10006 Santa Fe Springs Road
Santa Fe Springs, CA 90670 USA
Made in China
80002
Rev 80002-20080228
Owner’s Manual and Operating Instructions
60-90A
MIG WELDER
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
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.
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.
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”).
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
Rev 80002-20080228 1
Manual Conventions
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.
CAUTION
CAUTION indicates a potentially hazardous
situation which, if not avoided,
minor or moderate injury.
may
result in
CAUTION
DANGER
DANGER indicates an imminently hazardous
situation which, if not avoided,
or serious injury.
will
result in death
WARNING
WARNING indicates a potentially hazardous
situation which, if not avoided,
death or serious injury.
could
result in
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.
2 Rev 80002-20080228
Safety Rules
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
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
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
WARNING
Magnetic fields can affect pacemakers.
Pacemaker wearers keep away
WARNING
Noise can damage hearing.
Wear appropriate ear protection if noise level is
high
Rev 80002-20080228 3
Controls and Features
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.
4 Rev 80002-20080228
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
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)
Rev 80002-20080228 5
Assembly
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 (nongas) 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
6
Assembly
NOTE
If the wire does not feed, view the Wire Feed
Unit and see if the wire is being pushed. If it is
not, turn the welder OFF and add more tension
to the Wire Feed Adjusting Spring.
13. Turn the welder on again and press the
trigger.
14. Once the wire is exposed, turn the
welder OFF.
15. Slide the Contact Tip over the wire and
screw it into the Torch Handle.
16. Replace the Nozzle and cut off any
excess wire over 2 inches
17. Secure the cover
Changing Polarity
The model 80002 welder is wired for Flux
core welding (straight polarity). This means
that the welding gun is attached to the
negative (-) lead and the work clamp is
attached to the positive (+) lead.
If you wish to use the CO2 gas-protected
welding method, you must switch
polarity. The welding gun must be
attached to the positive lead (+) and the
work clamp to the negative lead (-).
7
Operation
Starting the Welder (MIG)
Operation
Welder Location
Place on a flat surface free of vibration.
This unit may be placed on a certified
welding cart (not included) and can be set at
an angle of 10 degrees.
Place the welder in a well-ventilated area.
DO NOT place the welder near vents or
intakes where exhaust fumes could be drawn
into occupied or confined spaces. Carefully
consider wind and air currents when
positioning welder. Place the welder in a
clean, dry place.
Starting the Welder (Flux
Welding)
Before Welding
• Read and understand the safety rules
section of this manual (page 3).
• Be sure all flammable materials are
removed the work area.
• There is good ventilation around the
welding unit and the area that you will be
working.
• Be sure you have fire-extinguisher ready
in-case of an accident
• Put on appropriate protective clothing and
insulated leather gloves
1. Connect work clamp onto metal to be
welded
2. Before plugging in: Adjust amperage
and wire feed speed according to
material type and thickness, and the
wire size.
3. Cut wire down to ¼” from the tip of
the welding gun
4. Plug in to power source. Then switch
on machine.
5. Position tip of welding gun ¼” from
the point where the weld is to begin.
6. Hold the mask in front of your eyes
7. Press the trigger, and when the arc
strikes, move the torch slowly in the
chosen direction.
8. If the arc gives a humming sound and
blob begins to form at the end of the
wire, you wire speed must be
increased.
NOTE
Unit must have MIG conversion kit installed
1. Obtain gas cylinder and secure to
stationary support.
2. Install regulator/flowmeter to cylinder
valve.
3. Connect gas hose between
regulator/flowmeter and gas input valve
on back of welder unit.
4. Turn flow adjust screw to increase or
decrease gas flow. Flow rate should be
set when gas is flowing through welding
power source and welding gun. Press
gun trigger to start gas flow. Refer to
welding wire manufacturer’s
recommended flow rate for the
particular wire you are using.
8 Rev 80002-20080228
Maintenance and Storage
Use a soft bristle brush to remove dirt.
Maintenance
The owner/operator is responsible for all
periodic maintenance.
WARNING
Never operate a damaged or defective welder.
WARNING
Improper maintenance will void your warranty.
Use an air compressor (25 PSI) to clear dirt
and debris from the welder.
Inspect all air vents and cooling slots to
ensure that they are clean and unobstructed.
Every 3 months
Repair or replace cracked cables
Every 6 months
Vacuum or blow out inside. During heavy
service, clean out inside monthly
Welder Maintenance
Make certain that the welder is kept clean
and stored properly. Only operate the unit in
a clean, dry operating environment. DO
NOT expose the unit to extreme conditions,
excessive dust, dirt, moisture or corrosive
vapors.
CAUTION
DO NOT use a garden hose to clean the welder.
Water will enter the welder through the cooling
slots and damage the electrical connections.
Storage
1. Allow the welder to cool completely
before storage.
