Table of Contents SAFETY Safety.......................................................... 2 Specifications.............................................. 7 Setup........................................................... 7 Basic Welding............................................. 12 Welding Tips............................................... 18 Maintenance............................................... 22 Parts Lists and Diagrams........................... 26 Warranty.....................................
SAFETY Fume and Gas Safety FUMES AND GASES can be hazardous to your health. 2. Do not use near degreasing or painting operations. 3. Keep head out of fumes. Do not breathe exhaust fumes. 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.
Electrical Safety ELECTRIC SHOCK can KILL. SAFETY 1. Turn off, disconnect power, and discharge electrode to ground before setting down torch/electrode holder and before service. 6. Do not expose welders to rain or wet conditions. Water entering a welder will increase the risk of electric shock. 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.
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. 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. SETUP 2.
Grounding SAFETY 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 SETUP 1.
Specifications Capacity Duty Cycle SETUP Open Circuit Voltage KVA Welder Tips / Wire Size Wire Spool Capacity 120V~ / 20A 60 ~ 120 A, AC 18 gauge (0.048″) to 3/16″ (0.19″) mild steel only Not for welding aluminum or stainless steel 20% @ 90A (See explanation on page 14) 27 2.38 Installed tip will accept .030″ to .035″ FLUX CORE wire 4″ diameter / 2 lb.
Wire Spool Installation GUN 90 AMP FLUX WIRE WELDER ITEM 68887 SAFETY 1. Turn the Welder to OFF and unplug it before proceeding. WIRE FEED SPEED ON MIN OFF MAX Wire .030″-.035″ Flux-core Capacity XX Ga. – X/X″ Steel Plate Electrode – X′ Cables Ground Clamp – X′ GROUND 120V~ 60Hz 20A Cover SETUP 2. Press in the pin at the top center of the control panel and open the cover. Wire Spool BASIC WELDING Knob 3. Remove the Knob, Spring and the Top Plate.
0″ 0″ .03 Feed Swing Arm 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 .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. SAFETY .03 6.
SAFETY 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. SETUP 2. Do not touch internal welder components while it is plugged in. GUN 90 AMP FLUX WIRE WELDER BASIC WELDING 14. Do not touch the Gun’s Trigger. Plug the Power Cord into its electrical outlet and turn the welder to ON.
SAFETY 0″ .03 Incrementally increase tension until wire bends. 2-3 ″ SETUP 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. GUN 90 AMP FLUX WIRE WELDER ITEM 68887 MIN OFF MAX BASIC WELDING WIRE FEED SPEED Wire .030″-.
Basic Welding SAFETY Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before welding. SETUP 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.
GUN 90 AMP FLUX WIRE WELDER Overload Indicator ITEM 68887 Current Switch WIRE FEED SPEED MAX Wire .030″-.035″ Flux-core Capacity XX Ga. – X/X″ Steel Plate Electrode – X′ Cables Ground Clamp – X′ Power Switch BASIC WELDING OFF GROUND 120V~ 60Hz 20A Ground Cable 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.
Weld Settings Chart SAFETY NOTE: The numbers within the spaces are the approximate wire feed settings recommended* for this wire size and material thickness. .030″ Wire Size (Flux Core, Mild Steel) .035″ Wire Size (Flux Core, Mild Steel) Material Thickness (Steel) 18 Gauge 16 Gauge 14 Gauge MIN current 1.5 2 4 speed speed speed 1.5 2 3 speed speed speed 1/ ″ 8 3/ ″ 16 MAX current 8 9 speed speed 8 9.
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. SAFETY Setting Up The Weld clamps workpieces 2. Use clamps (not included) to hold the workpieces in position so that you can concentrate on proper welding technique.
Basic Welding Technique SAFETY 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. stringer bead weave bead For a wider weld, draw the wire back and forth across the joint, this is called a weave bead. SETUP BASIC WELDING 3. Hold Gun in one hand and the face shield in the other.
GUN ITEM 68887 Gun MIN concrete slab MAX SAFETY Note: If Welder is used too long, the amber Overload 90 AMP FLUX WIRE WELDER Indicator will light and the Welder Gun will shut off until the welder cools. If this happens, rest the Gun on 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.
Welding Tips SAFETY 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 SETUP TO PREVENT SERIOUS INJURY: Continue to wear ANSI-approved safety goggles and protective wear when cleaning a weld.
Weld Diagnosis PROPER PENETRATION EXCESS PENETRATION OR BURN-THROUGH Not hot enough Ideal heat Too hot How to increase workpiece heat and increase penetration: How to reduce workpiece heat and limit penetration: (to weld THICKER workpieces properly) (to weld THINNER workpieces properly) c. Use faster wire feed a. Use MIN setting c. Use slower wire feed b. Weld more slowly d. Use shorter stickout b. Weld more quickly d.
Weld Problems Penetration (Workpiece Heat Control) SAFETY 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 SETUP BASIC WELDING POSSIBLE CAUSES AND SOLUTIONS 1. Workpiece overheating: Reduce wire feed speed. Use MIN setting. 2.
Coat of Slag Over Weld Excessive Spatter 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 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. Wire feeding too fast: Reduce wire feed speed. 3.
Maintenance SAFETY 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. SETUP 2. Store in a clean and dry location. 3.
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. 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. Nozzle Contact Tip SETUP 3.
Troubleshooting IMPORTANT! SAFETY 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 SETUP 1. Insufficient wire feed tension: Increase wire feed tension properly - follow number 16 on page 11. 2.
TROUBLESHOOTING (continued) Power Switch Lights, But Welder Does Not Function When Switched On SETUP 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.
Parts Lists and Diagrams Wiring Schematic SAFETY J G 1 2 3 4 1 2 3 1234 SETUP 24V T1 A BASIC WELDING S1 R Q S2 WELDING TIPS MAX B MIN C b Parts List MAINTENANCE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Grounding Cable MIG Torch Potentiometer Knob Indicator MIG Torch Holder Font Panel Left Panel Middle Panel Wire Feeder Pin Latch Latch Bracket Top Cover Handle Transformer 1 1 1 1 1 1 1 1 1 1 1 1 1 1 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Heat Relay Fan Fan Motor Bottom Right Panel Spool H
BASIC WELDING SETUP SAFETY Assembly Diagram Part 9 Detail 9e 9d WELDING TIPS 9f (hidden by part 9e) 9b MAINTENANCE .03 0″ 9c 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 For technical questions, please call 1-800-444-3353.
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.
