Kawasaki 840641 User's Manual
Contents
1. 19 SECTION FOUR MAINTENANCE AND CLEANING 20 ACCESSORIES dia bade dade aa 20 SPECIFICATIONS cee sae eae kes eae aes 21 OTHER CONSUMER DO IT YOURSELF DIY TOOLS 21 SECTION FIVE YEAR LIMITED WARRANTY 21 24 CONGRATULATIONS Thanks for choosing this product At Alltrade our aim is to provide you with quality products at an affordable price and we want you to be totally satisfied with your product and our Customer Service If any help and advice is needed please contact us at 1 800 590 3723 Properly cared for this tool will give you many years of satisfaction INTENDED USE This tool is intended for consumer use only This tool is not designed for profes sional use The power cord should only be used in approved electrical outlets as described in this manual Failure to use the proper power cords and or extension cords may result in fire or possible damage to the welder GENERAL SAFETY RULES 4 WARNING READ AND UNDERSTAND ALL INSTRUCTIONS Failure to follow all instructions in this manual may result severe electrical shock fire and or serious personal injury or death RECOGNIZE SAFETY SYMBOLS WORDS AND LABELS The safety instructions provided in this manual are not intended to cover all possi ble conditions and practices that may occur when operating maintaini2. 15 Lift torch handle and press trigger 9 until 2 of wire feeds through the tip 16 If the wire does not feed view wire feed unit to ensure wire is being fed If not turn the welder OFF and add more tension to the wire feed adjustment spring 17 Turn welder ON and press trigger One flux core wire is exposed turn welder OFF 18 Slide contact tip 8 over the flux core wire 10 and screw it into the torch end 11 19 Replace nozzle and cut off any flux core wire in excess of a 1 4 inch 20 Close the cover on top of the welder OPERATING THE ARC WELDER Ensure the Arc Welder is turned OFF Ensure the work piece is free of chemicals or oily substances that may catch fire or impair the welding process Ground the object to be worked by attaching the grounding clamp If the work piece is secured to a metal work bench grounding the work bench is an accept able alternate e Set the Current Switch The thicker the work piece the higher the current Set the Wire Speed Control to 5 Adjust as needed CAUTION Plug in the power cord to an approved AC outlet If an extension cord is used refer to the manufacturer s instructions to ensure it is heavy enough to handle the load If the extension cord is too light it may become overheated and ignite WARNING the Torch away from any grounded object Contact with a grounded object may cause the torch to inadvertent
3. 1 800 590 3723 Cordless Drills Screwdrivers Reciprocating Saws Impact Wrenches Routers Sanders Rotary Tools Jigsaws Corded and Cordless Multi Purpose Tools Circular Saws Wide Range of Accessories and more Angle Grinders 3 YEAR LIMITED WARRANTY Express and Exclusive Limited Warranty to Original Retail Buyer Alltrade Tools LLC hereinafter Alltrade expressly warrants to the original retail purchaser of the accompanying KAWASAKI power tool and no one else all parts of the product except those parts referred to below which are specifically exclud ed from such warranty see Exclusions to be free from defects in materials and workmanship for a period of three years from original date of purchase except that such warranty with regard to the battery shall be for a period of two years from original date of purchase unless the tool is used for commercial or rental purposes SPECIAL WARRANTY NOTE FOR COMMERCIAL OR RENTAL USE The above warranty for this Kawasaki power tool including the battery shall be effective for only 90 days from the original date of purchase if this tool is used for any COMMERCIAL OR RENTAL PURPOSE The date of purchase shall be the date of shipment to the original purchaser or the date the original purchaser took possession custody or control of the product whichever occurred first This warranty shall be null and void if the product or any component thereof is modified or altered This warranty does
4. 70T GS E AWG classification for self shielding wire 7 Weld Strength times 10 000 Ibs per square inch 0 Welding Positions 0 Flat 1 All other positions T Tubular Flux core Wire GS Flux Type The Internet can be used for additional information on the American Welding Society AWS Standards http www aws org HEAT SETTING Obtaining the correct heat setting involves adjusting the Welder to the required set ting The proper heat setting is based on 1 diameter and type of welding wire 2 position of the weld and 3 the thickness of the work piece Labeling on the Welder list recommendations for proper heat settings for most projects WELD ANGLE The weld angle is the angle to which the torch head is held during the welding process The correct weld angle ensures proper heat penetration and bead forma tion This becomes increasingly important in order to obtain a satisfactory weld Weld Angles involve two positions travel angle and work angle Travel Angle is the angle in the line of welding that could vary from 5 to 45 from vertical depending on welding conditions Work Angle is the angle from horizontal measured in right angles to the line of welding Typically a 45 travel angle and a 45 work angle is sufficient If special applications are needed consult an arc welding handbook WIRE SPEED A knob on the front of the Arc Welder controls the wire speed The speed needs to be tuned to the proper rate at wh
