Northern Industrial Tools Welder 628575 User Manual

Flux Core 125  
Item# 628575  
OPERATOR’S MANUAL  
Read carefully and understand RULES FOR SAFE OPERATION and instructions before  
operating. Failure to follow the safety rules and other basic safety precautions may  
result in serious personal injury.  
 
Northern Industrial Welder  
Operating Instructions and Parts Manual  
Flux Core 125  
Please read and save these instructions. Read through this owner’s manual carefully before  
using product. Protect yourself and others by observing all safety information, warnings, and  
cautions. Failure to comply with instructions could result in personal injury and/or damage to  
product or property. Please retain instructions for future reference.  
Wire Feed, Gasless Welder  
Description  
Flux Core 125 portable Gasless Wire  
Feed Welder. Uses AC single phase  
115v (110-120V), 60Hz/20amp with  
time delayed fuse or circuit breaker.  
Features two heat settings, infinite wire  
speed control, over load and thermal  
protection.  
Ideal for use welding mild steel 18  
gauge to 3/16” for light industrial  
applications (for use with Flux Core  
wire only).  
Specifications and Dimension  
DESCRIPTION  
SPECIFICATION  
Power supply  
1ph-115V-60HZ  
No-load voltage  
Output Range  
Duty cycle  
27V  
60-80A (Peak 125A)  
20%  
Suggested wire  
Wire Diameter  
Dimension (L x W x H)  
Weight  
Flux Core wire  
.030”, .035”  
17.7”x9.3”x14.3”  
38 lbs  
Removing from carton  
1.1 Remove cartons, bags or Styrofoam containing the welder and accessories.  
1.2 Check the contents with the packing list below.  
ITEM  
QTY.  
1 unit  
Portable Wire Feed Welder  
Contact tip, .030”  
2pc  
Sample spool Flux Core wire, .030”  
Large spool adapter  
Chipping hammer/ wire brush  
Operator’s Manual  
1 spool  
1pc  
1pc  
1set  
1
 
Northern Industrial Welder  
Operating Instructions and Parts Manual  
Flux Core 125  
Wire Feed, Gasless Welder  
1.3 After unpacking unit, inspect for any damage that may have occurred during  
transit. Check for loose, missing, or damaged parts. Shipping damage claim  
must be filed with carrier.  
Know your Welder  
Wire Compartment  
1-2 voltage  
Setting  
On/off switch  
Wire speed  
setting  
Thermal  
Overload  
indicator  
MIG Gun  
Ground cable  
and clamp  
ON/OFF Switch  
In the “OFF” position no power is being supplied to the MIG gun/torch. In the  
“ON” position power is supplied to the main transformer and control circuit  
Wire compartment  
Inside the wire compartment are the wire feeder, spool hub, and set up chart.  
1-2 Voltage Setting  
1 (low), 2 (high) voltage switch is on the front panel of the machine, Refer to the  
“set up” chart inside the wire feed compartment for initial adjustment settings.  
Wire speed setting  
Adjustment of the wire feed speed (amperage).  
Ground cable and clamp  
The ground cable and clamp are attached to the work piece to complete the  
circuit allowing the flow of current needed to weld.  
Welding Cable and MIG gun/torch  
The welding wire is driven through the welding cable and MIG gun/torch to the  
work piece. It is attached to the drive system, the gun trigger activates the drive  
motor.  
Thermal Indicator  
If the duty cycle of the welder is exceeded the internal temperature will exceed  
safe temperatures the machine will shut down and the thermal overload light will  
come on.Allow 15 minutes for cool down before the light will go off and the  
temperature to fall into an allowable operating range.  
Power Cord  
2
 
Northern Industrial Welder  
Operating Instructions and Parts Manual  
Flux Core 125  
Wire Feed, Gasless Welder  
The power cord connects the welder to the 115 volt power supply. Plug the 15  
amp plug into a 115 volt/20 amp receptacle to supply power to the welder.  
General Safety Information  
1.1 Your Welding Environment  
-Keep the environment you will be  
welding in free from flammable  
materials.  
wire or wire feed system is wet. Do  
not immerse them in water. These  
components and the welder must be  
completely dry before attempting to  
use the welder.  
-Follow the instructions in this manual.  
-Keep welder in the off position when  
not in use.  
-Connect ground lead as close to the  
area being welded as possible to  
ensure a good ground.  
-Do not allow any body part to come  
in contact with the welding wire if you  
are in contact with the material being  
welded, ground or electrode from  
another welder.  
-Do not weld if you are in an awkward  
position. Always have a secure  
stance while welding to prevent  
accidents. Wear a safety harness if  
working above ground.  
-Do not drape cables over or around  
your body.  
-Always keep a fire extinguisher  
accessible to your welding  
environment.  
-Always have a qualified person  
install and operate this equipment.  
-Make sure the area is clean, dry and  
ventilated. Do not operate the welder  
in humid, wet or poorly ventilated  
areas.  
-Always have your welder maintained  
by a qualified technician in  
accordance with local, state and  
national codes.  
-Always be aware of your work  
environment. Be sure to keep other  
people, especially children, away  
from you while welding.  
-Keep harmful arc rays shielded from  
the view of others.  
-Mount the welder on a secure bench  
or cart that will keep the welder  
secure and prevent it from tipping  
over or falling.  
-Wear a full coverage helmet with  
appropriate shade lens (see ANSI  
Z87.1 safety standard) and safety  
glasses while welding.  
-Wear proper gloves and protective  
clothing to prevent your skin from  
being exposed to hot metals, UV and  
IR rays.  
-Do not overuse or overheat your  
welder. Allow proper cooling time  
between duty cycles.  
-Keep hands and fingers away from  
moving parts and stay away from the  
drive rolls.  
-Do not point MIG gun at any body  
part of yourself or anyone else.  
1.2 Your Welder’s Condition  
-Check ground cable, power cord and  
welding cable to be sure the  
insulation is not damaged. Always  
replace or repair damaged  
components before using the welder.  
-Check all components to ensure they  
are clean and in good operating  
condition before use.  
1.3 Use of Your Welder  
Do not operate the welder if the  
output cable, electrode, MIG gun,  
3
 
