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Fume and Gas Safety
FUMES AND GASES can be hazardous to your health.
1. Exposure to welding or cutting
4. Use enough ventilation, exhaust at arc, or
both, to keep fumes and gases from breathing
zone and general area. If engineering controls
are not feasible, use an approved respirator.
exhaust fumes can increase the risk
of developing certain cancers, such as
cancer of the larynx and lung cancer.
Also, some diseases that may be linked to exposure
to welding or cutting exhaust fumes are:
5. Work in a confined area only if it
is well-ventilated, or while wearing
an air-supplied respirator.
• Early onset of Parkinson’s Disease
• Heart disease
• Ulcers
6. Have a recognized specialist in
Industrial Hygiene or Environmental Services
check the operation and air quality
and make recommendations
• Damage to the reproductive organs
• Inflammation of the small intestine or
stomach
• Kidney damage
• Respiratory diseases such as
emphysema, bronchitis, or pneumonia
for the specific welding situation.
Follow OSHA guidelines for
Permissible Exposure Limits (PEL’s) and
the American Conference of Governmental
Industrial Hygienists recommendations for
Threshold Limit Values (TLV’s) for fumes and gases.
2. Do not use near degreasing or
painting operations.
3. Keep head out of fumes.
Do not breathe exhaust fumes.
Arc Ray Safety
ARC RAYS can injure eyes and burn skin.
1. Wear ANSI-approved welding eye protection
4. Wear an approved head covering to protect
the head and neck. Use aprons, cape, sleeves,
shoulder covers, and bibs designed and
featuring at least a number 10 shade lens rating.
2. Wear leather leggings, fire resistant shoes
or boots during use. Do not wear pants with
cuffs, shirts with open pockets, or any clothing
that can catch and hold molten metal or sparks.
approved for welding and cutting procedures.
5. When welding/cutting overhead or in confined
spaces, wear flame resistant ear plugs or
ear muffs to keep sparks out of ears.
3. Keep clothing free of grease, oil,
solvents, or any flammable substances.
Wear dry, insulating gloves and protective clothing.
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Electrical Safety
ELECTRIC SHOCK can KILL.
1. Turn off, disconnect power, and
6. Do not expose welders to rain or wet conditions.
Water entering a welder will increase
the risk of electric shock.
discharge electrode to ground before setting
down torch/electrode holder and before service.
2. Do not touch energized electrical parts.
Wear dry, insulating gloves. Do not touch electrode
holder, electrode, welding torch, or welding wire with
bare hand. Do not wear wet or damaged gloves.
7. Do not abuse the cord. Never use the cord
for carrying, pulling or unplugging the welder.
Keep cord away from heat, oil, sharp edges
or moving parts. Damaged or entangled
cords increase the risk of electric shock.
3. Connect to grounded, GFCI-protected
power supply only.
8. Do not use outdoors.
4. Do not use near water or damp objects.
9. Insulate yourself from the workpiece and ground.
Use nonflammable, dry insulating material if possible,
or use dry rubber mats, dry wood or plywood, or
other dry insulating material large enough to cover
your full area of contact with the work or ground.
5. People with pacemakers should consult their
physician(s) before use. Electromagnetic fields
in close proximity to heart pacemaker could cause
pacemaker interference or pacemaker failure.
10. Use care not to touch the welding tip to
grounded material whenever the unit is
plugged in. Electric shock, fire, or burns may
happen if appropriate precautions are not taken.
Fire Safety
ARC AND HOT SLAG can cause fire.
1. Clear away or protect flammable objects.
Remove or make safe all combustible materials for a
radius of 35 feet (10 meters) around the work area.
Use a fire resistant material to cover or block all open
doorways, windows, cracks, and other openings.
5. If working on a metal wall, ceiling, etc.,
prevent ignition of combustibles on the
other side by moving the combustibles to a
safe location. If relocation of combustibles is
not possible, designate someone to serve as
a fire watch, equipped with a fire extinguisher,
during the cutting process and for at least one
half hour after the cutting is completed.
2. Keep ABC-type fire extinguisher near
work area and know how to use it.
3. Maintain a safe working environment.
Keep the work area well lit.
6. Do not weld or cut on materials having
a combustible coating or combustible
Make sure there is adequate surrounding workspace.
Keep the work area free of obstructions,
grease, oil, trash, and other debris.
internal structure, as in walls or ceilings, without
an approved method for eliminating the hazard.
7. Do not dispose of hot slag in containers
4. Do not operate welders in atmospheres
containing dangerously reactive or
holding combustible materials.
flammable liquids, gases, vapors, or dust.
Provide adequate ventilation in work areas
to prevent accumulation of such substances.
Welders create sparks which may ignite flammable
substances or make reactive fumes toxic.
8. After welding, make a thorough examination
for evidence of fire. Be aware that easily
visible smoke or flame may not be present
for some time after the fire has started.
9. Do not apply heat to a container that has held
an unknown substance or a combustible
material whose contents, when heated,
can produce flammable or explosive vapors.
Clean and purge containers before applying heat.
Vent closed containers, including castings,
before preheating, welding, or cutting.
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Welder use and care
1. Do not use the welder if the switch does not turn
it on and off. Any welder that cannot be controlled
with the switch is dangerous and must be repaired.
