POWDER COATING SYSTEM
42802
SET uP AND OPERATING INSTRuCTIONS
Distributed exclusively by Harbor Freight Tools®.
3491 Mission Oaks Blvd., Camarillo, CA 93011
Read this material before using this product.
Failure to do so can result in serious injury.
SAVE THIS MANuAl.
Copyright© 2000 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
improvements, 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.
Manual Revised 09d
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10. Maintain tools with care. Keep
tools sharp and clean for better and
safer performance. Follow instruc-
tions for lubricating and changing
accessories. Inspect tool cords peri-
odically and, if damaged, have them
repaired by an authorized technician.
The handles must be kept clean, dry,
and free from oil and grease at all
times.
16. Replacement parts and acces-
sories. When servicing, use only
identical replacement parts. Use of
any other parts will void the warranty.
Only use accessories intended for
use with this tool. Approved accesso-
ries are available from Harbor Freight
Tools.
17. Do not operate tool if under the in-
fluence of alcohol or drugs. Read
warning labels on prescriptions to
determine if your judgment or reflex-
es are impaired while taking drugs. If
there is any doubt, do not operate the
tool.
11. Disconnect power. Unplug trans-
former when not in use.
12. Avoid unintentional starting. Be
sure the switch is in the Off position
when not in use and before plugging
in. Do not carry any tool with your
finger on the trigger, whether it is
plugged in or not.
18. use proper size and type extension
cord. If an extension cord is required,
it must be of the proper size and type
to supply the correct current to the
tool without heating up. Otherwise,
the extension cord could melt and
catch fire, or cause electrical damage
to the tool. This tool requires use of
an extension cord of 0 to 10 amps
capability (up to 50 feet), with wire
size rated at 18 AWG. Longer exten-
sion cords require larger size wire. If
you are using the tool outdoors, use
an extension cord rated for outdoor
use (signified by “WA” on the jacket).
13. Stay alert. Watch what you are do-
ing, use common sense. Do not oper-
ate any tool when you are tired.
14. Check for damaged parts. Before
using any tool, any part that ap-
pears damaged should be carefully
checked to determine that it will oper-
ate properly and perform its intended
function. Check for alignment and
binding of moving parts; any broken
parts or mounting fixtures; and any
other condition that may affect proper
operation. Any part that is damaged
should be properly repaired or re-
placed by a qualified technician. Do
not use the tool if any switch does not
turn On and Off properly.
19. Maintenance. For your safety,
service and maintenance should be
performed regularly by a qualified
technician.
20. The warnings, cautions, and instruc-
tions discussed in this instruction
15. Guard against electric shock.
Prevent body contact with grounded
surfaces such as pipes, radiators,
ranges, and refrigerator enclosures.
Never touch the object being coated
with one hand while spraying with the
other.
manual cannot cover all possible con-
ditions 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
SKU 42802
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product, but must be supplied by the
operator.
unpacking
When unpacking, check to make sure
the following parts are included (Refer to
the Parts List and Assembly Drawing at
the end of this manual):
Additional Safety Warnings for
the Powder Coating System
1. The powder dust is flammable
when floating in the air.
- Spray Gun,
- Foot Switch,
- In-line Filters,
- Transformer,
- Ventilate the area well.
- Verify that there are no flames or
ignition source nearby.
- Control excess dust by cleaning up
after each use.
- Never vacuum up the dust using a
non-explosion proof vacuum cleaner.
- Never cure coated object in a gas
oven as the fumes recreated can be
flammable; only use an electric oven.
- Never smoke while using the Pow-
der Coating System.
- two Powder Cups
- three Scatter Tips
- Ground Clip Cable
If any parts are missing or broken,
please call Harbor Freight Tools at the
number on the cover of this manual as
soon as possible.
2. Avoid electrical shock!
- Never touch the emitter (metal tip)
of the Spray Gun. After use (and
turned OFF), touch the emitter to the
Ground Clip to discharge it.
- Do not use the Spray Gun if you
carry and use any electronic medical
devices.
- Never touch the metal object during
coating.
3. Avoid powder contamination.
- Protect your lungs by using an ap-
proved dust mask.
- Never cure objects in an electric
oven that is used for food also.