Northern Industrial Welder  
Operating Instructions and Parts Manual  
Flux Core 125  
Wire Feed, Gasless Welder  
-Always use this welder in the rated  
duty cycle to prevent excessive heat  
and failure.  
-Do not breathe in fumes emitted by  
the welding process. Make sure your  
breathing air is clean and safe.  
-Work only in a well-ventilated area or  
use a ventilation device to remove  
welding fumes from the environment  
where you will be working.  
1.4 Specific Areas of Danger,  
Caution or Warning  
Electrical Shock  
-Do not weld on coated materials  
(galvanized, cadmium plated or  
containing zinc, mercury or barium).  
They will emit harmful fumes that are  
dangerous to breathe. If necessary  
use a ventilator, respirator with air  
supply or remove the coating from the  
material in the weld area.  
-The fumes emitted from some  
metals when heated are extremely  
toxic. Refer to the material safety  
data sheet for the manufacturer’s  
instructions.  
Electric arc welders can  
produce a shock that  
can cause injury or  
death. Touching electrically live parts  
can cause fatal shocks and severe  
burns. While welding, all metal  
components connected to the wire  
are electrically hot. Poor ground  
connections are a hazard, so secure  
the ground lead before welding.  
-Wear dry protective apparel: coat,  
shirt, gloves and insulated footwear.  
-Insulate yourself from the work piece.  
Avoid contacting the work piece or  
ground.  
- Do not attempt to repair or maintain  
the welder while the power is on.  
-Inspect all cables and cords for any  
exposed wire and replace damaged  
or wore cables immediately.  
-Use recommended replacement  
cables and cords.  
-Always attach ground clamp to the  
work piece or work table as close to  
the weld area as possible.  
-Do not weld near materials that will  
emit toxic fumes when heated.  
Vapors from cleaners, sprays and  
degreasers can be highly toxic when  
heated.  
UV and IR Arc Rays  
The welding arc  
produces ultraviolet (UV)  
and infrared (IR) rays  
that can cause injury to your eyes  
and skin. Do not look at the welding  
arc without proper eye protection.  
-Always use a helmet that covers  
your full face from the neck to top of  
head and to the back of each ear.  
-Use a lens that meets ANSI  
-Do not touch the welding wire and  
the ground or grounded work piece at  
the same time.  
-Do not use a welder to thaw frozen  
pipes.  
Fumes and Gases  
standards and safety glasses. For  
welders under 160 Amps output, use  
a shade 10 lens; for above 160 Amps,  
use a shade 12. Refer to the ANSI  
standard Z87.1 for more information.  
-Cover all bare skin areas exposed to  
the arc with protective clothing and  
-Fumes emitted from the  
welding process displace  
clean air and can result in  
injury or death.  
4
 
Northern Industrial Welder  
Operating Instructions and Parts Manual  
Flux Core 125  
Wire Feed, Gasless Welder  
shoes. Flame-retardant cloth or  
leather shirts, coats, pants or  
coveralls are available for protection.  
-Use screens or other barriers to  
protect other people from the arc rays  
emitted from your welding.  
-Warn people in your welding area  
when you are going to strike an arc  
so they can protect themselves.  
Fire Hazards  
-To prevent any unintended arcs, cut  
wire back to ¼" stick out after welding.  
Hot Materials  
Welded materials are hot  
and can cause severe  
burns if handled  
improperly.  
-Do not touch welded materials with  
bare hands.  
-Do not touch MIG gun nozzle after  
welding until it has had time to cool  
down.  
Do not weld on containers  
or pipes that contain or  
have had flammable,  
Sparks/Flying Debris  
gaseous or liquid combustibles in  
them. Welding creates sparks and  
heat that can ignite flammable and  
explosive materials.  
-Do not operate any electric arc  
welder in areas where flammable or  
explosive materials are present.  
-Remove all flammable materials  
within 35 feet of the welding arc. If  
removal is not possible, tightly cover  
them with fireproof covers.  
Welding creates hot  
sparks that can cause  
injury. Chipping slag off  
welds creates flying debris.  
-Wear protective apparel at all times:  
ANSI-approved safety glasses or  
shield, welder’s hat and ear plugs to  
keep sparks out of ears and hair.  
Electromagnetic Field  
-Take precautions to ensure that  
flying sparks do not cause fires or  
explosions in hidden areas, cracks or  
areas you cannot see.  
-Electromagnetic fields  
can interfere with various  
electrical and electronic  
devices such as pacemakers.  
-Consult your doctor before using any  
electric arc welder or cutting device  
-Keep people with pacemakers away  
from your welding area when welding.  
-Do not wrap cable around your body  
while welding.  
-Keep a fire extinguisher close in the  
case of fire.  
-Wear garments that are oil-free with  
no pockets or cuffs that will collect  
sparks.  
-Do not have on your person any  
items that are combustible, such as  
lighters or matches.  
-Keep work lead connected as close  
to the weld area as possible to  
prevent any unknown, unintended  
paths of electrical current from  
causing electrical shock and fire  
hazards.  
-Wrap MIG gun and ground cable  
together whenever possible.  
-Keep MIG gun and ground cables on  
the same side of your body.  
Shielding Gas Cylinder  
can explore  
5
 