4. Store idle welders out of the reach of children and
do not allow persons unfamiliar with the welder or
these instructions to operate the welder. Welders
are dangerous in the hands of untrained users.
2. Disconnect the plug from the power
source before making any adjustments,
changing accessories, or storing welders.
Such preventive safety measures reduce the
risk of starting the welder accidentally.
5. Use the welder and accessories in accordance
with these instructions, taking into account the
working conditions and the work to be performed.
Use of the welder for operations different from those
intended could result in a hazardous situation.
3. Prevent unintentional starting.
Ensure the switch is in the off-position before
connecting to power source or moving
the welder. Carrying or energizing welders
that have the switch on invites accidents.
Maintenance
1. Maintain welders. Check for misalignment or
binding of moving parts, breakage of parts
and any other condition that may affect the
welder’s operation. If damaged, have the
welder repaired before use. Many accidents
are caused by poorly maintained welders.
3. Maintain labels and nameplates on the Welder.
These carry important information.
If unreadable or missing, contact
Harbor Freight Tools for a replacement.
4. Unplug before maintenance. Unplug the Welder
from its electrical outlet before any inspection,
maintenance, or cleaning procedures.
2. Have your welder serviced by a qualified
repair person using only identical
replacement parts. This will ensure that
the safety of the welder is maintained.
SAVE THESE INSTRUCTIONS.
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Grounding
TO PREVENT ELECTRIC SHOCK AND DEATH FROM INCORRECT GROUNDING WIRE
CONNECTION:
Check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded.
Have a plug installed by a certified electrician. Do not use the Welder if the power cord or plug is
damaged. If damaged, have it repaired by a service facility before use. If the plug will not fit the
outlet, have a proper outlet installed by a qualified electrician.
Grounded Welders
1. The grounding prong in the plug is connected
through the green wire inside the cord to the
grounding system in the Welder. The green wire
in the cord must be the only wire connected to
the Welder’s grounding system and must never
be attached to an electrically “live” terminal.
2. The Welder must be plugged into an appropriate
outlet, properly installed and grounded in
accordance with all codes and ordinances.
Extension Cords
1. If an extension cord is used, it must have
the following wire size: up to 30 feet, use
10 AWG size wire; 30 to 50 feet, use 8 AWG
wire; Over 50 feet, use 6 AWG wire.
4. When using more than one extension cord to
make up the total length, make sure each cord
contains at least the minimum wire size required.
5. If you are using one extension cord for more than
one welder, add the nameplate amperes and use the
sum to determine the required minimum cord size.
2. As the distance from the supply outlet increases,
you must use a heavier gauge extension cord.
Using extension cords with inadequately sized
wire causes a serious drop in voltage, resulting
in loss of power and possible welder damage.
6. If you are using an extension cord outdoors, make
sure it is marked with the suffix “W-A” (“W” in
Canada) to indicate it is acceptable for outdoor use.
3. The smaller the gauge number of the wire,
the greater the capacity of the cord. For
example, a 14 gauge cord can carry a
higher current than a 16 gauge cord.
7. Make sure the extension cord is properly wired
and in good electrical condition. Always replace
a damaged extension cord or have it repaired
by a qualified electrician before using it.
8. Protect the extension cords from sharp objects,
excessive heat, and damp or wet areas.
Symbology
Wire Feed (Speed)
Workpiece Ground Cable
Gun Cable
Volts Alternating Current
V~
A
OCV
KVA
Amperes
Open Circuit Voltage
Kilovolt Amperes
(Volts / 1000 * Amperes)
Overheat Shutdown Indicator
Cooling Fan
Inches Per Minute
IPM
Housing Ground Point
American Wire Gauge
AWG
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Specifications
Electrical Rating
120V~ / 20A
Welding Output
60 ~ 120 A, AC
18 gauge (0.048″) to 3/16″ (0.19″) mild steel only
Not for welding aluminum or stainless steel
Capacity
20% @ 90A
(See explanation on page 14)
Duty Cycle
Open Circuit Voltage
KVA
27
2.38
Welder Tips / Wire Size
Wire Spool Capacity
Installed tip will accept .030″ to .035″ FLUX CORE wire
4″ diameter / 2 lb. spool
Setup
Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this
manual including all text under subheadings therein before set up or use of this product.
TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION:
Turn the Power Switch off and unplug the welder before assembly.
Cover Assembly
1. Slide the Handle into the slot on
the Cover from the back.
notch drops
into slot on
Cover here
Handle
Screw
2. The notch on the front of the Handle should drop
into the slot in the Cover. Both ends of the Handle
should lay flush against the top of the Cover.
Cover
3. Secure with Screw at front of unit.
SKU 68887
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Wire Spool Installation
ITEM 68887
ON
MIN
1. Turn the Welder to OFF and unplug
it before proceeding.
OFF
Wire
.030″-.035″ Flux-core
D SPEED
Capacity XX Ga. – X/X″ Steel Plate
Electrode – X′
Ground Clamp – X′
Cables
Cover
2. Press in the pin at the top center of
the control panel and open the cover.
Wire
Spool
Knob
3. Remove the Knob, Spring and the Top Plate.
If replacing a Spool, remove the old Spool
and all remaining wire from the liners.