5. Parts returned freight prepaid and insured to Alltrade s facility see above address will be inspected and at Alltrade s option repaired and or replaced free of charge if found to be defective and subject to warranty Alltrade retains the sole discretion to determine whether any item or part is nonconforming and if so whether the item and or part will be repaired and or replaced If the unit is repaired new or reconditioned replacement parts may be used If Alltrade chooses to replace the product it may replace it with a new or reconditioned one of the same or comparable design The repaired or replaced unit will be warranted under the terms of the remainder of the warranty period Typically a defective product that is returned within the first 30 days after the purchase date will be replaced for items returned after the first 30 days and within the warranty period covered defective parts not subject to normal wear and tear or other exclusions will be repaired or replaced at Alltrade s option During the warranty period Alltrade will be responsi ble for the return shipping charges Alltrade s repair and or replacement of any non conforming item and or part thereof shall constitute fulfillment of all obligations to the purchaser Alltrade shall not be responsible or liable for any expense including freight charges or repairs made outside Alltrade s facility unless expressly agreed to by Alltrade in writing Under no circumstances
6. SPEED wire speed TOO FAST travel speed HEAT TOO TRAVEL SPEED LOW WIRE SPEED TOO SLOW TOO FAST 17 18 TROUBLESHOOTING CHART WELDER SYMPTOM No Output Wire tangles at drive roller Gun nozzle arcs to work piece Wire does not feed POSSIBLE CAUSES S Duty cycle exceeded Poor work clamp connection Defective ON OFF switch Tripper circuit breaker blown fuse Wrong size gun tip Gun liner clogged or damaged Gun tip clogged or damaged Feed roller worn Not enough tension Slag inside gun nozzle Poor contact Wire jammed Out of wire Not enough tension Wire liner worn 19 CORRECTIVE ACTION 1 Allow welder to cool down until ON OFF Switch lamp goes out Be sure all connections are secure and attaching surface is clean Replace switch Reduce circuit load reset breaker or replace fuse Use proper size gun tip Clean or replace gun liner Clean or replace gun tip Replace feed roller Tighten tensioning screw Clean slag from gun nozzle Ensure all connections are secure and attaching surface is clean Reload wire Replace wire spool Tighten tensioning screws if wire is slipping 4 Replace liner WARNING always UNPLUG the Arc Welder from the AC MAINTENANCE AND CLEANING power source before cleaning or maintenance Keep the Arc Welder clean and dust free Never use water to clean th
7. shall Alltrade bear any responsibility for loss of the unit loss of time or rental inconvenience commercial loss or consequential damages 22 Exclusions This warranty does not cover parts damaged due to normal wear abnormal conditions misapplication misuse abuse accidents operation at other than recommended pressures or temperatures improper storage or freight damage Parts damaged or worn by operation in dusty environments are not warranted Failure to follow recommended operating and maintenance procedures also voids warranty This limited warranty does not apply to accessory items such as drill bits screwdriving bits circular saw blades jigsaw blades grinding wheels sanding sheets and other related items DAMAGE TO THE PRODUCT RESULTING FROM TAMPERING ACCIDENT ABUSE NEGLIGENCE FAILURE TO FOLLOW INSTRUCTIONS UNAUTHORIZED REPAIRS OR ALTERATIONS DAMAGE WHILE IN TRANSIT TO OUR SERVICE FACILITY USE OF UNAPPROVED OR IMPROPER ATTACHMENTS OR ACCESSORIES COMMERCIAL AND RENTAL APPLICATIONS OR OTHER CAUSES UNRELATED TO PROBLEMS WITH MATERIAL OR WORKMANSHIP ARE NOT COVERED BY THIS WARRANTY Alltrade will not be liable for the following labor charges loss or damage resulting from improper operation maintenance or repairs made by other persons pre delivery services such as assembly oil or lubricants and adjustment maintenance services that are normally required to maintain the product The use of other than genuine All
