Page 2 - Table of Contents; IMPORTANT SAFETY INFORMATION; General Safety; SAFETY
Page 2 For technical questions, please call 1-800-444-3353. SKU 68887 Table of Contents Safety ......................................................... 2Specifications ............................................. 7Setup .......................................................... 7Basic Welding .......
Page 3 - Fume and Gas Safety; Arc Ray Safety
Page 3 For technical questions, please call 1-800-444-3353. SKU 68887 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 68887 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 68887 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; Grounded Welders; Symbology; OCV
Page 6 For technical questions, please call 1-800-444-3353. SKU 68887 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 - Cover Assembly
Page 7 For technical questions, please call 1-800-444-3353. SKU 68887 Specifications Electrical Rating 120V~ / 20A Welding Output 60 ~ 120 A, AC Capacity 18 gauge (0.048″) to 3/16″ (0.19″) mild steel only Not for welding aluminum or stainless steel Duty Cycle 20% @ 90A (See explanation on page 14) O...
Page 8 - Wire Spool Installation
Page 8 For technical questions, please call 1-800-444-3353. SKU 68887 1. Turn the Welder to OFF and unplug it before proceeding. 2. Press in the pin at the top center of the control panel and open the cover. 3. Remove the Knob, Spring and the Top Plate. If replacing a Spool, remove the old Spool and...
Page 10 - WARNING; The following steps require applying power to the welder; To prevent serious injury from fire or electric shock:
Page 10 For technical questions, please call 1-800-444-3353. SKU 68887 WARNING The following steps require applying power to the welder with the cover open. To prevent serious injury from fire or electric shock: 1. Do not touch anything, especially not the Ground Clamp, with the Gun or welding wire ...
Page 12 - Basic Welding; Practice your welding
Page 12 For technical questions, please call 1-800-444-3353. SKU 68887 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 13 - Control Panel Layout
Page 13 For technical questions, please call 1-800-444-3353. SKU 68887 Control Panel Layout ON MIN OFF MAX WIRE FEED SPEED GUN GROUND 120V~ 60Hz 20A 90 AMP FLUX WIRE WELDER I TEM 68887 Wire .030″-.035″ Flux-core Capacity XX Ga. – X / X ″ Steel Plate Cables Electrode – X ′ Ground Clamp – X ′ Wire Spe...
Page 14 - Weld Settings Chart
Page 14 For technical questions, please call 1-800-444-3353. SKU 68887 Weld Settings Chart NOTE: The numbers within the spaces are the approximate wire feed settings recommended* for this wire size and material thickness. Material Thickness (Steel) 18 Gauge 16 Gauge 14 Gauge 1 / 8 ″ 3 / 16 ″ MIN cur...
Page 15 - Setting Up The Weld
Page 15 For technical questions, please call 1-800-444-3353. SKU 68887 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 16 - Stickout; Drag Angle; Basic Welding Technique
Page 16 For technical questions, please call 1-800-444-3353. SKU 68887 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 17 - After practice welding for a few
Page 17 For technical questions, please call 1-800-444-3353. SKU 68887 Note: If Welder is used too long, the amber Overload Indicator will light and the Welder Gun will shut off until the welder cools. If this happens, rest the Gun on an electrically non-conductive, heat-resistant surface, such as a...
Page 18 - Welding Tips
Page 18 For technical questions, please call 1-800-444-3353. SKU 68887 A good way to test welding technique is to examine a weld’s appearance after it has cooled and the slag has been removed. Then, better welding can be learned by adjusting your weld technique to remedy any problems found. Cleaning...
Page 19 - Weld Diagnosis; Workpiece Heat Control / Weld Penetration; How to increase workpiece heat; Example Weld Diagrams
Page 19 For technical questions, please call 1-800-444-3353. SKU 68887 Weld Diagnosis Workpiece Heat Control / Weld Penetration EXCESS PENETRATION OR BURN-THROUGH PROPER PENETRATION INADEQUATE PENETRATION Not hot enough Too hot Ideal heat How to increase workpiece heat and increase penetration: (to ...
Page 20 - Weld Not Adhering Properly; Bend at Joint; Weld Problems
Page 20 For technical questions, please call 1-800-444-3353. SKU 68887 Weld Not Adhering Properly Gaps present between weld and previous bead or between weld and workpiece. See areas below. POSSIBLE CAUSES AND SOLUTIONS 1. Incorrect welding technique: Place stringer bead at correct place in joint. A...
Page 22 - Maintenance; Nozzle Inspection, Cleaning, and Replacement
Page 22 For technical questions, please call 1-800-444-3353. SKU 68887 Maintenance TO PREVENT SERIOUS INJURY, FIRE AND BURNS: Unplug the Welder, rest the Gun on a heat-proof, electrically non-conductive surface, and allow all parts of the Welder to cool thoroughly before service. 1. Periodically rem...
Page 24 - Troubleshooting; Wire Feed Motor Runs But Wire Does Not Feed Properly; Wire Creates A Bird’s Nest During Operation
Page 24 For technical questions, please call 1-800-444-3353. SKU 68887 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 POSSI...
Page 25 - Power Switch Does Not Light When Switched On; Welding Arc Not Stable; Weak Arc Strength
Page 25 For technical questions, please call 1-800-444-3353. SKU 68887 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 Lights, But Welder Does Not Funct...
Page 26 - Parts Lists and Diagrams; Wiring Schematic; Parts List
Page 26 For technical questions, please call 1-800-444-3353. SKU 68887 Parts Lists and Diagrams Wiring Schematic R MAX S2 S1 T1 MIN B b Q A C 1 1 2 3 2 3 4 J G 1 2 3 4 24V Parts List 1 Grounding Cable 1 2 MIG Torch 1 3 Potentiometer Knob 1 4 Indicator 1 5 MIG Torch Holder 1 6 Font Panel 1 7 Left Pan...
Page 27 - Part 9 Detail; Assembly Diagram
Page 27 For technical questions, please call 1-800-444-3353. SKU 68887 Part 9 Detail .030″ 9a 9d 9f (hidden by part 9e) 9e 9b 9c 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 illustrati...
Page 28 - Limited 90 Day Warranty; PLEASE READ THE FOLLOWING CAREFULLY
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...
