Soldering Station
Model 96375
aSSeMbly and operation inStructionS
Due to continuing improvements, actual product may differ slightly from the product described herein.
3491 Mission Oaks Blvd., Camarillo, CA 93011
to preVent SeriouS injury, read and underStand
all warningS and inStructionS before uSe.
©
®
Copyright 2007 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 or replacement parts, please call 1-800-444-3353.
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electrical Safety
1.
2.
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.
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.
4.
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 immediately. Dam-
aged Power Cords increase the risk of electric shock.
5.
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
1.
2.
Stay alert. watch what you are doing, and use common sense when operat-
ing a power tool. do not use a power tool while tired or under the influence
of drugs, alcohol, or medication. A moment of inattention while operating 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.
3.
4.
avoid accidental starting. be sure the power Switch is off before plugging in.
Plugging in power tools with the Power Switch on, invites accidents.
do not overreach. keep proper balance at all times. Proper footing and balance
enables better control of the power tool in unexpected situations.
5.
6.
work in a well-ventilated area. Soldering fumes can be hazardous.
use safety equipment. always wear eye protection. Dust mask, heavy-duty
work gloves, nonskid safety shoes, hard hat, or hearing protection must be used
for appropriate conditions. Always wear ANSI-approved safety goggles and a dust
mask/respirator when using or performing maintenance on this tool.
SKU 96375
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tool uSe and care
1.
2.
3.
4.
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.
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 force
the tool and do not use the tool for a purpose for which it is not intended.
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.
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. always unplug the tool
from its electrical outlet before performing any inspection, maintenance, or
cleaning procedures.
5.
6.
Store idle tools out of reach of children and other untrained persons. Tools
are dangerous in the hands of untrained users.
check for 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 maintained tools.
7.
only use soldering tips 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
1.
2.
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 instruc-
tions 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 tool. These carry important information.
If unreadable or missing, contact Harbor Freight Tools for a replacement.
Maintain a safe working environment. Make sure there is adequate surrounding
workspace. Do not use this product in a damp or wet location.
SKU 96375
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3.
4.
always keep the extension cord away from heated parts of the tool.
never 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.
5.
6.
use caution when handling the Soldering tip; it comes to a sharp point and
is especially dangerous when heated.
warning:this product, when used for welding, plasma cutting, soldering, or
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.)
grounding
warning!
improperly connecting the grounding wire can result in the risk of electric shock.
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 facil-
ity 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.
2.
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 resis-
tance path to carry electricity away from the user, reducing the risk of electric shock.
(See 3-prong plug and outlet.)
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.)
SKU 96375
for technical questions, please call 1-800-444-3353.
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3.
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 3-prong plug and outlet.)
3-prong plug and outlet
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 seri-
ous 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.
5.
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.)
If you are using one extension cord for more than one tool, add the nameplate am-
peres and use the sum to determine the required minimum cord size.
(See table a.)
6.
7.
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.
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 electri-
cian before using it.
8.
Protect your extension cords from sharp objects, excessive heat, and damp or wet
areas.
SKU 96375
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recoMMended MiniMuM wire gauge for extenSion cordS*
(120 or 240 Volt)
naMeplate
aMpereS
(at full load)
extenSion cord lengtH
25 feet
50 feet
75 feet 100 feet 150 feet
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
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
Canadian Standards Association
Underwriters Laboratories, Inc.
Volts Alternating Current
V~
A
Amperes
No Load Revolutions per Minute (RPM)
n xxxx/min.
0
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 the number shown on the
cover of this manual as soon as possible.
aSSeMbly inStructionS
note: For additional information regarding the parts listed in the following pages, refer to
the Assembly Diagram near the end of this manual.
SKU 96375
for technical questions, please call 1-800-444-3353.
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1.
2.
warning! Make sure the Power Switch (8) of the Soldering Station is in the
“OFF” position and that the tool is unplugged from an electrical outlet before making
any adjustments to the tool.
Match up holes in Soldering Cord Sleeve (28) to pins in Soldering Cord Connection
(7), plug in, and secure with Soldering Cord Retainer (29).
3.
4.
5.
Place Sponge in the bottom of the handle rest reservoir.
Set up handle rest within easy reach of the Soldering Station.
Plug Soldering Station into any standard, 110V AC electrical outlet.
operation inStructionS
1.
Check for breakage, worn parts, damaged power cords, or any other condition that
may affect the tool’s operation. If damaged, have the tool serviced before using.
2.
3.
Tighten the Tip Retainer (25) on the Soldering Tip.
Select the correct solder for the intended use. Read the directions for the solder
being used to determine the temperature level that the Soldering Station needs to
be set at. To minimize the risk of damage to surrounding components, select the
minimum heat required to melt the solder chosen for the application.
4.
5.
Plug Soldering Station in and turn Power Switch (8) to the “ON” position. Set the
desired temperature with the Temperature Dial (5).
Place Handle on the Rest and wait about 1 minute, 20 seconds until Soldering Tip
heats up.
Handle in Handle rest
Sponge
preparing the metal to be soldered
6.
If wires are to be soldered, thoroughly clean and scrape the wires so that only the
clean copper is showing. Splice wires that are to be soldered together.
SKU 96375
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7.
If other metals are to be soldered, thoroughly clean and scrape the metal surfaces.
It may be necessary to apply acid flux (not included) to clean the metal surfaces
before soldering.
note: If soldering on printed circuit boards, too much heat can soften the plastic form
or loosen the metal eyelet connections. Use the lowest heat setting possible (see
manufacturer’s directions) to perform the soldering operation. Never use acid core
solder or acid flux on wiring circuits.
