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
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.
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:
PARA EL SERVICIO
PARA EL CONSUMIDOR
©COPYRIGHT 2007 ALLTRADE TOOLS, LLC.
1431 VIA PLATA
1-800-590-3723
LONG BEACH, CA 90810-1462 USA
8400641 – 80 Amp Wire Feed Arc Welder_Rev. 6/21/07
Printed in China
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WORK AREA
CAUTION
indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury.
Ensure the work area is clean of debris and other foreign material that may
ignite or expllode upon contact with welding sparks or slag.
CAUTION
used without the safety alert symbol
indicates a potentially hazardous situation which,
if not avoided, may result in property damage.
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.
NOTE
provides additional information that is useful
Keep the work area adequately ventilated. Breathing the fumes
can lead to serious health problems such as bronchitis, pneumo-
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.
for proper use and maintenance of this tool. If a
NOTE is indicated make sure it is fully understood.
IMPORTANT SAFEGUARDS
DO NOT operate the Arc Welder is areas containing flammable
Read and understand all instructions before attempting to use the Arc
liquids, gases, or dust.
The welder creates sparks and extreme-
Welder.
Failure to follow and adhere to all safety precautions may lead to seri-
ly hot metal droplets or “slag” which can ignite the flammable liq-
uids, gases, or dust resulting in severe burns and/or death.
ous personal injury and/or death.
DO NOT immerse any part of this equipment in water.
Should
Keep bystanders, children, and visitors safely away from the Arc Welder dur-
the Arc Welder or attachments become wet for any reason, DO
NOT use until completely dry. Using the Arc Welder when it is
ing operation.
MUST
wear protective welding gear,
All persons in the work area
especially properly filtered goggles of welding helmets to prevent permanent,
serious injury to the eyes or blindness.
DEATH
damp could lead to severe burns and/or
shock.
from electric
DO NOT use the Arc Welder in confined spaces where inhala-
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.
ELECTRICAL SAFETY
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 DAMAGGED POWER CORDS
People with ellectronic 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.
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.
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
Wash hands after handling.
other reproductive harm.
SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE.
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PERSONAL SAFETY
TOOL USE AND CARE
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
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.
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.
Store this equipment properly when not in use and keep out of reach of chil-
dren and untrained persons.
hands of untrained users.
This equipment is extremely dangerous in the
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
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.
Alltrade’s Customer Service Department
be damaged or defective parts, call
1-800-590-3723 DO NOT ATTEMPT to repair the Arc Welder yourself.
Only
at
.
Always disconnect the power cord from the power source before
making any adjustments, changing accessories, or storing the
arc welder.
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 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.
• Use impact resistant safety goggles.
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
Do not used damaged equipment.
• Wear non-skid safety shoes.
• Always wear an approved welding helmet with the proper filters for the type
of welding you are doing.
clean, dry, and free from oily substances.
DO NOT attempt to repair the Arc Welder. Only a qualified technician should
make repairs to this tool.
• Always wear leather welding gloves and flame resistant clothing with long
sleeves.
Do not force this equipment. ALWAYS use the correct equipment for the
application being worked on.
safer at the rate for which it was designed.
The correct equipment will do the job better and
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.
SERVICE
• Always wear ANSI compliant, protective, electrically nonconductive welding
gear including protective clothing, leather welding gloves, welding helmet,
and insulated footwear.
Use only authorized replacement parts for the Arc Welder.
ONLY qualified repair technicians using authorized replacement parts must perform
equipment service. Service or maintenance by unqualified personnel could result in
Use of unauthorized parts or failure to follow
considerable risk of personal injury.
maintenance instructions may create a risk of injury and/or death from electrical
shock.
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SPECIFIC SAFETY RULES AND/OR SYMBOLS
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.
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
Always keep power cords and welding cables away from your
body at all times.
“live” and shock the operator.
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.
off before leaving the area. Trim any excess welding wire protruding from the
torch before storage.
Always shut the equipment
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 work.
When welding above your head, ALWAYS wear ear plugs to prevent sparks
or hot metal drops from falling into the ear canal.
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
Maintain ALL labels and nameplates on the Arc Welder.
These carry important
information. Should they become unreadable, contact Alltrade for replacements.
operations.
Failure to use properly filtered goggles or helmet could cause per-
SYMBOLS
blindness The UV radiation
manent severe damage to your eyes or even cause
will burn your skin and has been known to cause certain types of skin cancer
.
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.
BE AWARE that arc welding produces sparks and drops of HOT metal.
sparks and hot metal can cause severe burns.
