Grizzly T10499 User manual
For questions or help with this product contact Tech Support at (570) 546-9663 or techsupport@grizzly.com
MODEL T10499/T10500
PORTABLE
BLADE WELDER
INSTRUCTIONS
WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE
OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL, INC.
Introduction
Hot sparks from the welding process can
damage your eyes and skin. During welding
operations, always wear safety goggles and
protective gear, and keep the spark deflec-
tor over the welding clamps to reduce your
risk.
Specifications
T10499:
T10500:
Figure 1.
Identification
To reduce the risk of
serious injury when using
this machine, read and
understand this entire
manual before beginning
any operations.
Figure 2.
Safety for Blade Welders
WELDING FUMES.
PREVENT FIRES.
PERSONAL PROTECTIVE EQUIPMENT.
ABRASION INJURIES.
ELECTRIC & MAGNETIC FIELDS (EMF).
EQUIPMENT MAINTENANCE.
STABLE WORK SURFACE.
BLADE BREAKAGE.
If you have never used this type of welder before, WE STRONGLY RECOMMEND that you read
books, trade magazines, or get formal training before beginning any projects. Regardless of the
content in this section, Grizzly Industrial will not be held liable for accidents caused by lack of
training.
Electrocution, fire, or
equipment damage may
occur if machine is not
correctly grounded and
connected to the power
supply.
Full-Load Current Rating
The full-load current rating is the amperage a
machine draws at 100% of the rated output power.
On machines with multiple motors, this is the
amperage drawn by the largest motor or sum of all
motors and electrical devices that might operate
at one time during normal operations.
T10499 Full-Load Current Rating........ 8 Amps
T10500 Full-Load Current Rating...... 20 Amps
The full-load current is not the maximum amount
of amps that the machine will draw. If the machine
is overloaded, it will draw additional amps beyond
the full-load rating.
If the machine is overloaded for a sufficient length
of time, damage, overheating, or fire may result—
especially if connected to an undersized circuit.
To reduce the risk of these hazards, avoid over-
loading the machine during operation and make
sure it is connected to a power supply circuit that
meets the requirements in the following section.
A power supply circuit includes all electrical
equipment between the breaker box or fuse panel
in the building and the machine. The power sup-
ply circuit used for this machine must be sized to
safely handle the full-load current drawn from the
machine for an extended period of time. (If this
machine is connected to a circuit protected by
fuses, use a time delay fuse marked D.)
Circuit Information
Note: The circuit requirements listed in this man-
ual apply to a dedicated circuit—where only one
machine will be running at a time. If this machine
will be connected to a shared circuit where mul-
tiple machines will be running at the same time,
consult a qualified electrician to ensure that the
circuit is properly sized for safe operation.
For your own safety and protection of
property, consult an electrician if you are
unsure about wiring practices or electrical
codes in your area.
Grounding Requirements
This machine MUST be grounded. In the event
of certain malfunctions or breakdowns, grounding
reduces the risk of electric shock by providing a
path of least resistance for electric current.
Improper connection of the equipment-grounding
wire can result in a risk of electric shock. The
wire with green insulation (with or without yellow
stripes) is the equipment-grounding wire. If repair
or replacement of the power cord or plug is nec-
essary, do not connect the equipment-grounding
wire to a live (current carrying) terminal.
Check with a qualified electrician or service per-
sonnel if you do not understand these grounding
requirements, or if you are in doubt about whether
the tool is properly grounded. If you ever notice
that a cord or plug is damaged or worn, discon-
nect it from power, and immediately replace it with
a new one.
Power Supply
T10499 Circuit Requirements
Nominal Voltage ........................................ 115V
Cycle ..........................................................60 Hz
Phase........................................... Single-Phase
Power Supply Circuit ......................... 15 Amps
Plug/Receptacle ............................. NEMA 5-15
Figure 3
T10500 Circuit Requirements
Nominal Voltage ........................................230V
Cycle ..........................................................60 Hz
Phase........................................... Single-Phase
Power Supply Circuit ......................... 20 Amps
Plug/Receptacle ............................. NEMA 6-20
Figure 4
Figure 3.
