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

EASY-FLUX125
56355

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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 Read this material before using this product.
any shape or form without the express written consent of Harbor Freight Tools. Failure to do so can result in serious injury.
Diagrams within this manual may not be drawn proportionally. Due to continuing SAVE THIS MANUAL.
improvements, actual product may differ slightly from the product described herein.
Tools required for assembly and service may not be included.
 table of contents
Safety ......................................................... 2 Welding Tips .............................................. 20
Specifications ............................................. 7 Maintenance .............................................. 24
Setup .......................................................... 8 Parts List and Diagram .............................. 27
SaFEty

Basic Welding ............................................ 12 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.
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Indicates a hazardous situation which, if not avoided,

could result in minor or moderate injury.

Addresses practices not related to personal injury.

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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 5. Stay alert, watch what you are doing and use
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manufacturer′s instructions, common sense when operating a welder.

Material Safety Data Sheets (MSDS′s), do not use a welder while you are tired or under
employer′s safety practices, and ANSI Z49.1. the influence of drugs, alcohol or medication.
2. Keep out of reach of children. A moment of inattention while operating welders
Keep children and bystanders away while operating. may result in serious personal injury.

3. place the welder on a stable location before use. 6. avoid unintentional starting. Make sure you are
If it falls while plugged in, severe injury, prepared to begin work before turning on the Welder.
electric shock, or fire may result. 7. never leave the Welder unattended while
4. do not overreach. energized. Turn power off if you have to leave.
Keep proper footing and balance at all times. 8. the warnings, precautions, and instructions
discussed in this instruction manual cannot
cover all possible conditions and situations
MaintEnancE

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.

Page 2 For technical questions, please call 1-888-380-0318. Item 56355

 SaFEty
Fume and gas Safety
INHALATION HAZARD:
Welding and plasma cutting produce toxic fumes.

1. Exposure to welding or cutting exhaust 3. Keep head out of fumes.

fumes can increase the risk of developing Do not breathe exhaust fumes.
certain cancers, such as cancer of the
larynx and lung cancer. Also, some diseases 4. use enough ventilation, exhaust at arc, or
that may be linked to exposure to welding both, to keep fumes and gases from breathing
or plasma cutting exhaust fumes are: zone and general area. If engineering controls
are not feasible, use an approved respirator.

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• Early onset of Parkinson’s Disease
• Heart disease 5. Work in a confined area only if it
is well-ventilated, or while wearing
• Ulcers an air-supplied respirator.
• Damage to the reproductive organs
6. Have a recognized specialist in
• Inflammation of the small intestine or stomach industrial Hygiene or Environmental Services
• Kidney damage check the operation and air quality
• Respiratory diseases such as and make recommendations
for the specific welding situation.

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emphysema, bronchitis, or pneumonia
Follow OSHA guidelines for
Use natural or forced air ventilation and wear
Permissible Exposure Limits (PEL’s) and
a respirator approved by NIOSH to protect
the American Conference of Governmental
against the fumes produced to reduce the
Industrial Hygienists recommendations for
risk of developing the above illnesses.
Threshold Limit Values (TLV’s) for fumes and gases.
2. do not use near degreasing or
painting operations.

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arc Ray Safety
aRc RayS can injure eyes and burn skin.

1. Wear anSi-approved welding eye protection 4. Wear an approved head covering to protect
featuring at least a number 10 shade lens rating. the head and neck. Use aprons, cape, sleeves,
shoulder covers, and bibs designed and
2. Wear leather leggings, fire resistant shoes approved for welding and cutting procedures.
or boots during use. Do not wear pants with
cuffs, shirts with open pockets, or any clothing 5. When welding/cutting overhead or in confined
that can catch and hold molten metal or sparks. spaces, wear flame resistant ear plugs or
MaintEnancE

ear muffs to keep sparks out of ears.

3. Keep clothing free of grease, oil,
solvents, or any flammable substances.
Wear dry, insulating gloves and protective clothing.

Item 56355 For technical questions, please call 1-888-380-0318. Page 3

 Electrical Safety
ElEctRic SHOcK can Kill.

1. turn off, disconnect power, and 6. do not expose welders to rain or wet conditions.
SaFEty

discharge electrode to ground before setting Water entering a welder will increase
down torch/electrode holder and before service. the risk of electric shock.

2. do not touch energized electrical parts. 7. do not abuse the cord. never use the cord
Wear dry, insulating gloves. Do not touch electrode for carrying, pulling or unplugging the welder.
holder, electrode, welding torch, or welding wire with Keep cord away from heat, oil, sharp edges
bare hand. Do not wear wet or damaged gloves. or moving parts. Damaged or entangled
cords increase the risk of electric shock.
3. connect to grounded, gFci-protected
power supply only. 8. do not use outdoors.

