Flux Wire Welder

8/2/2019 Flux Wire Welder

1/34

90 AMP FLUX WIRE WELdERModel 98871

SEt UP And OPERAtIng InStRUctIOnS

Visi our websie a: p://www.arborfrei.om

Rea is maerial before usi is prou.Failure o o so a resul i serious iur.SAVE thIS MAnUAL.

Copyright2008 by Harbor Freight Tools. All rights reserved. No portion of this manual or any artworkcontained herein may be reproduced in any shape or form without the express written consent ofHarbor 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 forassembly and service may not be included.

For eial uesios or replaeme pars, please all 1-800-444-3353.

Maual Revise 10


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Page 3For eial uesios, please all 1-800-444-3353.SKU 98871

do o abuse e or. never used.e or for arri, pulli oruplui e weler. Keep orawa from ea, oil, sarp ees ormovi pars. Damaged or entangledcords increase the risk of electric shock.

We operai a weler ouoors,e.use a exesio or suiable forouoor use. Use of a cord suitable foroutdoor use reduces the risk of electricshock.

If operai a weler i a ampf.loaio is uavoiable, use a grouFaul cirui Ierruper (gFcI)proee suppl. Use of a GFCIreduces the risk of electric shock.

Persoal safe3.

Sa aler, wa wa ou area.oi a use ommo sese weoperai a weler. do o use aweler wile ou are ire or uerthe inuence of drugs, alcohol or

meiaio. A moment of inattentionwhile operating welders may result inserious personal injury.

Use safe euipme.b. Always wear

ANSI-approved safety glasses and arcshaded, impact safety full face shield.Safety equipment such as NIOSH-approved respirator, heavy-duty workgloves, non-skid safety shoes, orhearing protection used for appropriateconditions will reduce personal injuries.

Preve uieioal sari. Esurec.e swi is i e off-posiiobefore oei o power soure

or movi e weler. Carrying orenergizing welders that have the switchon invites accidents.

do o overrea. Keep properd.fooi a balae a all imes. Thisenables better control of the welder inunexpected situations.

Ol use safe euipme a ase.bee approve b a appropriaesaars ae. Unapproved safetyequipment may not provide adequateprotection. Eye protection must beANSI-approved and breathing protectionmust be NIOSH-approved for the specic

hazards in the work area.

Weler use a are4.

do o use e weler if e swia.oes o ur i o a off. Any welderthat cannot be controlled with the switchis dangerous and must be repaired.

disoe e plu from eb.power soure before maki aausmes, ai aessories,

or sori welers. Such preventivesafety measures reduce the risk ofstarting the welder accidentally.

Sore ile welers ou of e reac.of ilre a o o allow persosufamiliar wi e weler or eseisruios o operae e weler.Welders are dangerous in the hands ofuntrained users.

Maiai welers. cek ford.

misalime or bii of movipars, breakae of pars a aoer oiio a ma affe ewelers operaio. If amae,ave e weler repaire before use.Many accidents are caused by poorlymaintained welders.

Use e weler a aessories ie.aorae wi ese isruios,aki io aou e worki

oiios a e work o beperforme. Use of the welder foroperations different from those intendedcould result in a hazardous situation.


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Page 4 For eial uesios, please all 1-800-444-3353. SKU 98871

SAFEty

SERVI cE

BASI cWELdI ng

WELdI ngtI PS

SEtUP

Servie5.

have our weler servie b aa.qualied repair person using only

ieial replaeme pars. This willensure that the safety of the welder ismaintained.

Weler Safe Waris

Maiai labels a ameplaes o1.e Weler. These carry importantinformation. If unreadable or missing,contact Harbor Freight Tools for areplacement.

Maiai a safe worki evirome.2.Keep the work area well lit. Makesure there is adequate surroundingworkspace. Always keep the work areafree of obstructions, grease, oil, trash,and other debris.

Avoi uieioal sari.3. Makesure you are prepared to begin workbefore turning on the Welder.

Uplu before performi4.maieae. Unplug the Welder fromits electrical outlet before performing any

inspection, maintenance, or cleaningprocedures.

never leave e Weler uaee5.wile eerie. Turn power off if youhave to leave the Welder.

6. Preve ee iur aburs. Wearing and usingANSI-approved personalsafety clothing and safety

devices reduce the risk for injury.Wear ANSI-approved safety impacteye goggles underneath welding eyeprotection featuring at least a number10 shade lens rating, such as the oneincluded.

Leatherleggings,reresistantshoesor

boots should be worn when using thisproduct. Do not wear pants with cuffs,shirts with open pockets, or any clothingthat can catch and hold molten metal orsparks.

Keep clothing free of grease, oil,solvents,oranyammablesubstances.

Wear dry, insulating gloves andprotective clothing.

Wear an approved head covering toprotect the head and neck. Use aprons,cape, sleeves, shoulder covers, andbibs designed and approved for weldingand cutting procedures.

When welding/cutting overhead or in

connedspaces,wearameresistantear plugs or ear muffs to keep sparksout of ears.

7. Prevent accidental res.Remove any combustiblematerial from the work area.

When possible, move the work to alocation well away from combustiblematerials. If relocation is not possible,

protect the combustibles with a covermadeofreresistantmaterial.

Remove or make safe all combustiblematerials for a radius of 35 feet (10meters) around the work area. Use areresistantmaterialtocoverorblock

all open doorways, windows, cracks,and other openings.

