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MODEL T10499/T10500
PORTABLE
BLADE WELDER
INSTRUCTIONS
For questions or help with this product contact Tech Support at (570) 546-9663 or techsupport@grizzly.com
Introduction
t his portable blade welder can cut, weld, anneal,
and grind bandsaw blades, which is commonly
done in the following situations:
• to re-join a blade that has been purposely
cut for making an internal contour cut.
• to repair a broken blade that is still sharp and
hot sparks from the welding process can
useful.
damage y
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Identification Anneal Clamp strength pressure Anneal Main switch switch Welding Button on/oFF Button switch Blade shear Carrying handle (1 of 2) Clamping Jaws spark deflector grinder switch grinding Wheel figure 2. identification. To reduce the risk of serious injury when using this machine, read and understand this entire manual before beginning any operations. -2- t 10499/t 10500 Blade Welder
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Safety for Blade Welders WELDINg fUMES. Breathing welding fumes can ELECTRIC & MAg NETIC f IELDS (EMf ). Welding cause respiratory damage. Maintain adequate ven- operations create eMF around the welding equip- tilation during and after welding operations. ment and workpieces. Workers who have pace- makers must consult with their physician before PREvENT f IRES. Welding work zones must be using this equipment or stay at least 50 feet from kept clear of flammable liquids or gases, such as weldi
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Power Supply Note: The circuit requirements listed in this man- full-Load Current Rating ual apply to a dedicated circuit—where only one The full-load current rating is the amperage a machine will be running at a time. If this machine machine draws at 100% of the rated output power. will be connected to a shared circuit where mul- On machines with multiple motors, this is the tiple machines will be running at the same time, amperage drawn by the largest motor or sum of all consult a quali
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T10499 Circuit Requirements T10500 Circuit Requirements t his machine is prewired to operate on a 115V t his machine is prewired to operate on a 230V power supply circuit that has a verified ground and power supply circuit that has a verified ground and meets the following requirements: meets the following requirements: Nominal voltage ........................................ 115v Nominal voltage ........................................230v Cycle ...............................................
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t he alignment wings keep the blade straight when Extension Cords cutting with the shear. We do not recommend using an extension cord with this machine. If you must use an extension Tools Needed Qty cord, only use it if absolutely necessary and only phillips s crewdriver #2 ...................................... 1 on a temporary basis. Wrench or socket 10mm ................................... 1 Extension cords cause voltage drop, which may To attach the blade shear wings: damage electrical
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Operations Overview Blade Preparation t his blade welder uses electrical resistance (induc- When welding the blade, the ends must evenly tion) to weld bandsaw blade ends. Afterwards, the butt up against each other and be square. t his annealing process gives the weld strength and will ensure the that the weld is of even thickness flexibility. for the full width of the blade. To prepare the blade for welding: 1. turn the main on/oFF switch ON (it is locat- ed on top of the welder). 2. Be sur
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Note: You can make sure that the blade 3. r otate the clamp pressure switch ends are even with each other by stacking (see figure 12) to zero. this spreads the them together with the teeth facing in oppo- clamps apart to allow proper positioning of site directions (see Figure 11), then grinding the blade ends. them. Regardless of the grinding angle, the blade ends will match evenly for welding. Welding Clamps Clamp pressure switch Clamp Levers figure 12. Clamping controls. figure 11. Blade
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7. place the other blade end in the left welding 8. use the tables below to set the clamp pres- clamp and position it so that it evenly butts up sure switch and the anneal strength (see against the opposing blade end, then clamp figure 16). it in place by rotating the left clamp lever up (see figure 14). • For T10499: Clamp Anneal Blade Width pressure strength 1 1 ⁄8"– ⁄4" 1–2 Low 3 1 ⁄8"– ⁄2" 3–4+ high • For T10500: Clamp Anneal Blade Width pressure strength 3 1 ⁄8"– ⁄2" 1–2 Low 1 3 ⁄2"
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16. inspect the weld. the welded joint should be even across the width of the blade with no gaps (see figure 17). hot sparks from the blade welding opera- tion could be thrown in all directions and cause burns or fire. Correct 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. Not Correct DO NOT weld near flammables. Not Correct NOTICE f or good metal-to-metal con
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5. Allow the blade to completely cool. Annealing Weld When the blade ends are welded, the metal 6. remove the blade from the clamps. becomes hard and brittle, which is not suitable for a bandsaw blade that must continuously bend Correct 7. grind the weld flat on both sides so the blade smoothly under stress. will run smoothly on the bandsaw wheels. t o bring the weld strength and flexibility to accept- Note: Make sure not to grind the teeth or able levels for a bandsaw blade, the annealin
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Troubleshooting 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. s ymptom possible Cause possible solution Machine does not 1. plug/receptacle is at fault or wired 1. test for good contacts; correct the wiring. start or a breaker incorrectly.
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Defond Defond T10499 Wiring Diagram Main Anneal Power Switch Strength Switch HY29G 20/15A 277V ENEC T120/55 Welding Button Anneal Button Clamp COM Pressure Cam COM NO NC NO NC 115VAC Welding NC NO NEMA 5-15 Plug/Receptacle Unit (As Recommended) COM Ground 1 2 3 4 5 6 E Transformer A174-0001 1.2KVA 120V Run Capacitor 2M 250V 115V Grinder Motor 4 5 3 6 1 2 -13- t 10499/t 10500 Blade Welder OFF Hot Neutral Ground Defond Grinder ON/OFF Switch CS R1328F ON
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Defond Defond T10500 Wiring Diagram Main Anneal Power Switch Strength Switch HY29G 20/15A 277V ENEC T120/55 Welding Button Anneal Button Clamp COM Pressure Cam COM NO NC NO NC G 230VAC Welding NC NO NEMA 6-20 Plug/Receptacle Unit (As Recommended) COM Ground 1 2 3 4 5 6 E Transformer A174-0023 4.2KVA 240V Run Capacitor 2M 250V 230V Grinder Motor 4 5 3 6 2 -14- t 10499/t 10500 Blade Welder OFF Hot Hot Ground Defond Grinder ON/OFF Switch CS R1328F ON
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Cabinet Parts 4 37 1 5 6 3 2 28 32 13 10 11 34 13 14 30 31 9 29 15 14 13 7 24 11 33 35 24 21 8 36 22 12 16 17 18 26 27 19 18 9 20 17 25 6 11 6 15 23 11 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 P
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Controls & Electrical -16- t 10499/t 10500 Blade Welder 104 95 64 102 104 84 95 103 106 101 108 90 64 105 109 110 83 108 85 114 92 98 112 96 91 116 111 117 82 62 54 80 86 79 88 87 115 65 83 73 67 78 107 93 100 59 68 94 58 75 54 61 51 63 55 76 74 64 52 81 77 64 70 53 72 60 69 89 71 67 78 85 56 108 59 68 97 57 99 61 60 113 63 64 66 89
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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
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Machine Labels 126 119 118 120 125 121 122 123 127 124 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 S
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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 t
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