Page 1
Page 2
Table of Contents
Safety ......................................................... 2
Specifications ............................................. 6
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP
Setup .......................................................... 7
Basic Welding ............................................ 12
Welding Tips .............................................. 18
Maintenance .............................................. 22
Parts List and Diagrams ............................ 25
Warranty .................................................... 28
WARNING SYMBOLS AND DEFINITIONS
This is the safety alert symbol. It is used to alert you to potential
personal injury hazards. Obey all safety messages that
follow this symbol to avoid possible injury or death.
Indicates a hazardous situation which, if not avoided,
will result in death or serious injury.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
Addresses practices not related to personal injury.
IMPORTANT SAFETY INFORMATION
Read all safety warnings and instructions.
Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.
Save all warnings and instructions for future reference.
General Safety Information
PROTECT yourself and others. Read and understand this information.
1. Before use, read and understand
manufacturer′s instructions,
Material Safety Data Sheets (MSDS),
employer′s safety practices, and ANSI Z49.1.
2. Keep out of reach of children.
Keep children and bystanders away while operating.
3. Place the Welder on a stable location before use.
If it falls while plugged in, severe injury,
electric shock, or fire may result.
4. Stay alert, watch what you are doing and use
common sense when operating a welder.
Do not use a welder while you are tired or under
the influence of drugs, alcohol or medication.
A moment of inattention while operating welders
may result in serious personal injury.
5. Do not overreach.
Keep proper footing and balance at all times.
6. Avoid unintentional starting. Make sure you are
prepared to begin work before turning on the Welder.
7. Never leave the Welder unattended while
energized. Turn power off if you have to leave.
8. The warnings, precautions, and instructions
discussed in this instruction manual cannot
cover all possible conditions and situations
that may occur. It must be understood by the
operator that common sense and caution are
factors which cannot be built into this product,
but must be supplied by the operator.
Page 2 For technical questions, please call 1-800-444-3353. Item 68887
Page 3
9. This product, when used for welding and similar
applications, contains or produces a chemical
known to the State of California to cause cancer
and birth defects (or other reproductive harm).
(California Health & Safety Code § 25249.5, et seq.)
Fume and Gas Safety Information
10. Handling the cord on this product will expose
you to lead, a chemical known to the State of
California to cause cancer, and birth defects or
other reproductive harm.
Wash hands after handling.
(California Health & Safety Code § 25249.5, et seq.)
FUMES AND GASES can be hazardous to your health.
1. Exposure to welding or cutting
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:
• Early onset of Parkinson’s Disease
• Heart disease • Ulcers
• Damage to the reproductive organs
• Inflammation of the small intestine or
stomach • Kidney damage
• Respiratory diseases such as
emphysema, bronchitis, or pneumonia
2. Do not use near degreasing or
painting operations.
3. Keep head out of fumes.
Do not breathe exhaust fumes.
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP
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.
5. Work in a confined area only if it
is well-ventilated, or while wearing
an air-supplied respirator.
6. Have a recognized specialist in
Industrial Hygiene or Environmental Services
check the operation and air quality
and make recommendations
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.
Arc Ray Safety Information
ARC RAYS can injure eyes and burn skin.
1. Wear ANSI-approved welding eye protection
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.
3. Keep clothing free of grease, oil,
solvents, or any flammable substances.
Wear dry, insulating gloves and protective clothing.
4. Wear an approved head covering to protect
the head and neck. Use aprons, cape, sleeves,
shoulder covers, and bibs designed and
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.
Page 3For technical questions, please call 1-800-444-3353.Item 68887
Page 4
Electrical Safety Information
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP
1. Turn off, disconnect power, and
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.
3. Connect to grounded, GFCI-protected
power supply only.
4. Do not use near water or damp objects.
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.
6. Do not expose welders to rain or wet conditions.
Water entering a welder will increase
the risk of electric shock.
ELECTRIC SHOCK can KILL.
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.
8. Do not use outdoors.
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.
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 Information
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.
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.
Make sure there is adequate
surrounding workspace. Keep the work area free
of obstructions, grease, oil, trash, and other debris.