8. AND OR REPRESENTATION WRITTEN OR ORAL ARISES BY OPERATION OF LAW AND OR EQUITY AND OR BY ANY ACT OR OMISSION OF ALLTRADE AND OR ITS REPRESENTATIVE S OR THE PURCHASER INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTY OF MERCHANTABILITY AND THE WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY EXPRESSLY EXCLUDED AND DISCLAIMED BY ALLTRADE AND OR ITS REPRESENTATIVES PURCHASER KNOWINGLY AND WILLINGLY WAIVES ANY AND ALL SUCH WARRANTIES AND RIGHTS CLAIMS AND OR CAUSES OF ACTION ARISING THEREFROM OR BASED THEREON PURCHASER S SOLE AND EXCLUSIVE REMEDY IS AS STATED ABOVE Limitation Of Liability IN NO EVENT SHALL ALLTRADE AND OR ITS REPRESENTATIVE S BE LIABLE FOR INDIRECT INCIDENTAL SPECIAL AND OR CONSEQUENTIAL DAMAGES OF ANY KIND ARISING OUT OF OR RELATED TO DIRECTLY OR INDIRECTLY ANY BREACH OF ANY PROVISION OF ANY AGREEMENT BETWEEN ALLTRADE AND OR ITS REPRESENTATIVE S AND PURCHASER ANY WARRANTY HEREUNDER AND OR THE EXISTENCE DESIGN MANUFACTURE PURCHASE USE AND OR OPERATION OF ANY ITEM S SOLD HEREUNDER EVEN IF ALLTRADE AND OR ITS REPRESENTATIVE S HAS BEEN ADVISED OF THE POSSIBILITY OF ANY SUCH DAMAGES IN NO EVENT WHETHER AS A RESULT OF A BREACH OF CONTRACT WARRANTY TORT INCLUDING NEGLIGENCE OR OTHERWISE SHALL ALLTRADE S AND OR ITS REPRESENTATIVE S LIABILITY EXCEED THE PRICE OF THE PRODUCT ANY AND ALL LIABILITY CONNECTED WITH THE USE OF THIS PRODUCT SHALL TERMINATE UPON THE EXPIRATION OF THE WARRANTY PERIODS SPECIFI
9. CONGRATULATIONS 2 INTENDED USE cj eck deed cba eee Vena a toda ages 2 SECTION ONE GENERAL SAFETY RULES 3 RECOGNIZE SAFETY SYMBOLS WORDS AND LABELS 2 3 IMPORTANT SAFEGUARDS 3 WORK AREA 4 ELECTRICAL SAFETY 2 0 0 4 PERSONAL SAFETY 5 TOOL USE AND CARE 6 SERVICE Sad peta he gad a ta 6 SECTION TWO SPECIFIC SAFETY RULES AND OR SYMBOLS 7 IMPORTANT SAFETY RULES FOR USING ARC WELDERS 7 8 SYMBOLS sisa oink sa eE a eE a ede ea eae lies 8 SECTION THREE FUNCTIONAL DESCRIPTION 9 ASSEMBLY uy ay Alice Aad wakana bea 10 13 ATTACHING THE HANDLE 10 ASSEMBLE WELDING HELMET 11 LOAD REPLACE FLUX CORE WELDING WIRE 12 13 OPERATING THE ARC WELDER 14 19 DUTY CYCLE AND THERMAL OVERLOAD OPERATION 14 WEEDING TIPS 15 WELDING GUIDELINES 15 17 ADDITIONAL SAFETY STANDARDS 17 TROUBLESHOOTING WELDS 17 18 TROUBLESHOOTING WELDER
10. ED ABOVE Limitations on Warranty Disclaimers Some states do not allow limitations on how long an implied warranty lasts and some states do not allow the exclusion or limitation of the incidental or consequential damages so part or all of the above limitations or exclusions may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state If your product is not covered by this warranty please call our Customer Service Department toll free at 1 800 590 3723 for general repair information and charges 24
11. FOR CUSTOMER SERVICE POUR LE SERVICE APRES VENTE OU DU CONSOMMATEUR PARA EL SERVICIO PARA EL CONSUMIDOR 1 800 590 3723 Printed in China Kawasaki Motors U S A F OFFICIAL LICENSED PRODUCT 87 1904 60957 KAWASAKI IS A TRADEMARK LICENSED BY KAWASAKI MOTORS CORP U S A WHICH DOES NOT MANUFACTURE OR DISTRIBUTE THIS PRODUCT CONSUMER INQUIRES SHOULD BE DIRECTED TO COPYRIGHT 2007 ALLTRADE TOOLS LLC 1431 VIA PLATA LONG BEACH CA 90810 1462 USA 8400641 80 Amp Wire Feed Arc Welder_Rev 6 21 07 COMPONENT Kawasaki 80 AMP WIRE FEED ARC WELDER INSTRUCTION MANUAL THS MANUAL CONTAINS IMPORTANT INFORMATION REGARDING SAFETY OPERATION MAINTENANCE AND STORAGE OF THS PRODUCT BEFORE USE READ CAREFULLY AND UNDERSTAND ALL CAUTIONS WARNINGS INSTRUCTIONS AND PRODUCT LABELS FAILURE TO DO SO COULD RESULT IN SERIOUS PERSONAL IN URY AND OR PROPERTY DAMACE IF YOU SHOULD HAVE ANY QUESTIONS OR EXPERIENCE A PROBLEM WTH YOUR ALLTRADE PRODUCT DO NOT RETURN THS PRODUCT TO THE STORE PLEASE CALL OUR CUSTOMER DEPARTMENT 1 800 590 3723 BEFORE YOU CALL HAVE THE FOLLOWING INFORMATION AVAILABLE MODEL No DATE PURCHASED AND STORE LOCATION AN ALLTRADE REPRESENTATIVE CAN RESOLVE YOUR PROBLEM OVER THE PHONE IF YOU WOULD LIKE TO MAKE A SUGGESTION OR COMMENT GYE US A CALL OR EMAIL US INFO ALLTRADETOOLS COM YOUR FEEDBACK IS VITAL TO US TABLE OF CONTENTS
12. assages can cause the Arc Welder to overheat UNPACKING All welding accessories except for the welding helmet and leather gloves are stored inside the wire feed compartment on the top of the welder Lift and remove the wire feed cover to find the handle work clamp grounding cable and wire spool ASSEMBLY WARNING Disconnect the power plug from the AC N power source before any assembly adjustments or adding removing accessories Following this preventative step reduces the risk of the Arc Welder coming on accidentally and the risk of damage to the workpiece and injury to the operator ATTACH HANDLE 1 Place the handle 1 on top of the cover 2 Secure the handle using the screws and washers 2 ASSEMBLE WELDING HELMET LOAD REPLACE FLUX CORE WELDING WIRE 1 Position the headgear inside the helmet Assemble the helmet by inserting the stud screw through the headgear and helmet into the tension nut DO NOT WARNING Ensure the welder is off before attempt ing to load the flux core wire Do not turn the welder until instructed Failure to follow these instructions could result in tighten the tension nut at this time serious personal injury Do not touch anything with the torch head as it may ignite LOADING THE FLUX CORE WIRE 1 Ensure the welder is OFF Lift the cover Unscrew the wing nut by turning it counterclockwise Remove the empty wir
