Ultratech Tactical Welder 4800 Operation Manual Download Page 4

1-904-292-1611 · tacticalwelder.com

4

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 

Summary of Contents for Tactical Welder 4800

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

Page 2: ...n 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...

Page 3: ...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 allow...

Page 4: ...nt 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 wel...

Page 5: ...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 wel...

Page 6: ...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...

Page 7: ...n 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 charge...

Page 8: ...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 tens...

Page 9: ...9...

Page 10: ...gun connectors Allow the gun to cool before handling without protective equipment 8 InspecttheTacticalWelderequipmentforanydamageandclean where necessary 9 If the battery charge was depleted charge t...

Page 11: ...n 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 n...

Page 12: ...ace 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 i...

Page 13: ...ons 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 dist...

Page 14: ...ch 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 P...

Page 15: ...15 Tactical Welder Circuit Diagram...

Page 16: ...UltraTech International Inc 11542 Davis Creek Court Jacksonville FL 32256 1 904 292 1611 tacticalwelder com ULTRATECH INTERNATIONAL INC...

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