Chicago Electric MIG-100 44567 User manual

CHICAGO

ELECTRIC

INDUST]ITAL

iIIG.IOO

WELDER

.tiElt

44567

ASSEMBLYAND

OPERATING

INSTRUCTIONS

t-(f

!,t!,f'tt

WITH

THERMAT

OUERTOAD

rwu'",,fU{Cl9C

230 ''[3',"

J- -

3491

Mission

Oaks

Blvd.,Camarillo,

CA93011

itou

rWeb

site

athttp:r7www.

harborf

rei

ht.com

@2000byHarborFreightTools@.All

rightsreserved.

portion

this

manual

oranyartwork

contained

hereinmaybereproduced

inanyshapeor

formwithoutthe

express

writtenconsentof

HarborFreight

Tools.

Fortechnical

questions

andreplacement

parts,

please

call1-800-444-3353

RevisedCoverPage02103 -

Specif

ications

ITEM DESCRIPTION

Welding

Cunent 63- 68amps;

High

setting:

- 90amps

Duty

Cycle 12/"

at70

amps;

1ff/"

aI50

amps

Power

Consumption 110

VAC,

amps

Heat

Control 2settings

Ground

Cable 4AWG,

single

insulation,

6 foot

Torch

Power

Cable I AWG,

single

insulation,

6foot

Power

Cord 3-core,

double

insulated,

AWG,

U.L.

apprwed

Power

Cord

Plug CSA738

Thermal

Overload

with

Light Low

setting:

'10

min.

shutdown,3

min.

bacx

High

setting:

5min.

shutdown,

3min.

bacx

Welder

Tip qgqq (aty

2);Will

also

0.023"

wetder

tip

Wire

Size 0.030

inch

flex

core

wire

Wire

Spool

Size 4 inches

diameter(2

lb.

spool)

Overall

Dimensions 14-1/2(L)

x B-1/2

(V14

x 1s-1t2

(H)

inches

Weight 34.45

lbs.

Accessories Spare

Welder

Tip

Wdding

Face

Shield

Wire

Brush

/ Hammer

combination

Save

This

Manual

You

will

need

the

manual

for

the

safety

warnings

and

precautions,

assembly

instructions,

operating

and

maintenance

procedures,

parts

list

and

diagram.

Keepyour

invoice

with

this

manual.

Write

theinvoice

number

the

inside

ofthe

front

cover.

Keep

the

manual

and

invoice

asafe

and

dry

place

for

future

reference.

Safety

Warnings

andprecautions

WARNING:

When

using

tool,

basic

safety

precautions

should

always

followed

to re-

duce

therisk

of personal

injury

and

damage

toequipment.

Read

all

instructions

before

using

this

tool!

1. Keep

workarea

clean. cluttered

areas

invite

injuries.

2. Observe

workarea

conditions. Do

not

use

machines

orpower

tools

damp

wet

locations.

Don't

expose

to rain. Keep

work

areawell

lighted.

Donot

use

electrically

powered

tools

the

presence

flammable

gases

orliquids.

3. Keep

children

away.

Children

must

never

beallowed

the

work

area.

not

let

them

handle

machines,

tools,

extension

cords.

4' Store

idle

equipment.

When

not

use,

tools

must

stored

adry

location

inhibit

rust.

Always

lock

tools

and

keep

out

ofreach

ofchildren.

sKU

44567 Page

2REV

10/03

5. Donotforce

tool. ltwill

the

job

betterandmoresafelyattheratefor

whichitwas

intended.Donot

useinappropriate

attachmentsinanattemptto

exceedthetoolcapacity.

6. Use

theright

toolforthe

job. Donot

attemptto

force

asmalltool

orattachmentto

dothe

work

of a larger

industrial

tool.There

arecertainapplicationsforwhich

thistoolwas

designed.Donot

modify

thistool

anddo

not

use

thistoolfor

apurpose

for

whichitwas

notintended

7. Dress

properly.

Donot

wearloose

clothingor

jewelry

they

canbecaught

inmoving

parts. Protective,

electricallynon-conductive

clothesand non-skid

footwear

are

recommended

whenworking.

Wearrestrictivehair

coveringtocontainlonghair.

8. Use

eyeandear

protection.

AlwayswearANSI

approved,arcshaded,impact

safety

face

shield.

