Ultratech Tactical Welder 4800 User manual

UltraTech International, Inc.
11542 Davis Creek Court
Jacksonville, FL 32256
1-904-292-1611 · tacticalwelder.com
Operations Manual
Part Number 4800

1-904-292-1611 · tacticalwelder.com
2
Warranty Information...........................................................................................................................................................................................................3
Tactical Welder Warranty/Restocking Fee
Safety.........................................................................................................................................................................................................................................4-5
Tactical Welder Safety Instructions
General
Proper use
Environmental Conditions
Protecting yourself and others
Danger from toxic gases vapors
Specific areas of risk
Safety and Operation references
Frequently asked questions...............................................................................................................................................................................................6
Tactical Welder FAQ
Important Operating Tips....................................................................................................................................................................................................7
Charging the Tactical Welder.............................................................................................................................................................................................7
Set up.........................................................................................................................................................................................................................................8
Safety checks on Welding unit
Loading Welding gun
Connecting gun to power unit
Welding Gun Exploded Diagram........................................................................................................................................................................................10
Operation..................................................................................................................................................................................................................................10
Setting wire feed speed
Clamping ground wire
PPE
Starting arc
Weld Time capability
Charging Unit
Storing Unit
Routine Maintenance............................................................................................................................................................................................................11
Preventative Maintenance Recommendations
Battery Pack Maintenance
Replacing Tip Assembly Components
Recommended Periodic Maintenance............................................................................................................................................................................11
Lubricating weld gun
Battery checks
Troubleshooting - Welder....................................................................................................................................................................................................11
Troubleshooting - Spool Gun ..............................................................................................................................................................................................11
Applications Table.................................................................................................................................................................................................................13
Steel
Aluminum
Stainless Steel
General Guidelines ................................................................................................................................................................................................................13
Thin Metal Welding................................................................................................................................................................................................................14
Aluminum Welding.................................................................................................................................................................................................................14
Tactical Welder Circuit Diagram.......................................................................................................................................................................................15
Table of Contents

3
Warranty Information
LIMITED WARRANTY − Subject to the terms and conditions below,
UltraTech International, Inc. Jacksonville, Florida, warrants to its
original retail purchaser that new Tactical Welders sold after the
effective date of this limited warranty is free of defects in material and
workmanship at the time it is shipped by UltraTech.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES,
EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABI-
LITY AND FITNESS.
Within the warranty time frames outlined herein, UltraTech will repair
or replace any warranted parts or components that fail due to such
defects in material or workmanship. UltraTech must be notified in writ-
ing within thirty (30) days of such defect or failure. Upon notification,
UltraTech will provide instructions on the warranty claim procedures
to be followed. Any warranty claim that is submitted must include a
detailed description of the fault and the troubleshooting steps taken
to identify failed components and the cause of their failure. UltraTech
shall honor warranty claims on warranted equipment listed below in
the event of such a failure within the warranty time periods. All war-
ranty time periods start on the delivery date of the Tactical Welder to
the original end-user purchaser, and not to exceed twelve months af-
ter the Tactical Welder is shipped to an UltraTech distributor.
1 Year Parts and Labor on the Tactical Welder, Part Number 5400. Ul-
traTech’s Limited Warranty shall not apply to: 1. Consumable compo-
nents; such as contact tips, contactors, or parts that fail due to nor-
mal wear. 2. Equipment that has been modified by any party other than
UltraTech, or equipment that has been improperly installed, improperly
operated or misused based upon industry standards, or equipment
which has not had reasonable and necessary maintenance, or equip-
ment which has been used for operation outside of the specifications
for the equipment.
ULTRATECH PRODUCTS ARE INTENDED FOR PURCHASE AND USE
BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND
EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the exclu-
sive remedies shall be, at UltraTech’s option: (1) repair; or (2) replace-
ment; or, where authorized in writing by UltraTech in appropriate cas-
es; or (3) payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. UltraTech’s option of repair or replace-
ment will be F.O.B., Factory in Boulder, Colorado or F.O.B. at any other
UltraTech authorized facility as determined by UltraTech. No compen-
sation or reimbursement for transportation costs of any kind will be
allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HERE-
IN ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL
ULTRATECH BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER
BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY. ANY EXPRESS
WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED
WARRANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND
ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL
THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICA-
TION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS
FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY ULTRATECH IS EXCLUDED AND DISCLAIMED BY ULTRAT-
ECH.
Some states in the U.S.A. do not allow limitations of how long an im-
plied warranty lasts, or the exclusion of incidental, indirect, special or
consequential damages, so the above limitation or exclusion may not
apply to you. This warranty provides specific legal rights, and other
rights may be available, but may vary from state to state. In Canada,
legislation in some provinces provides for certain additional warran-
ties or remedies other than as stated herein, and to the extent that
they may not be waived, the limitations and exclusions set out above
may not apply. This Limited Warranty provides specific legal rights, and
other rights may be available, but may vary from province to province.
Warranty Questions? Call 1-800-353-1611 or 904-292-1611 or email us at
[e-mail].
RESTOCKING FEE - A 15% fee is charged on all returns and a credit will be
issued, provided: (a) the customer prepays the return freight cost*; (b) prod-
uct is received in a clean, unused condition, able to be resold without exten-
sive cleaning or repackaging; (c) the product is received at our designated
location or the location indicated on the RMA 90 days or less from date the
end user received the product from UltraTech or its distributor; the product is
shipped in its original packaging and shipped according to applicable ship-
ping standards for the hazardous nature of the lithium ion batteries. UltraTech
reserves the right to refuse a return if any of these conditions are not met.
* IMPORTANT NOTE: Because of the size of the Tactical Welder’s battery, it
must be shipped in accordance with hazardous material (HAZMAT) regula-
tions. Please contact us for more information on the requirements.
This Restocking Fee Policy is expressly in lieu of all other UltraTech
Restocking Fee Policies.

