!"#"$%&'(%)*+#"$*%,$-%.$$/-00)))1.,(+&(2(*"3.$14&5
65,"7%&'(%$*4.8"4,7%#'//&($%,$-%/(&9'4$#'//&($:.,(+&(2(*"3.$14&5
EASY- FLUX125
56355
Owner’s Manual & Safety Instructions
Save This Manual Keep this manual for the safety warnings and precautions, assembly,
operating, inspection, maintenance and cleaning procedures. Write the product’s serial number in the
back of the manual near the assembly diagram (or month and year of purchase if product has no number).
Keep this manual and the receipt in a safe and dry place for future reference. 19l
When unpacking, make sure that the product is intact
and undamaged. If any parts are missing or broken,
please call 1-888-380-0318 as soon as possible.
Copyright
©
2019 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 fo r assembly and service may not be included.
Read this material before using this product.
Failure to do so can result in serious injury.
SAVE THIS MANUAL.
Page 2 ;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?A@B?BA>@1 Item 56355
CD;6EF GDHIE6IDIJ6KDCHJ%L6MNHIO L6MNHIO%EHPCC6EQP
E,+7*%&2%J&8$*8$#
Safety ......................................................... 2
Specifications ............................................. 7
Setup .......................................................... 8
Basic Welding ............................................ 12
Welding Tips .............................................. 20
Maintenance .............................................. 24
Parts List and Diagram .............................. 27
Warranty .................................................... 28
LDRIHIO%CFGKSMC%DIN%N6;HIHEHSIC
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.
HGPSREDIE%CD;6EF%HI;SRGDEHSI
R*,9%,77%#,2*$T%),(8"83#%,89%"8#$('4$"&8#1%%
Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.
C,U*%,77%),(8"83#%,89%"8#$('4$"&8#%2&(%2'$'(*%(*2*(*84*1
O*8*(,7%C,2*$T
PRSE6JE%T&'(#*72%,89%&$.*(#1%%R*,9%,89%'89*(#$,89%$."#%"82&(5,$"&81
1. K*2&(*%'#*=%(*,9%,89%'89*(#$,89%
manufacturer′s instructions,
Material Safety Data Sheets (MSDS′s),
employer′s safety practices, and ANSI Z49.1.
2. V**/%&'$%&2%(*,4.%&2%4."79(*81%%%
Keep children and bystanders away while operating.
3. P7,4*%$.*%)*79*(%&8%,%#$,+7*%7&4,$"&8%+*2&(*%'#*1%%%
If it falls while plugged in, severe injury,
electric shock, or fire may result.
4. N&%8&$%&U*((*,4.1%%%
V**/%/(&/*(%2&&$"83%,89%+,7,84*%,$%,77%$"5*#1
5. C$,T%,7*($=%),$4.%).,$%T&'%,(*%9&"83%,89%'#*%
4&55&8%#*8#*%).*8%&/*(,$"83%,%)*79*(1%%
N&%8&$%'#*%,%)*79*(%)."7*%T&'%,(*%$"(*9%&(%'89*(%
$.*%"827'*84*%&2%9('3#=%,74&.&7%&(%5*9"4,$"&81
A moment of inattention while operating welders
may result in serious personal injury.
6. DU&"9%'8"8$*8$"&8,7%#$,($"831%%Make sure you are
prepared to begin work before turning on the Welder.
7. I*U*(%7*,U*%$.*%L*79*(%'8,$$*89*9%)."7*%
*8*(3"W*91%Turn power off if you have to leave.
8. E.*%),(8"83#=%/(*4,'$"&8#=%,89%"8#$('4$"&8#%
9"#4'##*9%"8%$."#%"8#$('4$"&8%5,8',7%4,88&$%
4&U*(%,77%/&##"+7*%4&89"$"&8#%,89%#"$',$"&8#%
$.,$%5,T%&44'(1%%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.
Page 3;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?A@B?BA>@1Item 56355
CD;6EFGDHIE6IDIJ6 KDCHJ%L6MNHIOL6MNHIO%EHPC C6EQP
;'5*%,89%O,#%C,2*$T
INHALATION HAZARD:%
L*79"83%,89%P7,#5,%J'$$"83%P(&9'4*%$&X"4%2'5*#1
1. 6X/&#'(*%$&%)*79"83%&(%4'$$"83%*X.,'#$%
2'5*#%4,8%"84(*,#*%$.*%("#Y%&2%9*U*7&/"83%
4*($,"8%4,84*(#=%#'4.%,#%4,84*(%&2%$.*%
7,(T8X%,89%7'83%4,84*(1 Also, some diseases
that may be linked to exposure to welding
or plasma 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
Use natural or forced air ventilation and wear
a respirator approved by NIOSH to protect
against the fumes produced to reduce the
risk of developing the above illnesses.
2. N&%8&$%'#*%8*,(%9*3(*,#"83%&(%
/,"8$"83%&/*(,$"&8#1
3. V**/%.*,9%&'$%&2%2'5*#1%%
Do not breathe exhaust fumes.
4. Q#*%*8&'3.%U*8$"7,$"&8=%*X.,'#$%,$%,(4=%&(%
+&$.=%$&%Y**/%2'5*#%,89%3,#*#%2(&5%+(*,$."83%
W&8*%,89%3*8*(,7%,(*,1%%If engineering controls
are not feasible, use an approved respirator.