Spring
Top Plate
Wire Spool
Spindle
4. Place the new flux core Wire Spool
over the Spool Spindle.
To prevent wire feed problems, set the Spool
so that it will unwind counterclockwise
.
5. Replace the Top Plate (turned as shown in
illustration), the Spring and the Knob.
wire must
unwind this
direction
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6. Turn the Feed Tensioner counterclockwise to
loosen it enough to pull it up, releasing tension.
Swing the Feed Swing Arm out. (Note: Do
not loosen the Feed Tensioner too
much, or it will come apart.)
Feed Swing
Arm
Feed
Tensioner
7. Loosen and remove the Feed Knob. Compare
the wire diameter marked on the Wire Spool with
the stamped number on the top of the Feed Roller.
The Roller’s groove size must be compatible with
the wire diameter -
Feed
Knob
Feed
Roller
.8mm rollers also work with .030″ wire &
.9mm rollers also work with .035″ wire.
Flip the Feed Roller as needed and confirm that the
number facing up is the same as the wire diameter
on the Spool.
Replace and secure the Feed Knob.
IMPORTANT:
Securely hold onto the end of the welding wire and
keep tension on it during the following steps.
If this is not done, the welding wire will unravel
and create a tangled “bird’s nest”, wasting wire.
Wire
Liner
HOLD WIRE
SECURELY
welding
wire
8. Cut off all bent and crimped wire.
Make sure that the cut end has no burrs
or sharp edges; cut again if needed.
9. Keep tension on the wire and guide at least
12 inches of wire into the Wire Liners.
Wire
Spool
leader
wire liner
10. Swing the Feed Swing Arm closed, and swing
the Feed Tensioner across the tip of the Arm, to
latch it. Make sure the Welding Wire is resting in
the top groove of the Feed Roller, then turn the
Feed Tensioner clockwise a couple of turns.
After the wire is held by the Feed
Feed
Tensioner
Tensioner, you may release it.
Feed Swing
Arm
Gun
11. Pull the Nozzle to remove it.
12. Using the third oval hole on the Multi-wrench, turn
the Contact Tip counterclockwise and remove.
Nozzle
13. Lay the Gun Cable out in a straight line so that the
wire moves through it easily. Leave the cover open,
so that the feed mechanism can be observed.
Contact
Tip
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WARNING
The following steps require applying power to the welder
with the cover open.
To prevent serious injury from fire or electric shock:
1. Do not touch anything, especially not the Ground Clamp,
with the Gun or welding wire or an arc will be ignited.
2. Do not touch internal welder components
while it is plugged in.
ITEM 68887
14. Do not touch the Gun’s Trigger.
Plug the Power Cord into its electrical
outlet and turn the welder to ON.
ON
MIN
OFF
Wire
.030″-.035″ Flux-core
D SPEED
Capacity XX Ga. – X/X″ Steel Plate
Electrode – X′
Ground Clamp – X′
Cables
15. Point the Gun away from all objects and press the
Trigger until the wire feeds out of the gun two inches.
The Wire Liner may come out with the welding
wire, this is normal, just push the Wire Liner
back into the Gun.
Gun
Welding
Wire
If the wire does not feed properly and the
Spool is stationary, turn the welder to OFF,
unplug it, and slightly tighten the Feed
Tensioner clockwise before retrying.
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16. To check the wire’s drive tension, feed the wire
against a piece of wood from 2 to 3 inches away. If
the wire stops instead of bending, turn the welder to
OFF, unplug it, slightly tighten the Feed Tensioner
clockwise , and try again.
Incrementally
increase tension
until
If the wire bends from the feed tension,
then the tension is set properly.
wire bends.
ITEM 68887
ON
MIN
17. TURN THE WELDER TO OFF.
OFF
Wire
.030″-.035″ Flux-cor
D SPEED
Capacity XX Ga. – X/X″ Steel Plate
Electrode – X′
Ground Clamp – X′
Cables
18. Select a Contact Tip that is compatible with the
welding wire used. The included Tip (.035″) will work
with both .030″ and .035″ wire. Slide the Contact
Tip over the wire and thread it clockwise into the
Gun. Tighten the Contact Tip using a wrench.
Gun
Nozzle
19. Replace the Nozzle and cut the wire
1
1
off at / ″ from tip ( / ″ stickout).
2
2
Contact
Tip
20. Swing the Cover closed until the
Cover Latch locks in place.
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Basic Welding
Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of
this manual including all text under subheadings therein before welding.
TO PREVENT SERIOUS INJURY:
Protective gear must be worn when using the
Welder; minimum shade number 10 full face shield
(or welding mask), ear protection, welding gloves,
sleeves and apron, NIOSH-approved respirator, and
fire resistant work clothes without pockets should be
worn when welding.
Light from the arc can cause permanent damage to
the eyes and skin.
Do not breathe arc fumes.
87
TO PREVENT SERIOUS INJURY,
FIRE AND BURNS:
ON
MIN
Keep welding tip clear of grounded
objects whenever unit is plugged in.
OFF
=
.030″-.035″ Flux-core
acity XX Ga. – X/X″ Steel Plate
Electrode – X′
Ground Clamp – X′
es
120V~
The Flux Wire Welder is used to weld sheet metal
and low carbon steel. Good welding takes a degree
of skill and experience. Practice a few sample
welds on scrap before welding your first project.
