Chicago Electric 54878 Assembly and Bedienungsanleitung

MIG-100 WELDER

WITH THERMAL OVERLOAD

Model

54878

ASSEMBLY AND OPERATION INSTRUCTIONS

Due to continuing improvements, actual product may differ slightly from the product described herein.

3491 Mission Oaks Blvd., Camarillo, CA 93011

Visit our website at: http://www.harborfreight.com

TO PREVENT SERIOUS INJURY, READ AND UNDERSTAND

ALL WARNINGS AND INSTRUCTIONS BEFORE USE.

or any artwork contained herein may be reproduced in any shape or form without the

express written consent of Harbor Freight Tools.

For technical questions or replacement parts, please call 1-800-444-3353.

(Manual revised 03/07)

Page 2SKU 54878 For technical questions, please call 1-800-444-3353.

Speciﬁcations

Welding Current

.8 mm wire on 16

ga. sheet steel

104.3/95.5 Amps

(Maximum/Minimum Setting)

.8 mm wire on 1/4”

steel plate

103.7/103.1 Amps

(Maximum/Minimum Setting)

Duty Cycle 10% @ 90 Amps (Maximum Setting) or

10% @ 80 Amps (Minimum Setting, actual 11%)

Power Consump-

tion 120 VAC, 24 Amps

Ground Cable 4 AWG, single insulation, 6 foot

Torch Power Cable 8 AWG, single insulation, 6 foot

Power Cord 3-wire, double insulated, 14 AWG, UL Listed

Power Cord Plug UL Listed

Thermal Overload Both settings: 10 min. shutdown, 3 min. back on with Light

Welder Tip 0.030”; Spare: Welder Tip 0.035”;

Will also accept a 0.023” welder tip (not included)

Wire Size 0.030” ﬂux core wire (when using 0.030” Welder Tip)

Wire Spool Size 4” diameter

Overall Dimensions 14-1/2” (L) x 7-7/8” (W) x 15-1/2” (H)

Weight 34.45 lb.

Accessories Spare Welder Tip (0.035”)

Save This Manual

You will need the manual for the safety warnings and precautions, assembly instructions,

operating and maintenance procedures, parts list and diagram. Keep your invoice with this

manual. Write the invoice number on the inside of the front cover. Keep the manual and

invoice in a safe and dry place for future reference.

Safety Warnings and Precautions

WARNING: When using tool, basic safety precautions should always be followed to

reduce the risk of personal injury and damage to equipment.

Read all instructions before using this tool!

1. Keep work area clean. Cluttered areas invite injuries.

2. Observe work area conditions. Do not use machines or power tools in damp or wet

locations. Don’t expose to rain. Keep work area well lighted. Do not use electrically

powered tools in the presence of ﬂammable gases or liquids.

3. Keep children away. Children must never be allowed 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 a dry location to inhibit

rust. Always lock up tools and keep out of reach of children.

5. Do not force tool. It will do the job better and more safely at the rate for which it was

intended. Do not use inappropriate attachments in an attempt to exceed the tool

capacity.

Page 3SKU 54878 For technical questions, please call 1-800-444-3353.

6. Use the right tool for the job. Do not attempt to force a small tool or attachment to do

the work of a larger industrial tool. There are certain applications for which this tool was

designed. Do not modify this tool and do not use this tool for a purpose for which it was

not intended.

7. Dress properly. Do not wear loose clothing or jewelry as they can be caught in

moving parts. Protective, electrically nonconductive clothes and nonskid footwear are

recommended when working. Wear restrictive hair covering to contain long hair.

8. Use eye and ear protection. Always wear ANSI-approved, arc-shaded, impact safety

face shield. Always use the full face shield when welding. Wear a NIOSH-approved dust

mask or respirator when working around metal, chemical dusts, fumes and mists.

9. Do not overreach. Keep proper footing and balance at all times. Do not reach over or

across running machines.