Always

usethe

full

face

shield

(provided)

when

arcwelding.Wear

anANSI

approved

dustmask

orrespiratorwhen

workingaroundmetal,

chemicaldusts,fumes

andmists.

9. Donotoverreach.

Keep

proper

footing

and

balanceatalltimes.Do

notreach

over

acrossrunning

machines.

10. Maintain

toolswith

care.Keep

tools

sharparrd

cleanforbetter

andsafer

performance.

instructions

forlubricating

andchangingaccessories.

Inspect

tool

cords

periodically

and,if

damaged,have

themrepaired

byanauthorizedtechnician.Thehandles

must

kept

clean.dry,

and

free

from

oiland

grease

alltrmes.

11. Disconnect

power.

Unplugtoolwhen

notinuse.

12. Remove

adjustingkeys

andwrenches.

Checkthat

keys

andadjusting

wrenches

are

removed

from

thetool

ormachinework

surfacebefore

plugging

itin.

13. Avoid

unintentional

starting.

Besurethe

switch

isin

theOff

position

when

notin

use

andbefore

plugging

in.Donot

carryanytool

with

your

finger

thetrigger,

whether

itis

plugged

ornot.

14. Stay

aJert.

Watch

what

you

aredoing,

usecommonsense.Donotoperate

anytoolwhen

you

aretrred.

15. Checkfor

damaged

parts.

Before

usingany

tool.

any

part

thatappears

damaged

should

becarefully

checkedto

determine

that

willoperate

properly

and

perform

itsintended

function.

Check

for

alignment

and

bindingof

moving

parts;

any

broken

parts

mounting

fixtures;

andanyother

conditionthat

mayaffect

proper

operation.Any

part

thatis

damaged

shouldbe

properly

repaired

replaced

bya

qualified

technician.Donot

usethe

toolif

any

switchdoesnotturn

Onand

Off

properly.

16. Guardagainst

electric

shock. Preve.nt

bodycontact

with

grounded

surfaces

suchas

pipes,

radiators,ranges,

andrefrigerator

enclosures.

17. Replacement

parts

andaccessories.

Whenservicing,

useonly

identical

replacement

parts.

Usec riiyother

parts

willvoid

thewarranty.

Only

useaccessories

intended

for

use

with

thisiool.

Approved

accessories

areavailable

fromHarbor

FreightTools.

18. Donot

operate

toolifunder

theinfluence

ofalcoholordrugs.Read

warninglabels

prescriptions

todetermineif

your

judgment

reflexes

are

impaired

while

taking

drugs.

lfthere

isany

doubt,donot

operatethetool.

19. Maintenance.

Foryoursafety,

serviceand

nraintenance

should

performed

regularly

bya

qualified

technician.

sKU

44s67 Page

20. Use

proper

sizeandtypeextensioncord.

extensioncord

isrequired,itmust

beof

theproper

sizeandtypeto supply

the

correctcurrent

tothetool

withoutheating

up.

Otherwise,

theextensioncordcould

melt

andcatch

fire,orcauseelectricaldamageto

thetool.Thistool

requires

useofanextension

cordof20amps

minimum

capability

(up

to30

feet),withwire

size

ratedat10AWG.Longerextension

cords

requrre

largersize

wire.lfyou

are

usingthetooloutdoors,useanextension

cord

ratedfor

outdooruse.

(signified

"WA"

onthe

jacket).

Note:

Performanceofthistoolmay

vary

dependingon

variationsinlocal

linet,oltaEe.

Exten-

sion

cordusage

may

alsoaffect

tool

performance.

Warning:Thewarnings,cautions,and

instructionsdiscussed

thisinstructionmanual

cannot

coverall

possible

conditionsandsituations

that

mayoccui'.lt must

beunder-

stoodby theoperatorthatcommonsenseandcaution

are

factorswhich

cannotbe

built

intothis product,

butmustbesuppliedbythe

operator.

Arc Welding

SafetyWarningsand Precautions

Warning:This

product,

whenusedforwelding

and

sirnilarapplications.

produces

chemi-

cals

known

totheStateof California

tocausecancer

andbirthdefects

(or

other

repro-

ductiveharm). California

Health

& SafetyCode 25249.5,etseq.