Additional practice periods are recommended whenever
you weld a different thickness of material or weld a
different type of connection.
Practice your welding
technique on scrap
pieces before welding
anything of value.
Make practice welds on pieces of scrap to practice
technique before welding anything of value.
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Control Panel Layout
GUN
Gun
Cable
90 AMP FLUX WIRE WELDER
Overload
Indicator
ITEM 68887
ON
MIN
Wire
Speed
Dial
Current
Switch
OFF
MAX
Wire
.030″-.035″ Flux-core
WIRE FEED SPEED
Capacity XX Ga. – X/X″ Steel Plate
Electrode – X′
Ground Clamp – X′
Power
Switch
Cables
GROUND
120V~
60Hz
20A
Power
Cord
Ground
Cable
Gun Cable:
Overload Indicator:
The welding Gun connects here. The wire and welding
current feeds to the weld through here.
The welding Gun is energized whenever
the Power Switch is on.
This lights up if duty cycle work period is exceeded
and the welder is overheated. Rest the Gun on an
electrically non-conductive, heat-resistant surface, such
as a concrete slab, well clear of the ground clamp while
allowing the welder to cool with the Power Switch on, so
the Fan can help cool the welder. Once the welder cools
enough to be used again, use shorter welding periods
and longer rest periods to prevent needless wear.
Wire Speed Dial:
This controls the speed that the welding wire feeds out of
the welding Gun.
Adjust this according to the weld settings chart
to achieve a good weld. (See next page.)
Current Switch:
This controls the output amperage of the welder.
Adjust this according to the weld settings
chart to achieve a good weld.
Ground Cable:
This connects to the base metal to provide a good
connection for the current to travel back to the welder.
Power Switch:
This turns on power to the Welding Gun
and internal cooling fan.
Power Cord:
Plug the Power Cord into a properly grounded
120 V~ outlet, on at least a 20 amp dedicated circuit
with delayed action type circuit breaker or fuses.
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Weld Settings Chart
NOTE: The numbers within the
spaces are the approximate wire
feed settings recommended* for this
wire size and material thickness.
Material Thickness (Steel)
1
3
18 Gauge 16 Gauge 14 Gauge
MIN current
/ ″
8
/ ″
16
MAX current
1.5
2
4
8
9
.030″ Wire Size
(Flux Core, Mild Steel)
speed
speed
speed
speed
speed
1.5
2
3
8
9.5
.035″ Wire Size
(Flux Core, Mild Steel)
speed
speed
speed
speed
speed
* This chart is only intended to show general guidelines for different wire sizes and for different
thicknesses of material. The settings should only be used at the beginning of a weld and must be
adjusted after stopping and carefully inspecting the weld. Proper welding takes experience.
Duty Cycle (Duration of Use)
Avoid damage to the Welder by not welding
for more than the prescribed duty cycle time.
The Duty Cycle defines the number of minutes, within
a 10 minute period, during which a given welder can
produce a particular welding current without overheating.
For example, this Welder with a 20% duty cycle at
rated output (90A) must be allowed to rest for at
least 8 minutes after every 2 minutes of continuous weld.
Failure to carefully observe duty cycle limitations
can easily over-stress a welder’s power generation
system contributing to premature welder failure.
20% Rated Duty Cycle
at 90A output
2 minutes welding
followed by
at least 8 minutes of rest
This welder has an internal thermal protection
ITEM 68887
system to help prevent this sort of over-stress.
Gun
When the unit overheats, it automatically shuts down and
the Overload Indicator lights. The welder automatically
returns to service after cooling off. Rest the Gun on
an electrically non-conductive, heat-proof surface,
such as a concrete slab, well clear of the ground clamp
while allowing the welder to cool with the Power Switch
on, so that the internal Fan will help cool the welder.
When the welder can be used again, use shorter welding
periods and longer rest periods to prevent needless wear.
ON
MIN
OFF
MAX
concrete slab
(or other heat-proof,
non-conductive
surface)
Wire
.030″-.035″ Flux-core
Capacity XX Ga. – X/X″ Steel Plate
SPEED
Electrode – X′
Ground Clamp – X′
Cables
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Setting Up The Weld
1. Make practice welds on pieces of scrap the same
thickness as your intended workpiece to practice
technique before welding anything of value.
Clean the weld surfaces thoroughly with
a wire brush or angle grinder; there must
clamps
be no rust, paint, oil, or other materials on
the weld surfaces, only bare metal.
workpieces
2. Use clamps (not included) to hold the workpieces
in position so that you can concentrate on
proper welding technique. The distance
Clean
surfaces to
bare metal.
(if any) between the two workpieces must be
controlled properly to allow the weld to hold
both sides securely while allowing the weld
to penetrate fully into the joint. The edges of
thicker workpieces may need to be chamfered
(or beveled) to allow proper weld penetration.
Chamfer thick workpieces.
GUN
Workpiece
3. Clamp Ground Cable to bare metal on the
workpiece near the weld area, or to metal work
bench where the workpiece is clamped.
90 AMP FLUX WIRE WELDER
ITEM 68887
ON
MIN
Clean
surface to
bare metal.
OFF
MAX
Wire
Capacity XX Ga.