4. do not use near water or damp objects. 9. insulate yourself from the workpiece and
ground. Use nonflammable, dry insulating
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5. people with pacemakers should consult their material if possible, or use dry rubber mats,
physician(s) before use. Electromagnetic fields dry wood or plywood, or other dry insulating
in close proximity to heart pacemaker could cause material large enough to cover your full
pacemaker interference or pacemaker failure. area of contact with the work or ground.
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Fire Safety
aRc and HOt Slag can cause fire.

1. clear away or protect flammable objects. 5. if working on a metal wall, ceiling, etc.,
Remove or make safe all combustible materials for a prevent ignition of combustibles on the
radius of 35 feet (10 meters) around the work area. other side by moving the combustibles to a
Use a fire resistant material to cover safe location. If relocation of combustibles is
or block all open doorways, windows, not possible, designate someone to serve as
cracks, and other openings. a fire watch, equipped with a fire extinguisher,
during the cutting process and for at least one
2. Keep aBc-type fire extinguisher near half hour after the cutting is completed.
WElding tipS

work area and know how to use it.

6. do not weld or cut on materials having
3. Maintain a safe working environment. a combustible coating or combustible
Keep the work area well lit. internal structure, as in walls or ceilings, without
Make sure there is adequate an approved method for eliminating the hazard.
surrounding workspace. Keep the work area free
of obstructions, grease, oil, trash, and other debris. 7. do not dispose of hot slag in containers
holding combustible materials.
4. do not operate welders in atmospheres
containing dangerously reactive or 8. after welding, make a thorough examination
flammable liquids, gases, vapors, or dust. for evidence of fire. Be aware that easily
Provide adequate ventilation in work areas visible smoke or flame may not be present
to prevent accumulation of such substances. for some time after the fire has started.
MaintEnancE

Welders create sparks which may ignite flammable

substances or make reactive fumes toxic. 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.

Page 4 For technical questions, please call 1-888-380-0318. Item 56355

Welder use and care
1. do not use the welder if the switch does not turn 4. Store idle welders out of the reach of
it on and off. Any welder that cannot be controlled children and do not allow persons unfamiliar
with the switch is dangerous and must be repaired. with the welder or these instructions to

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operate the welder. Welders are dangerous
2. disconnect the plug from the power in the hands of untrained users.
source before making any adjustments,
changing accessories, or storing welders. 5. use the welder and accessories in
Such preventive safety measures reduce the accordance with these instructions, taking
risk of starting the welder accidentally. into account the working conditions and
the work to be performed. Use of the welder
3. prevent unintentional starting. for operations different from those intended
Ensure the switch is in the off- could result in a hazardous situation.
position before connecting to power
source or moving the welder. Carrying 6. do not use the welder for pipe thawing.
or energizing welders that have the
switch on invites accidents.

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Maintenance
1. Maintain welders. check for misalignment or 3. Maintain labels and nameplates on the Welder.
binding of moving parts, breakage of parts These carry important information.

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and any other condition that may affect the If unreadable or missing, contact
welder’s operation. if damaged, have the Harbor Freight Tools for a replacement.
welder repaired before use. Many accidents
are caused by poorly maintained welders. 4. unplug before maintenance. Unplug the Welder
from its electrical outlet before any inspection,
2. Have your welder serviced by a qualified maintenance, or cleaning procedures.
repair person using only identical
replacement parts. This will ensure that
the safety of the welder is maintained.

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SaVE tHESE inStRuctiOnS.
MaintEnancE

Item 56355 For technical questions, please call 1-888-380-0318. Page 5

 grounding

tO pREVEnt ElEctRic SHOcK and dEatH

SaFEty

FROM incORREct gROunding WiRE cOnnEctiOn:

check with a qualified electrician if you are in doubt as to whether the outlet is
properly grounded.
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,
do not use adapter plugs.

1. The green wire inside the cord is connected to 2. Make sure the tool is connected to an outlet having
the grounding system in the Welder. The green the same configuration as the plug. If the tool must
wire in the cord must be the only wire connected be reconnected for use on a different type of electric
to the Welder’s grounding system and must circuit, the reconnection should be made by qualified
never be attached to an electrically “live” terminal. service personnel; and after reconnection, the tool
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Never leave the grounding wire disconnected should comply with all local codes and ordinances.
or modify the Power Cord Plug in any way.

Extension cords
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do not use an extension cord on this Welder.

Replacement cords
1. use only the supplied power cord for this 3. do not patch cords of any length
Welder or an identical replacement cord. together for this item. patches may allow
moisture to penetrate the insulation,
2. do not install a thinner or longer resulting in electric shock.
cord on this Welder.
WElding tipS
MaintEnancE

Page 6 For technical questions, please call 1-888-380-0318. Item 56355

Symbology

Wire Feed (Speed)

ipM Inches Per Minute

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Workpiece Ground Cable aWg American Wire Gauge

Electric Shock Hazard.