Enclosetheworkareawithportablere

resistant screens. Protect combustible

walls,ceilings,oors,etc.,fromsparksandheatwithreresistantcovers.

If working on a metal wall, ceiling, etc.,prevent ignition of combustibles on theother side by moving the combustiblesto a safe location. If relocation ofcombustibles is not possible, designatesomeonetoserveasarewatch,


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equippedwithareextinguisher,during

the cutting process and for at least onehalf hour after the cutting is completed.

Do not weld or cut on materials havinga combustible coating or combustibleinternal structure, as in walls or ceilings,

without an approved method foreliminating the hazard.

Do not dispose of hot slag in containersholding combustible materials. Keep areextinguishernearbyandknowhow

to use it.

After spot welding, make a thoroughexaminationforevidenceofre.Be

awarethateasilyvisiblesmokeorame

may not be present for some time after

therehasstarted.Donotweldorcutin atmospheres containing dangerouslyreactiveorammablegases,vapors,

liquids, and dust. Provide adequateventilation in work areas to preventaccumulationofammablegases,

vapors, and dust. Do not apply heat toa container that has held an unknownsubstance or a combustible materialwhose contents, when heated, canproduceammableorexplosivevapors.

Clean and purge containers beforeapplying heat. Vent closed containers,including castings, before preheating,welding, or cutting.

Avoi overexposure o fumes a8.ases. Always keep your head out ofthe fumes. Do not breathe the fumes.Use enough ventilation or exhaust, orboth, to keep fumes and gases from yourbreathing zone and general area.

Where ventilation is questionable,haveaqualiedtechniciantakeanair

sampling to determine the need forcorrective measures. Use mechanicalventilation to improve air quality. Ifengineering controls are not feasible,use an approved respirator.

Workinaconnedareaonlyifitis

well-ventilated, or while wearing an air-supplied respirator.

Follow OSHA guidelines for PermissibleExposure Limits (PELs) for variousfumes and gases.

Follow the American Conference ofGovernmental Industrial Hygienistsrecommendations for Threshold LimitValues (TLVs) for fumes and gases.

Have a recognized specialist inIndustrial Hygiene or EnvironmentalServices check the operation and airquality and make recommendations forthespecicweldingorcuttingsituation.

WARnIng

InhALAtIOn hAzARd:Weli a Plasma cui Proue

tOXIc FUMES.

Exposure to welding or cutting exhaustfumes can increase the risk of developing

certain cancers, such as cancer of thelarynx and lung cancer. Also, somediseases that may be linked to exposure towelding or plasma cutting exhaust fumesare:

EarlyonsetofParkinsonsDisease

Heartdisease Ulcers

Damagetothereproductiveorgans

Inammationofthesmallintestineor

stomach Kidneydamage

Respiratorydiseasessuchasemphysema, bronchitis, or pneumonia

Use natural or forced air ventilation andwear a respirator approved by NIOSH toprotect against the fumes produced toreduce the risk of developing the aboveillnesses.


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SAFEty

SERVI cE

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SEtUP

do o ou live elerial pars9. .Wear dry, insulating gloves. Do not touchwelding wire or gun with bare hand. Donot wear wet or damaged gloves.

Proe ourself from eleri sok.10.Do not use outdoors. Insulate yourself

from the workpiece and ground. Usenonammable,dryinsulatingmaterial

if possible, or use dry rubber mats, drywood or plywood, or other dry insulatingmaterial big enough to cover your fullarea of contact with the work or ground.

People wi paemakers soul11.osul eir psiia(s) beforeusi is prou. Electromagneticeldsincloseproximitytoaheart

pacemaker could cause interference to,or failure of the pacemaker.

Use are o o ou e weli ip12.o roue maerial weever eui is plue i. tis ui is wais referre o as a o ip weler,meai a urre is available oe wire a all imes a e powerSwi (7a) is i e On posiio.Electricshock,re,orburnsmayhappen

if appropriate precautions are not taken.

Esure a e ui is plae o a13.sable loaio before use. If this unitfalls while plugged in, severe injury,electricshock,orremayresult.

This product, when used for welding14.and similar applications, contains orproduces a chemical known to the Stateof California to cause cancer and birth

defects (or other reproductive harm).(California Health & Safety Code 25249.5, et seq.)

Handling the cord on this product will15.expose you to lead, a chemical known tothe State of California to cause cancer,and birth defects or other reproductiveharm. Wash hands after handling.(California Health & Safety Code 25249.5, et seq.)

The warnings, precautions, and16.instructions discussed in this instructionmanual cannot cover all possibleconditions and situations that may occur.It must be understood by the operatorthat common sense and caution arefactors which cannot be built into thisproduct, but must be supplied by theoperator.

SAVE thESEInStRUctIOnS.

gROUndIng

tO PREVEntELEctRIc ShOcK

And dEAth FROM IncORREctgROUndIng WIRE

cOnnEctIOn:Check with a qualied electrician

if ou are i oub as o weere oule is properl roue.have a plu isalle b acertied electrician. Do not use

e weler if e power or orplu is amae. If amae,ave i repaire b a serviefaili before use. If e plu willnot t the outlet, have a proper

outlet installed by a qualiedeleriia.


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groue Welers

The grounding prong in the plug is1.connected through the green wire insidethe cord to the grounding system inthe welder. The green wire in the cordmust be the only wire connected to thewelders grounding system and mustnever be attached to an electrically liveterminal.

The welder must be plugged into an2.appropriate outlet, properly installed andgrounded in accordance with all codesand ordinances.

