90 AMP Flux Wire welder

94056
Set up and Operating Instructions

Distributed exclusively by Harbor Freight Tools®.

3491 Mission Oaks Blvd., Camarillo, CA 93011
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© 2005 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.

REV 06g, 09e, 09h

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 Specifications
.8 mm wire on 16 ga. 104.3/95.5 A
sheet steel (Max/Min Setting)
Welding Current
.8 mm wire on 1/4” 103.7/103.1 A
steel plate (Max/Min Setting)
10% @ 90 Amps (Max Setting) or
Duty Cycle
10% @ 80 Amps (Min Setting, actual 11%)
Power Consumption 120 V~, 24 A
Ground Cable 4 AWG, single insulation, 6’
Torch Power Cable 8 AWG, single insulation, 6’
Both settings:
Thermal Overload
10 min. shutdown, 3 min. back on with Light
0.030”; Spare: Welder Tip 0.035”;
Welder Tip
Will also accept a 0.023” welder tip (not included)
Wire Size 0.030” flux core wire (using 0.030” Welder Tip)
Wire Spool Size 4” diameter
Overall Dimensions 14-1/2” (L) x 7-7/8” (W) x 15-1/2” (H)
Weight 34.45 lb.
Accessories Spare Welder Tip (0.035”)

Note: Performance of this tool may vary depending on variations in local line voltage.
Extension cord usage may also affect tool performance.

Save This Manual 1. Keep work area clean. Cluttered

areas invite injuries.
You will need the manual for
the safety warnings and precautions, 2. Observe work area conditions. Do
assembly instructions, operating and not use machines or power tools in
maintenance procedures, parts list and damp or wet locations. Don’t expose
diagram. Keep your invoice with this to rain. Keep work area well lighted.
manual. Write the invoice number on the Do not use electrically powered tools
inside of the front cover. Keep the manual in the presence of flammable gases
and invoice in a safe and dry place for or liquids.
future reference. 3. Keep children away. Children must
never be allowed in the work area.
Safety Warnings and Do not let them handle machines,
tools, or extension cords.
Precautions
4. Store idle equipment. When not
WARNING: When using tool, basic in use, tools must be stored in a dry
safety precautions should always location to inhibit rust. Always lock
be followed to reduce the risk of up tools and keep out of reach of
personal injury and damage to children.
equipment.
5. Do not force tool. It will do the job
Read all instructions before using this
better and more safely at the rate
tool!
REV 06l

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 for which it was intended. Do not 11. Disconnect power. Unplug tool
use inappropriate attachments in an when not in use.
attempt to exceed the tool capacity.
12. Remove adjusting keys and
6. Use the right tool for the job. Do wrenches. Check that keys and
not attempt to force a small tool or adjusting wrenches are removed
attachment to do the work of a larger from the tool or machine work surface
industrial tool. There are certain before plugging it in.
applications for which this tool was
designed. Do not modify this tool and 13. Avoid unintentional starting. Be
do not use this tool for a purpose for sure the switch is in the Off position
which it was not intended. when not in use and before plugging
in. Do not carry any tool with your
7. Dress properly. Do not wear loose finger on the trigger, whether it is
clothing or jewelry as they can be plugged in or not.
caught in moving parts. Protective,
electrically nonconductive clothes and 14. Stay alert. Watch what you are
nonskid footwear are recommended doing, use common sense. Do not
when working. Wear restrictive hair operate any tool when you are tired.
covering to contain long hair. 15. Check for damaged parts. Before
8. Use eye and ear protection. Always using any tool, any part that appears
wear ANSI-approved, arc-shaded, damaged should be carefully checked
impact safety face shield. Always use to determine that it will operate
the full face shield when welding. properly and perform its intended
Wear a NIOSH-approved dust mask function. Check for alignment and
or respirator when working around binding of moving parts; any broken
metal, chemical dusts, fumes and parts or mounting fixtures; and any
mists. other condition that may affect proper
operation. Any part that is damaged
9. Do not overreach. Keep proper should be properly repaired or
footing and balance at all times. Do replaced by a qualified technician. Do
not reach over or across running not use the tool if any switch does not
machines. turn On and Off properly.
10. Maintain tools with care. Keep 16. Guard against electric shock.
tools sharp and clean for better Prevent body contact with grounded
and safer performance. Follow surfaces such as pipes, radiators,
instructions for lubricating and ranges, and refrigerator enclosures.
changing accessories. Inspect tool
cords periodically and, if damaged, 17. Replacement parts and
have them repaired by an authorized accessories. When servicing, use
technician. The handles must be only identical replacement parts.
kept clean, dry, and free from oil and Use of any other parts will void the
grease at all times. warranty. Only use accessories
intended for use with this tool.

