Kawasaki Welder 840641 User 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  
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  
 
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.  
3
4
 
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.  
5
6
 
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  
7
 
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.  
1
2
3
4
5
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.  
15  
ASSEMBLY  
Disconnect the power plug from the AC  
8
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  
7
14  
10  
ATTACH HANDLE:  
9
1. Place the handle (1) on top of the cover.  
11  
13  
2. Secure the handle, using the screws and washers (2).  
12  
1
CONTROLS AND COMPONENTS:  
1. Welder  
ACCESSORIES:  
10. Wire Reel Washer and Wing Nut  
2
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.  
9
10  
 
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).  
1
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.  
5
4
A.  
C.  
B.  
D.  
11  
 
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  
5
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"  
7
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.  
8
1/4"  
DUTY CYCLE AND THERMAL OVERLOAD OPERATION  
8
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  
11  
ON.”  
cycle is exceeded the red lamp on the front of the Arc Welder will turn  
OFF. ”  
Resume welding when the red lamp turns  
14  
13  
 
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  
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  
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  
17  
18  
 
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  
20  
 
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  
22  
 
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. PURCHASERS 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  
ALLTRADES 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. PURCHASERS  
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  
23  
24  
 

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