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Safety & Warnings
General
The device is manufactured using state-of-the-art technology and
according to recognized standards. However BE AWARE, SERIOUS
INJURY OR DEATH MAY RESULT, if welding equipment is not properly
installed, used, and maintained.
Misuse of this equipment and other practices can be both hazardous
and dangerous to operator and any persons in the general work
area. The operator, supervisor, and helper must read and understand
the following safety warnings and instructions before installing or
using any welding equipment.
The welding process is used in many potentially dangerous and
hazardous conditions. In environments such as elevated heights,
areas of limited ventilation, close quarters, around water, uncertain
power sources, in hostile environments, etc., it is important that
the operators are aware of the dangers and limitations associated
with working in these types of conditions. Only properly trained
and experienced operator(s) trained in safe practices for the
environments in which they are expected to work and are under
competent supervision should use this welder. It is essential that
the operator, supervisor, and others in the work area are aware of
the dangers of the welding process. Training and supervision are
both important and necessary for a safe work place. Please keep
these instructions for future use.
Electrical Hazards
ELECTRIC SHOCK CAN CAUSE INJURY OR DEATH.
Install and maintain the equipment in accordance with the National
Electric Code NFPA 70 and local codes. Do not service or repair
equipment with power on or batteries connected. Do not operate
equipment with protective insulators or covers removed. Service
or repair of equipment must be done by qualified and/or trained
personnel only.
Operator should not and must not contact electrically live parts. Do
not touch electrode with bare skin and electrical ground at the same
time. Always wear dry welding gloves in good condition. Be aware
aluminized protective clothing can become part of the electrical
path. Keep gas cylinders, chains, wire ropes, cranes, hoists, and
elevators away from any part of the electrical path. All ground
connections must be checked periodically to determine that they
are mechanically strong and electrically adequate for the required
current. When welding is to be suspended for any sustained period
of time, such as during lunch or overnight, the welding gun should
be disconnected from the battery pack when not in use. Never
immerse the welding gun or ground connection in water.
During MIG or Flux-core welding, the welding wire, the wire spool,
the drive rollers and all metal parts that are in contact with the weld
wire are live when the trigger of the gun is depressed. It is always
best to place the weld gun in its proper position in the pack or on
an insulated surface when not in use for short periods of time. All
cables and leads must be complete, undamaged, insulated and
adequately dimensioned. Loose connections, scorched, damaged
or inadequately dimensioned cables or leads must be repaired/
replaced immediately.
Turn off Power Pack and unplug the gun from the pack when not in
use.
Proper Use
The device is to be used exclusively for its intended purpose. The
device is intended exclusively for the welding process described in
the instructions. Any use above or beyond this purpose is deemed
improper. The manufacturer shall not be liable for any damage
resulting from such improper use.
Utilization in accordance with the “intended purpose” also includes
• Reading carefully and following all operating instructions
• Studying and obeying all safety and danger notices
• Performing all stipulated inspection and servicing work
The device is designed for use in industrial areas, workshops and
“in the field” work. The manufacturer accepts no responsibility for
any damage caused through use in a domestic setting.
The manufacturer likewise accepts no responsibility for unexpected
or incorrect results.
Environmental Conditions
Operation or storage of the device outside of the stipulated area will
be deemed as not in accordance with the intended purpose. The
manufacturer shall not be held liable for any damage arising from
such usage.
Ambient temperature range:
• During operation: -30°C to +55°C
• During storage: -40°C to +60°C
Protecting Yourself and Others
BE AWARE, ARC RAYS, HOT SLAG AND SPARKS CAN AND DO CAUSE
INJURY TO EYES AND SKIN
The welding process produces extreme localized heat and strong
ultraviolet rays. Never attempt to weld without proper welding
equipment, including, but not limited to, a welding helmet with the
proper lens, which complies with federal guidelines. A number 12
to 14 shade filter lens on the helmet provides the best protection
against arc radiation. Please take precautions to prevent reflected