5. L&(Y%"8%,%4&82"8*9%,(*,%&87T%"2%"$%
"#%)*77?U*8$"7,$*9=%&(%)."7*%)*,("83%
,8%,"(?#'//7"*9%(*#/"(,$&(1
6. Z,U*%,%(*4&38"W*9%#/*4",7"#$%"8%
H89'#$(",7%ZT3"*8*%&(%68U"(&85*8$,7%C*(U"4*#%
4.*4Y%$.*%&/*(,$"&8%,89%,"(%<',7"$T%
,89%5,Y*%(*4&55*89,$"&8#%
2&(%$.*%#/*4"2"4%)*79"83%#"$',$"&81%%
Follow OSHA guidelines for
Permissible Exposure Limits (PEL’s) and
the American Conference of Governmental
Industrial Hygienists recommendations for
Threshold Limit Values (TLV’s) for fumes and gases.
D(4%R,T%C,2*$T
DRJ%RDFC%4,8%"8['(*%*T*#%,89%+'(8%#Y"81
1. L*,(%DICH?,//(&U*9%)*79"83%*T*%/(&$*4$"&8%
2*,$'("83%,$%7*,#$%,%8'5+*(%>B%#.,9*%7*8#%(,$"831
2. L*,(%7*,$.*(%7*33"83#=%2"(*%(*#"#$,8$%#.&*#%
&(%+&&$#%9'("83%'#*1%%Do not wear pants with
cuffs, shirts with open pockets, or any clothing
that can catch and hold molten metal or sparks.
3. V**/%47&$."83%2(**%&2%3(*,#*=%&"7=%
#&7U*8$#=%&(%,8T%27,55,+7*%#'+#$,84*#1%%
Wear dry, insulating gloves and protective clothing.
4. L*,(%,8%,//(&U*9%.*,9%4&U*("83%$&%/(&$*4$%
$.*%.*,9%and neck. Use aprons, cape, sleeves,
shoulder covers, and bibs designed and
approved for welding and cutting procedures.
5. L.*8%)*79"8304'$$"83%&U*(.*,9%&(%"8%4&82"8*9%
#/,4*#=%)*,(%27,5*%(*#"#$,8$%*,(%/7'3#%&(%
*,(%5'22#%$&%Y**/%#/,(Y#%&'$%&2%*,(#1
Page 4 ;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?A@B?BA>@1 Item 56355
CD;6EF GDHIE6IDIJ6KDCHJ%L6MNHIO L6MNHIO%EHPCC6EQP
67*4$("4,7%C,2*$T
6M6JERHJ%CZSJV%4,8%VHMM1
1. E'(8%&22=%9"#4&88*4$%/&)*(=%,89%
9"#4.,(3*%*7*4$(&9*%$&%3(&'89%+*2&(*%#*$$"83%
9&)8%$&(4.0*7*4$(&9*%.&79*(%,89%+*2&(*%#*(U"4*1
2. N&%8&$%$&'4.%*8*(3"W*9%*7*4$("4,7%/,($#1%%
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. J&88*4$%$&%3(&'89*9=%O;JH?/(&$*4$*9%
/&)*(%#'//7T%&87T1
4. N&%8&$%'#*%8*,(%),$*(%&(%9,5/%&+[*4$#1
5. P*&/7*%)"$.%/,4*5,Y*(#%#.&'79%4&8#'7$%$.*"(%
physician(s) before use. Electromagnetic fields
in close proximity to heart pacemaker could cause
pacemaker interference or pacemaker failure.
6. N&%8&$%*X/&#*%)*79*(#%$&%(,"8%&(%)*$%4&89"$"&8#1%%%
Water entering a welder will increase
the risk of electric shock.
7. N&%8&$%,+'#*%$.*%4&(91%%I*U*(%'#*%$.*%4&(9%
2&(%4,((T"83=%/'77"83%&(%'8/7'33"83%$.*%)*79*(1%%
V**/%4&(9%,),T%2(&5%.*,$=%&"7=%#.,(/%*93*#%
&(%5&U"83%/,($#1%%Damaged or entangled
cords increase the risk of electric shock.
8. N&%8&$%'#*%&'$9&&(#1
9. H8#'7,$*%T&'(#*72%2(&5%$.*%)&(Y/"*4*%,89%
3(&'891%Use nonflammable, dry insulating
material if possible, or use dry rubber mats,
dry wood or plywood, or other dry insulating
material large enough to cover your full
area of contact with the work or ground.
;"(*%C,2*$T
DRJ%DIN%ZSE%CMDO%4,8%4,'#*%2"(*1
1. J7*,(%,),T%&(%/(&$*4$%27,55,+7*%&+[*4$#1%%%
Remove or make safe all combustible materials for a
radius of 35 feet (10 meters) around the work area.
Use a fire resistant material to cover
or block all open doorways, windows,
cracks, and other openings.
2. V**/%DKJ?$T/*%2"(*%*X$"83'"#.*(%8*,(%
)&(Y%,(*,%,89%Y8&)%.&)%$&%'#*%"$1
3. G,"8$,"8%,%#,2*%)&(Y"83%*8U"(&85*8$1%%%
Keep the work area well lit.
