Safety 90 AMP FLUX WIRE welder Read this material before using this product. Failure to do so can result in serious injury. Save this manual. Copyright© 2008 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.
NOTICE is used to address practices not related to personal injury. Save This Manual Safety Keep this manual for the safety warnings and precautions, assembly, operating, inspection, maintenance and cleaning procedures. Write the product’s serial number in the back of the manual near the assembly diagram (or month and year of purchase if product has no number). Keep this manual and the receipt in a safe and dry place for future reference.
Personal safety a. 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. a. 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. b.
5. Safety • Leather leggings, fire resistant shoes or boots should be worn when using this product. Do not wear pants with cuffs, shirts with open pockets, or any clothing that can catch and hold molten metal or sparks. Service a. 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. • Keep clothing free of grease, oil, solvents, or any flammable substances.
8. Avoid overexposure to fumes and gases. Always keep your head out of the fumes. Do not breathe the fumes. Use enough ventilation or exhaust, or both, to keep fumes and gases from your breathing zone and general area. • Where ventilation is questionable, have a qualified technician take an air sampling to determine the need for corrective measures. Use mechanical ventilation to improve air quality. If engineering controls are not feasible, use an approved respirator.
9. Safety Do not touch live electrical parts. Wear dry, insulating gloves. Do not touch welding wire or gun with bare hand. Do not wear wet or damaged gloves. Setup 10. Protect yourself from electric shock. Do not use outdoors. 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 big enough to cover your full area of contact with the work or ground. 11.
8. Protect the extension cords from sharp objects, excessive heat, and damp or wet areas. Symbology Extension Cords 1. 2. 3. 4. 5. Wire Feed (Speed) 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. Workpiece Ground Cable Gun Cable As the distance from the supply outlet increases, you must use a heavier gauge extension cord.
Specifications Safety Power Input Welding Output Capacity Setup Duty Cycle Open Circuit Voltage KVA Wire Speed Cable Sizes Basic Welding Welder Tips / Wire Size Wire Spool Capacity Internal Fuse Accessories 120 V~, 24 A (peak), 1-phase Connect to at least 20 A dedicated circuit DCEN MIN: 63 ~ 68 A MAX: 79 ~ 90 A HOT TIP welder 22 gauge (0.03”) to 3/16” (0.19”) mild steel only Not for welding aluminum or stainless steel 25% at MAX setting 45% at MIN setting (See explanation on page 16) 31 3.
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. Safety SETUP To prevent serious injury from accidental operation: Turn the Power Switch off and unplug the welder before assembly. Round Tab A A A. press the tabs through the holes and then Face Shield (viewed from front) B. slide the tabs forward from the back, locking the round tab in place. Handle Cover (31) Assembly 1.
Gun Wire Spool (27) Installation Safety 4 5 6 Turn the welder OFF and unplug it before proceeding. On mAx OFF 8 2 1. min 7 3 9 1 0 10 wire-Feed Speed 90 Amp Flux wire welder 120 V~ 60 Hz Cover (31) Setup 2. Press in the Cover Latch (8) on the front of the handle, then open the Cover (31). Cover Latch (8) Wire Spool (27) Basic Welding Wing Nut (25) 3. 4. Welding Tips 5. Remove the Wing Nut (25) and the Spool Retaining Nut (26).
Safety Setup Compare the wire diameter marked on the Wire Spool (27) with the stamped number on the top of the Feed Roller (34). 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. If it is not compatible or the number on the Roller is hidden: A Screws (45), Washers (46) A. Remove the Screws (45) and Washers (46) from the Feed Roller Bracket (44). B B. Remove the Feed Roller Bracket.
Safety 10. Swing the Wire Feed Swing Arm (36) closed, and swing the Feed Tensioner (37) across the tip of the Arm, to latch it. Make sure the Welding Wire is resting in the top groove of the Feed Roller (34), then turn the Feed Tensioner knob clockwise a couple of turns. After the wire is held by the Tensioner, you may release it. Feed Tensioner (37) Feed Swing Arm (36) Setup Gun 11. Pull the Nozzle (3) to remove it. 12.
2” Safety Gun 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 OFF, unplug it, slightly tighten the Feed Tensioner (37) clockwise, and try again. If the wire bends from the feed tension, then the tension is set properly. ” 2-3 Incrementally increase tension until wire bends. Gun 4 5 6 min On mAx OFF 7 3 17. Turn the welder OFF.
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 Basic 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.
