Harbor Freight Tools 98871 User's Manual
Contents
1. Page 18 For technical questions please call 1 800 444 3353 SKU 98871 Note If Welder is used too long the amber al 9 Overload Indicator 22 will light and the 3 Gun Welder Gun will shut off until the welder cools If this happens rest the Gun on an C s electrically non conductive heat resistant Li surface such as a concrete slab well wax oF concrete slab clear of the ground clamp Wait about cotei ee A A i ina non conductive 8 10 minutes with the Power Switch ON surface P FLUX WIRE WELDER 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 After practice welding for a few seconds STOP and examine After welding the test weld on a piece of scrap for a few seconds stop your weld using the guidelines and check your progress Clean then starting on the next page compare your weld s appearance with the diagrams and descriptions in the Welding FOLLOW DUTY CYCLE Tips section starting on the next page O After making any necessary adjustments za continue to weld while carefully Q following the DUTY CYCLE guidelines a ae lilies page aD TT as explained on page 16 welding on MAX setting welding on MIN setting T a HOLD p GUN When the weld is complete lift the Gun CLEAR Me I l t and welding wire clearly away from any p H grounded object and turn the2. dead blow hammer SCRAP workpiece GOOD WELD 1 After two scraps have been welded bends and is not brittle 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 AGOOD WELD will deform but not break as shown on top as A POOR WELD will be brittle and snap at the weld as shown on bottom POOR WELD snaps or cracks Page 20 For technical questions please call 1 800 444 3353 SKU 98871 clamp dead blow hammer SCRAP workpiece WELD DIAGNOSIS Workpiece Heat Control Weld Penetration EXCESS PENETRATION OR BURN THROUGH INADEQUATE PENETRATION PROPER PENETRATION Not hot enough Ideal heat Too hot How to increase workpiece heat How to reduce workpiece heat and increase penetration 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 Use longer stickout Example Weld Diagrams Liti l V A Good Current Current Weld Speed Weld Speed Stickout oO Weld Too Low Too High or Too Fast Too Slow Too Long 2 Wire Feed A Too Fast J TO CORRECT TO CORRECT TO CORRECT TO CORRECT TO CORRECT awe Tr a mD shna or weld weld than 1 2 i Bg slower
3. pull it up releasing tension Do not loosen the Tensioner knob too much or the Tensioner will come apart Then swing the Feed Swing Arm 36 out 7 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 amp 9mm rollers also work with 035 wire If it is not compatible or the number on Screws 45 the Roller is hidden Washers 46 A Remove the Screws 45 and Washers 46 from the Feed Roller Bracket 44 B Remove the Feed Roller Bracket Flip the Feed Roller 34 as needed and confirm that the number facing up is the same as the wire diameter on the Spool Feed Roller Bracket 44 C Reassemble using the Feed Roller Bracket Washers and Screws Feed Roller 34 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 wire HOLD 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 leader wire liner SKU 98871 For technical questions please call 1 800 444 3353 Page 11 10 Swing the Wire Feed Swing Arm 36 F
4. wire 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 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 035 tip for 030 035 wire Reinstall the Tip and securely reinstall the Nozzle as well Lu gt oc m V SKU 98871 For technical questions please call 1 800 444 3353 Page 25 V ul J O m 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 step 16 on page 13 2 Incorrect wire feed roll size Replace with the proper wire feed roll follow the Wire Spool Installation instructions starting on page 10 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 step 16 on page 13 2 Incorrect contact tip size Replace with the proper tip for the wire 3 Gun end not inserted i
5. f ANEAN Mf fees WS me Cb BM MN pe j f i A ff el PG i ar 3 aa E M _ bo Bad et SG S A a f e V ul J O m Page 32 For technical questions please call 1 800 444 3353 SKU 98871 Detail of Part 23 INSTALLING WIRE r OFF and unplug It EXERCISE EXTREME S CAUTION RISK OF ELECTRIC SHO T ing K The tolio 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 Lu gt oc m V SKU 98871 For technical questions please call 1 800 444 3353 Page 33 V ul J O m LIMITED 1 YEAR 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 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 This Limited 90 Day 1 Year Warranty shall not apply to consumable parts such as tips welding wire and gas nozzles Harbor Freight Tools also warrants to the original purchaser for a period of one year from date of purchase that the transformer and rectifier are free from defects in materia
