90 Amp flux wire WELDER 55167 ASSEMBLY AND OPERATING INSTRUCTIONS ® 3491 Mission Oaks Blvd., Camarillo, CA 93011 Visit our Web site at http://www.harborfreight.com To prevent serious injury, Read and understand all warnings and instructions before use. Copyright© 2007 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.
Contents Specifications..............................................................................3 General Safety Rules...................................................................3 Specific Safety Rules............................................................................ 5 Grounding.............................................................................................. 8 Symbology............................................................................................
Specifications Welding Current 63 ~ 68 amps; High setting: 79 ~ 90 amps Duty Cycle 10% at 80 amps; 18% at 60 amps (See explanation of Duty Cycle on page 15.) Power Consumption 120 VAC, 24 amps peak, single phase Should be connected to a 20 amp minimum dedicated circuit Heat Control 2 settings Ground Cable 6 AWG, 6 foot Torch Power Cable 8 AWG, 6 foot Power Cord 3-wire, 14 AWG, UL listed Welder Tip Included tips will accept 0.030” flux core wire (0.
Distractions can cause you to lose control. Protect others in the work area from debris such as chips and sparks. Provide barriers or shields as needed. Electrical Safety 4. 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. 5. Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock. 6.
15. Use clamps (not included) or other practical ways to secure and support the workpiece to a stable platform. Holding the work by hand or against your body is unstable and may lead to loss of control. 16. Do not force the tool. Use the correct tool for your application. The correct tool will do the job better and safer at the rate for which it is designed. 17. Do not use the power tool if the Power Switch does not turn it on or off.
4. Unplug before performing maintenance. Always unplug the Welder from its electrical outlet before performing any inspection, maintenance, or cleaning procedures. 5. Never leave the Welder unattended while energized. Turn power off if you have to leave the Welder. 6. 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. 7. Prevent eye injury and burns.
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 combustible material whose contents, when heated, can produce flammable or explosive vapors.
12. 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. 13. WARNING! People with pacemakers should consult their physician(s) before using this product.
3. Your tool must be plugged into an appropriate outlet, properly installed and grounded in accordance with all codes and ordinances. The plug and outlet should look like those in the following illustration. (See 3-Prong Plug and Outlet.) 3-Prong Plug and Outlet Outlets for 2-Prong Plug Double Insulated Tools: Tools With Two Prong Plugs 1. Tools marked “Double Insulated” do not require grounding.
areas. RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS* NAMEPLATE AMPERES (At Full Load) EXTENSION CORD LENGTH 25 Feet 50 Feet 75 Feet 100 Feet 150 Feet 0 - 2.0 18 18 18 18 16 2.1 - 3.4 18 18 18 16 14 3.5 - 5.0 18 18 16 14 12 5.1 - 7.0 18 16 14 12 12 7.1 - 12.0 18 14 12 10 - 12.1 - 16.0 14 12 10 - - 16.1 - 20.0 12 10 - - - FIGURE C * Based on limiting the line voltage drop to five volts at 150% of the rated amperes.
Unpacking When unpacking, check to make sure the following parts are included: Flux Wire Welder, Shade #10 Face Shield (38), Torch (1), Ground Cable (33), Wire Brush / Hammer (39), Power Cord (32), Wire Spool, Spare Welding Tip, and Contact Tip Wrench (43). This unit is packed with a protective light film of oil, wipe the unit of with a clean rag prior to assembly. If any parts are missing or broken, please call Harbor Freight Tools at the number on the cover of this manual as soon as possible. Assembly 1.
Wire Feed Adjusting Spring (36) Tension Adjusting Screw (37) Wire Sheath Cover (31) Handle (30) Cover Locking Spring (8) Wire Reel (27) Installing the Wire Reel 1. WARNING! Turn the welder OFF and unplug it before proceeding. 2. Press on the Cover Locking Spring (8), then lift the Cover (31) using Handle (30), to expose the Wire Feed Unit (23). 3. Unscrew the Wing Nut (25) and remove the Reel Locking Knob (26).
9. Turn the Nozzle (3) counterclockwise while pulling to remove. 10. Using the third oval hole on the provided Wrench (43), turn the Contact Tip (2b) counterclockwise and remove. 11. Lay the Torch Cable out in a straight line so that the wire moves through it easily. Leave the cover open, so that the feed mechanism can be observed. Exercise extreme caution - Risk of fire and/or electric shock! The following steps require applying power to the welder.
