Table of Contents SAFETY Safety ......................................................... 2 Specifications ............................................. 6 Setup .......................................................... 7 Basic Welding ............................................ 12 Welding Tips .............................................. 18 Maintenance .............................................. 22 Parts List and Diagrams ............................ 25 Warranty ...................................
Fume and Gas Safety Information FUMES AND GASES can be hazardous to your health. 2. Do not use near degreasing or painting operations. 3. Keep head out of fumes. Do not breathe exhaust fumes. 4. Use enough ventilation, exhaust at arc, or both, to keep fumes and gases from breathing zone and general area. If engineering controls are not feasible, use an approved respirator. 5. Work in a confined area only if it is well-ventilated, or while wearing an air-supplied respirator. 6.
Electrical Safety Information ELECTRIC SHOCK can KILL. SAFETY 1. Turn off, disconnect power, and discharge electrode to ground before setting down torch/electrode holder and before service. 2. Do not touch energized electrical parts. Wear dry, insulating gloves. Do not touch electrode holder, electrode, welding torch, or welding wire with bare hand. Do not wear wet or damaged gloves. 3. Connect to grounded, GFCI-protected power supply only. 4. Do not use near water or damp objects. SETUP 5.
1. Do not use the Welder if the switch does not turn it on and off. Any welder that cannot be controlled with the switch is dangerous and must be repaired. 2. Disconnect the plug from the power source before making any adjustments, changing accessories, or storing welders. Such preventive safety measures reduce the risk of starting the Welder accidentally. 5. Use the Welder and accessories in accordance with these instructions, taking into account the working conditions and the work to be performed.
Grounding SAFETY TO PREVENT ELECTRIC SHOCK AND DEATH FROM INCORRECT GROUNDING WIRE CONNECTION: Check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded. Have a plug installed by a certified electrician. Do not use the Welder if the power cord or plug is damaged. If damaged, have it repaired by a service facility before use. If the plug will not fit the outlet, have a proper outlet installed by a qualified electrician. Grounded Welders SETUP 1.
Symbology Gun Cable Overheat Shutdown Indicator Cooling Fan Housing Ground Point V Alternating Current SAFETY Workpiece Ground Cable ~ A OCV KVA IPM AWG Amperes Open Circuit Voltage Kilovolt Amperes (Volts / 1000 * Amperes) Inches Per Minute American Wire Gauge SETUP Wire Feed (Speed) Volts BASIC WELDING Setup Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before set up or use of this product.
Wire Spool Installation GUN 90 AMP FLUX WIRE WELDER ITEM 61207 SAFETY 1. Turn the Welder to OFF and unplug it before proceeding. ON MIN OFF MAX Specifications WIRE FEED SPEED Wire 0.030" – 0.035" Flux-Core Capacity 18 Ga. – 3/16" Steel Plate Weldable Mild, Low Alloy Steel Materials (Not for Aluminum or Stainless Steel) GROUND 120V~ 60Hz 20A Cover SETUP 2. Press in the pin at the top center of the control panel and open the Cover. Wire Spool BASIC WELDING Knob 3.
0″ 0″ .03 .03 6. Turn the Feed Tensioner counterclockwise to loosen it enough to pull it up, releasing tension. Swing the Feed Swing Arm out. Feed Tensioner Feed Knob Feed Roller .03 0″ SETUP 7. Loosen and remove the Feed Knob. Compare the wire diameter marked on the Wire Spool with the stamped number on the top of the Feed Roller. The Roller’s groove size must be compatible with the wire diameter.
SAFETY WARNING The following steps require applying power to the Welder with the cover open. To prevent serious injury from fire or electric shock: 1. Do not touch anything, especially not the Ground Clamp, with the Gun or welding wire or an arc will be ignited. SETUP 2. Do not touch internal Welder components while it is plugged in. GUN 90 AMP FLUX WIRE WELDER ITEM 61207 BASIC WELDING 14. Do not touch the Gun’s Trigger. Plug the Power Cord into its electrical outlet and turn the Welder to ON.