6. faster x gt SKU 98871 For technical questions please call 1 800 444 3353 Page 21 amp WELD PROBLEMS Penetration Workpiece Heat Control EXCESS PENETRATION OR BURN THROUGH Weld droops on top and underneath or falls through entirely making a hole Y PROPER PENETRATION Weld is visible underneath and bulges slightly on top x ajea INADEQUATE PENETRATION Weld does not contact the joint fully just on the surface PROFILE VIEWS 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 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 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 Page 22 m i z Z a U o Place stringer bead at correct place in joint For technical questions plea
7. lose control Electrical safety a Welder plugs must match the outlet Never modify the plug in any way Do not use any adapter plugs with grounded welders Unmodified plugs and matching outlets will reduce risk of electric shock b Avoid body contact with grounded surfaces such as pipes radiators ranges and refrigerators There is an increased risk of electric shock if your body is grounded c Do not expose welders to rain or wet conditions Water entering a welder will increase the risk of electric shock SKU 98871 d 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 e When operating a welder outdoors use an extension cord suitable for outdoor use Use of a cord suitable for outdoor use reduces the risk of electric shock f If operating a welder in a damp location is unavoidable use a Ground Fault Circuit Interrupter GFCI protected supply Use of a GFCI reduces the risk of electric shock 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 b Use safety equipment Always wear ANSIl approved safety glasses and arc
8. CHICAGO WELDING 90 AMP FLUX WIRE WELDER ZH 28871 SET UP AND OPERATING INSTRUCTIONS AA Br poe ree SP nen gL oamp Ft MIREWER E C 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 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 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 Manual Revised 10d gt E Lu LL lt wn BASIC WELDING WELDING TIPS SERVICE on gt ml m lt SAVE THIS MANUAL 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 IMPORTANT SAFETY INFORMATION In this manual on the labeling and all other information provided with thi
9. ERIOUS AWARNING NJuRy 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 Q 3 TO PREVENT SERIOUS AWARNING INJURY FIRE AND BURNS and fire resistant work clothes P Keep welding tip clear of 4 grounded objects whenever unit E is plugged in OL i This welder is a hot tip welder meaning that current is available without pockets should be worn when welding to the wire whenever the Power Di Switch is on A Light from the arc can cause permanent damage to the eyes and skin Do not breathe arc fumes The Flux Wire Welder is used to weld sheet metal and low carbon steel Good welding takes a degree of skill and experience Practice your welding Practice a few sample welds on scrap before t on echnique on scra welding your first project Additional practice q p periods are recommended whenever you pieces before welding weld a different thickness of material or weld anything of value a different type of connection Make practice welds on pieces of scrap to practice technique before welding anything of value REV 09f Page 14 For technical questions please call 1 800 444 3353 SKU 98871 Control Panel Layout Gun 1 Cable Overload Indicator 22 gum Wire i 7 Power Speed q Switch 7a Dial 9 e
10. Power Switch off Yt MP FLUX WIRE WELDER Gun Set the Gun down on a heat proof i gt ez electrically non conductive surface concrete slab Unplug the Power Cord or other heat proof non conductive surface SKU 98871 For technical questions please call 1 800 444 3353 Page 19 m m z Z a U o WELDING TIPS A good way to test welding technique is Atypicak Fux core Wire FCAW Welg before cleaning to examine a weld s appearance after it has weld bead cooled and the slag has been removed Then slag spatter better welding can be learned by adjusting your A weld technique to remedy any problems found base m tal Cleaning the Weld TO PREVENT AWARNING SERIOUS INJURY Continue to wear ANSI approved safety goggles and protective o wear when cleaning a weld Chipping Sparks or chips may fly when Hammer cleaning 1 A weld from flux core wire will be covered by slag use the Chipping Hammer to knock this off Be careful not to damage the weld or base material Wire Brush 2 Then use the 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 GOGGLES DURING THIS PROCEDURE 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 clamp