2. Store in a clean, dry place out of direct
sunlight
Rev 80002-20080228 9
Specifications
Specifications
RatedInput
Voltage 120V
Phase 1
Frequency 60Hz
Current 20A
Duty Cycle and Overheating
Duty Cycle is a percentage of 10 minutes that the unit can weld at a given rated load withou t
overheating. For example a 20% duty cycle means 2 minutes welding, 8 minutes resting. If unit
overheats, wait 15 minutes for unit to cool, reduce amperage or duty cycle when welding resumes.
RatedOutput 90A(max) 66A 50A 26A
DutyCycle 20% 35% 60% 100%
Voltage 18.5V 17.3V 16.5V 15.3V
80002
10 Rev 80002-20080228
Specifications
Parts Diagram
11
Specifications
Parts List
Item# Part # Description Qty
1 80002-01 Ground Clamp 1
2 80002-02 Lock Sleeve of Cable PA6 2
3 80002-03 Tapping Screw M3 x 12 4
4 80002-04 Welding Gun and Cable Host 1
5 80002-05 Lock Nut of Cable PA66 1
6 80002-06 Lock Bolt of Cable PA66 1
7 80002-07 Clip of Cable PA66 1
8 80002-08 Tapping Screw M4 x 10 16
9 80002-09 Screw M3 x 10 1
10 80002-10 Voltage Adjustment Knob 1
11 80002-11 Screw M4 x 12 2
12 80002-12 Power ON/OFF Switch 1
13 80002-13 Overheat Indicator 1
14 80002-14 Front Panel PP 1
15 80002-15 Knob of Feed Wire Speed Adjustment 1
16 80002-16 Bolt M4 x 20 2
17 80002-17 Rheostat of Feed Wire Speed 1
18 80002-18 Spring-Washer 2
19 80002-19 Nut M4 2
20 80002-20 Voltage Adjustment Switch 1
21 80002-21 Baffle PA66 1
22 80002-22 Washer DMC 1
23 80002-23 Copper Screw M8 x 48 2
24 80002-24 Insulating Washer DMC 1
25 80002-25 Nut M8 4
26 80002-26 Flat - Washer Φ8 8
27 80002-27 Locknut M8, Red, Black 2
28 80002-28 Rubber mount 4
29 80002-29 Nut M4 4
30 80002-30 Flat - Washer Φ4 8
31 80002-31 Bolt M4 x 12 4
32 80002-32 Frame 1
33 80002-33 Screw M4 x 8 7
34 80002-34 Spring - Washer Φ4 8
35 80002-35 Lock washer Φ4 2
36 80002-36 Gas Inlet, Copper 1
37 80002-37 Flat - Washer Φ10 1
38 80002-38 Nut M10 1
39 80002-39 Electric Fan 1
40 80002-40 Nut M4 4
41 80002-41 Spring - Washer Φ4 8
42 80002-42 Bolt M4 x 14 4
43 80002-43 Plug, FP-003 250V/16A 1
44 80002-44 Bolt M4 x 12 4
45 80002-45 Spring - Washer Φ4 8
46 80002-46 Inductor Assembly 1
47 80002-47 U-shaped Fastener δ=2mm 2
48 80002-48 Bolt M5 x 20 4
49 80002-49 Transformer 1
50 80002-50 Thermal Cutout 1
51 80002-51 Aluminum Piece 1
52 80002-52 Bolt M4 x 16 4
53 80002-53 Bolt M4 x 10 4
54 80002-54 Screw M4 x 12 2
12
Specifications
Item# Part # Description Qty
55 80002-55 Shaft Support, PA66 1
56 80002-56 Feed Roller, Mild Steel 1
57 80002-57 Bracket, Pa66 1
58 80002-58 Pressure Arm Compl. 1
59 80002-59 Feed Roller, Mild Steel 1
60 80002-60 Shaft, Mild Steed 1
61 80002-61 Pressure Set, Mild Steel 1
62 80002-62 Connection Peg, Aluminum, 4 x 8mm 1
63 80002-63 Wire Guide in 1
64 80002-64 Nut M6 1
65 80002-65 Pressure Device M6 x 24 1
66 80002-66 Bolt, Copper 1
67 80002-67 Nut M12 1
68 80002-68 Flat - Washer Φ12 1
69 80002-69 Wire Guide Out, Mild Steel 1
70 80002-70 Middle Clapboard, Mild Steel 1
71 80002-71 Wire Feed Unit, KD241 (DC24V) 1
72 80002-72 Diode Bridge UQD 180A 1
73 80002-73 Butterfly Nut M8 1
74 80002-74 Shaft Cover Φ8 1
75 80002-75 Shaft, L=70mm 1
76 80002-76 Shaft of Wire Tray, PA6 1
77 80002-77 Big Washer Mild Steel 1
78 80002-78 Flat - Washer Φ10 1
79 80002-79 Flat - Washer Φ10 1
80 80002-80 Spring - Washer Φ10 1
81 80002-81 Bolt M8 x 20 1
82 80002-82 PCB 1
83 80002-83 Panel Lock, PA66 1
84 80002-84 Side Panel (Right), Mild Steel 1
85 80002-85 Hinge,PA66 1
86 80002-86 Side Panel (Lift), Mild Steel 1
87 80002-87 Handle, ABS 1
88 80002-88 Spring - Washer Φ6 2
89 80002-89 Flat - Washer Φ6 2
90 80002-90 Bolt M6 x 16 2
13
Troubleshooting
Troubleshooting
Problem Cause Solution
No weld output and fan is not running Power switch is OFF Switch ON
Fuse overload Reset breakers if necessary
Weld output but fan does not run Blocked fan movement Remove item that is blocking fan or
Erratic weld current Loose cable connections Clean and tighten cable connections
Erratic arc with excessive spatter Poor, damaged electrodes Use dry, properly stored electrodes
Long arc length Shorten arc length
High amperage setting Reduce amperage setting
Electrode wire feeding stops during
welding