1. Avoidelectricalshock.Do

not

permit

electricaliy

live

parts,

cables.orelectrodesto

contact

skin,clothing,or

qloves.

Protective

ciothingshorric

ni,ile-free.

dry.andANSI

approveo.

This

unitdrawsenoughcurrent

tocause

senous

iniury

ordeath

Beforeturningthewelder

on,check

the

electrode

holderto

surethatthereare

protrudrng

screwheads,

and

thatall

insulationis

secure.

Donot

weidunless

vou

are

rnsulated

rom

qrcrrnd

andthe

work

piece.

2. Avoidbreathing

fumes

or gases.

Theycancauseserious

health

1-lrobienrs

LJsean

active

v€ntilation

systemdirectlyabovetheweldingarea.

Keep

your

head

outofthe

fumes.

InhalationF{aearsf;

Welding

ProducesTOXICFUMES

and

G,ASSES.

Exposureto weldinggas$es

can increasethe risk t.rf

':eveloping

certaincancers,sucnascancer

oftheiarynxandlting

cancei'.

Aiso,

somediseasesthai maybe linked

to er;rosureto welding

gasses

fumesare:

. EarlyonsetofParkinson'sDisease

. Damagetothereproductive

orgarls

. lnflanrmationofthesmallintestineor storriach . Kidneydarnage

. Respiratorydiseasessuchas

enrphyserna,bronchrtisor p;reunroni:

Safety

precautions,

suchasusingnatural

orforcedairventilationand

wearingan ANSIapprovedrespirator,are ES$ENTiAL

to reducethe

riskof developingtheabove

illrresses.

. HeartDisease

. rJlcers

sKU

44567 Page4 REV

05/04

Avoid

eye

and

bodydamage.

Arc

rays

and

infrared

radiation

caninjure

eyesand

burn

skin.Wear

ANSI

approved

eyeand

body

protection.

notallowviewing

visitors

without

proper

eyeand

body

protection.

Use

the

provided

Face

Shieldwith

arcshaded

filter

plate.

Knowproper

arc welding

practices.

Read

andunderstand

themanufacturer's

instructions,

aswell

your

employer's

safety

practices

for

arcwelding.

Connect

onlytoacode

approved

power

source.Connectonlyto

grounding

power

source

conforming

theNational

Electrical

CodeandLocal

Codes.

Avoid

fire

andexplosion.

Remove

flammable

and

explosivematerialfrom

least

feet

from

thewelding

arcto

prevent

welding

sparksor

molten

metalfrom

startingafire.

Keep

atypeABC

fire

extinguisher

within

easyreach.Thoroughly

cleanthe

objectbeing

welded

ofany

paint,

grease,

other

foreign

material.

Avoid

being

burned.

Always

wear

ANSI

approved

welding

gear:

leather

gloves,

leather

apron,

and

shoes.

Unpacking

when

unpacking,

checktomake

surethe

following

parts

are

included.

Face

Shield

(38) MIG-100Welder

Torch

(1)

PowerCord

(32)

Ground

Cable

(33)

WeldingTipnot

shownhere.

any

parts

aremissing

broken,

please

callHarborFreight

Tools

thenumber

the

cover

this

manual

assoon

possible.

Assembly

Attach

theHandle

(30)

tothe

Cover

(31)

usingscrew

(29)

insertedfrom

theHandle

top-

rear.

Refer

tothe

photo

atthe

top

page

andtheAssembly

Drawing

page

10.

Attach

the

CoverLocking

Spring

(8)

toth,:front

oftheBase

Frame

(14)

usingthe

supplied

self-tapping

screw.

sKU44567

Page

WireReel(27)

Cover

Locking

Spring

(8)

Operation

TheMIG100Welderis

usedtoweldsheetmetaland

light

carbon

steel.

Overload

IndicatorLight

(22)

Switch

(7)

CurrentMin./Max.

Switch

(7)

Power

/ Off

Torch

(1)

Cable

WireFeed

Speed

Knob

(9)

GroundCable

(33) PowerCord

(32)

Caution:

Beforearcwelding,

read

andunderstandall

safety

precautions

andwarnings

listed

onpages

2through

1. SecurelyclamptheGroundCableClamp

(33)

ascloseas

possible

tothe

metal

object

welded,

tothemetalwork

bench

where

the

object

ismounted

andelectrically

connected.