Exesio cors

If a exesio or is use, i mus1.ave e followi wire sie: up o 30fee, use 10 AWg sie wire; 30 o 50fee, use 8 AWg wire; Over 50 fee,use 6 AWg wire.

As the distance from the supply outlet2.increases, you must use a heavier gaugeextension cord. Using extension cordswith inadequately sized wire causes aserious drop in voltage, resulting in loss

of power and possible welder damage.

The smaller the gauge number of the3.wire, the greater the capacity of the cord.For example, a 14 gauge cord can carrya higher current than a 16 gauge cord.

When using more than one extension4.cord to make up the total length, makesure each cord contains at least theminimum wire size required.

If you are using one extension cord5.for more than one welder, add thenameplateamperes and use the sum todetermine the required minimum cordsize.

If you are using an extension cord6.outdoors, make sure it is marked with thesufxW-A(WinCanada)toindicateit

is acceptable for outdoor use.

Make sure the extension cord is properly7.wired and in good electrical condition.

Always replace a damaged extensioncordorhaveitrepairedbyaqualied

electrician before using it.

Protect the extension cords from sharp8.objects, excessive heat, and damp orwet areas.

SyMBOLOgy

Wire Feed (Speed)

Workpiece Ground Cable

Gun Cable

Overheat Shutdown Indicator

Cooling Fan

Housing Ground Point

V~ Volts Alternating Current

A Amperes

OcV Open Circuit Voltage

KVA Kilovolt Amperes(Volts / 1000 * Amperes)

IPM Inches Per Minute

AWg American Wire Gauge


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SPEcIFIcAtIOnS

Power Ipu120 V~, 24 A (peak), 1-pasecoe o a leas 20 A eiae irui

Weli Oupu

dcEnMIn: 63 ~ 68 A

MAX: 79 ~ 90 AhOt tIP weler

capai22 aue (0.03) o 3/16 (0.19) mil seel olno for weli alumium or sailess seel

du cle25% a MAX sei45% a MIn sei(See explaaio o pae 16)

Ope cirui Volae 31

KVA 3.6

Wire Spee 101 342 IPM

cable Siesgrou: 6 AWg, 6gu: 8 AWg, 6Power: 3-wire, 14 AWg

Weler tips / Wire Sie Isalle ip will aep .030 o .035 FLUX cORE wire

Wire Spool capai 4 iameer / 2 lb. spool

Ieral Fuse 2 A 250 V tube fuse (see pae 27)

AessoriesSpare Weler tip (for .030 o .035 wire)Weli Fae Sielcombiaio Wire Brus / cippi hammer

UnPAcKIng

When unpacking, make sure that the item is intact and undamaged. If any parts aremissing or broken, please call Harbor Freight Tools at 1-800-444-3353 as soon as possible.


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Fae Siel (38) Assembl

Attach the handle to the Face Shield (38)by lining up the two rectangular tabs onthe handle with the corresponding holes inthe face shield and

press the tabs through the holes andA.then

slide the tabs forward from the back,B.locking the round tab in place.

cover (31) Assembl

1. Slide the Handle (30) into the slot on theCover (31) from the front.The notch on the back of the Handleshould drop into the slot in the Cover.BothendsoftheHandleshouldlayush

against the top of the Cover.Then, secure using Screw (29) as shown.

2. Attach the Cover Latch (8) to the front oftheBaseFrame(14)usingtheBolt(42),

Washer (40), Lock Washer (50) and Nut(41) as shown.

haleFae

Siel

(viewe from fro)

AA

BB

Routab

hale (30)o ropsio slo o

cover ere

Srew

(29)

cover(31)

coverLa (8)

Bol(42)

Waser

(40)

nu(41)

LokWaser (50)

SEtUP

Rea e EntIRE IMPORtAnt SAFEty InFORMAtIOn seio a e beiiof is maual ilui all ex uer subeais erei before se up or useof is prou.

tO PREVEnt SERIOUS InjURy FROM AccIdEntAL OPERAtIOn:

tur e Power Swi off a uplu e weler before assembl.


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SAFEty

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Wire Spool (27) Isallaio

1. tur e weler OFF a uplu ibefore proeei.

2. Press in the Cover Latch (8) on the frontof the handle, then open the Cover (31).

3. Remove the Wing Nut (25) and the SpoolRetaining Nut (26). If replacing a Spool,remove the old Spool and all remainingwire from the liners.

Make sure the Spool Spring (24) is in4.

place on the Spool Spindle (28).Place the new x Wire Spool overthe Spool Spindle (28) and on top of theSpool Spring (24) as illustrated.to preve wire fee problems,se e Spool so a i will uwiouerlokwise.

Secure Spool in place with the Spool5.

Retaining Nut (26), then the Wing Nut(25).

P FLUX WIRE WELdER

120 V~

60 h

PEEd

6

7

8

9

10MAX

MIn On

OFF

WireSpool

(27)

coverLa (8)

cover (31)

Wi nu (25)

Spool Reaii nu (26)

Wire Spool (27)

Spool Spri (24)

Spool Spile (28)

wire musuwi is

ireio


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6. Turn the Feed Tensioner (37) knobcounterclockwise to loosen it enough topull it up, releasing tension.Do not loosen the Tensioner knob toomuch, or the Tensioner will come apart.Then, swing the Feed Swing Arm (36)out.