Torch Cable Do not touch energized parts.

Overheat Shutdown Indicator Inhalation Hazard.

Keep head out of fumes
and use proper ventilation.
Cooling Fan

Read manual before

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Housing Ground Point setup and/or use.

Vac Volts Alternating Current Fire Hazard.

Keep flammable materials
away during welding. Spatter
a Amperes can cause accidental fires.
Arc Ray Hazard.
OcV Open Circuit Voltage Wear welding helmet with

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properly rated filter lens.

KVa Kilovolt Amperes

(Volts / 1000 * Amperes)
Pacemaker Hazard.
Welding processes may
interfere with pacemakers.
Consult doctor before use.

Specifications

power input 120 VAC / 60 Hz

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current input 23.5 A
Welding current Range 30 –125 A
Rated duty cycle 30% @ 90 A
Open circuit Voltage 21 V
Wire Speed 60 – 200 IPM
Welding Wire capacity 0.030" / 0.035" Flux Cored
Wire Spool capacity 2 lb spool
MaintEnancE

Item 56355 For technical questions, please call 1-888-380-0318. Page 7

 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.
SaFEty

tO pREVEnt SERiOuS inJuRy FROM accidEntal OpERatiOn:

turn the power Switch off and unplug the Welder before setup.

note: Remove the protective foam and cardboard from the Welder before setup.

Wire Spool Installation / Wire Setup

1. turn the power Switch OFF and unplug power

Switch
the Welder before proceeding.
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door
door
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latch
2. Push back on the Door Latch,
then open the Door.

Spool
Knob

Spring

3. Remove the Spool Knob, Spring, and Spool

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Spool Plate. Remove the old Spool and plate

all remaining wire from the liners.
Spool
Spindle Wire
Spool

Welder
Wall
4. Place the new Wire Spool over the Spool Spindle
as illustrated.
to prevent wire feed problems, set the Spool
so that it will unwind counterclockwise.
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5. Replace the Spool Plate and Spring

over the Spool Spindle and secure
Spool in place with the Spool Knob.
notice: 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.
Wire must unwind
in this direction

Page 8 For technical questions, please call 1-888-380-0318. Item 56355

 Feed tensioner
idler arm
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.

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Feed Roller
7. Feed Roller instructions: Knob
Check that the Feed Roller is turned to properly
match the wire size marked on the Wire Spool:

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a

a. Twist the Feed Roller Knob

counterclockwise to release it.

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Feed
B Roller

b. Remove the Feed Roller Knob to

V-groove

V-groove
expose the Feed Roller.
0.030

0.035

c. Flip or replace the Feed Roller as needed

and confirm that the number showing is the

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same as the wire diameter on the Spool.

d
d. Twist the Feed Roller Knob back into
place to secure the Feed Roller.
MaintEnancE

Item 56355 For technical questions, please call 1-888-380-0318. Page 9

 iMpORtant
Securely hold onto the end of the welding wire and keep
tension on it during the following steps.
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if this is not done, the welding wire will unravel and unspool
which can cause tangling and feeding problems.

HOld WiRE Feed

Wire SEcuREly guide
Spool
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 Welding

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least 12 inches of wire into the Wire Wire Wire inlet

Inlet Liner and Feed Guide. liner

10. Make sure the welding wire is resting in the idler arm Feed tensioner
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.
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note: 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.

WaRning
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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.

13. Turn the Power Switch off and do not touch the
MaintEnancE

Gun’s Trigger and before connecting Power Cord:

power
14. Plug the Power Cord into a properly Switch
grounded, GFCI protected 120 VAC (20
amp rated) receptacle that matches the
plug and turn the Power Switch ON.
note: The circuit must be equipped with
delayed action-type circuit breaker or fuses.

Page 10 For technical questions, please call 1-888-380-0318. Item 56355

15. Point the Gun away from all objects. Flux gun
Press and hold the Cold Feed Switch
until the wire feeds through the 2"
end of the Gun two inches.
the wire liner may come out with the welding

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wire. this is normal, just turn off the Welder
and push the wire liner back into the gun. Welding
Wire
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

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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
incrementally
clockwise, and try again. If the wire bends from
increase tension
the feed pressure, then the tension is set properly.
until
wire bends. 2–3"

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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. contact
Flux gun
tip
19. Slide the Nozzle onto the gun as well.