Northern Industrial Welder  
Operating Instructions and Parts Manual  
Flux Core 125  
Wire Feed, Gasless Welder  
High pressure cylinders can explode  
if damaged, so treat them carefully.  
-Never expose cylinders to high heat,  
sparks, open flames, mechanical  
shocks or arcs  
delayed fuse or circuit breaker is  
required. DO NOT OPERATE THIS  
UNIT if the ACTUAL power source  
voltage is less than 105 volts ac or  
greater than 132 volts ac.  
-Do not touch cylinder with MIG gun.  
-Do not weld on the cylinder.  
-Always secure cylinder upright to a  
cart or stationary object cart or  
stationary object  
-Do not touch cylinder with MIG gun.  
-Do not weld on the cylinder.  
-Always secure cylinder upright to a  
cart or stationary object.  
-Keep cylinders away from welding or  
electrical circuits.  
-Use the proper regulators, gas hose  
and fittings for the specific application  
• High voltage danger from power  
source! Consult a qualified  
electrician for proper installation of  
receptacle. This welder must be  
grounded while in use to protect  
the operator from electrical shock.  
• Do not remove grounding prong  
or alter the plug in any way. Do  
not use any adapters between the  
welder’s power cord and the power  
source receptacle. Make sure the  
POWER switch is OFF when  
connecting your welder’s power  
cord to a properly grounded 115  
VAC, 60Hz, 1 phase, 20 amp input  
power supply.  
Assembly  
INSTALLING THE HANDLE  
1. Line up the holes in the handles  
with the holes on the top of the  
welder.  
2. Extension cord  
We do not recommend an extension  
cord because of the voltage drop they  
produce. This drop in voltage can  
affect the performance of the welder.  
If you need to use an extension cord  
it must be a size #12 gauge or larger.  
Do not use an extension cord over 25  
ft. in length.  
2 Place a lock washer then a washer  
onto the welder handle screws.  
3 Insert the screws with the washers  
through the holes on the welder  
handle and into the top of the welder  
and tighten.  
3. Install the wire roller  
Open the wire feed compartment.  
Before installing any welding wire into  
the unit, the proper sized groove must  
be placed into position on the wire  
drive mechanism. Adjust the drive  
roller according to the following steps,  
see following picture about the wire  
feeder structure:  
MIG gun/torch assembled,  
some assembly required for  
ground cable.  
Installation  
1. Power requirement  
AC single phase 115v (110-120V),  
60HZ fused with a 20amp time  
6
 
Northern Industrial Welder  
Operating Instructions and Parts Manual  
Flux Core 125  
Wire Feed, Gasless Welder  
outside edge of the wire spool and  
bend it over to hold the wire in place.  
Remove the spool of wire from the  
drive compartment of the welder.  
3.4. Rotate the Drive Roller Cap  
counterclockwise and remove it from  
the Drive Roller.  
Drive  
tension  
arm  
Inlet Guide  
Tube  
Gun  
liner  
Drive  
Roller  
Drive  
Tension  
Adjustment  
3.1. Open the door to the welder drive  
compartment.  
3.5. Pull the Drive Roller off of the  
Drive Roller Shaft.  
3.2. Remove the drive tension (see 1)  
by loosening the tension adjusting  
knob and lifting the Drive Tension  
Adjustor away from the Drive Tension  
Arm (see 2). Lift the drive tension arm  
away from the drive roller (see 3).  
See following images for reference  
3.6 Based on the wire diameter,  
select the correct groove using the  
following table.  
Wire Diameter  
.030 inch  
.035 inch  
Roller Groove  
0.9  
0.9  
The drive roller has two wire size  
grooves built into it. When installing  
the drive roller, the number stamped  
on the drive roller for the wire size  
you are using should be facing you.  
Push the drive roller onto the drive  
roller shaft.  
3.3. If there is wire already installed in  
the welder, roll it back onto the wire  
spool by hand-turning the spool  
clockwise. Be careful not to allow the  
wire to come out of the rear end of  
the inlet guide tube without holding  
onto it or it will unspool itself. Put the  
end of the wire into the hole on the  
7
 