7. Compare the wire diameter marked onthe Wire Spool (27) with the stampednumber on the top of the Feed Roller(34). The Rollers groove size must becompatible with the wire diameter -.8mm rollers also work with .030 wire &

.9mm rollers also work with .035 wire.If i is o ompaible or e umber oe Roller is ie:

Remove the Screws (45) and WashersA.(46)fromtheFeedRollerBracket(44).

RemovetheFeedRollerBracket. B.Flip the Feed Roller (34) as needed andconrmthatthenumberfacingupisthe

same as the wire diameter on the Spool.

Reassemble using the Feed RollerC.

Bracket,Washers,andScrews.

IMPORtAnt:

Seurel ol oo e e of e weliwire a keep esio o i uri efollowi seps.

If is is o oe, e weli wire willuravel a reae a ale birs es,wasi wire.

Cut off all bent and crimped wire. Make8.sure that the cut end has no burrs orsharp edges; cut again if needed.

9. Keep tension on the wire and guide atleast 12 inches of wire into the WireLiners.

Fee Swi

Arm (36)

Fee

tesioer (37)

Srews (45),Wasers (46)

FeeRoller (34)

.030

Fee Roller

Brake (44)

A

B

c

WireSpool

weliwire

hOLd WIRE

SEcURELy

Wire

Lier(4)

leaerwire lier


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SAFEty

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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 restingin the top groove of the Feed Roller(34), then turn the Feed Tensioner knobclockwise a couple of turns.After the wire is held by the Tensioner,you may release it.

11. Pull the Nozzle (3) to remove it.

Using the third oval hole on the Multi-12.wrench (43), turn the Contact Tip (2b)counterclockwise and remove.

Lay the Gun Cable out in a straight line13.so that the wire moves through it easily.Leave the cover open, so that the feedmechanism can be observed.

WARnIngThe following steps require applying power to the welder

with the cover open.To prevent serious injury from re or electric shock:

do o ou ai, espeiall o e grou clamp,1.wi e gu or weli wire or a ar will be iie.

do o ou ieral weler ompoes wile i is2.plue i.

14. Do not touch the Guns Trigger (1c).Plug the Power Cord into its electricaloutlet and turn the welder ON.

Fee SwiArm (36)

Fee

tesioer (37)

gu

nole(3)

coatip (2b)

MP FLUX WIRE WELdER

120 V~60 h

SPEEd

6

7

8

9

10

MAX

MIn On

OFF


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15. Point the Gun away from all objects andpress the Trigger (1c) until the wire feedsout of the gun two inches.te Wire Lier (4) ma ome ou wie weli wire, is is ormal, uspus e Wire Lier bak io e gu.If the wire does not feed properly and theSpool is stationary, turn the welder OFF,unplug it, and slightly tighten the FeedTensioner (37) clockwise before retrying.

16. To check the wires drive tension, feed thewire against a piece of wood from 2 to 3inches 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.

17. tURn thE WELdER OFF.

18. Select a Contact Tip that is compatiblewith the welding wire used. The includedTip (2b, .035) will work with both .030and .035 wire. Slide the Contact Tip over

the wire and thread it clockwise into theGun. Tighten the Contact Tip using theMulti-wrench (43).

Replace the Nozzle (3) and cut the wire19.off at 1/2 from tip (

1/2 stickout).

Swing the Cover (31) closed until the20.Cover Latch (8) locks in place.

WeliWire

gu2

2-3

Iremeallirease esio

uilwire bes.

MP FLUX WIRE WELdER

120 V~

60 h

SPEEd

6

7

8

9

10

MAX

MIn On

OFF

gu

nole

(3)

coatip (2b)


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SAFEty

SERVI cE

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WELdI ngtI PS

SEtUP

BASIc WELdIng

Rea e EntIRE IMPORtAntSAFEty InFORMAtIOnseio a e beii of ismaual ilui all ex uer

subeais erei beforeweli.

tO PREVEnt SERIOUSInjURy:

Proeive ear mus be worwe usi e Weler; miimumsae umber 10 full fae siel(or weli mask), ear proeio,weli loves, sleeves aapro, nIOSh-approve respiraor,

and re resistant work clotheswiou pokes soul be worwe weli.Li from e ar a ausepermae amae o e eesa ski.do o breae ar fumes.

tO PREVEnt SERIOUSInjURy, FIRE And

BURnS:Keep weli ip lear ofroue obes weever uiis plue i.tis weler is a o ip weler,meai a urre is availableo e wire weever e PowerSwi is o.

The Flux Wire Welder is used to weldsheet metal and low carbon steel. Good

welding takes a degree of skill and experience.Practice a few sample welds on scrap beforeweldingyourrstproject.Additionalpractice

periods are recommended whenever youweld a different thickness of material or welda different type of connection. Make praiewels o piees of srap o praieeiue before weli ai of value.

=IRE WELdER

120 V~

60 h

MAX

MIn On

OFF

Praie our welieiue o srap

piees before weliai of value.

REV 09f


15/34


corol Pael Laou

90 AMP FLUX WIRE WELdER

120 V~60 h

gu

WIRE-FEEd SPEEd

0

1

2

3

45

6

7

8

9

10MAX

MIn On

OFF

Wire

Speedial (9)

gu (1)cable

grou

cable (33)

PowerSwi (7a)

curre

Swi (7b)

OverloaIiaor

(22)

Powercor (32)

gu cable: The welding Gun connects here.The wire and welding current feeds tothe weld through here.The welding Gun is energized wheneverthe Power Switch is on.