These
SYMBOL
NAME
EXPLANATION
Voltage (Potential)
Current
Frequency (Cycles per Second)
Power
Weight
Type of Current
Type of Current
Keep the work area clear of combustible materials. The sparks and hot drops
of metal can cause certain materials to ignite or even explode.
V
A
Hz
W
Kg
Volts
Amperes
Hertz
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
Watt
Kilograms
Alternating Current
Direct Current
DO NOT
been removed, work in a well ventilated area and
the welding fumes.
inhale
Alternating or Direct Current Type of Current
Always keep a fire extinguisher nearby when the Arc Welder is
in use.
welding operation can cause fires. Keep rags, paper, and other
combustible chemicals away from welding operations at all
times.
Sparks and/or hot drops of metal discharged during the
Earthing Terminal
Minutes
Seconds
Grounding Terminal
Time
Time
min
s
Diameter
Size of Drill Bits,
ALWAYS ground the work piece first.
to the work piece before you begin welding.
touch the grounded work piece and the flux core wire at the same time.
To do this, clamp the grounding clamp
NEVER let any part of your body
Grinding Wheels, etc.
No load speed
No-load Rotational Speed
This
.../min
Revolutions per Minute
Revolutions, Surface Speed,
Strokes, etc. per Minute
could cause severe electrical shock resulting in severe injury or even death.
1,2,3, …
Ring Selector Settings
Speed, Torque or Position Settings
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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 obstruc-
tions. Blocked air passages can cause the Arc Welder to overheat.
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2
3
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UNPACKING
6
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.
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ASSEMBLY
Disconnect the power plug from the AC
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power source before any assembly, adjustments, or
adding/removing accessories.
reduces the risk of the Arc Welder coming on accidentally and the
risk of damage to the workpiece and injury to the operator.
Following this preventative step
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ATTACH HANDLE:
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1. Place the handle (1) on top of the cover.
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2. Secure the handle, using the screws and washers (2).
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1
CONTROLS AND COMPONENTS:
1. Welder
ACCESSORIES:
10. Wire Reel Washer and Wing Nut
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2
2. Torch
11. Flux Core Wire
3. Overload Indicator
4. Power Switch
12. Wire Brush/Hammer
13. Contact Tip
5. Wire Speed Control
6. Amperage Selection Switch
7. Ground Cable
14. Leather Welding Gloves
15. Wrench
8. Power Cord
9. Helmet
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 prroperly.
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.
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ASSEMBLE WELDING HELMET:
LOAD/REPLACE FLUX CORE WELDING WIRE
Ensure the welder is “off” before attempt-
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.
ing to load the flux-core wire.
“on”
until
Do not turn the welder
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-COREE WIRE
“OFF. ”
1. Ensure the welder is
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).
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2
3
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.
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4
A.
C.
B.
D.
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BRINGING WELDING WIRE THROUGH THE TORCH HEAD
10.Turn the torch handle nozzle (7) counterclockwise and pull to remove.
OPERATING THE ARC WELDER
“OFF. ”
• Ensure the Arc Welder is turned
11.Turn contact tip (8) counterclockwise and remove.
• Ensure the work piece is free of chemicals or oily substances that may catch
fire or impair the welding process.
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.
• 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.
“MAX”
“ON.”
and turn the welder
14.Press the current switch to
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,
Current Switch.
• Set the
• Set the
The thicker the work piece, the higher the current.
Wire Speed Control
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to . Adjust as needed.
“OFF”
turn the welder
spring.
and add more tension to the wire feed adjustment
If an
Plug in the power cord to an approved AC outlet.
“ON”
17.Turn welder
and press trigger. One flux-core wire is exposed, turn
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.
“OFF. ”
welder
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.
Contact
Hold the Torch away from any grounded object.
with a grounded object may cause the torch to inadvertently ignite.
“ON.”
• Turn the Arc Welder
• 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"
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8
9
• 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.
10
“OFF. ”
• Turn the Arc Welder
• Unplug the AC power cord from the receptacle.
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1/4"
DUTY CYCLE AND THERMAL OVERLOAD OPERATION
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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
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“ON.”
cycle is exceeded the red lamp on the front of the Arc Welder will turn
“OFF. ”
Resume welding when the red lamp turns
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HEAT SETTING
WELDING TIPS
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.
• 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.
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.
• 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.
•
WIRE SPEED
WELDING GUIDELINES
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 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.
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.
TRAVEL SPEED
WIRE SELECTION
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.
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-70T-GS
SLAG REMOVAL
E-
7
0
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
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 red, 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.
T
-GS
Flux Type
The Internet can be used for additional information on the American Welding
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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
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.