4. Do not operate welders in atmospheres
containing dangerously reactive or
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.
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.
6. Do not weld or cut on materials having
a combustible coating or combustible
internal structure, as in walls or ceilings, without
an approved method for eliminating the hazard.
7. Do not dispose of hot slag in containers
holding combustible materials.
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.
Page 4 For technical questions, please call 1-800-444-3353. Item 68887
Page 5
Operation Specific Safety Information
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.
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.
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.
Service Specific Safety Information
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.
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.
4. Store idle Welder 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.
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. 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.
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP
SAVE THESE INSTRUCTIONS.
Page 5For technical questions, please call 1-800-444-3353.Item 68887
Page 6
Grounding
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP
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.
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.
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.
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.
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.
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.
Specifications
Electrical Rating 120 V~ / 20 A
Welding Output 60 ~ 120 A, AC
Capacity
Duty Cycle
Open Circuit Voltage 27
KVA 2.38
Welder Tips / Wire Size Installed tip will accept 0.030" Flux-Core wire
Wire Spool Capacity 4" diameter / 2 lb. spool
Page 6 For technical questions, please call 1-800-444-3353. Item 68887
18 gauge (0.048") to 3/16" (0.19") mild steel only
Not for welding aluminum or stainless steel
20% @ 90 A
(See explanation on page 14)
Page 7
Symbology
Setup
V
Wire Feed (Speed)
Workpiece Ground Cable
Gun Cable
Overheat Shutdown Indicator
Cooling Fan
Housing Ground Point
Volts
~
A
OCV
KVA
IPM
AWG
Alternating Current
Amperes
Open Circuit Voltage
Kilovolt Amperes
(Volts / 1000 * Amperes)
Inches Per Minute
American Wire Gauge
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS 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.
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.
3. Secure with Screw at front of unit.
Notch drops
into slot on
Cover here
Handle
Cover
Screw
Page 7For technical questions, please call 1-800-444-3353.Item 68887
Page 8
Wire Spool Installation
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP
1. Turn the Welder to OFF and unplug
it before proceeding.
2. Press in the pin at the top center of
the control panel and open the Cover.
ITEM 68887
ON MIN
OFF MAX
Specications
Wire 0.030" – 0.035" Flux-Core
Capacity 18 Ga. – 3/16" Steel Plate
Weldable
Mild, Low Alloy Steel
(Not for Aluminum or Stainless Steel)
Materials
Cover
Wire
Spool
3. Remove the Knob, Spring and the Top Plate.
If replacing a Spool, remove the old Spool
and all remaining wire from the liners.
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.
Knob
Spring
Top Plate
Wire Spool
Spindle
.030″
wire must
unwind in this
direction
Page 8 For technical questions, please call 1-800-444-3353. Item 68887
Page 9
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.
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. 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.
.030″
Feed Swing
Arm
Feed
Knob
Feed
Tensioner
Feed
Roller
.030″
.030″
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP
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.
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.
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
Tensioner, you may release it.
Wire
Liner
.030″
Feed Swing
Arm
HOLD WIRE
SECURELY
welding
wire
.030″
leader
wire liner
Wire
Spool
Feed
Tensioner
.030″
11. Pull the Nozzle to remove it.
12. Turn the Contact Tip
counterclockwise and remove.
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.
Gun
Nozzle
Contact
Tip
Page 9For technical questions, please call 1-800-444-3353.Item 68887
Page 10
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP
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.
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.
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.
Welding
Wire
2″
ON MIN
OFF MAX
Specications
Wire 0.030" – 0.035" Flux-Core
Capacity 18 Ga. – 3/16" Steel Plate
Weldable
Mild, Low Alloy Steel
(Not for Aluminum or Stainless Steel)
Materials
Gun
Page 10 For technical questions, please call 1-800-444-3353. Item 68887
Page 11
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.
If the wire bends from the feed tension,
then the tension is set properly.
17. TURN THE WELDER TO OFF.
.030″
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP
Incrementally
increase tension
until
2-3″
wire bends.