Wire Spee dial: This controls the speedthat the welding wire feeds out of the

welding Gun.Adjust this according to the weld settingschart to achieve a good weld.

grou cable: This connects to the basemetal to provide a good connection forthe current to travel back to the welder.

Power cor: Plug the Power Cord into aproperly grounded 120 V~ outlet, on atleast a 20 amp dedicated circuit withdelayed action type circuit breaker orfuses.

curre Swi: This controls the outputamperage of the welder.

Adjust this according to the weld settingschart to achieve a good weld.

Power Swi: This turns on power to thewelding Gun and internal cooling fan.The welding Gun is energized wheneverthe Power Switch is on.

Overloa Iiaor: This lights up ifduty cycle work period is exceeded,overheating the welder. Rest the Gunon an electrically non-conductive, heat-

resistant surface, such as a concreteslab, well clear of the ground clampwhile allowing the welder to cool with thePower Switch on, so the Fan can helpcool the welder. Once the welder coolsenough to be used again, use shorterwelding periods and longer rest periodsto prevent needless wear.


16/34


SAFEty

SERVI cE

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SEtUP

Wel Seis car

nOtE: te umbers wii e

spaes are e approximae wirefee seis reommee* for is

wire sie a maerial ikess.

Maerial tikess (Seel)

22gaue

18gaue

16gaue

14gaue

1/83/16

MIn urre MAX urre

.030 Wire Sie(Flux core, Mil Seel)

1spee

1.5spee

2spee

4spee

8spee

9spee

.035 Wire Sie(Flux core, Mil Seel)

0.5spee

1.5spee

2spee

3spee

8spee

9.5spee

* tis ar is ol iee o sow eeral uielies for iffere wire sies a for iffereikesses of maerial. te seis soul ol be use a e beii of a wel a mus be

ause afer soppi a arefull ispei e wel. Proper weli akes experiee.

du cle (duraio of Use)

Avoi amae o e Weler b oweli for more a e presribeu le ime. TheDutyCycledenesthenumber of minutes, within a 10 minute period,during which a given welder can produce aparticular welding current without overheating.For example, this Welder with a 25% dutycycle on MAX setting must be allowed torest for at least 7 minutes, 30 seconds afterevery 2 minutes, 30 seconds of continuous

weld. Failure to carefully observe duty cyclelimitations can easily over-stress a welderspower generation system contributing topremature welder failure.

This welder has an internal thermalprotection system to help prevent this sortof over-stress. When the unit overheats, itautomatically shuts down and the OverloadIndicator (22) lights, then the welderautomatically returns to service after cooling

off. Rest the Gun on an electrically non-conductive, heat-proof surface, such as aconcrete slab, well clear of the ground clampwhile allowing the welder to cool with thePower Switch on, so that the internal Fan willhelp cool the welder. When the welder can beused again, use shorter welding periods andlonger rest periods to prevent needless wear.

25% du cle a MAX sei2 miues, 30 seos weli

followe ba leas 7 miues, 30 seos of res

45% du cle a MIn sei4 miues, 30 seos weli

followe ba leas 5 miues, 30 seos of res

P FLUX WIRE WELdER

EEd

6

7

8

9

10MAX

MIn On

OFF

gu

oree slab(or oer ea-proof,

o-ouive

surfae)


17/34


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6. Hold the Gun, without touching theTrigger, with the wire and tip clearly out ofthe way of any grounded objects.Then, turn the Power Switch ON.

Basi Weli teiue

Press (and hold) Trigger and contact area1.to be welded with electrode wire to ignitearc.

2. For a narrow weld, you can usually drawthe wire in a steady straight line,

this is called a ng ba.

For a wider weld, draw the wire back andforth across the joint,this is called a av ba.

Hold Gun in one hand and the face shield3.in the other. If a hands-free weldingshield (not included, see #6, page 4 forguidelines) is used, then both hands canbe used to control Gun.

4. Direct the welding wire straight into thejoint. This gives an angle of 90 (straightup and down) for butt (end to end) welds,andanangleof45forllet(T-shaped)

welds.

5. The end of gun should be tilted so thatwire is angled anywhere in-betweenstraight on and 15 in the direction youare welding. The amount of tilt is calledthe ag ang.

The welding wire should extend no more6.than 1/2 past the tip.This distance is called kor CTWD- Contact Tip to Work Distance.

MP FLUX WIRE WELdER

120 V~

60 h

SPEEd

6

7

8

9

10MAX

MIn On

OFF

hOLdgUn

cLEAR

srier bea weave bea

Wel gu ales,viewe from fro of wel oi.

45

llet weld joint

90

bu wel oi

Sikou(up o 1/2)Wel

direio

dra Ale

0-15


19/34


noe: If Welder is used too long, the amberOverload Indicator (22) will light and theWelder Gun will shut off until the weldercools. If this happens, rest the Gun on anelectrically non-conductive, heat-resistantsurface, such as a concrete slab, wellclear of the ground clamp. Wait about8-10 minutes with the Power Switch ONfor the welder to cool. When the weldercan be used again, use shorter weldingperiods and longer rest periods to helpprevent needless wear.

7. A ng n a p ap a n, stop,and check your progress. Clean, then

compare your welds appearance with thediagrams and descriptions in the Welitips section starting on the next page.After making any necessary adjustments,continue to weld ang duty cycle gn

a xpan n pag 16.

