Cutlass Fasteners CLASSIC+CD User manual

CLASSIC+ CD MANUAL
COPYRIGHT CFI 2009 email: [e-mail] PAGE - 1 -
Cutlass Fasteners, Inc.
83 Vermont Ave., Unit 6, Warwick, RI 02888
Tel: [phone] Fax: [phone]
cutlass-studwelding.com
Stud Welding…
Fasteners
Equipment
Service
PLEASE READ THIS OPERATION AND MAINTENANCE MANUAL
CAREFULLY BEFORE USING YOUR NEW CUTLASS STUD WELDER.
MODEL : CLASSIC+ CD MANUAL
PART NO. : LBS-075-T / LBS-075-B
SERIAL NO. :

CLASSIC+ CD MANUAL
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Cutlass Fasteners, Inc.
83 Vermont Ave., Unit 6, Warwick, RI 02888
Tel: [phone] Fax: [phone]
cutlass-studwelding.com
Stud Welding…
Fasteners
Equipment
Service
WARRANTY
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.

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Cutlass Fasteners, Inc.
83 Vermont Ave., Unit 6, Warwick, RI 02888
Tel: [phone] Fax: [phone]
cutlass-studwelding.com
Stud Welding…
Fasteners
Equipment
Service
SUGGESTED SAFETY PRECAUTIONS
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.

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Cutlass Fasteners, Inc.
83 Vermont Ave., Unit 6, Warwick, RI 02888
Tel: [phone] Fax: [phone]
cutlass-studwelding.com
Stud Welding…
Fasteners
Equipment
Service
THE CAPACITOR DISCHARGE STUD WELDING PROCESS
HOW THE STUD WELD IS MADE:
1. The stud is located on the spot 2. Stored energy is discharged
to which it is to be welded. through the precisely engineered
weld tip at the base of the fastener.
3. The stud is plunged into the 4. The weld gun is withdrawn
molten weld pool, and fusion leaving the fastener permanently
is achieved across the complete welded to the workpiece.
section of the weld.
WELD CHUCK
WELD STUD
WORKPIECE

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Cutlass Fasteners, Inc.
83 Vermont Ave., Unit 6, Warwick, RI 02888
Tel: [phone] Fax: [phone]
cutlass-studwelding.com
Stud Welding…
Fasteners
Equipment
Service
HOW TO INSTALL YOUR CUTLASS CLASSIC
1. Attach the twin ground cable to the workpiece with the “C” clamp. Connect the other end of the cable to
the left socket on the CLASSIC panel.
2. Connect the Control Plug (7 pin connector) on the Gun cable, to the 7 Pin Socket on the front panel of
the CLASSIC.
3. Connect the Weld Cable Plug on the Gun cable to the right socket on the front of the CLASSIC.
4. Connect the power lead to a 120 volt supply.
NOTE: UNIT IS SHIPPED FROM THE FACTORY TAPPED FOR 120 VOLT OPERATION. FOR 220/240 VOLT
OPERATION THE TRANSFORMER MUST BE RE-TAPPED. CALL CUTLASS FOR THE CORRECT PROCEDURE.
Attach gun control
cable here
Attach gun weld
cable here
Attach twin ground
cable here

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Cutlass Fasteners, Inc.
83 Vermont Ave., Unit 6, Warwick, RI 02888
Tel: [phone] Fax: [phone]
cutlass-studwelding.com
Stud Welding…
Fasteners
Equipment
Service
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
when optional PHM-1A GAP weld gun is connected.
Capacitor charge status:
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
insideClassic exceeds 80ºC.
Chargeing cycles will be longer 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.

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Cutlass Fasteners, Inc.
83 Vermont Ave., Unit 6, Warwick, RI 02888
Tel: [phone] Fax: [phone]
cutlass-studwelding.com
Stud Welding…
Fasteners
Equipment
Service
CD STUD/BASE METAL COMBINATION WELDING CAPABILITIES
* Generally full strength results, depending upon the combination of stud size and base metal.
BASE MATERIAL
STUD MATERIAL
MILD STEEL
1008-1010
STAINLESS
302, 304, 305
ALUMINUM
1100, 5356, 6061
BRASS
70/30, 65/35
MILD STEEL
1006-1030
Excellent
Excellent
-------------
Excellent
MEDIUM CARBON STEEL
1030-1050
Good*
Good*
-------------
Good*
GALVANIZED DUCT
Excellent
Excellent
-------------
Excellent
STRUCTURAL STEEL
A-36, A-108
Excellent
Excellent
-------------
Excellent
STAINLESS STEEL
405, 410, 430, AND 300 SERIES
EXCEPT 303
Excellent
Excellent
-------------
Excellent
LEAD FREE BRASS,
ELECTROLYTIC COPPER,
LEAD FREE ROLLED COPPER
Excellent
Excellent
-------------
Excellent
MOST ALUMINUM ALLOYS OF
THE 1100, 3000, 5000, AND 6000
SERIES
-------------
-------------
Excellent
-------------
DIE-CAST ZINC ALLOYS
Good*
Good*
Excellent
Good*
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).