Grounding Prong
Neutral Hot
5-15 PLUG
GROUNDED
5-15 RECEPTACLE
SHOCK HAZARD!
Two-prong outlets do not meet the grounding
requirements for this machine. Do not modify
or use an adapter on the plug provided—if
it will not fit the outlet, have a qualified
electrician install the proper outlet with a
verified ground.
Figure 4.
Grounding Prong
Current Carrying Prongs
6-20 PLUG
GROUNDED
6-20 RECEPTACLE
No adapter should be used with the
required plug. If the plug does not fit the
available receptacle, or the machine must
be reconnected for use on a different type
of circuit, the reconnection must be made
by a qualified electrician and comply with all
local codes and ordinances.
Tools Needed Qty
To attach the blade shear wings:
1.
Figure 6
Note: Keep the spacers that separate the two
plates in place.
Figure 6.
2. Step 1
Figure 7
Figure 7.
Assembly
Figure 5
Figure 5.
Extension Cords
We do not recommend using an extension cord
with this machine. If you must use an extension
cord, only use it if absolutely necessary and only
on a temporary basis.
Extension cords cause voltage drop, which may
damage electrical components and shorten motor
life. Voltage drop increases as the extension cord
size gets longer and the gauge size gets smaller
(higher gauge numbers indicate smaller sizes).
Any extension cord used with this machine must
contain a ground wire, match the required plug
and receptacle, and meet the following require-
ments:
T10499 Minimum Gauge Size..............14 AWG
T10500 Minimum Gauge Size..............12 AWG
Maximum Length (Shorter is Better).......25 ft.
Operations
Blade Preparation
To prepare the blade for welding:
1. ON
2.
Figures 9–10
Note: Make sure the blade ends are even
with each other after grinding them.
Figure 10.
Welding Zone
Grind Off
Figure 9.
Hot sparks from the welding process can
damage your eyes and skin. During welding
operations, always wear safety goggles and
protective gear, and keep the spark deflec-
tor over the welding clamps to reduce your
risk.
Blade Shear
Figure 8
Figure 8.
Overview
Note: You can make sure that the blade
ends are even with each other by stacking
them together with the teeth facing in oppo-
site directions (see Figure 11), then grinding
them. Regardless of the grinding angle, the
blade ends will match evenly for welding.
Figure 11.
3.
Note: To prevent dulling the teeth, keep the
emery cloth away from them when sanding
the blade surface.
Welding
1. OFF
2.
3.
Figure 12
Figure 13.
4.
5.
Figure 13
6.
Figure 12.
7.
Figure 14
8.
Figure 16
• ForT10499:
• ForT10500:
Note: As you rotate the clamp pressure
switch, the left clamp will move and apply
pressure toward the right. This pressure is
necessary to maintain contact between the
blade ends as the metal melts during the
welding operation.
Note: To ensure a good blade weld, it is
critical that the blade ends are secured in the
welding clamps evenly and with no overlap
(see Figure 15).
Blade Ends Butt Evenly
Blade Ends Flat w/No Overlap
Figure 15.
9.
10.
11.
ON
Figure 14.
Figure 16.
12.
Note: A limit switch senses the electrical
resistance between the blade ends. If there
is an adequate amount of welded material,
the limit switch will not allow the weld button
to activate the operation again.
13.
14.
15.
Before welding a blade back together to per-
form an internal cut, insulate the entire blade
from the metal surfaces of the bandsaw to
ensure a good flow of current through the
blade.
Correct
Not Correct
Not Correct
Correct
Not Correct
Figure 17.
Blade Preparation
Welding
Page 7
Hot sparks from the blade welding opera-
tion could be thrown in all directions and
cause burns or fire.
When using the blade welder, always keep
the spark deflector over the clamps and
protect yourself from the flying sparks.