13. d the slag can be removed Use a chipping ham mer this may be located on top of a wire brush handle to break the slag away from the weld Final cleanup is done with the wire brush 16 WELDING POSITIONS TROUBLESHOOTING CHART WELDS Welding positions can be categorized into four basic types flat horizontal vertical and overhead Welding in the flat position is the easiest of all the different types SYMPTOM POSSIBLE CAUSES S CORRECTIVE ACTION because welding speed can be increased and the molten metal has a less tendency to run better penetration can be achieved and the work is less fatiguing Welding is performed with wire at a 45 travel angle and a 45 work angle Other positions Ragged 1 Travel Speed too fast 1 Decrease travel speed depressions 2 Wire speed too fast 2 Decrease wire speed require different welding techniques such as weaving pass circular pass or jogging of 3 Output heat setting too high 3 Reduce output heat setting pass These techniques should only be attempted as the welder s skills improve over time Overhead welding is least desirable position as it is the most dangerous and 1 Inconsistent ravel speed 1 Decrease and maintain constant most difficult Heat setting and wire selections are more critical in this type The Weld bead travel speed same special requirements are true for horizontal and vertical welding For specific does not 2 Output heat setting too low 2 Increase output heat set
14. d or DEATH from electric shock DO NOT use the Arc Welder in confined spaces where inhala 2 tion of fumes is possible Use only in well ventilated areas GA Breathing the fumes can lead to serious health problems such as N bronchitis pneumonia or emphysema Additional severe health risks include ulcers intestinal inflammation reproductive organ damage kidney damage heart disease and early onset of Parkinson s disease Keep your head away from the fumes at all times If you are at risk of breathing the fumes wear an appropriate respirator People with electronic devices such as pacemakers should consult their physician s before using this product Operation WQ of electrical equipment in close proximity to a heart pacemak er could cause failure or interference of the pacemaker WARNING Handling the power cord on this product may expose you to lead a chemical known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE 3 WORK AREA Ensure the work area is clean of debris and other foreign material that may ignite or explode upon contact with welding sparks or slag Keep the work area well lit at all times Cluttered work benches and dark work areas may be prone to accidents resulting in serious injury Keep the work area adequately ventilated Breathing the fumes 2 can lead to serious health probl
15. e Arc Welder Always use compressed air to blow out dust e DO NOT attempt to repair the Arc Welder yourself If the unit is not working properly DO NOT use it until it has been repaired and inspected by a qualified technician ACCESSORIES 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 Always attach grounded 3 prong extension cords to grounded 3 hole outlets If you must use an extension cord be sure that the gauge is large enough to carry the amount of current necessary for your power tool If not your tool may experi ence a loss of power excessive voltage drop or overheating The smaller the gauge number the heavier the cord see table below RECOMMENDED SIZES OF EXTENSION CORDS 120 VOLT AC 60 HZ TOOLS TOOL CURRENT RATING CONDUCTOR SIZE IN A W G AMPERE 10FT 25FT 50FT 100FT 3 6 18 18 18 18 6 8 18 18 18 16 8 10 18 18 18 14 10 12 16 16 14 14 12 16 14 12 12 16 20 12 12 12 SPECIFICATIONS SPECIFICATIONS Input 120V N 60 Hz 20 No Load Output 28VAC Rated Output 19 5VAC 62 Min Max 21 2VAC 80A Duty Cycle 20 62A 10 80A OTHER CONSUMER DO IT YOURSELF DIY TOOLS Alltrade offers a full range of Kawasaki tools that make DIY jobs easy If you would like further information on the following products please contact Alltrade Customer Service Department at
16. e equipment Check the power cord for breaks and other damage and replace if necessary Make sure the equipment is clean dry and free from oily substances Do not used damaged equipment DO NOT attempt to repair the Arc Welder Only a qualified technician should make repairs to this tool Do not force this equipment ALWAYS use the correct equipment for the application being worked on The correct equipment will do the job better and safer at the rate for which it was designed SERVICE Use only authorized replacement parts for the Arc Welder and insulated footwear ONLY qualified repair technicians using authorized replacement parts must perform equipment service Service or maintenance by unqualified personnel could result in considerable risk of personal injury Use of unauthorized parts or failure to follow maintenance instructions may create a risk of injury and or death from electrical shock SPECIFIC SAFETY RULES AND OR SYMBOLS 4 WARNING Hold tool by insulated gripping surfaces when perform ing an operation where the cutting tool may contact hidden wiring or it s own cord Contact with a live wire will also make exposed metal parts of the tool live and shock the operator IMPORTANT SAFETY RULES FOR USING ARC WELDERS A WARNING Do not overreach or reach across operating equipment Maintain proper foot ing and balance at all times Do not turn on the ON OFF switch until you are prepared to begin w
