Chicago Electric 68887 Instruction Manual

Page 2 For technical questions, please call 1-800-444-3353. SKU 68887
Table of Contents
Safety ......................................................... 2
Specifications ............................................. 7
Setup .......................................................... 7
Basic Welding............................................ 12
Welding Tips .............................................. 18
Maintenance.............................................. 22
Parts Lists and Diagrams .......................... 26
Warranty .................................................... 28
WARNING SYMBOLS AND DEFINITIONS
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.
Indicates a hazardous situation which, if not avoided,
will result in death or serious injury.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
Addresses practices not related to personal injury.
IMPORTANT SAFETY INFORMATION
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.
General Safety
PROTECT yourself and others. Read and understand this information.
1. Before use, read and understand
manufacturer′s instructions,
Material Safety Data Sheets (MSDS′s),
employer′s safety practices, and ANSI Z49.1.
2. Keep out of reach of children.
Keep children and bystanders away while operating.
3. Place the welder on a stable location before use.
If it falls while plugged in, severe injury,
electric shock, or fire may result.
4. Do not overreach.
Keep proper footing and balance at all times.
5. 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.
6. Avoid unintentional starting. Make sure you are
prepared to begin work before turning on the Welder.
7. Never leave the Welder unattended while
energized. Turn power off if you have to leave.
8. 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.
9. 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 & Safety Code § 25249.5, et seq.)
10. 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 & Safety Code § 25249.5, et seq.)
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP

Page 3For 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 diseases that may be linked to exposure
to welding or cutting exhaust fumes are:
• Early onset of Parkinson’s Disease
• Heart disease • Ulcers
• Damage to the reproductive organs
• Inflammation of the small intestine or
stomach • Kidney damage
• Respiratory diseases such as
emphysema, bronchitis, or pneumonia
2. Do not use near degreasing or
painting operations.
3. Keep head out of fumes.
Do not breathe exhaust fumes.
4. Use enough ventilation, exhaust at arc, or
both, to keep fumes and gases from breathing
zone and general area. If engineering controls
are not feasible, use an approved respirator.
5. Work in a confined area only if it
is well-ventilated, or while wearing
an air-supplied respirator.
6. Have a recognized specialist in
Industrial Hygiene or Environmental Services
check the operation and air quality
and make recommendations
for the specific welding situation.
Follow OSHA guidelines for
Permissible Exposure Limits (PEL’s) and
the American Conference of Governmental
Industrial Hygienists recommendations for
Threshold Limit Values (TLV’s) for fumes and gases.
Arc Ray Safety
ARC RAYS can injure eyes and burn skin.
1. Wear ANSI-approved welding eye protection
featuring at least a number 10 shade lens rating.
2. Wear leather leggings, fire resistant shoes
or boots during use. Do not wear pants with
cuffs, shirts with open pockets, or any clothing
that can catch and hold molten metal or sparks.
3. Keep clothing free of grease, oil,
solvents, or any flammable substances.
Wear dry, insulating gloves and protective clothing.
4. 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.
5. When welding/cutting overhead or in confined
spaces, wear flame resistant ear plugs or
ear muffs to keep sparks out of ears.
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP

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, insulating gloves. Do not touch electrode
holder, electrode, welding torch, or welding wire with
bare hand. Do not wear wet or damaged gloves.
3. Connect to grounded, GFCI-protected
power supply only.
4. Do not use near water or damp objects.
5. People with pacemakers should consult their
physician(s) before use. Electromagnetic fields
in close proximity to heart pacemaker could cause
pacemaker interference or pacemaker failure.
6. Do not expose welders to rain or wet conditions.
Water entering a welder will increase
the risk of electric shock.
7. 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.
8. Do not use outdoors.
9. 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 large enough to cover
your full area of contact with the work or ground.
10. Use care not to touch the welding tip to
grounded material whenever the unit is
plugged in. Electric shock, fire, or burns may
happen if appropriate precautions are not taken.
Fire Safety
ARC AND HOT SLAG can cause fire.
1. Clear away or protect flammable objects.
Remove or make safe all combustible materials for a
radius of 35 feet (10 meters) around the work area.
Use a fire resistant material to cover or block all open
doorways, windows, cracks, and other openings.
2. Keep ABC-type fire extinguisher near
work area and know how to use it.
3. Maintain a safe working environment.
Keep the work area well lit.
Make sure there is adequate surrounding workspace.
Keep the work area free of obstructions,
grease, oil, trash, and other debris.
4. Do not operate welders in atmospheres
containing dangerously reactive or
flammable liquids, gases, vapors, or dust.
Provide adequate ventilation in work areas
to prevent accumulation of such substances.
Welders create sparks which may ignite flammable
substances or make reactive fumes toxic.
5. 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, equipped with a fire extinguisher,
during the cutting process and for at least one
half hour after the cutting is completed.
6. 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.
7. Do not dispose of hot slag in containers
holding combustible materials.
8. After 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.
9. 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.
Clean and purge containers before applying heat.
Vent closed containers, including castings,
before preheating, welding, or cutting.
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP

Page 5For 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 making any adjustments,
changing accessories, or storing welders.
Such preventive safety measures reduce the
risk of starting the welder accidentally.
3. 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.
4. 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
are dangerous in the hands of untrained users.
5. 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.
Maintenance
1. 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.
2. Have your welder serviced by a qualified
repair person using only identical
replacement parts. This will ensure that
the safety of the welder is maintained.
3. Maintain labels and nameplates on the Welder.
These carry important information.
If unreadable or missing, contact
Harbor Freight Tools for a replacement.
4. Unplug before maintenance. Unplug the Welder
from its electrical outlet before any inspection,
maintenance, or cleaning procedures.
SAVE THESE INSTRUCTIONS.
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP

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 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.
Grounded Welders
1. 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.
2. The Welder must be plugged into an appropriate
outlet, properly installed and grounded in
accordance with all codes and ordinances.
Extension Cords
1. 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.
2. 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.
3. 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.
4. When using more than one extension cord to
make up the total length, make sure each cord
contains at least the minimum wire size required.
5. 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.
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
Wire Feed (Speed)
Workpiece Ground Cable
Gun Cable
Overheat Shutdown Indicator
Cooling Fan
Housing Ground Point
V~ Volts Alternating Current
AAmperes
OCV Open Circuit Voltage
KVA Kilovolt Amperes
(Volts / 1000 * Amperes)
IPM Inches Per Minute
AWG American Wire Gauge
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP

Page 7For 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)
Open Circuit Voltage 27
KVA 2.38
Welder Tips / Wire Size Installed tip will accept .030″ to .035″ FLUX CORE wire
Wire Spool Capacity 4″ diameter / 2 lb. spool
Setup
Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this
manual including all text under subheadings therein before set up or use of this product.
TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION:
Turn the Power Switch off and unplug the welder before assembly.
Cover Assembly
1. Slide the Handle into the slot on
the Cover from the back.
2. The notch on the front of the Handle should drop
into the slot in the Cover. Both ends of the Handle
should lay flush against the top of the Cover.
3. Secure with Screw at front of unit.
Handle
notch drops
into slot on
Cover here
Screw
Cover
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP

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 all remaining wire from the liners.
4. Place the new flux core Wire Spool
over the Spool Spindle.
To prevent wire feed problems, set the Spool
so that it will unwind counterclockwise .
5. Replace the Top Plate (turned as shown in
illustration), the Spring and the Knob.
ON MIN
OFF MAX
WIRE FEED SPEED
GUN
GROUND
120V~
60Hz
20A
90 AMP FLUX WIRE WELDER
IT EM 68887
Wire .030″-.035″ Flux-core
Capacity XX Ga. – X/X″ Steel Plate
Cables Electrode – X′
Ground Clamp – X′
Wire
Spool
Cover
Wire Spool
Spring
Top Plate
Knob
Spindle
.030″
wire must
unwind this
direction
Wire Spool Installation
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP

Page 9For technical questions, please call 1-800-444-3353.SKU 68887
6. Turn the Feed Tensioner counterclockwise to
loosen it enough to pull it up, releasing tension.
Swing the Feed Swing Arm out. (Note: Do
not loosen the Feed Tensioner too
much, or it will come apart.)
7. Loosen and remove the Feed Knob. Compare
the wire diameter marked on the Wire Spool with
the stamped number on the top of the Feed Roller.
The Roller’s groove size must be compatible with
the wire diameter -
.8mm rollers also work with .030″ wire &
.9mm rollers also work with .035″ wire.
Flip the Feed Roller as needed and confirm that the
number facing up is the same as the wire diameter
on the Spool.
Replace and secure the Feed Knob.
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”, wasting 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.
10. Swing the Feed Swing Arm closed, and swing
the Feed Tensioner across the tip of the Arm, to
latch it. Make sure the Welding Wire is resting in
the top groove of the Feed Roller, then turn the
Feed Tensioner clockwise a couple of turns.
After the wire is held by the Feed
Tensioner, you may release it.
11. Pull the Nozzle to remove it.
12. Using the third oval hole on the Multi-wrench, turn
the Contact Tip counterclockwise and remove.
13. Lay the Gun 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.
Feed Swing
Arm
Feed
Tensioner
.030″ .030″
Feed
Roller
Feed
Knob
.030″
.030″
Wire
Spool
welding
wire
HOLD WIRE
SECURELY
Wire
Liner
leader
wire liner
Feed Swing
Arm
Feed
Tensioner
.030″ .030″
Gun
Nozzle
Contact
Tip
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP

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 or an arc will be ignited.
2. Do not touch internal welder components
while it is plugged in.
14. Do not touch the Gun’s Trigger.
Plug the Power Cord into its electrical
outlet and turn the welder to ON.
15. Point the Gun away from all objects and press the
Trigger until the wire feeds out of the gun two inches.
The Wire Liner may come out with the welding
wire, this is normal, just push the Wire Liner
back into the Gun.
If the wire does not feed properly and the
Spool is stationary, turn the welder to OFF,
unplug it, and slightly tighten the Feed
Tensioner clockwise before retrying.
ON MIN
OFF MAX
WIRE FEED SPEED
GUN
GROUND
120V~
60Hz
20A
90 AMP FLUX WIRE WELDER
IT EM 68887
Wire .030″-.035″ Flux-core
Capacity XX Ga. – X/X″ Steel Plate
Cables Electrode – X′
Ground Clamp – X′
Welding
Wire
Gun
2″
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP

Page 11For technical questions, please call 1-800-444-3353.SKU 68887
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 to
OFF, unplug it, slightly tighten the Feed Tensioner
clockwise , and try again.
If the wire bends from the feed tension,
then the tension is set properly.
17. TURN THE WELDER TO OFF.
18. Select a Contact Tip that is compatible with the
welding wire used. The included Tip (.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 a wrench.
19. Replace the Nozzle and cut the wire
off at 1/2″ from tip (1/2″ stickout).
20. Swing the Cover closed until the
Cover Latch locks in place.
.030″
2-3″
Incrementally
increase tension
until
wire bends.
ON MIN
OFF MAX
WIRE FEED SPEED
GUN
GROUND
120V~
60Hz
20A
90 AMP FLUX WIRE WELDER
IT EM 68887
Wire .030″-.035″ Flux-core
Capacity XX Ga. – X/X″ Steel Plate
Cables Electrode – X′
Ground Clamp – X′
Gun
Nozzle
Contact
Tip
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP

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 the
Welder; minimum shade number 10 full face shield
(or welding mask), ear protection, welding gloves,
sleeves and apron, NIOSH-approved respirator, and
fire resistant work clothes without pockets should be
worn when welding.
Light from the arc can cause permanent damage to
the eyes and skin.
Do not breathe arc fumes.
TO PREVENT SERIOUS INJURY,
FIRE AND BURNS:
Keep welding tip clear of grounded
objects whenever unit is plugged in.
The Flux Wire Welder is used to weld sheet metal
and low carbon steel. Good welding takes a degree
of skill and experience. Practice a few sample
welds on scrap before welding your first project.
Additional practice periods are recommended whenever
you weld a different thickness of material or weld a
different type of connection.
Make practice welds on pieces of scrap to practice
technique before welding anything of value.
=
ON MIN
OFF MAX
WIRE FEED SPEED
GUN
GROUND
120V~
60Hz
20A
90 AMP FLUX WIRE WELDER
IT EM 68887
Wire
.030″-.035″ Flux-core
Capacity
XX Ga. – X/X″ Steel Plate
Cables
Electrode – X′
Ground Clamp – X′
Practice your welding
technique on scrap
pieces before welding
anything of value.
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP

Page 13For 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
ITEM 68887
Wire .030″-.035″ Flux-core
Capacity XX Ga. – X/X″ Steel Plate
Cables Electrode – X′
Ground Clamp – X′
Wire
Speed
Dial
Gun
Cable
Ground
Cable
Current
Switch
Power
Switch
Overload
Indicator
Power
Cord
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. (See next page.)
Ground Cable:
This connects to the base metal to provide a good
connection for the current to travel back to the welder.
Overload Indicator:
This lights up if duty cycle work period is exceeded
and the welder is overheated. 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 welder cools
enough to be used again, use shorter welding periods
and longer rest periods to prevent needless wear.
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.
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.
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP

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 current MAX current
.030″ Wire Size
(Flux Core, Mild Steel)
1.5
speed
2
speed
4
speed
8
speed
9
speed
.035″ Wire Size
(Flux Core, Mild Steel)
1.5
speed
2
speed
3
speed
8
speed
9.5
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 20% duty cycle at
rated output (90A) must be allowed to rest for at
least 8 minutes after every 2 minutes 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.
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 lights. The welder automatically
returns to service after cooling off. Rest the Gun on
an electrically non-conductive, heat-proof surface,
such as a concrete slab, well clear of the ground clamp
while allowing the welder to cool with the Power Switch
on, so that the internal Fan will help cool the welder.
When the welder can be used again, use shorter welding
periods and longer rest periods to prevent needless wear.
20% Rated Duty Cycle
at 90A output
2 minutes welding
followed by
at least 8 minutes of rest
ON MIN
OFF MAX
WIRE FEED SPEED
GUN
GROUND
120V~
60Hz
20A
90 AMP FLUX WIRE WELDER
IT EM 68887
Wire .030″-.035″ Flux-core
Capacity XX Ga. – X/X″ Steel Plate
Cables Electrode – X′
Ground Clamp – X′
Gun
concrete slab
(or other heat-proof,
non-conductive
surface)
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP

Page 15For 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 no rust, paint, oil, or other materials on
the weld surfaces, only bare metal.
2. Use clamps (not included) to hold the workpieces
in position so that you can concentrate on
proper welding technique. The distance
(if any) between the two workpieces must be
controlled properly to allow the weld to hold
both sides securely while allowing the weld
to penetrate fully into the joint. The edges of
thicker workpieces may need to be chamfered
(or beveled) to allow proper weld penetration.
3. Clamp Ground Cable to bare metal on the
workpiece near the weld area, or to metal work
bench where the workpiece is clamped.
4. Set the Wire Speed Dial and
the Current Switch to the desired settings.
Refer to the chart on the welder
or the chart on the facing page.
WARNING! DO NOT SWITCH THE
CURRENT WHILE WELDING.
5. Flip the Power Switch to the OFF position, then plug
the Welder into a dedicated, 120 V~, 20 A circuit
with delayed action type circuit breaker or fuses.
6. Hold the Gun, without touching the Trigger, with the
wire and tip clearly away from any grounded objects.
Then, turn the Power Switch to ON.
clamps
workpieces
Chamfer thick workpieces.
Clean
surfaces to
bare metal.
ON MIN
OFF MAX
WIRE FEED SPEED
GUN
GROUND
120V~
60Hz
20A
90 AMP FLUX WIRE WELDER
ITEM 68887
Wire .030″-.035″ Flux-core
Capacity XX Ga. – X/X″ Steel Plate
Cables Electrode – X′
Ground Clamp – X′
Workpiece
Ground
Clamp
Clean
surface to
bare metal.
ON MIN
OFF MAX
WIRE FEED SPEED
GUN
GROUND
120V~
60Hz
20A
90 AMP FLUX WIRE WELDER
IT EM 68887
Wire .030″-.035″ Flux-core
Capacity XX Ga. – X/X″ Steel Plate
Cables Electrode – X′
Ground Clamp – X′
ON MIN
OFF MAX
WIRE FEED SPEED
GUN
GROUND
120V~
60Hz
20A
90 AMP FLUX WIRE WELDER
IT EM 68887
Wire
.030″-.035″ Flux-core
Capacity XX Ga. – X/X
″ Steel Plate
Cables Electrode – X′
Ground Clamp – X′+
20 Amp minimum circuit
ON MIN
OFF MAX
WIRE FEED SPEED
GUN
GROUND
120V~
60Hz
20A
90 AMP FLUX WIRE WELDER
IT EM 68887
Wire .030″-.035″ Flux-core
Capacity XX Ga. – X/X″ Steel Plate
Cables Electrode – X′
Ground Clamp – X′
ON MIN
OFF MAX
WIRE FEED SPEED
GUN
GROUND
120V~
60Hz
20A
90 AMP FLUX WIRE WELDER
IT EM 68887
Wire .030″-.035″ Flux-core
Capacity XX Ga. – X/X″ Steel Plate
Cables Electrode – X′
Ground Clamp – X′
HOLD
GUN
CLEAR
Setting Up The Weld
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP

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 the wire back and forth
across the joint, this is called a weave bead.
3. Hold Gun in one hand and the face shield in the
other. If a hands-free welding shield (not included,
see Arc Ray Safety on page 3 for guidelines) is
used, then both hands can be used to control Gun.
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.
5. The end of Gun should be tilted so that 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.
6. The welding wire should extend no more than 1/2″
past the tip.
This distance is called stickout or CTWD
- Contact Tip to Work Distance.
stringer bead weave bead
Weld Gun angles,
viewed from front of weld joint.
45°
fillet weld joint
90°
butt weld joint
Stickout
(up to 1/2″)
Weld
Direction
Drag Angle
0-15°
Basic Welding Technique
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP

Page 17For 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 concrete slab, well clear of the ground
clamp. Wait about 8-10 minutes with the Power
Switch to ON 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.
7. After welding the test weld on a piece of scrap for a
few seconds, stop, and check your progress. Clean,
then compare your weld’s appearance with the diagrams
and descriptions in the Welding Tips section starting on
the next page. After making any necessary adjustments,
continue to weld while carefully following the
DUTY CYCLE guidelines as explained on page 14.
8. When the weld is complete,
lift the Gun and welding wire clearly away from any
grounded object, and turn the Power Switch off.
9. Set the Gun down on a heat-proof, electrically
non-conductive surface. Unplug the Power Cord.
ON MIN
OFF MAX
WIRE FEED SPEED
GUN
GROUND
120V~
60Hz
20A
90 AMP FLUX WIRE WELDER
IT EM 68887
Wire .030″-.035″ Flux-core
Capacity XX Ga. – X/X″ Steel Plate
Cables Electrode – X′
Ground Clamp – X′
Gun
concrete slab
(or other heat-proof,
non-conductive
surface)
After practice welding for a few
seconds, STOP and examine
your weld using the guidelines
starting on the next page.
FOLLOW DUTY CYCLE!
up to 2 minutes welding
at rated output
ON MIN
OFF MAX
WIRE FEED SPEED
GUN
GROUND
120V~
60Hz
20A
90 AMP FLUX WIRE WELDER
IT EM 68887
Wire .030″-.035″ Flux-core
Capacity XX Ga. – X/X″ Steel Plate
Cables Electrode – X′
Ground Clamp – X′
HOLD
GUN
CLEAR
Gun
concrete slab
(or other heat-proof,
non-conductive
surface)
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP

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 the Weld
TO PREVENT SERIOUS INJURY:
Continue to wear ANSI-approved safety
goggles and protective wear when
cleaning a weld.
Sparks or chips may fly when cleaning.
1. A weld from flux core wire will be covered by slag:
use a Chipping Hammer to knock this off.
Be careful not to damage the
weld or base material.
2. Then, use a 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-APPROVED SAFETY 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.
1. After two scraps have been welded 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. A GOOD WELD will deform but not break,
as shown on top.
A POOR WELD will be brittle and snap
at the weld, as shown on bottom.
A typical Flux-core Wire (FCAW) Weld
before cleaning.
base metal
weld bead
slag spatter
clamp
SCRAP
workpiece
GOOD WELD
bends and is not brittle
dead-blow hammer
clamp
SCRAP
workpiece
POOR WELD
snaps or cracks
dead-blow hammer
Welding Tips
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP

Page 19For technical questions, please call 1-800-444-3353.SKU 68887
Weld Diagnosis
Workpiece Heat Control / Weld Penetration
EXCESS PENETRATION OR
BURN-THROUGH
PROPER PENETRATIONINADEQUATE PENETRATION
Not hot enough Too hotIdeal heat
How to increase workpiece heat
and increase penetration:
(to weld THICKER workpieces properly)
How to reduce workpiece heat
and limit penetration:
(to weld THINNER workpieces properly)
a.Use MAX setting
b.Weld more slowly
c. Use faster wire feed
d.Use shorter stickout
a.Use MIN setting
b.Weld more quickly
c. Use slower wire feed
d.Use longer stickout
Good
Weld
Example Weld Diagrams
Weld Speed
Too Slow
TO CORRECT:
weld
faster
Current
Too Low
TO CORRECT:
ON MIN
OFF MAX
WIRE FEED SPEED
GUN
GROUND
120V~
60Hz
20A
90 AMP FLUX WIRE WELDER
IT EM 68887
Wire .030″-.035″ Flux-core
Capacity XX
Ga. – X/X″ Steel Plate
Cables Electrode – X′
Ground Clamp – X′
TO CORRECT:
maintain
less
than 1/2″
stickout
Stickout
Too Long
TO CORRECT:
weld
slower
Weld Speed
Too Fast
TO CORRECT:
ON MIN
OFF MAX
WIRE FEED SPEED
GUN
GROUND
120V~
60Hz
20A
90 AMP FLUX WIRE WELDER
IT EM 68887
Wire .030″-.035″ Flux-core
Capacity XX Ga. – X/X″ Steel Plate
Cables Electrode – X′
Ground Clamp – X′
or
ON MIN
OFF MAX
WIRE FEED SPEED
GUN
GROUND
120V~
60Hz
20A
90 AMP FLUX WIRE WELDER
IT EM 68887
Wire .030″-.035″ Flux-core
Capacity XX Ga. – X/X″ Steel Plate
Cables Electrode – X′
Ground Clamp – X′
Current
Too High or
Wire Feed
Too Fast
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP

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.
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.
PROFILE
VIEW
Bend at Joint
POSSIBLE CAUSES AND SOLUTIONS
1. Improper clamping:
Clamp workpieces securely.
Make tack welds to hold workpieces.
2. Excessive heat:
Weld a small portion and allow to cool before
proceeding.
Increase weld speed.
Reduce wire feed speed.
PROFILE
VIEW
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.
POSSIBLE CAUSES 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.
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 contact the joint
fully, just on the surface.
PROFILE VIEWS
Weld Problems
Penetration (Workpiece Heat Control)
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP