid accidental starting. Be sure the Power Switch is off before plugging  
in. Carrying power tools with your finger on the Power Switch, or plugging in  
power tools with the Power Switch on, invites accidents.  
Remove adjusting keys or wrenches before turning the power tool on. A  
wrench or a key that is left attached to a rotating part of the power tool may result  
in personal injury.  
Do not overreach. Keep proper footing and balance at all times. Proper  
footing and balance enables better control of the power tool in unexpected  
situations.  
Use safety equipment. Always wear eye protection. Dust mask, non-skid  
safety shoes, hard hat, or hearing protection must be used for appropriate  
conditions.  
TOOL USE AND CARE  
16.  
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.  
18.  
Do not force the tool. Use the correct tool for your application. The correct  
tool will do the job better and safer at the rate for which it is designed.  
Do not use the power tool if the Power Switch does not turn it on or off.  
Any tool that cannot be controlled with the Power Switch is dangerous and must  
be replaced.  
19.  
Disconnect the Power Cord Plug from the power source before making any  
adjustments, changing accessories, or storing the tool. Such preventive  
safety measures reduce the risk of starting the tool accidentally.  
20.  
21.  
Store idle tools out of reach of children and other untrained persons. Tools  
are dangerous in the hands of untrained users.  
Maintain tools with care. Keep cutting tools sharp and clean. Properly  
maintained tools with a sharp cutting edge are less likely to bind and are easier  
to control. Do not use a damaged tool. Tag damaged tools “Do not use” until  
repaired.  
22.  
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 serviced before using. Many accidents are caused by poorly main-  
tained tools.  
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23.  
Use only accessories that are recommended by the manufacturer for your  
model. Accessories that may be suitable for one tool may become hazardous  
when used on another tool.  
SERVICE  
24.  
25.  
Tool service must be performed only by qualified repair personnel. Service  
or maintenance performed by unqualified personnel could result in a risk of injury.  
When servicing a tool, use only identical replacement parts. Follow  
instructions in the “Inspection, Maintenance, And Cleaning” section of this  
manual. Use of unauthorized parts or failure to follow maintenance instructions  
may create a risk of electric shock or injury.  
SPECIFIC SAFETY RULES  
1.  
2.  
Maintain labels and nameplates on the Soldering Gun. These carry impor-  
tant information. If unreadable or missing, contact Harbor Freight Tools for a  
replacement.  
Always wear safety impact eye goggles and heavy work gloves when using  
the Soldering Gun. Using personal safety devices reduce the risk for injury.  
Safety impact eye goggles and heavy work gloves are available from Harbor  
Freight Tools.  
3.  
Maintain a safe working environment. Keep the work area well lit. Make sure  
there is adequate surrounding workspace. Always keep the work area free of  
obstructions, grease, oil, trash, and other debris. Do not use a power tool in areas  
near flammable chemicals, dusts, and vapors. Do not use this product in a damp  
or wet location.  
4.  
Make sure to read and understand all instructions and safety precautions as  
outlined in the instruction manual.  
5.  
6.  
Always keep the extension cord away from heated parts on the tool.  
Avoid unintensional starting. Make sure you are prepared to begin work  
before turning on the Soldering Gun.  
7.  
When using the Soldering Gun, always maintain a firm grip on the tool.  
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PAGE 5  
 