17. e reel from the shaft a WwW Secure the full wire reel 1 to the shaft 2 with the washer 3 wing nut 4 by turning it clockwise Po Position the adjustment arms on both sides of the helmet Place the small pins through the helmet and into one of the small holes on the adjustment arms This controls the fit of the helmet when lowered over the face and can be easily repositioned if necessary Unwind the flux core wire 5 a counterclockwise direction 7 Press down on the tension spring 6 to remove tension 8 Guide at least 12 of wire into the torch sheath If the wire end is crimped or bent cut it off and remove any visible burrs 9 Replace the tension on the tension spring 6 3 Try on the welding helmet Adjust the headgear ratchet band to a comfortable position and lower the helmet If the helmet is too far away or too close to the face use a different hole in the adjustment arm Adjust the tension nuts so the helmet can easily be lowered over the face by nodding the head 11 BRINGING WELDING WIRE THROUGH THE TORCH HEAD 10 Turn the torch handle nozzle 7 counterclockwise and pull to remove 11 Turn contact tip 8 counterclockwise and remove 12 Lay torch sheath out in a straight line so the flux core wire moves through easily 13 Plug the welder s power cord into an approved AC outlet 14 Press the current switch to MAX and turn the welder ON
18. elding operation A WARNING Always remain alert Be aware of your surroundings while using the Arc Welder Do not use the Arc Welder while under the influence of prescription medication or alcohol Using prescription medication or alcohol can affect your senses and slow your reaction time resulting in a serious personal injury or even death Before use inspect the Arc Welder for damaged or defective parts DO NOT use the Arc Welder if any portion or accessory is damaged or defective Carefully inspect the Welder and all the accessories for damage Check for breakage of parts damage to guards and switches misalignment and or seizure of moving parts that could affect the Welder s operation Ensure the Welder will operate properly and perform its intended function If there should be damaged or defective parts call Alltrade s Customer Service Department at 1 800 590 3723 DO NOT ATTEMPT to repair the Arc Welder yourself Only trained technicians should repair this tool DO NOT use the Arc Welder if the ON OFF does not function properly Always use ANSI compliant safety equipment Always wear eye and ear protection Use impact resistant safety goggles e Wear non skid safety shoes Always wear an approved welding helmet with the proper filters for the type of welding you are doing Always wear leather welding gloves and flame resistant clothing with long sleeves Dress Properly Do not wear loose cl
19. ems such as bronchitis pneumo 9 nia or emphysema Additional severe health risks include ulcers intestinal inflammation reproductive organ damage kidney dam age heart disease and early onset of Parkinson s disease Keep your head away from the fumes at all times If you are at risk of breathing the fumes wear an appropriate respirator N Z DO NOT operate the Arc Welder is areas containing flammable liquids gases or dust The welder creates sparks and extreme ly hot metal droplets or slag which can ignite the flammable liq uids gases or dust resulting in severe burns and or death Keep bystanders children and visitors safely away from the Arc Welder dur ing operation All persons in the work area MUST wear protective welding gear especially properly filtered goggles of welding helmets to prevent permanent serious injury to the eyes or blindness ELECTRICAL SAFETY A WARNING Do not abuse the power cord or use a damaged power cord NEVER use the power cord to carry or pull the equipment Never use the power cord to disconnect the plug from a power outlet ALWAYS keep power cords away from heat oil sharp or jagged edges or moving parts REPLACE DAMAGED POWER CORDS IMMEDIATELY Damaged power cords increase the risk of severe electrical shock or burns resulting in serious injury and or death _ Always make sure the work piece is properly grounded and secured before attempting any w
