AllTrade Kawasaki 80A Arc Welder 840641 User Manual

							80 AMP WIRE FEED ARC WELDER INSTRUCTION MANUAL
COMPONENT
#840641
FOR CUSTOMER SERVICE
POUR LE SERVICE APRÉS VENTE
OU DU CONSOMMATEUR
PARA EL SERVICIO
PARA EL CONSUMIDOR1-800-590-3723
Printed in China 
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.
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: [email protected].
YOUR FEEDBACK IS VITAL TO US.
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 USA8400641 – 80 Amp Wire Feed Arc Welder_Rev. 6/21/07
87-1904-60957 
						

							C CO
ON
NG
GR
RA
AT
TU
UL
LA
AT
TI
IO
ON
NS
S!
!
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.
I IN
NT
TE
EN
ND
DE
ED
D 
 U
US
SE
E
This tool is intended for consumer use only. This tool is not designed for profes-
sional use. The power cord should only be used in approved electrical outlets as
described in this manual. Failure to use the proper power cords and/or extension
cords may result in fire or possible damage to the welder.
G GE
EN
NE
ER
RA
AL
L 
 S
SA
AF
FE
ET
TY
Y 
 R
RU
UL
LE
ES
S
R RE
EA
AD
D 
 A
AN
ND
D 
 U
UN
ND
DE
ER
RS
ST
TA
AN
ND
D 
 A
AL
LL
L 
 I
IN
NS
ST
TR
RU
UC
CT
TI
IO
ON
NS
S.
.
Failure to follow all instructions in this manual may result severe
electrical shock, fire and/or serious personal injury or death.
R RE
EC
CO
OG
GN
NI
IZ
ZE
E 
 S
SA
AF
FE
ET
TY
Y 
 S
SY
YM
MB
BO
OL
LS
S,
, 
 W
WO
OR
RD
DS
S 
 A
AN
ND
D 
 L
LA
AB
BE
EL
LS
S
The safety instructions provided in this manual are not intended to cover all possi-
ble conditions and practices that may occur when operating, maintaining and clean-
ing power tools.
Always use common sense and pay particular attention to all the D DA
AN
NG
GE
ER
R
, 
W WA
AR
RN
NI
IN
NG
G
, C CA
AU
UT
TI
IO
ON
N
and N NO
OT
TE
E
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.
D DA
AN
NG
GE
ER
R
indicates an imminently hazardous 
situation which, if not avoided, will result in death
or serious injury.
W WA
AR
RN
NI
IN
NG
G
indicates a potentially hazardous 
situation which, if not avoided, could result in
death or serious injury.
T TA
AB
BL
LE
E 
 O
OF
F 
 C
CO
ON
NT
TE
EN
NT
TS
S
C CO
ON
NG
GR
RA
AT
TU
UL
LA
AT
TI
IO
ON
NS
S!
!
 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
I IN
NT
TE
EN
ND
DE
ED
D 
 U
US
SE
E
 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
S SE
EC
CT
TI
IO
ON
N 
 O
ON
NE
E
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
S SE
EC
CT
TI
IO
ON
N 
 T
TW
WO
O
SPECIFIC SAFETY RULES AND/OR SYMBOLS  . . . . . . . . . . . . . . . . . . . 7
IMPORTANT SAFETY RULES FOR USING ARC WELDERS  . . . . . . . 7-8
SYMBOLS  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
S SE
EC
CT
TI
IO
ON
N 
 T
TH
HR
RE
EE
E
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 SE
EC
CT
TI
IO
ON
N 
 F
FO
OU
UR
R
MAINTENANCE AND CLEANING  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
ACCESSORIES  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
OTHER CONSUMER DO-IT-YOURSELF (DIY) TOOLS  . . . . . . . . . . . . . . 21
S SE
EC
CT
TI
IO
ON
N 
 F
FI
IV
VE
E
3 YEAR LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-24
2 1 
						

							W WO
OR
RK
K 
 A
AR
RE
EA
A
E En
ns
su
ur
re
e 
 t
th
he
e 
 w
wo
or
rk
k 
 a
ar
re
ea
a 
 i
is
s 
 c
cl
le
ea
an
n 
 o
of
f 
 d
de
eb
br
ri
is
s 
 a
an
nd
d 
 o
ot
th
he
er
r 
 f
fo
or
re
ei
ig
gn
n 
 m
ma
at
te
er
ri
ia
al
l 
 t
th
ha
at
t 
 m
ma
ay
y
i ig
gn
ni
it
te
e 
 o
or
r 
 e
ex
xp
pl
lo
od
de
e 
 u
up
po
on
n 
 c
co
on
nt
ta
ac
ct
t 
 w
wi
it
th
h 
 w
we
el
ld
di
in
ng
g 
 s
sp
pa
ar
rk
ks
s 
 o
or
r 
 s
sl
la
ag
g.
.
K Ke
ee
ep
p 
 t
th
he
e 
 w
wo
or
rk
k 
 a
ar
re
ea
a 
 w
we
el
ll
l 
 l
li
it
t 
 a
at
t 
 a
al
ll
l 
 t
ti
im
me
es
s.
.
Cluttered work benches and dark work
areas may be prone to accidents resulting in serious injury. 
K Ke
ee
ep
p 
 t
th
he
e 
 w
wo
or
rk
k 
 a
ar
re
ea
a 
 a
ad
de
eq
qu
ua
at
te
el
ly
y 
 v
ve
en
nt
ti
il
la
at
te
ed
d.
.
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.
D DO
O 
 N
NO
OT
T 
 o
op
pe
er
ra
at
te
e 
 t
th
he
e 
 A
Ar
rc
c 
 W
We
el
ld
de
er
r 
 i
is
s 
 a
ar
re
ea
as
s 
 c
co
on
nt
ta
ai
in
ni
in
ng
g 
 f
fl
la
am
mm
ma
ab
bl
le
e
l li
iq
qu
ui
id
ds
s,
, 
 g
ga
as
se
es
s,
, 
 o
or
r 
 d
du
us
st
t.
.
The welder creates sparks and extreme-
ly hot metal droplets or “slag” which can ignite the flammable liq-
uids, gases, or dust resulting in severe burns and/or death. 
K Ke
ee
ep
p 
 b
by
ys
st
ta
an
nd
de
er
rs
s,
, 
 c
ch
hi
il
ld
dr
re
en
n,
, 
 a
an
nd
d 
 v
vi
is
si
it
to
or
rs
s 
 s
sa
af
fe
el
ly
y 
 a
aw
wa
ay
y 
 f
fr
ro
om
m 
 t
th
he
e 
 A
Ar
rc
c 
 W
We
el
ld
de
er
r 
 d
du
ur
r-
-
i i
n
ng
g 
 o
op
pe
er
ra
at
ti
io
on
n.
.
All persons in the work area M MU
US
ST
T
wear protective welding gear,
especially properly filtered goggles of welding helmets to prevent permanent,
serious injury to the eyes or blindness.
E EL
LE
EC
CT
TR
RI
IC
CA
AL
L 
 S
SA
AF
FE
ET
TY
Y
D Do
o 
 n
no
ot
t 
 a
ab
bu
us
se
e 
 t
th
he
e 
 p
po
ow
we
er
r 
 c
co
or
rd
d 
 o
or
r 
 u
us
se
e 
 a
a 
 d
da
am
ma
ag
ge
ed
d 
 p
po
ow
we
er
r 
 c
co
or
rd
d.
. 
 
