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Keep your head out of the fumes. SKU 91124Page 4 REV 05/04 3. Avoid eye and body damage. Arc 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 the provided Face Shield with arc shaded filter plate. 4. Know proper arc welding practices. Read and understand the manufacturer’s instructions, as well as your employer’s safety practices for arc 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 arc 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. Wire Spool and Spare Welding Tip not shown here. Torch (1) Face Shield (38) MIG-100 Welder Power Cord (32) Wire Brush / Hammer (39) Ground Cable (33) 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 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. SKU 91124 Page 5 Cover Locking Spring (8) Cover (31) Handle (30) Wire Reel (27) Cover Locking Spring (8) Cover (31) Handle (30) Wire Reel (27) 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 current. 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 The MIG 100 Welder is used to weld sheet metal and light carbon steel. Switch (7) Power On / Off Switch (7) Current Min. / Max.* Overload Indicator Light (22) Wire Feed Speed Knob (9) Torch (1) Cable Ground Cable (33) Power Cord (32) * NOTE:THIS UNIT IS NOT ADJUSTABLE. SKU 91124 Page 6 Caution: Before arc welding, read and understand all safety precautions and warnings listed on pages 2 through 5. Caution: Before arc welding, read and understand all safety precautions and warnings listed on pages 2 through 5. . 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. This unit is not adjustable. Current switch is set at 90 AMPs. 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 the 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 breath arc 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 MIG Welder, the Thermal Overload protector will activate, the amber indicator will light, and the Arc 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 wi...