Kawasaki 840641 User's Manual

COMPONENT
#840641
80 AMP WIRE FEED ARC WELDER
INSTRUCTION MANUAL
THIS MANUAL CONTAINS IMPORTANT INFORMATION REGARDING SAFETY, OPERATION,
MAINTENANCE AND STORAGE OF THIS PRODUCT. BEFORE USE, READ CAREFULLY AND
UNDERSTAND ALL CAUTIONS, WARNINGS, INSTRUCTIONS AND PRODUCT LABELS. FAILURE TO DO
SO COULD RESULT IN SERIOUS PERSONAL INJURY AND/OR PROPERTY DAMAGE.
FOR CUSTOMER SERVICE
POUR LE SERVICE APRÉS VENTE
OU DU CONSOMMATEUR
PARA EL SERVICIO
PARA EL CONSUMIDOR
1-800-590-3723
Printed in China
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
IF YOU SHOULD HAVE ANY QUESTIONS OR EXPERIENCE A PROBLEM WITH YOUR ALLTRADE
PRODUCT, DO NOT RETURN THIS PRODUCT TO THE STORE. PLEASE CALL OUR CUSTOMER SERVICE
DEPARTMENT AT 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, GIVE US A CALL OR EMAIL US AT: INFO@ALLTRADETOOLS.COM.
YOUR FEEDBACK IS VITAL TO US.
TABLE OF CONTENTS
CONGRATULATIONS! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INTENDED USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SECTION ONE
GENERAL SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
RECOGNIZE SAFETY SYMBOLS, WORDS AND LABELS . . . . . . . . 2-3
IMPORTANT SAFEGUARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
WORK AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ELECTRICAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PERSONAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TOOL USE AND CARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SECTION TWO
SPECIFIC SAFETY RULES AND/OR SYMBOLS . . . . . . . . . . . . . . . . . . . 7
IMPORTANT SAFETY RULES FOR USING ARC WELDERS . . . . . . . 7-8
SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SECTION THREE
FUNCTIONAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
WELDING TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
WELDING GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-17
ADDITIONAL SAFETY STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . 17
TROUBLESHOOTING WELDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-18
TROUBLESHOOTING WELDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
S EC T I O N F O U R
MAINTENANCE AND CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
OTHER CONSUMER DO-IT-YOURSELF (DIY) TOOLS . . . . . . . . . . . . . . 21
SECTION FIVE
3 YEAR LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-24
1
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 professional 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
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 possible conditions and practices that may occur when operating, maintaining and cleaning power tools.
Always use common sense and pay particular attention to all the DANGER,
WARNING, CAUTION and NOTE statements of this manual.
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.
WARNING indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
2
CAUTION indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury.
WORK AREA
CAUTION used without the safety alert symbol
indicates a potentially hazardous situation which,
if not avoided, may result in property damage.
Ensure the work area is clean of debris and other foreign material that may
ignite or explode upon contact with welding sparks or slag.
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
We l d e r. Failure to follow and adhere to all safety precautions may lead to serious personal injury and/or death.
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 and/or DEATH from electric
shock.
DO NOT use the Arc W e l d e r i n c o n f i n e d s p a c e s w h e r e i n h a l a tion of fumes is possible. Use only in well ventilated areas.
Breathing the fumes can lead to serious health problems such as
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
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.
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
can lead to serious health problems such as 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.
DO NOT operate the Arc W e l d e r i s a r e a s c o n t a i n i n g f l a m m a b l e
liquids, gases, or dust. The welder creates sparks and extremely hot metal droplets or “slag” which can ignite the flammable liquids, gases, or dust resulting in severe burns and/or death.
Keep bystanders, children, and visitors safely away from the Arc We l d e r d u r 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
Do not abuse the power cord or use a damaged power cord.
NEVER use the power cord to carr y o r p u l l t h e e q u i p m e n t . N e v e r
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 DAMAG ED 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 welding operation.
SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE.
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4
PERSONAL SAFETY
TOOL USE AND CARE
Always remain alert. Be aware of your surroundings while using the Arc
We l d e r. 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.
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.
Before use, inspect the Arc Welder for damaged or defective parts. DO NOT
use the Arc W e l d e r i f a n y p o r t i o n o r a c c e s s o r y i s d a m a g e d o r d e f e c t i v e .
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 A l l t r a d e ’s Customer Ser vice 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.
• 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 clothing, 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,
and insulated footwear.
5
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 serious 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 the 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 We l d e r. 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 We l d e r.
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 injur y and/or death from electrical
shock.
6
SPECIFIC SAFETY RULES AND/OR SYMBOLS
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.
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 injur y and/or even death.
Always keep power cords and welding cables away from your
body at all times.
