Chicago Electric MIG-100 44567 User manual

CHICAGO
ELECTRIC
INDUST]ITAL
iIIG.IOO
WELDER
.tiElt
44567
ASSEMBLYAND
OPERATING
INSTRUCTIONS
a
It
P
r'
t-(f
!,t!,f'tt
WITH
THERMAT
OUERTOAD
rwu'",,fU{Cl9C
230 ''[3',"
J- -
3491
Mission
Oaks
Blvd.,Camarillo,
CA93011
Vi
s
itou rWeb
site
athttp:r7www.
harborf
rei
g
ht.com
Copyright
@2000byHarborFreightTools@.All
rightsreserved.
No
portion
of
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:
79
- 90amps
Duty
Cycle 12/"
at70
amps;
1ff/"
aI50
amps
Power
Consumption 110
VAC,
23
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,
14
AWG,
U.L.
apprwed
Power
Cord
Plug CSA738
Thermal
Overload
with
Light Low
setting:
'10
min.
shutdown,3
min.
bacx
on
High
setting:
5min.
shutdown,
3min.
bacx
on
Welder
Tip qgqq (aty
2);Will
also
accept
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
on
the
inside
ofthe
front
cover.
Keep
the
manual
and
invoice
in
asafe
and
dry
place
for
future
reference.
Safety
Warnings
andprecautions
WARNING:
When
using
tool,
basic
safety
precautions
should
always
be
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
in
damp
or
wet
locations.
Don't
expose
to rain. Keep
work
areawell
lighted.
Donot
use
electrically
powered
tools
in
the
presence
of
flammable
gases
orliquids.
3. Keep
children
away.
Children
must
never
beallowed
in
the
work
area.
Do
not
let
them
handle
machines,
tools,
or
extension
cords.
4' Store
idle
equipment.
When
not
in
use,
tools
must
be
stored
in
adry
location
to
inhibit
rust.
Always
lock
up
tools
and
keep
out
ofreach
ofchildren.
sKU
44567 Page
2REV 10/03

5. Donotforce
tool. ltwill
do
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
as
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
or
acrossrunning
machines.
10. Maintain
toolswith
care.Keep
tools
sharparrd
cleanforbetter
andsafer
performance.
Follow
instructions
forlubricating
andchangingaccessories.
Inspect
tool
cords
periodically
and,if
damaged,have
themrepaired
byanauthorizedtechnician.Thehandles
must
be
kept
clean.dry,
and
free
from
oiland
grease
at
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
on
thetrigger,
whether
itis
plugged
in
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
it
willoperate
properly
and
perform
itsintended
function.
Check
for
alignment
and
bindingof
moving
parts;
any
broken
parts
or
mounting
fixtures;
andanyother
conditionthat
mayaffect
proper
operation.Any
part
thatis
damaged
shouldbe
properly
repaired
or
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
on
prescriptions
todetermineif
your
judgment
or
reflexes
are
impaired
while
taking
drugs.
lfthere
isany
doubt,donot
operatethetool.
19. Maintenance.
Foryoursafety,
serviceand
nraintenance
should
be
performed
regularly
bya
qualified
technician.
sKU
44s67 Page
3
-

20. Use
proper
sizeandtypeextensioncord.
lf
an
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
by
"WA"
onthe
jacket).
Note:
Performanceofthistoolmay
vary
dependingon
variationsinlocal
linet,oltaEe.
Exten-
sion
cordusage
may
alsoaffect
tool
performance.
Warning:Thewarnings,cautions,and
instructionsdiscussed
in
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
be
ni,ile-free.
dry.andANSI
approveo.
This
unitdrawsenoughcurrent
tocause
senous
iniury
ordeath
Beforeturningthewelder
on,check
the
electrode
holderto
be
surethatthereare
no
protrudrng
screwheads,
and
thatall
insulationis
secure.
Donot
weidunless
vou
are
rnsulated
f
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$es can increasethe risk t.rf
':eveloping
certaincancers,sucnascancer
oftheiarynxandlting
cancei'.
Aiso,
somediseasesthai maybe linked
to er;rosureto welding
gasses
or
fumesare:
. EarlyonsetofParkinson'sDisease
. Damagetothereproductive
orgarls
. lnflanrmationofthesmallintestineor storriach . Kidneydarnage
. Respiratorydiseasessuchas
enrphyserna,bronchrtisor p;reunroni:
Safety
precautions,
suchasusingnatural
orforcedairventilationand
wearingan ANSIapprovedrespirator,are ES$ENTiAL
to reducethe
riskof developingtheabove
illrresses.
. HeartDisease
. rJlcers
sKU
44567 Page4 REV
05/04

