41185 90 Amp Flux Wire Welder Instruction Manual Need help with your new arc welder? Call our customer service hotline at 1-800-386-0191 SAVE THESE INSTRUCTIONS
s SAFETY BEGINS WITH YOU It is the owner and/or operator’s responsibility to study all WARNINGS, operating, and maintenance instructions contained on the product label and instruction manual prior to operation of this flux wire welder. The owner/operator shall retain product instructions for future reference. The owner and/or operator are responsible for maintenance, maintaining all decals or warning labels and while in use, maintaining the unit in good working order.
Improper installation of the grounding plug can result in a risk of electric shock. If repair or replacement of the cord is necessary, do not connect the grounding wire to either flat blade terminal. The wire with insulation having an outer surface that is green with or without yellow stripes is the grounding wire. This product is for use on a nominal 120-volt circuit and has a three-prong grounding plug that looks like the plug illustrated.
IMPORTANT SAFETY RULES - FOR ARC WELDERS SAVE THESE INSTRUCTIONS ARC Welding can be hazardous. Protect yourself and others from possible serious injury or death. Keep children away. Pacemaker wearers should consult with their doctor before operating. Read and understand all instructions. Failure to follow all instructions included with this product could result in serious personal injury PROP and/or property damage.
PROP 65 osion • Do not drape cables over your body. • If earth grounding of the workpiece is required, ground it directly with a separate cable. • Do not allow any part of the body to touch the electrode if you are in contact with the ground or grounded work piece. Electric Flying Repair or replaceRays Prop. 65 Burns • Use only well-maintained equipment. damaged parts at once. Maintain unit according to manual. • Always keep all panels andSparks covers securely in place when operating the welder.
PROP FLYING METAL can injure eyes! 65 65 • Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag. • Wear ANSI approved safety glasses with side shields under your welding helmet. PROP tric ck Flying Sparks tric ck Flying Sparks ys Burns Rays can cause severe Burnsburns! HOT PARTS Prop. 65 PROP • Never touch hot parts bare handed. • Allow adequate cooling period before touching work piece. 65 Burns Prop. 65 PROP Rays Prop.
ns California Proposition 65 Warnings • Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) • Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.
SPECIFICATIONS: Type: Input Voltage: Rated Output: Output Power Settings: Output Current: Maximum Output Voltage: Power Switch: Power Cord: Ground Cable & Clamp: Ground Cable Connection: Welding Cable: Welding Wire: 90 Amp gasless flux-core wire welder 120 Volt (1~60Hz) 90 Amps @ 10% Duty Cycle Switchable high/low adjustment 63.6 Amps - Low power output setting / 20% Duty cycle 90 Amps - High power output setting / 10% Duty cycle 32VAC Illuminated On/Off Switch 6 Ft 15 Amp Power Plug 4.
1) Verify that welder is turned OFF and is disconnected from the power source. 2) Unlock top cover panel and lift cover back to expose wire feed mechanism. 3) Push and rotate spool lock 1/4 turn counter-clockwise direction and pull to remove knob, spring and spool spacer. 4) Loosen wire feed tensioning screw on drive mechanism, lift tensioning spring arm up and hinge back the arm to allow easier installation of wire.
65 ays Prop. 65 Burns OPERATION Be sure to read, understand and comply with all precautions in the Important Safety Rules section. Be sure to read the entire section entitled Welding Guidelines prior to using this equipment. Wire Length 1/4" MANUAL To Work Piece ctrode ce 1) Turn welder OFF and unplug from power source during preparation for welding. ring Read Heat & Sparks 2) Verify that the surfaces of metals to be joined are free from dirt, rust, paint, oil, scale or other contaminants.
Metal Thickness Output Current Settings (Amps) 18 - 14 Gauge LOW (64A) Thicker than 14 Gauge HIGH (90A) NOTE: Above settings are intended to serve as a general guideline only. Heat settings may vary according to welding conditions and materials being welded. Grounding against any metallic surface may produce an arc which could cause sparks and damage eyesight. 5) Set wire speed by rotating wire speed control knob to the middle position.