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20. Cut the wire off at 1/2" from tip (1/2" stickout).

door
door
latch
21. Close the Door. Make sure Door is securely latched.
MaintEnancE

Item 56355 For technical questions, please call 1-888-380-0318. Page 11

 Basic Welding

Read the EntiRE iMpORtant SaFEty inFORMatiOn section at the beginning of this manual
including all text under subheadings therein before welding.
SaFEty

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.
Flux-cored wire welding is used to weld mild steel
and stainless steel without shielding gas.
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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)
Make practice welds on pieces of scrap to practice
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technique before welding anything of value.

power
On

tO pREVEnt SERiOuS inJuRy,

=
WElding tipS

FiRE and BuRnS:

Keep welding tip clear of grounded
objects whenever unit is plugged
in and turned on.

practice your welding

technique on scrap
MaintEnancE

pieces before welding

anything of value.

Page 12 For technical questions, please call 1-888-380-0318. Item 56355

Front panel controls

alarm
indicator

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power
indicator

Voltage
Knob
Flux gun

5 6

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4 7

3 8
Wire
Speed 2 9

1
Knob 10

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WElding tipS
ground
clamp

MaintEnancE

Item 56355 For technical questions, please call 1-888-380-0318. Page 13

 interior controls
Feed tensioner idler arm
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Wire
Spool

Spool
Knob
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Wire inlet Feed cold Feed

liner Roller Knob Switch

Weld Settings
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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.
WElding tipS
MaintEnancE

Page 14 For technical questions, please call 1-888-380-0318. Item 56355

Duty Cycle (Duration of Use)
avoid damage to the Welder by not welding For example, a welder with a 30% duty cycle at 90 A
for more than the prescribed duty cycle time. welding current must be allowed to rest for at least
The Duty Cycle defines the number of minutes, within a 7 minutes after every 3 minutes of continuous welding.
10 minute period, during which a given welder can

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produce a particular welding current without overheating. 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
For 10 continuous Minutes

3 7
Minutes Minutes
Welding Resting

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This Welder has an internal thermal protection
system to help prevent this sort of over-stress.
When the Welder overheats, it automatically

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shuts down and the Overload Indicator lights.
The Welder automatically returns to service Flux gun
Overload
after cooling off. Should this occur, rest the
indicator
Flux Gun on an electrically non-conductive, 5 6
7

heat-proof surface, such as a concrete

4

3 8

slab, well clear of the ground clamp. 2

1 10
9

allow the Welder to cool with the

power Switch on, so that the internal concrete slab
Fan will help cool the Welder. (or other heat-proof,
non-conductive surface)
When the Overload Indicator is no longer power
lit and the Welder can be used again, Switch
use shorter welding periods and longer
rest periods to prevent needless wear.

WElding tipS
MaintEnancE

Item 56355 For technical questions, please call 1-888-380-0318. Page 15

 Setting up the Weld
1. Make practice welds on pieces of scrap the
same thickness as your intended workpiece
to practice technique before welding anything
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of value. Clean the weld surfaces thoroughly

with a wire brush or angle grinder; there
must be no rust, paint, oil, or other materials
clamps
on the weld surfaces, only bare metal.

2. Use clamps (not included) to hold the workpieces

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 clean
both sides securely while allowing the weld surfaces to
to penetrate fully into the joint. The edges of bare metal.
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thicker workpieces may need to be chamfered

(or beveled) to allow proper weld penetration.
chamfer thick workpieces.
notice: 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.
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Workpiece

clean
3. Clamp Ground Cable to bare metal on the surface to
workpiece near the weld area, or to metal work ground bare metal.
bench where the workpiece is clamped. clamp
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4. Set the Wire Speed and Voltage Knobs to

the desired settings. Refer to the Settings
Chart on the inside of the Welder door.

note: The initial settings may need to be adjusted 4

5 6
7
MaintEnancE

after stopping and carefully inspecting the weld. 3

2
8

Proper welding takes experience. 1 10

Page 16 For technical questions, please call 1-888-380-0318. Item 56355

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 power
Switch
properly grounded, GFCI protected 120 VAC
(20 amp rated) receptacle that matches the
plug and turn the Power Switch ON.

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note: The circuit must be equipped with
delayed action-type circuit breaker or fuses.

power

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6. Set Flux Gun down on nonconductive, Switch
nonflammable surface away from any grounded
objects. Turn the Power Switch ON.

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WElding tipS
MaintEnancE

Item 56355 For technical questions, please call 1-888-380-0318. Page 17

 Basic Welding technique
1. Press (and hold) Trigger and contact the area
to be welded with electrode wire to ignite arc.
stringer bead weave bead
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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.

Weld Flux gun angles,

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viewed from front of weld joint.

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.