20. eres Current Hz Hertz Frequency Cycles per Second W Watt Power Kg Kilograms Weight No Alternating Current Type of Current Direct Current Type of Current Alternating or Direct Current Type of Current Earthing Terminal Grounding Terminal min Minutes Time 5 Seconds Time Diameter Size of Drill Bits Grinding Wheels etc Ny No load speed No load Rotational Speed Revolutions per Minute Revolutions Surface Speed Strokes etc per Minute 1 2 3 Ring Selector Settings Speed Torque or Position Settings FUNCTIONAL DESCRIPTION CONTROLS AND COMPONENTS ACCESSORIES 1 Welder 10 Wire Reel Washer and Wing Nut 2 Torch 11 Flux Core Wire 3 Overload Indicator 12 Wire Brush Hammer 4 Power Switch 13 Contact Tip 5 Wire Speed Control 14 Leather Welding Gloves 6 Amperage Selection Switch 15 Wrench 7 Ground Cable 8 Power Cord 9 Helmet A CAUTION This arc welder requires a dedicated 120V 60 Hz 30 AMP circuit at Max amperage setting or 20 Amp circuit at Min amperage setting to function properly Do not run other lights appli ances or tools on this circuit while the Arc Welder is in operation Failure to comply with this CAUTION will result in tripped circuit breakers and or blown fuses LOCATION Position the Arc Welder on a secure level surface in a dry location where there is free circulation of clean air Ensure all air passages are clean and free of obstruc tions Blocked air p
21. gin welding NEVER let any part of your body touch the grounded work piece and the flux core wire at the same time This could cause severe electrical shock resulting in severe injury or even death N A WARNING Make sure the contents of closed containers are known and steps are made to properly ventilate or flush the contents to prevent possible explosions that could result in fire serious burns and injury and or even death _ Always keep power cords and welding cables away from your body at all times Always uncoil the welding cable before use Coiled cables may overheat Never touch the work piece immediately after welding Allow the metal to cool before handling in order to prevent serious injury Never leave the Arc Welder running unattended Always shut the equipment off before leaving the area Trim any excess welding wire protruding from the torch before storage When welding above your head ALWAYS wear ear plugs to prevent sparks or hot metal drops from falling into the ear canal Maintain ALL labels and nameplates on the Arc Welder These carry important information Should they become unreadable contact Alltrade for replacements SYMBOLS IMPORTANT Some of the following symbols may be used on your tool Please study them and learn their meaning Proper interpretation of these symbols will allow you to operate the tool better and safer SYMBOL EXPLANATION Volts Voltage Potential A Amp
22. ich the wire is being melted in the arc Tuning is one of the most critical functions in wire feed welding This procedure should be performed on a scrap piece of metal that is the type and thickness as the work piece Using the scrap piece begin welding by dragging the torch nozzle across the sur face with one hand while adjusting the speed with the other If the speed is too slow sputtering will occur and the wire will burn up into the contact tip If the speed is too fast sputtering will also occur but the wire will push into the plate before melt ing A smooth buzzing sound indicates the wire speed is correctly tuned Repeat this procedure anytime the work piece changes or there is a change in heat setting or wire diameter TRAVEL SPEED The travel speed is the rate at which the welding wire is moved across the work piece Factors such as type and diameter of the weld wire amperage position and work piece thickness all affect the travel speed necessary for a good weld If the speed is too fast the bead becomes narrow and the bead ripples are pointed When the weld speed is too slow the weld metal piles up and bead becomes high and wide SLAG REMOVAL After completing the welding project wait for the metal pieces to cool before con tinuing A protective coating called slag covers the weld bead preventing contami nants in the air from reacting with the molten metal After the weld has cooled to the point it is no longer glowing re
23. ly ignite Turn the Arc Welder ON Test the speed of the wire feed Adjust as necessary Cut off excess wire so only 1 4 inch is protruding from the torch tip Put on welding goggles or lower welding helmet Ignite the arc by passing the electrode wire back and forth over the work piece When finished welding lift the torch away from the work piece or any other grounded objects Turn the Arc Welder OFF Unplug the AC power cord from the receptacle DUTY CYCLE AND THERMAL OVERLOAD OPERATION This Arc Welder is designed to operate at the maximum duty cycle which is a per centage of actual weld time For example for a ten minute interval at 10 maximum duty cycle the actual welding time would be one minute The Arc Welder should then cool for nine minutes The Arc Welder has an automatic thermal switch which protects the internal components and accessories from overheating If the duty cycle is exceeded the red lamp on the front of the Arc Welder will turn ON Resume welding when the red lamp turns OFF 14 WELDING TIPS Make sure you move the torch across the weld at the proper speed You want the weld metal to flow smoothly onto the work piece If the bead is too high or too wide your speed is too slow If the bead is too narrow your speed is too fast If the flux core wire is burning up before leaving the contact tip the wire speed is too slow More tension should be added
