The electrical and mechanical components of the Cutlass Stud Welders are thoroughly
performance inspected prior to assembly in the Welder. The assembled Welder is completely
performance checked. The Welder is delivered to you in perfect electro-mechanical condition.
All parts used in the assembly of the Welder are fully warranted for a period of twelve (12)
months from the date of delivery.
Under this warranty, the manufacturer reserves the right to repair or replace, at its option,
defective parts which fail during the warranty period. Notice of any claim for warranty repair or
replacement must be furnished to the manufacturer, by the purchaser, within five (5) days
after the defect is first discovered. The manufacturer does not assume any liability for paying
shipping costs, or for any labor or material furnished where such costs are not expressly
authorized in writing.
We do not warrant the Cutlass Stud Welders, parts or accessories against failures resulting
from misuse, abuse, improper installation, normal wear and tear, maladjustment or use not in
accordance with the operating instructions furnished by the manufacturer. Cutlass shall never
be liable for any consequential damages.
In any welding operation, it is the responsibility of the welder to observe certain safety rules to insure his personal
safety and to protect those working near him.
Reference is directed without endorsement or recommendation, to ANSI Z49.1, Safety in Welding and Cutting,
and to AWG Publication A6, 1-66 Recommended Safe Practices for Gas-Shielded Arc Welding.
1. Danger! Wearers of cardiac pacemakers must keep clear of welding & stud welding systems.
2. Always treat electricity with respect. Under open circuit conditions, the welding machine output may be
dangerous.
3. Do not work on live circuits and conductors. Disconnect the main power line before checking the machine or
performing any maintenance operations.
4. Ensure the welding machine cabinet is properly grounded to a good electrical ground.
5. Do not stand in water or on damp floors while welding or weld in the rain. Avoid wearing wet or sweaty
clothes when welding.
6. Do not operate with worn or poorly connected cables, and do not operate weld gun with loose cable
connections. Inspect all cables frequently for insulation failures, exposed wires, loose connections and repair
as needed.
7. Do not overload weld cables or continue to operate with hot cables.
8. Do not weld near flammable materials or liquids, in or near atmospheres, or on ducts carrying explosive
gases.
9. Do not weld on containers which have held combustible or flammable materials, or on materials which give
off flammable or toxic vapors when heated, without proper cleaning, purging, or inerting.
10. Ensure adequate ventilation is provided when welding in confined spaces.
11. Never look at the electrical arc without wearing eye shields.
12. Always use proper protective clothing, gloves etc. Never weld close to a bystander who is unaware of the
possible dangers of ultraviolet light and weld splatter on their eyes.
13. Installation, servicing and trouble shooting should only be done by qualified personnel, familiar with this type
of equipment.
LED red….capacitors charging. LED
green…capacitors charged.
LED off …capacitors discharging.
Potentiometer: For setting capacitor
charge.
Contact:: LED orange…complete
weld circuit…stud is connected to
workpiece.
Trigger: LED green…trigger button is
pressed to start weld sequence.
Solenoid: LED orange…PHM-1A
weld gun is connected
Power: LED green…Classic is
connected to power supply and
turned on.
Temperature: LED red…temperature
inside Classic exceeds 80ºC.
Chargeing cycles will belonger due to
the elevated temperature.
Blocked: LED red…the gun has not
been withdrawn after welding stud.
Residual voltage may have been
greater than 36 volts.
Main Switch: LED green…Classic is
switched on.
CLASSIC+ CD MANUAL
INDICATORS AND SYMBOLS
START CHECK
The Main Switch and the following LED‟s must light up when CLASSIC is turned on…
a) Power LED
b) Capacitor charge LED…lights up red briefly and green when CLASSIC is ready.
c) Contact light…when stud in gun is touched to workpiece (grounds must be connected).
d) Hold the gun in the air and pull trigger…trigger LED should illuminate.
e) Solenoid light will not come on with PKM-1B connected. Solenoid light only illuminates
Welding studs with ignition tip can be positioned
exactly on center punch marks or scribed lines.
Since the welding process is started by the ignition
tip, marking must be performed carefully.