SYMPTOM
POSSIBLE CAUSES(S)
CORRECTIVE ACTION
Ragged
1. Travel Speed too fast
2. Wire speed too fast
1. Decrease travel speed
2. Decrease wire speed
depressions
at edge of
weld
3. Output heat setting too high 3. Reduce output heat setting
1. Inconsistent ravel speed 1. Decrease and maintain constant
travel speed
Weld bead
does not
penetrate
base metal
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
ADDITIONAL SAFETY STANDARDS
1. Damp wire
1. Use dry wire and store in dry place
2. Reduce wire speed
ANSI Standard Z49.1:
•
•
•
From the American Welding Society.
Wire
sputters
and sticks
2. Wire speed too fast
3. Wrong type of wire
Safety and Health Standards:
OSHA 29 CFR 1910.
3. Use FLUX CORE wire only - do not
use MIG or copper color wire
National Electriccal Code: NPFA Standards 51B and 70 from the National fire
Protection Association.
BELOW ARE SEVERAL DIFFERENT TYPES OF WELD APPEARANCES.
Code For Safety in Welding and Cutting:
Canadian Standards Association.
•
•
CSA Standard W117.2, from
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
speed
1. Decrease and maintain constant
travel speed
Bead is
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
intermittently
too thick
travel speed
speed
2. Output heat setting too high 2. Reduce output heat setting
HEAT TOO
HIGH
WIRE SPEED
TOO SLOW
TRAVEL SPEED
TOO FAST
Normal heat,
wire speed,
travel speed
HEAT TOO
LOW
TRAVEL SPEED
TOO SLOW
WIRE SPEED
TOO FAST
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TROUBLESHOOTING CHART – WELDER
MAINTENANCE AND CLEANING
SYMPTOM
No Output
POSSIBLE CAUSES(S)
1. Duty cycle exceeded
CORRECTIVE ACTION
Always UNPLUG the Arc Welder from the AC
power source before cleaning or maaintenance.
1. Allow welder to cool down until
ON/OFF Switch lamp goes out
2. Be sure all connections are secure
and attaching surface is clean
3. Replace switch
4. Reduce circuit load, reset breaker
or replace fuse
2. Poor work clamp
connection
3. Defective ON/OFF switch
4. Tripper circuit breaker or
blown fuse
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.
1. Wrong size gun tip
2. Gun liner clogged or
damaged
3. Gun tip clogged or
damaged
4. Feed roller worn
1. Use proper size gun tip
2. Clean or replace gun liner
ACCESSORIES
Wire tangles
at drive roller
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.
3. Clean or replace gun tip
4. Replace feed roller
Always attach grounded (3-prong) extension cords to grounded (3-hole) outlets.
5. Not enough tension
5. Tighten tensioning screw
If you must use an extension cord, be sure that the gauge is large enough to carry
Gun nozzle
the amount of current necessary for your power tool.
If not, your tool may experi-
arcs to work 1. Slag inside gun nozzle 1. Clean slag from gun nozzle
piece
ence a loss of power, excessive voltage drop or overheating. The smaller the gauge
number, the heavier the cord (see table below).
Work clamp
1. Ensure all connections are secure
and/or cable 1. Poor contact
and attaching surface is clean
gets hot
RECOMMENDED SIZES OF EXTENSION CORDS 120 VOLT AC 60 HZ TOOLS
TOOL CURRENT RATING
CONDUCTOR SIZE IN A.W.G
AMPERE
3-6
6-8
8-10
10-12
12-16
16-20
10FT.
18
18
18
16
25FT.
18
18
18
16
50FT.
18
18
18
14
100FT.
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
18
16
14
14
-
Wire does
not feed
4. Wire liner worn
14
12
12
12
12
12
-
19
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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.
SPECIFICATIONS
SPECIFICATIONS
Input
No Load Output
Rated Output
(Min./Max.)
120V
28VAC
60 Hz 20A
19.5VAC 62A
21.2VAC 80A
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 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 shall Alltrade
bear any responsibility for loss of the unit, loss of time or rental, inconvenience,
commercial loss or consequential damages.
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 1-800-590-3723.
Cordless Drills/Screwdrivers
Impact Wrenches
Sanders
Reciprocating Saws
Routers
Rotary Tools
Jigsaws
Corded and Cordless Multi-Purpose Tools
Wide Range of Accessories and more
Circular Saws
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
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Exclusions
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.
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.
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.
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.
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.
EXCLUSION AND DISCLAIMER OF ALL IMPLIED WARRANTIES, INCLUDING THE
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
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