N NE
EV
VE
ER
R 
 u
us
se
e 
 t
th
he
e 
 p
po
ow
we
er
r 
 c
co
or
rd
d 
 t
to
o 
 c
ca
ar
rr
ry
y 
 o
or
r 
 p
pu
ul
ll
l 
 t
th
he
e 
 e
eq
qu
ui
ip
pm
me
en
nt
t.
. 
 N
Ne
ev
ve
er
r
u us
se
e 
 t
th
he
e 
 p
po
ow
we
er
r 
 c
co
or
rd
d 
 t
to
o 
 d
di
is
sc
co
on
nn
ne
ec
ct
t 
 t
th
he
e 
 p
pl
lu
ug
g 
 f
fr
ro
om
m 
 a
a 
 p
po
ow
we
er
r 
 o
ou
ut
tl
le
et
t.
.
A AL
LW
WA
AY
YS
S 
 k
ke
ee
ep
p 
 p
po
ow
we
er
r 
 c
co
or
rd
ds
s 
 a
aw
wa
ay
y 
 f
fr
ro
om
m 
 h
he
ea
at
t,
, 
 o
oi
il
l,
, 
 s
sh
ha
ar
rp
p 
 o
or
r 
 j
ja
ag
gg
ge
ed
d
e ed
dg
ge
es
s,
, 
 o
or
r 
 m
mo
ov
vi
in
ng
g 
 p
pa
ar
rt
ts
s.
. 
 R
RE
EP
PL
LA
AC
CE
E 
 D
DA
AM
MA
AG
GE
ED
D 
 P
PO
OW
WE
ER
R 
 C
CO
OR
RD
DS
S
I IM
MM
ME
ED
DI
IA
AT
TE
EL
LY
Y.
.
Damaged power cords increase the risk of severe
electrical shock or burns resulting in serious injury and/or death.
A Al
lw
wa
ay
ys
s 
 m
ma
ak
ke
e 
 s
su
ur
re
e 
 t
th
he
e 
 w
wo
or
rk
k 
 p
pi
ie
ec
ce
e 
 i
is
s 
 p
pr
ro
op
pe
er
rl
ly
y 
 g
gr
ro
ou
un
nd
de
ed
d 
 a
an
nd
d 
 s
se
ec
cu
ur
re
ed
d 
 b
be
ef
fo
or
re
e
a at
tt
te
em
mp
pt
ti
in
ng
g 
 a
an
ny
y 
 w
we
el
ld
di
in
ng
g 
 o
op
pe
er
ra
at
ti
io
on
n.
.
4 3
C
CA
AU
UT
TI
IO
ON
N
indicates a potentially hazardous 
situation which, if not avoided, may result in
minor or moderate injury.
C CA
AU
UT
TI
IO
ON
N
used without the safety alert symbol
indicates a potentially hazardous situation which,
if not avoided, may result in property damage.
N NO
OT
TE
E
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.
I IM
MP
PO
OR
RT
TA
AN
NT
T 
 S
SA
AF
FE
EG
GU
UA
AR
RD
DS
S
R Re
ea
ad
d 
 a
an
nd
d 
 u
un
nd
de
er
rs
st
ta
an
nd
d 
 a
al
ll
l 
 i
in
ns
st
tr
ru
uc
ct
ti
io
on
ns
s 
 b
be
ef
fo
or
re
e 
 a
at
tt
te
em
mp
pt
ti
in
ng
g 
 t
to
o 
 u
us
se
e 
 t
th
he
e 
 A
Ar
rc
c
W We
el
ld
de
er
r.
.
Failure to follow and adhere to all safety precautions may lead to seri-
ous personal injury and/or death. 
D DO
O 
 N
NO
OT
T 
 i
im
mm
me
er
rs
se
e 
 a
an
ny
y 
 p
pa
ar
rt
t 
 o
of
f 
 t
th
hi
is
s 
 e
eq
qu
ui
ip
pm
me
en
nt
t 
 i
in
n 
 w
wa
at
te
er
r.
.
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 D DE
EA
AT
TH
H
from electric
shock.
D DO
O 
 N
NO
OT
T 
 u
us
se
e 
 t
th
he
e 
 A
Ar
rc
c 
 W
We
el
ld
de
er
r 
 i
in
n 
 c
co
on
nf
fi
in
ne
ed
d 
 s
sp
pa
ac
ce
es
s 
 w
wh
he
er
re
e 
 i
in
nh
ha
al
la
a-
-
t ti
io
on
n 
 o
of
f 
 f
fu
um
me
es
s 
 i
is
s 
 p
po
os
ss
si
ib
bl
le
e.
. 
 U
Us
se
e 
 o
on
nl
ly
y 
 i
in
n 
 w
we
el
ll
l 
 v
ve
en
nt
ti
il
la
at
te
ed
d 
 a
ar
re
ea
as
s.
.
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.
P Pe
eo
op
pl
le
e 
 w
wi
it
th
h 
 e
el
le
ec
ct
tr
ro
on
ni
ic
c 
 d
de
ev
vi
ic
ce
es
s,
, 
 s
su
uc
ch
h 
 a
as
s 
 p
pa
ac
ce
em
ma
ak
ke
er
rs
s,
, 
 s
sh
ho
ou
ul
ld
d
c co
on
ns
su
ul
lt
t 
 t
th
he
ei
ir
r 
 p
ph
hy
ys
si
ic
ci
ia
an
n(
(s
s)
) 
 b
be
ef
fo
or
re
e 
 u
us
si
in
ng
g 
 t
th
hi
is
s 
 p
pr
ro
od
du
uc
ct
t.
. 
 O
Op
pe
er
ra
at
ti
io
on
n
o of
f 
 e
el
le
ec
ct
tr
ri
ic
ca
al
l 
 e
eq
qu
ui
ip
pm
me
en
nt
t 
 i
in
n 
 c
cl
lo
os
se
e 
 p
pr
ro
ox
xi
im
mi
it
ty
y 
 t
to
o 
 a
a 
 h
he
ea
ar
rt
t 
 p
pa
ac
ce
em
ma
ak
k-
-
e er
r 
 c
co
ou
ul
ld
d 
 c
ca
au
us
se
e 
 f
fa
ai
il
lu
ur
re
e 
 o
or
r 
 i
in
nt
te
er
rf
fe
er
re
en
nc
ce
e 
 o
of
f 
 t
th
he
e 
 p
pa
ac
ce
em
ma
ak
ke
er
r.
.
W WA
AR
RN
NI
IN
NG
G:
: 
 
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.
W Wa
as
sh
h 
 h
ha
an
nd
ds
s 
 a
af
ft
te
er
r 
 h
ha
an
nd
dl
li
in
ng
g.
.
S
SA
AV
VE
E 
 T
TH
HE
ES
SE
E 
 I
IN
NS
ST
TR
RU
UC
CT
TI
IO
ON
NS
S 
 F
FO
OR
R 
 F
FU
UT
TU
UR
RE
E 
 R
RE
EF
FE
ER
RE
EN
NC
CE
E.
. 
						