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Cutlass Fasteners, Inc.
83 Vermont Ave., Unit 6, Warwick, RI 02888
Tel: [phone] Fax: [phone]
cutlass-studwelding.com
Stud Welding…
Fasteners
Equipment
Service
WELD GUN SETUP
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.
DAMAGE TO WELD CHUCK OR CONTROLLER WILL OCCUR.
1/8”
3/16”
LEG
FOOTPIECE
WELD
STUD
WORKPIECE
SECTION THRU
FOOTPIECE
TOO COLD
COLD
GOOD WELD
TOO HOT
No weld visible
Too much spatter around
head of fastener.
Weld just visible around
head of fastener.

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Cutlass Fasteners, Inc.
83 Vermont Ave., Unit 6, Warwick, RI 02888
Tel: [phone] Fax: [phone]
cutlass-studwelding.com
Stud Welding…
Fasteners
Equipment
Service
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.
ADJUSTING THE PKM-1B WELD GUN
WORKPIECE
MATERIAL
STUD MATERIAL AND DIAMETER
MILD STEEL
STAINLESS STEEL
ALUMINUM ALLOY
#6 #8 #10 1/4 5/16
#6 #8 #10 1/4 5/16
#6 #8 #10 1/4 5/16
STEEL
1-2 1-2 1-2 1-2 1-2
1-2 1-2 1-2 1-2 1-2
-----
STEEL GALVANIZED
1-2 1-2 1-2 1-2 -
1-2 1-2 1-2 1-2 1-2
-----
STAINLESS STEEL
1-3 1-3 1-3 1-3 1-3
1-3 1-3 1-3 1-3 1-3
-----
ALUMINUM ALLOY
- ----
-----
4-6* 4-6* 4-6* 4-6* -
* 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

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Cutlass Fasteners, Inc.
83 Vermont Ave., Unit 6, Warwick, RI 02888
Tel: [phone] Fax: [phone]
cutlass-studwelding.com
Stud Welding…
Fasteners
Equipment
Service
RECOMMENDED CHARGE VOLTAGE
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 aboveare 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.
DAMAGE TO WELD CHUCK OR CONTROLLER WILL OCCUR.
TOO COLD
COLD
GOOD WELD
TOO HOT
No weld visible
Too much spatter around
head of fastener.
Weld just visible around
head of fastener.
WORKPIECE
MATERIAL
STUD MATERIAL AND DIAMETER
MILD STEEL
STAINLESS STEEL
ALUMINUM ALLOY
#6 #8 #10 1/4 5/16
#6 #8 #10 1/4 5/16
#6 #8 #10 1/4 5/16
STEEL
2 3 4 6 8
2 3 4 6 8
-----
STEEL GALVANIZED
3 4 5 7 9-10
3 4 5 7 9-10
-----
STAINLESS STEEL
1 2 3 4 7
1 2 3 5 7
-----
ALUMINUM ALLOY
- ----
- ----
2 3 4 5 -

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Cutlass Fasteners, Inc.
83 Vermont Ave., Unit 6, Warwick, RI 02888
Tel: [phone] Fax: [phone]
cutlass-studwelding.com
Stud Welding…
Fasteners
Equipment
Service
CAUSES OF POOR OR ERRATIC WELDS
1. Loose weld chuck –does not grip stud tightly.
2. Faulty or loose ground connections.
3. Dirty base material (oil, grease, rust etc).
4. Voltage too high or too low.
5. Broken or loose cables.
6. Gun binding –dirt in weld gun preventing free movement.
7. Leg and/or footpiece incorrectly set.
8. Use of center punch.
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.
FAILURE TO COMPLY COULD INVALIDATE YOUR WARRANTY

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Cutlass Fasteners, Inc.
83 Vermont Ave., Unit 6, Warwick, RI 02888
Tel: [phone] Fax: [phone]
cutlass-studwelding.com
Stud Welding…
Fasteners
Equipment
Service
INCH SIZES
STUD SIZE
"L" LENGTH
PART NUMBER
2-56UNC
1.3/8"
669-232
12GA., 4-40UNC
1.3/8"
669-219
1/8
1.3/8"
669-230
10GA., 6-32 UNC
1.3/8"
669-220
8-32 UNC
1.3/8"
669-222
3/16, 10-24UNC, 10-32UNF
1.3/8"
669-216
0.217
1.3/8"
669-217
1/4
1.3/8"
669-218
5/16
1.3/8"
669-228
3/8
1.3/8"
669-229
METRIC SIZES
STUD SIZE
"L" LENGTH
PART NUMBER
3MM
1.3/8"
669-243
4MM
1.3/8"
669-231
5MM
1.3/8"
669-244
6MM
1.3/8"
669-235
8MM
1.3/8"
669-228
10MM
1.3/8"
669-247
ACCESSORIES
ITEM
PART NUMBER
B COLLET TAPER BASE
669-223
BUTTON STOP
669-225A
UNIVERSAL STOP
669-225
L
3/8 Ø
TAPER - 'B' BASE
BUTTON STOP
UNIVERSAL STOP