10. Maintain tools with care. Keep tools sharp and clean for better and safer performance.

Follow instructions for lubricating and changing accessories. Inspect tool cords periodically

and, if damaged, have them repaired by an authorized technician. The handles must be

kept clean, dry, and free from oil and grease at all times.

11. Disconnect power. Unplug tool when not in use.

12. Remove adjusting keys and wrenches. Check that keys and adjusting wrenches are

removed from the tool or machine work surface before plugging it in.

13. Avoid unintentional starting. Be sure the switch is in the Off position when not in use

and before plugging in. Do not carry any tool with your ﬁnger on the trigger, whether it

is plugged in or not.

14. Stay alert. Watch what you are doing, use common sense. Do not operate any tool when

you are tired.

15. Check for damaged parts. Before using any tool, any part that appears damaged

should be carefully checked to determine that it will operate properly and perform its

intended function. Check for alignment and binding of moving parts; any broken parts

or mounting ﬁxtures; and any other condition that may affect proper operation. Any part

that is damaged should be properly repaired or replaced by a qualiﬁed technician. Do

not use the tool if any switch does not turn On and Off properly.

16. Guard against electric shock. Prevent body contact with grounded surfaces such as

pipes, radiators, ranges, and refrigerator enclosures.

17. Replacement parts and accessories. When servicing, use only identical replacement

parts. Use of any other parts will void the warranty. Only use accessories intended for

use with this tool. Approved accessories are available from Harbor Freight Tools.

18. Do not operate tool if under the inﬂuence of alcohol or drugs. Read warning labels

on prescriptions to determine if your judgment or reﬂexes are impaired while taking drugs.

If there is any doubt, do not operate the tool.

19. Maintenance. For your safety, service and maintenance should be performed regularly

by a qualiﬁed technician.

Page 4SKU 54878 For technical questions, please call 1-800-444-3353.

20. Use proper size and type extension cord. If an extension cord is required, it must be

of the proper size and type to supply the correct current to the tool without heating up.

Otherwise, the extension cord could melt and catch ﬁre, or cause electrical damage to

the tool. This tool requires use of an extension cord of 20 amps minimum capability (up

to 30 feet), with wire size rated at 12 AWG. Longer extension cords require larger size

wire. If you are using the tool outdoors, use an extension cord rated for outdoor use

(signiﬁed by “WA” on the jacket).

Note: Performance of this tool may vary depending on variations in local line voltage. Exten-

sion cord usage may also affect tool performance.

Warning:The warnings, cautions, and instructions discussed in this instruction manual

cannot cover all possible conditions and situations that may occur. It must be under-

stood by the operator that common sense and caution are factors which cannot be built

into this product, but must be supplied by the operator.

Welding Safety Warnings and Precautions

Warning: This product, when used for welding and similar applications, produces

chemicals known to the State of California to cause cancer and birth defects (or other

reproductive harm). California Health & Safety Code 25249.5, et seq.

1. Avoid electrical shock. Do not permit electrically live parts, cables, or electrodes to

contact skin, clothing, or gloves. Protective clothing should be hole-free, dry, and ANSI-

approved.

This unit draws enough current to cause serious injury or death. Before turning the welder

on, check the electrode holder to be sure that there are no protruding screw heads, and

that all insulation is secure. Do not weld unless you are insulated from ground and the

work piece.

2. Avoid breathing fumes or gases. They can cause serious health problems. Use an

active ventilation system directly above the welding area. Keep your head out of the

fumes.

Page 5SKU 54878 For technical questions, please call 1-800-444-3353.

Assembly

1. Attach the Handle (30) to the Cover (31) using screw (29) inserted from the Handle top-

rear. Refer to the photo at the top of page 6, and the Assembly Drawing on page 10.

2. Attach the Cover Locking Spring (8) to the front of the Base Frame (14) using the supplied

self-tapping screw.

Unpacking

When unpacking, check to make sure the following parts are included.

Wire Spool and Spare

Welding Tip not shown

Torch (1)

MIG-100 Welder

Power Cord

Ground Cable

If any parts are missing or broken, please call Harbor Freight Tools at the number on the

cover of this manual as soon as possible.