							T TO
OO
OL
L 
 U
US
SE
E 
 A
AN
ND
D 
 C
CA
AR
RE
E
D Do
o 
 n
no
ot
t 
 u
us
se
e 
 t
th
he
e 
 a
ar
rc
c 
 w
we
el
ld
de
er
r 
 i
if
f 
 t
th
he
e 
 p
po
ow
we
er
r 
 s
sw
wi
it
tc
ch
h 
 d
do
oe
es
s 
 n
no
ot
t 
 t
tu
ur
rn
n 
 “
“o
on
n”
” 
 o
or
r 
 “
“o
of
ff
f!
!”
”
Any equipment that cannot be controlled with the power switch is dangerous
and should be repaired or replaced immediately.
S St
to
or
re
e 
 t
th
hi
is
s 
 e
eq
qu
ui
ip
pm
me
en
nt
t 
 p
pr
ro
op
pe
er
rl
ly
y 
 w
wh
he
en
n 
 n
no
ot
t 
 i
in
n 
 u
us
se
e 
 a
an
nd
d 
 k
ke
ee
ep
p 
 o
ou
ut
t 
 o
of
f 
 r
re
ea
ac
ch
h 
 o
of
f 
 c
ch
hi
il
l-
-
d dr
re
en
n 
 a
an
nd
d 
 u
un
nt
tr
ra
ai
in
ne
ed
d 
 p
pe
er
rs
so
on
ns
s.
.
This equipment is extremely dangerous in the
hands of untrained users.
D Do
o 
 n
no
ot
t 
 a
at
tt
te
em
mp
pt
t 
 t
to
o 
 u
us
se
e 
 t
th
hi
is
s 
 e
eq
qu
ui
ip
pm
me
en
nt
t 
 a
at
t 
 a
a 
 c
cu
ur
rr
re
en
nt
t 
 s
se
et
tt
ti
in
ng
g 
 o
or
r 
 d
du
ut
ty
y 
 c
cy
yc
cl
le
e 
 t
th
ha
at
t
e ex
xc
ce
ee
ed
ds
s 
 t
th
ho
os
se
e 
 s
sp
pe
ec
ci
if
fi
ie
ed
d 
 b
by
y 
 t
th
he
e 
 m
ma
an
nu
uf
fa
ac
ct
tu
ur
re
er
r.
.
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.
A Al
lw
wa
ay
ys
s 
 d
di
is
sc
co
on
nn
ne
ec
ct
t 
 t
th
he
e 
 p
po
ow
we
er
r 
 c
co
or
rd
d 
 f
fr
ro
om
m 
 t
th
he
e 
 p
po
ow
we
er
r 
 s
so
ou
ur
rc
ce
e 
 b
be
ef
fo
or
re
e
m ma
ak
ki
in
ng
g 
 a
an
ny
y 
 a
ad
dj
ju
us
st
tm
me
en
nt
ts
s,
, 
 c
ch
ha
an
ng
gi
in
ng
g 
 a
ac
cc
ce
es
ss
so
or
ri
ie
es
s,
, 
 o
or
r 
 s
st
to
or
ri
in
ng
g 
 t
th
he
e
a ar
rc
c 
 w
we
el
ld
de
er
r.
.
U Us
se
e 
 c
cl
la
am
mp
ps
s 
 (
(n
no
ot
t 
 i
in
nc
cl
lu
ud
de
ed
d)
) 
 o
or
r 
 o
ot
th
he
er
r 
 p
pr
ra
ac
ct
ti
ic
ca
al
l 
 w
wa
ay
ys
s 
 t
to
o 
 s
se
ec
cu
ur
re
e 
 t
th
he
e
w wo
or
rk
kp
pi
ie
ec
ce
e 
 t
to
o 
 a
a 
 s
st
ta
ab
bl
le
e 
 p
pl
la
at
tf
fo
or
rm
m.
. 
 E
En
ns
su
ur
re
e 
 t
th
he
e 
 w
wo
or
rk
k 
 p
pi
ie
ec
ce
e 
 i
is
s 
 p
pr
ro
op
pe
er
rl
ly
y 
 g
gr
ro
ou
un
nd
de
ed
d
b b
e
ef
fo
or
re
e 
 b
be
eg
gi
in
nn
ni
in
ng
g 
 a
an
ny
y 
 w
we
el
ld
di
in
ng
g 
 o
op
pe
er
ra
at
ti
io
on
ns
s.
.
B Be
ef
fo
or
re
e 
 u
us
se
e,
, 
 c
ch
he
ec
ck
k 
 f
fo
or
r 
 d
da
am
ma
ag
ge
ed
d 
 p
pa
ar
rt
ts
s 
 a
an
nd
d 
 e
ex
xa
am
mi
in
ne
e 
 a
al
ll
l 
 m
mo
ou
un
nt
ti
in
ng
g 
 b
bo
ol
lt
ts
s 
 a
an
nd
d
o ot
th
he
er
r 
 m
mo
ov
vi
in
ng
g 
 p
pa
ar
rt
ts
s 
 b
be
ef
fo
or
re
e 
 u
us
si
in
ng
g 
 t
th
he
e 
 e
eq
qu
ui
ip
pm
me
en
nt
t.
.
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. D Do
o 
 n
no
ot
t 
 u
us
se
ed
d 
 d
da
am
ma
ag
ge
ed
d 
 e
eq
qu
ui
ip
pm
me
en
nt
t.
.
D DO
O 
 N
NO
OT
T 
 a
at
tt
te
em
mp
pt
t 
 t
to
o 
 r
re
ep
pa
ai
ir
r 
 t
th
he
e 
 A
Ar
rc
c 
 W
We
el
ld
de
er
r.
. 
 O
On
nl
ly
y 
 a
a 
 q
qu
ua
al
li
if
fi
ie
ed
d 
 t
te
ec
ch
hn
ni
ic
ci
ia
an
n 
 s
sh
ho
ou
ul
ld
d
m ma
ak
ke
e 
 r
re
ep
pa
ai
ir
rs
s 
 t
to
o 
 t
th
hi
is
s 
 t
to
oo
ol
l.
.
D Do
o 
 n
no
ot
t 
 f
fo
or
rc
ce
e 
 t
th
hi
is
s 
 e
eq
qu
ui
ip
pm
me
en
nt
t.
. 
 A
AL
LW
WA
AY
YS
S 
 u
us
se
e 
 t
th
he
e 
 c
co
or
rr
re
ec
ct
t 
 e
eq
qu
ui
ip
pm
me
en
nt
t 
 f
fo
or
r 
 t
th
he
e
a ap
pp
pl
li
ic
ca
at
ti
io
on
n 
 b
be
ei
in
ng
g 
 w
wo
or
rk
ke
ed
d 
 o
on
n.
.
The correct equipment will do the job better and
safer at the rate for which it was designed.
S SE
ER
RV
VI
IC
CE
E
U Us
se
e 
 o
on
nl
ly
y 
 a
au
ut
th
ho
or
ri
iz
ze
ed
d 
 r
re
ep
pl
la
ac
ce
em
me
en
nt
t 
 p
pa
ar
rt
ts
s 
 f
fo
or
r 
 t
th
he
e 
 A
Ar
rc
c 
 W
We
el
ld
de
er
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. U Us
se
e 
 o
of
f 
 u
un
na
au
ut
th
ho
or
ri
iz
ze
ed
d 
 p
pa
ar
rt
ts
s 
 o
or
r 
 f
fa
ai
il
lu
ur
re
e 
 t
to
o 
 f
fo
ol
ll
lo
ow
w
m ma
ai
in
nt
te
en
na
an
nc
ce
e 
 i
in
ns
st
tr
ru
uc
ct
ti
io
on
ns
s 
 m
ma
ay
y 
 c
cr
re
ea
at
te
e 
 a
a 
 r
ri
is
sk
k 
 o
of
f 
 i
in
nj
ju
ur
ry
y 
 a
an
nd
d/
/o
or
r 
 d
de
ea
at
th
h 
 f
fr
ro
om
m 
 e
el
le
ec
ct
tr
ri
ic
ca
al
l
s sh
ho
oc
ck
k.
.
P PE
ER
RS
SO
ON
NA
AL
L 
 S
SA
AF
FE
ET
TY
Y
A Al
lw
wa
ay
ys
s 
 r
re
em
ma
ai
in
n 
 a
al
le
er
rt
t.
. 
 B
Be
e 
 a
aw
wa
ar
re
e 
 o
of
f 
 y
yo
ou
ur
r 
 s
su
ur
rr
ro
ou
un
nd
di
in
ng
gs
s 
 w
wh
hi
il
le
e 
 u
us
si
in
ng
g 
 t
th
he
e 
 A
Ar
rc
c
W We
el
ld
de
er
r.
. 
 D
Do
o 
 n
no
ot
t 
 u
us
se
e 
 t
th
he
e 
 A
Ar
rc
c 
 W
We
el
ld
de
er
r 
 w
wh
hi
il
le
e 
 u
un
nd
de
er
r 
 t
th
he
e 
 i
in
nf
fl
lu
ue
en
nc
ce
e 
 o
of
f 
 p
pr
re
es
sc
cr
ri
ip
pt
ti
io
on
n
m me
ed
di
ic
ca
at
ti
io
on
n 
 o
or
r 
 a
al
lc
co
oh
ho
ol
l.
.
Using prescription medication or alcohol can affect
your senses and slow your reaction time resulting in a serious personal injury
or even death.
B Be
ef
fo
or
re
e 
 u
us
se
e,
,  i
in
ns
sp
pe
ec
ct
t 
 t
th
he
e 
 A
Ar
rc
c 
 W
We
el
ld
de
er
r 
 f
fo
or
r 
 d
da
am
ma
ag
ge
ed
d 
 o
or
r 
 d
de
ef
fe
ec
ct
ti
iv
ve
e 
 p
pa
ar
rt
ts
s.
.D
DO
O 
 N
NO
OT
T
u us
se
e 
 t
th
he
e 
 A
Ar
rc
c 
 W
We
el
ld
de
er
r 
 i
if
f 
 a
an
ny
y 
 p
po
or
rt
ti
io
on
n 
 o
or
r 
 a
ac
cc
ce
es
ss
so
or
ry
y 
 i
is
s 
 d
da
am
ma
ag
ge
ed
d 
 o
or
r 
 d
de
ef
fe
ec
ct
ti
iv
ve
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 Al
ll
lt
tr
ra
ad
de
e’
’s
s 
 C
Cu
us
st
to
om
me
er
r 
 S
Se
er
rv
vi
ic
ce
e 
 D
De
ep
pa
ar
rt
tm
me
en
nt
t
at 1 1-
-8
80
00
0-
-5
59
90
0-
-3
37
72
23
3
. D DO
O 
 N
NO
OT
T 
 A
AT
TT
TE
EM
MP
PT
T 
 t
to
o 
 r
re
ep
pa
ai
ir
r 
 t
th
he
e 
 A
Ar
rc
c 
 W
We
el
ld
de
er
r 
 y
yo
ou
ur
rs
se
el
lf
f.
.
Only
trained technicians should repair this tool.
D DO
O 
 N
NO
OT
T 
 u
us
se
e 
 t
th
he
e 
 A
Ar
rc
c 
 W
We
el
ld
de
er
r 
 i
if
f 
 t
th
he
e 
 “
“O
ON
N/
/O
OF
FF
F”
” 
 d
do
oe
es
s 
 n
no
ot
t 
 f
fu
un
nc
ct
ti
io
on
n 
 p
pr
ro
op
pe
er
rl
ly
y.
.
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.
56 
						