Make sure there is adequate
surrounding workspace. Keep the work area free
of obstructions, grease, oil, trash, and other debris.
4. N&%8&$%&/*(,$*%)*79*(#%"8%,$5&#/.*(*#%
4&8$,"8"83%9,83*(&'#7T%(*,4$"U*%&(%
27,55,+7*%7"<'"9#=%3,#*#=%U,/&(#=%&(%9'#$1%%
Provide adequate ventilation in work areas
to prevent accumulation of such substances.
Welders create sparks which may ignite flammable
substances or make reactive fumes toxic.
5. H2%)&(Y"83%&8%,%5*$,7%),77=%4*"7"83=%*$41=%
/(*U*8$%"38"$"&8%&2%4&5+'#$"+7*#%&8%$.*%
&$.*(%#"9*%+T%5&U"83%$.*%4&5+'#$"+7*#%$&%,%
#,2*%7&4,$"&81 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. N&%8&$%)*79%&(%4'$%&8%5,$*(",7#%.,U"83%
,%4&5+'#$"+7*%4&,$"83%&(%4&5+'#$"+7*%
"8$*(8,7%#$('4$'(*=%,#%"8%),77#%&(%4*"7"83#=%)"$.&'$%
,8%,//(&U*9%5*$.&9%2&(%*7"5"8,$"83%$.*%.,W,(91
7. N&%8&$%9"#/&#*%&2%.&$%#7,3%"8%4&8$,"8*(#%
.&79"83%4&5+'#$"+7*%5,$*(",7#1
8. D2$*(%)*79"83=%5,Y*%,%$.&(&'3.%*X,5"8,$"&8%
2&(%*U"9*84*%&2%2"(*1%%Be aware that easily
visible smoke or flame may not be present
for some time after the fire has started.
9. N&%8&$%,//7T%.*,$%$&%,%4&8$,"8*(%$.,$%.,#%.*79%
,8%'8Y8&)8%#'+#$,84*%&(%,%4&5+'#$"+7*%
5,$*(",7%).&#*%4&8$*8$#=%).*8%.*,$*9=%
4,8%/(&9'4*%27,55,+7*%&(%*X/7&#"U*%U,/&(#1%%
Clean and purge containers before applying heat.
Vent closed containers, including castings,
before preheating, welding, or cutting.
Page 5;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?A@B?BA>@1Item 56355
CD;6EFGDHIE6IDIJ6 KDCHJ%L6MNHIOL6MNHIO%EHPC C6EQP
L*79*(%Q#*%,89%J,(*
1. N&%8&$%'#*%$.*%)*79*(%"2%$.*%#)"$4.%9&*#%8&$%$'(8%
"$%&8%,89%&221%%Any welder that cannot be controlled
with the switch is dangerous and must be repaired.
2. N"#4&88*4$%$.*%/7'3%2(&5%$.*%/&)*(%
#&'(4*%+*2&(*%5,Y"83%,8T%,9['#$5*8$#=%
4.,83"83%,44*##&("*#=%&(%#$&("83%)*79*(#1%%
Such preventive safety measures reduce the
risk of starting the welder accidentally.
3. P(*U*8$%'8"8$*8$"&8,7%#$,($"831%
68#'(*%$.*%#)"$4.%"#%"8%$.*%&22?
/&#"$"&8%+*2&(*%4&88*4$"83%$&%/&)*(%
#&'(4*%&(%5&U"83%$.*%)*79*(1 Carrying
or energizing welders that have the
switch on invites accidents.
4. C$&(*%"97*%)*79*(#%&'$%&2%$.*%(*,4.%&2%
4."79(*8%,89%9&%8&$%,77&)%/*(#&8#%'82,5"7",(%
)"$.%$.*%)*79*(%&(%$.*#*%"8#$('4$"&8#%$&%
&/*(,$*%$.*%)*79*(1%%Welders are dangerous
in the hands of untrained users.
5. Q#*%$.*%)*79*(%,89%,44*##&("*#%"8%
,44&(9,84*%)"$.%$.*#*%"8#$('4$"&8#=%$,Y"83%
"8$&%,44&'8$%$.*%)&(Y"83%4&89"$"&8#%,89%
$.*%)&(Y%$&%+*%/*(2&(5*91 Use of the welder
for operations different from those intended
could result in a hazardous situation.
6. N&%8&$%'#*%$.*%)*79*(%2&(%/"/*%$.,)"831
G,"8$*8,84*
1. G,"8$,"8%)*79*(#1%%J.*4Y%2&(%5"#,7"385*8$%&(%
+"89"83%&2%5&U"83%/,($#=%+(*,Y,3*%&2%/,($#%
,89%,8T%&$.*(%4&89"$"&8%$.,$%5,T%,22*4$%$.*%
)*79*(\#%&/*(,$"&81%%H2%9,5,3*9=%.,U*%$.*%
)*79*(%(*/,"(*9%+*2&(*%'#*1 Many accidents
are caused by poorly maintained welders.
2. Z,U*%T&'(%)*79*(%#*(U"4*9%+T%,%<',7"2"*9%
(*/,"(%/*(#&8%'#"83%&87T%"9*8$"4,7%
(*/7,4*5*8$%/,($#1%%This will ensure that
the safety of the welder is maintained.