3. Avoid eye and body damage. Welding rays and infrared radiation can injure eyes and

burn skin. Wear ANSI-approved eye and body protection. Do not allow viewing by visitors

without proper eye and body protection. Use a face shield with arc-shaded ﬁlter plate.

4. Know proper welding practices. Read and understand the manufacturer’s instructions,

as well as your employer’s safety practices for welding.

5. Connect only to a code approved power source. Connect only to a grounding power

source conforming to the National Electrical Code and Local Codes.

6. Avoid ﬁre and explosion. Remove ﬂammable and explosive material from at least 35

feet from the welding site to prevent welding sparks or molten metal from starting a ﬁre.

Keep a type ABC ﬁre extinguisher within easy reach. Thoroughly clean the object being

welded of any paint, grease, or other foreign material.

7. Avoid being burned. Always wear ANSI-approved welding gear: leather gloves, leather

apron, and shoes.

Page 6SKU 54878 For technical questions, please call 1-800-444-3353.

Note: What does the term “duty cycle mean?

Duty cycle is a welding equipment speciﬁcation, which deﬁnes the number of minutes, within

a 10-minute period, during which a given welder can safely produce a particular welding cur-

rent. For example, this 90 amp welder with a 10% duty cycle must be rested for at least 9

minutes after 1 minute of continuous welding.

Failure to carefully observe duty cycle limitations can easily over stress a welder’s

power generation system contributing to premature welder failure. Many welders do

not have internal protection systems that prevent this sort of over stress -- leaving the

task to the owner or operator.

Operation

This Welder is used to weld sheet metal and light carbon steel.

Caution: Before welding, read and understand all safety precautions and warnings

listed on pages 2 through 5.

Cover Locking Spring (8)

Cover (31)

Handle (30)

Wire Reel (27)

Switch (7) Power On / Off

Switch (7) Current Min. / Max.

Overload Indicator Light

Wire Feed Speed Knob (9)

Torch (1) Cable

Ground Cable (33) Power Cord (32)

Page 7SKU 54878 For technical questions, please call 1-800-444-3353.

1. Securely clamp the Ground Cable Clamp (33) as close as possible to the metal object

to be welded, or to the metal work bench where the object is mounted and electrically

connected.

2. Set the switch on the control panel to MIN or MAX, as appropriate.

3. Verify that the Power Switch is in the OFF position, then plug the MIG-100 Welder

plug into a dedicated, 110 VAC, 20 amp line with delayed action type circuit breaker or

fuses.

If an extension cord is used, it must have the following wire size: up to 30 feet, use 12

AWG size wire; 30 to 50 feet, use 10 AWG wire; Over 50 feet, use 8 AWG wire.

4. While holding the Torch Cable Clamp with electrode wire clearly out of the way of any

grounded objects, turn the Power Switch to the ON position.

5. Momentarily press the Torch switch to test the wire feed speed.

Adjust the speed by turning the Wire Feed Speed Knob (9).

6. Orient yourself on the area to be welded, then place a face shield over your eyes.

Warning: Never look at the ignited arc without ANSI-approved,

arc-shaded, eye protection in a full face shield. Permanent

eye damage or blindness can occur. Skin burns can occur.

Never breathe welding fumes.

7. Press (and hold) the Torch button and stroke the area to

be welded with the electrode wire to ignite the arc.

Never tap the electrode wire into the welding surface to

ignite the arc. This damages its external coating on the

electrode which prevents oxygen in the air from coming

into contact with the molten metal, causing it to oxidize.

8. Once the arc is ignited, tilt the electrode wire forward at an angle of approximately 35°.

The wire feeds automatically at a speed dependent on the Min. or Max. current setting.

Note: If too much current is drawn from the Welder, the Thermal Overload protector will

activate, the amber indicator will light, and the Welder will turn off until it cools down. If this

happens, turn the Power Switch to the OFF position and wait about 3 ~ 5 minutes.