2. Set

theCurrentSwitch

(7)to

the

desiredcurrent

setting.

Minimum:

- 68amps

forthinnermetals;Maximum:

- 90

ampsforheaviermetals.

sKU

44567 Page6

3. Verify

thatthePower

Switch

isin

theOFF

position,

then

plug

theMIG-100Welder

plug

into

adedicated,110VAC,20

amp

linewith

delayed

action

type

circuit

breakeror

fuses.

anextensioncordisused,itmusthave

the

followingwiresize:up

feet,use10

AWG

sizewire;30to

feet,

use

AWGwire;Over50

feet,use

AWG

wire.

4. Whileholding

theTorch

CableClampwithelectrode

wire

clearly

outofthe

way

ofany

grounded

objects,turnthePower

Switch

totheON

position.

5. Momentarily

press

theTorchswitch

totest

thewirefeedspeed.

Adjustthe

speedbyturningtheWireFeed

Speed

Knob

(9).

6. Orient

yourself

onthe

area

welded,

then

place

theFaceShieldover

your

eyes.

Warning:

Neverlook

attheignited

arc

withoutANSI

approved,

arcshaded,eye

protec-

tionin

full

faceshield.Permanent

eye

damageor

blindnesscanoccur.Skin

burnscan

occur.Never

breatharcfumes.

7. Press

(and

hold)

theTorch

buttonandstrokethearea

tobewelded

with

theelectrode

wiretoignite

thearc.

Nevertap

theelectrodewireinto

theweldingsurface

ignite

the

arc.

This

damagesits

externalcoatingon

the

electrodewhich

prevents

oxygen

theair

from

coming

into

contactwith

themoltenmetal,

causing

tooxidize.

8. Once

the

arc

isignited,

tiltthe

electrode

wireforward

angleofapproximately

35".

Thewirefeeds

automaticallyataspeeddependent

onthe

Min.

Max.

currentsetting.

Note: lftoomuch

current

drawnfromtheMIGWelder,theThermal

Overload

protector

will

activate,the

amber

indicatorwill

light,

and

theArcWelderwillturnoffuntilitcoolsdown.lfthis

happens,turnthePower

Switch

tothe

OFF

position

and

wait

about3 - 5minutes.

9. When

the

weldis

complete,liftthe

electrode

wire

clearlyaway

from

any

grounded

object,setthe

Face

Shielddownandturntowardthe

MIG-100Welder

andturn

the

Power

Switch

tothe

OFF

position.

10. Unplug

thePower

Cordfromthe

electricaloutlet.

Maintenance

Caution:

Before

performing

anymaintenanoe

onthe

MIGWelder,

unplug

thePower

Cord

fromtheelectrical

outlet.

1. Periodically

rennove

the

Right

andLeft

side

panels

(12

and13),andusingcompressed

air,blow

outalldust

from

theinterior.

2. Store

inaclean

anddry

location.

sKU

44567 PageT

Replacing

theWire

Reel

When

thewire

ontheFeed

Reel

used

up,

you

willneed

toreplaceit

asfollows.

Tension

Adjusting ffi

WireFeed

Adjusting

Spring

(36) Screw

(37) _ Wire

Sheath

1. Press

onthe

Cover

Locking

Spring

(B),

thenliftthe

Cover

(31)

using

Handle

(30)

expose

theWireFeed

Unit

(23).

2. Unscrewthe

wingNut

(25)

andremove

the

ReerLocking

Knob

(26).

3. Remove

the

empty

Wire

Reel

(27).

4. Place

the

new

wireReel

overthe

shaftand

ontotheReer

spring

(24).

The

wire

onthereel

should

unwind

counterclockwise

(see

photo

above).

5. Replace

the

Reel

Locking

Knob

andtheWing

Nut.Tighten

well.

6. Liftthe

WireFeed

Adjusting

Spring

(36)

toremove

tension.

7. Guide

least

inches

ofwireinto

theTorch

Sheath.

lfthe

end

ofthewire

crimped

orbent,

cutit

off.

Replace

tension

tothe

WireFeed

Adjusting

Spring

(36).

Turn

theTorch

Handle

Nozzle

counterclockwise

and

pull

toremove.

10. Turn

the

Contact

Tip

counterclockwise

and

remove.

11. Lay

theTorch

Sheath

outin

astraight

line

that

thewire

moves

through

easily.