3. G,"8$,"8%7,+*7#%,89%8,5*/7,$*#%&8%$.*%L*79*(1%%%
These carry important information.
If unreadable or missing, contact
Harbor Freight Tools for a replacement.
4. Q8/7'3%+*2&(*%5,"8$*8,84*1%Unplug the Welder
from its electrical outlet before any inspection,
maintenance, or cleaning procedures.
%CD!6%EZ6C6%HICERQJEHSIC1
Page 6 ;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?A@B?BA>@1 Item 56355
CD;6EF GDHIE6IDIJ6KDCHJ%L6MNHIO L6MNHIO%EHPCC6EQP
O(&'89"83
ES%PR6!6IE%6M6JERHJ%CZSJV%DIN%N6DEZ%%
;RSG%HIJSRR6JE%ORSQINHIO%LHR6%JSII6JEHSI-%
J.*4Y%)"$.%,%<',7"2"*9%*7*4$("4",8%"2%T&'%,(*%"8%9&'+$%,#%$&%).*$.*(%$.*%&'$7*$%"#%
/(&/*(7T%3(&'89*91%%%
N&%8&$%'#*%$.*%L*79*(%"2%$.*%/&)*(%4&(9%&(%/7'3%"#%9,5,3*91%%H2%9,5,3*9=%.,U*%"$%(*/,"(*9%+T%,%#*(U"4*%
2,4"7"$T%+*2&(*%'#*1%%H2%$.*%/7'3%)"77%8&$%2"$%$.*%&'$7*$=%.,U*%,%/(&/*(%&'$7*$%"8#$,77*9%+T%,%<',7"2"*9%*7*4$("4",8=%
9&%8&$%'#*%,9,/$*(%/7'3#1
1. The green wire inside the cord is connected 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.
Never leave the grounding wire disconnected
or modify the Power Cord Plug in any way.
2. Make sure the tool is connected to an outlet having
the same configuration as the plug. If the tool must
be reconnected for use on a different type of electric
circuit, the reconnection should be made by qualified
service personnel; and after reconnection, the tool
should comply with all local codes and ordinances.
6X$*8#"&8%J&(9#
N&%8&$%'#*%,8%*X$*8#"&8%4&(9%&8%$."#%L*79*(1
R*/7,4*5*8$%J&(9#
1. Q#*%&87T%$.*%#'//7"*9%/&)*(%4&(9%2&(%$."#%
L*79*(%&(%,8%"9*8$"4,7%(*/7,4*5*8$%4&(91
2. N&%8&$%"8#$,77%,%$."88*(%&(%7&83*(%
4&(9%&8%$."#%L*79*(1
3. N&%8&$%/,$4.%4&(9#%&2%,8T%7*83$.%
$&3*$.*(%2&(%$."#%"$*51%%P,$4.*#%5,T%,77&)%
5&"#$'(*%$&%/*8*$(,$*%$.*%"8#'7,$"&8=%
(*#'7$"83%"8%*7*4$("4%#.&4Y1
Page 7;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?A@B?BA>@1Item 56355
CD;6EFGDHIE6IDIJ6 KDCHJ%L6MNHIOL6MNHIO%EHPC C6EQP
CT5+&7&3T
Wire Feed (Speed)
Workpiece Ground Cable
Torch Cable
Overheat Shutdown Indicator
Cooling Fan
Housing Ground Point
!DJ
Volts Alternating Current
D
Amperes
SJ!
Open Circuit Voltage
V!D
Kilovolt Amperes
(Volts / 1000 * Amperes)
HPG
Inches Per Minute
DLO
American Wire Gauge
Electric Shock Hazard.
Do not touch energized parts.
Inhalation Hazard.
Keep head out of fumes
and use proper ventilation.
Read manual before
setup and/or use.
Fire Hazard.
Keep flammable materials
away during welding. Spatter
can cause accidental fires.
Arc Ray Hazard.
Wear welding helmet with
properly rated filter lens.
Pacemaker Hazard.
Welding processes may
interfere with pacemakers.
Consult doctor before use.
C/*4"2"4,$"&8#
P&)*(%H8/'$ 120 VAC / 60 Hz
J'((*8$%H8/'$ 23 A
L*79"83%J'((*8$%R,83* 30 –125 A
R,$*9%N'$T%JT47* 30% @ 90 A
S/*8%J"(4'"$%!&7$,3* 42 V
L"(*%C/**9 60 – 200 IPM
L*79"83%L"(*%J,/,4"$T 0.030" / 0.035" Flux Cored
L"(*%C/&&7%J,/,4"$T 2 lb spool
Page 8 ;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?A@B?BA>@1 Item 56355
CD;6EF GDHIE6IDIJ6KDCHJ%L6MNHIO L6MNHIO%EHPCC6EQP
1. E'(8%$.*%P&)*(%C)"$4.%S;;%,89%'8/7'3%
$.*%L*79*(%+*2&(*%/(&4**9"831
2. Push back on the Door Latch,
then open the Door.
3. Remove the Spool Knob, Spring, and
Spool Plate. Remove the old Spool and
all remaining wire from the liners.
4. Place the new Wire Spool over the Spool Spindle
as illustrated.