11. Size Installed tip will accept 030 to 035 FLUX CORE wire Wire Spool Capacity 4 diameter 2 Ib spool Internal Fuse 2 A 250 V Tube fuse see page 27 Spare Welder Tip for 030 to 035 wire Accessories Welding Face Shield Combination Wire Brush Chipping Hammer UNPACKING When unpacking make sure that 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 Page 8 For technical questions please call 1 800 444 3353 SKU 98871 SETUP Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning A of this manual including all text under subheadings therein before set up or use of this product TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION AWARNING Turn the Power Switch off and unplug the welder before assembly Face Shield 38 Assembly Attach the handle to the Face Shield 38 by lining up the two rectangular tabs on the handle with the corresponding holes in the face shield and A press the tabs through the holes and then B slide the tabs forward from the back Shield locking the round tab in place viewed from front Cover 31 Assembly 1 Slide the Handle 30 into the slot on the notch drops ote Pangea Cover 31 from the front la slaton 5 D over here z TERA The notch on the back of the Handle should drop into the slot in the Cover Both ends of the Handle sho
12. ancers 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 e Early onset of Parkinson s Disease e Heart disease e Ulcers e Damage to the reproductive organs e Inflammation of the small intestine or stomach e Kidney damage e 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 Page 5 gt H LLI LL lt wn V gt a m lt 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 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 People with pacemakers should consult their physician s before using this product Electromagnetic fields in close proximity to a heart pacemaker could cause interference to or failure of the pacemaker Use care not to touch the welding tip to grounded material whenever the unit is plugged in This unit is what is referred to as a hot tip we
13. are dangerous in the hands of untrained users d 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 e 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 Page 3 gt Lu LL lt V 5 Service e Leather leggings fire resistant shoes or a Have your welder serviced by a boots should be worn when using this on gt mn m lt Page 4 qualified repair person using only identical replacement parts This will ensure that the safety of the welder is maintained Welder Safety Warnings Maintain labels and nameplates on the Welder These carry important information If unreadable or missing contact Harbor Freight Tools for a replacement Maintain a safe working environment Keep the work area well lit Make sure there is adequate surrounding workspace Always keep the work area free of obstructions grease oil trash and other debris Avoid unintentional starting Make sure you are prepared to begin work before turning on the Welder Unplug before performing maintenance Unplug the Welder from its e
14. cle at MIN setting 4 minutes 30 seconds welding followed by at least 5 minutes 30 seconds of rest 25 Duty Cycle at MAX setting 2 minutes 30 seconds welding followed by at least 7 minutes 30 seconds of rest Ww gt o O zZ m m z Z O 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 22 lights then the welder automatically returns to service after cooling H off Rest the Gun on an electrically non Gun conductive heat proof surface such as a amp concrete slab well clear of the ground clamp a while allowing the welder to cool with the iS e E H gt Power Switch on so that the internal Fan will concrete slab help cool the welder When the welder can be or other heat proof used again use shorter welding periods and poniconduciive surface longer rest periods to prevent needless wear P FLUX WIRE WELDER Page 16 For technical questions please call 1 800 444 3353 SKU 98871 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 workpieces Use cla
15. ct and repair replace as necessary 6 Adjust current setting Make sure setting matches recommended setting on chart SKU 98871 For technical questions please call 1 800 444 3353 Page 29 Lu gt oc m V V ul J O m PARTS LISTS AND DIAGRAMS Wiring Schematic Overload Indicator Page 30 For technical questions please call 1 800 444 3353 SKU 98871 Parts List Part _ Description Q ty 6 Gun Cable ClampB 1 8 CoverLatch _ _ _ _ 1 9 Wire Speed Dial 1 Description Q ty PLEASE READ THE FOLLOWING CAREFULLY 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 SKU 98871 Lu gt oc m p For technical questions please call 1 800 444 3353 Page 31 Assembly Diagram _ ar h if