Warning:

The

following

steps

require

applying

power

to thewelder.

Donottouchany-

thingwith

theTorch

Handle

oranarcmay

beignited.

12. Plug

thePower

Cordinto

its

electrical

outlet,

press

the

Current

Switchto

Max.,

and

turn

thewelder

ON.

13. Lift

theTorch

Handle

and

continue

pressing

theTrigger

untilthewire

feeds

through

two

inches.

sKU44567 Page

thewire

doesnotfeed,

view

the

WireFeed

Unitandseeif

thewireis

being

pushed.

itisnot,

turnthe

welder

OFFand

addmoretension

totheWire

FeedAdjusting

Spring

(36).

14. Turn

the

welder

ONagain

and

press

theTrigger.

15. Oncethe

wireis

exposed,

turn

thewelder

OFF.

16. slidethe

contact

Tip

overthe

wire

andscrewitinto

TorchHandle.

17. Replace

the

Nozzle

andcut

offanv

excesswire

overtwoinches.

i8. Securethe

Cover. Parts

List

Item# Description oty

'l Torch 1

zContact1lp 1

Nozzle 1

aLiner 1

qFixing

Pole

(A)

for

Gun

Body

6Fixing

Pole

(B)

for

GunBody 1

7Switch z

8C,overLocking

Spnng 1

IKnob 1

10 Nut 1

11 Speed

Contrcl

CircuitBoard 1

12 Rrght

SidePanel 1

13 Left

SidePanel 1

BaseFrame 1

Fool 4

to Washer A

17 Selftapping

Screw.

ST4.2'

1B Transformer

Carriage z

19 Thermostat 1

20 Transformer 1

Item# Description otv

21 Middle

Partition

Board 1

22 Overload

Indicator

Lamo 1

23 WireFeed

Unit 1

24 Reel

Spring 1

25 Wing

Nut,M6

26 ReelLocking

Knob 1

WireReel 1

28 Reel

Holder 1

29 Self-tapping

Screw,

4.2.25 1

30 Handle 1

31 Cover 'I

32 Porq/er

Cord 1

GroundCable 1

34 WireFeed

Roller 1

WireFeed

Bearing 1

36 WireFeed

Adjusting

Spring 1

37 Adjustment

Screw 1

36 Face

Shield 1

39 Wire

Brush

i Hammer "l

PLEASE

READ

THE

FOLLOWING

CAREFULLY

THE

MANUFACTURER

AND/OR

DISTRIBUTOR

HAS

PROVIDEDTHE

PARTS

DIAGRAM

INTHIS

MANUAL

AREFERENCE

TOOL

ONLY.

NEITHER

THEMANUFACTURER

NORDISTRIBUTOR

MAKES

AI.IYREPRESENTATION

ORWARRANTY

ANY

KINDTO

THEBUYER

THAT

SHEIS

QUALIFIEDTO

MAKEANY

REPAIRSTOTHE

PRODUCT

ORTHATHE

SHEIS

QUALI-

FIEDTO

REPLACE

ANY

PARTS

THE

PRODUCT.

FACT,THE

MANUFACTURER

AND/OR

DISTHIBUTOR

EXPRESSLY

STATESTHAT

ALL

REPAIRSAND

PAI]TSREPLACEMENTS

SHOULD

UNDFFTAKEN

CERTIFIED

AND

LICENSED

TECHNICIANS

ANDNOT

BYTHE

BUYER.

THE

BUYER

ASSUMES

ALL

RISK

AND

LIABILITY

ARISING

OUT

HIS

ORHER

REPAIRS

THE

ORiGINALPRODUCT

ORREPLACEMENT

PARTS

THEFETC.

ARISiNG

OUT

HIS

ERINSTALLATI

OFR

EPLAC

ENT

PARTS

TI-"1ERETO.

sKU44567 Page

t.- {

Assembly

Drawings

a-\

;

','1

' :i{

/o-\

lI,'

.z-gt

iE) (').I)

L,.,,

l'i

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/i/ ./ .t/

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/'\\/i

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'ta 3

NOTE:Some

parts

are

listedandshown

for

illustration

purposes

onlyand

arenotavail-

able

individuallyas

replacement

parts.

\ za)

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.9"'8

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sKU

44567 Page

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