.030″-.035″ Flux-core
WIRE FEED SPEED
–
X/X″ Steel Plate
X′
Ground Clamp
Electrode
–
Cables
–
X′
Ground
Clamp
GROUND
120V~
60Hz
20A
ITEM 68887
ITEM 68887
4. Set the Wire Speed Dial and
the Current Switch to the desired settings.
Refer to the chart on the welder
or the chart on the facing page.
WARNING! DO NOT SWITCH THE
CURRENT WHILE WELDING.
ON
MIN
ON
MIN
OFF
MAX
F
MAX
+
Wire
.030″-.035″ Flux-core
Capacity XX Ga. – X/X″ Steel Plate
Wire
.030″-.035″ Flux-core
Capacity XX Ga. – X/X″ Steel P
ED
WIRE FEED SPEED
Electrode – X′
Ground Clamp – X′
Electrode – X′
Ground Clamp – X′
Cables
Cables
GROUND
ITEM 68887
5. Flip the Power Switch to the OFF position, then plug
the Welder into a dedicated, 120 V~, 20 A circuit
with delayed action type circuit breaker or fuses.
ON
MIN
OFF
Wire
.030″-.035″ Flux-co
EED
Capacity XX Ga. – X/X″ Steel Plate
Electrode – X′
Ground Clamp – X′
Cables
20 Amp minimum circuit
ITEM 68887
HOLD
GUN
CLEAR
ON
MIN
6. Hold the Gun, without touching the Trigger, with the
wire and tip clearly away from any grounded objects.
Then, turn the Power Switch to ON.
OFF
X
Wire
.030″-.035″ Flux-core
D SPEED
Capacity XX Ga. – X/X″ Steel Plate
Electrode – X′
Ground Clamp – X′
Cables
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Basic Welding Technique
1. Press (and hold) Trigger and contact area to
be welded with electrode wire to ignite arc.
stringer bead
weave bead
2. For a narrow weld, you can usually draw the wire in
a steady straight line,
this is called a stringer bead.
For a wider weld, draw the wire back and forth
across the joint, this is called a weave bead.
Weld Gun angles,
viewed from front of weld joint.
3. Hold Gun in one hand and the face shield in the
other. If a hands-free welding shield (not included,
see Arc Ray Safety on page 3 for guidelines) is
used, then both hands can be used to control Gun.
4. Direct the welding wire straight into the joint.
This gives an angle of 90° (straight up and
down) for butt (end to end) welds, and an
angle of 45° for fillet (T-shaped) welds.
90°
butt weld joint
45°
fillet weld joint
5. The end of Gun should be tilted so that wire
is angled anywhere in-between straight on
and 15° in the direction you are welding. The
amount of tilt is called the drag angle.
Drag Angle
0-15°
1
6. The welding wire should extend no more than / ″
2
past the tip.
This distance is called stickout or CTWD
- Contact Tip to Work Distance.
Stickout
1
(up to / ″)
2
Weld
Direction
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Note: If Welder is used too long, the amber Overload
Indicator will light and the Welder Gun will shut off
until the welder cools. If this happens, rest the Gun on
an electrically non-conductive, heat-resistant surface,
such as a concrete slab, well clear of the ground
clamp. Wait about 8-10 minutes with the Power
Switch to ON for the welder to cool. When the welder
can be used again, use shorter welding periods and
longer rest periods to help prevent needless wear.
ITEM 68887
Gun
ON
MIN
OFF
MAX
concrete slab
(or other heat-proof,
non-conductive
surface)
Wire
.030″-.035″ Flux-core
SPEED
Capacity XX Ga. – X/X″ Steel Plate
Electrode – X′
Ground Clamp – X′
Cables
After practice welding for a few
seconds, STOP and examine
your weld using the guidelines
starting on the next page.
7. After welding the test weld on a piece of scrap for a
few seconds, stop, and check your progress. Clean,
then compare your weld’s appearance with the diagrams
and descriptions in the Welding Tips section starting on
the next page. After making any necessary adjustments,
continue to weld while carefully following the
FOLLOW DUTY CYCLE!
DUTY CYCLE guidelines as explained on page 14.
up to 2 minutes welding
at rated output
ITEM 68887
HOLD
GUN
CLEAR
ON
MIN
8. When the weld is complete,
lift the Gun and welding wire clearly away from any
grounded object, and turn the Power Switch off.
OFF
Wire
.030″-.035″ Flux-co
D SPEED
Capacity XX Ga. – X/X″ Steel Plate
Electrode – X′
Ground Clamp – X′
Cables
120V~
9. Set the Gun down on a heat-proof, electrically
non-conductive surface. Unplug the Power Cord.
Gun
concrete slab
(or other heat-proof,
non-conductive
surface)
SKU 68887
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Page 17
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Welding Tips
A good way to test welding technique is to
examine a weld’s appearance after it has
cooled and the slag has been removed.
Then, better welding can be learned by adjusting your
weld technique to remedy any problems found.
A typical Flux-core Wire (FCAW) Weld
before cleaning.
weld bead
slag
spatter
base metal
Cleaning the Weld
TO PREVENT SERIOUS INJURY:
Continue to wear ANSI-approved safety
goggles and protective wear when
cleaning a weld.
