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Harbor Freight Tools 98871 - page 1
90 AMP FLUX WIRE WELdER Model 98871 SEt UP And OPERA tIng InStRUctIOnS Visit our website at: http://www .harborfreight.com Read this material before using this product. Failure to do so can result in serious injury . SA VE thIS MAnUAL. Copyright © 2008 by Harbor Freight T ools ® . All rights reserved. No portion of this manual or any artwork cont ...
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Harbor Freight Tools 98871 - page 2
Page 2 For technical questions, please call 1-800-444-3353. SKU 98871 SAFEty SER VIcE BASIc WELdIng WELdIng tIPS SEtUP SA VE 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 dia ...
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Harbor Freight Tools 98871 - page 3
Page 3 For technical questions, please call 1-800-444-3353. SKU 98871 SAFEty SER VIcE BASIc WELdIng WELdIng tIPS SEtUP do not abuse the cord. never use d. the cord for carrying, pulling or unplugging the welder . Keep cord away from heat, oil, sharp edges or moving parts. Damaged or entangled cords increase the risk of electric shock. When operatin ...
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Harbor Freight Tools 98871 - page 4
Page 4 For technical questions, please call 1-800-444-3353. SKU 98871 SAFEty SER VIcE BASIc WELdIng WELdIng tIPS SEtUP Service 5. have your welder serviced by a a. qualied repair person using only identical replacement parts. This will ensure that the safety of the welder is maintained. W elder Safety W arnings Maintain labels and nameplates on ...
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Harbor Freight Tools 98871 - page 5
Page 5 For technical questions, please call 1-800-444-3353. SKU 98871 SAFEty SER VIcE BASIc WELdIng WELdIng tIPS SEtUP equippedwithareextinguisher ,during the cutting process and for at least one half hour after the cutting is completed. Do not weld or cut on materials having • a combustible coating or combustible internal ...
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Harbor Freight Tools 98871 - page 6
Page 6 For technical questions, please call 1-800-444-3353. SKU 98871 SAFEty SER VIcE BASIc WELdIng WELdIng tIPS SEtUP do not touch live electrical parts 9. . Wear dry , insulating gloves. Do not touch welding wire or gun with bare hand. Do not wear wet or damaged gloves. Protect yourself from electric shock. 10. Do not use outdoors. Insulate yours ...
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Harbor Freight Tools 98871 - page 7
Page 7 For technical questions, please call 1-800-444-3353. SKU 98871 SAFEty SER VIcE BASIc WELdIng WELdIng tIPS SEtUP grounded W elders The grounding prong in the plug is 1. connected through the green wire inside the cord to the grounding system in the welder . The green wire in the cord must be the only wire connected to the welder ’s groundin ...
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Harbor Freight Tools 98871 - page 8
Page 8 For technical questions, please call 1-800-444-3353. SKU 98871 SAFEty SER VIcE BASIc WELdIng WELdIng tIPS SEtUP SPEcIFIcA tIOnS Power Input 120 V~, 24 A (peak), 1-phase connect to at least 20 A dedicated circuit Welding Output dcEn MIn: 63 ~ 68 A MAX: 79 ~ 90 A hOt tIP welder capacity 22 gauge (0.03”) to 3/16” (0.19”) mild steel only n ...
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Harbor Freight Tools 98871 - page 9
Page 9 For technical questions, please call 1-800-444-3353. SKU 98871 SAFEty SER VIcE BASIc WELdIng WELdIng tIPS SEtUP Face Shield (38) Assembly Attach the handle to the Face Shield (38) by lining up the two rectangular tabs on the handle with the corresponding holes in the face shield and press the tabs through the holes and A. then slide the tabs ...
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Harbor Freight Tools 98871 - page 10
Page 10 For technical questions, please call 1-800-444-3353. SKU 98871 SAFEty SER VIcE BASIc WELdIng WELdIng tIPS SEtUP Wire Spool (27) Installation 1. t urn the welder OFF and unplug it before proceeding. 2. Press in the Cover Latch (8) on the front of the handle, then open the Cover (31). 3. Remove the Wing Nut (25) and the Spool Retaining Nut (2 ...
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Harbor Freight Tools 98871 - page 11
Page 1 1 For technical questions, please call 1-800-444-3353. SKU 98871 SAFEty SER VIcE BASIc WELdIng WELdIng tIPS SEtUP 6. T urn the Feed T ensioner (37) knob counterclockwise to loosen it enough to pull it up, releasing tension. Do not loosen the T ensioner knob too much, or the T ensioner will come apart. Then, swing the Feed Swing Arm (36) out. ...
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Harbor Freight Tools 98871 - page 12
Page 12 For technical questions, please call 1-800-444-3353. SKU 98871 SAFEty SER VIcE BASIc WELdIng WELdIng tIPS SEtUP 10. Swing the Wire Feed Swing Arm (36) closed, and swing the Feed T ensioner (37) across the tip of the Arm, to latch it. Make sure the Welding Wire is resting in the top groove of the Feed Roller (34), then turn the Feed T ension ...