Safety Control Panel Layout Gun Gun (1) Cable Overload Indicator (22) 5 6 min Wire Speed Dial (9) On 7 Power Switch (7a) 8 2 Setup 4 3 9 1 mAx 0 OFF 10 wire-Feed Speed Current Switch (7b) 90 Amp Flux wire welder 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) Setup .035” Wire Size (Flux Core, Mild Steel) Material Thickness (Steel) 22 Gauge 18 Gauge 16 Gauge 1 speed 0.5 speed MIN current 1.5 2 speed speed 1.5 2 speed speed 14 Gauge 4 speed 3 speed 1/ ” 8 3/ ” 16 MAX current 8 9 speed speed 8 9.
1. Safety Setting Up The Weld 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. clamps Use clamps (not included) to hold the workpieces in position so that you can concentrate on proper welding technique.
Gun Safety 6. Hold the Gun, without touching the Trigger, with the wire and tip clearly out of the way of any grounded objects. Then, turn the Power Switch ON. Hold Gun Clear 4 5 6 min On mAx OFF 7 3 8 2 9 1 0 10 wire-Feed Speed 90 Amp Flux wire welder 120 V~ 60 Hz Basic Welding Technique Setup 1. Press (and hold) Trigger and contact area to be welded with electrode wire to ignite arc. 2.
Gun 7 1 9 min On mAx OFF 8 2 0 concrete slab 10 (or other heat-proof, non-conductive surface) wire-Feed Speed 7. Safety 6 120 V~ 60 Hz After practice welding for a few seconds, STOP and examine your weld using the guidelines starting on the next page. After welding the test weld on a piece of scrap for a few seconds, stop, and check your progress.
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. Sparks or chips may fly when cleaning.
Inadequate Penetration 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) a. Use MAX setting 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 Safety 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. Setup Profile Views Basic Welding Possible Causes and Solutions 1. Workpiece overheating: Reduce wire feed speed. Use MIN setting. 2.
Top View Excessive Spatter 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 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.
Service Safety TO PREVENT SERIOUS INJURY, FIRE AND Gun 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. Setup Basic Welding 1. Periodically remove the Right and Left side panels (12 and 13), and using compressed air, blow out all dust from the interior. 2. Store in a clean and dry location. 3.
Remove the Nozzle as explained in the previous subheading. Using the third oval hole on the Multi-wrench (43), 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 (.035” tip for .030–.035” wire). Examine the shape of the hole at the end of the Contact Tip.
Troubleshooting Safety 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 Setup Possible Causes and Solutions 1. Insufficient wire feed tension: Increase wire feed tension properly - follow step 16 on page 13. 2.
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. Safety Troubleshooting (continued) a. WARNING! Turn the welder OFF and unplug it before proceeding. b. Press on the Cover Latch (8), then lift the Cover (31) using Handle (30). Remove Left Side Panel (13). c. Examine fuse on panel to see if metal wire inside is broken or not. See illustration.
Troubleshooting (continued) Safety 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 (7a) does not light when switched on Setup 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.
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. Safety Troubleshooting (continued) Weak Arc strength 2. 3. 4. 5. 6. Service 1. Possible Causes and Solutions Wire not feeding properly: See first Troubleshooting section - Wire feed motor runs but wire does not feed properly. Incorrect contact tip size: Replace with the proper tip for .030” wire.
Parts Lists and Diagrams Safety Wiring Schematic L1 N 1 2 PE Setup S1 4 3 CS 100 6 5 4 3 2 1 Basic Welding M Fan 4 Overload Indicator + A MIN/MAX S2 3 1 A B C S3 D Welding Tips T0 PT 5 6 E F T0 PT 2 Service Page 30 For technical questions, please call 1-800-444-3353.
Part 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 4 4 2 1 1 1 1 1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 Description Spool Spring Wing Nut, M6 Spool Retaining Nut Wire Spool Spool Spindle Screw, ST4.
Assembly Diagram 39 Safety Setup Welding Tips 50 Basic Welding Service Page 32 For technical questions, please call 1-800-444-3353.
36 Safety Detail of Part 23 37 Setup 35 44 Basic Welding 34 23 Welding Tips 45 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. SKU 98871 For technical questions, please call 1-800-444-3353.
Safety Limited 1 Year / 90 day warranty Setup Basic Welding Welding Tips 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 for a period of ninety days from date of purchase that the Gun, liner, wire feed mechanism (if applicable), welding clamps, electrode holders, cables and accessories packed with the welder are free of defects in materials and workmanship.
