Kawasaki 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 CONSUMIDOR

1-800-590-3723

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: [e-mail].
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 USA

8400641 – 80 Amp Wire Feed Arc Welder_Rev. 6/21/07

87-1904-60957

CCOONNGGRRAATTUULLAATTIIOONNSS!!

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.

IINNTTEENNDDEEDD UUSSEE

This tool is intended for consumer use only. This tool is not designed for profes­sional use. The power cord should only be used in approved electrical outlets as
described in this manual. Failure to use the proper power cords and/or extension
cords may result in fire or possible damage to the welder.

GGEENNEERRAALL SSAAFFEETTYY RRUULLEESS

RREEAADD AANNDD UUNNDDEERRSSTTAANNDD AALLLL IINNSSTTRRUUCCTTIIOONNSS..
Failure to follow all instructions in this manual may result severe
electrical shock, fire and/or serious personal injury or death.

RREECCOOGGNNIIZZEE SSAAFFEETTYY SSYYMMBBOOLLSS,, WWOORRDDSS AANNDD LLAABBEELLSS

The safety instructions provided in this manual are not intended to cover all possi­ble conditions and practices that may occur when operating, maintaining and clean­ing power tools.

Always use common sense and pay particular attention to all the

DDAANNGGEERR

,

WWAARRNNIINNGG, CCAAUUTTIIOONN

and

NNOOTTEE

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.

DDAANNGGEERR

indicates an imminently hazardous
situation which, if not avoided, will result in death
or serious injury.

WWAARRNNIINNGG

indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.

TTAABBLLEE OOFF CCOONNTTEENNTTSS

CCOONNGGRRAATTUULLAATTIIOONNSS!!

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

IINNTTEENNDDEEDD UUSSEE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SSEECCTTIIOONN OONNEE

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

SSEECCTTIIOONN TTWWOO

SPECIFIC SAFETY RULES AND/OR SYMBOLS . . . . . . . . . . . . . . . . . . . 7

IMPORTANT SAFETY RULES FOR USING ARC WELDERS . . . . . . . 7-8

SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SSEECCTTIIOONN TTHHRREEEE

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

SSEEC

CTTIIOONN FFOOUURR

MAINTENANCE AND CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

OTHER CONSUMER DO-IT-YOURSELF (DIY) TOOLS . . . . . . . . . . . . . . 21

SSEECCTTIIOONN FFIIVVEE

3 YEAR LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-24

21

WWOORRKK AARREEAA

EEnnssuurree tthhee wwoorrkk aarreeaa iiss cclleeaann ooff ddeebbrriiss aanndd ootthheerr ffoorreeiiggnn mmaatteerriiaall tthhaatt mmaayy
iiggnniittee oorr eexxppl

looddee uuppoonn ccoonnttaacctt wwiitthh wweellddiinngg ssppaarrkkss oorr ssllaagg..

KKeeeepp tthhee wwoorrkk aarreeaa wweellll lliitt aatt aallll ttiimmeess..

Cluttered work benches and dark work

areas may be prone to accidents resulting in serious injury.

KKeeeepp tthhee w

woorrkk aarreeaa aaddeeqquuaatteellyy vveennttiillaatteedd..

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.

DDOO NNOOTT ooppeerraattee tthhee AArrcc WWeellddeerr iiss aarreeaass ccoonnttaaiinniinngg ffllaammmmaabbllee
lliiqquui

iddss,, ggaasseess,, oorr dduusstt..

The welder creates sparks and extreme­ly hot metal droplets or “slag” which can ignite the flammable liq­uids, gases, or dust resulting in severe burns and/or death.

KKeeeepp bbyyssttaannddeerrss,, cchhiillddrreenn,, aanndd vviissiittoorrss ssaaffeellyy aawwaayy ffrroomm tthhee AArrcc WWeellddeerr dduurr--
ii

nngg ooppeerraattiioonn..

All persons in the work area

MMUUSSTT

wear protective welding gear ,
especially properly filtered goggles of welding helmets to prevent permanent,
serious injury to the eyes or blindness.

EELLEECCTTRRIICCAALL SSAAFFEETTYY

DDoo nnoott aabbuussee tthhee ppoowweerr ccoorrdd oorr uussee aa ddaammaaggeedd ppoowweerr ccoorrdd..

NNEEVVEERR uussee tthhee ppoowweerr ccoorrd

d ttoo ccaarrrryy oorr ppuullll tthhee eeqquuiippmmeenntt.. NNeevveerr

uussee tthhee ppoowweerr ccoorrdd ttoo ddiissccoonnnneecctt tthhee pplluugg ffrroomm aa ppoowweerr oouuttlleet

t..