Sparks or chips may fly when cleaning.
1. A weld from flux core wire will be covered by slag:
use a Chipping Hammer to knock this off.
Be careful not to damage the
weld or base material.
2. Then, use a Wire Brush to further
clean the weld or use an angle grinder
(sold separately) to shape the weld.
clamp
Strike Test
dead-blow hammer
SCRAP
workpiece
A test weld on a PIECE OF SCRAP can be
tested by using the following procedure.
WEAR ANSI-APPROVED SAFETY GOGGLES
DURING THIS PROCEDURE.
WARNING! This test WILL damage the weld it is
performed on. This test is ONLY an indicator of weld
technique and is not intended to test working welds.
GOOD WELD
bends and is not brittle
1. After two scraps have been welded together and the
weld has cooled, clamp one scrap in a sturdy vise.
2. Stay clear from underneath while you strike
the opposite scrap with a heavy hammer,
preferably a dead-blow hammer.
clamp
dead-blow hammer
3. A GOOD WELD will deform but not break,
as shown on top.
SCRAP
workpiece
A POOR WELD will be brittle and snap
at the weld, as shown on bottom.
POOR WELD
snaps or cracks
Page 18
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SKU 68887
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Weld Diagnosis
Workpiece Heat Control / Weld Penetration
EXCESS PENETRATION OR
BURN-THROUGH
INADEQUATE PENETRATION
PROPER PENETRATION
Not hot enough
Ideal heat
Too hot
How to increase workpiece heat
How to reduce workpiece heat
and increase penetration:
(to weld THICKER workpieces properly)
and limit penetration:
(to weld THINNER workpieces properly)
a.Use MAX setting
b.Weld more slowly
c.Use faster wire feed
d.Use shorter stickout
a.Use MIN setting
c.Use slower wire feed
d.Use longer stickout
b.Weld more quickly
Example Weld Diagrams
Good
Weld
Current
Too Low
Current
Too High or
Wire Feed
Too Fast
Weld Speed
Too Fast
Weld Speed
Too Slow
Stickout
Too Long
TO CORRECT:
TO CORRECT:
TO CORRECT:
TO CORRECT:
TO CORRECT:
maintain
ON
MIN
ON
MIN
OFF
MAX
less
than / ″
stickout
30″-.035″ Flux-core
X Ga. – X/X″ Steel Plate
1
2
weld
slower
weld
faster
or
OFF
MAX
ON
OF
030″-.035″ Flux-core
X Ga. – X/X″ Steel Plate
Wire
.030″
SKU 68887
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Page 19
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Weld Problems
Penetration (Workpiece Heat Control)
EXCESS PENETRATION OR
BURN-THROUGH
Weld droops on top and
underneath or falls through
entirely, making a hole.
PROPER PENETRATION
Weld is visible underneath and
bulges slightly on top.
INADEQUATE PENETRATION
Weld does not contact the joint
fully, just on the surface.
PROFILE VIEWS
POSSIBLE CAUSES AND SOLUTIONS
1. Workpiece overheating:
POSSIBLE CAUSES AND SOLUTIONS
1. Incorrect welding technique:
1
Reduce wire feed speed.
Maintain / ″ or less stickout.
2
Use MIN setting.
Keep arc on leading edge of weld puddle.
Hold gun at proper angles.
2. Welding speed too slow:
Increase welding speed and ensure
that welding speed is kept steady.
2. Insufficient weld heat:
Reduce welding speed.
Use MAX setting.
3. Excessive material at weld:
Reduce wire feed speed.
3. Workpieces too thick/close:
Bevel thick workpieces, allow slight
gap, and weld in several passes.
4. Insufficient weld material:
Increase wire feed speed.
Weld Not Adhering Properly
Bend at Joint
Gaps present between weld and previous bead or
between weld and workpiece. See areas below.
PROFILE
VIEW
PROFILE
VIEW
POSSIBLE CAUSES AND SOLUTIONS
1. Improper clamping:
Clamp workpieces securely.
Make tack welds to hold workpieces.
POSSIBLE CAUSES AND SOLUTIONS
1. Incorrect welding technique:
2. Excessive heat:
Place stringer bead at correct place in joint.
Adjust workpiece position or weld angle to permit
proper welding to bottom of piece.
Pause briefly at sides during weave bead.
Keep arc on leading edge of weld puddle.
Hold gun at proper angles.
Weld a small portion and allow to cool before
proceeding.
Increase weld speed.
Reduce wire feed speed.
2. Insufficient weld heat:
Increase current and/or wire feed speed.
3. Dirty workpiece:
Clean workpiece down to bare metal.
4. Insufficient weld material:
Increase wire feed speed.
Page 20
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SKU 68887
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Coat of Slag Over Weld
Excessive Spatter
Fine spatter is normal.
Spatter that is grainy and large is a problem.
TOP
VIEW
TOP
VIEW
PARTIALLY CHIPPED AWAY TO SHOW WELD
Slag is a necessary part of a flux-
core wire weld. It shields the weld from
impurities. Clean off the slag with the Chipping
Hammer and Wire Brush after welding.
POSSIBLE CAUSES AND SOLUTIONS
1. Dirty workpiece or welding wire:
Clean workpiece down to bare metal.
Make certain that wire is clean and free
from oil, coatings, and other residues.
