Chicago Electric MIG 180 Assembly instructions

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Email our technical support at: [email protected]
Read this material before using this product.
Failure to do so can result in serious injury.
SAVE THIS MANUAL.
Copyright©2011 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. Diagrams
within this manual may not be drawn proportionally. Due to continuing
improvements, actual product may differ slightly from the product described
herein. Tools required for assembly and service may not be included.
When unpacking, make sure that the product is intact
and undamaged. If any parts are missing or broken,
please call 1-800-444-3353 as soon as possible.
Save This Manual Keep this manual for the safety warnings and precautions, assembly, operating,
inspection, maintenance and cleaning procedures. Write the product’s serial number in the back of the manual
near the assembly diagram (or month and year of purchase if product has no number). Keep this manual and
the receipt in a safe and dry place for future reference.
Owner’s Manual & Safety Instructions

Page 2 For technical questions, please call 1-800-444-3353. SKU 68886
Table of Contents
Safety ......................................................... 2
Setup .......................................................... 7
Specifications ............................................. 7
Basic Welding............................................ 15
Welding Tips .............................................. 23
Maintenance.............................................. 27
Parts List and Diagrams ............................ 30
Warranty .................................................... 32
WARNING SYMBOLS AND DEFINITIONS
This is the safety alert symbol. It is used to alert you to potential personal injury hazards.
Obey all safety messages that follow this symbol to avoid possible injury or death.
Indicates a hazardous situation which, if not avoided,
will result in death or serious injury.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
Addresses practices not related to personal injury.
IMPORTANT SAFETY INFORMATION
Read all safety warnings and instructions.
Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.
Save all warnings and instructions for future reference.
General Safety
PROTECT yourself and others. Read and understand this information.
1. Before use, read and understand
manufacturer′s instructions,
Material Safety Data Sheets (MSDS′s),
employer′s safety practices, and ANSI Z49.1.
2. Keep out of reach of children.
Keep children and bystanders away while operating.
3. Place the welder on a stable location before use.
If it falls while plugged in, severe injury,
electric shock, or fire may result.
4. Do not overreach.
Keep proper footing and balance at all times.
5. Stay alert, watch what you are doing and use
common sense when operating a welder.
Do not use a welder while you are tired or under
the influence of drugs, alcohol or medication.
A moment of inattention while operating welders
may result in serious personal injury.
6. Avoid unintentional starting. Make sure you are
prepared to begin work before turning on the Welder.
7. Never leave the Welder unattended while
energized. Turn power off if you have to leave.
8. The warnings, precautions, 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.
9. This product, when used for welding and similar
applications, contains or produces a chemical
known to the State of California to cause cancer
and birth defects (or other reproductive harm).
(California Health & Safety Code § 25249.5, et seq.)
10. Handling the cord on this product will expose
you to lead, a chemical known to the State of
California to cause cancer, and birth defects or
other reproductive harm.
Wash hands after handling.
(California Health & Safety Code § 25249.5, et seq.)
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP

Page 3For technical questions, please call 1-800-444-3353.SKU 68886
Fume and Gas Safety
FUMES AND GASES can be hazardous to your health.
1. Exposure to welding or cutting
exhaust fumes can increase the risk
of developing certain cancers, such as
cancer of the larynx and lung cancer.
Also, some diseases that may be linked to exposure
to welding or cutting exhaust fumes are:
• Early onset of Parkinson’s Disease
• Heart disease • Ulcers
• Damage to the reproductive organs
• Inflammation of the small intestine or
stomach • Kidney damage
• Respiratory diseases such as
emphysema, bronchitis, or pneumonia
2. Do not use near degreasing or
painting operations.
3. Keep head out of fumes.
Do not breathe exhaust fumes.
4. Use enough ventilation, exhaust at arc, or
both, to keep fumes and gases from breathing
zone and general area. If engineering controls
are not feasible, use an approved respirator.
5. Work in a confined area only if it
is well-ventilated, or while wearing
an air-supplied respirator.
6. Have a recognized specialist in
Industrial Hygiene or Environmental Services
check the operation and air quality
and make recommendations
for the specific welding situation.
Follow OSHA guidelines for
Permissible Exposure Limits (PEL’s) and
the American Conference of Governmental
Industrial Hygienists recommendations for
Threshold Limit Values (TLV’s) for fumes and gases.
Arc Ray Safety
ARC RAYS can injure eyes and burn skin.
1. Wear ANSI-approved welding eye protection
featuring at least a number 10 shade lens rating.
2. Wear leather leggings, fire resistant shoes
or boots during use. Do not wear pants with
cuffs, shirts with open pockets, or any clothing
that can catch and hold molten metal or sparks.
3. Keep clothing free of grease, oil,
solvents, or any flammable substances.
Wear dry, insulating gloves and protective clothing.
4. Wear an approved head covering to protect
the head and neck. Use aprons, cape, sleeves,
shoulder covers, and bibs designed and
approved for welding and cutting procedures.
5. When welding/cutting overhead or in confined
spaces, wear flame resistant ear plugs or
ear muffs to keep sparks out of ears.
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP

Page 4 For technical questions, please call 1-800-444-3353. SKU 68886
Electrical Safety
ELECTRIC SHOCK can KILL.
1. Turn off, disconnect power, and
discharge electrode to ground before setting
down torch/electrode holder and before service.
2. Do not touch energized electrical parts.
Wear dry, insulating gloves. Do not touch electrode
holder, electrode, welding torch, or welding wire with
bare hand. Do not wear wet or damaged gloves.
3. Connect to grounded, GFCI-protected
power supply only.
4. Do not use near water or damp objects.
5. People with pacemakers should consult their
physician(s) before use. Electromagnetic fields
in close proximity to heart pacemaker could cause
pacemaker interference or pacemaker failure.
6. Do not expose welders to rain or wet conditions.
Water entering a welder will increase
the risk of electric shock.
7. Do not abuse the cord. Never use the cord
for carrying, pulling or unplugging the welder.
Keep cord away from heat, oil, sharp edges
or moving parts. Damaged or entangled
cords increase the risk of electric shock.
8. Do not use outdoors.
9. Insulate yourself from the workpiece and ground.
Use nonflammable, dry insulating material if possible,
or use dry rubber mats, dry wood or plywood, or
other dry insulating material large enough to cover
your full area of contact with the work or ground.
Fire Safety
ARC AND HOT SLAG can cause fire.
1. Clear away or protect flammable objects.
Remove or make safe all combustible materials for a
radius of 35 feet (10 meters) around the work area.
Use a fire resistant material to cover or block all open
doorways, windows, cracks, and other openings.
2. Keep ABC-type fire extinguisher near
work area and know how to use it.
3. Maintain a safe working environment.
Keep the work area well lit.
Make sure there is adequate surrounding workspace.
Keep the work area free of obstructions,
grease, oil, trash, and other debris.
4. Do not operate welders in atmospheres
containing dangerously reactive or
flammable liquids, gases, vapors, or dust.
Provide adequate ventilation in work areas
to prevent accumulation of such substances.
Welders create sparks which may ignite flammable
substances or make reactive fumes toxic.
5. If working on a metal wall, ceiling, etc.,
prevent ignition of combustibles on the
other side by moving the combustibles to a
safe location. If relocation of combustibles is
not possible, designate someone to serve as
a fire watch, equipped with a fire extinguisher,
during the cutting process and for at least one
half hour after the cutting is completed.
6. Do not weld or cut on materials having
a combustible coating or combustible
internal structure, as in walls or ceilings, without
an approved method for eliminating the hazard.
7. Do not dispose of hot slag in containers
holding combustible materials.
8. After welding, make a thorough examination
for evidence of fire. Be aware that easily
visible smoke or flame may not be present
for some time after the fire has started.
9. Do not apply heat to a container that has held
an unknown substance or a combustible
material whose contents, when heated,
can produce flammable or explosive vapors.
Clean and purge containers before applying heat.
Vent closed containers, including castings,
before preheating, welding, or cutting.
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP

Page 5For technical questions, please call 1-800-444-3353.SKU 68886
Welder use and care
1. Do not use the welder if the switch does not turn
it on and off. Any welder that cannot be controlled
with the switch is dangerous and must be repaired.
2. Disconnect the plug from the power
source before making any adjustments,
changing accessories, or storing welders.
Such preventive safety measures reduce the
risk of starting the welder accidentally.
3. Prevent unintentional starting.
Ensure the switch is in the off-position before
connecting to power source or moving the welder.
Carrying or energizing welders that have
the switch on invites accidents.
4. Store idle welders out of the reach of children and
do not allow persons unfamiliar with the welder or
these instructions to operate the welder. Welders
are dangerous in the hands of untrained users.
5. Use the welder and accessories in accordance
with these instructions, taking into account the
working conditions and the work to be performed.
Use of the welder for operations different from those
intended could result in a hazardous situation.
Maintenance
1. Maintain welders. Check for misalignment or
binding of moving parts, breakage of parts
and any other condition that may affect the
welder’s operation. If damaged, have the
welder repaired before use. Many accidents
are caused by poorly maintained welders.
2. Have your welder serviced by a qualified
repair person using only identical
replacement parts. This will ensure that
the safety of the welder is maintained.
3. Maintain labels and nameplates on the Welder.
These carry important information.
If unreadable or missing, contact
Harbor Freight Tools for a replacement.
4. Unplug before maintenance. Unplug the Welder
from its electrical outlet before any inspection,
maintenance, or cleaning procedures.
Gas Shielded Welding - Cylinder safety
Cylinders can explode when damaged.
1. Never weld on a pressurized or a closed cylinder.
2. Never allow an electrode holder,
electrode, welding torch, or welding
wire to touch the cylinder.
3. Keep cylinders away from any electrical circuits,
including welding circuits.
4. Keep protective cap in place over the valve
except when the cylinder is in use.
5. Use only correct gas shielding equipment
designed specifically for the type of welding
you will do. Maintain this equipment properly.
6. Protect gas cylinders from heat, being struck,
physical damage, slag, flames, sparks, and arcs.
7. Always use proper procedures to move cylinders.
SAVE THESE INSTRUCTIONS.
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP

Page 6 For technical questions, please call 1-800-444-3353. SKU 68886
Grounding
TO PREVENT ELECTRIC SHOCK AND DEATH
FROM INCORRECT GROUNDING WIRE CONNECTION:
Check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded.
Have a plug installed by a certified electrician.
Do not use the welder if the power cord or plug is damaged. If damaged, have it repaired by a service facility
before use. If the plug will not fit the outlet, have a proper outlet installed by a qualified electrician,
do not use adapter plugs.
1. The green wire inside the cord is connected to
the grounding system in the welder. The green
wire in the cord must be the only wire connected
to the welder’s grounding system and must never
be attached to an electrically “live” terminal.
Never leave the grounding wire disconnected
or modify the Power Cord Plug in any way.
2. Make sure the tool is connected to an outlet having
the same configuration as the plug. If the tool must
be reconnected for use on a different type of electric
circuit, the reconnection should be made by qualified
service personnel; and after reconnection, the tool
should comply with all local codes and ordinances.
3. A 250 V~ plug will need to be installed
by a certified electrician before use.
4. The plug shown (NEMA 6-50p) is for use on a
50 A circuit. A different 250 V~ plug and outlet
combination may be used, provided it is rated
to handle the electrical requirements of the tool
and is installed by a certified electrician.
250 V~ 3-Prong Plug (6-50p) and Outlet (6-50r)
(for up to 250 V~ and up to 50 A)
DO NOT USE
125 V~ PLUG.
NOTE SIZE
DIFFERENCE.
Extension Cords
Do not use an extension cord on this welder.
Replacement Cords
1. A qualified electrician can install either of the
following UL-listed, 3 wire cords as a replacement
cord for this welder:
12 AWG up to 6 feet long,
10 AWG up to 75 feet long, or
6 AWG up to 175 feet long.
2. Do not install a thinner or longer
cord on this welder.
3. Do not patch cords of any length together for this
item, patches may allow moisture to penetrate
the insulation, resulting in electric shock.
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP

Page 7For technical questions, please call 1-800-444-3353.SKU 68886
Symbology
Wire Feed (Speed)
Workpiece Ground Cable
Torch Cable
Overheat Shutdown Indicator
Cooling Fan
Housing Ground Point
V~ Volts Alternating Current
AAmperes
OCV Open Circuit Voltage
KVA Kilovolt Amperes
(Volts / 1000 * Amperes)
IPM Inches Per Minute
AWG American Wire Gauge
Specifications
Power Input 240 V~, 24 A
Welding Output DCEN/DCEP
30-180 A
Capacity 18 gauge (0.048″) to 1/4″ (0.25″) mild or stainless steel
Not for welding aluminum
Rated Duty Cycle 20% at 140A
(See explanation on page 16)
Open Circuit Voltage 34
KVA 5.75
Wire Speed 30 – 700 IPM
Cable Sizes
Ground: 6′, 7 AWG
Torch: 6′, 7 AWG
Power: 3-wire, 6′ 5″, 12 AWG
6-50P NEMA plug type
Wire Spool Capacity up to 10 lb. spool
(one 1 lb. spool of flux-core wire included)
Accessories
Spare Welder Tips (one each for .023″ and .030″– .035″ wire)
Welding Face Shield
Combination Wire Brush / Chipping Hammer
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP

Page 8 For technical questions, please call 1-800-444-3353. SKU 68886
1. Attach the handle to the Face Shield by lining
up the two rectangular tabs on the handle with
the corresponding holes in the face shield and
A. press the tabs through the holes and then
B. slide the tabs forward from the back,
locking the round tab in place.
2. Wear heavy-duty work gloves, the edges of the
filter lens may be sharp. Remove any protective
film from both sides of the filter lens. Slide the
filter lens into the helmet behind the holding tabs.
Make sure that the filter lens fits securely and
that light cannot leak around its edges.
Handle
Face Shield
(viewed from front)
AA
BB
Round
Tab
Face Shield
(viewed from back)
Filter Lens
Setup
Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual
including all text under subheadings therein before set up or use of this product.
TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION:
Turn the Power Switch off and unplug the welder before assembly.
Note: Remove the protective foam and cardboard from the welder before setup.
Face Shield Assembly
Plug Attachment
1. A 250 V~ plug will need to be installed
by a certified electrician before use.
2. The plug shown is for use on a 50 A circuit. A
different 250 V~ plug and outlet combination
may be used, provided it is rated to handle
the electrical requirements of the tool and
is installed by a certified electrician.
Note: Although 125 V~ plugs may look similar,
the required plug is much larger, see illustration.
250 V~ 3-Prong Plug (6-50p) and Outlet (6-50r)
(for up to 250 V~ and up to 50 A)
DO NOT USE
125 V~ PLUG.
NOTE SIZE
DIFFERENCE.
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP

Page 9For technical questions, please call 1-800-444-3353.SKU 68886
Wire Spool Installation
1. Turn the welder OFF and unplug
it before proceeding.
2. Pull up on the door latch,
then open the Door.
3. Remove the Spool Knob, Spool Spring, and upper
Spool Plate. If replacing a Spool, remove the old
Spool and all remaining wire from the liners.
4. Place the new Wire Spool over the Spool Spindle
and on top of the lower Spool Plate as illustrated.
To prevent wire feed problems, set the
Spool so that it will unwind clockwise.
5. Secure Spool in place with the upper Spool Plate
(narrower end against the Spool),
then the Spool Spring and Spool Knob.
MIG 180
WIRE FEED WELDER
ITEM 68886
WIRE FEED SPEED
240V~
I
O
door
latch
Door
Spool Knob
Wire Spool
Lower
Spool Plate
Upper
Spool Plate
Spool Spring
Spool Spindle
wire must
unwind this
direction
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP

Page 10 For technical questions, please call 1-800-444-3353. SKU 68886
6a. Flux Core (Gas-less) Wire Setup:
Remove the two Knobs securing the cables.
Connect the Black Ground Cable to the rear, red,
positive Terminal using the Knob.
Connect the Red Torch Cable to the front, black,
negative Terminal using the other Knob.
This is the initial setup, called
Direct Current Electrode Negative (DCEN).
6b. Solid Core (Gas Shielded) Wire Setup:
a. Remove the two Knobs securing the cables.
Connect the Black Ground Cable to the front,
black, negative Terminal using the Knob.
Connect the Red Torch Cable to the rear, red,
positive Terminal using the other Knob.
This is called Direct Current Electrode Positive
(DCEP).
b. Determine which type of shielding gas
would be appropriate for the welding
you will do - see chart on welder.
c. With assistance, set the cylinder
(not included) onto a shelf or cart near
the welder and secure the cylinder in
place with two straps (not included).
d. Remove the protective cap from the cylinder (if
present). Stand to the side of the valve opening,
and open the valve briefly to blow dust and dirt
from the valve opening. Close the cylinder valve.
e. Obtain an appropriate Regulator/Flowmeter
(not included) and close its valve completely.
Thread its inlet connector onto the
cylinder and wrench tighten.
Note: If the threads do not match, then the Regulator/
Flowmeter is likely for a different type of cylinder/gas.
f. Attach the Gas Hose securely to the
outlet of the Regulator/Flowmeter
using a hose clamp (sold separately).
–+
Ground Polarity: +
Ground
(Black)
Flux Core (Gas-less) Polarity Setup
DCEN
Torch Polarity: –
Knobs
Torch
(Red)
–+
Ground Polarity: –
Torch
(Red)
Solid Core (Gas Shielded) Polarity Setup
DCEP
Torch Polarity: +
Knobs
Ground
(Black)
fe
c
Briefly open valve
to clean,
then close
valve.
d
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP

Page 11For technical questions, please call 1-800-444-3353.SKU 68886
7. Turn the Feed Tensioner knob counterclockwise to
loosen it enough to pull it down to remove tension.
(Do not loosen the Tensioner knob too much, or the
Tensioner will come apart.)
Then, swing the Feed Swing Arm up.
8. Feed Roller Instructions:
Check that the Feed Roller is turned to properly
match the wire size marked on the Wire Spool:
A. Twist the Feed Roller Knob about 1/3 of a
turn counterclockwise until it stops.
B. Pull the Feed Roller Knob straight
off to expose the Feed Roller.
C. Flip the Feed Roller as needed and
confirm that the number facing you is the
same as the wire diameter on the Spool.
(0.8mm = .030" & 0.6mm = .023")
D. Place the Feed Roller Knob back into place in
the same orientation it was removed in, and twist
it about 1/3 of a turn clockwise to secure it.
Feed Swing
Arm
Feed
Tensioner
Feed
Roller
Knob
Feed
Roller
A
C
B
D
.030/.035 groove
and stamp
.023 groove
and stamp
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP

Page 12 For technical questions, please call 1-800-444-3353. SKU 68886
IMPORTANT:
Securely hold onto the end of the
welding wire and keep tension on
it during the following steps.
If this is not done, the welding wire
will unravel and create a tangled
“bird’s nest”, wasting wire.
9. Cut off all bent and crimped wire.
The cut end must have no burrs or
sharp edges; cut again if needed.
10. Keep tension on the wire and guide at least
12 inches of wire into the Wire Liners.
11. Swing the wire feed swing arm down, and swing
the feed tensioner up to latch it across the tip of
the arm. Make sure the Welding Wire is resting in
the bottom groove of the Feed Roller, then turn the
feed tensioner knob clockwise a couple of turns.
After the wire is held by the tensioner,
you may release it.
12. Pull the Nozzle to remove it.
13. Using the third oval hole on the Multi-wrench, turn
the Contact Tip counterclockwise and remove.
14. Lay the Torch Cable out in a straight line so that
the wire moves through it easily. Leave the cover
open, so that the feed mechanism can be observed.
Wire
Spool
welding
wire
HOLD WIRE
SECURELY
Wire
Liner
leader
wire liner
feed
swing arm
feed
tensioner
Feed Roller
Torch
Nozzle
Contact
Tip
Multi-wrench
hole for
Contact Tip
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP