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Cutlass Fasteners, Inc.
83 Vermont Ave., Unit 6, Warwick, RI 02888
Tel: [phone] Fax: [phone]
cutlass-studwelding.com
Stud Welding…
Fasteners
Equipment
Service
STANDARD ACCESSORIES
INCH
STUD SIZE
PART NUMBER
2-56UNC
015-509
12GA, 4-40UNC
602-467A
1/8
015-511
10GA, 6-32UNC
602-451A
STUD SIZE
PART NUMBER
8-32UNC
602-452A
3MM
605-111
#10, 3/16
605-101A
4MM
602-423A
0.217
605-112
5MM
605-102
1/4
605-104A
6MM
605-103
5/16
605-105A
8MM
605-105A
3/8
605-106A
10MM
605-106
LONGER LENGTHS AVAILABLE ON REQUEST
SIZE
„D‟ DIA.
PART NO.
SMALL
7/8”
023-252
MEDIUM
1.160”
023-252M
DESCRIPTION
PART NO.
JIG LOCATING BUSH
D = 7/8”
650-691
NAIL GUIDE
D = 7/8”
601-350
CHUCK DRIFT
000-374
SPARK SHIELD, SML.
D = 1.16”, A =3/16”
999-013
SPARK SHIELD, LGE.
D = 1.16”, A =1/2”
999-018
METRIC
STANDARD
ADJUSTABLE
WELD CHUCKS
CD FOOTPIECE
D
JIG LOCATING BUSH
CHUCK DRIFT
SPARK SHIELD
NAIL GUIDE
D
A
D
* 2.5/8”

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Cutlass Fasteners, Inc.
83 Vermont Ave., Unit 6, Warwick, RI 02888
Tel: [phone] Fax: [phone]
cutlass-studwelding.com
Stud Welding…
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Service
PKM-1B GUN PARTS
ITEM
PART NO.
DESCRIPTION
QTY
1A
80-40-1741
B COLLET ADAPTOR
1
22A
80-40-1739
SINGLE LEG FACEPLATE
1
22B
80-40-1113
TWIN LEG FACEPLATE
1
ALTERNATE PARTS…

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Cutlass Fasteners, Inc.
83 Vermont Ave., Unit 6, Warwick, RI 02888
Tel: [phone] Fax: [phone]
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Stud Welding…
Fasteners
Equipment
Service
PKM-1B GUN PARTS
ITEM
PART NO.
DESCRIPTION
QTY
PKM-1B
COMPLETE WELD GUN
1
1
80-40-1738
TAPER CHUCK ADAPTOR
1
2
80-40-1097
BELLOWS
1
3
80-40-1023
INSULATING BUSH
1
4
80-40-1020
GUIDE BUSH
1
6
80-40-1740
SPINDLE
1
7
80-15-1011
M5 X 8 SOC. HD. SCREW
1
8
80-40-1027
SPRING PLATE
1
9
80-40-1031
MAIN SPRING
1
11
80-15-1022
M3 X 12 SOC. HD. SCREW
1
12
80-40-1015
ADJUSTING NUT
1
13
80-40-1603
SPRING ADJUSTING SCREW
1
16
80-40-1028
BACK CAP
1
21
80-40-1012
TRIPOD LEG
3
22
80-40-1013
TRIPOD FACEPLATE
1
23
80-15-1010
M5 X 4 SOC. HD. SCREW
1
24
80-40-1602
GUN BODY (TOP & BOTTOM)
1
31
80-15-1013
HANDLE SCREW
3
32
80-40-1016
TRIGGER BUTTON
1
33
80-40-1017
TRIGGER SLEEVE
1
34
80-10-1015
CABLE CLIP
1
36
80-15-1061
M2.5 X 8 SCREW
2
37
80-50-1013
TRIGGER SWITCH
1
38
80-15-1015
M2.0 X 10
2
39
80-72-1012
INTERNAL WELD CABLE
1
41
80-15-1016
M4 LOCK WASHER
1
42
80-15-1012
M4 X 8 SOC. HD. CAP SCREW 1
1
90
80-72-1039
WELD/CONTROL CABLE (16FT.)
1
91
80-10-1011
CONTROL CABLE SLEEVE
1
92
80-10-1013
WELD CABLE SLEEVE
1
93
80-35-1134
CABLE CONNECTING BLOCK
1
94
600-627
CABLE SLEEVE
1
96
999-136
CONTROL PLUG C/M
1
97
650-669
WELD PLUG C/M
1

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Cutlass Fasteners, Inc.
83 Vermont Ave., Unit 6, Warwick, RI 02888
Tel: [phone] Fax: [phone]
cutlass-studwelding.com
Stud Welding…
Fasteners
Equipment
Service
CLASSIC CONTROLLER PARTS

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Cutlass Fasteners, Inc.
83 Vermont Ave., Unit 6, Warwick, RI 02888
Tel: [phone] Fax: [phone]
cutlass-studwelding.com
Stud Welding…
Fasteners
Equipment
Service
CLASSIC CONTROLLER PARTS (continued)

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Cutlass Fasteners, Inc.
83 Vermont Ave., Unit 6, Warwick, RI 02888
Tel: [phone] Fax: [phone]
cutlass-studwelding.com
Stud Welding…
Fasteners
Equipment
Service