2. Wire feeding too fast:
Reduce wire feed speed.
3. Stickout too long:
Reduce stickout.
Porosity
Small cavities or holes in the bead.
TOP
VIEW
POSSIBLE CAUSES AND SOLUTIONS
1. Dirty workpiece or welding wire:
Clean workpiece down to bare metal.
Make certain that wire is clean and free
from oil, coatings, and other residues.
Burn-Through
Base material melts away,
leaving a hole in the weld.
2. Inconsistent welding speed:
Maintain steady weld speed.
3. Stickout too long:
TOP
VIEW
Reduce stickout.
POSSIBLE CAUSES AND SOLUTIONS
1. Workpiece overheating:
Reduce current and/or wire feed speed.
2. Welding speed too slow:
Increase welding speed and ensure
that welding speed is kept steady.
Crooked/Wavy Bead
3. Excessive material at weld:
Reduce wire feed speed.
TOP
VIEW
POSSIBLE CAUSES AND SOLUTIONS
1. Inaccurate welding:
Use two hands or rest hand on steady surface.
2. Inconsistent welding speed:
Maintain steady weld speed.
3. Stickout too long:
Reduce stickout.
SKU 68887
For technical questions, please call 1-800-444-3353.
Page 21
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Maintenance
Gun
TO PREVENT SERIOUS INJURY,
FIRE AND BURNS:
Unplug the Welder,
rest the Gun on a heat-proof,
electrically non-conductive surface,
and allow all parts of the Welder to cool thoroughly
before service.
concrete slab
+
(or other heat-proof,
non-conductive
surface)
1. Periodically remove the Right and Left
side panels, and using compressed air,
blow out all dust from the interior.
2. Store in a clean and dry location.
3. For optimal weld quality, clean and
inspect the Contact Tip and Nozzle
before each use. See below.
Nozzle Inspection, Cleaning, and Replacement
1. Make sure that the entire Gun is completely
cool and that the Power Cord is unplugged
from the electrical outlet before proceeding.
Gun
2. Turn the Nozzle counterclockwise
while pulling to remove.
3. Scrub the interior of the Nozzle
clean with a wire brush.
Nozzle
4. Examine the end of the Nozzle. The end should be
flat and even. If the end is uneven, chipped, melted,
cracked, or otherwise damaged, the Nozzle will
adversely affect the weld and should be replaced.
Contact
Tip
5. Reinstall the Nozzle after inspecting
and cleaning the Contact Tip.
Page 22
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SKU 68887
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Contact Tip Inspection,
Cleaning, and Replacement
1. Make sure that the entire Gun is completely
cool and that the Power Cord is unplugged
from the electrical outlet before proceeding.
2. Remove the Nozzle as explained in the previous
subheading. Using the third oval hole on the
Multi-wrench, turn the Contact Tip counterclockwise
and slide it off the welding wire.
Gun
3. Scrub the exterior of the Tip clean with a wire brush.
Clean out the inside of the
Nozzle
tip with a tip cleaner (sold separately).
Check that the Tip is the proper type for the
wire size used (.035″ tip for .030–.035″ wire).
Contact
Tip
4. Examine the shape of the hole at the end of
the Contact Tip. It should be an even circle;
it should not be oblong or have any bulges in it.
5. If any problems are noted, Contact Tip replacement
would be advisable. Make sure to select a
new Tip that is the correct size for the welding
wire used (.035″ tip for .030–.035″ wire).
6. Reinstall the Tip and securely
reinstall the Nozzle as well.
SKU 68887
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Page 23
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Troubleshooting
IMPORTANT!
Be CERTAIN to shut off the Welder, disconnect it from power, and discharge the Gun to ground
before adjusting, cleaning, or repairing the unit.
Wire Feed Motor Runs But Wire Does Not Feed Properly
POSSIBLE CAUSES AND SOLUTIONS
1. Insufficient wire feed tension:
Increase wire feed tension properly - follow number 16 on page 11.
2. Incorrect wire feed roll size:
Replace with the proper wire feed roll - follow the Wire Spool Installation instructions, starting on page 8.
Flip over wire feed roll if necessary.
3. Damaged Gun, cable, or liner assembly:
Have a qualified technician inspect these parts and replace as necessary.
Wire Creates A Bird’s Nest During Operation
POSSIBLE CAUSES AND SOLUTIONS
1. Excess wire feed tension:
Adjust wire feed tension properly - follow number 16 on page 11.
2. Incorrect contact tip size:
Replace with the proper tip for the wire.
3. Gun end not inserted into drive housing properly:
Loosen gun securing bolt and push gun end into housing just enough
so that it does not touch wire feed mechanism.
4. Damaged liner:
Have a qualified technician inspect and repair/replace as necessary.
Wire Feeds, But Arc Does Not Ignite
POSSIBLE CAUSES AND SOLUTIONS
1. Improper ground connection:
Make certain that the workpiece is contacted properly by the Ground Clamp and that the
workpiece is properly cleaned near the ground clamp and the welding location.
2. Improperly sized or excessively worn Contact Tip:
Verify that Contact Tip is the proper size for the wire. Check that the hole in the tip
is not deformed or enlarged. Also, check that the tip is not dirty; this would prevent a
good connection. If needed, replace Contact Tip with proper size and type.
