90 AMP Flux Wire welder
94056
Set up and Operating Instructions
Distributed exclusively by Harbor Freight Tools®.
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit our website at: http://www.harborfreight.com
Read this material before using this product. Failure to do so can result in serious injury. Save this manual.
Copyright© 2005 by Harbor Freight Tools®. All rights reserved. No portion of this manual or any artwork contained herein may be reproduced in any shape or form without the express written consent of Harbor Freight Tools. Diagrams within this manual may not be drawn proportionally. Due to continuing improvements, actual product may differ slightly from the product described herein. Tools required for assembly and service may not be included.
For technical questions or replacement parts, please call 1-800-444-3353.
REV 06g, 09e, 09h
Specifications
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.8 mm wire on 16 ga. |
104.3/95.5 A |
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Welding Current |
sheet steel |
(Max/Min Setting) |
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.8 mm wire on 1/4” |
103.7/103.1 A |
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steel plate |
(Max/Min Setting) |
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Duty Cycle |
10% @ 90 Amps (Max Setting) or |
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10% @ 80 Amps (Min Setting, actual 11%) |
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Power Consumption |
120 V~, 24 A |
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Ground Cable |
4 AWG, single insulation, 6’ |
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Torch Power Cable |
8 AWG, single insulation, 6’ |
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Thermal Overload |
Both settings: |
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10 min. shutdown, 3 min. back on with Light |
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Welder Tip |
0.030”; Spare: Welder Tip 0.035”; |
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Will also accept a 0.023” welder tip (not included) |
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Wire Size |
0.030” flux core wire (using 0.030” Welder Tip) |
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Wire Spool Size |
4” diameter |
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Overall Dimensions |
14-1/2” (L) x 7-7/8” (W) x 15-1/2” (H) |
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Weight |
34.45 lb. |
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Accessories |
Spare Welder Tip (0.035”) |
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Note: Performance of this tool may vary depending on variations in local line voltage.
Extension cord usage may also affect tool performance.
Save This Manual
You will need the manual for the safety warnings and precautions, assembly instructions, operating and
maintenance procedures, parts list and diagram. Keep your invoice with this manual. Write the invoice number on the inside of the front cover. Keep the manual and invoice in a safe and dry place for future reference.
Safety Warnings and
Precautions
WARNING: When using tool, basic safety precautions should always be followed to reduce the risk of personal injury and damage to equipment.
Read all instructions before using this tool!
1.Keep work area clean. Cluttered areas invite injuries.
2.Observe work area conditions. Do not use machines or power tools in damp or wet locations. Don’t expose to rain. Keep work area well lighted. Do not use electrically powered tools in the presence of flammable gases or liquids.
3.Keep children away. Children must never be allowed in the work area.
Do not let them handle machines, tools, or extension cords.
4.Store idle equipment. When not in use, tools must be stored in a dry location to inhibit rust. Always lock up tools and keep out of reach of children.
5.Do not force tool. It will do the job better and more safely at the rate
For technical questions, please call 1-800-444-3353. |
Page 2 |
for which it was intended. Do not use inappropriate attachments in an attempt to exceed the tool capacity.
6.Use the right tool for the job. Do not attempt to force a small tool or attachment to do the work of a larger industrial tool. There are certain applications for which this tool was designed. Do not modify this tool and do not use this tool for a purpose for which it was not intended.
7.Dress properly. Do not wear loose clothing or jewelry as they can be caught in moving parts. Protective, electrically nonconductive clothes and nonskid footwear are recommended when working. Wear restrictive hair covering to contain long hair.
8.Use eye and ear protection. Always wear ANSI-approved, arc-shaded, impact safety face shield. Always use the full face shield when welding.
Wear a NIOSH-approved dust mask or respirator when working around metal, chemical dusts, fumes and mists.
9.Do not overreach. Keep proper footing and balance at all times. Do not reach over or across running machines.
10.Maintain tools with care. Keep tools sharp and clean for better and safer performance. Follow instructions for lubricating and changing accessories. Inspect tool cords periodically and, if damaged,
have them repaired by an authorized technician. The handles must be kept clean, dry, and free from oil and grease at all times.
REV 06g
11.Disconnect power. Unplug tool when not in use.
12.Remove adjusting keys and wrenches. Check that keys and adjusting wrenches are removed from the tool or machine work surface before plugging it in.