ITEM 68887
ON MIN
OFF MAX
Specications
Wire 0.030" – 0.035" Flux-Core
Capacity 18 Ga. – 3/16" Steel Plate
Weldable
Mild, Low Alloy Steel
(Not for Aluminum or Stainless Steel)
Materials
18. Select a Contact Tip that is compatible with the
welding wire used. The included Tip (0.030")
will work with 0.030" flux-core wire only. To
use 0.035" wire install a 0.035 tip (both sold
separately). Slide the Contact Tip over the
wire and thread it clockwise into the Gun.
19. Replace the Nozzle and cut the wire
off at 1/2" from tip (1/2" stickout).
20. Swing the Cover closed until the
Cover Latch locks in place.
Gun
Nozzle
Contact
Tip
Page 11For technical questions, please call 1-800-444-3353.Item 68887
Page 12
Basic Welding
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP
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.
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,
FIRE AND BURNS:
Keep welding tip clear of grounded
objects whenever unit is plugged in.
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.
Make practice welds on pieces of scrap to practice
technique before welding anything of value.
ON MIN
OFF MAX
Specications
0.030" – 0.035" Flux-Core
18 Ga. – 3/16" Steel Plate
Mild, Low Alloy Steel
(Not for Aluminum or Stainless Steel)
=
Practice your welding
technique on scrap
pieces before welding
anything of value.
Page 12 For technical questions, please call 1-800-444-3353. Item 68887
Page 13
Control Panel Layout
Gun
Cable
Wire
Speed
Dial
Ground
Cable
GUN
90 AMP FLUX WIRE WELDER
WIRE FEED SPEED
GROUND
ITEM 68887
ON MIN
OFF MAX
Wire 0.030" – 0.035" Flux-Core
Capacity 18 Ga. – 3/16" Steel Plate
Weldable
Materials
Specications
Mild, Low Alloy Steel
(Not for Aluminum or Stainless Steel)
120V~
60Hz
20A
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP
Overload
Indicator
Current
Switch
Power
Switch
Power
Cord
Gun Cable:
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.
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.)
Ground Cable:
This connects to the base metal to provide a good
connection for the current to travel back to the Welder.
Overload Indicator:
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.
Current Switch:
This controls the output amperage of the Welder.
Adjust this according to the weld settings
chart to achieve a good weld.
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.
Page 13For technical questions, please call 1-800-444-3353.Item 68887
Page 14
Weld Settings Chart
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP
NOTE: The numbers within the
spaces are the approximate wire
feed settings recommended*
for this wire size and material
thickness.
18 Gauge 16 Gauge 14 Gauge
0.030″ Wire Size
(Flux-Core, Mild Steel)
0.035″ Wire Size
(Flux-Core, Mild Steel)
* 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 (90 A) 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.
1.5
speed
1.5
speed
Material Thickness (Steel)
1
/8"
MIN current MAX current
2
speed
2
speed
4
speed
3
speed
20% Rated Duty Cycle
at 90 A output
2 minutes welding
followed by
at least 8 minutes of rest
8
speed
8
speed
3
/16"
9
speed
9.5
speed
This Welder has an internal thermal protection
system to help prevent this sort of over-stress.
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.
ITEM 68887
ON MIN
OFF MAX
Specications
Wire 0.030" – 0.035" Flux-Core
Capacity 18 Ga. – 3/16" Steel Plate
Weldable
Mild, Low Alloy Steel
(Not for Aluminum or Stainless Steel)
Materials
Gun
concrete slab
(or other heat-proof,
non-conductive
surface)
Page 14 For technical questions, please call 1-800-444-3353. Item 68887
Page 15
MIN
MAX
GUN
90 AMP FLUX WIRE WELDER
Flux-Core
Plate
Stainless Steel)
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
be no rust, paint, oil, or other materials on
the weld surfaces, only bare metal.
2. Use clamps (not included) to hold the workpieces
in position so that you can concentrate on
proper welding technique. The distance
(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.
3. Clamp Ground Cable to bare metal on the
workpiece near the weld area, or to metal work
bench where the workpiece is clamped.