IMPORTANT SAFETY RULES FOR USING ARC WELDERS
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 We l d e r. These carry important
information. Should they become unreadable, contact Alltrade for replacements.
Do not overreach or reach across operating equipment. Maintain proper footing and balance at all times. Do not turn on the “ON/OFF” switch until you are
prepared to begin work.
NEVER look at the arc welder flame without approved eye pro 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 permanent 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,
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 We l d e r i s
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 begin 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.
7
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
V
A
Hz
W
Kg
min
s
␾
NAME
Volts
Amperes
Hertz
Watt
Kilograms
Alternating Current
Direct Current
Alternating or Direct Current
Earthing Terminal
Minutes
Seconds
Diameter
.../min
No load speed
Revolutions per Minute
1,2,3, …
Ring Selector Settings
EXPLANATION
Voltage (Potential)
Current
Frequency (Cycles per Second)
Power
Weight
Type of Current
Type of Current
Type of Current
Grounding Terminal
Time
Time
Size of Drill Bits,
Grinding Wheels, etc.
No-load Rotational Speed
Revolutions, Surface Speed,
Strokes, etc. per Minute
Speed, Torque or Position Settings
FUNCTIONAL DESCRIPTION
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 obstructions. Blocked air passages can cause the Arc Welder to overheat.
1
2
3
5
4
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.
6
15
ASSEMBLY
8
7
14
10
Disconnect the power plug from the AC
p o w e r s o u r c e b e f o r e a n y a s s e m b l y, a d j u s t m e n t s , o r
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.
9
11
13
2. Secure the handle, using the screws and washers (2).
12
1
CONTROLS AND COMPONENTS:
1. Welder
2. Torch
3. Overload Indicator
4. Power Switch
5. Wire Speed Control
6. Amperage Selection Switch
7. Ground Cable
8. Power Cord
9. Helmet
ACCESSORIES:
10. Wire Reel Washer and Wing Nut
11. Flux Core Wire
12. Wire Brush/Hammer
13. Contact Tip
14. Leather Welding Gloves
15. Wrench
2
2
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, appliances, 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.
9
10
ASSEMBLE WELDING HELMET:
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
tighten the tension nut at this time.
LOAD / REPLACE FLUX CORE WELDING WIRE
Ensure the welder is “off” before attempt ing to load the flux-core wire. Do not turn the welder “ o n ” until
instructed. Failure to follow these instructions could result in
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 “ O F F. ”
2. Lift the cover.
3. Unscrew the wing nut by turning it counterclockwise.
4. Remove the empty wire reel from the shaft.
5. Secure the full wire reel (1) to the shaft (2) with the washer (3) wing nut (4)
by turning it clockwise.
2. 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.
6. Unwind the flux-core wire (5) in 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).
1
2
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
3
5
4
A.
B.
C.
D.
BRINGING WELDING WIRE THROUGH THE TORCH HEAD
10. Turn the torch handle nozzle (7) counterclockwise and pull to remove.
OPERATING THE ARC WELDER
• Ensure the Arc Welder is turned “ O F F. ”
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 “ M A X ” and turn the welder “ O N . ”
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 “ O F F ” and add more tension to the wire feed adjustment
spring.
17. Turn welder “ O N ” and press trigger. One flux-core wire is exposed, turn
welder “ O F F. ”
18. Slide contact tip (8) over the flux-core wire (10) and screw it into the torch
end (11).
• 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 acceptable alternate.
• Set the Current Switch. The thicker the work piece, the higher the current.
• Set the Wire Speed Control to 5. Adjust as needed.
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.
19. Replace nozzle and cut off any flux-core wire in excess of a 1/4 inch.
Hold the Torch away from any grounded object. Contact
with a grounded object may cause the torch to inadvertently ignite.
20.Close the cover on top of the welder.
• Turn the Arc Welder “ O N . ”
• 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.
2"
7
• Put on welding goggles or lower welding helmet.
8
• Ignite the arc by passing the electrode wire back and forth over the work piece.
9
• When finished welding, lift the torch away from the work piece or any other
grounded objects.
10
• Turn the Arc Welder “ O F F. ”
8
1/4"
• Unplug the AC power cord from the receptacle.
DUTY CYCLE AND THERMAL OVERLOAD OPERATION
8
This Arc Welder is designed to operate at the maximum duty cycle, which is a percentage 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 “ O N . ”
Resume welding when the red lamp turns “ O F F. ”
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13
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 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 welding 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 project. Factors such as welding position, work piece material type, thickness, and surface 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-70T-GS
E7
0
T
-GS
AWG classification for self-shielding wire
Weld Strength, times 10,000 lbs per square inch
Welding Positions: 0 = Flat, 1 = All other positions
Tubular Flux-core Wire
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 setting. 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 formation. 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 which 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 surface 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 melting. 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 continuing. A protective coating called slag covers the weld bead preventing contaminants in the air from reacting with the molten metal. After the weld has cooled to
the point it is no longer glowing red, the slag can be removed. Use a chipping hammer (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
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
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
require different welding techniques such as weaving pass, circular pass, or jogging
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
most difficult. Heat setting and wire selections are more critical in this type. The
same special requirements are true for horizontal and vertical welding. For specific
applications, consult an arc welding technical manual.