5. Remove the Wire Feed Roller (34) and install one with the proper size (.030”) facing up. 6. Reassemble the Roller Bracket (44), Screws (45), and Washers (46). Put the welding wire into the top groove on the Roller, if it is not already in place. 7. Swing the Wire Feed Adjusting Spring (36) down while pressing it forward to latch it over the Tension Adjusting Screw (37). Tighten the Tension Adjusting Screw until the Wire Feed Bearing (35) just touches the wire and then three full turns farther. 8.
6. Connect the new Switch (1c); polarity does not matter. When reinstalling, make sure that the new Switch fits securely in place. 7. Reassemble, reversing the steps on the previous page. 8. Put on appropriate safety equipment, as explained in the safety section of this manual. After the unit is fully assembled, plug the Welder back in and turn it back ON. Carefully point the torch away from yourself and conductive materials, and check that the new switch functions properly. 9.
Setting Up The Weld WARNING! 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” welder, 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. The Flux Wire Welder is used to weld sheet metal and light carbon steel.
objects, turn the Power Switch to the ON position. 6. Orient yourself on the area to be welded, then place the Face Shield over your eyes. Warning: Never look at the ignited arc without ANSI approved, arc shaded, eye protection in a full face shield. Permanent eye damage or blindness can occur. Skin burns can occur. Never breathe arc fumes. Holding The Torch 7. Hold the Torch (1) in one hand and the face shield in the other.
NOTE: The numbers within the spaces are the approximate wire feed settings recommended* for this wire size and material thickness. Wire Size (Flux Core, Mild Steel) .030” Weld Settings Chart 14 Gauge Minimum Current 12 Gauge 6 Maximum Current Material Thickness (Steel) 16 Gauge Minimum Current 7 /8” Minimum Current 4 1 1 *This chart is only intended to show general guidelines for different wire sizes and for different thicknesses of material.
Weld Diagnosis Weld Penetration Excess or burn-through Weld droops on top and underneath, or falls through entirely, making a hole. Proper Weld is visible underneath and bulges slightly on top. Inadequate Weld does not contact the joint fully, just on the surface. Cross Sections Possible Causes and Solutions Possible Causes and Solutions 1. Excessive material at weld: 1. Workpieces too thick/close: Reduce wire feed speed. Joint design must allow weld to reach bottom of groove and allow proper welding 2.
Crooked/wavy bead Porosity Small cavities or holes in the bead. Top View Top View Possible Causes and Solutions 1. Stickout too long: Reduce stickout. 2. Dirty workpiece or welding wire: Make certain that workpiece and wire are both clean and free from oil, coatings, and other residues. Possible Causes and Solutions 1. Stickout too long: Reduce stickout. 2. Inaccurate welding: Use two hands or rest hand on steady surface. Excessive Spatter Spatter that is grainy and large. Fine spatter is normal.
Maintenance Warning: Before performing any maintenance on the Welder, unplug the Power Cord from the electrical outlet and allow all parts of the welder to cool thoroughly. 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 quality, clean and inspect the Contact Tip (2b) and Nozzle (3) before each use, as follows: Nozzle Inspection, Cleaning, and Replacement A.
Parts Lists and Diagrams Wiring Schematic SKU 55167 For technical questions, please call 1-800-444-3353; Troubleshooting section at end of manual.
Parts List Part Description Q’ty Part Description Q’ty 1a Back Handle 1 23 Wire Feed Unit 1 1b Front Handle 1 24 Reel Spring 1 1c Trigger Switch 1 25 Wing Nut, M6 1 1d Handle Lock Ring 1 26 Reel Locking Knob 1 1e Torch Tube 1 27 Wire Reel 1 2b .9 mm Contact Tip 1 28 Reel Holder 1 3 Nozzle 1 29 Self-tapping Screw, ST4.
Assembly Diagram NOTE: Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts. SKU 55167 For technical questions, please call 1-800-444-3353; Troubleshooting section at end of manual.
SKU 55167 For technical questions, please call 1-800-444-3353; Troubleshooting section at end of manual.
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 Possible Causes and Solutions 1. Insufficient wire feed pressure: Increase wire feed pressure properly - follow steps 12-15 on page 13. 2. Incorrect wire feed roll size: Replace with the proper one - .8 mm (.
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 (7a) does not light when switched on Possible Causes and Solutions 1. Unit is not connected to outlet properly or outlet is unpowered: Verify the voltage at the outlet and the connection to the outlet.
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. 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.