1RUWKHUQꢁ,QGXVWULDOꢁ:HOGHU  
2SHUDWLQJꢁ,QVWUXFWLRQVꢁDQGꢁ3DUWVꢁ0DQXDOꢁ  
)OX[ꢁ&RUHꢁꢂꢃꢄꢁ  
:LUHꢀ)HHGꢁꢀ*DVOHVVꢀ:HOGHUꢀ  
127(ꢄ  
‡ꢁ%HIRUHꢁLQVWDOOLQJꢍꢁPDNHꢁVXUHꢁWKDWꢁ\RXꢁ  
KDYHꢁUHPRYHGꢁDQ\ꢁROGꢁZLUHꢁIURPꢁWKHꢁ  
0,*ꢁJXQꢁ$VVHPEO\ꢆꢁ7KLVꢁZLOOꢁKHOSꢁWRꢁ  
SUHYHQWꢁWKHꢁSRVVLELOLW\ꢁRIꢁWKHꢁZLUHꢁ  
MDPPLQJꢁLQVLGHꢁWKHꢁJXQꢁ/LQHUꢆ  
‡ꢁ%HꢁYHU\ꢁFDUHIXOꢁZKHQꢁUHPRYLQJꢁWKHꢁ  
ZHOGLQJꢁQR]]OHꢆꢁ7KHꢁFRQWDFWꢁWLSꢁRQꢁ  
WKLVꢁZHOGHUꢁLVꢁOLYHꢁZKHQHYHUꢁWKHꢁWRUFKꢁ  
WULJJHUꢁLVꢁSXOOHGꢆꢁ0DNHꢁFHUWDLQꢁ  
32:(5ꢁLVꢁWXUQHGꢁ2))ꢆꢁꢁ  
ꢈꢆꢃꢆꢂꢁ5HPRYHꢁWKHꢁQR]]OHꢁDQGꢁFRQWDFWꢁ  
WLSꢁIURPꢁWKHꢁHQGꢁRIꢁWKHꢁWRUFKꢁDVVHPEO\ꢁ  
ꢎ6HHꢁEHORZꢏꢆꢁꢁ  
ꢅꢆꢇꢆꢁ5HLQVWDOOꢁWKHꢁ'ULYHꢁ5ROOHUꢁ&DSꢁ  
DQGꢁORFNꢁLQꢁSODFHꢁE\ꢁWXUQLQJꢁLWꢁ  
FORFNZLVHꢆ  
ꢅꢆꢀꢆꢁ&ORVHꢁWKHꢁGRRUꢁWRꢁWKHꢁZHOGHUꢁ  
GULYHꢁFRPSDUWPHQWꢆ  
ꢂꢃꢀ,QVWDOOꢀWKHꢀZLUH  
ꢈꢆꢂꢁ6HOHFWLQJꢁWKHꢁZLUH  
$YDLODEOHꢁZLUHꢁIRUꢁWKLVꢁPDFKLQH  
:LUHꢁ7\SHꢁ  
0,*ꢁZLUHꢁꢁ  
$YDLODEOHꢁRUꢁQRWꢁ  
1Rꢁ  
)OX[ꢁ&RUHꢁZLUHꢁ <HV  
ꢉꢆꢉꢅꢉꢁLQFKꢁ  
ꢈꢆꢃꢆꢃꢁ0DNHꢁVXUHꢁWKHꢁSURSHUꢁJURRYHꢁRQꢁ  
WKHꢁGULYHꢁUROOHUꢁLVꢁLQꢁSODFHꢁIRUꢁWKHꢁZLUHꢁ  
LQVWDOOHGꢆꢁ,IꢁQRWꢍꢁFKDQJHꢁWKHꢁGULYHꢁ  
UROOHUꢁDVꢁGHVFULEHGꢁLQꢁVHFWLRQꢆꢁꢅꢁDERYHꢆꢁꢁ  
ꢈꢆꢃꢆꢅꢁ5HPRYHꢁWKHꢁSDFNDJLQJꢁIURPꢁWKHꢁ  
VSRROꢁRIꢁZLUHꢁDQGꢁWKHQꢁLGHQWLI\ꢁWKHꢁ  
OHDGLQJꢁHQGꢁRIꢁWKHꢁZLUHꢁVHFXUHGꢁRQꢁ  
WKHꢁHGJHꢁRIꢁWKHꢁVSRROꢆꢁ'2ꢁ127ꢁ  
81+22.ꢁ,7ꢁ$7ꢁ7+,6ꢁ7,0(ꢆ  
ꢈꢆꢃꢆꢈꢁ3ODFHꢁWKHꢁVSRROꢁRQꢁWKHꢁVSRROꢁ  
KXEꢁZLWKꢁWKHꢁZLUHꢁFRPLQJꢁRIIꢁWKHꢁ  
ERWWRPꢁRIꢁWKHꢁVSRROꢆꢁ7KHꢁZHOGLQJꢁZLUHꢁ  
VKRXOGꢁDOZD\VꢁFRPHꢁRIIꢁWKHꢁERWWRPꢁRIꢁ  
WKHꢁVSRROꢁLQWRꢁWKHꢁGULYHꢁPHFKDQLVPꢆꢁ  
6HHꢁIROORZLQJꢁILJXUHꢆꢁ  
)OX[ꢁ&RUHꢁZLUHꢁ <HV  
ꢉꢆꢉꢅꢄꢁLQFKꢁ  
%RWKꢁIRXUꢁLQFKꢁRUꢁHLJKWꢁLQFKꢁZLUHꢁ  
VSRROVꢁRIꢁꢆꢉꢅꢉꢁLQFKꢁRUꢁꢆꢉꢅꢄꢁLQFKꢁVHOIꢁ  
VKLHOGLQJꢁ)OX[ꢊ&RUHꢁZLUHꢁFDQꢁEHꢁXVHGꢁ  
RQꢁWKLVꢁZHOGHUꢆꢁ6WHHOꢁIURPꢂꢀꢁJDXJHꢁ  
XSꢁWRꢁꢅꢋꢂꢌꢁLQFKꢁWKLFNꢁFDQꢁEHꢁZHOGHGꢁ  
ZLWKꢁWKLVꢁZLUHꢆꢁꢁ  
127(ꢄ  
‡ꢁ0HWDOꢁWKLQQHUꢁWKDQꢁꢂꢀꢁJDXJHꢁFDQQRWꢁ  
EHꢁZHOGHGꢁZLWKꢁWKLVꢁPDFKLQHꢆꢁ  
$WWHPSWLQJꢁWRꢁGRꢁVRꢁZLOOꢁFDXVHꢁEXUQꢁ  
WKURXJKꢁLQꢁWKHꢁPHWDOꢁ\RXꢁDUHꢁLQWHQGLQJꢁ  
WRꢁZHOGꢆꢁ  
‡ꢁ5HPRYHꢁDQ\ꢁZLUHꢁWKDWꢁLVꢁUXVW\ꢍꢁLIꢁWKHꢁ  
ZKROHꢁVSRROꢁLVꢁUXVW\ꢁGLVFDUGꢁLWꢆ  
ꢈꢆꢃꢁ,QVWDOOꢁWKHꢁZLUHꢁ  
(OHFWULFꢀVKRFNꢀFDQꢀNLOOꢁꢀ$OZD\VꢀWXUQꢀ  
WKHꢀ32:(5ꢀVZLWFKꢀ2))ꢀDQGꢀ  
XQSOXJꢀWKHꢀSRZHUꢀFRUGꢀIURPꢀWKHꢀDFꢀ  
SRZHUꢀVRXUFHꢀEHIRUHꢀLQVWDOOLQJꢀZLUHꢂꢀꢀ  
 
Northern Industrial Welder  
Operating Instructions and Parts Manual  
Flux Core 125  
Wire Feed, Gasless Welder  
unspool itself when the trigger is  
released. Readjust the spool tension  
using the wing nut as necessary to  
correct for either problem.  
4.2.7. With the welder disconnected  
from the power source, remove the  
leading end of the wire from the spool.  
Hold on to it securely, so as not to  
allow unspooling or tangling of the  
wire as it will result in tangled wire  
and lost time.  
4.2.5 The welder can use either 4” or  
8” spools, see the following figure for  
additional reference. 8” spool requires  
an adaptor. The wing nut controls the  
tension on the spool.  
4.2.8. Cut off any bent portion of the  
wire using a wire cutter.  
4.2.9. Loosen the tension adjusting  
knob holding the drive tension arm in  
place and lift the tension arm up off  
the drive roller.  
4.2.10. Insert the wire into the inlet  
guide tube, feed it across the drive  
roller and into the torch assembly  
about six inches.  
Wing  
nut  
8” wire  
spool  
4” wire  
spool  
8” spool  
Adaptor  
• Make certain that the welding  
wire is actually going into the torch  
liner. If not, the wire will jam up in  
the mechanism.  
4.2.6. Setting the wire spool tension:  
a) Turn the spool of wire with one  
hand.  
b) Increase the spool tension by  
tightening (turn clockwise) the wing  
nut while turning the spool. Turn the  
spool while tightening the wing nut  
until the spool slows down and  
operator feels a slight drag.  
Stop tightening the wing nut, operator  
may need to repeat these steps until  
proper spool tension is achieved.  
NOTE:  
If TOO MUCH tension is applied to  
the wire spool, the wire will slip on the  
drive roller or will not be able to feed  
at all. If TOO LITTLE tension is  
applied, the spool of wire will want to  
4.2.11 Line the wire up with the  
correct groove in the drive roller.  
Place the drive tension arm back  
above the drive roller.  
4.2.12 Place the drive tension  
adjustment arm back in place.  
4.2.13 Tighten (turn clockwise) the  
drive tension adjusting knob until the  
tension roller is applying enough  
force on the wire to prevent it from  
slipping in the drive rollers.  
4.2.14. NOW YOU CAN LET GO OF  
THE WIRE.  
4.2.15. Plug in and turn the welder  
ON. Set the VOLTAGE switch to the  
voltage (heat) setting recommended  
for the gauge metal that is to be  
9
 