Page 24
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SKU 68887
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TROUBLESHOOTING (continued)
IMPORTANT!
Be CERTAIN to shut off the Welder, disconnect it from power, and discharge the Gun to ground
before adjusting, cleaning, or repairing the unit.
Power Switch Lights,
But Welder Does Not Function When Switched On
POSSIBLE CAUSES AND SOLUTIONS
1. Tripped thermal protection device:
Shut the welder’s switch to off and allow it to cool for at least 20 minutes.
Reduce duration or frequency of welding periods to help reduce wear on the welder.
Refer to Duty Cycle section on page 14.
2. Faulty or improperly connected Trigger:
Qualified technician must check and secure/replace Trigger.
Power Switch Does Not Light When Switched On
POSSIBLE CAUSES AND SOLUTIONS
Unit is not connected to outlet properly or outlet is unpowered:
Verify the voltage at the outlet and the connection to the outlet.
If voltage is not present at outlet, check circuit breaker/GFCI devices; if any are tripped,
determine and remedy cause before resetting. Verify that the circuit is designed to
supply the required input amperage as detailed on the Specifications table.
Weak Arc Strength
POSSIBLE CAUSES AND SOLUTIONS
1. Incorrect line voltage:
Check the line voltage and, if insufficient, have a licensed electrician remedy the situation.
2. Improper gauge or length of extension cord:
Extension cords are not recommended. If possible, eliminate the use of an extension cord.
If an extension cord is needed, refer to the guidelines on page 6.
Welding Arc Not Stable
POSSIBLE CAUSES AND SOLUTIONS
1. Wire not feeding properly:
See first Troubleshooting section - Wire feed motor runs but wire does not feed properly.
2. Incorrect contact tip size:
Replace with the proper tip for .030″ wire.
3. Incorrect wire feed speed:
Adjust wire feed speed to achieve a more stable arc.
4. Loose Gun cable or ground cable:
Check to ensure that all connections are tight.
5. Damaged Gun or loose connection within Gun:
Have a qualified technician inspect and repair/replace as necessary.
6. Adjust current setting:
Make sure setting matches recommended setting on chart.
SKU 68887
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Page 25
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Parts Lists and Diagrams
Wiring Schematic
1 2 3
J
1 2 3 4
24V
T1
A
S1
R
Q
S2
MAX
MIN
B
C
b
Parts List
1
2
3
4
5
6
7
8
9
Grounding Cable
MIG Torch
Potentiometer Knob
Indicator
MIG Torch Holder
Font Panel
Left Panel
1
1
1
1
1
1
1
1
1
1
1
1
1
1
15 Heat Relay
16 Fan
17 Fan Motor
18 Bottom
19 Right Panel
20 Spool Holder
21 Fan Bracket
22 Control Transformer
23 PCB
24 PCB Holder
25 Cable Holder
26 Setting Switch
27 Power Cord
28 Switch
1
1
1
1
1
1
4
1
1
1
2
1
1
1
Middle Panel
Wire Feeder
10 Pin Latch
11 Latch Bracket
12 Top Cover
13 Handle
14 Transformer
REV 12a
Page 26
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SKU 68887
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Assembly Diagram
Part 9 Detail
9f (hidden by part 9e)
9e
9d
9c
9b
9a
Record Product’s Serial Number Here:
Note: If product has no serial number, record month and year of purchase instead.
Note: Some parts are listed and shown for illustration purposes only, and
are not available individually as replacement parts.
REV 12a
SKU 68887
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Page 27
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Limited 90 Day Warranty
Harbor Freight Tools Co. makes every effort to assure that its products meet high quality and durability standards,
and warrants to the original purchaser that this product is free from defects in materials and workmanship for the
period of 90 days from the date of purchase. This warranty does not apply to damage due directly or indirectly,
to misuse, abuse, negligence or accidents, repairs or alterations outside our facilities, criminal activity, improper
installation, normal wear and tear, or to lack of maintenance. We shall in no event be liable for death, injuries
to persons or property, or for incidental, contingent, special or consequential damages arising from the use of
our product. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the
above limitation of exclusion may not apply to you. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS.
To take advantage of this warranty, the product or part must be returned to us with transportation charges
prepaid. Proof of purchase date and an explanation of the complaint must accompany the merchandise.
If our inspection verifies the defect, we will either repair or replace the product at our election or we may
elect to refund the purchase price if we cannot readily and quickly provide you with a replacement. We will
return repaired products at our expense, but if we determine there is no defect, or that the defect resulted
from causes not within the scope of our warranty, then you must bear the cost of returning the product.
This warranty gives you specific legal rights and you may also have other rights which vary from state to state.
PLEASE READ THE FOLLOWING CAREFULLY
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM IN THIS MANUAL
AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER NOR DISTRIBUTOR MAKES ANY
REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO
MAKE ANY REPAIRS TO THE PRODUCT OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS
OF THE PRODUCT. IN FACT, THE MANUFACTURER AND/OR DISTRIBUTOR EXPRESSLY STATES
THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND
LICENSED TECHNICIANS AND NOT BY THE BUYER. THE BUYER ASSUMES ALL RISK AND LIABILITY
ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS
THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO.
3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-3353
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