16. e Wire Liner back into the Gun Wire If the wire does not feed properly and the Spool is stationary turn the welder OFF unplug it and slightly tighten the Feed Tensioner 37 clockwise before retrying 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 Incrementally increase tension clockwise and try again _ until If the wire bends from the feed tension wire bends then the tension is set properly a WE me p A 17 TURN THE WELDER OFF BE MP FLUX WIRE WELDER 18 Select a Contact Tip that is compatible with the welding wire used The included Tip 2b 035 will work with both 030 and 035 wire Slide the Contact Tip over the wire and thread it clockwise into the Gun Tighten the Contact Tip using the Gun Multi wrench 43 Nozzle 19 Replace the Nozzle 3 and cut the wire off at 1 2 from tip 1 2 stickout Contact Tip 2b 20 Swing the Cover 31 closed until the Cover Latch 8 locks in place SKU 98871 For technical questions please call 1 800 444 3353 Page 13 u gt o O Z m m z Z O BASIC WELDING Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before welding TO PREVENT S
17. eed Swing Feed closed and swing the Feed Tensioner Arm 36 Tensioner 37 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 11 Pull the Nozzle 3 to remove it Gun 12 Using the third oval hole on the Multi wrench 43 turn the Contact Tip 2b counterclockwise and remove ar 13 Lay the Gun Cable out in a straight line so that the wire moves through it easily Contact Leave the cover open so that the feed Tip 2b mechanism can be observed The following steps require applying power to the welder with the cover open To prevent serious injury from fire or electric shock Do not touch anything especially not the Ground Clamp with the Gun or welding wire or an arc will be ignited Do not touch internal welder components while it is plugged in 14 Do not touch the Gun s Trigger 1c Plug the Power Cord into its electrical outlet and turn the welder ON SPEED MP FLUX WIRE WELDER 120v 60 Hz Page 12 For technical questions please call 1 800 444 3353 SKU 98871 15 Point the Gun away from all objects and press the Trigger 1c until the wire feeds out of the gun two inches The Wire Liner 4 may come out with the welding wire this is normal just Welding push th
18. ers around the work area Use a fire resistant material to cover or block all open doorways windows cracks and other openings e Enclose the work area with portable fire resistant screens Protect combustible walls ceilings floors etc from sparks and heat with fire resistant covers e 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 SKU 98871 equipped with a fire extinguisher during the cutting process and for at least one half hour after the cutting is completed e 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 e Do not dispose of hot slag in containers holding combustible materials Keep a fire extinguisher nearby and know how to use it e After spot 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 Do not weld or cut in atmospheres containing dangerously reactive or flammable gases vapors liquids and dust Provide adequate ventilation in work areas to prevent accumulation of flammable gases vapors and dust Do not apply heat to a container that has held an unknown substance or a combustib
19. he welder have a qualified technician replace the fuse d If the fuse is broken carefully support the circuit board with a gloved hand while you remove the old fuse Support the circuit board from behind while you install a new 2 Amp 250 Volt fuse of the same type NEVER use another type or size fuse e Reinstall the Left Side Panel 13 close the Cover 31 and test the unit for proper function before use Lu gt oc m V SKU 98871 For technical questions please call 1 800 444 3353 Page 27 TROUBLESHOOTING continued 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 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 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
20. lder meaning that current is available to the wire at all times that the power Switch 7a is in the ON position Electric shock fire or burns may happen if appropriate precautions are not taken Ensure that the unit is placed on a stable location before use f this unit falls while plugged in severe injury electric shock or fire may result 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 amp Safety Code 25249 5 et seq Page 6 15 AWARNING For technical questions please call 1 800 444 3353 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 amp Safety Code 25249 5 et seq 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 SAVE THESE INSTRUCTIONS GROUNDING 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 pr
21. le 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 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 e 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 SKU 98871 For technical questions please call 1 800 444 3353 e Work in a confined area only if it is well ventilated or while wearing an air supplied respirator e Follow OSHA guidelines for Permissible Exposure Limits PEL s for various fumes and gases e Follow the American Conference of Governmental Industrial Hygienists recommendations for Threshold Limit Values TLV s for fumes and gases e Have a recognized specialist in Industrial Hygiene or Environmental Services check the operation and air quality and make recommendations for the specific welding or cutting situation INHALATION HAZARD Welding and Plasma Cutting Produce TOXIC FUMES Exposure to welding or cutting exhaust fumes can increase the risk of developing certain c