8.
If uncertain on how to proceed, it may be wise to practice on a scrap workpiece first.
Place the Soldering Tip on the wiring, joint, or metal to be soldered.
9.
Apply solder to the joint, wiring, or metal to be soldered, not to the Soldering Tip.
When the metal is hot enough, it will melt the solder and allow it to flow around the
wiring or metal being soldered. Slowly move SolderingTip around to coat the entire
area being soldered.
10.
11.
12.
When the entire wiring or metal surface is encased in solder, remove the Soldering
Tip and place in Rest.
Allow the soldering to cool completely before pulling gently on the item to ensure
a secure hold.
When you are finished soldering, wipe the Soldering Tip thoroughly on the Sponge
and apply a small amount of rosin-core solder to coat the Soldering Tip and keep
it clean.
Soldering tips
1.
2.
3.
4.
The soldering process bonds two metal objects together using a metallic bonding
material (solder) which has a lower melting point than the items being joined. Sol-
dering is not appropriate for non-metallic objects such as plastic or wood.
Check to be sure the objects being joined will not be damaged by the heat of
soldering. This tool generates a temperature up to 896° F. Test a scrap piece or
inconspicuous area of your work piece with the soldering tip before proceeding.
Be sure the surfaces being soldered are clean before beginning. If necessary, use
a soldering flux (not included) for cleaning. Apply the flux to the parts being joined,
and heat the parts until the flux burns away.
Heat the parts being joined with the soldering tool, not the solder. Once the parts
being joined are sufficiently heated, touch the solder to the work pieces. The solder
will melt and adhere to the work pieces. Remove the soldering tip from the work
pieces, and hold the pieces together until they have cooled enough for the solder
to solidify.
5.
Solder will “follow the heat”. Once a workpiece is sufficiently hot to melt the solder,
the solder can be dragged along the workpiece by moving the soldering tip. The
SKU 96375
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solder will follow the heat. This technique is helpful when soldering joints, such as
a tube in a coupling. By applying solder to the edge of the coupling and then mov-
ing the soldering tip away from the edge, solder can be dragged into a concealed
joint as it follows the heat.
6.
7.
8.
lead warning: Some solders contain lead and some do not. Be extremely
careful not to breathe vapors from any solder, especially ones containing lead.
Lead is a heavy metal which can accumulate in the body and cause serious health
problems.
Solder is available in various types. Some solders have a flux core and some do
not. Flux core solders contain flux and reduce the need to clean the work pieces
before joining. Solid core solders do not contain flux, and require careful cleaning
of the work material, and application of flux for additional cleaning.
Solder is available in various melting points. The heat range of solder may be ex-
pressed in temperature, or may be expressed as “easy,” “medium” or “hard”. When
making several solder joints on a single workpiece, you may use a mix of solder
temperatures. “Easy” solder will melt before “medium”, “medium” will melt before
“hard”, and “hard” will melt at only the highest temperatures.
replacing the Soldering tip
1.
Turn Power Switch (8) to the “OFF” position and unplug the Soldering Station from
the electrical outlet. Allow adequate time for all surfaces to cool down.
2.
3.
Unscrew Soldering Cord Retainer (29) from Soldering Cord Connection (7).
Unscrew Tip Retainer (25) holding Soldering Tip onto Handle Sleeve (24) and re-
move. Remove the Soldering Tip.
4.
Place new Soldering Tip on Handle Sleeve, replace Tip Retainer, and secure firmly.
Do not overtighten.
Soldering tip
tip retainer
Handle Sleeve
inSpection, Maintenance, and cleaning
1.
2.
warning! Make sure the Power Switch of the tool 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 tool. Check for loose
screws, misalignment or binding of moving parts, cracked or broken parts, dam-
SKU 96375
for technical questions, please call 1-800-444-3353.
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aged 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.
3.
4.
The tip should be cleaned periodically during use with a damp sponge.
After use, allow the Soldering Tip and all accessories to cool down to room tem-
perature before performing maintenance or being stored.
5.
6.
Wipe the tool down with a damp cloth to remove any grease, flux or dirt.
If Soldering Tip cracks or becomes eroded it must be replaced. The Soldering Tip
cannot heat up properly when cracked or eroded.
pleaSe read tHe following carefully
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEM-
BLY 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.
liMited 90 day warranty
Harbor FreightTools Co.makes every effort to assure that its products meet high quality and durabil-
ity 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 facili-
ties, 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 WAR-
RANTIES 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 merchan-
dise. 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.
3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-3353
SKU 96375
for technical questions, please call 1-800-444-3353.
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partS liSt and aSSeMbly diagraM
part
1
description
Qty
1
1
1
1
1
1
1
1
4
1
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Shell
Base
Panel
2
3
4
Transformer
5
Temperature Dial
Rubber Plug
6
7
Soldering Cord Connection
Power Switch
8
9
Screw PT4x2
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
PCB Board
Power Wire
Screw PT3.5x48
Press Board
Press Screw PT3x8
Axis Sleeve
Screw Sleeve
Iron Tip
Stainless Steel Sleeve
Bakelite Contact
Heat Wire Group
Grounding Spring
PCB Board
Handle
Handle Sleeve
Tip Retainer
Fastener
Silica Gel Wire
Soldering Cord Sleeve
Soldering Cord Retainer
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.
SKU 96375
for technical questions, please call 1-800-444-3353.
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