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Chicago Welding 98871 User Manual

Chicago Welding 98871
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90 AMP FLUX WIRE WELDER
Model
98871
SET UP AND OPERATING 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.
SAVE THIS MANUAL.
Copyright
©
2008 by Harbor Freight Tools
®
. All rights reserved. No portion of this manual or any artwork
contained herein may be reproduced in any shape or form without the express written consent of
Harbor Freight Tools. Diagrams within this manual may not be drawn proportionally. Due to continuing
improvements, actual product may differ slightly from the product described herein. Tools required for
assembly and service may not be included.
For technical questions or replacement parts, please call 1-800-444-3353.
Manual Revised 10d
SAFETYSERVICE BASIC WELDINGWELDING TIPS SETUP
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Chicago Welding 98871 Specifications

General IconGeneral
BrandChicago Welding
Model98871
CategoryWelding System
LanguageEnglish

Summary

Safety Precautions

Save This Manual

Keep manual for safety, assembly, operation, inspection, and maintenance procedures.

General Safety Warnings

Obey all safety warnings and instructions to avoid injury, electric shock, or fire.

Personal and Welder Safety

Personal Safety

Stay alert, use common sense, wear safety equipment, and maintain footing.

Welder Use and Care

Instructions on operating, maintaining, and storing the welder safely.

Welder Safety Warnings

Maintain Safe Working Environment

Keep work area well lit, free of obstructions, grease, oil, and debris.

Prevent Accidental Fires

Remove combustibles, use fire-resistant materials, and have a fire watch.

Fume and Gas Safety

Avoid Fume and Gas Exposure

Use ventilation or exhaust to keep fumes from breathing zone, wear a respirator.

Electrical and Product Safety

Electrical Safety Precautions

Warnings about electrical hazards, avoid touching live parts and grounded surfaces.

Pacemaker and Product Warnings

Advice for pacemaker users and warnings about lead exposure and general precautions.

Welder Setup and Assembly

Face Shield Assembly

Attach the handle to the Face Shield by lining up tabs and securing them.

Cover Latch and Handle Assembly

Attach the cover latch to the base frame and secure the handle to the cover.

Wire Spool Installation and Adjustment

Wire Spool Installation

Mount the wire spool, ensuring correct unwind direction and secure it with nuts.

Feed Roller and Tension Adjustment

Compare wire diameter, adjust feed roller, and set tension for proper wire feeding.

Basic Welding Techniques

Essential Protective Gear

Wear safety gear like face shields, ear protection, gloves, and fire-resistant clothing.

Welding Technique Fundamentals

Learn about drag angle, stickout, and practice on scrap material.

Weld Settings and Duty Cycle

Weld Settings Chart

Recommended wire feed and current settings for different material thicknesses.

Understanding Duty Cycle

Learn about duty cycle limitations to prevent welder overheating and damage.

Welding Tips and Weld Analysis

Welding Gun Control

Proper grip, angle, drag angle, and stickout for effective welding.

Weld Bead Types

Understand stringer beads and weave beads for different weld widths.

Service and Maintenance

Nozzle Inspection and Cleaning

How to inspect, clean, and replace the welding nozzle for optimal weld quality.

Contact Tip Inspection and Cleaning

Inspect, clean, and replace the contact tip for proper wire size and condition.

Troubleshooting Common Issues

Wire Feed Problems

Solutions for wire not feeding or creating a bird's nest during operation.

Power Switch and Fuse Issues

Troubleshoot when the power switch lights but welder fails, or if the fuse is blown.

Parts Lists and Diagrams

Wiring Schematic

Electrical diagram illustrating the welder's internal connections and components.

Parts List

A comprehensive list of all parts with their descriptions and quantities.

Warranty Information

Warranty Coverage and Claims

Details of the warranty period, coverage, exclusions, and how to make a claim.

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