5
arc rays from entering around the helmet. It is important to make
sure others are protected from arc rays and sparks. Approved
shielding curtains and/ or appropriate goggles should be used by
all persons working in close proximity of the welding area to protect
them from arc rays and sparks. Skin should and must be protected
from arc rays, heat and molten metal. The operator must always
wear protective gloves and clothing which will not allow skin to
become exposed. All clothing pockets should be closed and cuffs
sewn shut. Leather aprons, sleeves, leggings, etc. should and must
be worn for out-of-position welding. High top work shoes provide
adequate protection against foot burns; for added protection, use
leather spats. Flammable hair products should not be used when
welding.
Keep all persons, especially children, out of the work area while any
devices are in operation or welding is in progress. If however, there
are people in the vicinity,
• Make them aware of the dangers (risk of dazzling by the arc,
injury from flying sparks, inhaling welding fumes, noise, possible
danger from mains or welding current, etc.).
• Provide suitable protective equipment or
• Erect suitable safety screens/curtains.
• Danger from Toxic Welding Fumes
• The fumes produced during welding contain harmful gases and
vapors.
• Welding fumes contain substances that may, under certain
circumstance cause birth defects or cancer.
• Keep your face away from welding fumes and gases.
• Fumes and hazardous gases
· Must not be breathed in
· Must be extracted from work area using appropriate methods
• Ensure an adequate supply of fresh air with a ventilation rate of
at least 20 cubic meters/hour.
• Otherwise, a protective mask with an air supply must be worn.
• Close the shielding gas cylinder valve or main gas supply if no
welding is taking place.
• If there is any doubt about whether the extraction capacity
is sufficient, the measured toxic emission values should be
compared with the permissible limit values.
Specific Areas of Risk
BE AWARE, WELDING SPARKS CAN AND DO CAUSE FIRES AND
EXPLOSIONS
Causes of fire and explosions are: combustibles reached by the
arc, flame, flying sparks, hot slag, or heated materials. Remove
combustible materials and items from the work area and/or
provide a fire watch. Avoid oily or greasy clothing as a spark can
ignite them. It is necessary and required that the operator have
a fire extinguisher nearby and have knowledge and training in its
use. Be aware and alert to the danger of conduction or radiation.
For example, if welding is to be done on a metal wall or partition,
ceiling or roof, precautions must be taken to prevent ignition of
combustibles on the other side. Do not weld near combustible or
containers that have combustibles. All hollow spaces, cavities and
containers should and must be vented prior to welding to permit the
escape or air or gases. Purging with inert gas is recommended. Use
onlyinert gases orinert gas mixturesasrequiredbythe process.Use
of combustible compressed gases can cause explosions resulting
in personal injury or death. Arcing against any compressed gases
can cause explosions resulting in personal injury or death.
A high risk of injury exists when the welding wire emerges from the
welding gun (piercing of the hand, injuries to the face and eyes,
etc.). Always keep the gun well away from the body, and wear
suitable protective goggles.
Never touch the work piece during or after welding – risk of burns.
Slag can sometimes fly off work pieces as they cool down. The
specified protective equipment must therefore also be worn when
reworking work pieces, and steps must be taken to ensure that
other people are also adequately protected. Welding guns, torches
and other parts with high operating temperature must be allowed to
cool down before handling.
Safety and Operation References
1. Code of Federal Regulations, (OSHA) Section 29 Part 1910.95, 251-254
and 1000. U.S. Government Printing Office, Washington, D.C. 20402
2. ANSI Z49.1 “Safety in Welding and Cutting” American National Standard
Institute, 1430 Broadway, New York, NY 10018
3. ANSI Z87.1 “Practice of Occupational and Education Eye and Face
Protection” American National Standard Institute, 1430 Broadway,
New York, NY 10018
4. ANSI Z88.2 “Standard Practice for Respiratory Protection” American
National Standard Institute, 1430 Broadway, New York, NY 10018
5. AWS F4.1 “ Recommended Safe Practices for Welding and Cutting
Containers” The American Welding Society 550 NW Lejeune Road PO
Box 351040, Miami, FL 33135
6. NFPA-51B “ Fire Prevention in Cutting and Welding Processes” National
Fire Protection Association, Battery Park, Quincy, MA 02269
7. NFPA-7 “National Electrical Code” National Fire Protection Association,
Battery Park, Quincy, MA 02269
8. CSA Standard W117.2 “Safety in Welding, Cutting and Allied Processes”
Canadian Standards Association, 178 Rexdale, Ontario, Canada M9W
1R3