REV 06g

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 Approved accessories are available
from Harbor Freight Tools. WARNING
18. Do not operate tool if under the
influence of alcohol or drugs.
Read warning labels on prescriptions
to determine if your judgment or
reflexes are impaired while taking Inhalation Hazard:
drugs. If there is any doubt, do not Welding and Plasma Cutting Produce
operate the tool. toxic fumes.

19. Maintenance. For your safety, Exposure to welding or cutting

service and maintenance should be exhaust fumes can increase the risk
performed regularly by a qualified of developing certain cancers, such as
technician. cancer of the larynx and lung cancer.
Also, some diseases that may be linked
20. Use proper size and type to exposure to welding or plasma cutting
extension cord. If an extension cord exhaust fumes are:
is required, it must be of the proper • Early onset of Parkinson’s Disease
size and type to supply the correct • Heart disease • Ulcers
current to the tool without heating • Damage to the reproductive organs
up. Otherwise, the extension cord • Inflammation of the small intestine or
could melt and catch fire, or cause stomach • Kidney damage
electrical damage to the tool. This • Respiratory diseases such as
tool requires use of an extension cord emphysema, bronchitis, or pneumonia
of 20 amps minimum capability (up
Use natural or forced air ventilation and
to 30 feet), with wire size rated at 12
wear a respirator approved by NIOSH to
AWG. Longer extension cords require
protect against the fumes produced to
larger size wire. If you are using the
reduce the risk of developing the above
tool outdoors, use an extension cord
illnesses.
rated for outdoor use (signified by
“WA” on the jacket).
22. Avoid breathing fumes or gases.
21. Avoid electrical shock. Do not They can cause serious health
permit electrically live parts, cables, problems. Use an active ventilation
or electrodes to contact skin, clothing, system directly above the welding
or gloves. Protective clothing should area. Keep your head out of the
be hole-free, dry, and ANSI-approved. fumes.
This unit draws enough current to
cause serious injury or death. Before 23. Avoid eye and body damage.
turning the welder on, check the Welding rays and infrared radiation
electrode holder to be sure that there can injure eyes and burn skin.
are no protruding screw heads, and Wear ANSI-approved eye and body
that all insulation is secure. Do not protection. Do not allow viewing by
weld unless you are insulated from visitors without proper eye and body
ground and the work piece. protection. Use a face shield with arc-
shaded filter plate.

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24. Know proper welding practices. Unpacking
Read and understand the
manufacturer’s instructions, as well When unpacking, check to make sure
as your employer’s safety practices the item is intact and undamaged. If any
for welding. parts are missing or broken, please call
Harbor Freight Tools at 1-800-444-3353 as
25. Connect only to a code approved soon as possible.
power source. Connect only to a
grounding power source conforming
to the National Electrical Code and Assembly
Local Codes.
26. Avoid fire and explosion. Remove Cover (31)
flammable and explosive material
from at least 35 feet from the welding Handle (30)
site to prevent welding sparks or
molten metal from starting a fire.
Keep a type ABC fire extinguisher Wire
Cover Reel (27)
within easy reach. Thoroughly clean Locking
the object being welded of any paint, Spring (8)
grease, or other foreign material.
1. Attach the Handle (30) to the Cover
27. Avoid being burned. Always wear
(31) using screw (29) inserted from the
ANSI-approved welding gear: leather
Handle top-rear.
gloves, leather apron, and shoes.
2. Attach the Cover Locking Spring (8) to
28. WARNING: This product, when used
the front of the Base Frame (14) using
for welding, plasma cutting, soldering,
the supplied self-tapping screw.
or similar applications, produces
chemicals known to the State of
California to cause cancer and birth
defects (or other reproductive harm).
(California Health & Safety Code §
25249.5, et seq.)
29. The warnings, cautions, 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.

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 Controls

Overload Indicator Light (22)

Switch (7) Current Min. / Max.