90°
45°
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fillet weld joint butt weld joint

drag angle
0-15°

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 Weld
direction
and 15° in the direction you are welding.
The amount of tilt is called the drag angle.
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Flux-cored Wire
5. The Contact Tip should remain within 1/2″
of the work surface. This distance is called
CTWD - Contact Tip to Work Distance.

ctWd
(up to 1/2")
MaintEnancE

Page 18 For technical questions, please call 1-888-380-0318. Item 56355

note: 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-
Overload Flux gun
conductive, heat-proof surface, such as a

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concrete slab, away from the ground clamp. 5 6
indicator
4 7

allow the Welder to cool with the 3

2
8

power Switch on, so that the internal 1 10

Fan will help cool the Welder.

When the Overload Indicator is no longer concrete slab
lit and the Welder can be used again, use (or other heat-proof,
shorter welding periods and longer rest non-conductive surface)
periods to help prevent needless wear. power
Switch

6. After welding the test weld on a piece

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of scrap for a few seconds, stop, and
check your progress. Clean, then compare
your weld’s appearance with the diagrams after practice welding
and descriptions in the Welding tips section for a few seconds, StOp
starting on the next page. After making any and examine your weld
necessary adjustments, continue to weld using the guidelines
while carefully following the DUTY CYCLE starting on the next page.
guidelines as explained on page 15.

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cautiOn! Weld will be hot, do not touch.

7. When welding is complete, set the

Flux gun down on a heat-proof, electrically Flux gun
non-conductive surface.
Turn the Power Switch OFF.

8. Allow Welder to cool down, then

unplug the Power Cord.
concrete slab

WElding tipS
(or other heat-proof,
non-conductive surface)
9. Remove Ground Clamp from workpiece
or table and disconnect Flux Gun.

power
10. Respool wire by clipping wire, removing Switch
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.
MaintEnancE

Item 56355 For technical questions, please call 1-888-380-0318. Page 19

 Welding tips

A typical flux-cored wire (FCAW) weld

A good way to test welding technique is to examine a before cleaning.
SaFEty

weld’s appearance after it has cooled and the slag weld bead
slag
has been removed. Then, better welding can be spatter
learned by adjusting your weld technique to remedy
any problems found.
base metal

cleaning the Weld

SEtup

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.
chipping
1. A weld from flux-cored wire will be Hammer
covered by slag. Use a chipping hammer
to knock this off. Be careful not to
damage the weld or base material.
BaSic WElding

2. Use a wire brush to further clean the weld

or use an angle grinder (sold separately) to
shape the weld.
Wire Brush

Strike test
a test weld on a piEcE OF ScRap can be tested by clamp
using the following procedure. dead-blow hammer
ScRap
WEaR anSi-appROVEd SaFEty gOgglES workpiece
duRing tHiS pROcEduRE.
WElding tipS

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 gOOd WEld
weld has cooled, clamp one scrap in a sturdy vise. bends and is not brittle
2. Stay clear from underneath while you strike clamp
the opposite scrap with a heavy hammer, dead-blow hammer
ScRap
preferably a dead-blow hammer.
workpiece
3. A gOOd WEld will deform but not break,
as shown on top.
A pOOR WEld will be brittle and snap at the weld,
MaintEnancE

as shown on bottom.

pOOR WEld
snaps or cracks

Page 20 For technical questions, please call 1-888-380-0318. Item 56355

Weld diagnosis

Workpiece Heat control / Weld penetration

SaFEty
EXcESS pEnEtRatiOn OR
inadEQuatE pEnEtRatiOn pROpER pEnEtRatiOn
BuRn-tHROugH

not hot enough ideal heat too hot

SEtup
How to increase workpiece heat How to reduce workpiece heat
and increase penetration: and limit penetration:
(to weld tHicKER workpieces properly) (to weld tHinnER workpieces properly)
a. increase weld current c. use faster wire feed a. decrease weld current c. use slower wire feed
b. decrease travel speed d. use shorter ctWd b. increase travel speed d. use longer ctWd

Example Weld diagrams

BaSic WElding
WElding tipS
good Voltage Voltage travel Speed travel Speed ctWd
Weld too low or too High or too Fast too Slow too long
Wire Feed Wire Feed
too Slow too Fast

tO cORREct: tO cORREct: tO cORREct: tO cORREct: tO cORREct:

maintain
less
than 1/2"
ctWd
MaintEnancE

5 6
5 6
4 7
4 7

travel travel
3 8

or or
3 8

2 9
2 9
1 10
1 10

slower faster
5 6
5 6
4 7
4 7

3 8
3 8

2 9
2 9
1 10
1 10

Item 56355 For technical questions, please call 1-888-380-0318. Page 21

 Weld problems

Penetration (Workpiece Heat Control)

SaFEty

EXcESS pEnEtRatiOn OR pROpER pEnEtRatiOn inadEQuatE pEnEtRatiOn

BuRn-tHROugH Weld is visible underneath and Weld does not penetrate the
Weld droops on top and bulges slightly on top. joint fully, just on the surface.
underneath, or falls through
entirely, making a hole.