E&%/(*U*8$%)"(*%2**9%/(&+7*5#=%#*$%$.*%C/&&7%
#&%$.,$%"$%)"77%'8)"89%4&'8$*(47&4Y)"#*1
5. Replace the Spool Plate and Spring
over the Spool Spindle and secure
Spool in place with the Spool Knob.
I&$"4*- If Wire Spool can spin freely, Spool Knob is too
loose. This will cause the welding wire to unravel and
unspool which can cause tangling and feeding problems.
P&)*(%
C)"$4.
N&&(%
M,$4.
N&&(
L*79*(%
L,77
C/&&7%
V8&+
L"(*%
C/&&7
C/&&7%
P7,$*
C/("83
C/&&7%
C/"897*
L"(*%5'#$%'8)"89%
"8%$."#%9"(*4$"&8
C*$'/
R*,9%$.*%6IEHR6%HGPSREDIE%CD;6EF%HI;SRGDEHSI%#*4$"&8%,$%$.*%+*3"88"83%&2%$."#%5,8',7%
"847'9"83%,77%$*X$%'89*(%#'+.*,9"83#%$.*(*"8%+*2&(*%#*$%'/%&(%'#*%&2%$."#%/(&9'4$1
ES%PR6!6IE%C6RHSQC%HI]QRF%;RSG%DJJHN6IEDM%SP6RDEHSI-%
E'(8%$.*%P&)*(%C)"$4.%&22%,89%'8/7'3%$.*%L*79*(%+*2&(*%#*$'/1
I&$*-%Remove the protective foam and cardboard from the Welder before setup.
Wire Spool Installation / Wire Setup
Page 9;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?A@B?BA>@1Item 56355
CD;6EFGDHIE6IDIJ6 KDCHJ%L6MNHIOL6MNHIO%EHPC C6EQP
6. Turn the Feed Tensioner knob counterclockwise to
loosen it enough to pull it down to remove tension.
The spring-loaded Idler Arm will move up as shown.
7. ;**9%R&77*(%H8#$('4$"&8#-%
Check that the Feed Roller is turned to properly
match the wire size marked on the Wire Spool:
a. Twist the Feed Roller Knob
counterclockwise to release it.
b. Remove the Feed Roller Knob to
expose the Feed Roller.
c. Flip or replace the Feed Roller as needed
and confirm that $.*%8'5+*(%#.&)"83%"#%$.*%
#,5*%,#%$.*%)"(*%9",5*$*(%&8%$.*%C/&&71
d. Twist the Feed Roller Knob back into
place to secure the Feed Roller.
.030″
.030″
H97*(%D(5
;**9%E*8#"&8*(
.030″
;**9%R&77*(%
V8&+
.030″
.030″
;**9%
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!?3(&&U*
.030″
Page 10 ;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?A@B?BA>@1 Item 56355
CD;6EF GDHIE6IDIJ6KDCHJ%L6MNHIO L6MNHIO%EHPCC6EQP
HGPSREDIE
C*4'(*7T%.&79%&8$&%$.*%*89%&2%$.*%)*79"83%)"(*%,89%Y**/%
$*8#"&8%&8%"$%9'("83%$.*%2&77&)"83%#$*/#1
H2%$."#%"#%8&$%9&8*=%$.*%)*79"83%)"(*%)"77%'8(,U*7%,89%'8#/&&7%
)."4.%4,8%4,'#*%$,837"83%,89%2**9"83%/(&+7*5#1
8. Cut off all bent and crimped wire.
The cut end must have 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
Inlet Liner and Feed Guide.
10. Make sure the welding wire is resting in the
groove of the Feed Roller, then push the wire
Idler Arm down, and swing the Feed Tensioner
up to latch it across the tip of the arm.
After the wire is held by the Tensioner,
you may release it.
I&$*- The tension should be 2 – 3.
Too much force on flux-cored wire will
crush it and cause feeding issues.
11. Unscrew the Contact Tip
counterclockwise and remove.
12. Lay the Flux Gun Cable out in a straight line so
that the welding wire moves through it easily.
Leave the cover open, so that the feed
mechanism can be observed.
LDRIHIO
The following steps require applying power to the Welder
with the cover open.
E&%/(*U*8$%#*("&'#%"8['(T%2(&5%2"(*%&(%*7*4$("4%#.&4Y-
1. N&%8&$%$&'4.%,8T$."83=%*#/*4",77T%8&$%$.*%O(&'89%J7,5/=%
)"$.%$.*%O'8%&(%)*79"83%)"(*%&(%,8%,(4%)"77%+*%"38"$*91
2. N&%8&$%$&'4.%"8$*(8,7%L*79*(%4&5/&8*8$#%
)."7*%"$%"#%/7'33*9%"81
13. Turn the Power Switch off and do not touch the
Gun’s Trigger and before connecting Power Cord:
14. Plug the Power Cord into a properly
grounded, GFCI protected 120 VAC (20
amp rated) receptacle that matches the
plug and turn the Power Switch ON.
I&$*- The circuit must be equipped with
delayed action-type circuit breaker or fuses.