24. ng and clean ing power tools Always use common sense and pay particular attention to all the DANGER WARNING CAUTION and NOTE statements of this manual A 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 an imminently hazardous situation which if not avoided will result in death or serious injury DANGER WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury A CAUTION CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury CAUTION CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided may result in property damage NOTE NOTE provides additional information that is useful for proper use and maintenance of this tool If a NOTE is indicated make sure it is fully understood IMPORTANT SAFEGUARDS Read and understand all instructions before attempting to use the Arc Welder Failure to follow and adhere to all safety precautions may lead to seri ous personal injury and or death 0 DO NOT immerse any part of this equipment in water Should the Arc Welder or attachments become wet for any reason DO NOT use until completely dry Using the Arc Welder when it is damp could lead to severe burns an
25. not apply to any other product and or component thereof manufactured or distributed by Alltrade and does not apply to products and or components thereof designed manufactured and or assembled by others for which Alltrade makes no warranties whatsoever THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF Warranty Performance By purchasing the product purchaser expressly acknowledges and agrees that their sole and exclusive remedy under this warranty shall be strictly limited to the repair or replacement of any covered nonconforming items or parts thereof provided that any such nonconforming item and or part is promptly returned to Alltrade s facility postage pre paid and insured address ALLTRADE Warranty Claims amp Repair 1431 Via Plata Long Beach CA 90810 Attn Customer Service 1 800 590 3723 within the applicable warranty period with a written request by purchaser that Alltrade repair and or replace the nonconforming item and or part We recommend that you keep the original product packaging in the event you need to ship the unit We suggest the package be insured against loss or in transit damage When sending your product include your name address phone number dated proof of purchase or copy and a statement about the nature of problem Warranty coverage is conditioned upon purchaser furnishing Alltrade with adequate written proof that they are the original purchaser and of the original purchase date
26. ork NEVER look at the arc welder flame without approved eye pro x tection Arc welding operations produce intense light heat and ultraviolet UV radiation Always wear a welders helmet or goggles with the proper filtration when performing arc welding operations Failure to use properly filtered goggles or helmet could cause per manent severe damage to your eyes or even cause blindness The UV radiation will burn your skin and has been known to cause certain types of skin cancer BE AWARE that arc welding produces sparks and drops of HOT metal These sparks and hot metal can cause severe burns Keep the work area clear of combustible materials The sparks and hot drops of metal can cause certain materials to ignite or even explode Some metals have coatings that produce extremely toxic fumes when heated When working with metals containing beryllium AP zinc mercury or metals that use cadmium or galvanize plating remove the coating before welding Even after the coating has been removed work in a well ventilated area and DO NOT inhale the welding fumes Always keep a fire extinguisher nearby when the Arc Welder is TS in use Sparks and or hot drops of metal discharged during the welding operation can cause fires Keep rags paper and other combustible chemicals away from welding operations at all times ALWAYS ground the work piece first To do this clamp the grounding clamp to the work piece before you be