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Frequently Asked Questions
What kind of power does the Tactical Welder have?
It holds about ½ kW of energy and 300 amps. It is 26.4
Volts.
What kind of welding is the Tactical Welder capable of?
The Welder is capable of MIG and flux core welding using a
wire feed gun.
What is the warranty on the Tactical Welder?
There is a one-year warranty on parts and labor. Please
see the written warranty for full details.
How long can the Tactical Welder operate?
It can continuously weld for approximately 18 minutes. At a
30% duty cycle, the Welder can weld for approximately 54
minutes. The Welder’s gun holds a 2 lb spool of wire. The
Welder has shown to be able to weld 1 lb of 0.035 wire on
a single charge. The actual amount of weld or wire used is
dependent on a number of factors. Results may vary.
What comes with the Tactical Welder?
The Tactical Welder includes a Battery Management System
(includes the batteries), a welding wire feed gun (variable
speed), a 300A ground clamp, a 7A, 120/240 V battery
recharger and a custom backpack.
What size wire does the Tactical Welder use?
The Welder can use wire from 0.030” to 0.052”.
What thicknesses of steel or metal can be welded with
the Tactical Welder?
From 1/8” to 1/2” (3.2 mm to 12.7 mm).
How long does it take to recharge the battery pack?
From full discharge, the battery pack takes approximately
2.5 hours to charge fully. From partial discharge, it takes
approximately 1 to 1.3 hours.
What type of safety features are built into the Battery
Management System (BMS)?
The BMS monitors discharge and re-charge of each cell,
and controls the power and heat during working cycles.
If the temperature of the cells gets too high, the BMS is
capable of cutting the power o to protect the battery.
Are Battery Packs available separately?
Yes, Battery Packs can be purchased separately to provide
a back-up.
How much does the Tactical Welder weigh?
The complete system (including the backpack) weight 27
lbs.
Is the Tactical Welder capable of welding aluminum?
Yes, but thinner aluminum could be burned through if the
user is not adept at welding aluminum.
Does it have a “cold tip” feature?
Yes, as well as some other features to promote maximum
safety.
How long are the leads?
The leads are six feet in length.
Can the Tactical Welder be used with argon or another
inert gas?
Yes, there is a tube in the gun for connecting to an inert
gas. To allow a gas bottle to fit into the backpack with
the welder, we recommend using a “paint ball” size gas
cylinder.
Can the Tactical Welder be used underwater?
No, it should not be submerged in water for any reason.
Can the unit TIG or stick weld?
The Tactical Welder cannot TIG or stick weld.

7
Important Operating Tips
Charging the Tactical Welder
Safety
Never open the welding gun if it is connected to the Power Pack!
Opening the wire housing cover while the gun is powered will likely
cause severe damage to the circuit board and other parts inside the
gun. This damage will not be covered by the warranty. Also, never
leave the power connected to the gun, always disconnect the gun
from the Power Pack when not in use.
Clean Metal Surfaces
The metal surfaces to be welded together should be clean and free
from any “mill scale” deposits found on most steel products as they
come from the foundry. Grinding the surfaces to be welded down to
shiny bare metal will greatly improve the strength and penetration
of the weld. Because MIG welding is an electrical process, any
action taken which improves the conductivity of the metal being
welded will improve the final results. This also applies to the surface
to which the large ground clamp is connected to as well. Make sure
the ground clamp is attached to clean, bare metal on the piece
being welded. Remember, the cleaner the surfaces welded, the
stronger the weld.
Wall Charging
1. Connect the charge connector to the Power Pack’s charging
port. Assure the connector is indexed correctly. Do not force it.
2. Turn on the Tactical Welder switch and note the charge indication
on the battery meter.
3. Connect the Charger to a 110V AC/220V AC power source, using
the AC plug and turn on the charger switch.
4. Allow unit to charge until the “LED2” light on the charger turns
green. The onboard “fuel gage” should indicate a full charge. Full
charge may take up to 3 hours with the 7A charger, 2 hours with
the 12A charger depending on the Depth of Discharge (DOD) of
the battery.
5. When charging is complete, turn off the Tactical Welder switch
and the charger, disconnect the charger from the Power Pack,
and unplug the AC cord.
Car Charging
1. Connect the 12V or 24V AC inverter to the vehicles battery or
power port. Connect the AC battery charger to the Tactical
Welder as above and plug the AC battery charger into the
inverter socket.
2. Turn on the inverter, the AC battery charger and the Tactical
Welder main switch.
3. Allow the battery to fully charge.
4. When charging is complete, turn off the Tactical Welder switch,
the battery charger, and the inverter. Disconnect the charger
from the Power Pack and unplug it from the inverter. Disconnect
the inverter from the vehicle battery or power port.
WARNING: Electric shock can be fatal. Do not open the charger case.
NOTICE: The Tactical Welder Power Pack must be fully charged before using the Welder for the first time.
NOTICE: The Tactical Welder is designed to be charged using only the included battery charger, using a different charger may damage
the unit. Damages resulting from using a charger other than the included charger will not be covered under the warranty.
What’s Included
Included:
• Tactical Welder Power Pack
with built in battery management system
• Spool gun
• Ground cable
• Charger
• Custom backpack for storage and transport
• Consumables replacement kit