- Ventilate the area well.
- Wear an activated charcoal respi-
rator when oven curing the coated
object.
SKU 42802
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MAIN COMPONENTS
Control Box (1)
Ground Clip (10)
Scatter Tip (12)
Pedal Switch (11)
Regulating Screw (14)
Disposable Moisture Separator (8)
Connect Air Hose
8. Setup a dedicated electric oven (with
adequate ventilation) for curing the
coated objects with a temperature
capability from 300 to 500° F.
PREPARATION
1. Setup an air supply with an air pres-
sure regulator and moisture trap (do
not use an inline air oiler). The air
compressor must provide an air pres-
sure of 20 to 40 PSI.
WARNING: Never use a gas oven, the
fumes from curing can be explo-
sive. Never use a home oven that
is also used for food. Contamina-
tion of food will occur.
2. Select a safe location for spraying
and curing with:
- adequate lighting
- active ventilation
- no flame or ignition source
- an area dry, clean, and covered --
free of flammable material
9. Clean the object to be powder coated
of any old coatings, rust, grease and
oil.
OPERATION
3. Have an activated charcoal filter
respirator availability for use when
curing.
1. Place or hang the cleaned object to
be coated near the ventilation sys-
tem.
4. Have disposable dust masks avail-
able for use when powder spraying.
If the object has grooves or recesses,
position the object so that gravity as-
sists the powder mist to fall into the
grooves or recesses.
5. Have a pair of vinyl gloves for
use when handling the power and
sprayed objects.
2. Connect the Disposable Moisture
Separator (8) to the Spray Gun (2).
6. Use ANSI-approved safety glasses.
7. If using an extension cord, it must
have a ground prong.
SKU 42802
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Power Switch (17)
Power
Indicator
light (15)
Cup (4)
Scatter Tip (12)
Running
Indicator
light (16)
Ground
Clip (10)
Connection
Regulating Screw (14)
Trigger (7)
line Cord
Pressure Reducer Valve (18)
Spray Gun (2) Pedal Switch
Connection Connection (11)
3. Unscrew the Cup (4) from the Spray
Gun (2) and fill with up to two inches
of coating powder (not supplied).
- Turn the Cup upside down and
place on a clean piece of paper.
- Put on a pair of disposal vinyl
gloves.
6. Turn ON the Power Switch (17) of the
Control Box (1).
7. Turn ON the compressor and adjust
the air pressure to between 20 and
40 PSI.
This can be done at the compressor
if it has a pressure value, or on the
Spray Gun by adjusting the Pressure
Reducer Valve (18).
- Open the powder coating container,
and using a piece of clean paper as a
guide,
pour the powder into the Cup.
- Turn the Spray Gun upside down
and screw the Cup back into the
Spray Gun.
8. Press the Spray Gun Trigger (7) and
Pedal Switch (11) at the same time
and test the spray pattern on a piece
of scrap metal.
- Reseal powder container.
The Trigger controls the air and pow-
der flow. The Pedal Switch controls
the electrical charge. If the pattern
is too small or too large, change the
Scatter Tip (12). Remember that the
pointed end of the Scatter Tip faces
toward the Spray Gun and screws on.
The spray pattern can also be adjust-
ed using the Regulating Screw (14):
loosen to expand the pattern, tighten
to reduce the pattern size.
Note: Only use the provided cups with
this system. Other cups will not seal
properly.
4. Connect the 1/4 inch air hose to the
Disposable Moisture Separator (8).
5. Attach the Ground Clip (10) to the
metal object being coated.
Securely attach the Ground Clip to
an area which is not being coated if
possible. This connection is abso-
lutely necessary to draw the electri-
cally charged (power) particles to the
metal object.
9. When coating, keep the Spray Gun
approximately eight inches from the
metal object.
- Point the Spray Gun toward the ob-
ject at different angles to guarantee
that all areas are coated.
REV 09d
SKU 42802
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- When completed, the object should
be completely coated with a dull,
opaque coat of powder.
15. When cured, turn the oven OFF and
open the oven door slightly to allow
the object to cool gradually before
removing.
10. When finished spraying:
- remove your foot from the Pedal
Switch (11),
When the object is cooled too rapidly,
a dull finish may result.