Northern Industrial Welder  
Operating Instructions and Parts Manual  
Flux Core 125  
Wire Feed, Gasless Welder  
welded. Refer to the set up chart on  
the back side of the drive  
certain that the wire coming out of  
the end of the torch does not come  
in contact with work piece, ground  
clamp or any grounded material  
during the drive tension setting  
process or arcing will occur.  
5.1. Press the trigger on the gun.  
5.2. Turn the drive tension adjustment  
knob clockwise, increasing the drive  
tension until the wire seems to feed  
smoothly without slipping.  
compartment door.  
CAUTION:  
The welding wire is electrically hot  
when the power is on and the MIG  
gun trigger is activated.  
.
4.2.16. Set the WIRE SPEED control  
to the middle of the wire speed range.  
4.2.17. Straighten the MIG gun cable  
and pull the trigger in the gun handle  
to feed the wire through the torch  
assembly. When at least one inch of  
the wire sticks out past the end of the  
torch, release the trigger.  
Operation  
High voltage danger from power  
source! Consult a qualified  
4.2.18 Turn the Power Switch to the  
OFF position.  
electrician for proper installation of  
receptacle at the power source.  
This welder must be grounded  
while in use to protect the operator  
from electrical shock. If you are  
not sure if your outlet is properly  
grounded, have it checked by a  
qualified electrician. Do not cut off  
the grounding prong or alter the  
plug in any way and do not use  
any adapters between the welder’s  
power cord and the power source  
receptacle. Make sure the POWER  
switch is OFF then connect your  
welder’s power cord to a properly  
grounded 115 Vac (110v-120v),  
60Hz, single phase, 20 amp power  
source.  
4.2.19 Select a contact tip stamped  
with the same diameter as the wire  
being used.  
NOTE:  
Due to inherent variances in Flux-  
Cored welding wire, it may be  
necessary to use a contact tip one  
size larger than your Flux Core wire if  
wire jams occur.  
4.2.20. Slide the contact tip over the  
wire (protruding from the end of the  
MIG gun). Thread the contact tip into  
the end of the gun and hand-tighten  
securely.  
4.2.21. Install the nozzle on the gun  
assembly. To keep spatter from  
sticking to inside of the nozzle use  
anti-spatter spray or gel.  
1. Main control component  
Power switch - The power switch  
supplies electrical current to the  
welder. Whenever the power switch is  
in the ON position, the welding circuit  
is activated. ALWAYS turn the power  
switch to the OFF position and unplug  
the welder before performing any  
maintenance.  
4.2.22 Cut off excess wire that  
extends past the end of the nozzle  
more than ¼”.  
4.2.23. Turn the welder ON  
5. Setting the wire tension  
Arc flash can injure eyes! To  
reduce the risk of arc flash, make  
10  
 
Northern Industrial Welder  
Operating Instructions and Parts Manual  
Flux Core 125  
Wire Feed, Gasless Welder  
Voltage selector - The voltage  
selector controls the welding heat.  
This unit has two step voltage control.  
Refer to the label inside the welder  
side door for recommended voltage  
selector settings for your welding job.  
Wire speed control - The wire speed  
control adjusts the speed at which the  
wire is fed out of the welding torch.  
The wire speed needs to be closely  
matched (tuned-in) to the rate at  
which it is being melted off. Some  
things that affect wire speed selection  
are the type and diameter of the wire  
being used, the heat setting selected,  
and the welding position to be used.  
Note: The wire will feed faster without  
an arc. When an arc is being drawn,  
the wire speed will slow down.  
2. Hold the torch (MIG gun)  
The best way to hold the welding  
torch is the way that feels most  
comfortable to you. While practicing  
to use your new welder, experiment  
holding the torch in different positions  
until you find the one that seems to  
work best for you.  
3. Position the torch to the work  
piece  
There are two angles of the torch  
nozzle in relation to the work piece  
that must be considered when  
welding.  
3.1. Angle A can be varied, but in  
most cases the optimum angle will be  
60 degrees, the point at which the  
torch handle is parallel to the work  
piece. If angle A is increased,  
penetration will increase. If angle A is  
decreased, penetration will decrease  
also.  
3.2. Angle B can be varied for two  
reasons: to improve the ability to see  
the arc in relation to the weld puddle  
and to direct the force of the arc.  
4. Distance from the work piece  
If the nozzle is held off the work  
piece, the distance between the  
nozzle and the work piece should be  
kept constant and should not exceed  
1/4 inch or the arc may begin  
sputtering, signaling a loss in welding  
performance.  
5. Tuning in the wire speed  
This is one of the most important  
parts of MIG welder operation and  
must be done before starting each  
welding job or whenever any of the  
following variables are changed: heat  
setting, wire diameter, or wire type.  
EXPOSURE TO A WELDING ARC  
IS EXTREMELY HARMFUL TO THE  
EYES AND SKIN!  
Prolonged exposure to the welding  
arc can cause blindness and burns.  
Never strike an arc or begin  
welding until you are adequately  
11  
 