PROFILE VIEWS
SEtup

pOSSiBlE cauSES and SOlutiOnS pOSSiBlE cauSES and SOlutiOnS

1. Workpiece overheating: 1. incorrect welding technique:
Reduce wire feed speed. Maintain 1/2" or less CTWD.
Decrease weld current. Keep arc on leading edge of weld puddle.
2. travel speed too slow: Hold Flux Gun at proper angles.
Increase travel speed and ensure 2. insufficient weld heat:
that travel speed is kept steady. Reduce travel speed.
3. Excessive material at weld: Increase weld current.
BaSic WElding

Reduce wire feed speed. 3. Workpieces too thick/close:

Bevel thick workpieces, allow slight
gap, and weld in several passes.
Bend at Joint
4. insufficient weld material:
Increase wire feed speed.

PROFILE
VIEW
Weld not adhering properly
pOSSiBlE cauSES and SOlutiOnS gaps present between weld and previous bead or
1. improper clamping: between weld and workpiece. See areas below.
Clamp workpieces securely.
Make tack welds to hold workpieces.
WElding tipS

2. Excessive heat: PROFILE

Weld a small portion and allow to cool before VIEW
proceeding.
Increase travel speed.
Reduce wire feed speed.
pOSSiBlE cauSES and SOlutiOnS
1. incorrect welding technique:
coat of Slag Over Weld 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.
TOP Keep arc on leading edge of weld puddle.
VIEW Hold Flux Gun at proper angles.
MaintEnancE

2. insufficient weld heat:

PARTIALLY CHIPPED AWAY TO SHOW WELD Increase current.
Increase wire feed speed.
Slag is a necessary part of a flux-cored wire weld. 3. dirty workpiece:
it shields the weld from impurities. Clean workpiece down to bare metal.
clean off the slag with a chipping Hammer 4. insufficient weld material:
and Wire Brush after welding. Increase wire feed speed.
5. Workpiece gap too narrow:
Widen groove or increase bevel.

Page 22 For technical questions, please call 1-888-380-0318. Item 56355

porosity Excessive Spatter
Small cavities or holes in the bead. Fine spatter is normal.

SaFEty
Spatter that is grainy and large is a problem.

TOP
VIEW TOP
VIEW

pOSSiBlE cauSES and SOlutiOnS

1. dirty workpiece or welding wire: pOSSiBlE cauSES and SOlutiOnS
Clean workpiece down to bare metal. 1. dirty workpiece or welding wire:
Make certain that wire is clean and free Clean workpiece down to bare metal.
from oil, coatings, and other residues. Make certain that wire is clean and free
2. inconsistent travel speed: from oil, coatings, and other residues.

SEtup
Maintain steady travel speed. 2. Wire feeding too fast:
3. ctWd too long: Reduce wire feed speed.
Reduce CTWD. 3. ctWd too long:
Reduce CTWD.

BaSic WElding
WElding tipS
crooked/Wavy Bead Burn-through
Base material melts away,
leaving a hole in the weld.
TOP
VIEW
TOP
VIEW

pOSSiBlE cauSES and SOlutiOnS

1. inaccurate welding: pOSSiBlE cauSES and SOlutiOnS
Use two hands or rest hand on steady surface. 1. Workpiece overheating:
Reduce current and/or wire feed speed.
MaintEnancE

2. inconsistent travel speed:

Maintain steady travel speed. 2. travel speed too slow:
3. ctWd too long: Increase travel speed and ensure
Reduce CTWD. that travel speed is kept steady.
3. Excessive material at weld:
Reduce wire feed speed.

Item 56355 For technical questions, please call 1-888-380-0318. Page 23

 Maintenance
SaFEty

tO pREVEnt SERiOuS inJuRy, FiRE and BuRnS:

unplug the Welder, rest the Flux gun on a heat-proof, electrically non-conductive surface, and
allow all parts of the Welder to cool thoroughly before service.

1. BEFORE EacH uSE, inspect the general 2. Periodically, have a qualified

condition of the Welder. Check for: technician remove the Rear Panel
• loose hardware and use compressed air to blow
out all dust from the interior.
• misalignment or binding of moving parts
• damaged cord / electrical wiring 3. Store in a clean and dry location.
SEtup

• frayed or damaged cables 4. For optimal weld quality, clean

• cracked or broken parts and inspect the contact tip before
each use, as explained below.
• any other condition that may
affect its safe operation.

nozzle and contact tip inspection and cleaning

BaSic WElding

1. Make sure that the entire Flux gun is completely

cool and that the power cord is unplugged
from the electrical outlet before proceeding.

2. Pull the Nozzle to remove it.

3. Scrub the Nozzle clean with a wire brush.

4. Unscrew the Contact Tip counterclockwise

and slide it off the welding wire to remove.