GUN
90 AMP FLUX WIRE WELDER
WIRE FEED SPEED
GROUND
Clamps
Workpieces
Clean
surfaces to
bare metal.
Chamfer thick workpieces.
ITEM 68887
ON MIN
OFF MAX
Specications
Wire 0.030" – 0.035" Flux-Core
Capacity 18 Ga. – 3/16" Steel Plate
Weldable
Mild, Low Alloy Steel
(Not for Aluminum or Stainless Steel)
Materials
120V~
60Hz
20A
Ground
Clamp
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP
Workpiece
Clean
surface to
bare metal.
4. Set the Wire Speed Dial and
5. Flip the Power Switch to the OFF position, then plug
6. Hold the Gun, without touching the Trigger, with the
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.
the Welder into a dedicated, 120 V~, 20 A circuit
with delayed action type circuit breaker or fuses.
wire and tip clearly away from any grounded objects.
Then, turn the Power Switch to ON.
WIRE FEED SPEED
GROUND
ITEM 68887
ON MIN
OFF MAX
Specications
Wire 0.030" – 0.035" Flux-Core
Capacity 18 Ga. – 3/16" Steel Plate
Weldable
Mild, Low Alloy Steel
(Not for Aluminum or Stainless Steel)
Materials
HOLD
GUN
CLEAR
ITEM 68887
ON
OFF
Specications
Wire 0.030" – 0.035"
Capacity 18 Ga. – 3/16" Steel
Weldable
Mild, Low Alloy Steel
(Not for Aluminum or
Materials
ITEM 68887
ON MIN
OFF MAX
+
Specications
Wire 0.030" – 0.035" Flux-Core
Capacity 18 Ga. – 3/16" Steel Plate
Weldable
Mild, Low Alloy Steel
(Not for Aluminum or Stainless Steel)
Materials
20 Amp minimum circuit
ITEM 68887
Wire 0.030" – 0.035" Flux-Core
Capacity 18 Ga. – 3/16" Steel Plate
Weldable
Materials
ON MIN
OFF MAX
Specications
Mild, Low Alloy Steel
(Not for Aluminum or Stainless Steel)
Page 15For technical questions, please call 1-800-444-3353.Item 68887
Page 16
Basic Welding Technique
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP
1. Press (and hold) Trigger and contact area to
be welded with electrode wire to ignite arc.
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.
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 Information
on page 3 for guidelines) is used, then
both hands can be used to control Gun.
stringer bead weave bead
Weld Gun angles,
viewed from front of weld joint.
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.
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.
6. The welding wire should extend no more than 1/2"
past the tip.
This distance is called stickout or CTWD
– Contact Tip to Work Distance.
45°
fillet weld joint
Drag Angle
0-15°
Weld
Direction
90°
butt weld joint
Stickout
(up to 1/2")
Page 16 For technical questions, please call 1-800-444-3353. Item 68887
Page 17
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.
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 Duty Cycle
guidelines as explained on page 14.
ITEM 68887
Gun
ON MIN
OFF MAX
Specications
Wire 0.030" – 0.035" Flux-Core
Capacity 18 Ga. – 3/16" Steel Plate
Weldable
Mild, Low Alloy Steel
(Not for Aluminum or Stainless Steel)
Materials
concrete slab
(or other heat-proof,
non-conductive
surface)
After practice welding for a few
seconds, STOP and examine
your weld using the guidelines
starting on the next page.
FOLLOW DUTY CYCLE!
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP
8. When the weld is complete,
lift the Gun and welding wire clearly away from any
grounded object, and turn the Power Switch off.
9. Set the Gun down on a heat-proof, electrically
non-conductive surface. Unplug the Power Cord.
HOLD
GUN
CLEAR
Gun
up to 2 minutes welding
at rated output
ITEM 68887
Wire 0.030" – 0.035" Flux-Core
Capacity 18 Ga. – 3/16" Steel Plate
Weldable
Materials
ON MIN
OFF MAX
Specications
Mild, Low Alloy Steel
(Not for Aluminum or Stainless Steel)
120V~
concrete slab
(or other heat-proof,
non-conductive
surface)
Page 17For technical questions, please call 1-800-444-3353.Item 68887
Page 18
Welding Tips
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP
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 welding technique
to remedy any problems found.