Northern Industrial Welder  
Operating Instructions and Parts Manual  
Flux Core 125  
Wire Feed, Gasless Welder  
protected. Wear flameproof  
diameter wire, or a different type of  
welding wire.  
6. Welding Techniques  
welding gloves, a heavy long  
sleeved shirt, trousers with out  
cuffs, high topped shoes, and an  
ANSI approved welding helmet.  
5.1. Connect the Ground Clamp to a  
scrap piece of the same type of  
material which you will be welding. It  
should be equal to or greater than the  
thickness of the actual work piece,  
and free of oil, paint, rust, etc.  
EXPOSURE TO A WELDING ARC  
IS EXTREMELY HARMFUL TO THE  
EYES AND SKIN! Prolonged  
exposure to the welding arc can  
cause blindness and burns. Never  
strike an arc or begin welding until  
you are adequately protected.  
Wear flameproof welding gloves, a  
heavy long sleeved shirt, trousers  
with out cuffs, high topped shoes  
and an ANSI approved welding  
helmet.  
5.2. Select a heat setting.  
5.3. Hold the torch in one hand,  
allowing the nozzle to rest on the  
edge of the work piece farthest away  
from you, and at an angle similar to  
that which will be used when welding.  
(See HOLDING THE TORCH if you  
are uncertain of the angle at which  
you will be welding).  
ELECTRIC SHOCK CAN KILL! To  
prevent ELECTRIC SHOCK, do not  
perform any welding while  
standing, kneeling, or lying directly  
on the grounded work.  
5.4. With your free hand, turn the  
Wire Speed Dial to maximum and  
continue to hold onto the knob.  
5.5. Lower your welding helmet and  
pull the trigger on the torch to start an  
arc, then begin to drag the torch  
toward you while simultaneously  
turning the Wire Speed Dial counter-  
clockwise.  
5.6. LISTEN! As you decrease the  
wire speed, the sound that the arc  
makes will change from a sputtering  
to a high-pitched buzzing sound and  
then will begin sputtering again if you  
decrease the wire speed too much.  
The point on the wire speed  
adjustment where the high-pitched  
buzzing sound is achieved is the  
correct setting. You can use the wire  
speed control to slightly increase or  
decrease the heat and penetration for  
a given heat setting by selecting  
higher or lower wire speed settings.  
Repeat this tune-in procedure if you  
select a new heat setting, a different  
6.1 Moving the torch  
Torch travel refers to the movement  
of the torch along the weld joint and is  
broken into two elements: Direction  
and Speed. A solid weld bead  
requires that the welding torch be  
moved steadily and at the right speed  
along the weld joint. Moving the torch  
too fast, too slow, or erratically will  
prevent proper fusion or create a  
lumpy, uneven bead.  
Travel direction is the direction the  
torch is moved along the weld joint in  
relation to the weld puddle. The torch  
is either PUSHED into the weld  
puddle or PULLED away from the  
weld puddle.  
12  
 
Northern Industrial Welder  
Operating Instructions and Parts Manual  
Flux Core 125  
Wire Feed, Gasless Welder  
For most welding jobs you will pull the  
torch along the weld joint to take  
advantage of the greater weld puddle  
visibility.  
Travel speed is the rate at which the  
torch is being pushed or pulled along  
the weld joint. For a fixed heat setting,  
the faster the travel speed, the lower  
the penetration and the lower and  
narrower the finished weld bead.  
Likewise, the slower the travel speed,  
the deeper the penetration and the  
higher and wider the finished weld  
bead.  
6.3 Welding position  
FLAT POSITION is easiest of the  
welding positions and is most  
commonly used. It is best if you can  
weld in the flat position if at all  
possible as good results are easier to  
achieve.  
6.2 Types of welding beads  
As you become more familiar with  
your new welder and better at laying  
some simple weld beads, you can  
begin to try some different weld bead  
types.  
The STRINGER BEAD is formed by  
traveling with the torch in a straight  
line while keeping the wire and nozzle  
centered over the weld joint. See  
following figure.  
HORIZONTAL POSITION Is  
performed very much the same as  
the flat weld except that angle B (see  
HOLDING THE TORCH) is such that  
the wire, directed more toward the  
metal above the weld joint is to help  
prevent the weld puddle from running  
downward while still allowing slow  
enough travel speed. A good starting  
point for angle B is about 30 degrees  
DOWN from being perpendicular to  
the work piece.  
The WEAVE BEAD Used when you  
want to deposit metal over a wider  
space than would be possible with a  
stringer bead. It is made by weaving  
from side to side while moving with  
the torch. It is best to hesitate  
momentarily at each side before  
weaving back the other way.  
VERTICAL POSITION It is easier for  
many people to Pull the torch from  
top to bottom. It can be difficult to  
prevent the puddle from running  
downward. Pushing the torch from  
13  
 
Northern Industrial Welder  
Operating Instructions and Parts Manual  
Flux Core 125  
Wire Feed, Gasless Welder  
bottom to top may provide better  
puddle control and allow slower rates  
of travel speed to achieve deeper  
penetration. When vertical welding,  
angle B (see HOLDING THE TORCH)  
is usually always kept at zero, but  
angle A will generally range from 45  
to 60 degrees to provide better  
puddle control.  
The illustrations in following figure  
show the sequence for laying multiple  
pass beads into a single “V” butt joint.  
OVERHEAD POSITION Is the most  
difficult welding position. Angle A (see  
HOLDING THE TORCH) should be  
maintained at 60 degrees.  
Maintaining this angle will reduce the  
chances of molten metal falling into  
the nozzle. Angle B should be held at  
zero degrees so that the wire is  
aiming directly into the weld joint. If  
you experience excessive dripping of  
the weld puddle, select a lower heat  
setting. Also, the weave bead tends  
to work better than the stringer.  
NOTE:  
WHEN USING SELF-SHIELDING  
FLUX-CORE WIRE it is very  
important to thoroughly chip and  
brush the slag off each completed  
weld bead before making another  
pass or the next pass will be of poor  
quality.  
Fillet Weld Joints. Most fillet weld  
joints, on metals of moderate to  
heavy thickness, will require multiple  
pass welds to produce strong joint.  
The illustrations in Figure 19 show  
the sequence of laying multiple pass  
beads into a T fillet joint and a lap  
fillet joint.  
6.4 Multiple pass welding  
Butt Weld Joints When butt welding  
thicker materials, you will need to  
prepare the edges of the material to  
be joined by grinding a bevel on the  
edge of one or both pieces of the  
metal being joined. When this is done,  
a “V” is created between the two  
pieces of metal, that will have to be  
welded closed. In most cases more  
than one pass or bead will need to be  
laid into the joint to close the “V”.  
Laying more than one bead into the  
same weld joint is known as a  
6.5 Spot welding  
There are three methods of spot  
welding: Burn-Through, Punch and  
Fill, and Lap. Each has advantages  
multiple-pass weld.  
14  
 