3.
4.
6.
7.
Avoid
eye
and
bodydamage.
Arc
rays
and
infrared
radiation
caninjure
eyesand
burn
skin.Wear
ANSI
approved
eyeand
body
protection.
Do
notallowviewing
by
visitors
without
proper
eyeand
body
protection.
Use
the
provided
Face
Shieldwith
arcshaded
filter
plate.
Knowproper
arc welding
practices.
Read
andunderstand
themanufacturer's
instructions,
aswell
as
your
employer's
safety
practices
for
arcwelding.
Connect
onlytoacode
approved
power
source.Connectonlyto
a
grounding
power
source
conforming
to
theNational
Electrical
CodeandLocal
Codes.
Avoid
fire
andexplosion.
Remove
flammable
and
explosivematerialfrom
at
least
35
feet
from
thewelding
arcto
prevent
welding
sparksor
molten
metalfrom
startingafire.
Keep
atypeABC
fire
extinguisher
within
easyreach.Thoroughly
cleanthe
objectbeing
welded
ofany
paint,
grease,
or
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.
lf
any
parts
aremissing
or
broken,
please
callHarborFreight
Tools
at
thenumber
on
the
cover
of
this
manual
assoon
as
possible.
Assembly
Attach
theHandle
(30)
tothe
Cover
(31)
usingscrew
(29)
insertedfrom
theHandle
top-
rear.
Refer
tothe
photo
atthe
top
of
page
6,
andtheAssembly
Drawing
on
page
10.
Attach
the
CoverLocking
Spring
(8)
toth,:front
oftheBase
Frame
(14)
usingthe
supplied
self-tapping
screw.
sKU44567
1.
2.
Page
5

WireReel(27)
Cover
Locking
Spring
(8)
Operation
TheMIG100Welderis
usedtoweldsheetmetaland
light
carbon
steel.
Overload
IndicatorLight
(22)
Switch
(7)
CurrentMin./Max.
Switch
(7)
Power
On
/ Off
Torch
(1)
Cable
WireFeed
Speed
Knob
(9)
GroundCable
(33) PowerCord
(32)
Caution:
Beforearcwelding,
read
andunderstandall
safety
precautions
andwarnings
listed
onpages
2through
5.
1. SecurelyclamptheGroundCableClamp
(33)
ascloseas
possible
tothe
metal
object
to
be
welded,
or
tothemetalwork
bench
where
the
object
ismounted
andelectrically
connected.
2. Set theCurrentSwitch
(7)to
the
desiredcurrent
setting.
Minimum:
63
- 68amps
forthinnermetals;Maximum:
79
- 90
ampsforheaviermetals.
I
I
I
\
sKU
44567 Page6

I
I
3. Verify thatthePower
Switch
isin
theOFF
position,
then
plug
theMIG-100Welder
plug
into
adedicated,110VAC,20
amp
linewith
delayed
action
type
circuit
breakeror
fuses.
lf
anextensioncordisused,itmusthave
the
followingwiresize:up
to
30
feet,use10
AWG
sizewire;30to
50
feet,
use
8
AWGwire;Over50
feet,use
6
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
to
be
welded,
then
place
theFaceShieldover
your
eyes.
Warning:
Neverlook
attheignited
arc
withoutANSI
approved,
arcshaded,eye
protec-
tionin
a
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
to
ignite
the
arc.
This
damagesits
externalcoatingon
the
electrodewhich
prevents
oxygen
in
theair
from
coming
into
contactwith
themoltenmetal,
causing
it
tooxidize.
8. Once the
arc
isignited,
tiltthe
electrode
wireforward
at
an
angleofapproximately
35".
Thewirefeeds
automaticallyataspeeddependent onthe
Min.
or
Max.
currentsetting.
Note: lftoomuch
current
is
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.
I
l
sKU
44567 PageT

Replacing
theWire
Reel
When
thewire
ontheFeed
Reel
is
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)
to
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
at
least
12
inches
ofwireinto
theTorch
Sheath.
lfthe
end
ofthewire
is
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
so
that
thewire
moves
through
it
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.
8.
9.
sKU44567 Page
8

lf
thewire
doesnotfeed,
view
the
WireFeed
Unitandseeif
thewireis
being
pushed.
lf
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
A
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'
1
3A
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,
Sf
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
AS
AREFERENCE
TOOL
ONLY.
NEITHER
THEMANUFACTURER
NORDISTRIBUTOR
MAKES
AI.IYREPRESENTATION
ORWARRANTY
OF
ANY
KINDTO
THEBUYER
THAT
HE
OR
SHEIS
QUALIFIEDTO
MAKEANY
REPAIRSTOTHE
PRODUCT
ORTHATHE
OR
SHEIS
QUALI-
FIEDTO
REPLACE
ANY
PARTS
OF
THE
PRODUCT.
IN
FACT,THE
MANUFACTURER
AND/OR
DISTHIBUTOR
EXPRESSLY
STATESTHAT
ALL
REPAIRSAND
PAI]TSREPLACEMENTS
SHOULD
BE
UNDFFTAKEN
BY
CERTIFIED
AND
LICENSED
TECHNICIANS
ANDNOT
BYTHE
BUYER.
THE
BUYER
ASSUMES
ALL
RISK
AND
LIABILITY
ARISING
OUT
OF
HIS
ORHER
REPAIRS
TO
THE
ORiGINALPRODUCT
ORREPLACEMENT
PARTS
THEFETC.
CR
ARISiNG
OUT
OF
HIS
OR
H
ERINSTALLATI
ON
OFR EPLAC
E
TU
ENT
PARTS
TI-"1ERETO.
sKU44567 Page
9

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44567 Page
1
0

n
19
sKU
44567 Page11

Schematic
Diagram
L1
N
PE
MP
282 / MP28s
sKU
44567 Page
12