Eastwood flux core 90 Quick reference guide

Part #20280
FLUX CORE 90
WELDER
ASSEMBLY & OPERATING
INSTRUCTIONS

3Eastwood Technical Assistance: 800.544.5118 >> [email protected]
STATEMENT OF LIMITED WARRANTY
The Eastwood Company (hereinafter “Eastwood”) warrants to the end user (purchaser) of all new welding and cutting equipment
(collectively called the “products”) that it will be free of defects in workmanship and material. This warranty is void if the
equipment has been subjected to improper installation, improper care or abnormal operations.
WARRANTY PERIOD:
All warranty periods begin on the date of purchase from Eastwood. Warranty Periods are listed below, along with the products
covered during those warranty periods:
1 Year Warranty on Material, Workmanship, and Defects:
• Eastwood Flux Core 90 Welder
Items not covered under this warranty: Contact tips, nozzles, wire, and ground clamp and cable.
All other components are covered by the warranty and will be repaired or replaced at the discretion of Eastwood.
CONDITIONS OF WARRANTY TO OBTAIN WARRANTY COVERAGE:
Purchaser must first contact Eastwood at 1-800-345-1178 for an RMA# before Eastwood will
accept any welder returns. Final determination of warranty on welding and cutting equipment
will be made by Eastwood.
WARRANTY REPAIR:
If Eastwood confirms the existence of a defect covered under this warranty plan, Eastwood will determine whether repair or
replacement is the most suitable option to rectify the defect. At Eastwood’s request, the purchaser must return, to
Eastwood, any products claimed defective under Eastwood’s warranty.
FREIGHT COSTS:
The purchaser is responsible for shipment to and from Eastwood.
WARRANTY LIMITATIONS:
EASTWOOD WILL NOT ACCEPT RESPONSIBILITY OR LIABILITY FOR REPAIRS UNLESS MADE BY EASTWOOD.
EASTWOOD’S LIABILITY UNDER THIS WARRANTY SHALL NOT
EXCEED THE COST OF CORRECTING THE DEFECT OF THE EASTWOOD PRODUCT. EASTWOOD WILL NOT BE LIABLE
FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES (SUCH
AS LOSS OF BUSINESS, ETC.) CAUSED BY THE DEFECT OR THE TIME INVOLVED TO CORRECT THE DEFECT. THIS
WRITTEN WARRANTY IS THE ONLY EXPRESS WARRANTY PROVIDED BY EASTWOOD WITH RESPECT TO ITS
PRODUCTS. WARRANTIES IMPLIED BY LAW SUCH AS THE WARRANTY OF MERCHANTABILITY ARE LIMITED TO THE
DURATION OF THIS LIMITED WARRANTY FOR THE EQUIPMENT INVOLVED. THIS WARRANTY GIVES THE PURCHASER
SPECIFIC LEGAL RIGHTS.
THE PURCHASER MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.
SPECIFICATIONS
Output
Amperage
No
Load
Voltage
Max. Input
Amperage
Input
Voltage
Rated
Duty
Cycle
Welding
Wire
Spool
Size
Wire
Type
Wire
Diameter
Weight
Dimensions
90
27
20 Amp
120V,
1ph,
60Hz
20%
@ 90
Amps
4"
Flux-
Core
0.030"-
0.035”
(0.8-
0.9mm)
35.5lbs.
18.3" x
9.75" x
13.8"
DUTY CYCLE
The rated Duty cycle refers to the amount of welding that can be done within an amount of time. It is
easiest to look at your welding time in blocks of 10 Minutes and the Duty Cycle being a percentage
of that 10 Minutes. If welding at 90 Amps with a 20% Duty Cycle, within a 10 Minute block of time
you can weld for 2 Minutes with 8 Minutes of cool down time for the machine.

To order parts and supplies: 800.345.1178 >> eastwood.com 4
SAFETY INFORMATION
•Separate yourself from the welding circuit by using insulating mats to prevent
contact from the work surface
•The welder power switch is to be in the OFF position and the power supply is to be
disconnected when performing any maintenance or consumable changes.
•Always wear dry, protective clothing and leather welding gloves and insulated
footwear.
•Always operate the welder in a clean, dry, well ventilated area. Do not operate the
welder in humid, wet, rainy or poorly ventilated areas.
•Be sure that the work piece is properly supported and grounded prior to beginning
an electric welding operation.
•The electrode and work (or ground) circuits are electrically “hot” when the welder is
on. Do not touch these “hot” parts with your bare skin or wet clothing.
•Disconnect from power supply before assembly, disassembly or maintenance
of the torch or contact tip or changing wire spools.
•Always attach the ground clamp to the piece to be welded and as close to the weld
area as possible.
This will give the least resistance and best weld.
FUMES AND WELDING GASES CAN BE DANGEROUS!
•Do not breathe fumes that are produced by the welding operation. These fumes are
dangerous. Keep your head and face out of welding fumes. Do not breathe the
welding fumes.
•Always work in a properly ventilated area. Wearing an OSHA-approved respirator
when welding is recommended!
•Never weld coated materials including but not limited to: cadmium plated,
galvanized, lead based paints.
•Refer to the MSDS (Material Safety Data Sheet) for any consumables or materials
used during welding for additional safety instructions.
WELDING SPARKS CAN CAUSE FIRE OR EXPLOSION!
•Do not operate electric arc welder in areas where flammable or explosive vapors
are present.
•Always keep a fire extinguisher nearby while welding.
READ INSTRUCTIONS!
Thoroughly read and understand this instruction manual before using the
welder.
ELECTRIC SHOCK CAN
KILL!
•
Improper use of an electric welder can cause electric shock, injury and death! Read all precautions
described
in this manual to reduce the possibility of electric
shock.
•
Do not touch any electrical components that may be
live.