Northern Industrial Welder  
Operating Instructions and Parts Manual  
Flux Core 125  
Wire Feed, Gasless Welder  
and disadvantages depending on the  
specific application as well as  
personal preference.  
3. The LAP SPOT METHOD directs  
the welding arc to penetrate the  
bottom and top pieces, at the same  
time, right along each side of the lap  
joint seam. Select the wire diameter,  
heat setting, and tune in the wire  
speed as if you were welding the  
same thickness material with a  
continuous bead.  
6.6 SPOT WELDING  
1. The BURN-THROUGH METHOD  
welds two overlapped pieces of metal  
together by burning through the top  
piece and into the bottom piece. With  
the burn-through method, larger wire  
diameters tend to work better than  
smaller diameters. Wire diameters  
that tend to work best, with the burn-  
through method are 0.035 inch self-  
shielding Flux-Core wire. Do not use  
0.030 inch self-shielding Flux Core  
wires when using the burn-through  
method unless the metal is VERY thin  
or excessive filler metal build-up and  
minimal penetration is acceptable.  
Always select the HIGH heat setting  
with the burn-through method and  
tune in the wire speed prior to making  
a spot weld.  
INSTRUCTIONS  
1. Select the wire diameter and heat  
setting recommended above for the  
method of spot welding you intend to  
use.  
2. Tune in the wire speed as if you  
were going to make a continuous  
weld.  
3. Hold the nozzle piece completely  
perpendicular to and about 1/4 inch  
off the work piece.  
4. Pull the trigger on the torch and  
release it when it appears that the  
desired penetration has been  
achieved.  
5. Make practice spot welds on scrap  
metal, varying the length of time you  
hold the trigger, until a desired spot  
weld is made.  
6. Make spot welds on the actual  
work piece at desired locations.  
2. The PUNCH AND FILL METHOD  
produces a weld with the most  
finished appearance of the three spot  
weld methods. In this method, a hole  
is punched or drilled into the top  
piece of metal and the arc is directed  
through the hole to penetrate into the  
bottom piece. The puddle is allowed  
to fill up the hole leaving a spot weld  
that is smooth and flush with the  
surface of the top piece. Select the  
wire diameter, heat setting, and tune  
in the wire speed as if you were  
welding the same thickness material  
with a continuous bead.  
Maintenance  
The welder needs the regular  
maintenance as following:  
Periodically clean dust, dirt, grease,  
etc. from your welder. Every six  
months, or as necessary, remove the  
cover panel from the welder and air-  
blow any dust and dirt that may have  
accumulated inside the welder.  
Replace power cord, ground cable,  
ground clamp, or electrode assembly  
when damaged or worn.  
15  
 
Northern Industrial Welder  
Operating Instructions and Parts Manual  
Flux Core 125  
Wire Feed, Gasless Welder  
MINOR AND ROUTINE  
When transporting or storing the  
welder after use, it is recommended  
to repack the product as it was  
received for protection. (Cleaning is  
required before storage and you must  
seal the plastic bag in the box for  
storage  
MAINTENANCE  
Store in a clean, dry location away  
from corrosive gas, excess dust and  
high humidity. In temperatures from  
10eF̢120°F and a relative humidity  
less than 90%.  
Trouble shooting Chart  
Symptom (s)  
Welder does not  
work when the  
main switch is  
turned on  
Possible Causes(s)  
Corrective Action(s)  
1.No power input  
1.Check circuit or fuse of  
2. Power cord or power plug power source  
is broken  
2.Replace power cord  
3.Replace switch  
4.Replace transformer  
1.Check the power source  
2.Check for proper  
grounding to the work  
piece.  
3.Check output connection  
4. Clean surfaces  
5. Use correct wire  
3.Main switch is broken  
4.Transformer is broken  
1.Incorrect power input  
2.Inadequate current at  
output  
Will not weld  
3.Poor connection of output  
cable  
4. Dirty surfaces  
5. Wrong welding wire  
Blown fuse or  
tripped circuit  
breaker  
Inadequate fuse or circuit  
breaker  
Check the fuse in power  
source should be 20amp  
Arc is hard to start  
1. Wrong welding wire  
2. Base metal not grounded  
reliable  
1.Use correct one  
2.Make sure the  
connection is good  
1. Tighten the drive  
tension adjustor on wire  
Inconsistent arc or  
wire feed  
1. Not enough drive roller  
pressure  
2. Spool hub tension too tight feeder  
or loose  
2. Adjust the wing nut on  
3. Contact tip worn or wrong  
size  
the spool holder  
3. Replace contact tip  
4. Replace wire.  
Northern 800#  
4. Rusty or corroded wire  
Misc  
Please provide the following:  
-
-
-
Model Number  
Serial Number (if any)  
Part description and number as shown on parts list  
16  
 
Northern Industrial Welder  
Operating Instructions and Parts Manual  
Flux Core 125  
Wire Feed, Gasless Welder  
Repair Parts List  
Reference  
number  
Description  
Part number  
Qty  
1
Left panel  
1.1.01.02.0280  
2.07.40.370  
2.20.09.014  
2.20.09.601  
2.07.52.005  
2.07.52.014  
1.2.07.02.0036  
2.07.80.301  
1.2.01.01.0756  
2.06.29.301  
1.1.02.01.0762  
1
1
1
1
1
1
1
1
1
1
1
2
2A  
2B  
3
Wire feeder  
Drive roller  
Roller cover  
Fuse holder  
Fuse  
4
5
Control Transformer  
Circuit breaker  
Spool holder  
Rear bushing  
Spool baffle  
6
7
7A  
7B  
17  
 