Have fire extinguishing equipment readily
available.
DO NOT weld near flammables.
NOTICE
For good metal-to-metal contact between
the welding clamps and the blade, make
sure the blades and the clamps are free
from any debris, coatings, or flash before
and after each use of the welding station.
16.
Figure 17
Annealing Weld
To anneal the weld:
1.
2.
3.
Step 8Page 9
4.For Carbon Steel Blades:
Figure 18
For Bi-Metal Blades:
Correct
Not Correct
Not Correct
Correct
Not Correct
Figure 19.
5.
6.
7.
Note: Make sure not to grind the teeth or
blade body. Do not overheat the blade during
grinding—this will weaken the blade.
8.For Bi-Metal Blades Only: Steps
3–5Step 6
9.
Figure 19
Blade Preparation Welding
Page 7
10.
11.
Figure 18.
Review the troubleshooting and procedures in this section if a problem develops with your machine. If you
need replacement parts or additional help with a procedure, call our Technical Support at (570) 546-9663.
Note: Please gather the serial number and manufacture date of your machine before calling.
Troubleshooting
OFF
ON
NotePage 8
Page 8
Page 9
Page 8
NotePage 8
Page 11
T10499 Wiring Diagram
Clamp
Pressure
Cam
115VAC
NEMA 5-15 Plug/Receptacle
(As Recommended)
Transformer
A174-0001 1.2KVA 120V
1
2 3 4 5 6
Anneal
Button
Anneal
Strength Switch
Main
Power Switch
Welding
Button
Grinder ON/OFF
Switch
CS R1328F
ON
OFF
115V
Grinder
Motor
Ground
Hot
Neutral
Ground
Welding
Unit
Run
Capacitor
2M 250V
COM
NO NC
Defond
ENEC
T120/55
COM
NO NC
Defond
COM
NONC
Defond
E
54
6
2
3
1
HY29G
20/15A 277V
T10500 Wiring Diagram
Clamp
Pressure
Cam
230VAC
NEMA 6-20 Plug/Receptacle
(As Recommended)
Transformer
A174-0023 4.2KVA 240V
1
2 3 4 5 6
Anneal
Button
Anneal
Strength Switch
Main
Power Switch
Welding
Button
Grinder ON/OFF
Switch
CS R1328F
ON
OFF
230V
Grinder
Motor
Ground
Ground
HY29G
20/15A 277V
Welding
Unit
Run
Capacitor
2M 250V
COM
NO NC
Defond
ENEC
T120/55
COM
NO NC
Defond
COM
NONC
Defond
E
54
6
3
2
Hot
Hot
G
Cabinet Parts
REF PART # DESCRIPTION REF PART # DESCRIPTION
1 PT10499001 CABINET 19 PT10499019 UPPER SHEAR BLADE
2 PB18M HEX BOLT M6-1 X 15 20 PT10499020 RIGHT SHEAR BRACKET
3 PT10499003 HANDLE 21 PT10499021 HANDLE KNOB 3/8-16
4 PT10499004 POWER CORD 14G 3W 5-15 (T10499) 22 PT10499022 STUD-DE 3/8-16 X 4-3/8 3/8, 3/4
4 PT10500004 POWER CORD 14G 3W (T10500) 23 PT10499023 BLADE CAM
5 PT10499005 STRAIN RELIEF LT, STRAIGHT 24 PT10499024 SPACER
6 PN01M HEX NUT M6-1 25 PT10499025 RIGHT ALIGNMENT BRACKET
7 PS31M PHLP HD SCR M6-1 X 35 26 PT10499026 CAPTIVE PIN
8 PT10499008 LEFT ALIGNMENT BRACKET 27 PT10499027 SPACER
9 PEC09M E-CLIP 6MM 28 PT10499028 LEFT SPARK DEFLECTOR BRACKET
10 PCAP06M CAP SCREW M6-1 X 25 29 PT10499029 SPARK DEFLECTOR
11 PW03M FLAT WASHER 6MM 30 PT10499030 RIGHT SPARK DEFLECTOR BRACKET
12 PS81M PHLP HD SCR M6-1 X 40 31 PN04M HEX NUT M4-.7
13 PS05M PHLP HD SCR M5-.8 X 8 32 PS02M PHLP HD SCR M4-.7 X 12
14 PLW01M LOCK WASHER 5MM 33 PS15M PHLP HD SCR M6-1 X 14