L"(*%L"(*%
C/&&7C/&&7
L*79"83%
L"(*
ZSMN%LHR6%
C6JQR6MF
;**9%
O'"9*
L"(*%H87*$%
M"8*(
.030″
.030″
.030″
H97*(%D(5
;**9%E*8#"&8*(
P&)*(%
C)"$4.
Page 11;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?A@B?BA>@1Item 56355
CD;6EFGDHIE6IDIJ6 KDCHJ%L6MNHIOL6MNHIO%EHPC C6EQP
15. Point the Gun away from all objects.
Press and hold the Cold Feed Switch
until the wire feeds through the
end of the Gun two inches.
E.*%)"(*%7"8*(%5,T%4&5*%&'$%)"$.%$.*%)*79"83%
)"(*1%%E."#%"#%8&(5,7=%['#$%$'(8%&22%$.*%L*79*(%
,89%/'#.%$.*%)"(*%7"8*(%+,4Y%"8$&%$.*%O'81
If the wire does not feed properly and
the Spool is stationary, turn OFF and
unplug the Welder and slightly tighten the
Feed Tensioner clockwise before retrying.
16. To check the wire’s drive tension, press and hold
Cold Feed Switch to feed the wire against a piece
of wood from 2 to 3 inches away.
If the wire stops instead of bending, unplug
the Welder, slightly tighten the Feed Tensioner
clockwise, and try again. If the wire bends from
the feed pressure, then the tension is set properly.
17. Turn OFF the Power Switch and unplug the
Power Cord from its electrical outlet.
18. Select a Contact Tip that is compatible with
the welding wire used. Slide the Contact
Tip over the wire and thread it clockwise into
the Flux Gun. Tighten the Contact Tip.
19. Slide the Nozzle onto the gun as well.
20. Cut the wire off at 1/2" from tip (1/2" stickout).
21. Close the Door. Make sure Door is securely latched.
;7'X%O'8
L*79"83%
L"(*
_`
.030″
H84(*5*8$,77T%%
"84(*,#*%$*8#"&8%%
'8$"7%%
)"(*%+*89#1
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N&&(%
M,$4.
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Page 12 ;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?A@B?BA>@1 Item 56355
CD;6EF GDHIE6IDIJ6KDCHJ%L6MNHIO L6MNHIO%EHPCC6EQP
K,#"4%L*79"83
R*,9%$.*%6IEHR6%HGPSREDIE%CD;6EF%HI;SRGDEHSI%#*4$"&8%,$%$.*%+*3"88"83%&2%$."#%5,8',7%
"847'9"83%,77%$*X$%'89*(%#'+.*,9"83#%$.*(*"8%+*2&(*%)*79"831
ES%PR6!6IE%C6RHSQC%HI]QRF-%
P(&$*4$"U*%3*,(%5'#$%+*%)&(8%).*8%'#"83%$.*%L*79*(b%5"8"5'5%#.,9*%8'5+*(%>B%2'77%2,4*%#."*79%
(or welding mask), ear protection, welding gloves, sleeves and apron, NIOSH-approved respirator, and fire
(*#"#$,8$%)&(Y%47&$.*#%)"$.&'$%/&4Y*$#%#.&'79%+*%)&(8%).*8%)*79"831%%%
M"3.$%2(&5%$.*%,(4%4,8%4,'#*%/*(5,8*8$%9,5,3*%$&%$.*%*T*#%,89%#Y"81%%
N&%8&$%+(*,$.*%,(4%2'5*#1
Flux-cored wire welding is used to weld mild steel
and stainless steel without shielding gas.
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
• a different type of material
• a different type of connection
• using a different process (MIG vs. Flux)
G,Y*%/(,4$"4*%)*79#%&8%/"*4*#%&2%#4(,/%$&%/(,4$"4*%
$*4.8"<'*%+*2&(*%)*79"83%,8T$."83%&2%U,7'*1
ES%PR6!6IE%C6RHSQC%HI]QRF=%%
;HR6%DIN%KQRIC-%
V**/%)*79"83%$"/%47*,(%&2%3(&'89*9%
&+[*4$#%).*8*U*(%'8"$%"#%/7'33*9%
"8%,89%$'(8*9%&81
P&)*(%
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c
P(,4$"4*%T&'(%)*79"83%
$*4.8"<'*%&8%#4(,/%
/"*4*#%+*2&(*%)*79"83%
,8T$."83%&2%U,7'*1
Page 13;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?A@B?BA>@1Item 56355
CD;6EFGDHIE6IDIJ6 KDCHJ%L6MNHIOL6MNHIO%EHPC C6EQP
;(&8$%P,8*7%J&8$(&7#
L"(*%
C/**9%
V8&+
!&7$,3*%
V8&+
;7'X%O'8
O(&'89%
J7,5/
D7,(5%
H89"4,$&(
P&)*(%
H89"4,$&(
1
2
3
4
5
6
7
8
9
A
B
C
D
E
F
G
H
I
J
10
Page 14 ;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?A@B?BA>@1 Item 56355
CD;6EF GDHIE6IDIJ6KDCHJ%L6MNHIO L6MNHIO%EHPCC6EQP
H8$*("&(%J&8$(&7#
H97*(%D(5
L"(*%
C/&&7
C/&&7%
V8&+
;**9%E*8#"&8*(
L"(*%H87*$%
M"8*(
;**9%%
R&77*(%V8&+
J&79%;**9%
C)"$4.