Northern Industrial Welder  
Operating Instructions and Parts Manual  
Flux Core 125  
Wire Feed, Gasless Welder  
7C  
7D  
7E  
7F  
7G  
7H  
8
8” spool adaptor  
4” spool holder  
Washer  
2.05.17.008  
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
1.1.03.01.0050  
1.1.02.01.0799  
2.05.17.010  
Front Bushing  
Mat washer  
Wing nut  
2.06.17.005  
2.06.05.002  
Plastic hinge  
Fan bracket  
Fan motor  
2.05.05.064  
9
1.1.02.01.0609  
1.2.07.02.0027  
2.07.89.707  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
Fan blade  
Back panel  
Cable holder  
Power cord  
Vertical Middle panel  
Right panel  
Bottom  
1.1.01.03.0704  
2.05.05.201  
1.2.07.01.0050  
1.1.01.03.0703  
1.1.01.02.0281  
1.1.01.03.0705  
2.05.05.016  
Feet  
Thermal relay  
Main Transformer  
Handle  
2.07.36.527  
1.1.04.01.0482  
2.05.05.042  
PCB Board  
PCB support  
Front panel  
Cable holder  
Ground Cable clamp  
Torch  
1.1.05.02.0168  
2.05.05.106  
2.05.05.073  
2.05.05.202  
1.2.08.02.0079  
1.2.07.02.0935  
2.07.11.009  
Potentiometer Knob  
18  
 
Northern Industrial Welder  
Operating Instructions and Parts Manual  
Flux Core 125  
Wire Feed, Gasless Welder  
29  
30  
31  
32  
33  
Indicator  
1.2.07.02.0057  
2.07.80.211  
2.07.80.031  
2.04.31.107  
2.08.07.803  
1
1
1
1
1
Main Switch  
Setting Switch  
Cable holder  
Door Bolt  
Schematic diagram  
24V  
~110V  
Black wire  
White wire  
Green wire  
Other Safety and Standards Information  
This manual is designed to inform the operator of safety and general use of this  
model only. For further information about welding safety refer to the following  
standards and comply with them where applicable.  
• ANSI Standard Z49.1 — SAFETY IN  
WELDING AND CUTTING obtainable  
from: American Welding Society 550 NW  
Le Jeune Road, Miami, FL 33126  
Tel. (800) 443-9353  
Fax (305) 443-7559  
19  
 
Northern Industrial Welder  
Operating Instructions and Parts Manual  
Flux Core 125  
Wire Feed, Gasless Welder  
• ANSI Standard Z87.1 — SAFE PRACTICE  
FOR OCCUPATION AND EDUCATIONAL  
EYE AND FACE PROTECTION  
Obtainable from: American National  
Standards Institute (ANSI) 11 West 42nd  
St. New York, NY 10036  
Tel. (212) 642-4900  
• NFPA Standard 51B — CUTTING AND  
WELDING PROCESS obtainable from:  
National Fire Protection Association,  
1 Batterymarch Park, P.O. Box 9101  
Quincy, MA 02269-9101  
Tel. (617) 770-3000  
• OSHA Standard 29 CFR, Part 1910,  
Subpart Q. —WELDING, CUTTING AND  
BRAZING obtainable from your state  
OSHA office or from: U. S. Dept. of Labor  
OSHA, Office of Public Affairs Room  
N3647, 200 Constitution Ave. NW  
• CSA Standard W117.2 — Code for  
SAFETY IN WELDING AND CUTTING  
Obtainable from: Canadian Standards  
Association, 178 Rexdale Blvd.,  
Etobicoke, Ontario M9W 1R3  
• American Welding Society Standard A6.0  
—WELDING AND CUTTING CONTAINERS  
WHICH HAVE HELD COMBUSTIBLES  
Obtainable from: American  
Welding Society, 550 NW Le Jeune Road  
Miami, FL 33126  
Tel. (800) 443-9353  
Fax (305) 443-7559  
20  
 
Warranty  
Northern Tool + Equipment  
Effective Jan 1, 2009  
Limited Warranty  
This warranty applies to the original purchaser and is subject to the terms and conditions listed below.  
This Limited Warranty is for new equipment sold after the above date, providing coverage for defects  
in material and workmanship at the time it is shipped from the factory.  
Limited to the warranty periods listed below, Northern Tool + Equipment will repair or replace the item  
under warranty that fails due to defects in material and workmanship. Northern Tool + Equipment  
must be notified within 30 days of the failure, so as to provide instructions on how to proceed with the  
repair of your welder and warranty claim processing. Warranty period begins at the time the welder is  
purchased from Northern Tool + Equipment.  
Warranty Periods  
Limited Warranty is divided into four categories: No warranty, 6 months, 1 year, 2 year.  
No Warranty  
Normal wear items, MIG gun parts (contact tips, nozzle, adapter, MIG gun liner), drive roll, electrode  
holder, are not covered under warranty.  
6 Months  
Parts and labor performed by authorized repair center with original equipment repair parts  
1Year  
MIG gun parts (except those listed under normal wear items), cables, regulator.  
2Year  
Includes: transformer, reactor, rectifier, solenoid valve, PC board, switches, controls, gas valve, drive  
motor, drive system.  
 
Northern Tool + Equipment Co.  
2800 Southcross Drive West  
PO Box 1219  
Burnsville MN 55337  
 

Miele Cooktop KM 5656 User Manual
Miele Dishwasher G 2830 SCi User Manual
Milan Technology Switch MIL S500 User Manual
Minolta Printer PI4700E User Manual
Multi Tech Systems Network Card BL Series User Manual
Murphy Switch L129 Series User Manual
NETGEAR Portable Multimedia Player NTV250 100NAS User Manual
NordicTrack Home Gym 831145955 User Manual
Ocean Kayak Boat Nalu User Manual
Panasonic Cell Phone KX TCA155 User Manual