- press the Control Box Power Switch
(17) to the OFF position,
Process Tips
- unplug the Control Box power cord
from the electrical outlet.
1. To remove an orange peel effect after
curing, wet-sand the object with 400
grit sandpaper, dry, and repeat the
coating process. Over-powder coat-
ing can cause this effect.
WARNING: The Spray Gun is still elec-
trically charged. Discharge Con-
ducting Pole before touching or
you could be shocked.
2. Polish with traditional paint polishes.
11. Touch the Conducting Pole (9) to the
Ground Clip (10) to discharge any
residual electricity.
3. Lightly buff with a loose wheel and
white rouge compound to remove
imperfections.
12. Wipe the Scatter Tip off with a clean
cloth.
4. Thoroughly clean the Cup before
changing powders.
Some powders are made from poly-
ester, while others are made from
polyurethane. A mixture of both can
cause pitting of the coated object.
13. Place the activated charcoal respira-
tor over your face mouth and hose.
WARNING: The fumes produced dur-
ing curing are hazardous to your
health. Do not breathe the fumes.
5. Porous metal objects may need a
thorough cleaning with a brush and
pre-painting cleaning solutions.
14. With the oven preheated to the de-
sired temperature (300 to 500 de-
grees F), place the object on the
oven rack, close the door, and turn
the ventilation system ON.
6. If the powder starts to buildup in one
place, blow off with light air pressure.
Moisture in the air will cause pow-
der buildup. Replace the Disposable
Moisture Separator (8).
- Typical curing time is 15 minutes.
Check the Powder Coating container
for recommended curing time and
temperature.
- If the object is large, curing may
take more time.
- The power coating should melt to
a smooth, gloss finish all over the
object.
- Check the curing object often to
prevent over-curing which can cause
roughness to the surface.
7. Poor disbursement can be caused by
low air pressure. Adjust the air pres-
sure or replace the Disposable Mois-
ture Separator. The Cup should have
at least one inch of powder during
coating.
8. Use automotive paint remover to
remove a cured coating.
SKU 42802
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WARNING: Powder clouds/mist are
explosive. Before cleaning, remove
any possible ignition source in the
area .
MAINTENANCE
1. Wear disposable vinyl gloves.
2. Unplug the Control Box line cord from
the electrical outlet.
6. Using compressed air, blow out the
Cup and all other parts that have col-
lected powder.
3. Discharge the Conducting Pole (9) to
the Ground Clip (10).
7. Uncontaminated powder residue can
be stored and reused.
4. Disconnect the air hose from the
Spray Gun.
8. Store powder and Powder Coating
System in a box located in a clean
and dry location.
5. Remove the Cup and pour any re-
maining powder back into it’s original
container.
PARTS lIST
Item
Description
Control Box
Spray Gun
Spray Gun Pipe
Cup*
Qty
1
1
1
1
1
1
1
1
2
3
4
5
6
7
Air Outlet Pipe
Air Input Pipe
Trigger
Disposable Moisture Separator
(reorder item #42980)
Conducting Pole
Ground Clip
Pedal Switch
Scatter Tip
8
1
9
1
1
1
1
1
1
1
1
1
1
1
10
11
12
13
14
15
16
17
18
19
Emitter
Regulating Screw
Power Indicator Light
Running Indicator Light
Power Switch
Pressure Reducer Valve
Hose Adapter
*Note:Replacement cups provided for other powder coating systems (such as SKU
93306, 94646, or 94244) may not seal properly. Only use the cups provided.
Note: Some parts are listed and shown for illustration purposes only and are not avail-
able individually as replacement parts.
REV 09d
SKU 42802
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ASSEMBlY DRAWING
PlEASE READ THE FOllOWING CAREFullY
THE MANUFACTURERAND/OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM IN THIS MANUAL
AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER NOR DISTRIBUTOR MAKES ANY
REPRESENTATION OR WARRANTY OFANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO
MAKEANY REPAIRS TO THE PRODUCT OR THAT HE OR SHE IS QUALIFIED TO REPLACEANY 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.
SKU 42802
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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 42802
For technical questions, please call 1-800-444-3353.
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