WeldMate 60A Manual
80002
Rev80002-20080228
10006SantaFeSpringsRoad
SantaFeSprings,CA90670USA
MadeinChina
60-90A
MIGWELDER
Owner’sManualandOperatingInstructions
Table of Contents
Introduction ..................................... 1
Portable Welder........................................ 1
This Booklet.............................................. 1
Manual Conventions.........................2
Safety Rules......................................3
Controls and Features.......................4
MIG/Flux Welder.....................................4
Parts Included ..........................................5
Assembly ..........................................6
Installing Wire Feed .............................6
Changing Polarity .................................7
Operation .........................................8
Welder Location .......................................8
Starting the Welder (Flux Welding).........8
Starting the Welder (MIG) ...................8
Maintenance.....................................9
Welder Maintenance ................................9
Storage .............................................9
Specifications .................................10
Duty Cycle and Overheating...............10
Parts Diagram..........................................11
Parts List................................................. 12
Troubleshooting .............................14
Warranty ........................................ 15
Warranty Qualifications .........................15
Repair/Replacement Warranty..............15
Do not return the unit to the place of
purchase..................................................15
Warranty Exclusions...............................15
Normal Wear.......................................15
Installation, Use and Maintenance.....15
Other Exclusions.................................15
Limits of Implied Warranty and
Consequential Damage...........................15
Contact Information ...............................15
Address................................................15
Customer Service ................................15
Technical Service................................. 15
Notes ..............................................16
Introduction
Rev 80002-20080228 1
Introduction
Congratulations on your purchase of a
Champion Power Equipment portable
welder. CPE designs and builds welders to
strict specifications. With proper use and
maintenance, this welder will bring years of
satisfying service.
Portable Welder
MIG Gas-Protected Welding Machine. It
can also be used for the welding of non-gas
protection Flux welding. It is designed for
medium to light duty welding (up to 3/16”).
This Booklet
Every effort has been made to ensure the
accuracy and completeness of the
information in this manual. We reserve the
right to change, alter and/or improve the
product and this document at any time
without prior notice.
Record the model and serial numbers as well as date and place of purchase for future reference.
Have this information available when ordering parts and when making technical or warranty
inquiries.
Champion Power Equipment Support
1-877-338-0999
Model Number
80002
Serial Number
Date of Purchase
Purchase Location
Manual Conventions
2 Rev 80002-20080228
Manual Conventions
This manual uses the following symbols to
help differentiate between different kinds of
information. The safety symbol is used with
a key word to alert you to potential hazards
in operating and owning power equipment.
Follow all safety messages to avoid or reduce
the risk of serious injury or death.
DANGER
DANGER indicates an imminently hazardous
situation which, if not avoided,
will
result in death
or serious injury.
WARNING
WARNING indicates a potentially hazardous
situation which, if not avoided,
could
result in
death or serious injury.
CAUTION
CAUTION indicates a potentially hazardous
situation which, if not avoided,
may
result in
minor or moderate injury.
CAUTION
CAUTION used without the safety alert symbol
indicates a potentially hazardous situation which,
if not avoided,
may
result in property damage.
NOTE
If you have questions regarding your welder, we
can help. Please call our help line at 1-877-338-
0999.
Safety Rules
Rev 80002-20080228 3
Safety Rules
WARNING
Read this manual thoroughly before operating
your welder. Failure to follow instructions could
result in serious injury or death.
DANGER
Breathing welding fumes can be hazardous to
your health
Keep head and face away from welding fumes.
Use enough ventilation to avoid the buildup of
gas and fumes in the immediate area. Do not
breathe in fumes.
Use of a ventilating fan may be necessary.
DANGER
Electric Shock can kill
Electric Shock can occur from wiring or welding
electrode
Do not touch electrode with bare hand.
Wear dry insulating gloves.
Do not touch live electrical parts.
Protect yourself from electric shock by insulating
yourself from work or ground.
Properly install and ground all equipment.
DANGER
Welding can cause fire or explosion.
Do not weld near flammable material.
Welding sparks can cause fires.
It is suggested that you have a fire extinguisher
nearby.
Do not weld on drums, tanks, or other closed
containers
Do not use welder in thermal overload condition
– prevent overheating
DANGER
ARC rays can burn eyes and skin.
Use welding helmet with correct shade of filter
lens.
Wear welders cap and safety glasses underneath
helmet. Use ear protection if welding in an area
with heavy sound reverberation.
Button shirt collar all the way up.
Wear oil-free protective clothing: leather gloves,
heavy shirt, cuff less pants, and high boots
WARNING
Hot parts
Do not touch hot parts bare handed.
Allow cooling period before adjusting gun or
torch
Use proper tools and/or wear heavy, insulated
gloves and clothing to prevent burns
WARNING
Magnetic fields can affect pacemakers.
Pacemaker wearers keep away
WARNING
Noise can damage hearing.
Wear appropriate ear protection if noise level is
high
Controls and Features
4 Rev 80002-20080228
Controls and Features
Read this owner’s manual before operating your welder. Familiarize yourself with the location
and function of the controls and features. Save this manual for future reference.
MIG/Flux Welder
Carrying handle (1)
Thermal Overload indicator (2) – Allow
welder to cool, reduce duty cycle.
On/Off switch (3) – Power On, Power Off.
MIG Welding Gun (4) – Wire fed torch
handle.
Ground Clamp (5) – “Work Clamp”, grip
workpiece to complete circuit.
Amperage control (6) – Dial adjustment,
from 26amps to 90amps.
Wire feed speed control (7) – Turn dial
adjustment wire feed speed.
Access Door (8) – Swing open this panel
to load/adjust wire spool.
Controls and Features
Rev 80002-20080228 5
Parts Included
Your 8000 ARC Welding unit ships with the following parts:
Handheld Welding Mask
Wire Brush/Slag Hammer
Torch Nozzle(1)
Wire Feed Roller (.6 dia. And .8 dia.)
Contact Tip (2)
Assembly
6
Assembly
Your welder requires some assembly.
If you have any questions regarding the
assembly of your welder, call our help line at
1-877-338-0999. Please have your serial
number and model number available.
This unit can be used for MIG/MAG (CO2
gas-protected) welding or Flux wire (non-
gas) welding. This unit does not include
equipment for gas-protected uses (CO2 gas
cylinder, pressure gauges, hoses, etc.)
Installing Wire Feed
This unit supports wire sizes of .6mm,
.8mm, .9mm Flux Core or Solid Wire. Make
sure the correct Wire Feed Roller is being
used. We have provided one in the
packaging.
1. Lift tab on side panel to access wire feed
mechanisms
2. Unscrew the wing nut and remove the
reel locking knob
3. Place the wire reel over the shaft. The
wire reel should unwind clockwise
4. Replace the reel locking knob and the
wing nut; tighten well
5. Lift the Wire Feed Adjusting Spring to
remove tension
6. Guide at least 12 inches of wire into the
Torch Sheath. If the end of the wire is
crimped or bent, cut it off and remove
any burrs.
7. Replace tension to the Wire Feed
Adjusting Spring
8. Turn the Torch Handle Nozzle
counterclockwise and pull to remove
9. Turn the Contact Tip counterclockwise
and remove
10. Lay the Torch Sheath out in a straight
line so that the wire moves through it
easily
WARNING
The following steps require applying power to the
welder. Do not touch anything with the Torch
Handle or an arc may be ignited
11. Plug the Power Cord into its electrical
outlet, turn the Amperage control to D,
and turn the welder ON.
12. Lift the Torch Handle and continue
pressing the trigger until the wire feeds
through two inches
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