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Installation Instructions for 81540 
MIG100 Gasless Welder 

 
PLEASE READ MANUAL CAREFULLY BEFORE USING. 
 

SAFETY INFORMATION 
 

Before using welder, please ensure that you know: 
 

1.  Arc welding can be dangerous. 
2.  This welding machine must be connected to a power source in accordance with appliance electrical codes. 
3.  For safety turn off and unplug machine when installing new wire spool, adjusting wire tension roller or replacing 

contact tip. 

4. 

The contact tip is electrically “hot” and if it contacts the grounded work piece it will cause damage. 

5.  All installation, maintenance, repair operation of this equipment should be performed by qualified technicians in 

accordance with national, state and local codes. 

6.  Electric shock could kill. 
7.  Disconnect from power source before assembling, disassembly or maintenance of the torch or contact tip or 

changing wire spools. 

8.  Fumes and welding gases can be dangerous. 
9.  Welding sparks can cause fire or explosion. 
10.  Arc rays can burn. 
11.  Hot metal will burn. 
12.  Electromagnetic fields may be dangerous. 

 

WARNING! 

PLEASE BE REMINDED TO WEAR ALL PROTECTION DEVICES BEFORE WELDING IN A SAFE PLACE. 

SPECIFICATION 

Process(s) 

 Flux-Cored MIG 

welding 

GAS/FLUX 

Flux 

Input Voltage 

110 V AC 

Input Current 

20 A 

Input Frequency 

60 Hz 

Output Current Range 

50-90A 

Rated Duty Cycle   

20% @90A 

Open Circuit Voltage 

27V AC 

Wire Feed Speed 

Infinite adjustable 

Current Settings 

4 Position 

Flux cored welding wire dia.(inch) 

0.03

’’-0.035’’ 

Insulation class 

Protection class 

IP21S 

 

                                         1-800-345-4545   jegs.com

 

Summary of Contents for MIG100

Page 1: ...s in accordance with national state and local codes 6 Electric shock could kill 7 Disconnect from power source before assembling disassembly or maintenance of the torch or contact tip or changing wire spools 8 Fumes and welding gases can be dangerous 9 Welding sparks can cause fire or explosion 10 Arc rays can burn 11 Hot metal will burn 12 Electromagnetic fields may be dangerous WARNING PLEASE BE...

Page 2: ...Page 2 1 800 345 4545 jegs com ...

Page 3: ...12 AWG cord for up to 25 feet CHANGING THE DRIVE ROLLER The MIG100 comes set up and ready to use 0 035 0 9mm Flux Core Wire If 0 03 0 8mm wire is to be used the drive roller needs to be adjusted Adjust the drive roller according to the following procedure 1 Open the top door of the welder 2 Lift the Pressure Adjuster PIC C1 out of the way and move the Rocker Arm PIC C2 away from the drive roller 3...

Page 4: ...Roller and into the torch hole 8 Reattach the Rocker arm and reset the Pressure Adjuster 9 Turn on the machine and set the wire speed 10 With the gun pointed away from you and others depress the trigger to begin feeding wire NOTE Watch the drive roller to see if any slippage is occurring between the roller and wire if so turn the machine off and tighten the Pressure Adjuster turn and test again 11...

Page 5: ...d welding turn off the welder TROUBLE SHOOTING Problem Possible Causes Arc unable excessive spatter Welding output too high Torch moved too slowly Lack of weld penetration Welding output too low Torch moved too fast Input voltage too low Burning holes in work piece Welding output too high Torch moved too slowly Welder does not operate mains indicator not lit no arc produced Check main supply conne...

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