9. When the weld is complete, lift the electrode wire clearly away from any grounded

object, set the face shield down, turn toward the Welder, and turn the Power Switch to

the OFF position.

10. Unplug the Power Cord from the electrical outlet.

Page 8SKU 54878 For technical questions, please call 1-800-444-3353.

Maintenance

Caution: Before performing any maintenance on the Welder, unplug the Power Cord

from the electrical outlet.

1. Periodically remove the Right and Left side panels (12 and 13), and using compressed

air, blow out all dust from the interior.

2. Store in a clean and dry location.

Replacing the Wire Reel

When the wire on the Feed Reel is used up, you will need to replace it as follows.

1. Press on the Cover Locking Spring (8), then lift the Cover (31) using Handle (30) to

expose the Wire Feed Unit (23).

2. Unscrew the Wing Nut (25) and remove the Reel Locking Knob (26).

3. Remove the empty Wire Reel (27).

4. Place the new Wire Reel over the shaft and onto the Reel Spring (24).

The wire on the reel should unwind counterclockwise (see

photo above).

5. Replace the Reel Locking Knob and the Wing Nut.

Tighten well.

6. Lift the Wire Feed Adjusting Spring (36) to remove

tension.

7. Guide at least 12 inches of wire into the Torch Sheath.

If the end of the wire is crimped or bent, cut it off.

8. Replace tension to the Wire Feed Adjusting Spring (36).

9. Turn the Torch Handle Nozzle counterclockwise and pull to remove.

Wire Sheath

Wire Feed Adjusting Spring (36)

Tension Adjusting

Screw (37)

Page 9SKU 54878 For technical questions, please call 1-800-444-3353.

10. Turn the Contact Tip counterclockwise and remove.

11. Lay the Torch Sheath out in a straight line so that the wire moves through it easily.

Warning: The following steps require applying power to the welder. Do not touch any-

thing with the Torch Handle or an arc may be ignited.

12. Plug the Power Cord into its electrical outlet, press the Current Switch to Max., and

turn the welder ON.

13. Lift the Torch Handle and continue pressing the Trigger until the wire feeds through two

inches.

If the wire does not feed, view the Wire Feed Unit and see if the wire is being pushed.

If it is not, turn the welder OFF and add more tension to the Wire Feed Adjusting

Spring (36).

14. Turn the welder ON again and press the Trigger.

15. Once the wire is exposed, turn the welder OFF and unplug it.

16. Slide the Contact Tip over the wire and screw it into Torch Handle.

17. Replace the Nozzle and cut off any excess wire over two inches.

18. Secure the Cover.

PLEASE READ THE FOLLOWING CAREFULLY

THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM IN THIS MANUAL

AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER NOR 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.

Page 10SKU 54878 For technical questions, please call 1-800-444-3353.

Welder Parts List

Item # Description Qty

1 Torch 1

2 Contact Tip 1

3 Nozzle 1

4 Liner 1

5 Fixing Pole (A) for Gun Body 1

6 Fixing Pole (B) for Gun Body 1

7 Switch 2

8 Cover Locking Spring 1

9 Knob 1

10 Nut 1

11 Speed Control Circuit Board 1

12 Right Side Panel 1

13 Left Side Panel 1

14 Base Frame 1

15 Foot 4

16 Washer 4

17 Self-tapping Screw, ST4.2*13 4

18 Transformer Carriage 2

19 Thermostat 1

20 Transformer 1

Item # Description Qty

21 Middle Partition Board 1

22 Overload Indicator Lamp 1

23 Wire Feed Unit 1

24 Reel Spring 1

25 Wing Nut, M6 1

26 Reel Locking Knob 1

27 Wire Reel 1

28 Reel Holder 1

29 Self-tapping Screw, ST4.2*25 1

30 Handle 1

31 Cover 1

32 Power Cord 1

33 Ground Cable 1

34 Wire Feed Roller 1

35 Wire Feed Bearing 1

36 Wire Feed Adjusting Spring 1

37 Adjustment Screw 1

38 Face Shield 1

39 Wire Brush / Hammer 1

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