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.
Strike Test
A test weld on a PIECE OF SCRAP can be
tested by using the following procedure.
WEAR ANSI-APPROVED SAFETY GOGGLES
DURING THIS PROCEDURE.
A typical Flux-Core Wire (FCAW) Weld
slag
dead-blow hammer
before cleaning.
weld bead
spatter
base metal
clamp
SCRAP
workpiece
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.
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.
3. A GOOD WELD will deform but not break,
as shown on top.
A POOR WELD will be brittle and snap
at the weld, as shown on bottom.
Page 18 For technical questions, please call 1-800-444-3353. Item 68887
dead-blow hammer
GOOD WELD
bends and is not brittle
clamp
SCRAP
workpiece
POOR WELD
snaps or cracks
Page 19
Weld Diagnosis
ON MIN
OFF MAX
GUN
90 AMP FLUX WIRE WELDER
ITEM 68887
Specications
OFF
Workpiece Heat Control / Weld Penetration
Not hot enough Too hotIdeal heat
How to increase workpiece heat
and increase penetration:
(to weld THICKER workpieces properly)
a. Use MAX setting
b. Weld more slowly
c. Use faster wire feed
d. Use shorter stickout
Example Weld Diagrams
PROPER PENETRATIONINADEQUATE PENETRATION
EXCESS PENETRATION OR
BURN-THROUGH
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP
How to reduce workpiece heat
and limit penetration:
(to weld THINNER workpieces properly)
a. Use MIN setting
b. Weld more quickly
c. Use slower wire feed
d. Use longer stickout
Good
Weld
Current
Too Low
TO CORRECT:
ON MIN
OFF MAX
Flux-Core
Ga. – 3/16" Steel Plate
Current
Too High or
Wire Feed
Too Fast
TO CORRECT:
ON MIN
MAX
Flux-Core
or
Weld Speed
Too Fast
TO CORRECT:
weld
slower
Weld Speed
Too Slow
TO CORRECT:
weld
faster
Stickout
Too Long
TO CORRECT:
maintain
less
than 1/2"
stickout
Page 19For technical questions, please call 1-800-444-3353.Item 68887
Page 20
Weld Problems
Penetration (Workpiece Heat Control)
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP
EXCESS PENETRATION OR
BURN-THROUGH
Weld droops on top and
underneath or falls through
entirely, making a hole.
POSSIBLE CAUSES AND SOLUTIONS
1. Workpiece overheating:
Reduce wire feed speed.
Use MIN setting.
2. Welding speed too slow:
Increase welding speed and ensure
that welding speed is kept steady.
3. Excessive material at weld:
Reduce wire feed speed.
PROPER PENETRATION
Weld is visible underneath and
bulges slightly on top.
PROFILE VIEWS
POSSIBLE CAUSES AND SOLUTIONS
1. Incorrect welding technique:
Maintain 1/2" or less stickout.
Keep arc on leading edge of weld puddle.
Hold gun at proper angles.
2. Insufficient weld heat:
Reduce welding speed.
Use MAX setting.
3. Workpieces too thick/close:
Bevel thick workpieces, allow slight
gap, and weld in several passes.
4. Insufficient weld material:
Increase wire feed speed.
INADEQUATE PENETRATION
Weld does not contact the joint
fully, just on the surface.
Weld Not Adhering Properly
Gaps present between weld and previous bead or
between weld and workpiece. See areas below.
PROFILE
VIEW
POSSIBLE CAUSES AND SOLUTIONS
1. Incorrect welding technique:
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.
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.
Bend at Joint
PROFILE
VIEW
POSSIBLE CAUSES AND SOLUTIONS
1. Improper clamping:
Clamp workpieces securely.
Make tack welds to hold workpieces.
2. Excessive heat:
Weld a small portion and allow to cool before
proceeding.
Increase weld speed.
Reduce wire feed speed.