22. lectrical outlet before performing any inspection maintenance or cleaning procedures Never leave the Welder unattended while energized Turn power off if you have to leave the Welder Prevent eye injury and burns Wearing and using ANSI approved personal safety clothing and safety devices reduce the risk for injury e Wear ANSI approved safety impact eye goggles underneath welding eye protection featuring at least a number 10 shade lens rating such as the one included For technical questions please call 1 800 444 3353 product Do not wear pants with cuffs shirts with open pockets or any clothing that can catch and hold molten metal or sparks e Keep clothing free of grease oil solvents or any flammable substances Wear dry insulating gloves and protective clothing e 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 e When welding cutting overhead or in confined spaces wear flame resistant ear plugs or ear muffs to keep sparks out of ears Prevent accidental fires Remove any combustible material from the work area e When possible move the work to a location well away from combustible materials If relocation is not possible protect the combustibles with a cover made of fire resistant material e Remove or make safe all combustible materials for a radius of 35 feet 10 met
23. ls and workmanship 90 days if used by a professional contractor or if used as rental equipment This warranty does not apply to damage due directly or indirectly to misuse abuse negligence or accidents repairs or alterations outside our facilities 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 Page 34 For technical questions please call 1 800 444 3353 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
24. mps not included to hold the gt workpieces in position so that you can concentrate on proper welding technique Clean The distance if any between the two surfaces to bare metal workpieces must be controlled properly to a allow the weld to hold both sides securely mee while allowing the weld to penetrate Chamfer thick workpieces fully into the joint The edges of thicker workpieces may need to be chamfered or beveled to allow proper weld penetration g y Workpiece O Clamp Ground Cable to bare metal on g the workpiece near the weld area or to Pee ai 2 an metal work bench where the workpieceis 1O E E Clean clamped a surface to oO 2 90 AMP FLUX WIRE WELDER Ground bare metal 2 I Clamp oO S P SS ae Set the Wire Speed Dial and the Current Switch to the desired settings au am 207 Refer to the chart on the welder or the chart on the facing page DO NOT SWITCH THE CURRENT WHILE WELDING 90 AMP FLUX WIRE WELDER 90 AMP FLUX WIRE WELDER A 120v Flip the Power Switch to the OFF position ps then plug the Welder into a dedicated 120 V 20 Acircuit with delayed action I type circuit breaker or fuses a 2 b gt FLUX WIRE WELDER 20 Amp minimum circuit SKU 98871 For technical questions please call 1 800 444 3353 Page 17 HOLD 73 N 6 Hold the Gun without touching the ae mes Trigger with the wi
25. nto 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 Page 26 For technical questions please call 1 800 444 3353 SKU 98871 TROUBLESHOOTING continued 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 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 16 2 Faulty or improperly connected Trigger 1c Qualified technician must check and secure replace Trigger 1c 3 Internal fuse blown Check replace according to the following directions 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 NOTE The circuit board is very delicate and will be damaged if it is not supported while the fuse is manipulated If you are have any doubts about doing this without damaging t
26. operly 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 SKU 98871 Grounded Welders 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 The welder must be plugged into an appropriate outlet properly installed and grounded in accordance with all codes and ordinances Extension Cords 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 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 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 When using more than one extension cord to make up the total length make sure each cord contains at least the minimum wire si