							M Ma
ak
ke
e 
 s
su
ur
re
e 
 t
th
he
e 
 c
co
on
nt
te
en
nt
ts
s 
 o
of
f 
 c
cl
lo
os
se
ed
d 
 c
co
on
nt
ta
ai
in
ne
er
rs
s 
 a
ar
re
e 
 k
kn
no
ow
wn
n 
 a
an
nd
d 
 s
st
te
ep
ps
s 
 a
ar
re
e 
 m
ma
ad
de
e
t to
o 
 p
pr
ro
op
pe
er
rl
ly
y 
 v
ve
en
nt
ti
il
la
at
te
e 
 o
or
r 
 f
fl
lu
us
sh
h 
 t
th
he
e 
 c
co
on
nt
te
en
nt
ts
s 
 t
to
o 
 p
pr
re
ev
ve
en
nt
t 
 p
po
os
ss
si
ib
bl
le
e 
 e
ex
xp
pl
lo
os
si
io
on
ns
s 
 t
th
ha
at
t
c co
ou
ul
ld
d 
 r
re
es
su
ul
lt
t 
 i
in
n 
 f
fi
ir
re
e,
, 
 s
se
er
ri
io
ou
us
s 
 b
bu
ur
rn
ns
s 
 a
an
nd
d 
 i
in
nj
ju
ur
ry
y 
 a
an
nd
d/
/o
or
r 
 e
ev
ve
en
n 
 d
de
ea
at
th
h.
.
A Al
lw
wa
ay
ys
s 
 k
ke
ee
ep
p 
 p
po
ow
we
er
r 
 c
co
or
rd
ds
s 
 a
an
nd
d 
 w
we
el
ld
di
in
ng
g 
 c
ca
ab
bl
le
es
s 
 a
aw
wa
ay
y 
 f
fr
ro
om
m 
 y
yo
ou
ur
r
b bo
od
dy
y 
 a
at
t 
 a
al
ll
l 
 t
ti
im
me
es
s.
.
A Al
lw
wa
ay
ys
s 
 u
un
nc
co
oi
il
l 
 t
th
he
e 
 w
we
el
ld
di
in
ng
g 
 c
ca
ab
bl
le
e 
 b
be
ef
fo
or
re
e 
 u
us
se
e.
.
Coiled cables may overheat.
N Ne
ev
ve
er
r 
 t
to
ou
uc
ch
h 
 t
th
he
e 
 w
wo
or
rk
k 
 p
pi
ie
ec
ce
e 
 i
im
mm
me
ed
di
ia
at
te
el
ly
y 
 a
af
ft
te
er
r 
 w
we
el
ld
di
in
ng
g.
.
Allow
the metal to cool before handling in order to prevent serious injury.
N Ne
ev
ve
er
r 
 l
le
ea
av
ve
e 
 t
th
he
e 
 A
Ar
rc
c 
 W
We
el
ld
de
er
r 
 r
ru
un
nn
ni
in
ng
g 
 u
un
na
at
tt
te
en
nd
de
ed
d.
.
Always shut the equipment
off before leaving the area. Trim any excess welding wire protruding from the
torch before storage.
W Wh
he
en
n 
 w
we
el
ld
di
in
ng
g 
 a
ab
bo
ov
ve
e 
 y
yo
ou
ur
r 
 h
he
ea
ad
d,
, 
 A
AL
LW
WA
AY
YS
S 
 w
we
ea
ar
r 
 e
ea
ar
r 
 p
pl
lu
ug
gs
s 
 t
to
o 
 p
pr
re
ev
ve
en
nt
t 
 s
sp
pa
ar
rk
ks
s
o or
r 
 h
ho
ot
t 
 m
me
et
ta
al
l 
 d
dr
ro
op
ps
s 
 f
fr
ro
om
m 
 f
fa
al
ll
li
in
ng
g 
 i
in
nt
to
o 
 t
th
he
e 
 e
ea
ar
r 
 c
ca
an
na
al
l.
.
M Ma
ai
in
nt
ta
ai
in
n 
 A
AL
LL
L 
 l
la
ab
be
el
ls
s 
 a
an
nd
d 
 n
na
am
me
ep
pl
la
at
te
es
s 
 o
on
n 
 t
th
he
e 
 A
Ar
rc
c 
 W
We
el
ld
de
er
r.
.
These carry important
information. Should they become unreadable, contact Alltrade for replacements.S SY
YM
MB
BO
OL
LS
S
I IM
MP
PO
OR
RT
TA
AN
NT
T:
: 
 