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Harbor Freight Tools 98871 - page 13
Page 13 For technical questions, please call 1-800-444-3353. SKU 98871 SAFEty SER VIcE BASIc WELdIng WELdIng tIPS SEtUP 15. Point the Gun away from all objects and press the T rigger (1c) until the wire feeds out of the gun two inches. the Wire Liner (4) may come out with the welding wire, this is normal, just push the Wire Liner back into the gun. ...
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Harbor Freight Tools 98871 - page 14
Page 14 For technical questions, please call 1-800-444-3353. SKU 98871 SAFEty SER VIcE BASIc WELdIng WELdIng tIPS SEtUP BASIc WELdIng Read the EntIRE IMPORt Ant SAFEty InFORMA tIOn section at the beginning of this manual including all text under subheadings therein before welding. tO PREVEnt SERIOUS InjUR y : Protective gear must be worn when using ...
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Harbor Freight Tools 98871 - page 15
Page 15 For technical questions, please call 1-800-444-3353. SKU 98871 SAFEty SER VIcE BASIc WELdIng WELdIng tIPS SEtUP control Panel Layout 90 AMP FLUX WIRE WELdER 120 V~ 60 hz gun WIRE-FEEd SPEEd 0 1 2 3 4 5 6 7 8 9 10 MAX MIn On OFF Wire Speed dial (9) gun (1) cable ground cable (33) Power Switch (7a) current Switch (7b) Overload Indicator (22) ...
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Harbor Freight Tools 98871 - page 16
Page 16 For technical questions, please call 1-800-444-3353. SKU 98871 SAFEty SER VIcE BASIc WELdIng WELdIng tIPS SEtUP W eld Settings chart nOtE: the numbers within the spaces are the approximate wire feed settings recommended* for this wire size and material thickness. Material thickness (Steel) 22 gauge 18 gauge 16 gauge 14 gauge 1 / 8 ” 3 / 1 ...
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Harbor Freight Tools 98871 - page 17
Page 17 For technical questions, please call 1-800-444-3353. SKU 98871 SAFEty SER VIcE BASIc WELdIng WELdIng tIPS SEtUP Setting Up the W eld Make practice welds on pieces of scrap 1. the same thickness as your intended workpiece to practice technique before welding anything of value. Clean the weld surfaces thoroughly with a wire brush or angle gri ...
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Harbor Freight Tools 98871 - page 18
Page 18 For technical questions, please call 1-800-444-3353. SKU 98871 SAFEty SER VIcE BASIc WELdIng WELdIng tIPS SEtUP 6. Hold the Gun, without touching the T rigger , with the wire and tip clearly out of the way of any grounded objects. Then, turn the Power Switch ON. Basic W elding t echnique Press (and hold) T rigger and contact area 1. to be w ...
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Harbor Freight Tools 98871 - page 19
Page 19 For technical questions, please call 1-800-444-3353. SKU 98871 SAFEty SER VIcE BASIc WELdIng WELdIng tIPS SEtUP note: If Welder is used too long, the amber Overload Indicator (22) will light and the Welder Gun will shut of f until the welder cools. If this happens, rest the Gun on an electrically non-conductive, heat-resistant surface, such ...
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Harbor Freight Tools 98871 - page 20
Page 20 For technical questions, please call 1-800-444-3353. SKU 98871 SAFEty SER VIcE BASIc WELdIng WELdIng tIPS SEtUP 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. cleanin ...
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Harbor Freight Tools 98871 - page 21
Page 21 For technical questions, please call 1-800-444-3353. SKU 98871 SAFEty SER VIcE BASIc WELdIng WELdIng tIPS SEtUP EXcESS PEnEtRA tIOn OR BURn-thROUgh PROPER PEnEtRA tIOn InAdEqUA tE PEnEtRA tIOn not hot enough t oo hot Ideal heat WELd dIAgnOSIS W orkpiece heat control / W eld Penetration good Weld current t oo Low Weld Speed t oo Slow Example ...
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Harbor Freight Tools 98871 - page 22
Page 22 For technical questions, please call 1-800-444-3353. SKU 98871 SAFEty SER VIcE BASIc WELdIng WELdIng tIPS SEtUP W eld not Adhering Properly gaps present between weld and previous bead or between weld and workpiece. See areas below . POSSIBLE cAUSES And SOLUtIOnS Incorrect welding technique: 1. Place stringer bead at correct place in joint. ...
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Harbor Freight Tools 98871 - page 23
Page 23 For technical questions, please call 1-800-444-3353. SKU 98871 SAFEty SER VIcE BASIc WELdIng WELdIng tIPS SEtUP coat of Slag Over W eld Slag is a necessary part of a ux- core wire weld. It shields the weld from impurities. clean off the slag with the chipping hammer and Wire Brush after welding. ? ...