L*79%C*$$"83#
Refer to the Settings Chart on the inside of the Welder door for Flux-Cored and MIG Weld settings.
The chart is only intended to show general guidelines for different wire sizes and for different
thicknesses of material. The initial settings used at the beginning of a weld may need to be
adjusted after stopping and carefully inspecting the weld. Proper welding takes experience.
Page 15;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?A@B?BA>@1Item 56355
CD;6EFGDHIE6IDIJ6 KDCHJ%L6MNHIOL6MNHIO%EHPC C6EQP
Duty Cycle (Duration of Use)
DU&"9%9,5,3*%$&%$.*%L*79*(%+T%8&$%)*79"83%
2&(%5&(*%$.,8%$.*%/(*#4("+*9%9'$T%4T47*%$"5*1%
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, a welder with a 40% duty cycle at 90 A
welding current must be allowed to rest for at least
6 minutes after every 4 minutes of continuous welding.
Failure to carefully observe any duty cycle limitations
can easily over-stress a welder’s power generation
system contributing to premature welder failure.
Rated Duty Cycle
30% Use at 90 A
;&(%>B%J&8$"8'&'#%G"8'$*#
%
A%
G"8'$*#%
L*79"83
%
d%
G"8'$*#%
R*#$"83
This Welder has an internal thermal protection
system to help prevent this sort of over-stress.
When the Welder overheats, it automatically
shuts down and the Overload Indicator lights.
The Welder automatically returns to service
after cooling off. Should this occur, rest the
Flux Gun on an electrically non-conductive,
heat-proof surface, such as a concrete
slab, well clear of the ground clamp.
D77&)%$.*%L*79*(%$&%4&&7%)"$.%$.*%
P&)*(%C)"$4.%&8=%#&%$.,$%$.*%"8$*(8,7%
;,8%)"77%.*7/%4&&7%$.*%L*79*(1
When the Overload Indicator is no longer
lit and the Welder can be used again,
use shorter welding periods and longer
rest periods to prevent needless wear.
P&)*(%
C)"$4.
1
2
3
4
5
6
7
8
9
A
B
C
D
E
F
G
H
I
J
10
SU*(7&,9%
H89"4,$&(
;7'X%O'8
4&84(*$*%#7,+%
e&(%&$.*(%.*,$?/(&&2=%
non-conductive surface)
Page 16 ;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?A@B?BA>@1 Item 56355
CD;6EF GDHIE6IDIJ6KDCHJ%L6MNHIO L6MNHIO%EHPCC6EQP
1. G,Y*%/(,4$"4*%)*79#%&8%/"*4*#%&2%#4(,/%$.*%
#,5*%$."4Y8*##%,#%T&'(%"8$*89*9%)&(Y/"*4*%
$&%/(,4$"4*%$*4.8"<'*%+*2&(*%)*79"83%,8T$."83%
&2%U,7'*1%%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.
I&$"4*- When welding equipment on a vehicle,
disconnect the vehicle battery power from both the
positive connection and the ground before welding.
This prevents damage to some vehicle electrical
systems and electronics due to the high voltage
and high frequency bursts common in welding.
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 and Voltage Knobs to
the desired settings. Refer to the Settings
Chart on the inside of the Welder door.
I&$*- The initial settings may need to be adjusted
after stopping and carefully inspecting the weld.
Proper welding takes experience.
47,5/#
)&(Y/"*4*#
J.,52*(%$."4Y%)&(Y/"*4*#1
J7*,8%
#'(2,4*#%$&%
+,(*%5*$,71
L&(Y/"*4*
O(&'89%
J7,5/
J7*,8%
#'(2,4*%$&%
+,(*%5*$,71
1
2
3
4
5
6
7
8
9
A
B
C
D
E
F
G
H
I
J
10
C*$$"83%Q/%E.*%L*79
Page 17;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?A@B?BA>@1Item 56355
CD;6EFGDHIE6IDIJ6 KDCHJ%L6MNHIOL6MNHIO%EHPC C6EQP
5. Turn the Power Switch off and do not touch
the Gun’s Trigger and before connecting
Power Cord: Plug the Power Cord into a
properly grounded, GFCI protected 120 VAC
(20 amp rated) receptacle that matches the
plug and turn the Power Switch ON.
I&$*- The circuit must be equipped with
delayed action-type circuit breaker or fuses.
6. Set Flux Gun down on nonconductive,
nonflammable surface away from any grounded
objects. Turn the Power Switch ON.
P&)*(%
C)"$4.
P&)*(%
C)"$4.
Page 18 ;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?A@B?BA>@1 Item 56355
CD;6EF GDHIE6IDIJ6KDCHJ%L6MNHIO L6MNHIO%EHPCC6EQP
1. Press (and hold) Trigger and contact the area
to be welded with electrode wire to ignite arc.
2. For a narrow weld, you can usually draw the wire in
a steady straight line.
This is called a stringer bead.
For a wider weld, draw the wire back and forth
across the joint.
This is called a weave bead and takes
practice to perform properly.
3. Direct the welding wire straight into the joint. This
gives an angle of 90° (straight up and down)
for butt (end to end) welds, and an angle
of 45° for fillet (T-shaped) welds.