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.
S SY
YM
MB
BO
OL
LN
NA
AM
ME
EE
EX
XP
PL
LA
AN
NA
AT
TI
IO
ON
N
V Volts Voltage (Potential)A Amperes CurrentHz Hertz Frequency (Cycles per Second)W Watt PowerKg Kilograms Weight
Alternating Current Type of CurrentDirect Current Type of CurrentAlternating or Direct Current Type of CurrentEarthing Terminal Grounding Terminal
min Minutes Times Seconds Time

Diameter Size of Drill Bits, 
Grinding Wheels, etc.
No load speed No-load Rotational Speed
.../min Revolutions per Minute Revolutions, Surface Speed, 
Strokes, etc. per Minute
1,2,3, … Ring Selector Settings Speed, Torque or Position Settings
S SP
PE
EC
CI
IF
FI
IC
C 
 S
SA
AF
FE
ET
TY
Y 
 R
RU
UL
LE
ES
S 
 A
AN
ND
D/
/O
OR
R 
 S
SY
YM
MB
BO
OL
LS
S
H Ho
ol
ld
d 
 t
to
oo
ol
l 
 b
by
y 
 i
in
ns
su
ul
la
at
te
ed
d 
 g
gr
ri
ip
pp
pi
in
ng
g 
 s
su
ur
rf
fa
ac
ce
es
s 
 w
wh
he
en
n 
 p
pe
er
rf
fo
or
rm
m-
-
i in
ng
g 
 a
an
n 
 o
op
pe
er
ra
at
ti
io
on
n 
 w
wh
he
er
re
e 
 t
th
he
e 
 c
cu
ut
tt
ti
in
ng
g 
 t
to
oo
ol
l 
 m
ma
ay
y 
 c
co
on
nt
ta
ac
ct
t 
 h
hi
id
dd
de
en
n 
 w
wi
ir
ri
in
ng
g 
 o
or
r 
 i
it
t’
’s
s 
 o
ow
wn
n
c co
or
rd
d.
.
Contact with a “live” wire will also make exposed metal parts of the tool
“live” and shock the operator.
I IM
MP
PO
OR
RT
TA
AN
NT
T 
 S
SA
AF
FE
ET
TY
Y 
 R
RU
UL
LE
ES
S 
 F
FO
OR
R 
 U
US
SI
IN
NG
G 
 A
AR
RC
C 
 W
WE
EL
LD
DE
ER
RS
S
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.
N NE
EV
VE
ER
R 
 l
lo
oo
ok
k 
 a
at
t 
 t
th
he
e 
 a
ar
rc
c 
 w
we
el
ld
de
er
r 
 f
fl
la
am
me
e 
 w
wi
it
th
ho
ou
ut
t 
 a
ap
pp
pr
ro
ov
ve
ed
d 
 e
ey
ye
e 
 p
pr
ro
o-
-
t te
ec
ct
ti
io
on
n.
. 
 A
Ar
rc
c 
 w
we
el
ld
di
in
ng
g 
 o
op
pe
er
ra
at
ti
io
on
ns
s 
 p
pr
ro
od
du
uc
ce
e 
 i
in
nt
te
en
ns
se
e 
 l
li
ig
gh
ht
t,
, 
 h
he
ea
at
t,
,
a an
nd
d 
 u
ul
lt
tr
ra
av
vi
io
ol
le
et
t 
 (
(U
UV
V)
) 
 r
ra
ad
di
ia
at
ti
io
on
n.
. 
 A
Al
lw
wa
ay
ys
s 
 w
we
ea
ar
r 
 a
a 
 w
we
el
ld
de
er
rs
s 
 h
he
el
lm
me
et
t 
 o
or
r
g go
og
gg
gl
le
es
s 
 w
wi
it
th
h 
 t
th
he
e 
 p
pr
ro
op
pe
er
r 
 f
fi
il
lt
tr
ra
at
ti
io
on
n 
 w
wh
he
en
n 
 p
pe
er
rf
fo
or
rm
mi
in
ng
g 
 a
ar
rc
c 
 w
we
el
ld
di
in
ng
g
o op
pe
er
ra
at
ti
io
on
ns
s.
.
Failure to use properly filtered goggles or helmet could cause per-
manent severe damage to your eyes or even cause b bl
li
in
nd
dn
ne
es
ss
s
. T Th
he
e 
 U
UV
V 
 r
ra
ad
di
ia
at
ti
io
on
n
w wi
il
ll
l 
 b
bu
ur
rn
n 
 y
yo
ou
ur
r 
 s
sk
ki
in
n 
 a
an
nd
d 
 h
ha
as
s 
 b
be
ee
en
n 
 k
kn
no
ow
wn
n 
 t
to
o 
 c
ca
au
us
se
e 
 c
ce
er
rt
ta
ai
in
n 
 t
ty
yp
pe
es
s 
 o
of
f 
 s
sk
ki
in
n 
 c
ca
an
nc
ce
er
r
.
B BE
E 
 A
AW
WA
AR
RE
E 
 t
th
ha
at
t 
 a
ar
rc
c 
 w
we
el
ld
di
in
ng
g 
 p
pr
ro
od
du
uc
ce
es
s 
 s
sp
pa
ar
rk
ks
s 
 a
an
nd
d 
 d
dr
ro
op
ps
s 
 o
of
f 
 H
HO
OT
T 
 m
me
et
ta
al
l.
.
These
sparks and hot metal can cause severe burns.
K Ke
ee
ep
p 
 t
th
he
e 
 w
wo
or
rk
k 
 a
ar
re
ea
a 
 c
cl
le
ea
ar
r 
 o
of
f 
 c
co
om
mb
bu
us
st
ti
ib
bl
le
e 
 m
ma
at
te
er
ri
ia
al
ls
s.
.
The sparks and hot drops
of metal can cause certain materials to ignite or even explode.
S So
om
me
e 
 m
me
et
ta
al
ls
s 
 h
ha
av
ve
e 
 c
co
oa
at
ti
in
ng
gs
s 
 t
th
ha
at
t 
 p
pr
ro
od
du
uc
ce
e 
 e
ex
xt
tr
re
em
me
el
ly
y 
 t
to
ox
xi
ic
c 
 f
fu
um
me
es
s
w whhe
en
n 
 h
he
ea
at
te
ed
d.
. 
 