8. We e wel is omplee, lift the Gunand welding wire clearly away from anygrounded object, and turn the PowerSwitch off.

9. Se e gu ow o a ea-proof,eleriall o-ouive surfae.Uplu e Power cor.

FLUX WIRE WELdER

Ed

6

7

8

9

10MAX

MIn On

OFF

gu


o-ouivesurfae)

Afer praie weli for a fewseos, StOP a examie

our wel usi e uieliessari o e ex pae.

FOLLOW dUty cycLE!

up o 2-1/2 miuesweli o MAX sei

up o 4-1/2 miuesweli o MIn sei

MP FLUX WIRE WELdER

120 V~

60 h

SPEEd

6

7

8

9

10MAX

MIn On

OFF

hOLdgUn

cLEAR

gu


o-ouivesurfae)


20/34


SAFEty

SERVI cE

BASI cWELdI ng

WELdI ngtI PS

SEtUP

A good way to test welding technique isto examine a welds appearance after it hascooled and the slag has been removed. Then,better welding can be learned by adjusting yourweld technique to remedy any problems found.

cleai e Wel

tO PREVEntSERIOUS InjURy:

coiue o wear AnSI-approvesafe oles a proeivewear we leai a wel.Sparks or chips may y when

leai.

1. Aweldfromuxcorewirewillbecoveredby slag, use the Chipping Hammer toknock this off. Be areful o o amaee wel or base maerial.

Then,usetheWireBrushtofurtherclean2.the weld or use an angle grinder (soldseparately) to shape the weld.

StRIKE tESt

A es wel o a PIEcE OF ScRAP a be ese b

usi e followi proeure.WEAR AnSI gOggLES dURIng thIS PROcEdURE.

WARnIng! tis es WILL amae e weli is performe o. tis es is OnLya iiaor of wel eiue a iso iee o es worki wels.

After two scraps have been welded1.together and the weld has cooled, clampone scrap in a sturdy vise.

Stay clear from underneath while you2. strike the opposite scrap with a heavyhammer, 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 atthe weld, as shown on bottom.

A pial Flux-ore Wire (FcAW) Wel

before leai.

base meal

wel beasla

spaer

cippi

hammer

Wire Brus

lamp

ScRAPworkpiee

gOOd WELdbes a is o brile

ea-blow ammer

lampScRAP

workpiee

POOR WELd

saps or raks

ea-blow ammer

WELdIng tIPS


21/34


EXcESS PEnEtRAtIOn ORBURn-thROUgh

PROPER PEnEtRAtIOnInAdEqUAtE PEnEtRAtIOn

no o eou too oIeal ea

WELd dIAgnOSIS

Workpiee hea corol / Wel Peeraio

gooWel

curretoo Low

Wel Speetoo Slow

Example Wel diarams

tO cORREct: tO cORREct: tO cORREct:

welslower

tO cORREct:

welfaser

tO cORREct:

maiailess

a 1/2

sikou

how o irease workpiee eaa irease peeraio:

(o wel thIcKER workpiees properl)

how o reue workpiee eaa limi peeraio:

(o wel thInnER workpiees properl)

Use MAX seia.

Wel more slowlb.

Use faser wire feec.

Use sorer sikoud.

Use MIn seia.

Wel more uiklb.

Use slower wire feec.

Use loer sikoud.

WIRE-FEEd SPEEd

0

1

2

3

45

6

7

8

9

10M

M

or

MAX

MIn On

OFF

8

MAX

MIn On

OFF

Sikoutoo Lo

Wel Speetoo Fas

curretoo hi or

Wire Feetoo Fas


22/34


23/34


coa of Sla Over Wel

Slag is a necessary part of a ux-

ore wire wel. I siels e wel fromimpuriies. clea off e sla wi ecippi hammer a Wire Brus aferweli.

toP

View

PArtiAlly chiPPed AwAy to show weld

Bur-trouBase maerial mels awa,

leavi a ole i e wel.

POSSIBLE cAUSES And SOLUtIOnS

Workpiee overeai:1.Reduce current and/or wire feed speed.

Weli spee oo slow:2.Increase welding speed and ensure thatwelding speed is kept steady.

Exessive maerial a wel:3.Reduce wire feed speed.

toP

View

PorosiSmall aviies or oles i e bea.


dir workpiee or weli wire:1.Clean workpiece down to bare metal.Make certain that wire is clean and freefrom oil, coatings, and other residues.

Iosise weli spee:2.Maintain steady weld speed.

Sikou oo lo:3.Reduce stickout.

toP

View

Exessive SpaerFie spaer is ormal.

Spaer a is rai a lare is a problem.


dir workpiee or weli wire:1.Clean workpiece down to bare metal.Make certain that wire is clean and freefrom oil, coatings, and other residues.

Wire feei oo fas:2.Reduce wire feed speed.


toP

View

crooke/Wav Bea

POSSIBLE cAUSES And SOLUtIOnSIaurae weli:1.Use two hands or rest hand on steadysurface.

Iosise weli spee:2.Maintain steady weld speed.


toP

View


24/34


SAFEty

SERVI cE

BASI cWELdI ng

WELdI ngtI PS

SEtUP

SERVIcE

tO PREVEnt SERIOUSInjURy, FIRE And

BURnS:Uplu e weler, res e gu

o a ea-proof, eleriallo-ouive surfae, aallow all pars of e Weler oool oroul before servie.

Periodically remove the Right and Left1.side panels (12 and 13), and usingcompressed air, blow out all dust from theinterior.

Store in a clean and dry location.2.