Gun Cabl Do not operate this welding machine with cracked or missing insulation on welding cables, welding torch, or power cord. PROP 65 Flying Sparks Every three months, or more frequently with heavy use: 1) Replace any unreadable labels on the welder. 2) Use compressed air to blow all dust and dirt from the ventilation openings. 3) Vacuum dirt from wire compartment. 4) Clean grooves in wire feed drive roll. Remove wire from mechanism and remove two screws from drive roll housing.
WELDING GUIDELINES LEARNING TO WELD Welding is a skill that requires practice and, like any new skill, cannot be mastered without experience. The following information is designed to help the inexperienced welder understand the basics of flux wire welding. It is not a substitute for practice and is not intended to serve as the only information resource for the beginning welder. GENERAL This welding machine utilizes a process known as Flux Cored Arc Welding (FCAW).
SHIELDED METAL ARC WELDING SETUP 5 2 4 1 14 1 Work Piece 2 Work Clamp 3 Mig Torch 4 Gas Nozzle 5 Solid Wire Electrode 6 Solidified Slag 7 Welding Hammer/Brush 3 6 7
STRIKING AN ARC 1) Be sure the work clamp is properly attached to the work piece. 2) Position gun over joint to be welded. The end of the wire may lightly touch the work piece. Burning of core materials inside the wire electrode provides a gas to shield the molten metal as it solidifies. Gas Nozzle 3) Position hand shield to protect face and eyes, squeeze trigger and begin .030"/.035" .024" welding. Shielding Gases Molten Slag (0.
0-15˚ Wire Electrode 1/4" 0-15˚ 45˚ Wire Length To upon Work Piece Travel angle is the angle in the line of welding and may vary from 5º to 45º from the vertical, depending welding 90˚ Work angle is the angle from horizontal, conditions 90˚ and technique required. measured at right angles to the line of Work Piece welding. For specific applications, consult an arc welding handbook.
SLAG REMOVAL Wear ANSI approved safety glasses (ANSI Standard Z87.1) and protective clothing when removing slag. Hot, flying debris can cause personal injury to anyone in the area. After completing the weld, wait for the welded sections PROP to cool. A protective coating called slag now covers the weld bead which prevents contaminants in the air from reacting with the molten metal. Once the weld cools to the point that it is no longer glowing red, the slag can be removed.
TROUBLESHOOTING GUIDE - WELDER Problem Encountered Possible Cause No power at receptacle. No weld output; wire does not feed; fan does not run. Unit is unplugged. Power switch is in the OFF position. Defective power switch. Broken or damaged power cable. No weld output; wire does not feed; fan continues to run. Welder gives trickle shocks. Welder overheats - blows fuses, trips circuit breaker. No weld output; wire feeds properly. Low weld output. No wire feed when gun trigger is pulled.
TROUBLESHOOTING GUIDE - WELDS Problem Encountered Possible Cause Corrective Action Inconsistent travel speed. Output amp setting incorrect. Adjust and maintain travel speed. Carefully watch and control the width of the molten weld bead. Ragged depressions at edge of weld. Travel speed too fast. Wire speed too fast. Output amp setting to high. Decrease travel speed. Decrease wire speed. Reduce output amp setting. Weld bead does not penetrate work piece. Inconsistent travel speed.
ONE YEAR LIMITED WARRANTY - STAR ASIA-USA, LLC ELECTRIC ARC WELDERS Star Asia-USA, LLC (hereinafter “seller”) warrants to the original purchaser only, that this product will be free from defects in material or workmanship for a period of one year from date of purchase for home domestic use. Warranty Performance Warranty coverage is conditioned upon purchaser furnishing seller or its authorized service center with adequate written proof of the original purchase date.
Distributed by Star Asia-USA, LLC P.O. Box 58399, Renton, WA 98058 Consumer Service: 800-386-0191 e-mail: info@titan-us.