27. peed Maintain steady weld speed 3 Stickout too long Reduce stickout SKU 98871 TOP VIEW For technical questions please call 1 800 444 3353 Excessive Spatter Fine spatter is normal Spatier that is grainy and large is a problem n P Hee fa TOP VIEW eee ee eae 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 Burn Through Base material melts away leaving a hole in the weld 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 TOP VIEW o A H g zZ A l LL Page 23 SERVICE TO PREVENT SERIOUS Gun AWARNING INJURY FIRE AND BURNS D N Unplug the welder rest the Gun S on a heat proof electrically E elea E A non conductive surface and or other heat proof allow all parts of the Welder to non conductive A surface cool thoroughly before service 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 For optimal weld q
28. 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 SKU 98871
29. r cools enough to be used again use shorter welding periods and longer rest periods to prevent needless wear Page 15 Weld Settings Chart NOTE The numbers within the Material Thickness Steel spaces are the approximate wire feed settings recommended for this 18 16 14 1 is 3 4 wire size and material thickness Gauge Gauge Gauge 16 MAX current MAX current 030 Wire Size 1 5 Flux Core Mild Steel iced speed seed seed seed esd 035 Wire Size 0 5 1 5 9 5 Flux Core Mild Steel speed speed od seed speed speed 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 25 duty cycle on MAX setting must be allowed to rest for at least 7 minutes 30 seconds after every 2 minutes 30 seconds 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 45 Duty Cy
30. re and tip clearly out of a H the way of any grounded objects lt gt bg Then turn the Power Switch ON 2 2 27 2 J s MP FLUX WIRE WELDER Basic Welding Technique 1 Press and hold Trigger and contact area to be welded with electrode wire to ignite arc stringer bead weave bead 2 For a narrow weld you can usually draw 2 the wire in a steady straight line this is called a stringer bead CEE For a wider weld draw the wire back and guidelines is used then both hands can be used to control Gun gt forth across the joint 2 this is called a weave bead 3 Hold Gun in one hand and the face shield a in the other If a hands free welding Weld Gun angles o shield not included see 6 page 4 for viewed from front of weld joint Z Q 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 90 fillet weld joint butt weld joint 5 The end of gun should be tilted so that Drag Angle 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 Stickout a Weld up to 1 2 6 The welding wire should extend no more Direction z than 1 2 past the tip This distance is called stickout or CTWD om Contact Tip to Work Distance
31. s product 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 DANGER indicates a A DANGER hazardous situation which if not avoided will result in death or serious injury AWARNING WARNING indicates a hazardous situation which if not avoided could result in death or serious injury ACAUTION CAUTION used with the safety alert symbol indicates a hazardous situation which if not avoided could result in minor or moderate injury Page 2 NOTICE f For technical questions please call 1 800 444 3353 CAUTION NOTICE is used to address practices not related to personal injury CAUTION without the safety alert symbol is used to address practices not related to personal injury General Safety Warnings WARNING 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 Work area safety a Keep work area clean and well lit Cluttered or dark areas invite accidents b Do not operate welders in explosive atmospheres such as in the presence of flammable liquids gases or dust Welders create sparks which may ignite the dust or fumes c Keep children and bystanders away while operating a welder Distractions can cause you to
32. se call 1 800 444 3353 POSSIBLE d 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 Bend at Joint PROFILE VIEW POSSIBLE CAUSES AND SOLUTIONS 1 Improper clamping Clamp workpieces securely Make tack welds to hold workpieces Excessive heat Weld a small portion and allow to cool before proceeding Increase weld speed Reduce wire feed speed SKU 98871 Coat of Slag Over Weld TOP VIEW PARTIALLY CHIPPED AWAY TO SHOW WELD Slag is a necessary part of a flux core 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 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 TOP VIEW Crooked Wavy Bead POSSIBLE CAUSES AND SOLUTIONS 1 Inaccurate welding Use two hands or rest hand on steady surface 2 Inconsistent welding s
33. shaded impact safety full face shield Safety equipment such as NIOSH approved respirator heavy duty work gloves non skid safety shoes or hearing protection used for appropriate conditions will reduce personal injuries c 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 d Do not overreach Keep proper footing and balance at all times This enables better control of the welder in unexpected situations SKU 98871 For technical questions please call 1 800 444 3353 e Only use safety equipment that has been approved by an appropriate standards agency Unapproved safety equipment may not provide adequate protection Eye protection must be ANSI approved and breathing protection must be NIOSH approved for the specific hazards in the work area Welder use and care 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 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 c Store idle welders out of the reach of children and do not allow persons unfamiliar with the welder or these instructions to operate the welder Welders