4. When using flux-cored wire, the end of the
Flux Gun should be tilted so that wire is
angled anywhere in-between straight on
and 15° in the direction you are welding.
The amount of tilt is called the drag angle.
5. The Contact Tip should remain within 1/2″
of the work surface. This distance is called
CTWD - Contact Tip to Work Distance.
#$("83*(%+*,9 )*,U*%+*,9
L*79%;7'X%O'8%,837*#=%%
U"*)*9%2(&5%2(&8$%&2%)*79%[&"8$1
45°
2"77*$%)*79%[&"8$
90°
+'$$%)*79%[&"8$
JELN%%
(up to 1/2")
L*79%
N"(*4$"&8
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0-15°0-15°
;7'X?J&(*9%L"(*
K,#"4%L*79"83%E*4.8"<'*
Page 19;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?A@B?BA>@1Item 56355
CD;6EFGDHIE6IDIJ6 KDCHJ%L6MNHIOL6MNHIO%EHPC C6EQP
I&$*-%%If Welder is used too long, the Overload
Indicator lights up and the unit automatically
shuts down. The Welder automatically returns
to service after cooling off. Should this occur,
rest the Flux Gun on an electrically non-
conductive, heat-proof surface, such as a
concrete slab, away from the ground clamp.
D77&)%$.*%L*79*(%$&%4&&7%)"$.%$.*%
P&)*(%C)"$4.%&8=%#&%$.,$%$.*%"8$*(8,7%
;,8%)"77%.*7/%4&&7%$.*%L*79*(1%%
When the Overload Indicator is no longer
lit and the Welder can be used again, use
shorter welding periods and longer rest
periods to help prevent needless wear.
6. 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 L*79"83%E"/# 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 15.
JDQEHSIf%%L*79%)"77%+*%.&$=%9&%8&$%$&'4.1
7. L.*8%)*79"83%"#%4&5/7*$*= #*$%$.*%
;7'X%O'8%9&)8%&8%,%.*,$?/(&&2=%*7*4$("4,77T%
8&8?4&89'4$"U*%#'(2,4*1
Turn the Power Switch OFF.
8. Allow Welder to cool down, then
unplug the Power Cord.
9. Remove Ground Clamp from workpiece
or table and disconnect Flux Gun.
10. Respool wire by clipping wire, removing
contact tip on Flux Gun, releasing Idler Arm
on Wire Feed mechanism, and rotating the
Wire Spool counterclockwise. Be sure to
securely hold wire as it is being respooled
because the end of wire has a tendency to
quickly unravel once it clears the wire feeder.
P&)*(%
C)"$4.
1
2
3
4
5
6
7
8
9
A
B
C
D
E
F
G
H
I
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10
SU*(7&,9%
H89"4,$&(
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4&84(*$*%#7,+%
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non-conductive surface)
D2$*(%/(,4$"4*%)*79"83%
2&(%,%2*)%#*4&89#=%CESP%
,89%*X,5"8*%T&'(%)*79%
'#"83%$.*%3'"9*7"8*#%
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non-conductive surface)
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Page 20 ;&(%$*4.8"4,7%<'*#$"&8#=%/7*,#*%4,77%>?@@@?A@B?BA>@1 Item 56355
CD;6EF GDHIE6IDIJ6KDCHJ%L6MNHIO L6MNHIO%EHPCC6EQP
L*79"83%E"/#
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.
J7*,8"83%$.*%L*79
ES%PR6!6IE%C6RHSQC%HI]QRF-%
J&8$"8'*%$&%)*,(%DICH?,//(&U*9%
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).*8%47*,8"83%,%)*791%%
C/,(Y#%&(%4."/#%5,T%27T%).*8%47*,8"831
1. A weld from flux-cored wire will be
covered by slag. Use a chipping hammer
to knock this off. K*%4,(*2'7%8&$%$&%
9,5,3*%$.*%)*79%&(%+,#*%5,$*(",71
2. Use a wire brush to further clean the weld
or use an angle grinder (sold separately) to
shape the weld.
C$("Y*%E*#$
D%$*#$%)*79%&8%,%PH6J6%S;%CJRDP%4,8%+*%$*#$*9%+T%
'#"83%$.*%2&77&)"83%/(&4*9'(*1
L6DR%DICH?DPPRS!6N%CD;6EF%OSOOM6C%
NQRHIO%EZHC%PRSJ6NQR61
LDRIHIOf%%E."#%$*#$%LHMM%9,5,3*%$.*%)*79%"$%"#%
/*(2&(5*9%&81%%E."#%$*#$%"#%SIMF%,8%"89"4,$&(%&2%)*79%
$*4.8"<'*%,89%"#%8&$%"8$*89*9%$&%$*#$%)&(Y"83%)*79#1
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 OSSN%L6MN will deform but not break,
as shown on top.
A PSSR%L6MN will be brittle and snap at the weld,
as shown on bottom.
47,5/
CJRDP%
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+*89#%,89%"#%8&$%+("$$7*
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#8,/#%&(%4(,4Y#
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A typical flux-cored wire (FCAW) weld %
+*2&(*%47*,8"831
+,#*%5*$,7
)*79%+*,9
#7,3
#/,$$*(
J."//"83%
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