5. Scrub the outside of the Tip clean with a wire brush.

Clean out the inside of the tip with a tip
cleaner (sold separately). Check that the Tip
is the proper type for the wire size used. contact
WElding tipS

nozzle Flux gun

tip
6. Examine the shape of the hole at the end of
the Contact Tip. It should be an even circle; it
should not be oblong or have any bulges in it.

7. If any problems are noted, replace the

Contact Tip. Select a new Tip of the
correct size for the welding wire used.

8. Reinstall the Tip and securely

reinstall the Nozzle as well.
MaintEnancE

Page 24 For technical questions, please call 1-888-380-0318. Item 56355

troubleshooting
iMpORtant!
Be cERtain to shut off the Welder, disconnect it from power, and discharge the Flux gun to
ground before adjusting, cleaning, or repairing the unit.

SaFEty
problem possible causes likely Solutions
1. Insufficient wire feed tension. 1. Increase wire feed tension properly.
Follow step 16 on page 11.
2. Incorrect wire feed roller size. 2. Flip roller to correct size, follow the
Wire feed motor Feed Roller instructions on page 9.
runs but wire does 3. Damaged Flux Gun, cable, or liner assembly. 3. Have a qualified technician inspect these
not feed properly parts and replace as necessary.
4. Feed Tensioner is too tight. 4. Loosen Feed Tensioner so it applies only
enough pressure to prevent continued
spinning after the Gun Trigger is released.
1. Excess wire feed tension. 1. Adjust wire feed pressure properly.

SEtup
Follow step 16 on page 11.
Wire creates a bird’s
2. Incorrect Contact Tip size. 2. Replace with the proper tip for wire used.
nest during operation
3. Damaged liner. 3. Have a qualified technician inspect
and repair/replace as necessary.
1. Gun cable is severely bent and Wire Feed 1. Straighten Gun cable.
mechanism cannot feed wire.
2. Gun liner is clogged or worn. 2. Check gun liner for obstruction. Replace if necessary.
3. Gun liner is too small for 3. Check that gun liner is correct size for wire.
welding wire being used.
Wire stops

BaSic WElding
during welding 4. Wire is tangled on the spool. 4. Check wire for cross winding or
tangled spool.
5. Wire is not making contact with Feed Rollers. 5. Check Feed Rollers and ensure correct
groove for wire diameter is being used.
6. Feed Roller is not making enough contact 6. Check Feed Tensioner and ensure it is set properly.
with wire or is crushing flux-cored wire.
1. Wire not feeding properly. 1. See first Troubleshooting section above.
2. Incorrect Contact Tip or liner 2. Replace with the proper tip or liner size for wire used.
size or excessive wear.
3. Incorrect wire feed speed. 3. Adjust wire feed speed to achieve a more stable arc.
Welding arc
not stable 4. Damaged Flux Gun. 4. Have a qualified technician inspect
and repair/replace as necessary.
5. Poor connection with workpiece. 5. Check the ground clamp connection
to the workpiece and machine.

WElding tipS
Ensure the Flux Gun is properly secured.
1. Incorrect line voltage. 1. Check the line voltage and, if insufficient, have
a licensed electrician remedy the situation.
2. Improper gauge or length of cord. 2. Do not use an extension cord on this Welder.
Weak arc strength
Use only one of the supplied power cords for
this Welder or an identical replacement cord.
3. Not enough current. 3. Switch current to proper setting for metal thickness.

Follow all safety precautions whenever diagnosing or servicing the equipment.

MaintEnancE

Item 56355 For technical questions, please call 1-888-380-0318. Page 25

 Troubleshooting (continued)
iMpORtant!
Be cERtain to shut off the Welder, disconnect it from power, and discharge the Flux gun to
ground before adjusting, cleaning, or repairing the unit.
SaFEty

problem possible causes likely Solutions

1. Tripped thermal protection device. 1. If the Alarm Indicator is illuminated without an error
code, Welder has overheated and shut down. Stop
and wait with the Power Switch ON for the Welder
to cool. The Welder automatically returns to service
after cooling off. Reduce duration or frequency of
When switched on, welding periods to help reduce wear on the Welder.
Power Indicator Refer to Duty Cycle (Duration of Use) on page 15.
lights but Welder
2. Faulty or improperly connected Trigger. 2. Ensure the gun connection is properly
does not function
seated on machine. Qualified technician
must check and secure/replace Trigger.
SEtup