15 PR11M EXT RETAINING RING 25MM 34 PB70 HEX BOLT 3/8-16 X 6
16 PT10499016 LEFT SHEAR BRACKET 35 PLW04 LOCK WASHER 3/8
17 PT10499017 SPACER 36 PN08 HEX NUT 3/8-16
18 PT10499018 LOWER SHEAR BLADE 37 PT10499037 MASTER POWER SWITCH
1
2
3
4
5
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Controls & Electrical
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64
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115
116
83
83
117
Controls & Electrical Parts List
REF PART # DESCRIPTION REF PART # DESCRIPTION
51 PT10499051 FRONT CABINET COVER 84 PT10499084 WELDING BUTTON
52 PT10499052 SPACER 85 PW05M FLAT WASHER 4MM
53 PT10499053 GRINDING WHEEL 65 X 16 X 7MM A60 86 PLW03M LOCK WASHER 6MM
54 PW03M FLAT WASHER 6MM 87 PT10499087 CLAMPING PRESSURE SHAFT
55 PN01M HEX NUT M6-1 88 PT10499088 CAM
56 PT10499056 GRINDING WHEEL GUARD 89 PS19M PHLP HD SCR M5-.8 X 6
57 PT10499057 GRINDING WHEEL COVER 90 PS64M PHLP HD SCR M4-.7 X 65
58 PFH08 FLAT HD SCR 10-24 X 1/2 91 PN01M HEX NUT M6-1
59 PEC09M E-CLIP 6MM 92 PT10499092 GUIDE BLOCK
60 PT10499060 ROUND KNOB M6-1 93 PN07M HEX NUT M3-.5
61 PT10499061 RIGHT CLAMPING LEVER 94 PT10499094 CAPACITOR AID ELECT 2M 250V
62 PFH30M FLAT HD SCR M5-.8 X 8 95 PT10499095 LIMIT SWITCH DEFOND 125/250V
63 PS15M PHLP HD SCR M6-1 X 14 96 PT10499096 GUIDE CASTING
64 PLW01M LOCK WASHER 5MM 97 PN07 HEX NUT 10-24
65 PS18 PHLP HD SCR 10-24 X 1/4 98 PS98M PHLP HD SCR M3-.5 X 16
66 PT10499066 RIGHT CLAMP 99 PW06 FLAT WASHER 1/4
67 PT10499067 ECCENTRIC SHAFT 100 PT10499100 FLAT WASHER 5MM BRASS
68 PSS02M SET SCREW M6-1 X 6 101 PT10499101 GUIDE BLOCK INSULATOR
69 PT10499069 STATIONARY CLAMPING JAW 102 PS13M PHLP HD SCR M3-.5 X 20
70 PT10499070 JAW INSULATOR 103 PN06M HEX NUT M5-.8
71 PT10499071 INSULATING SLEEVE 5MM 104 PCAP10M CAP SCREW M5-.8 X 15
72 PT10499072 INSULATING FLAT WASHER 5MM 105 PT10499105 LONG EXTENSION SPRING
73 PFH05M FLAT HD SCR M5-.8 X 12 106 PT10499106 SPRING BRACKET
74 PCAP10M CAP SCREW M5-.8 X 15 107 PT10499107 PHLP HD SCR M5-.8 X 10 BRASS
75 PT10499075 MOTOR 1/8HP 115V 1-PH (T10499) 108 PS05M PHLP HD SCR M5-.8 X 8
75 PT10500075 MOTOR 1/8HP 230V 1-PH (T10500) 109 PT10499109 SHORT EXTENSION SPRING
76 PT10499076 TRANSFORMER A174-0001 1.2KVA 120V (T10499) 110 PS12 PHLP HD SCR 1/4-20 X 5/8
76 PT10500076 TRANSFORMER A174-0023 4.2KVA 240V (T10500) 111 PT10499111 CLAMPING PRESSURE LEVER
77 PT10499077 LEFT CLAMP 112 PT10499112 BUSHING
78 PT10499078 LEFT CLAMPING LEVER 113 PN05 HEX NUT 1/4-20
79 PT10499079 MOVABLE CLAMPING JAW 114 PB98 HEX BOLT 1/4-20 X 2-1/2
80 PT10499080 GRINDER ON/OFF SWITCH CS-R1328F 115 PT10499115 TERMINAL BLOCK BRACKET
81 PT10499081 TRANSFORMER BRACKET 116 PT10499116 TERMINAL BLOCK 6P
82 PT10499082 CLAMPING PRESSURE KNOB 117 PT10499117 TOGGLE SWITCH HY29G 20/15A 125/277V
83 PT10499083 ANNEAL BUTTON ASSEMBLY
Machine Labels
Safety labels help reduce the risk of serious injury caused by machine hazards. If any label comes