For opimal wel uali, lea a3.ispe e coa tip (2b) a nole(3) before ea use, as follows:

nole (3) Ispeio,cleai, a Replaeme

Make sure a e eire gu is1.ompleel ool a a e Powercor is uplue from e elerialoule before proeei.

2. Turn the Nozzle counterclockwise whilepulling to remove.

Scrub the interior of the Nozzle clean with3.a wire brush.

Examine the end of the Nozzle. The4.endshouldbeatandeven.Iftheend

is uneven, chipped, melted, cracked,or otherwise damaged, the Nozzle will

adversely effect the weld and should bereplaced.

Reinstall the Nozzle after inspecting and5.cleaning the Contact Tip.

gu


o-ouivesurfae)+

gu

nole

(3)

coatip (2b)


25/34


coa tip (2b) Ispeio,cleai, a Replaeme

Make sure a e eire gu is1.ompleel ool a a e Powercor is uplue from e elerialoule before proeei.

2. Remove the Nozzle as explained in theprevious subheading. Using the third ovalhole on the Multi-wrench (43), turn theContact Tip counterclockwise and slide itoff the welding wire.

Scrub the exterior of the Tip clean with a3.wire brush. Clean out the inside of thetip with a tip cleaner (sold separately).Check that the Tip is the proper type for

the wire size used (.035 tip for .030.035wire).

Examine the shape of the hole at the end4.of the Contact Tip. It should be an evencircle, it should not be oblong or have anybulges in it.

If any problems are noted, Contact Tip5.replacement would be advisable. Makesure to select a new Tip that is the correct

size for the welding wire used (.035 tipfor .030.035 wire).

Reinstall the Tip and securely reinstall the6.Nozzle as well.

gu

nole(3)

coatip (2b)


26/34


SAFEty

SERVI cE

BASI cWELdI ng

WELdI ngtI PS

SEtUP

tROUBLEShOOtIng

IMPORtAnt!Be cERtAIn o su off e Weler, isoe i from power, a isare e gu o rou

before ausi, leai, or repairi e ui.

Wire fee moor rus bu wire oes o fee properl


Insufcient wire feed tension:1.Increase wire feed tension properly - follow step 16 on page 13.

Iorre wire fee roll sie:2.Replace with the proper wire feed roll - follow the w sp inaan instructions,starting on page 10.Flip over wire feed roll if necessary.

damae gu, able, or lier assembl:3.

Haveaqualiedtechnicianinspectthesepartsandreplaceasnecessary.

Wire reaes a birs es uri operaio


Exess wire fee esio:1.

Adjust wire feed tension properly - follow step 16 on page 13.Iorre oa ip sie:2.Replace with the proper tip for the wire.

gu e o isere io rive ousi properl:3.Loosen gun securing bolt and push gun end into housing just enough so that it does nottouch wire feed mechanism.

damae lier:4.Haveaqualiedtechnicianinspectandrepair/replaceasnecessary.


27/34


tROUBLEShOOtIng (oiue)



Power swi (7a) lis,bu weler oes o fuio we swie o


trippe ermal proeio evie:1.Shut the welders 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 d c section on page 16.

Faul or improperl oee trier (1):2.Qualiedtechnicianmustcheckandsecure/replaceTrigger(1c).

Ieral fuse blow:3.Check/replace according to the following directions.

WARnIng! tur e weler OFF a uplu i before proeei.a.

Press on the Cover Latch (8), then lift the Cover (31) using Handle (30). Remove Leftb.Side Panel (13).

c. Examine fuse on panel to see if metal wire inside is broken or not. See illustration.

nOtE: te irui boar is v a awill be amae if i is o supporewile e fuse is maipulae. If ou

are ave a oubs abou oi iswiou amai e weler, ave aqualied technician replace the fuse.

If the fuse is broken, carefully support thed.circuit board with a gloved hand while youremove the old fuse. Support the circuitboard from behind while you install a new2 Amp, 250 Volt fuse of the same type.nEVER use aoer pe or sie fuse.

Reinstall the Left Side Panel (13), closee.

the Cover (31), and test the unit forproper function before use.

Fuse


28/34


SAFEty

SERVI cE

BASI cWELdI ng

WELdI ngtI PS

SEtUP




Power swi (7a) oes o li we swie o


Ui is o oee o oule properl or oule is upowere: 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 supplythe required input amperage as detailed on the span table.

Wire Fees, bu ar oes o iie


Improper rou oeio:1.

Make certain that the workpiece is contacted properly by the Ground Clamp and that theworkpiece is properly cleaned near the ground clamp and the welding location.

Improperl sie or exessivel wor coa tip (2b):2.Verify that Contact Tip (2b) is the proper size for the wire. Check that the hole in the tip isnot deformed or enlarged. Also, check that the tip is not dirty; this would prevent a goodconnection. If needed, replace Contact Tip (2b) with proper size and type.


29/34


Weli ar o sable


Wire o feei properl:1.

Seersttbngsection - Wire fee moor rus bu wire oes o feeproperl.

Iorre oa ip sie:2.Replace with the proper tip for .030 wire.

Iorre wire fee spee:3.Adjust wire feed speed to achieve a more stable arc.

Loose gu able or rou able:4.Check to ensure that all connections are tight.

damae gu or loose oeio wii gu:5.Haveaqualiedtechnicianinspectandrepair/replaceasnecessary.

Aus urre sei:6.Make sure setting matches recommended setting on chart.




Weak Ar sre


Iorre lie volae:1.Checkthelinevoltageand,ifinsufcient,havealicensedelectricianremedythesituation.