3. Machine is in low- or 3. If the Alarm Light is illuminated, check input voltage

over-voltage protection. and ensure it falls within the specified range. If input
voltage is correct, turn Welder off and back on.
1. Unit is not connected to outlet properly. 1. Verify the voltage at the outlet and
the connection to the outlet.
2. Outlet is unpowered. 2. Check circuit breaker/GFCI devices;
if any are tripped, determine and
remedy cause before resetting.
Power ON Indicator 3. Circuit supplies insufficient input voltage or 3. Verify that the circuit is designed to supply the
does not light when amperage. required input voltage and amperage as detailed on
BaSic WElding

switched on the Specifications table. If the Voltage Input/Thermal

Overload Indicator is illuminated on machine, check
the input voltage to ensure it is within specified range.
4. Plug does not have correct rating. 4. Make sure installed plug is correct rating.
See Specifications on page 7.
5. Input Power Cord is not seated properly. 5. Ensure the input Power Cord is fully secured.
1. Improper ground connection. 1. 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. Improperly sized Contact Tip. 2. Verify that Contact Tip is the proper size
Wire feeds, but arc for welding wire. If needed, replace
does not ignite Contact Tip with proper size and type.
3. Excessively worn Contact Tip. 3. Check that the hole in the tip is not
deformed or enlarged. If needed, replace
WElding tipS

Contact Tip with proper size and type.

4. Dirty Contact Tip. 4. Properly clean Contact Tip.
1. Dirty workpiece. 1. Clean workpiece down to bare metal.
2. Gun is being used too far away from workpiece. 2. Check CTWD (contact tip to work
Porosity in the
distance) for the proper procedure.
weld metal
3. Dirty welding wire is introducing 3. Make certain that welding wire is clean
contamination into the weld. and free of rust and residues.

Follow all safety precautions whenever diagnosing or servicing the equipment.

MaintEnancE

Record Serial number Here:

note: If product has no serial number, record note: Some parts are listed and shown for illustration
month and year of purchase instead. purposes only, and are not available individually as
replacement parts. Parts may not be interchangeable.
Specify UPC 193175312525 when ordering parts.

Page 26 For technical questions, please call 1-888-380-0318. Item 56355

parts list and diagram

part description Qty part description Qty

1 Strap 1 21 Fast Recovery Diode 3
2 Top Cover 1 22 Rectifier Tube Radiator 1

SaFEty
3 Wire Feed 1 23 Bridge Rectifier 1
4 Latch 1 24 Side Cover (Left) 1
5 Side Cover (Right) 1 25 Electronic Switch Radiator 1
6 Middle Divider 1 26 Bridge Rectifier Radiator 1
7 Switch 1 27 Electronic Switch 4
8 MIG Torch 1 28 Capacitance 2
9 Control Panel PCB 1 29 Power Cable 1
10 Knob Ring 2 30 Rubber Blanket (Right) 1
11 Knob 2 31 Fan Hood 1
12 Control Panel 1 32 Fan 1
13 Front Panel 1 33 Switch 1
14 Base 1 34 Rubber Blanket (Left) 1

SEtup
15 Ground Clamp Asm. 1 35 Spool Spindle 1
16 Control PCB 1 36 Washer 1
17 Wire Feed Control PCB 1 37 Wire Roller (0.030/0.035", not shown) 1
18 Main PCB 1 38 Contact Tip (0.030", 1 spare, not shown) 1
19 Inductance 1
20 Transformer 1
5 4 3 2 1 36 35 34 33

BaSic WElding
32
6

31
7

30
8

29
9

WElding tipS
28
10

27

26
11
MaintEnancE

12 25

13 24

14 15 16 17 18 19 20 21 22 23

Item 56355 For technical questions, please call 1-888-380-0318. Page 27

plEaSE REad tHE FOllOWing caREFully
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM
IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER OR DISTRIBUTOR
MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS
QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT, OR THAT HE OR SHE IS QUALIFIED TO REPLACE
ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER AND/OR DISTRIBUTOR EXPRESSLY
STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND
LICENSED TECHNICIANS, AND NOT BY THE BUYER. THE BUYER ASSUMES ALL RISK AND LIABILITY
ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS
THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO.

Limited 90 Day Warranty

Harbor Freight Tools Co. makes every effort to assure that its products meet high quality and durability standards,
and warrants to the original purchaser that this product is free from defects in materials and workmanship for the
period of 90 days from the date of purchase. This warranty does not apply to damage due directly or indirectly,
to misuse, abuse, negligence or accidents, repairs or alterations outside our facilities, criminal activity, improper
installation, 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 of the complaint must accompany the merchandise.
If our inspection verifies the defect, we will either repair or replace the product at our election or we may
elect to refund the purchase price if we cannot readily and quickly provide you with a replacement. We will
return repaired products at our expense, but if we determine there is no defect, or that the defect resulted
from causes not within the scope of our warranty, then you must bear the cost of returning the product.
This warranty gives you specific legal rights and you may also have other rights which vary from state to state.

26541 Agoura Road • Calabasas, CA 91302 • 1-888-380-0318