SAFETY 0″ .03 Incrementally increase tension until wire bends. 2-3 ″ SETUP 16. To check the wire’s drive tension, feed the wire against a piece of wood from 2 to 3 inches away. If the wire stops instead of bending, turn the Welder to OFF, unplug it, slightly tighten the Feed Tensioner clockwise , and try again. If the wire bends from the feed tension, then the tension is set properly. GUN 90 AMP FLUX WIRE WELDER ITEM 61207 ON MIN OFF MAX BASIC WELDING 17. TURN THE WELDER TO OFF.
Basic Welding SAFETY Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before welding. SETUP TO PREVENT SERIOUS INJURY: Protective gear must be worn when using the Welder; minimum shade number 10 full face shield (or welding mask), ear protection, welding gloves, sleeves and apron, NIOSH-approved respirator, and fire resistant work clothes without pockets should be worn when welding.
GUN 90 AMP FLUX WIRE WELDER Overload Indicator ITEM 61207 ON Wire Speed Dial MIN SETUP Gun Cable SAFETY Control Panel Layout Current Switch OFF MAX Specifications BASIC WELDING Power Switch GROUND 120V~ 60Hz 20A Ground Cable Gun Cable: The welding Gun connects here. The wire and welding current feeds to the weld through here. The welding Gun is energized whenever the Power Switch is on. Wire Speed Dial: This controls the speed that the welding wire feeds out of the welding Gun.
Weld Settings Chart SAFETY NOTE: The numbers within the spaces are the approximate wire feed settings recommended* for this wire size and material thickness. 0.030″ Wire Size (Flux-Core, Mild Steel) 0.035″ Wire Size (Flux-Core, Mild Steel) Material Thickness (Steel) 18 Gauge 16 Gauge 14 Gauge MIN current 1.5 2 4 speed speed speed 1.5 2 3 speed speed speed 1/ " 8 3/ " 16 MAX current 8 9 speed speed 8 9.
Setting Up The Weld 1. Make practice welds on pieces of scrap the same thickness as your intended workpiece to practice technique before welding anything of value. Clean the weld surfaces thoroughly with a wire brush or angle grinder; there must be no rust, paint, oil, or other materials on the weld surfaces, only bare metal. SAFETY Clamps Workpieces 2. Use clamps (not included) to hold the workpieces in position so that you can concentrate on proper welding technique.
Basic Welding Technique SAFETY 1. Press (and hold) Trigger and contact area to be welded with electrode wire to ignite arc. stringer bead weave bead 2. For a narrow weld, you can usually draw the wire in a steady straight line. This is called a stringer bead. For a wider weld, draw the wire back and forth across the joint. This is called a weave bead. SETUP BASIC WELDING 3. Hold Gun in one hand and the face shield in the other.
GUN ITEM 61207 Gun MIN concrete slab MAX SAFETY 90 AMP FLUX WIRE WELDER Note: If Welder is used too long, the amber Overload Indicator will light and the Welder Gun will shut off until the Welder cools. If this happens, rest the Gun on ON an electrically non-conductive, heat-resistant surface, such as a concrete slab, well clear of the ground clamp. Wait about 8 –10 minutes with the Power Switch to ON for the Welder to cool.
Welding Tips SAFETY A good way to test welding technique is to examine a weld’s appearance after it has cooled and the slag has been removed. Then, better welding can be learned by adjusting your welding technique to remedy any problems found. Cleaning the Weld SETUP TO PREVENT SERIOUS INJURY: Continue to wear ANSI-approved safety goggles and protective wear when cleaning a weld. Sparks or chips may fly when cleaning. A typical Flux-Core Wire (FCAW) Weld before cleaning.
Weld Diagnosis PROPER PENETRATION EXCESS PENETRATION OR BURN-THROUGH Not hot enough Ideal heat Too hot How to increase workpiece heat and increase penetration: How to reduce workpiece heat and limit penetration: (to weld THICKER workpieces properly) (to weld THINNER workpieces properly) c. Use faster wire feed a. Use MIN setting c. Use slower wire feed b. Weld more slowly d. Use shorter stickout b. Weld more quickly d.