13.Avoid unintentional starting. Be sure the switch is in the Off position when not in use and before plugging in. Do not carry any tool with your finger on the trigger, whether it is plugged in or not.
14.Stay alert. Watch what you are doing, use common sense. Do not operate any tool when you are tired.
15.Check for damaged parts. Before using any tool, any part that appears damaged should be carefully checked to determine that it will operate properly and perform its intended function. Check for alignment and binding of moving parts; any broken parts or mounting fixtures; and any other condition that may affect proper operation. Any part that is damaged should be properly repaired or replaced by a qualified technician. Do not use the tool if any switch does not turn On and Off properly.
16.Guard against electric shock.
Prevent body contact with grounded surfaces such as pipes, radiators, ranges, and refrigerator enclosures.
17.Replacement parts and accessories. When servicing, use only identical replacement parts. Use of any other parts will void the warranty. Only use accessories intended for use with this tool.
SKU 94056 |
For technical questions, please call 1-800-444-3353. |
Page 3 |
Approved accessories are available from Harbor Freight Tools.
18.Do not operate tool if under the influence of alcohol or drugs.
Read warning labels on prescriptions to determine if your judgment or reflexes are impaired while taking drugs. If there is any doubt, do not operate the tool.
19.Maintenance. For your safety, service and maintenance should be performed regularly by a qualified technician.
20.Use proper size and type extension cord. If an extension cord is required, it must be of the proper size and type to supply the correct current to the tool without heating up. Otherwise, the extension cord could melt and catch fire, or cause electrical damage to the tool. This tool requires use of an extension cord of 20 amps minimum capability (up to 30 feet), with wire size rated at 12
AWG. Longer extension cords require larger size wire. If you are using the tool outdoors, use an extension cord rated for outdoor use (signified by
“WA” on the jacket).
21.Avoid electrical shock. Do not permit electrically live parts, cables, or electrodes to contact skin, clothing, or gloves. Protective clothing should be hole-free, dry, and ANSI-approved.
This unit draws enough current to cause serious injury or death. Before turning the welder on, check the electrode holder to be sure that there are no protruding screw heads, and that all insulation is secure. Do not weld unless you are insulated from ground and the work piece.
WARNING
Inhalation Hazard:
Welding and Plasma Cutting Produce toxic fumes.
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 plasma 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
Use natural or forced air ventilation and wear a respirator approved by NIOSH to protect against the fumes produced to reduce the risk of developing the above illnesses.
22.Avoid breathing fumes or gases. They can cause serious health problems. Use an active ventilation system directly above the welding area. Keep your head out of the fumes.
23.Avoid eye and body damage.
Welding rays and infrared radiation can injure eyes and burn skin. Wear ANSI-approved eye and body protection. Do not allow viewing by visitors without proper eye and body
protection. Use a face shield with arcshaded filter plate.
SKU 94056 |
For technical questions, please call 1-800-444-3353. |
Page 4 |
24.Know proper welding practices. Read and understand the manufacturer’s instructions, as well as your employer’s safety practices for welding.
25.Connect only to a code approved power source. Connect only to a grounding power source conforming to the National Electrical Code and
Local Codes.
26.Avoid fire and explosion. Remove flammable and explosive material from at least 35 feet from the welding site to prevent welding sparks or molten metal from starting a fire. Keep a type ABC fire extinguisher within easy reach. Thoroughly clean the object being welded of any paint, grease, or other foreign material.
27.Avoid being burned. Always wear ANSI-approved welding gear: leather gloves, leather apron, and shoes.
28.WARNING: This product, when used for welding, plasma cutting, soldering, or similar applications, produces chemicals known to the State of California to cause cancer and birth defects (or other reproductive harm).
(California Health & Safety Code § 25249.5, et seq.)
29.The warnings, cautions, 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.
Unpacking
When unpacking, check to make sure the item is intact and undamaged. If any parts are missing or broken, please call
Harbor Freight Tools at 1-800-444-3353 as soon as possible.
Assembly
Cover (31)
Handle (30)
Wire
Cover Reel (27)
Locking
Spring (8)
1.Attach the Handle (30) to the Cover
(31) using screw (29) inserted from the
Handle top-rear.
2.Attach the Cover Locking Spring (8) to the front of the Base Frame (14) using the supplied self-tapping screw.
SKU 94056 |
For technical questions, please call 1-800-444-3353. |
Page 5 |
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