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 D DO
O 
 N
NO
OT
T
inhale
the welding fumes. 
A Al
lw
wa
ay
ys
s 
 k
ke
ee
ep
p 
 a
a 
 f
fi
ir
re
e 
 e
ex
xt
ti
in
ng
gu
ui
is
sh
he
er
r 
 n
ne
ea
ar
rb
by
y 
 w
wh
he
en
n 
 t
th
he
e 
 A
Ar
rc
c 
 W
We
el
ld
de
er
r 
 i
is
s
i in
n 
 u
us
se
e.
.
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.
A AL
LW
WA
AY
YS
S 
 g
gr
ro
ou
un
nd
d 
 t
th
he
e 
 w
wo
or
rk
k 
 p
pi
ie
ec
ce
e 
 f
fi
ir
rs
st
t.
.
To do this, clamp the grounding clamp
to the work piece before you begin welding. N NE
EV
VE
ER
R 
 l
le
et
t 
 a
an
ny
y 
 p
pa
ar
rt
t 
 o
of
f 
 y
yo
ou
ur
r 
 b
bo
od
dy
y
t to
ou
uc
ch
h 
 t
th
he
e 
 g
gr
ro
ou
un
nd
de
ed
d 
 w
wo
or
rk
k 
 p
pi
ie
ec
ce
e 
 a
an
nd
d 
 t
th
he
e 
 f
fl
lu
ux
x 
 c
co
or
re
e 
 w
wi
ir
re
e 
 a
at
t 
 t
th
he
e 
 s
sa
am
me
e 
 t
ti
im
me
e.
.
This
could cause severe electrical shock resulting in severe injury or even death.7 
						

							L LO
OC
CA
AT
TI
IO
ON
N
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.
U UN
NP
PA
AC
CK
KI
IN
NG
G
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.
A AS
SS
SE
EM
MB
BL
LY
Y
D Di
is
sc
co
on
nn
ne
ec
ct
t 
 t
th
he
e 
 p
po
ow
we
er
r 
 p
pl
lu
ug
g 
 f
fr
ro
om
m 
 t
th
he
e 
 A
AC
C
p po
ow
we
er
r 
 s
so
ou
ur
rc
ce
e 
 b
be
ef
fo
or
re
e 
 a
an
ny
y 
 a
as
ss
se
em
mb
bl
ly
y,
, 
 a
ad
dj
ju
us
st
tm
me
en
nt
ts
s,
, 
 o
or
r
a ad
dd
di
in
ng
g/
/r
re
em
mo
ov
vi
in
ng
g 
 a
ac
cc
ce
es
ss
so
or
ri
ie
es
s.
.
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.
A AT
TT
TA
AC
CH
H 
 H
HA
AN
ND
DL
LE
E:
:
1. Place the handle (1) on top of the cover.
2. Secure the handle, using the screws and washers (2).  
10 9
F FU
UN
NC
CT
TI
IO
ON
NA
AL
L 
 D
DE
ES
SC
CR
RI
IP
PT
TI
IO
ON
N
C CO
ON
NT
TR
RO
OL
LS
S 
 A
AN
ND
D 
 C
CO
OM
MP
PO
ON
NE
EN
NT
TS
S:
:
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 
T Th
hi
is
s 
 a
ar
rc
c 
 w
we
el
ld
de
er
r 
 r
re
eq
qu
ui
ir
re
es
s 
 a
a 
 d
de
ed
di
ic
ca
at
te
ed
d 
 1
12
20
0V
V/
/6
60
0 
 H
Hz
z 
 -
-
3 30
0 
 A
AM
MP
P 
 c
ci
ir
rc
cu
ui
it
t 
 a
at
t 
 “
“M
Ma
ax
x”
” 
 a
am
mp
pe
er
ra
ag
ge
e 
 s
se
et
tt
ti
in
ng
g 
 o
or
r 
 2
20
0 
 A
Am
mp
p 
 c
ci
ir
rc
cu
ui
it
t 
 a
at
t 
 “
“M
Mi
in
n”
”
a am
mp
pe
er
ra
ag
ge
e 
 s
se
et
tt
ti
in
ng
g 
 t
to
o 
 f
fu
un
nc
ct
ti
io
on
n 
 p
pr
ro
op
pe
er
rl
ly
y.
.
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. 
A AC
CC
CE
ES
SS
SO
OR
RI
IE
ES
S:
:
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
1
2
3
1
2
456
9
15
13
7
1110
8
12
14 
						