Weld Problems Penetration (Workpiece Heat Control) SAFETY EXCESS PENETRATION OR BURN-THROUGH Weld droops on top and underneath or falls through entirely, making a hole. PROPER PENETRATION Weld is visible underneath and bulges slightly on top. INADEQUATE PENETRATION Weld does not contact the joint fully, just on the surface. SETUP PROFILE VIEWS BASIC WELDING POSSIBLE CAUSES AND SOLUTIONS 1. Workpiece overheating: Reduce wire feed speed. Use MIN setting. 2.
Coat of Slag Over Weld Excessive Spatter PARTIALLY CHIPPED AWAY TO SHOW WELD Slag is a necessary part of a fluxcore wire weld. It shields the weld from impurities. Clean off the slag with the Chipping Hammer and Wire Brush after welding. Porosity TOP VIEW POSSIBLE CAUSES AND SOLUTIONS 1. Dirty workpiece or welding wire: Clean workpiece down to bare metal. Make certain that wire is clean and free from oil, coatings, and other residues. 2. Wire feeding too fast: Reduce wire feed speed. 3.
Maintenance SAFETY + TO PREVENT SERIOUS INJURY, FIRE AND BURNS: Unplug the Welder, rest the Gun on a heat-proof, electrically non-conductive surface, and allow all parts of the Welder to cool thoroughly before service. 1. Periodically remove the Right and Left side panels, and using compressed air, blow out all dust from the interior. SETUP 2. Store in a clean and dry location. Gun concrete slab (or other heat-proof, non-conductive surface) 3.
Troubleshooting Be CERTAIN to shut off the Welder, disconnect it from power, and discharge the Gun to ground before adjusting, cleaning, or repairing the unit. Wire Feed Motor Runs But Wire Does Not Feed Properly SAFETY IMPORTANT! 1. Insufficient wire feed tension: Increase wire feed tension properly – follow number 16 on page 11. 2. Incorrect wire feed roll size: Replace with the proper wire feed roll – follow the Wire Spool Installation instructions, starting on page 8.
Troubleshooting (continued) IMPORTANT! SAFETY Be CERTAIN to shut off the Welder, disconnect it from power, and discharge the Gun to ground before adjusting, cleaning, or repairing the unit. Power Switch Does Not Light When Switched On POSSIBLE CAUSES AND SOLUTIONS SETUP Unit is not connected to outlet properly or outlet is unpowered: Verify the voltage at the outlet and the connection to the outlet.
For technical questions, please call 1-888-866-5797. FM MAINTENANCE PE N S1-2 AC120V 60Hz S1-1 Overheat Indicator MIN TH CN2 CN3 CN4 TR1 CR1 TR2 630V104K C1 WELDING TIPS t+ MAX S2 0.5A TS D1 1N4007 CR1 CR2-1 22µF 50V C2 R5 CR2-2 M CN1 G5LC-14 12DC CR2 1 2 3 4 5 6 7 D2 W08 BASIC WELDING R3 1KΩ R4 620Ω FUSE2 JQX-29F-A 12VDC 3.13A FUSE1 Item 61849 0.5Ω10W L TIP35C Q1 WR1 2.
Parts List and Diagrams (continued) Parts List SAFETY Part SETUP 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Description Power Cord and Plug Cable Grommet Ground Clamp and Cable Torch Torch Cable Sheath Potentiometer Knob Power Switch Current Switch Overload Indicator Front Panel Back Panel Foot Fan Circuit Board Bracket Circuit Board Transformer Bracket Transformer Screw Main Transformer Qty 1 2 1 1 1 1 1 1 1 1 1 4 1 1 1 2 4 1 Part 19 20 21 22 23 23a 23b 23c 23d 23e 23f 24 25 26 27 28 29 30 Descr
MAINTENANCE WELDING TIPS BASIC WELDING SETUP SAFETY Assembly Diagram Item 61849 For technical questions, please call 1-888-866-5797.
PLEASE READ THE FOLLOWING CAREFULLY THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER NOR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT.