AALLWWAAYYSS kkeeeepp ppoowweerr ccoorrddss aawwaayy ffrroomm hheeaatt,, ooiill,, sshhaarrpp oorr jjaaggggeedd
eeddggeess,, oorr mmoovviinngg ppaarrttss.. RREEPPLLAACCEE DDAAMMAAG

GEEDD PPOOWWEERR CCOORRDDSS

IIMMMMEEDDIIAATTEELLYY..

Damaged power cords increase the risk of severe

electrical shock or burns resulting in serious injury and/or death.
AAllwwaayyss mmaakkee ssuurree tthhee wwoorrkk ppiieeccee iiss pprrooppeerrllyy ggrroouunnddeedd aanndd sseeccuurreedd bbeeffoor

ree

aatttteemmppttiinngg aannyy wweellddiinngg ooppeerraattiioonn..

43

CCAAUUTTIIOONN

indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury.

CCAAUUTTIIOONN

used without the safety alert symbol
indicates a potentially hazardous situation which,
if not avoided, may result in property damage.

NNOOTTEE

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.

IIMMPPOORRTTAANNTT SSAAFFEEGGUUAARRDDSS

RReeaadd aanndd uunnddeerrssttaanndd aallll iinnssttrruuccttiioonnss bbeeffoorree aatttteemmppttiinngg ttoo uussee tthhee AArrcc
WWeellddeerr..

Failure to follow and adhere to all safety precautions may lead to seri-

ous personal injury and/or death.

DDOO NNOOTT iimmmmeerrssee aannyy ppaarrtt ooff tthhiiss eeqquuiippmmeenntt iinn wwaatteerr..

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

DDEEAATTHH

from electric

shock.
DDOO NNOOTT uussee tthhee AArrcc WWeellddeerr iinn ccoonnffiinneedd

ssppaacceess wwhheerree iinnhhaallaa--

ttiioonn ooff ffuummeess iiss ppoossssiibbllee.. UUssee oonnllyy iinn wweellll vveennttiillaatteedd aarreeaass..
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.

PPeeooppllee wwiitthh eel

leeccttrroonniicc ddeevviicceess,, ssuucchh aass ppaacceemmaakkeerrss,, sshhoouulldd

ccoonnssuulltt tthheeiirr pphhyyssiicciiaann((ss)) bbeeffoorree uussiinngg tthhiiss pprroodduucctt.. O

Oppeerraattiioonn

ooff eelleeccttrriiccaall eeqquuiippmmeenntt iinn cclloossee pprrooxxiimmiittyy ttoo aa hheeaarrtt ppaacceemmaakk--
eerr ccoouulldd ccaauussee ffaaiilluurree oorr iin

ntteerrffeerreennccee ooff tthhee ppaacceemmaakkeerr..

WWAARRNNIINNGG::

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.

WWaasshh hhaannddss aafftteerr hhaannddlliinngg..

SSAAVVEE TTHHEESSEE IINNSSTTRRUUCCTTIIOONNSS FFOORR FFUUTTUURREE RREEFFEERREENNCCEE..

TTOOOOLL UUSSEE AANNDD CCAARREE

DDoo nnoott uussee tthhee aarrcc wweellddeerr iiff tthhee ppoowweerr sswwiittcchh ddooeess nnoott ttuurrnn ““oonn”” oorr ““ooffff!!””
Any equipment that cannot be controlled with the power switch is dangerous
and should be repaired or replaced immediately.

SSttoorre

e tthhiiss eeqquuiippmmeenntt pprrooppeerrllyy wwhheenn nnoott iinn uussee aanndd kkeeeepp oouutt ooff rreeaacchh ooff cchhiill--

ddrreenn aanndd uunnttrraaiinneedd ppeerrssoonnss..

This equipment is extremely dangerous in the

hands of untrained users.
DDoo nnoott aatttteemmpptt ttoo uussee tthhiiss eeqquuiippmmeenntt aatt aa ccuurrrreenntt sseettttiinngg oorr dduuttyy ccyyccllee tthhaatt

eexxcceeeeddss tthhoossee ssppeecciiffiie

edd bbyy tthhee mmaannuuffaaccttuurreerr..

This Arc Welder is engineered
to be operated at the specifications shown on the attached labeling. Deviations
from these specifications could lead to damage to the equipment and/or seri­ous injury or death to the operator.