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Spool Gun Setup
WARNING: Always check the charger lead, welding gun, cables, grounding connection and battery pack for damage before every use. NOTICE: The Tactical
Welder Power Pack must be fully charged before using the welder for the first time.
1. Remove the swan-neck nozzle assembly (#1, #2, #3, and #4) and disconnect each of the parts from each other. Also remove the wire liner brass (#5).
2. Ensure that wire size to be installed is compatible with the contact tip (#2). If they are not compatible, replace the tip or choose a different wire size.
3. Open the wire housing protective cover (#14) and wire top housing (#10) on the spool gun.
4. Remove the spool retaining nut (#25A), the compression sleeve (#25B), and the rubber spacer (#25C).
5. Place the wire spool onto the spool holder. Hold and snip the wire from the spool, being sure to hold the wire to prevent rapid uncoiling.
a. Place the spool of wire onto the spool spindle
b. Insert the rubber spacer (#25C) onto the spool spindle
c. Place the compression sleeve (#25B) onto the spool spindle
d. Use the retaining nut to tighten the compression sleeve (#25B) and rubber spacer (#25C) enough so that the spindle can rotate with a certain amount
of friction. The spool should not be so loose that it wobbles around on the spindle, nor should it be so tight that the wire drive mechanism cannot pull the
wire off the spool. In some cases, the compression sleeve (#25B) may not be needed and/or the rubber spacer (#25C) may need lubrication.
6. Ensure the wire tension knob (#11) is unlocked. Swing the tensioner ( #27) aside. Check that the drive roller matches the wire diameter. Replace the roller if
necessary.
7. Carefully feed the wire through the inlet guide tube (#15).
8. Carefully feed the wire over the drive roller (#28) into the outlet guide tube and feed through to the opposite side. Pull 12” of wire through the end of the gun.
Check that the wire is in the drive roller’s groove. Close the tensioner, then lock down the wire tension knob.
9. Close the wire top housing.
10. Apply an adequate amount of pressure to the drive roller by turning the wire tension knob.
11. Adjust the spool holder tension with the retaining nut as needed.
12. Feed the wire liner brass (#5) over the wire.
13. Install the swan neck straight tube (#4), and then install the insulator (#3).
14. Fit the correct sized contact tip (#2) and feed the wire through it, screw the contact tip into the tip holder of the torch neck and nip it up tightly.
15. Fit the gas nozzle to the torch head and close the wire spool cover.
16. Plug in the gun to the battery using the 4-pin connector only.
17. Squeeze the trigger and adjust the speed controller if necessary - the wire should come out of the gun easily.
• If the spooling wire is slow to come out or does not come out, loosen the retaining nut (#25A) until the wire flows smoothly. The rubber spacer (#25C) may
need to be lubricated and/or the compression sleeve (#25B) may need to be removed.
• If the spool spins too freely, tighten the wire tension knob (#11) to increase pressure on the wire roller.
Spool Gun - Parts List
# Description Qty.
1 Nozzle Tweco 2 Style 22 Series 1
2 Contact Tip 14 Series Tweco Style 1
3 Insulator 1
4 Swan Neck Straight Tweco 2 Style 1
5 Wire Liner Brass 1
6 Trigger 1
7 Pin 1
8 Wire Feed Motor Complete 1
9 Handle 1
10 Wire Top Housing 1
11 Wire Tension Knob 1
12 Potentiometer Blank 1
13 Screw 1
14 Clear Plastic Wire Housing 1
15 Wire Guide 1
# Description Qty.
16 Ball Joint 1
17 Strain Relief 1
18 Coaxial Cable 1
19 Strain Relief Housing 1
20 Gun Plug Housing 1
21 Euro Connection Block 1
22 Euro Block Screw 1
23 Euro Housing 1
24 Connection Plug 9 Pin 1
25A Retaining Nut 1
25B Compression Sleeve 1
25C Rubber Spacer 1
26 Spool Spindle 1
27 Tensioner 1
28 Drive Roller 1