27. othing jewelry unrestrained long hair or any other attire that may become caught in moving parts of the equipment Always wear ANSI compliant protective electrically nonconductive welding gear including protective clothing leather welding gloves welding helmet TOOL USE AND CARE WARNING Do not use the arc welder if the power switch does not turn on or off Any equipment that cannot be controlled with the power switch is dangerous and should be repaired or replaced immediately Store this equipment properly when not in use and keep out of reach of chil dren and untrained persons This equipment is extremely dangerous in the hands of untrained users Do not attempt to use this equipment at a current setting or duty cycle that exceeds those specified by the manufacturer This Arc Welder is engineered to be operated at the specifications shown on the attached labeling Deviations from these specifications could lead to damage to the equipment and or seri ous injury or death to the operator Always disconnect the power cord from the power source before making any adjustments changing accessories or storing the arc welder Use clamps not included or other practical ways to secure the workpiece to a stable platform Ensure the work piece is properly grounded before beginning any welding operations Before use check for damaged parts and examine all mounting bolts and other moving parts before using th
28. ting applications consult an arc welding technical manual penetrate base metal 3 Extension cord too long 3 Use an extension cord no longer ADDITIONAL SAFETY STANDARDS Daley ie 1 Damp wire 1 Use dry wire and store dry plac ANSI Standard 249 1 From the American Welding Society Wire sputters 2 Wire speed too fast 2 Reduce wire speed Safety and Health Standards OSHA 29 CFR 1910 and sticks 3 Wrong type of wire 3 Use FLUX CORE wire only do not National Electrical Code NPFA Standards 51B and 70 from the National fire use MIG or copper color wire Protection Association Code For Safety in Welding and Cutting CSA Standard W117 2 from BELOW ARE SEVERAL DIFFERENT TYPES OF WELD APPEARANCES ee oe ee So s Safe Practices for Occupational and Educational Eye and Face Protection ANSI Standard Z87 1 from American National Standards Institute TROUBLESHOOTING CHART WELDS SYMPTOM POSSIBLE CAUSES S CORRECTIVE ACTION 8 Bead is 1 Inconsistent travel 1 Decrease and maintain constant intermittently speed travel speed eee Se too thin 2 Output heat setting too low 2 Increase output heat setting gion 1 Slow and or inconsistent 1 Increase and maintain travel intermittently travel speed too thick 2 Output heat setting too high 2 Reduce output heat setting Normal heat k u Toostow TRAVEL
29. to the wire feed adjustment spring If the flux core wire is leaving the contact tip before being completely melted the wire speed is too fast Less tension should be applied to the wire feed adjustment spring If the joint is not filled on the first pass continue making passes until the weld ing joint is secure Be sure to remove all remaining slag between passes Never use an electric arc welder to thaw frozen pipes WELDING GUIDELINES GENERAL The KAWASAKI 90 Amp Wire Feed Welder incorporates a process called Flux Cored Arc Welding FCAW The FCAW process uses a special tubular wire with flux inside When the current produced by the Welder flows through the circuit to the to the welding wire an electrical arc is created between the wire and the work piece Heat from the arc melts both the welding wire and the work piece The liquefied metal then flows into the molten crater on the work piece creating a welded bond ARC WELDING BASICS There are five general basics that can affect the output of the welded work piece wire selection heat setting weld angle wire speed and travel speed WIRE SELECTION The correct choice of welding wire can impact the effectiveness of the welding proj ect Factors such as welding position work piece material type thickness and sur face condition can affect the end results of the project The American Welding Society AWS has set guidelines for welding wire An example is shown below E
30. trade Repair Parts will void warranty Warranty Disclaimers EXCLUSION AND DISCLAIMER OF ALL OTHER EXPRESS WARRANTIES GUARANTIES AND OR REPRESENTATIONS EXCEPT FOR THE LIMITED WARRANTY PROVIDED ABOVE ALL OTHER EXPRESS WARRANTIES GUARANTIES AND OR REPRESENTATIONS BY ALLTRADE AND OR ITS REPRESENTATIVE S REGARDING THE DESIGN MANUFACTURE PURCHASE USE AND OR OPERATION OF THE PRODUCT OR ANY COMPONENT THEREOF SOLD HEREUNDER REGARDLESS OF WHETHER ANY SUCH WARRANTY GUARANTY AND OR REPRESENTATION WRITTEN OR ORAL ARISES BY OPERATION OF LAW AND OR EQUITY AND OR BY ANY ACT OR OMISSION OF ALLTRADE AND OR ITS REPRESENTATIVE S OR THE BUYER ARE HEREBY EXPRESSLY EXCLUDED AND DISCLAIMED BY ALLTRADE AND OR ITS REPRESENTATIVES PURCHASER KNOWINGLY AND WILLINGLY WAIVES ANY AND ALL SUCH WARRANTIES AND RIGHTS CLAIMS AND OR CAUSES OF ACTION ARISING THEREFROM OR BASED THEREON PURCHASER S SOLE AND EXCLUSIVE REMEDY IS AS STATED ABOVE EXCLUSION AND DISCLAIMER OF ALL IMPLIED WARRANTIES INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR 23 PURPOSE NO WARRANTY ORAL OR WRITTEN OTHER THAN THE ABOVE WARRANTY IS MADE WITH REGARD TO THIS PRODUCT ALL EXPRESS AND OR IMPLIED WARRANTIES GUARANTIES AND OR REPRESENTATIONS BY ALLTRADE AND OR ITS REPRESENTATIVE S REGARDING THE DESIGN MANUFACTURE PURCHASE USE AND OR OPERATION OF THE PRODUCT OR ANY COMPONENT THEREOF SOLD HEREUNDER REGARDLESS OF WHETHER ANY SUCH WARRANTY GUARANTY
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