Switch (7) Power On / Off

Torch (1) Cable

Wire Feed Speed Knob (9)

Ground Cable (33) Power Cord (32)

Duty cycle Operation

Duty cycle is a welding equipment This Welder is used to weld sheet
specification, which defines the number of metal and light carbon steel.
minutes, within a 10-minute period, during
which a given welder can safely produce Caution: Before welding, read and
a particular welding current. For example, understand all safety precautions and
this 90 amp welder with a 10% duty cycle warnings listed on pages 2 through 5.
must be rested for at least 9 minutes after 1. Securely clamp the Ground Cable
1 minute of continuous welding. Clamp (33) as close as possible to
Failure to carefully observe the metal object to be welded, or
duty cycle limitations can easily over to the metal work bench where the
stress a welder’s power generation object is mounted and electrically
system contributing to premature connected.
welder failure. Many welders do not 2. Set the switch on the control panel to
have internal protection systems MIN or MAX, as appropriate.
that prevent this sort of over stress
-- leaving the task to the owner or 3. Verify that the Power Switch is in the
operator. OFF position, then plug the Welder
plug into a dedicated, 110 VAC, 20
amp line with delayed action type
circuit breaker or fuses.
If an extension cord is used, it must
have the following wire size: up to 30
feet, use 12 AWG size wire; 30 to 50
feet, use 10 AWG wire; Over 50 feet,
use 8 AWG wire.
REV 09h

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4. While holding the Torch Cable Clamp speed dependent on the Min. or Max.
with electrode wire clearly out of the current setting.
way of any grounded objects, turn the
Power Switch to the ON position. Note: If too much current is drawn from
the Welder, the Thermal Overload
5. Momentarily press the Torch switch protector will activate, the amber
to test the wire feed speed. Adjust indicator will light, and the Welder
the speed by turning the Wire Feed will turn off until it cools down. If this
Speed Knob (9). happens, turn the Power Switch to
the OFF position and wait about 3 ~ 5
6. Orient yourself on the area to be minutes.
welded, then place a face shield over
your eyes. 9. When the weld is complete, lift the
electrode wire clearly away from any
Warning: Never look at the ignited grounded object, set the face shield
arc without ANSI-approved, down, turn toward the Welder, and
arc-shaded, eye protection in a turn the Power Switch to the OFF
full face shield. Permanent eye position.
damage or blindness can occur.
Skin burns can occur. Never 10. Unplug the Power Cord from the
breathe welding fumes. electrical outlet.
7. Press (and hold) the Torch button and
stroke the area to be welded with the
electrode wire to ignite the arc.
Never tap the electrode wire into the
welding surface to ignite the arc. This
damages its external coating on the
electrode which prevents oxygen
in the air from coming into contact
with the molten metal, causing it to
oxidize.

8. Once the arc is ignited, tilt the

electrode wire forward at an angle of
approximately 35°.
The wire feeds automatically at a

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 Maintenance Unwind wire this d i
r ec
ti
Caution: Before performing any

on
maintenance on the Welder, unplug
the Power Cord from the electrical
outlet. Wire
Wire
1. Periodically remove the Right and
Sheath
Left side panels (12 and 13), and
using compressed air, blow out all Wire Reel
dust from the interior.
4. Place the new Wire Reel over the
2. Store in a clean and dry location. shaft and onto the Reel Spring (24).
The wire on the reel should unwind
Replacing the Wire Reel counterclockwise so that it comes off
the reel straight into the wire sheath,
When the wire on the Feed Reel is as illustrated above.
used up, you will need to replace it as
follows. 5. Replace the Reel Locking Knob and
the Wing Nut. Tighten well.
Wire Feed Wire Feed
Arm (36a) Knob (37a) 6. Loosen the Wire Feed Knob (37a)
and swing it off the Wire Feed Arm
(36a) to remove tension.
7. If the end of the wire is crimped or
bent, cut it off. Guide at least 12
inches of wire into the Wire Sheath.
8. Swing the Wire Feed Knob (37a)
back onto the Wire Feed Arm (36a)
and tighten it until the spring starts to
compress.

Wire Sheath
1. Press on the Cover Locking Spring
(8), then lift the Cover (31) using
Handle (30) to expose the Wire Feed
Unit (23a).
9. Turn the Torch Handle Nozzle
2. Unscrew the Wing Nut (25) and counterclockwise and pull to remove.
remove the Reel Locking Knob (26).
10. Turn the Contact Tip
3. Remove the empty Wire Reel (27). counterclockwise and remove.