9

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10
Operation
1. Prepare the material that you will be welding using a grinder or
wire brush ensuring that everywhere you will be welding and the
location for the ground clamp, is shiny, bare metal.
2. Connect the ground clamp to the material to be welded assuring
a good electrical connection
3. Move the wire feed control knob to the appropriate speed for the
type of welding and thickness of the material to be welded.
4. Use appropriate protective equipment, ensuring that eyes and
skin are protected from injury on the operator as well as any
people in the work area.
5. Turn on the Tactical Welder Power Pack switch.
6. Squeeze the trigger on the gun to power the weld tip and activate
thewirefeedmechanism.MIGweldingcanbeperformedifthegas
tube at the power connector end of the gun cable is connected
to a gas supply at proper pressure and flow rate. As the weld wire
contacts the work piece a welding arc is established. You can
adjust the wire feed speed with the thumbwheel right on the gun
to control your weld.
7. When the welding job is complete; turn the Tactical welder off,
disconnect the ground clamp and gun connectors. Allow the gun
to cool before handling without protective equipment.
8. Inspect the Tactical Welder equipment for any damage and clean
where necessary.
9. If the battery charge was depleted, charge the unit.
10. Store the unit, in the back pack, in a dry location maintained
between -40°C and +60°C temperature.
1. Positive Power Connector
2. Negative Power Connector
3. Control/Charge Port
4. Battery Charge Indicator
5. Power Switch
23
4
5
1
Brand Size Model
Vulcan 0.03 63790
Vulcan 0.025 63796
Vulcan 0.035 63791
Chicago Electric 0.023 to 0.045, 5ea 65435
Lincoln Electric 0.025 KH710
Lincoln Electric 0.03 KH711
Lincoln Electric 0.035 KH712
Lincoln Electric 0.035 KH712
Blue Hawk 0.035 SGY-WELD22
Blue Hawk 0.03 SGY-WELD21
Blue Hawk 0.025 SGY-WELD20
Consumables
IMPORTANT: Keep in mind the duty cycle capabilities of the Tactical welder as shown in the weld time chart below. Weld operations
of 10 seconds or less are recommended with a minimum of 20 seconds between each weld operation. Do not run the unit for more
than 15 seconds without adequate off time of 30 seconds. This 33% duty cycle maximizes the life of the battery and avoids over
temperature shut down. It is best to complete your welding operation with 10 second weld cycles followed by a minimum of 20
seconds of off time for chipping and cleaning each weld.

11
Routine Maintenance
Recommended Periodic Maintenance
Tactical Welder
• Inspecting the case for damage, evidence of “hot spots”, or
corrosion
• Inspect and clean all ports
Welding Gun
• Keep grinding grit from getting into the gun. Do not lay the gun on
dirty or gritty surfaces and set the gun down as far away from
grinding activities and grit sources as possible.
• Proper lubrication of moving parts is essential for long life. We
recommend using fully synthetic motor oil for all the lubrication
needs of the welding gun. Be aware, use of petroleum based
lubricants can adversely affect the gun body and gas valve
action.
• Regularly blow the gun clean with compressed air.
Replacing Tip Assembly Components
• With use, the welding tips will need to be replaced intermittently.
Recommended replacement tips are standard #2 Tweco tips
or compatible. Dedicated tips should be used when welding
various types of metals (i.e., do not use the same tip for welding
aluminum and steel). When welding aluminum, be sure to use a
contact tip which is .005” larger than the feed wire itself.
Welding Gun
• Periodic lubrication of gun components is required for a long
service life. Note: Do not get oil on surface of the plastic roller
and main shaft. Use silicon oil on gears and shafts. Oil all parts
sparingly with a toothpick or Q-Tip.
Troubleshooting
Trouble Possible Problem Possible Solution
Welder not turning on Power Pack depleted Charge Power Pack. If the fuel gauge reads full
and the unit will not turn on contact support.
Welder shuts down while welding
Power Pack could be depleted or the Welder is
too hot
Check the fuel gauge if it shows the battery
is still full or near full, let the Power Pack rest.
Once the internal temperature is back in the
safe range, the unit will be able to be turned and
welding continued.
Wire not feeding when trigger is pressed on the
spool gun/and feed motor is activating
Wire feed speed is too low/ welding wire spool is
empty/ welding tip may be clogged.
Turn the wire feed speed knob counter
clockwise to increase the speed. (Turn unit off
before these steps) Check the spool. If the tip is
clogged you can attempt to clear it by filing the
tip to clear any melted weld wire stuck to the tip
or just swap out the tip.
Excessive spatter while welding
Ground polarity may be wrong/ gas pressure not
sufficient to properly shield the arc.
Turn the unit off and swap the ground and spool
gun connection (FCAW). Check shielding gas
pressure to ensure it set at the proper level for
the type of welding being performed (GMAW).
Tactical Welder

