Chicago Electric 54878 User Manual
MIG-100 WELDER
Model
54878
®
WITH THERMAL OVERLOAD
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.
Copyright© 2007 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.
For technical questions or replacement parts, please call 1-800-444-3353.
(Manual revised 03/07)
Specifications
.8 mm wire on 16
Welding Current
Duty Cycle
Power Consumption
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
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”)
ga. sheet steel
.8 mm wire on 1/4”
steel plate
10% @ 90 Amps (Maximum Setting) or
10% @ 80 Amps (Minimum Setting, actual 11%)
120 VAC, 24 Amps
0.030”; Spare: Welder Tip 0.035”;
Will also accept a 0.023” welder tip (not included)
104.3/95.5 Amps
(Maximum/Minimum Setting)
103.7/103.1 Amps
(Maximum/Minimum Setting)
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.
For technical questions, please call 1-800-444-3353.
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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.
For technical questions, please call 1-800-444-3353.
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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. Extension 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 understood 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 ANSIapproved.
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.
For technical questions, please call 1-800-444-3353.
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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.
Unpacking
When unpacking, check to make sure the following parts are included.
MIG-100 Welder
Torch (1)
Power Cord
Ground Cable
Wire Spool and Spare
Welding Tip not shown
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.
Assembly
1. Attach the Handle (30) to the Cover (31) using screw (29) inserted from the Handle toprear. 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.
For technical questions, please call 1-800-444-3353.
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