REV 09e

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11. Lay the Torch Sheath out in a straight PLEASE READ THE
line so that the wire moves through it
easily. FOLLOWING CAREFULLY
THE MANUFACTURER AND/OR DISTRIBUTOR
Warning: The following steps require HAS PROVIDED THE PARTS DIAGRAM IN
applying power to the welder. Do not THIS MANUAL AS A REFERENCE TOOL
touch anything with the Torch Handle ONLY. NEITHER THE MANUFACTURER NOR
or an arc may be ignited. DISTRIBUTOR MAKES ANY REPRESENTATION
OR WARRANTY OF ANY KIND TO THE BUYER
12. Plug the Power Cord into its electrical THAT HE OR SHE IS QUALIFIED TO MAKE
outlet, press the Current Switch to ANY REPAIRS TO THE PRODUCT OR THAT
HE OR SHE IS QUALIFIED TO REPLACE ANY
Max., and turn the welder ON. PARTS OF THE PRODUCT. IN FACT, THE
MANUFACTURER AND/OR DISTRIBUTOR
13. Lift the Torch Handle and continue
EXPRESSLY STATES THAT ALL REPAIRS
pressing the Trigger until the wire AND PARTS REPLACEMENTS SHOULD BE
feeds through two inches. UNDERTAKEN BY CERTIFIED AND LICENSED
If the wire does not feed, view the TECHNICIANS AND NOT BY THE BUYER. THE
Wire Feed Unit and see if the wire BUYER ASSUMES ALL RISK AND LIABILITY
ARISING OUT OF HIS OR HER REPAIRS TO
is being pushed. If it is not, turn the
THE ORIGINAL PRODUCT OR REPLACEMENT
welder OFF and tighten the Wire PARTS THERETO, OR ARISING OUT OF HIS OR
Feed Knob (37a). HER INSTALLATION OF REPLACEMENT PARTS
THERETO.
14. Turn the welder ON again and press
the Trigger.
15. Once the wire is exposed, turn the
welder OFF and unplug it.
16. Slide the Contact Tip over the wire
and screw it into Torch Handle.
17. Replace the Nozzle and cut off any
excess wire over two inches.
18. Secure the Cover.

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 Parts List and Diagrams
Parts list

Part Description Qty. Part Description Qty.

1 Torch 1 20 Transformer 1
2 Contact Tip 1 21 Middle Partition Board 1
3 Nozzle 1 22 Overload Indicator Lamp 1
4 Liner 1 23a Wire Feed Unit 1
5 Fixing Pole (A) for Gun Body 1 24 Reel Spring 1
6 Fixing Pole (B) for Gun Body 1 25 Wing Nut M6 1
7 Switch 2 26 Reel Locking Knob 1
8 Cover Locking Spring 1 27 Wire Reel 1
9 Knob 1 28 Reel Holder 1
10 Nut 1 29 Screw, ST 4.2 x 25 1
11 Speed Control Circuit Board 1 30 Handle 1
12 Right Side Panel 1 31 Cover 1
13 Left Side Panel 1 32 Power Cord 1
14 Base Frame 1 33 Ground Cable 1
15 Foot 4 34 Wire Feed Roller 1
16 Washer 4 35 Wire Feed Bearing 1
17 Screw, ST 4.2 x 13 4 36a Wire Feed Arm 1
18 Transformer Carriage 2 37a Wire Feed Knob 1
19 Thermostat 1

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.
REV 09e

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 Assembly Diagram

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 Welder Assembly Photographs

28 24 23a

20 11

19

36a 37a

35

34

23a

REV 09e

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 Wiring Schematic

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 Limited 1 Year / 90 day of the complaint must accompany the
merchandise. If our inspection verifies
warranty the defect, we will either repair or replace
Harbor Freight Tools Co. makes the product at our election or we may
every effort to assure that its products elect to refund the purchase price if
meet high quality and durability standards, we cannot readily and quickly provide
and warrants to the original purchaser you with a replacement. We will return
that for a period of ninety days from date repaired products at our expense, but if we
of purchase that the torch, liner, wire feed determine there is no defect, or that the
mechanism (if applicable), welding clamps, defect resulted from causes not within the
electrode holders, cables and accessories scope of our warranty, then you must bear
packed with the welder are free of defects the cost of returning the product.
in materials and workmanship. This This warranty gives you specific legal
Limited 90 Day/1 Year Warranty shall rights and you may also have other rights
not apply to consumable parts such which vary from state to state.
as tips, welding wire, and gas nozzles.
Harbor Freight Tools also warrants to the 3491 Mission Oaks Blvd. • PO Box
original purchaser, for a period of one year 6009 • Camarillo, CA 93011 • (800)
from date of purchase, that the transformer 444-3353
and rectifier are free from defects in
materials 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.
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
REV 06l

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