Page 2 - Table of Contents; IMPORTANT SAFETY INFORMATION; General Safety; SAFETY
Page 2 For technical questions, please call 1-800-444-3353. SKU 68886 Table of Contents Safety ......................................................... 2Setup .......................................................... 7Specifications ............................................. 7Basic Welding .......
Page 3 - Fume and Gas Safety; Arc Ray Safety
Page 3 For technical questions, please call 1-800-444-3353. SKU 68886 Fume and Gas Safety FUMES AND GASES can be hazardous to your health. 1. Exposure to welding or cutting exhaust fumes can increase the risk of developing certain cancers, such as cancer of the larynx and lung cancer. Also, some dis...
Page 4 - Electrical Safety; Fire Safety
Page 4 For technical questions, please call 1-800-444-3353. SKU 68886 Electrical Safety ELECTRIC SHOCK can KILL. 1. Turn off, disconnect power, and discharge electrode to ground before setting down torch/electrode holder and before service. 2. Do not touch energized electrical parts. Wear dry, insul...
Page 5 - SAVE THESE INSTRUCTIONS.
Page 5 For technical questions, please call 1-800-444-3353. SKU 68886 Welder use and care 1. 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. 2. Disconnect the plug from the power source before ma...
Page 6 - Grounding; Extension Cords
Page 6 For technical questions, please call 1-800-444-3353. SKU 68886 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 properly grounded. Have a plug installed by a certified ele...
Page 7 - Symbology; OCV; Specifications
Page 7 For technical questions, please call 1-800-444-3353. SKU 68886 Symbology Wire Feed (Speed) Workpiece Ground Cable Torch Cable Overheat Shutdown Indicator Cooling Fan Housing Ground Point V~ Volts Alternating Current A Amperes OCV Open Circuit Voltage KVA Kilovolt Amperes (Volts / 1000 * Amper...
Page 8 - Setup; Face Shield Assembly
Page 8 For technical questions, please call 1-800-444-3353. SKU 68886 1. Attach the handle to the Face Shield 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 thenB. slide the tabs forward from the back, l...
Page 9 - Wire Spool Installation
Page 9 For technical questions, please call 1-800-444-3353. SKU 68886 Wire Spool Installation 1. Turn the welder OFF and unplug it before proceeding. 2. Pull up on the door latch, then open the Door. 3. Remove the Spool Knob, Spool Spring, and upper Spool Plate. If replacing a Spool, remove the old ...
Page 10 - Solid Core (Gas Shielded) Polarity Setup
Page 10 For technical questions, please call 1-800-444-3353. SKU 68886 6a. Flux Core (Gas-less) Wire Setup: Remove the two Knobs securing the cables. Connect the Black Ground Cable to the rear, red, positive Terminal using the Knob. Connect the Red Torch Cable to the front, black, negative Terminal ...
Page 13 - WARNING; The following steps require applying power; To prevent serious injury from fire or electric shock:; IMPORTANT
Page 13 For technical questions, please call 1-800-444-3353. SKU 68886 WARNING The following steps require applying power to the welder with the cover open. To prevent serious injury from fire or electric shock: 1. Do not touch anything (especially not the Ground Clamp) with the Torch or welding wir...
Page 15 - Basic Welding; Practice your welding
Page 15 For technical questions, please call 1-800-444-3353. SKU 68886 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 SERIOUS INJURY: Protective gear must be worn when using th...
Page 16 - Control Panel Layout
Page 16 For technical questions, please call 1-800-444-3353. SKU 68886 Control Panel Layout Overload Indicator: This lights up if duty cycle work period is exceeded, resulting in overheating the welder. Rest the Torch on an electrically non-conductive, heat-resistant surface, such as a concrete slab...
Page 18 - Flux Weld Settings; MIG Weld Settings
Page 18 For technical questions, please call 1-800-444-3353. SKU 68886 Metal Thickness Flux Weld Settings DCEN Polarity NO GAS Material Being Welded Wire Type Shielding Gas Wire Diameter Suggested Settings 22 Ga .030″ 0.8mm 18 Ga .048″ 1.2mm 16 Ga .060″ 1.5mm 14 Ga .075″ 2.0mm 1/8″ 3.2mm 3/16″ 4.8mm...
