Ultratech Tactical Welder 4800, Operation Manual

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