8.  
Connect tool to properly grounded outlets. Caution: To provide continued  
protection against risk of electric shock, connect to properly grounded outlets only.  
Do not immerse the Soldering Gun in water.  
9.  
Use of any accessory or attachment other then those mentioned in the  
manual may result in personal injury and/or property damage.  
10.  
11.  
Avoid Serious Burns. The Soldering Gun reaches 1135o F. Do not point the  
Soldering Gun, or turn yourself toward another person while soldering.  
Do not open Soldering Gun. Do not attempt to open and repair this unit. It must  
be serviced by a qualified technician.  
12.  
13.  
Indoor use only. This product was designed primarily for indoor use only.  
Avoid damaging equipment and tools. Always de-energize any circuits or  
wires to be soldered before making connections and soldering.  
14.  
15.  
16.  
Do not breath soldering fumes. Never breath soldering fumes as they may  
make you ill.  
Never lay the Soldering Gun down where the heated parts can contact  
flammable materials or electrical wires.  
Never leave the Soldering Gun unattended when it is plugged into an  
electrical outlet. Turn off the tool, and unplug it from its electrical outlet before  
leaving.  
17.  
18.  
Always unplug the Soldering Gun from its electrical outlet before perform-  
ing and inspection, maintenance, or cleaning procedures.  
WARNING! People with pacemakers should consult their physician(s)  
before using this product. Operation of electrical equipment in close proximity to a  
heart pacemaker could cause interference or failure of the pacemaker.  
Note: Performance of this tool may vary depending on variations in local line voltage.  
Extension cord usage may also affect tool performance.  
Warning: The warnings, cautions, and instructions discussed in this instruction  
manual cannot cover all possibel conditions and situations that may occure. It  
must be understood by the operator that common sense and cautions are factors  
which cannot be built into this product, but must be supplied by the operator.  
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PAGE 6  
 
GROUNDING  
WARNING!  
Improperly connecting the grounding wire can result in the risk of electric  
shock. Check with a qualfified 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  
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 elec-  
tric shock. (See Figure A.)  
2.  
3.  
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 Figure A.)  
Your 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 following illustration. (See Figure A.)  
FIGURE A  
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DOUBLE INSULATED TOOLS: TOOLS WITH TWO PRONG PLUGS  
4.  
5.  
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. (See Figure B.)  
Double insulated tools may be used in either of the 120 volt outlets shown in the  
following illustration. (See Figure B.)  
FIGURE B  
EXTENSION CORDS  
1.  
2.  
Grounded tools require a three wire extension cord. Double Insulated tools  
can use either a two or three wire extension cord.  
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 Figure C, next page.)  
3.  
4.  
5.  
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 Figure C.)  
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 Figure C.)  
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 Figure C.)  
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PAGE 8  
 
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 your 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 your extension cords from sharp objects, excessive heat, and damp or  
wet areas.  
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FIGURE C  
SYMBOLOGY  
Double Insulated  
Canadian Standards  
Association  
Underwriters  
Laboratories, Inc.  
Volts Alternating Current  
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Amperes  
n
No Load Revolutions  
per Minute (RPM)  
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PAGE 9  
 