To order parts and supplies: 800.345.1178 >> eastwood.com 5
•Use welding blankets to protect painted surfaces, dash boards, engines, etc.
•Ensure power supply has properly rated wiring to handle power usage.
•Do not use on or near combustible surfaces.
•Remove all flammable items within 35 feet of the welding area.
•Do not weld frozen pipes.

6Eastwood Technical Assistance: 800.544.5118 >> [email protected]
SAFETY INFORMATION
ARC RAYS CAN BURN!
•Use a shield with the proper filter (a minimum of #11) to protect your eyes from
sparks and the rays of the arc when welding or when observing open arc welding.
(see ANSI Z49.1 and Z87.1 for safety standards).
•Use suitable clothing made from durable flame-resistant material to protect your
skin. Protect nearby individuals with a non-flammable barrier.
•Wear safety glasses under your welding helmet with side shields.
•If other persons are in the area of welding use welding screens to protect
bystanders from sparks and arc rays.
HOT METAL WILL BURN!
•Electric welding operations cause sparks and heat metal to temperatures that will
cause severe burns!
•Use protective gloves and clothing when performing any welding operations. Always
wear long pants, long-sleeved shirts and leather welding gloves.
•Make sure that all persons in the welding area are protected from heat, sparks and
ultraviolet rays. Use additional face shields and flame resistant barriers as needed.
•Never touch work piece until it has completely cooled.
ELECTROMAGNETIC FIELDS MAY BE DANGEROUS!
•The electromagnetic field that is generated during arc welding may interfere with
various electrical and electronic devices such as cardiac pacemakers. Anyone using
such devices should consult with their physician prior to performing any electric
welding operations.
•Exposure to electromagnetic fields while welding may have other health effects
which are not known.
WELDING WIRE CAN BE DANGEROUS!
•Never point the welding gun at any part of the body, other people, or metal
surfaces.
•Wear safety glasses and handle welding wire safety as it can be sharp and cause
injury.
MOVING PARTS CAN BE DANGEROUS!
•Use care when working near the drive motor assembly as it can pinch.
•Do not put fingers or other body parts between moving parts.
FLYING METAL CHIPS CAN CAUSE INJURY!
•Welding, brushing, hammering, chipping, and grinding can cause flying metal chips
and sparks.

7Eastwood Technical Assistance: 800.544.5118 >> [email protected]
•To prevent injury wear approved safety glasses.
MAGNETIC FIELDS CAN AFFECT PACEMAKERS!
•Any user with a pacemaker should consult their doctor before use.
•Anyone with a pacemaker should stay away from any welding without consultant
from a doctor.
NOTICE!
Do not touch the contact tip with the unit turned ‘ON’. Turn the unit ‘OFF’ before
changing tips or cleaning the nozzle.

To order parts and supplies: 800.345.1178 >> eastwood.com 8
UNPACKING
When unpacking your Eastwood Flux Core 90, check to make sure all of the parts listed below
are included:
•Flux Core 90 Welder with Welding Gun and Ground Cable
•Chipping Hammer / Wire Brush

To order parts and supplies: 800.345.1178 >> eastwood.com 9
•
1
lb. Spool of 0.030" (0.8mm) Flux-Core
Wire
•
Spare Contact
Tip
1
•
Instruction
Manual
COMPONENTS &
CONTROLS
1
.
Wire Speed
Control
2.
Power
Switch
3.
Thermal Overload
Indicator
4.
Voltage
Control
5.
Ground Cable and
Clamp
6.
Welding
Gun
7
.
Nozzl
e
8.
Contact
Tip
9.
Pressure
Adjuster
10
.
Rocker
Arm
11
.
Drive
Roller
12
.
Guide
Pipe
13
.
Wire
Spindle
2
3
4
1
5
6
7
8
9
10
11
12
13

10 Eastwood Technical Assistance: 800.544.5118 >> [email protected]
ASSEMBLY
INSTALLING THE HANDLE
1. Line up the holes in the handle with the holes
in the top in the welder.
2. On each screw place an included lock
washer followed by a flat washer.
3. Insert each screw through the handle and
into the top of the welder and tighten.
CONNECTING THE WELDER TO A POWER
SOURCE
The Eastwood Flux Core 90 welder requires a
dedicated 120 VAC, 20 Amp, 60 Hz grounded
outlet protected by a circuit breaker. Do not use
on power sources that have voltages less than
105 VAC or higher than 132 VAC. If using an
extension cord, use a minimum 12 AWG cord for
up to 25 feet.
CHANGING THE DRIVE ROLLER
The Eastwood Flux Core 90 comes set up and
ready to use 0.030" (0.8mm) Flux-Core Wire. If
0.035" (0.9mm) wire is to be used, the drive roller
needs to be adjusted. Adjust the drive roller
according to the following procedure:
1. Open the top door of the welder to access the
drive motor compartment.
2. Lift the Pressure Adjuster (FIG. B-B1) out of
the way and move the Rocker Arm (FIG. B-
B2) away from the drive roller.
3. Remove the Drive Roller Thumb Screw (FIG.
B-B3) by turning it counter clockwise and
pulling it away from the roller.
4. Remove the Drive Roller and view the wire sizes stamped on each side of the roller.
5. Install the Drive Roller in the orientation so that the size of the wire you are using is facing
you on the side of the drive roller.
6. Reinstall the Drive Roller Thumb Screw (FIG. B-B3).
7. Put the Rocker Arm (FIG. B-B2) back in place and reset the Pressure Adjuster (FIG. B-
B1).
FI
G
.
A
B1
FI
G
.
B
B2
B3