off or becomes unreadable, the owner of this machine MUST replace it in the original location
before resuming operations. For replacements, contact (800) 523-4777 or www.grizzly.com.
REF PART # DESCRIPTION REF PART # DESCRIPTION
118 PT10499118 MACHINE ID LABEL (T10499) 122 PT10499122 GRINDER WHEEL ROTATION LABEL
118 PT10500118 MACHINE ID LABEL (T10500) 123 PT10499123 GRINDER ON/OFF LABEL
119 PT10499119 POWER ON/OFF LABEL 124 PPAINT-01 GRIZZLY GREEN TOUCH-UP PAINT
120 PT10499120 EYE/SKIN HAZARD LABEL 125 PLABEL-12A READ MANUAL LABEL
121 PT10499121 SETTINGS LABEL (T10499) 126 PT10499126 CONTROL PANEL LABEL
121 PT10500121 SETTINGS LABEL (T10500) 127 PPAINT-11 GRIZZLY PUTTY TOUCH-UP PAINT
118 119
120
121
122
123
124
127
125
126
WARRANTY & RETURNS
Grizzly Industrial, Inc. warrants every product it sells for a period of 1 year to the original purchaser from
the date of purchase. This warranty does not apply to defects due directly or indirectly to misuse, abuse,
negligence, accidents, repairs or alterations or lack of maintenance. This is Grizzly’s sole written warranty
and any and all warranties that may be implied by law, including any merchantability or fitness, for any par-
ticular purpose, are hereby limited to the duration of this written warranty. We do not warrant or represent
that the merchandise complies with the provisions of any law or acts unless the manufacturer so warrants.
In no event shall Grizzly’s liability under this warranty exceed the purchase price paid for the product and
any legal actions brought against Grizzly shall be tried in the State of Washington, County of Whatcom.
We shall in no event be liable for death, injuries to persons or property or for incidental, contingent, special,
or consequential damages arising from the use of our products.
To take advantage of this warranty, contact us by mail or phone and give us all the details. We will then issue
you a “Return Number,’’ which must be clearly posted on the outside as well as the inside of the carton. We
will not accept any item back without this number. Proof of purchase must accompany the merchandise.
The manufacturers reserve the right to change specifications at any time because they constantly strive to
achieve better quality equipment. We make every effort to ensure that our products meet high quality and
durability standards and we hope you never need to use this warranty.
Please feel free to write or call us if you have any questions about the machine or the manual.
Thank you again for your business and continued support. We hope to serve you again soon.
Buy Direct and Save with Grizzly®– Trusted, Proven and a Great Value!
~Since 1983~
ORDER
24 HOURS A DAY!
1-800-523-4777
Visit Our Website Today For
Current Specials!
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1
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