							A AS
SS
SE
EM
MB
BL
LE
E 
 W
WE
EL
LD
DI
IN
NG
G 
 H
HE
EL
LM
ME
ET
T:
:
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.
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.
L LO
OA
AD
D/
/R
RE
EP
PL
LA
AC
CE
E 
 F
FL
LU
UX
X 
 C
CO
OR
RE
E 
 W
WE
EL
LD
DI
IN
NG
G 
 W
WI
IR
RE
E
E En
ns
su
ur
re
e 
 t
th
he
e 
 w
we
el
ld
de
er
r 
 i
is
s 
 “
“o
of
ff
f”
” 
 b
be
ef
fo
or
re
e 
 a
at
tt
te
em
mp
pt
t-
-
i in
ng
g 
 t
to
o 
 l
lo
oa
ad
d 
 t
th
he
e 
 f
fl
lu
ux
x-
-c
co
or
re
e 
 w
wi
ir
re
e.
.
Do not turn the welder “ “o
on
n”
”
until
instructed. Failure to follow these instructions could result in 
serious personal injury.
D Do
o 
 n
no
ot
t 
 t
to
ou
uc
ch
h 
 a
an
ny
yt
th
hi
in
ng
g 
 w
wi
it
th
h 
 t
th
he
e 
 t
to
or
rc
ch
h 
 h
he
ea
ad
d 
 a
as
s 
 i
it
t 
 m
ma
ay
y 
 i
ig
gn
ni
it
te
e.
.
L LO
OA
AD
DI
IN
NG
G 
 T
TH
HE
E 
 F
FL
LU
UX
X-
-C
CO
OR
RE
E 
 W
WI
IR
RE
E
1. Ensure the welder is “ “O
OF
FF
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.
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).
11
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.
B.D.
C.A.
5
2
1
3
4 
						

							B BR
RI
IN
NG
GI
IN
NG
G 
 W
WE
EL
LD
DI
IN
NG
G 
 W
WI
IR
RE
E 
 T
TH
HR
RO
OU
UG
GH
H 
 T
TH
HE
E 
 T
TO
OR
RC
CH
H 
 H
HE
EA
AD
D
10. Turn the torch handle nozzle (7) counterclockwise and pull to remove.
11. Turn contact tip (8) counterclockwise and remove.
12. Lay torch sheath out in a straight line so the flux-core wire moves through easily.
13. Plug the welder’s power cord into an approved AC outlet.
14. Press the current switch to “ “M
MA
AX
X”
”
and turn the welder “ “O
ON
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
OF
FF
F”
”
and add more tension to the wire feed adjustment
spring.
17. Turn welder “ “O
ON
N”
”
and press trigger. One flux-core wire is exposed, turn
welder “ “O
OF
FF
F.
.”
”
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.
8
10
9
8
78
11
132
1/4
O OP
PE
ER
RA
AT
TI
IN
NG
G 
 T
TH
HE
E 
 A
AR
RC
C 
 W
WE
EL
LD
DE
ER
R
•  Ensure the Arc Welder is turned “ “O
OF
FF
F.
.”
”
•  Ensure the work piece is free of chemicals or oily substances that may catch
fire or impair the welding process.
•  Ground the object to be worked by attaching the grounding clamp. If the work
piece is secured to a metal work bench, grounding the work bench is an accept-
able alternate.
• Set the C Cu
ur
rr
re
en
nt
t 
 S
Sw
wi
it
tc
ch
h.
.
The thicker the work piece, the higher the current.
• Set the W Wi
ir
re
e 
 S
Sp
pe
ee
ed
d 
 C
Co
on
nt
tr
ro
ol
l 
 
to 5 5
. Adjust as needed.
Plug in the power cord to an approved AC outlet. I If
f 
 a
an
n
e ex
xt
te
en
ns
si
io
on
n 
 c
co
or
rd
d 
 i
is
s 
 u
us
se
ed
d,
, 
 r
re
ef
fe
er
r 
 t
to
o 
 t
th
he
e 
 m
ma
an
nu
uf
fa
ac
ct
tu
ur
re
er
r’
’s
s 
 i
in
ns
st
tr
ru
uc
ct
ti
io
on
ns
s 
 t
to
o 
 e
en
ns
su
ur
re
e 
 i
it
t
i is
s 
 h
he
ea
av
vy
y 
 e
en
no
ou
ug
gh
h 
 t
to
o 
 h
ha
an
nd
dl
le
e 
 t
th
he
e 
 l
lo
oa
ad
d.
. 
 I
If
f 
 t
th
he
e 
 e
ex
xt
te
en
ns
si
io
on
n 
 c
co
or
rd
d 
 i
is
s 
 t
to
oo
o 
 l
li
ig
gh
ht
t,
, 
 i
it
t 
 m
ma
ay
y
b be
ec
co
om
me
e 
 o
ov
ve
er
rh
he
ea
at
te
ed
d 
 a
an
nd
d 
 i
ig
gn
ni
it
te
e.
.
Hold the Torch away from any grounded object. C Co
on
nt
ta
ac
ct
t
w wi
it
th
h 
 a
a 
 g
gr
ro
ou
un
nd
de
ed
d 
 o
ob
bj
je
ec
ct
t 
 m
ma
ay
y 
 c
ca
au
us
se
e 
 t
th
he
e 
 t
to
or
rc
ch
h 
 t
to
o 
 i
in
na
ad
dv
ve
er
rt
te
en
nt
tl
ly
y 
 i
ig
gn
ni
it
te
e.
.
•  Turn the Arc Welder “ “O
ON
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.
•  Put on welding goggles or lower welding helmet.
•  Ignite the arc by passing the electrode wire back and forth over the work piece.
• When finished welding, lift the torch away from the work piece or any other
grounded objects.
•  Turn the Arc Welder “ “O
OF
FF
F.
.”
”
• Unplug the AC power cord from the receptacle.
D DU
UT
TY
Y 
 C
CY
YC
CL
LE
E 
 A
AN
ND
D 
 T
TH
HE
ER
RM
MA
AL
L 
 O
OV
VE
ER
RL
LO
OA
AD
D 
 O
OP
PE
ER
RA
AT
TI
IO
ON
N
This Arc Welder is designed to operate at the maximum duty cycle, which is a per-
centage of actual weld time. For example, for a ten minute interval at 10% maximum
duty cycle, the actual welding time would be one minute. The Arc Welder should
then cool for nine minutes. The Arc Welder has an automatic thermal switch, which
protects the internal components and accessories from overheating. If the duty
cycle is exceeded the red lamp on the front of the Arc Welder will turn “ “O
ON
N.
.”
”
Resume welding when the red lamp turns “ “O
OF
FF
F.
.”
”
14 
						