Page 20 For technical questions, please call 1-800-444-3353. Item 68887
Page 21
Coat of Slag Over Weld
TOP
VIEW
PARTIALLY CHIPPED AWAY TO SHOW WELD
Slag is a necessary part of a fluxcore wire weld. It shields the weld from
impurities. Clean off the slag with the Chipping
Hammer and Wire Brush after welding.
Porosity
Small cavities or holes in the bead.
Excessive Spatter
Fine spatter is normal.
Spatter that is grainy and large is a problem.
TOP
VIEW
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP
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.
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.
2. Inconsistent welding speed:
Maintain steady weld speed.
3. Stickout too long:
Reduce stickout.
Crooked/Wavy Bead
TOP
VIEW
Burn-Through
Base material melts away,
leaving a hole in the weld.
TOP
VIEW
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.
3. Excessive material at weld:
Reduce wire feed speed.
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.
Page 21For technical questions, please call 1-800-444-3353.Item 68887
Page 22
Maintenance
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP
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.
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.
2. Turn the Nozzle counterclockwise
while pulling to remove.
5. Reinstall the Nozzle after inspecting
and cleaning the Contact Tip.
+
Gun
concrete slab
(or other heat-proof,
non-conductive
surface)
Gun
3. Scrub the interior of the Nozzle
clean with a wire brush.
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.
Nozzle
Contact
Tip
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. Turn the Contact Tip
counterclockwise and slide it off the welding wire.
3. Scrub the exterior of the Tip clean with a wire brush.
Clean out the inside of the Tip with a tip cleaner
(sold separately). Check that the Tip is the proper
type for the wire size used. The included 0.030"
Tip is for 0.030" wire. Install a 0.035" Tip for
use with 0.035" wire (both sold separately).
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 (0.030" Tip for
0.030" wire – 0.035" Tip for 0.035" wire).
6. Reinstall the Tip and securely
reinstall the Nozzle as well.
Nozzle
Contact
Tip
Gun
Page 22 For technical questions, please call 1-800-444-3353. Item 68887
Page 23
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.
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP
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.
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.
Page 23For technical questions, please call 1-800-444-3353.Item 68887
Page 24
Troubleshooting (continued)
IMPORTANT!
Be CERTAIN to shut off the Welder, disconnect it from power, and discharge the Gun to ground
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP
before adjusting, cleaning, or repairing the unit.
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 0.030" 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.
Page 24 For technical questions, please call 1-800-444-3353. Item 68887
Page 25
Parts List and Diagrams
Wiring Schematic
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP
S1
1 2 3 4
24V
1 2 3
1
2 3 4
G
J
T1
A
S2
MAX
MIN
R
Q
B
C
b
Page 25For technical questions, please call 1-800-444-3353.Item 68887
Page 26
Parts List and Diagrams (continued)
PLEASE READ THE FOLLOWING CAREFULLY
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP
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.
Parts List
1 Ground Clamp and Cable 1
2 MIG Torch 1
3 Potentiometer Knob 1
4 Overload Indicator 1
5 MIG Torch Cable Grommet 1
6 Front Panel 1
7 Left Panel 1
8 Middle Panel 1
9 Wire Feeder 1
9a Feed Tensioner 1
9b Swing Arm 1
9c Tension Roller 1
9d Liner 1
9e Feed Knob 1
9f Feed Roller 1
10 Cover Latch 1
11 Cover Latch Bracket 1
12 Top Cover 1
13 Handle 1
14 Transformer 1
15 Heat Relay 1
16 Fan 1
17 Fan Motor 1
18 Back Panel 1
19 Right Panel 1
20 Spool Holder 1
21 Foot 4
22 Control Transformer 1
23 PCB 1
24 PCB Holder 1
25 Cable Grommet 2
26 Current Switch 1
27 Power Switch 1
28 Power Cord 1
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.
Page 26 For technical questions, please call 1-800-444-3353. Item 68887
Page 27
Assembly Diagram
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP
Part 9 Detail
9f (hidden by part 9e)
.030″
9b9c
9e
9d
9a
Page 27For technical questions, please call 1-800-444-3353.Item 68887
Page 28
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.
3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-3353
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