Improper aue or le of exesio or:2.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 7.


30/34


SAFEty

SERVI cE

BASI cWELdI ng

WELdI ngtI PS

SEtUP

PARtS LIStS And dIAgRAMS

Wiri Semai

1

1

L1

n

PE

cS 100

2

2

2

3

1

4

3

3

4

4

A

-

+

5

5

6

6

S1

S2

S3

Pt

Pt

Fa

A

E F

B

MIn/MAX

c d

t0

t0

OverloaIiaor

M


31/34


Pars Lis

Par desripio q1a BackHandle 11b Front Handle 11c Trigger 11d Handle Lock Ring 11e Gun Tube 1

2b .9 mm Contact Tip 13 Nozzle 14 Wire Liner 15 Gun Cable Clamp A 16 GunCableClampB 1

7a Power Switch 17b Current Switch (MIN/MAX) 18 Cover Latch 19 Wire Speed Dial 1

10 Nut 111 FeedControlCircuitBoard 112 Right Side Panel 113 Left Side Panel 1

14 BaseFrame 115 Foot 416 Washer 417 Screw, ST4.2*13 418 TransformerBracket 219 Thermostat 120 Transformer 121 Middle Partition 122 Overload Indicator 123 Wire Feed Assembly 1

Par desripio q24 Spool Spring 125 Wing Nut, M6 126 Spool Retaining Nut 127 Wire Spool 128 Spool Spindle 1

29 Screw, ST4.2*25 130 Handle 131 Cover 132 Power Cord 133 Ground Cable 134 Feed Roller 135 FeedBearing 136 Feed Swing Arm 137 Feed Tensioner 138 Face Shield (shade #10) 139 WireBrush/ChippingHammer 140 Washer 141 Nut 1

42 Bolt 143 Multi-wrench (for Contact Tip) 144 FeedRollerBracket 145 RollerBracketScrew 246 RollerBracketWasher 247 Washer 148 SupportBracket 149 Fan 150 Lock Washer 1

PLEASE REAd thE FOLLOWIng cAREFULLy

THEMANUFACTURERAND/ORDISTRIBUTORHASPROVIDEDTHEPARTSDIAGRAM

IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER NORDISTRIBUTORMAKESANYREPRESENTATIONORWARRANTYOFANYKINDTOTHE

BUYERTHATHEORSHEISQUALIFIEDTOMAKEANYREPAIRSTOTHEPRODUCTORTHAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT. IN FACT,THEMANUFACTURERAND/ORDISTRIBUTOREXPRESSLYSTATESTHATALLREPAIRS

ANDPARTSREPLACEMENTSSHOULDBEUNDERTAKENBYCERTIFIEDANDLICENSED

TECHNICIANSANDNOTBYTHEBUYER.THEBUYERASSUMESALLRISKANDLIABILITY

ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENTPARTS THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENTPARTS THERETO.


32/34


SAFEty

SERVI cE

BASI cWELdI ng

WELdI ngtI PS

SEtUP

Assembl diaram

50

39


33/34


deail of Par 23

35

44

46 45 23

34

3736

Reor Prous Serial number here:

noe: If product has no serial number, record month and year of purchase instead.

noe: Some parts are listed and shown for illustration purposes only, and are not availableindividually as replacement parts.


34/34

SAFEty

SERVI c

BASI cWELdI ng

WELdI ngtI PS

SEtUP

LIMItEd 1 yEAR / 90 dAyWARRAnty

Harbor Freight Tools Co. makes everyeffort to assure that its products meethigh quality and durability standards, and

warrants to the original purchaser that for aperiod of ninety days from date of purchasethat the Gun, liner, wire feed mechanism(if applicable), welding clamps, electrodeholders, cables and accessories packed withthe welder are free of defects in materials andworkmanship. tis Limie 90 da/1 yearWarra sall o appl o osumablepars su as ips, weli wire, aas oles. Harbor Freight Tools alsowarrants to the original purchaser, for a

period of one year from date of purchase,thatthetransformerandrectierarefreefrom

defects in materials and workmanship (90days if used by a professional contractor orif used as rental equipment). This warrantydoes not apply to damage due directly orindirectly to misuse, abuse, negligence oraccidents, repairs or alterations outsideour facilities, normal wear and tear, or tolack of maintenance. We shall in no event

be liable for death, injuries to personsor property, or for incidental, contingent,special or consequential damages arisingfrom the use of our product. Some statesdo not allow the exclusion or limitation ofincidental or consequential damages, so theabove limitation of exclusion may not applyto you. THIS WARRANTY IS EXPRESSLYIN LIEU OF ALL OTHER WARRANTIES,EXPRESS OR IMPLIED, INCLUDING THEWARRANTIESOFMERCHANTABILITYAND

FITNESS.

To take advantage of this warranty,the product or part must be returned to uswith transportation charges prepaid. Proofof purchase date and an explanation of thecomplaint must accompany the merchandise.Ifourinspectionveriesthedefect,we

will either repair or replace the product atour election or we may elect to refund thepurchase price if we cannot readily andquickly provide you with a replacement. Wewill return repaired products at our expense,but if we determine there is no defect, or thatthe defect resulted from causes not within thescope of our warranty, then you must bear thecost of returning the product.

Thiswarrantygivesyouspeciclegal

rights and you may also have other rightswhich vary from state to state.

3491 Mn oak Bv. Po Bx 6009

cama, cA 93011 (800) 444-3353

Documents

Flux Wire Welder