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Troubleshooting
Trouble Possible Problem Possible Solution
Wire drive motor does not turn 1. Wire feed speed control at zero.
2. Trigger in not pressed.
3. Wire drive m otor is damaged.
4. Feed roller is not correctly installed.
1. Increase wire feed speed control.
2. Wire will feed only when the trigger is pressed.
3. Replace wire drive motor.
4. See installation section to correctly install the drive roller.
Wire feed inconsistently 1. Torch liner is plugged.
2. Wire diameter may vary on spool of wire
causing the wire to catch in the contact tip.
3. Too much or too little wire tension.
4. Too much or too little drive roll tension.
5. Drive roll is worn.
1. Clear or replace torch liner.
2. Increase the contact tip one size
3. See setup step 16 (pg. 8)
4. See setup step 16 (pg. 8)
5. Replace drive roll.
Cannot create an arc 1. Work piece is painted or rusty
2. Ground clamp is connected where there is
paint or rust
3. Ground clamp is not electrically connected
to the work piece
4. Trigger is not pressed.
5. Although wire is feeding, power is not
delivered to the tip because the battery is
too hot.
1. Remove all paint and rust.
2. Remove all paint and rust so ground clamp is connected to
bare metal.
3. Make certain the ground clamp is connected to the work
piece.
4. This unit is not electrically hot until you press the torch
trigger.
5. Allow the battery to cool for 20 seconds and try welding
again.
Welding arc is unstable,
excessive spatter
1. The contact tip is too large.
2. Torch liner is plugged.
3. No shielding gas.
4. Wire speed setting isincorrect.
1. Make certain the correct contact tip is installed.
2. Clear or replace torch liner.
3. Connect shielding gas supply and turn shielding gas on.
4. Refer to the label inside the wire compartment door for
wire speed setting recommendations.
Welding Gun

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Metal Type
Thickness of
Material Being
Welded Wire Type/ Size
Tweco
#2 Tip Size Shield Gas
Gas
Flow
Rate
Polarity/
Connection to
Tactical Welder
Wire Speed
Control
Setting
Steel
24 – 18 GA Solid Steel .023” .023” 75% Argon/ 25% CO2 15-30 DCEP Stitch
18 GA – 3/16” Solid Steel .030” .030” 75% Argon/ 25% CO2 15-30 DCEP Stitch - 1
1/8” Plus Solid Steel .035” .035” 75% Argon/ 25% CO2 15-30 DCEP Stitch – 2
1/4” Plus Solid Steel .040” .040” 75% Argon/ 25% CO2 15-30 DCEP 1 – 4
22 – 14 GA Flux-Core Steel .030” .030” None None DCEN Stitch – 1
1/8” – 3/8” Flux-Core Steel .035” .035” None None DCEN Stitch – 3
1/4” – 1/2” Plus Flux-Core Steel .040” .040” None None DCEN 3-6
Aluminum
.060”- 1/8” Aluminum .023” .030” 100% Argon 10-20 DCEP 1 – 2
1/8” – 1/2” Aluminum .035” .040” 100% Argon 15-30 DCEP 2 – 6
1/2” Plus Aluminum .040” .045” 100% Argon 20-50 DCEP 4 – 9
Stainless Steel
.080”- 1/8” Solid Stainless .030” .030” Tri-Mix* 20-40 DCEP Stitch – 1
1/8” Plus Solid Stainless .035” .035” Tri-Mix* 20-40 DCEP 1 – 6
1/8” Plus Flux-Core Stainless .035” .035” None None DCEN 1 – 6
Application Table
Weld Time per Charge
*Tri-Mix: The specific mix of gases and their respective proportions will be determined by 1. The alloy and thickness of the
stainless steel being welded, and 2. The alloy and thickness of the stainless welding feed wire being used. Please consult
your welding gas distributor or an appropriate reference manual to determine the proper mixture for your application.
General Guidelines
1. Stitch Mode Welding: When welding metal thinner than 1/8” with batteries as a power source, it is often necessary to use a stitch mode welding
procedure to avoid melting the metal being welded. Start by lowering the wire feed speed control to its lowest setting where the wire just begins to
feed. When you begin welding, a small bead will form and then the wire will melt back just enough to break the arc. The process will weld a series of
small beads with short breaks of time between them. This prevents heat from building up and melting through, known as globular transfer.
2. Aluminum Welding: We recommend using a contact tip which is .005” bigger than the aluminum feed wire itself and pulling the nozzle about 3/8”
farther out to reduce burn-back.
0
20
40
60
80
100
120
140
160
180
40 60 80 100 120 140 160 180 200 220 240 260 280 300 320
Weld Time in Minutes
Weld Current (Amps)
Weld Times Per Charge
10% Duty Cycle 20% Duty Cycle 33% Duty Cycle