34. sized or excessively worn Contact Tip 2b Verify that Contact Tip 2b 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 2b with proper size and type V ul J O m Page 28 For technical questions please call 1 800 444 3353 SKU 98871 TROUBLESHOOTING continued 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 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 7 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 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 inspe
35. uality clean and inspect the Contact Tip 2b and Nozzle 3 before each use as follows Nozzle 3 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 a 3 Scrub the interior of the Nozzle clean with Nozzl a wire brush 3 i 4 Examine the end of the Nozzle The Contact end should be flat and even If the end Tip 2b is uneven chipped melted cracked or otherwise damaged the Nozzle will adversely effect the weld and should be replaced 5 Reinstall the Nozzle after inspecting and cleaning the Contact Tip V ul J O m Page 24 For technical questions please call 1 800 444 3353 SKU 98871 Contact Tip 2b Inspection Cleaning and Replacement Make sure that the entire Gun is completely cool and that the Power Cord is unplugged from the electrical outlet before proceeding 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 Nozzle 3 Scrub the exterior of the Tip clean with a i wire brush Clean out the inside of the Contact tip with a tip cleaner sold separately Tip 2b Check that the Tip is the proper type for the wire size used 035 tip for 030 035
36. uld lay flush against the top of the Cover Then secure using Screw 29 as shown N Cover Latch 8 2 Attach the Cover Latch 8 to the front of the Base Frame 14 using the Bolt 42 Washer 40 Lock Washer 50 and Nut 41 as shown Washer 50 SKU 98871 For technical questions please call 1 800 444 3353 Page 9 Wire Spool 27 Installation F u E Turn the welder OFF and unplug it oe K before proceeding e MP FLUX WIRE WELDER Cover 31 Press in the Cover Latch 8 on the front Cover of the handle then open the Cover 31 Latch 8 QP wing nut 25 Remove the Wing Nut 25 and the Spool Retaining Nut 26 If replacing a Spool poor Rotalbing Nut 26 remove the old Spool and all remaining wire from the liners Wire Spool 27 Make sure the Spool Spring 24 is in place on the Spool Spindle 28 Place the new flux core Wire Spool over the Spool Spindle 28 and on top of the Spool Spring 24 as illustrated To prevent wire feed problems set the Spool so that it will unwind counterclockwise Spool Spring 24 Spool Spindle 28 Secure Spool in place with the Spool Retaining Nut 26 then the Wing Nut 25 wire must unwind this direction Page 10 For technical questions please call 1 800 444 3353 SKU 98871 6 Turn the Feed Tensioner 37 knob Feed Swing Feed counterclockwise to loosen it enough to Arm 36 Tensioner 37
37. y oO x ee Current 90 AMP FLUX WIRE WELDER Switch 7b a Ground fy Power Cable 33 Cord 32 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 Ground Cable This connects to the base metal to provide a good connection for the current to travel back to the welder SKU 98871 For technical questions please call 1 800 444 3353 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 o lt A l L S D lt m 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 The welding Gun is energized whenever the Power Switch is on Overload Indicator This lights up if duty cycle work period is exceeded overheating the welder 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 welde
38. ze required 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 SKU 98871 For technical questions please call 1 800 444 3353 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 SYMBOLOGY Qe w Feed Speed Workpiece Ground Cable h Overheat Shutdown Indicator Housing Ground Point Volts Alternating Current OA es Open Circuit Voltage KVA Kilovolt Amperes Volts 1000 Amperes IPM Inches Per Minute American Wire Gauge Page 7 gt H LLI LL lt V SPECIFICATIONS Power input 120 V 24 A peak 1 phase p Connect to at least 20 A dedicated circuit DCEN Welding Output a aa 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 Duty Cycle 45 at MIN setting See explanation on page 16 Open Circuit Voltage KVA Wire Speed Ground 6 AWG 6 Cable Sizes Gun 8 AWG Power 3 wire 14 AWG Welder Tips Wire
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