Page 19 - Setting Up The Weld
Page 19 For technical questions, please call 1-800-444-3353. SKU 68886 1. Make practice welds on pieces of scrap the same thickness as your intended workpiece to practice technique before welding anything of value. Clean the weld surfaces thoroughly with a wire brush or angle grinder; there must be ...
Page 21 - Stickout; Drag Angle; Basic Welding Technique
Page 21 For technical questions, please call 1-800-444-3353. SKU 68886 1. Press (and hold) Trigger and contact area to be welded with electrode wire to ignite arc. 2. For a narrow weld, you can usually draw the wire in a steady straight line, this is called a stringer bead . For a wider weld, draw t...
Page 22 - After practice welding for a few
Page 22 For technical questions, please call 1-800-444-3353. SKU 68886 Note: If Welder is used too long, the amber Overload Indicator will light and the Welder Torch will shut off until the welder cools. If this happens, rest the Torch on an electrically non-conductive, heat-resistant surface, such ...
Page 23 - Welding Tips; Cleaning the Weld
Page 23 For technical questions, please call 1-800-444-3353. SKU 68886 Welding Tips A good way to test welding technique is to examine a weld’s appearance after it has cooled and the slag has been removed. Then, better welding can be learned by adjusting your weld technique to remedy any problems fo...
Page 24 - Weld Diagnosis; Workpiece Heat Control / Weld Penetration; How to increase workpiece heat
Page 24 For technical questions, please call 1-800-444-3353. SKU 68886 EXCESS PENETRATION OR BURN-THROUGH PROPER PENETRATION INADEQUATE PENETRATION Not hot enough Too hot Ideal heat Weld Diagnosis Workpiece Heat Control / Weld Penetration Good Weld Current Too Low or Wire Feed Too Slow Current Too H...
Page 25 - Weld Problems; Weld Not Adhering Properly
Page 25 For technical questions, please call 1-800-444-3353. SKU 68886 EXCESS PENETRATION OR BURN-THROUGH Weld droops on top and underneath, or falls through entirely, making a hole. PROPER PENETRATION Weld is visible underneath and bulges slightly on top. INADEQUATE PENETRATION Weld does not contac...
Page 27 - Maintenance; Nozzle and Contact Tip Inspection and Cleaning
Page 27 For technical questions, please call 1-800-444-3353. SKU 68886 Maintenance TO PREVENT SERIOUS INJURY, FIRE AND BURNS: Unplug the welder, rest the Torch on a heat-proof, electrically non-conductive surface, and allow all parts of the Welder to cool thoroughly before service. 1. Periodically r...
Page 28 - Wire feed motor runs but wire does not feed properly; Wire creates a bird’s nest during operation; Weak Arc strength
Page 28 For technical questions, please call 1-800-444-3353. SKU 68886 Troubleshooting IMPORTANT! Be CERTAIN to shut off the Welder, disconnect it from power, and discharge the Torch to ground before adjusting, cleaning, or repairing the unit. Wire feed motor runs but wire does not feed properly POS...
Page 29 - Power switch does not light when switched on; Wire Feeds, but arc does not ignite
Page 29 For technical questions, please call 1-800-444-3353. SKU 68886 Troubleshooting (continued) IMPORTANT! Be CERTAIN to shut off the Welder, disconnect it from power, and discharge the Torch to ground before adjusting, cleaning, or repairing the unit. Power switch lights, but welder does not fun...
Page 30 - Parts List and Diagrams; Wiring Diagram
Page 30 For technical questions, please call 1-800-444-3353. SKU 68886 Parts List and Diagrams Wiring Diagram W elding T orch Gas/Gasless Gasless Gas Ground Clamp W ire Feed Motor Therm al Relay W elding T orch Switch Parts List Record Serial Number Here: Note: If product has no serial number, recor...
Page 31 - Assembly Diagram
Page 31 For technical questions, please call 1-800-444-3353. SKU 68886 Assembly Diagram 1 2 3 4 5 6 7 8 9 10 11 12 13 14 32 31 30 29 28 27 26 25 15 16 17 18 19 20 21 22 23 24 33 35 36 37 34 SAFETY MAINTENANCE BASIC WELDING WELDING TIPS SETUP
Page 32 - Limited 90 Day Warranty
3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-3353 Limited 90 Day Warranty Harbor Freight Tools Co. makes every effort to assure that its products meet high quality and durability standards, and warrants to the original purchaser that this product is free from defects in ma...