							W WE
EL
LD
DI
IN
NG
G 
 T
TI
IP
PS
S
• 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 weld-
ing joint is secure. Be sure to remove all remaining slag between passes.
• N Ne
ev
ve
er
r 
 u
us
se
e 
 a
an
n 
 e
el
le
ec
ct
tr
ri
ic
c 
 a
ar
rc
c 
 w
we
el
ld
de
er
r 
 t
to
o 
 t
th
ha
aw
w 
 f
fr
ro
oz
ze
en
n 
 p
pi
ip
pe
es
s.
.
W
WE
EL
LD
DI
IN
NG
G 
 G
GU
UI
ID
DE
EL
LI
IN
NE
ES
S
G GE
EN
NE
ER
RA
AL
L
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.
A AR
RC
C 
 W
WE
EL
LD
DI
IN
NG
G 
 B
BA
AS
SI
IC
CS
S
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.
W WI
IR
RE
E 
 S
SE
EL
LE
EC
CT
TI
IO
ON
N
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 E-
-7
70
0T
T-
-G
GS
SE- AWG classification for self-shielding wire7 Weld Strength, times 10,000 lbs per square inch0 Welding Positions: 0 = Flat, 1 = All other positionsT Tubular Flux-core Wire-GS Flux Type
The Internet can be used for additional information on the American Welding
Society (AWS) Standards: http://www.aws.org/
16
H HE
EA
AT
T 
 S
SE
ET
TT
TI
IN
NG
G
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.
W WE
EL
LD
D 
 A
AN
NG
GL
LE
E
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.
W WI
IR
RE
E 
 S
SP
PE
EE
ED
D
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.
T TR
RA
AV
VE
EL
L 
 S
SP
PE
EE
ED
D
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.
S SL
LA
AG
G 
 R
RE
EM
MO
OV
VA
AL
L
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. 
						

							17
W WE
EL
LD
DI
IN
NG
G 
 P
PO
OS
SI
IT
TI
IO
ON
NS
S
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.
A AD
DD
DI
IT
TI
IO
ON
NA
AL
L 
 S
SA
AF
FE
ET
TY
Y 
 S
ST
TA
AN
ND
DA
AR
RD
DS
S
• A AN
NS
SI
I 
 S
St
ta
an
nd
da
ar
rd
d 
 Z
Z4
49
9.
.1
1:
:
From the American Welding Society.
• S Sa
af
fe
et
ty
y 
 a
an
nd
d 
 H
He
ea
al
lt
th
h 
 S
St
ta
an
nd
da
ar
rd
ds
s:
:
OSHA 29 CFR 1910.
• N Na
at
ti
io
on
na
al
l 
 E
El
le
ec
ct
tr
ri
ic
ca
al
l 
 C
Co
od
de
e:
:
NPFA Standards 51B and 70 from the National fire
Protection Association.
• C Co
od
de
e 
 F
Fo
or
r 
 S
Sa
af
fe
et
ty
y 
 i
in
n 
 W
We
el
ld
di
in
ng
g 
 a
an
nd
d 
 C
Cu
ut
tt
ti
in
ng
g:
:
CSA Standard W117.2, from
Canadian Standards Association.
• S Sa
af
fe
e 
 P
Pr
ra
ac
ct
ti
ic
ce
es
s 
 f
fo
or
r 
 O
Oc
cc
cu
up
pa
at
ti
io
on
na
al
l 
 a
an
nd
d 
 E
Ed
du
uc
ca
at
ti
io
on
na
al
l 
 E
Ey
ye
e 
 a
an
nd
d 
 F
Fa
ac
ce
e 
 P
Pr
ro
ot
te
ec
ct
ti
io
on
n:
:
ANSI Standard Z87.1 from American National Standards Institute.
T TR
RO
OU
UB
BL
LE
ES
SH
HO
OO
OT
TI
IN
NG
G 
 C
CH
HA
AR
RT
T 
 –
– 
 W
WE
EL
LD
DS
S
S SY
YM
MP
PT
TO
OM
M 
 P
PO
OS
SS
SI
IB
BL
LE
E 
 C
CA
AU
US
SE
ES
S(
(S
S)
) 
 C
CO
OR
RR
RE
EC
CT
TI
IV
VE
E 
 A
AC
CT
TI
IO
ON
N
T
TR
RO
OU
UB
BL
LE
ES
SH
HO
OO
OT
TI
IN
NG
G 
 C
CH
HA
AR
RT
T 
 –
– 
 W
WE
EL
LD
DS
S
S SY
YM
MP
PT
TO
OM
M 
 P
PO
OS
SS
SI
IB
BL
LE
E 
 C
CA
AU
US
SE
ES
S(
(S
S)
) 
 C
CO
OR
RR
RE
EC
CT
TI
IV
VE
E 
 A
AC
CT
TI
IO
ON
N
B BE
EL
LO
OW
W 
 A
AR
RE
E 
 S
SE
EV
VE
ER
RA
AL
L 
 D
DI
IF
FF
FE
ER
RE
EN
NT
T 
 T
TY
YP
PE
ES
S 
 O
OF
F 
 W
WE
EL
LD
D 
 A
AP
PP
PE
EA
AR
RA
AN
NC
CE
ES
S.
.
Ragged
depressions
at edge of
weld
1. Travel Speed too fast
2. Wire speed too fast
3 . Output heat setting too high
1. Decrease travel speed
2. Decrease wire speed
3. Reduce output heat setting
Weld bead
does not
penetrate
base metal
1. Inconsistent ravel speed
2. Output heat setting too low
3. Extension cord too long
1. Decrease and maintain constant
travel speed
2. Increase output heat setting
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
Bead is 
intermittently
too thin
1. Inconsistent travel
speed
2. Output heat setting too low
1. Decrease and maintain constant
travel speed
2. Increase output heat setting
Bead is 
intermittently
too thick
1. Slow and/or inconsistent
travel speed
2 . Output heat setting too high
1. Increase and maintain travel 
speed
2. Reduce output heat setting
N No
or
rm
ma
al
l 
 h
he
ea
at
t,
,
w wi
ir
re
e 
 s
sp
pe
ee
ed
d,
,
t tr
ra
av
ve
el
l 
 s
sp
pe
ee
ed
d
HEAT TOO
LOW
HEAT TOO
HIGH
WIRE SPEED
TOO FAST
WIRE SPEED
TOO SLOW
TRAVEL SPEED
TOO SLOW
TRAVEL SPEED
TOO FAST
18