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Harbor Freight Tools 98871 - page 24
Page 24 For technical questions, please call 1-800-444-3353. SKU 98871 SAFEty SER VIcE BASIc WELdIng WELdIng tIPS SEtUP SER VIcE tO PREVEnt SERIOUS InjUR y , FIRE And BURnS: Unplug the welder , rest the gun on a heat-proof, electrically non-conductive surface, and allow all parts of the Welder to cool thoroughly before service. Periodically remove ...
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Harbor Freight Tools 98871 - page 25
Page 25 For technical questions, please call 1-800-444-3353. SKU 98871 SAFEty SER VIcE BASIc WELdIng WELdIng tIPS SEtUP contact t ip (2b) Inspection, cleaning, and Replacement Make sure that the entire gun is 1. completely cool and that the Power cord is unplugged from the electrical outlet before proceeding. 2. Remove the Nozzle as explained in th ...
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Harbor Freight Tools 98871 - page 26
Page 26 For technical questions, please call 1-800-444-3353. SKU 98871 SAFEty SER VIcE BASIc WELdIng WELdIng tIPS SEtUP tROUBLEShOOtIng IMPORt Ant! Be cERt AIn to shut off the Welder , disconnect it from power , and discharge the gun to ground before adjusting, cleaning, or repairing the unit. Wire feed motor runs but wire does not feed properly PO ...
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Harbor Freight Tools 98871 - page 27
Page 27 For technical questions, please call 1-800-444-3353. SKU 98871 SAFEty SER VIcE BASIc WELdIng WELdIng tIPS SEtUP tROUBLEShOOtIng (continued) IMPORt Ant! Be cERt AIn to shut off the Welder , disconnect it from power , and discharge the gun to ground before adjusting, cleaning, or repairing the unit. Power switch (7a) lights, but welder does n ...
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Harbor Freight Tools 98871 - page 28
Page 28 For technical questions, please call 1-800-444-3353. SKU 98871 SAFEty SER VIcE BASIc WELdIng WELdIng tIPS SEtUP tROUBLEShOOtIng (continued) IMPORt Ant! Be cERt AIn to shut off the Welder , disconnect it from power , and discharge the gun to ground before adjusting, cleaning, or repairing the unit. Power switch (7a) does not light when switc ...
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Harbor Freight Tools 98871 - page 29
Page 29 For technical questions, please call 1-800-444-3353. SKU 98871 SAFEty SER VIcE BASIc WELdIng WELdIng tIPS SEtUP W elding arc not stable POSSIBLE cAUSES And SOLUtIOnS Wire not feeding properly: 1. Seerst section - W ire feed motor runs but wire does not feed properly . Incorrect contact ...
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Harbor Freight Tools 98871 - page 30
Page 30 For technical questions, please call 1-800-444-3353. SKU 98871 SAFEty SER VIcE BASIc WELdIng WELdIng tIPS SEtUP P ARtS LIStS And dIAgRAMS Wiring Schematic 1 1 L1 n PE cS 100 2 2 2 3 1 4 3 3 4 4 A - + 5 5 6 6 S1 S2 S3 Pt Pt Fan A E F B MIn/MAX c d t 0 t 0 Overload Indicator M ...
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Harbor Freight Tools 98871 - page 31
Page 31 For technical questions, please call 1-800-444-3353. SKU 98871 SAFEty SER VIcE BASIc WELdIng WELdIng tIPS SEtUP Parts List Part description q’ty 1a BackHandle 1 1b Front Handle 1 1c T rigger 1 1d Handle Lock Ring 1 1e Gun T ube 1 2b .9 mm Contact T ip 1 3 Nozzle 1 4 Wire Liner 1 5 Gun Cable Clamp A 1 6 GunCableClampB 1 7a Powe ...
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Harbor Freight Tools 98871 - page 32
Page 32 For technical questions, please call 1-800-444-3353. SKU 98871 SAFEty SER VIcE BASIc WELdIng WELdIng tIPS SEtUP Assembly diagram 50 39 ...
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Harbor Freight Tools 98871 - page 33
Page 33 For technical questions, please call 1-800-444-3353. SKU 98871 SAFEty SER VIcE BASIc WELdIng WELdIng tIPS SEtUP detail of Part 23 35 44 46 45 23 34 37 36 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 o ...
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Harbor Freight Tools 98871 - page 34
Page 34 For technical questions, please call 1-800-444-3353. SKU 98871 SAFEty SER VIcE BASIc WELdIng WELdIng tIPS SEtUP LIMItEd 1 yEAR / 90 dA y W ARRAnty Harbor Freight T ools Co. makes every effort to assure that its products meet high quality and durability standards, and warrants to the original purchaser that for a period of ninety days from d ...
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