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Thin Metal Welding
Aluminum Welding
1. Use the Smallest Diameter of Feed Wire Available of the Type
Desired. The smaller the diameter of wire the less current it can
conduct, therefore use the smallest diameter feed wire you can
in any given application to cool down the bead to reduce melt-
through. Solid steel, stainless and aluminum wires come in .023”
diameter and will require the use of gas. Flux-Core wire comes in
.030”, typically as a minimum.
2.Use Increased Wire “Stick-Out” Length to Cool the Bead. The
greater the distance from the end of the contact tip to the bead,
the greater the resistance faced by the arc current. Increasing
wire “stick-out” works best flux-cored wire since you will not be
concerned about keeping any shielding gas focused on the bead
area.
3.“Stitch Welding” Mode. The use of this mode of welding should
allow you to successfully weld thin sheet metal using the Tactical
Welder without melt-through problems. By producing a series of
small, cooler beads, rather than a continuous bead, the stitch
mode process prevents the bead area from getting hot enough
to melt the surrounding metal. To use this process, turn the
welding gun’s wire feed speed control know to the “off” position
and then slowly advance it until the electrode wire just starts to
feed slowly out of the contact tip. Release the trigger and cut off
the excess wire which has been fed out. Aim the welding gun at
the thin metal you wish to weld and pull the trigger while allowing
for the maximum acceptable amount of wire “stick-out”. Keep
the trigger pulled during the entire stitch mode welding process.
When the feed wire makes contact and creates a small bead, the
feed wire will momentarily melt back to the point that the arc is
broken. The feed wire will feed out to the point that another bead
is formed where the previous bead ended. Repeat this process of
connecting small sequential beads until the job is complete. By
using the maximum wire “stick-out” you can reduce the likelihood
of wire “burn-back” clogging the contact tip.
4.Increase External Resistance. This will lower the output and can
be done in several different ways such as longer cable, smaller
cable or by attaching a piece of chain to the work piece and
adjusting the ground clamp up or down the chain, be aware that
increased resistance causes greater heat.
General Points
When welding aluminum, be sure to use a contact tip which is
.005” larger than the wire diameter itself, and extend out from the
nozzle approximately 3/8”, this helps reduce burn back (i.e. melting
the wire in the tip). As aluminum conducts heat so rapidly, some
operators find it preferable to increase wire speed and move more
quickly across the metal being welded, especially on thin aluminum
of 1/8” and less. Please consult application chart.
Preheating aluminum over 1/4” thick to approximately 250 degrees
F., is a widely recognized practice and helps on the start of the bead
while increasing penetration. Using a heat sink steel plate on the
back side of aluminum can help prevent burn through. Please note:
When welding, thin aluminum wire will help to reduce the voltage
and amperage. When welding on 1/8” thick aluminum or less, the
travel rate must be faster than on steel and movement must be
similar to drawing a line on a piece of paper. When the wire speed is
adjusted correctly there should be no spatter and the weld process
should be very quiet, similar to the sound of a gas leak. HINT: The
proper travel is to push with aluminum usually right to left if you’re
right handed, left to right if you’re left handed.
Ready to Weld with Aluminum
You are now ready to establish an arc and weld aluminum.
Depending on the thickness, and mass of aluminum to be welded,
a slight preheat in the area where you are going to start will help
provide a uniform weld bead. Your welding position should be with a
slight tilt of the welding gun into the direction of travel; this is called
the forehand technique. When you are ready to establish the arc,
hold the gun nozzle about 1/4” away from the grounded work piece.
Slowly depress the gun trigger to start the flow of argon shield
gas. Set the argon shield gas to 25-30 psi. Now pull the gun trigger
and establish the arc. The weld wire should burn off slightly above
the grounded work piece. If excess spatter or crackling sound are
detected, slow the wire speed just slightly until a quiet smooth-
running arc is achieved. If you are welding lighter gauge aluminum,
increasing travel speeds will help avoid burning through.

15
Tactical Welder Circuit Diagram

UltraTech International, Inc.
11542 Davis Creek Court
Jacksonville, FL 32256
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ULTRATECH
INTERNATIONAL, INC.