UNPACKING  
When unpacking, check to make sure all the parts shown on the Parts List on page 13  
are included. If any parts are missing or broken, please call Harbor Freight Tools at the  
number shown on the cover of this manual as soon as possible.  
Solder Flux  
Soldering Gun  
Roll of  
Solder  
Soldering Tips  
(1)  
Wrench (16)  
ASSEMBLY AND OPERATING INSTRUCTIONS  
NOTE: For additional information regarding the parts listed in the following pages, refer  
to the Assembly Diagram on page 14.  
CAUTION: Always make sure the Power Cord of the Soldering Gun is unplugged from  
its electrical outlet prior to making any adjustments to the tool.  
WARNING: This product contains lead, which is a chemical known to the State of Cali-  
fornia to cause cancer and birth defects or other reproductive harm. (California Health &  
Safety Code 25249.5, et seq.)  
This product, when used for soldering and similar applications, produces chemicals  
known to the State of California to cause cancer and birth defects (or other reproductive  
harm). (California Health & Safety Code 25249.5 et seq.)  
Preparing the Soldering Tip  
1. Using Wrench (16), check that the Soldering Tip Nuts (2) are not loose.  
Do not overtighten as you may strip the threads.  
2. Set the Soldering Gun on the workbench, and plug the Line Cord into an electrical  
outlet.  
3. Press on the Trigger Switch (12) until the Soldering Tip (1) heats up.  
4. Apply a sufficient amount of rosin-core solder to melt over the entire tip of the  
Soldering Gun. Wipe the tip with a rag until the tip is clean and shinny.  
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Preparing the Metal to be Soldered  
1. If wires are to be soldered, thoroughly clean or scrape the wires so that only the  
clean copper is showing. Make the wire splice.  
2. If other metals are to be soldered, thoroughly clean or scrape the metal surfaces. It  
may be necessary to apply acid flux (not supplied) to the metal surfaces before  
soldering.  
Caution: If soldering on printed circuit boards, too much heat can soften the  
plastic form and loosen the metal eyelet connections. Use minimal heat, or solder  
with a low wattage soldering pencil. Never use acid core solder on wiring circuits.  
Soldering  
1. Press on the Trigger Switch (12) until the Soldering Tip (1) heats up.  
2. Brush on solder flux, as needed, to the workpiece. Place the Soldering Tip to the  
joint, wiring splice, or metal to be soldered.  
3. Apply solder to the wire splice or metal to be soldered, not the Soldering Tip.  
When the splice or metal is hot enough, it will melt the solder causing it to flow  
within the splice or between the metal surfaces.  
4. When the solder has flowed over the entire wire splice or metal surface, remove the  
Soldering Tip and release the Trigger Switch.  
If you are new to soldering, you may find it helpful to practice soldering first on scrap  
wires and splices.  
Maintenance  
Note: Maintenance requiring disassembly of this tool should only be performed while the  
product is disconnected from the electrical supply circuit.  
1. When you are finished soldering, heat up the Soldering Tip (1) again and apply a  
small amount of rosin-core solder to coat the tip. Wipe off with a rag.  
This will leave the tip clean and ready for use again.  
2. If the Soldering Tip cracks or becomes eroded, the Soldering Tip needs to be  
replaced. In this condition, it will not heat up properly.  
Accessories  
Replacing the Soldering Tip  
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PAGE 11  
 
1. To replace the Soldering Tip, place the Wrench (16) over each Nut (2) and remove  
by turning counterclockwise.  
2. Push the Nuts toward the Soldering Tip end, exposing the opposite ends of the  
Soldering Tip.  
3. Guide the old Soldering Tip out of the Transformer Assembly (4) mounting posts (A).  
Refer to the Assembly Drawing on the next page.  
4. Straighten out the ends of the old Soldering Tip using pliers, and remove the Nuts  
(2).  
5. Place the Nuts over the mounting ends of the new Soldering Tip.  
6. Using pliers, bend the mounting ends of the new Soldering Tip so that about 3/16  
inch is at 90 degrees.  
If the bend is too long, the Nuts will not fit over mounting posts.  
7. Guide the bent ends into the mounting posts of the Transformer Assembly.  
8. Carefully tighten the Nuts over the mounting posts.  
Make sure that the Nuts fit squarely over threads or damage will occur to the  
mounting post threads. Do not overtighten.  
Replacing the Light Bulb  
1. Remove the Light Bulb Lens (15) from the front of the Soldering Gun.  
2. Pull out the burnt Light Bulb and replace with a new one of the same voltage and  
type (see Specifications).  
3. Replace the Light Bulb Lens  
INSPECTION, MAINTENANCE, AND CLEANING  
1.  
2.  
WARNING! Make sure the Power Switch (part #) of the Soldering Gun is in  
its “OFF” position and that the tool is unplugged from its electrical outlet before  
performing any inspection, maintenance, or cleaning procedures.  
BEFORE EACH USE, inspect the general condition of the Soldering Gun. Check  
for loose screws, misalignment or binding of moving parts, cracked or broken  
parts, damaged electrical wiring, and any other condition that may affect its safe  
operation. If abnormal noise or vibration occurs, have the problem corrected  
before further use. Do not use damaged equipment.  
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PAGE 12  
 
Parts List  
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NOTE: Some parts are listed and shown for illustration purposes only and are not available  
individually as replacement parts.  
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 MANUFACTUER 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.  
SKU 04328  
PAGE 13  
 
ASSEMBLY DIAGRAM  
NOTE: Some parts are listed and shown for illustration purposes only, and are not  
available individually as replacement parts.  
SKU 04328  
PAGE 14  
 

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