AAllwwaayyss ddiissccoonnnneecctt tthhee ppoowweerr ccoorrdd ffrroomm tthhee ppoowweerr ssoouurrccee bbeeffoorree
mmaakkiinngg aannyy aad

djjuussttmmeennttss,, cchhaannggiinngg aacccceessssoorriieess,, oorr ssttoorriinngg tthhee

aarrcc wweellddeerr..
UUssee ccllaammppss ((nnoott iinncclluuddeedd)) oorr ootthheerr pprraacct

tiiccaall wwaayyss ttoo sseeccuurree tthhee

wwoorrkkppiieeccee ttoo aa ssttaabbllee ppllaattffoorrmm.. EEnnssuurree tthhee wwoorrkk ppiieeccee iiss pprrooppeerrllyy ggrroouunnddeedd
bb

eeffoorree bbeeggiinnnniinngg aannyy wweellddiinngg ooppeerraattiioonnss..

BBeeffoorree uussee,, cchheecckk ffoorr ddaammaaggeedd ppaarrttss aanndd eexxaammiinnee aallll mmoouunnttiinngg

bboollttss aanndd

ootthheerr mmoovviinngg ppaarrttss bbeeffoorree uussiinngg tthhee eeqquuiippmmeenntt..

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.

DDoo nnoott uusseedd ddaammaaggeedd eeqquuiippmmeenntt..

DDOO NNOOTT aattt

teemmpptt ttoo rreeppaaiirr tthhee AArrcc WWeellddeerr.. OOnnllyy aa qquuaalliiffiieedd tteecchhnniicciiaann sshhoouulldd

mmaakkee rreeppaaiirrss ttoo tthhiiss ttooooll..
DDoo nnoott

ffoorrccee tthhiiss eeqquuiippmmeenntt.. AALLWWAAYYSS uussee tthhee ccoorrrreecctt eeqquuiippmmeenntt ffoorr tthhee

aapppplliiccaattiioonn bbeeiinngg wwoorrkkeedd oonn..

The correct equipment will do the job better and

safer at the rate for which it was designed.

SSEERRVVIICCEE

UUssee oonnllyy aauutthhoorriizzeedd rreeppllaacceemmeenntt ppaarrttss ffoorr tthhee AArrcc WWeellddeerr..
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.

UUssee ooff uunnaauutthhoorriizzeedd ppaarrttss oorr ffaaiilluurree ttoo ffoollllooww
mmaaiinntteennaannccee iinnssttrruuccttiioonnss mmaayy ccrreeaattee aa rriisskk ooff iinnjjuurryy aanndd//oorr ddeeaatthh ffrroomm eelleeccttrriiccaall
sshho

occkk..

PPEERRSSOONNAALL SSAAFFEETTYY

AAllwwaayyss rreemmaaiinn aalleerrtt.. BBee aawwaarree ooff yyoouurr ssuurrrroouunnddiinnggss wwhhiillee uussiinngg tthhee AArrcc
WWeellddeerr.. DDoo nno

ott uussee tthhee AArrcc WWeellddeerr wwhhiillee uunnddeerr tthhee iinnfflluueennccee ooff pprreessccrriippttiioonn

mmeeddiiccaattiioonn oorr aallccoohhooll..

Using prescription medication or alcohol can affect
your senses and slow your reaction time resulting in a serious personal injury
or even death.

BBeeffoorree uussee,,

iinnssppeecctt tthhee AArrcc WWeellddeerr ffoorr ddaammaaggeedd oorr ddeeffeeccttiivvee ppaarrttss.. DDOO NNOOTT

uussee tthhee AArrcc WWeellddeerr iiff aannyy ppoorrttiioonn oorr aac

ccceessssoorryy iiss ddaammaaggeedd oorr ddeeffeeccttiivvee..

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

AAllllttrraaddee’’ss CCuussttoommeerr SSeerrvviiccee DDeeppaarrttmmeenntt

at

11--880000--559900--33772233. DDOO NNOOTT AAT

TTTEEMMPPTT ttoo rreeppaaiirr tthhee AArrcc WWeellddeerr yyoouurrsseellff..

Only

trained technicians should repair this tool.
DDOO NNOOTT uussee tthhee AArrcc WWeellddeerr iiff tthhee ““OONN//OOFFFF”” ddooeess nnoott ffuunncctti

ioonn pprrooppeerrllyy..

Always use ANSI compliant safety equipment.

• Always wear eye and ear protection.

• Use impact resistant safety goggles.

• Wear non-skid safety shoes.

• Always wear an approved welding helmet with the proper filters for the type

of welding you are doing.

• Always wear leather welding gloves and flame resistant clothing with long

sleeves.

Dress Properly

• Do not wear loose clothing, jewelry, unrestrained long hair, or any other attire

that may become caught in moving parts of the equipment.

• Always wear ANSI compliant, protective, electrically nonconductive welding

gear including protective clothing, leather welding gloves, welding helmet,
and insulated footwear.

5 6