Gun cable/Gun malfunction Straighten gun cable and/or replace
Poor drive roll pressure Adjust drive roll
Defective contact tip Replace contact tip if blocked
Restricted drive assembly Assess and clear any restrictions at
replace fan motor
damaged parts
drive assembly and liner
14 Rev 80002-20080228
Warranty
as spark plugs, air filters, adjustments, fuel
Warranty
CHAMPION POWER EQUIPMENT
1 YEAR LIMITED WARRANTY
Effective September 1, 2006. Replaces all undated
warranties and all warranties dated before September 1,
2006.
Warranty Qualifications
Champion Power Equipment (CPE) will register
this warranty upon receipt of your Warranty
Registration Card and a copy of your sales receipt
from one of CPE's retail locations as proof of
purchase.
Please submit your warranty registration and
your proof of purchase within ten (10) days of the
date of purchase.
Repair/Replacement Warranty
CPE warrants to the original purchaser that the
mechanical and electrical components will be free
of defects in material and workmanship for a
period of one (1) year from the original date of
purchase (90 days for commercial & industrial
use). Transportation charges on product
submitted for repair or replacement under this
warranty are the sole responsibility of the
purchaser. This warranty only applies to the
original purchaser and is not transferable.
Do not return the unit to the place of
purchase
Contact CPE's Technical Service and CPE will
troubleshoot any issue via phone or e-mail. If the
problem is not corrected by this method, CPE
will, at its option, authorize evaluation, repair or
replacement of the defective part or component
at a CPE Service Center. CPE will provide you
with a case number for warranty service. Please
keep it for future reference. Repairs or
replacements without prior authorization, or at
an unauthorized repair facility, will not be
covered by this warranty.
Warranty Exclusions
This warranty does not cover the following
repairs and equipment:
Normal Wear
Welders need periodic parts and service to
perform well. This warranty does not cover repair
when normal use has exhausted the life of a part
or the equipment as a whole.
Installation, Use and Maintenance
This warranty will not apply to parts and/or labor
if this welder is deemed to have been misused,
neglected, involved in an accident, abused, loaded
beyond the welder’s limits, modified, installed
improperly or connected incorrectly to any
electrical component. Normal maintenance such
system cleaning and obstruction due to buildup is
not covered by this warranty.
Other Exclusions
This warranty excludes:
Cosmetic defects such as paint, decals, etc.
Wear items such as filter elements, o-rings, etc.
Accessory parts such as starting batteries, and
storage covers.
Failures to due acts of God and other force
majeure events beyond the manufacturer’s
control.
Problems cause by parts that are not original
Champion Power Equipment parts.
Limits of Implied Warranty and
Consequential Damage
Champion Power Equipment disclaims any
obligation to cover any loss of time, use of this
product, freight, or any incidental or
consequential claim by anyone from using this
welder. THIS WARRANTY IS IN LIEU OF ALL
OTHER WARRANTIES, EXPRESS OR IMPLIED,
INCLUDING WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE
A unit provided as an exchange will be subject to
the warranty of the original unit. The length of
the warranty governing the exchanged unit will
remain calculated by reference to the purchase
date of the original unit.
This warranty gives you certain legal rights which
may change from state to state. Your state may
also have other rights you may be entitled to that
are not listed within this warranty.
Contact Information
Address
Champion Power Equipment, Inc.
Customer Service
10006 Santa Fe Springs Rd.
Santa Fe Springs, CA 90670
Customer Service
Mon – Fri 8:30 AM – 5:00 PM (PST/PDT)
Toll Free: 1-877-338-0999
Fax no.: 1-562-236-9429
Technical Service
Mon – Fri 8:30 AM – 5:00 PM (PST/PDT)
Toll Free: 1-877-338-0999
tech@championpowerequipment.com
Rev 80002-20080228 15
Notes
Notes
16 Rev 80002-20080228
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