TROUBLESHOOTING CHART – WELDS
SYMPTOM
• Safety and Health Standards: OSHA 29 CFR 1910.
1. Travel Speed too fast
1. Decrease travel speed
2. Wire speed too fast
2. Decrease wire speed
3. Output heat setting too high 3. Reduce output heat setting
Weld bead
does not
penetrate
base metal
1. Inconsistent ravel speed 1. Decrease and maintain constant
travel speed
2. Output heat setting too low 2. Increase output heat setting
3. Extension cord too long 3. Use an extension cord no longer
than 20 feet
Wire
sputters
and sticks
1. Damp wire
2. Wire speed too fast
3. Wrong type of wire
1. Use dry wire and store in dry place
2. Reduce wire speed
3. Use FLUX CORE wire only - do not
use MIG or copper color wire
• National Electrical Code: NPFA Standards 51B and 70 from the National fire
Protection Association.
• Code For Safety in Welding and Cutting: CSA Standard W117.2, from
Canadian Standards Association.
CORRECTIVE ACTION
Ragged
depressions
at edge of
weld
ADDITIONAL SAFETY STANDARDS
• ANSI Standard Z49.1: From the American Welding Society.
POSSIBLE CAUSES(S)
BELOW ARE SEVERAL DIFFERENT TYPES OF WELD APPEARANCES.
• 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
1. Inconsistent travel
1. Decrease and maintain constant
Bead is
speed
travel speed
intermittently
too thin
2. Output heat setting too low 2. Increase output heat setting
1. Slow and/or inconsistent 1. Increase and maintain travel
Bead is
travel speed
speed
intermittently
too thick
2. Output heat setting too high 2. Reduce output heat setting
HEAT TOO
HIGH
Normal heat,
wire speed,
travel speed
HEAT TOO
LOW
17
WIRE SPEED
TOO SLOW
WIRE SPEED
TOO FAST
18
TRAVEL SPEED
TOO FAST
TRAVEL SPEED
TOO SLOW
TROUBLESHOOTING CHART – WELDER
SYMPTOM
POSSIBLE CAUSES(S)
CORRECTIVE ACTION
1. Duty cycle exceeded
No Output
1. Allow welder to cool down until
ON/OFF Switch lamp goes out
2. Be sure all connections are secure
2. Poor work clamp
and attaching surface is clean
connection
3.
Replace
switch
3. Defective ON/OFF switch
4. Tripper circuit breaker or 4. Reduce circuit load, reset breaker
or replace fuse
blown fuse
1. Wrong size gun tip
2. Gun liner clogged or
damaged
Wire tangles
3. Gun tip clogged or
at drive roller
damaged
4. Feed roller worn
5. Not enough tension
1. Use proper size gun tip
2. Clean or replace gun liner
3. Clean or replace gun tip
4. Replace feed roller
5. Tighten tensioning screw
Gun nozzle
arcs to work
piece
1. Slag inside gun nozzle
1. Clean slag from gun nozzle
Work clamp
and/or cable
gets hot
1. Poor contact
1. Ensure all connections are secure
and attaching surface is clean
Wire does
not feed
1. Wire jammed
2. Out of wire
3. Not enough tension
1. Reload wire
2. Replace wire spool
3. Tighten tensioning screws if wire
is slipping
4. Replace liner
4. Wire liner worn
19
MAINTENANCE AND CLEANING
Always UNPLUG the Arc W e l d e r f r o m t h e A C
power source before cleaning or maintenance.
• Keep the Arc Welder clean and dust free. Never use water to clean the Arc
Welder. Always use compressed air to blow out dust.
• 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 carr y
the amount of current necessar y for your power tool. If not, your tool may experience 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
-
20
SPECIFICATIONS
SPECIFICATIONS
Input
No Load Output
Rated Output
(Min./Max.)
Duty Cycle
120V
60 Hz 20A
28VAC
19.5VAC 62A
21.2VAC 80A
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 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 excluded 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 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 & 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. 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 responsible for the return shipping charges. Alltrade’s repair and/or replacement of any nonconforming 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 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 Alltrade 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 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 SPECIFIED ABOVE.
Limitations on Wa r r a n t y D i s c l a i m e r s
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