The weld cannot ignite on a center punch mark
which is too deep. Should the weld start the weld
strength may still be questionable.
Therefore make sure the depth of the center
punch mark does not exceed 0.012” (0.3mm).
CLASSIC+ CD MANUAL
CD STUD/BASE METAL COMBINATION WELDING CAPABILITIES
* Generally full strength results, depending upon the combination of stud size and base metal.
1. The weld chuck should be adjusted as shown. For longer
studs, as much of the stud should be held as possible. This
may require complete removal of the adjusting screw.
2. Seat weld chuck firmly in the front of weld gun and attach
leg and footpiece assembly. Set leg depth so approximately
3/16” of stud/chuck protrudes beyond the footpiece.
3. Place the weld gun perpendicular to the workpiece as
shown. Apply pressure to the gun so the footpiece lies firmly
on the workpiece.
4. Hold gun steady and pull trigger when stud is in required
position. After weld cycle withdraw gun from stud. Pull gun
straight back so weld chuck is not damaged.
5. Inspect weld and adjust setting as required.
TEST WELDING
Before making your first weld, check the ground clamp. It is essential that no power be lost through a poor
connection. The surface under the ground should be free from oil, scale, grease and rust. The test should be on
a piece of scrap material similar to the material to be used during actual production.
NOTE: IF WELD APPEARS COLD, DO NOT PLACE GUN ON WELDED STUD AND TRIGGER AGAIN.
* Aluminum studs can be welded using the contact method with limitations
The welding time depends on the speed of the stud as it
moves forward into the molten welding pool. The speed is
adjusted directly by changing the spring pressure. The greater
the spring pressure, the shorter the welding time.
To adjust, use a coin or broad bladed screw driver to turn the
adjusting knob in the center of the back cap: Clockwise to
increase spring pressure and Counterclockwise to reduce
spring pressure. Set the spring pressure by observing the
pointer in the window on the side of the weld gun. Re-tighten
the small screw in the back cap.
The gun is shipped from the factory in the 1-2 position. The
suggested spring settings are shown below…
Exploded view of window
scale on side of weld gun.
Lower spring
pressure
Higher spring
pressure
CLASSIC+ CD MANUAL
The electrical and mechanical parameters of the weld are set using the voltage control knob on the
front of the welder and by adjusting the spring pressure of the welding gun.
The welding current strength is regulated via the charge voltage of the capacitors in the Classic power
unit. To set the charge voltage, turn the knob on the front panel to the recommended setting from the
following table.
The settings shown below are to be used as a guide only, and we recommend test welding on
scrap material to ascertain optimum weld parameters for a specific application.
**The settings shown above are for standard Flanged welding studs. For Mini-Flanged or Non-Flanged Studs, lower settings will be required.
TEST WELDING
Before making your first weld, check the ground clamp. It is essential that no power be lost through a poor
connection. The surface under the ground should be free from oil, scale, grease and rust. The test should be on
a piece of scrap material similar to the material to be used during actual production.
NOTE: IF WELD APPEARS COLD, DO NOT PLACE GUN ON WELDED STUD AND TRIGGER AGAIN.
9. Weld cables coiled.
NOTE: The weld cables and ground cables should be laid out in a straight line or large loops. Poor weld
quality may result if welding cables are closely coiled.
WELDER MAINTENANCE
Your Cutlass welder is designed for long service with minimum care. Ordinary common sense maintenance will
keep it operating efficiently. Following are some tips on preventative maintenance:
1. Treat the welding and control cables with respect. Avoid sharp bends and kinks which may break the cables.
Do not use the cables as a “tow-line” to move the controller. Avoid damaging or straining the cables where
they enter the gun or connectors.
2. Ensure unit vents are not obstructed, and that the unit is not covered while in use. Avoid overheating.
3. Keep the welding gun free of dust and dirt. Periodically clean weld splatter from front of gun.
4. The welder should not be placed in close proximity to any MIG or TIG welders, nor should the CLASSIC
share a common power supply with MIG or TIG equipment. Similarly the main ground connection from the
CLASSIC to the workpiece should not be linked in any way to MIG or TIG grounds.