Page 13For technical questions, please call 1-800-444-3353.SKU 68886
WARNING
The following steps require applying power
to the welder with the cover open.
To prevent serious injury from fire or electric shock:
1. Do not touch anything (especially not the Ground Clamp)
with the Torch or welding wire, or an arc may be ignited.
2. Do not touch internal welder components
while it is plugged in.
15. Do not touch the Torch’s Trigger.
Plug the Power Cord into its electrical
outlet and turn the welder ON.
16. Point the Torch away from all objects and press the
trigger until the wire feeds through two inches.
The wire liner may come out with
the welding wire, this is normal,
just push the wire liner back into the Torch.
If the wire does not feed properly and the Spool is
stationary, turn the welder OFF, unplug it, and slightly
tighten the feed tensioner clockwise before retrying.
MIG 180
WIRE FEED WELDER
ITEM 68886
WIRE FEED SPEED
240V~
I
O
Welding
Wire
Torch
2″
IMPORTANT
Stainless steel wire is less exible than
other welding wire. Therefore, it is more
difcult to feed through the liner and torch.
It is especially important to keep the torch cable
straight while feeding stainless steel wire.
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP

Page 14 For technical questions, please call 1-800-444-3353. SKU 68886
17. To check the wire’s drive tension, feed the wire
against a piece of wood from 2 to 3 inches away.
If the wire stops instead of bending,
turn the welder OFF, unplug it,
slightly tighten the feed tensioner clockwise,
and try again.
If the wire bends from the feed pressure,
then the tension is set properly.
18. TURN THE WELDER OFF.
19. Select a Contact Tip that is compatible with the
welding wire used. The pre-installed Tip is .035″.
Slide the Contact Tip over the wire
and thread it clockwise into the Torch.
Tighten the Contact Tip using the Multi-wrench.
20. Replace the Nozzle and cut the wire
off at 1/2″ from tip (1/2″ stickout).
21. Swing the Door closed, lift the door latch, press
on the bottom center of the Door until the door
is completely closed, and release the latch.
MIG 180
WIRE FEED WELDER
ITEM 68886
WIRE FEED SPEED
240V~
I
O
Torch
Nozzle
Contact
Tip
door
latch
Door
2-3″
Incrementally
increase tension
until
wire bends.
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP

Page 15For technical questions, please call 1-800-444-3353.SKU 68886
Basic Welding
Read the ENTIRE IMPORTANT SAFETY
INFORMATION section at the beginning of this
manual including all text under subheadings
therein before welding.
TO PREVENT SERIOUS INJURY:
Protective gear must be worn when using the
Welder; minimum shade number 10 full face shield
(or welding mask), ear protection, welding gloves,
sleeves and apron, NIOSH-approved respirator, and
fire resistant work clothes without pockets should be
worn when welding.
Light from the arc can cause
permanent damage to the eyes and skin.
Do not breathe arc fumes.
Flux-core wire welding is used to weld sheet metal and
low carbon steel without shielding gas. MIG welding uses
solid-core wire and shielding gas, and is used to weld sheet
metal and low carbon steel. MIG welding can also be used
to weld thinner workpieces than flux-core welding can.
Good welding takes a degree of skill and experience.
Practice a few sample welds on scrap before
welding your first project. Additional practice
periods are recommended whenever you weld:
• a different thickness of material
• a different type of material
• a different type of connection
• using a different technique (MIG vs. flux)
Make practice welds on pieces of scrap to practice
technique before welding anything of value.
Practice your welding
technique on scrap
pieces before welding
anything of value.
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP

Page 16 For technical questions, please call 1-800-444-3353. SKU 68886
Control Panel Layout
Overload Indicator:
This lights up if duty cycle work period is exceeded,
resulting in overheating the welder.
Rest the Torch on an electrically non-conductive,
heat-resistant surface, such as a concrete slab, well
clear of the ground clamp while allowing the welder
to cool with the Power Switch on, so the Fan can
help cool the welder. Once the welder cools enough
to be used again, use shorter welding periods and
longer rest periods to prevent needless wear.
Power Switch:
This turns on power to the welding Torch and
internal cooling fan. The welding Torch is
energized whenever the Power Switch is on.
Current Switch:
This controls the output amperage of the welder.
Adjust this according to the weld settings
chart to achieve a good weld.
Wire Speed Dial:
This controls the speed that the welding wire
feeds out of the welding Torch and
adapts output amperage somewhat.
Adjust this according to the weld settings
chart to achieve a good weld.
Power Cord:
Plug the Power Cord into a properly grounded
240 V~ (at least 30 amp rating) outlet with
delayed action type circuit breaker or fuses.
Torch Cable:
The welding Torch connects here.
The wire and welding current feeds to
the weld through here. The welding Torch is
energized whenever the Power Switch is on.
Ground Cable:
This connects to the base metal to provide a good
connection for the current to travel back to the welder.
MIG 180
WIRE FEED WELDER
ITEM 68886
WIRE FEED SPEED
240V~
I
O
Wire
Speed
Dial
Torch
Cable
Ground
Cable
Power
Switch
Current
Switch
Overload
Indicator
Power
Cord
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP

Page 17For technical questions, please call 1-800-444-3353.SKU 68886
Avoid damage to the Welder by not welding
for more than the prescribed duty cycle time.
The Duty Cycle defines the number of minutes,
within a 10 minute period, during which a given
welder can produce a particular welding current
without overheating. For example, this Welder
with a 20% duty cycle at rated output (140A)
must be allowed to rest for at least 8 minutes
after every 2 minutes of continuous welding.
Failure to carefully observe any duty cycle limitations
can easily over-stress a welder’s power generation
system contributing to premature welder failure.
This welder has an internal thermal protection system
to help prevent this sort of over-stress. When the unit
overheats, it automatically shuts down and the Overload
Indicator lights, then the welder automatically returns
to service after cooling off. Rest the Torch on an
electrically non-conductive, heat-proof surface, such as
a concrete slab, well clear of the ground clamp while
allowing the welder to cool with the Power Switch on, so
that the internal Fan will help cool the welder. When the
welder can be used again, use shorter welding periods
and longer rest periods to prevent needless wear.
Note: The following charts are only intended
to show general guidelines for different wire
sizes and for different thicknesses of material.
The settings should only be used at the
beginning of a weld and must be adjusted after
stopping and carefully inspecting the weld.
Proper welding takes experience.
20% Rated Duty Cycle
at 140A output
2 minutes welding
followed by
at least 8 minutes
of rest
MIG 180
WIRE FEED WELDER
ITEM 68886
WIRE FEED SPEED
240V~
I
O
Torch
concrete slab
(or other heat-proof,
non-conductive
surface)
Duty Cycle (Duration of Use)
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP

Page 18 For technical questions, please call 1-800-444-3353. SKU 68886
Metal Thickness
Flux Weld Settings
DCEN
Polarity
NO
GAS
Material
Being
Welded
Wire
Type
Shielding
Gas
Wire
Diameter
Suggested
Settings
22 Ga
.030″
0.8mm
18 Ga
.048″
1.2mm
16 Ga
.060″
1.5mm
14 Ga
.075″
2.0mm
1/8″
3.2mm
3/16″
4.8mm
1/4″
6.4mm
Mild
Steel
Flux-core
(E71T-GS)
NO
GAS
Required
.030″ Current B C C D
Wire Feed 2.5 3 4 5
.035″ Current C C D D E
Wire Feed 45679
Metal Thickness
MIG Weld Settings
DCEP
Polarity
GAS
Material
Being
Welded
Wire
Type
Wire
Diameter
Shielding
Gas
Suggested
Settings
22 Ga
.030″
0.8mm
18 Ga
.048″
1.2mm
16 Ga
.060″
1.5mm
14 Ga
.075″
2.0mm
1/8″
3.2mm
3/16″
4.8mm
1/4″
6.4mm
Mild
Steel
Solid
(E70S-6)
.023″ 75% CO2
+25% Argon
6-8L / MIN
Current A B
Wire Feed 4.5 5
.030″ 75% CO2
+25% Argon
8-10L / MIN
Current A B B C C
Wire Feed 3.5 4 6 6 7
.035″ 75% CO2
+25% Argon
8-10L / MIN
Current A B B C D F
Wire Feed 3568910
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP

Page 19For technical questions, please call 1-800-444-3353.SKU 68886
1. Make practice welds on pieces of scrap the
same thickness as your intended workpiece
to practice technique before welding anything
of value. Clean the weld surfaces thoroughly
with a wire brush or angle grinder; there
must be no rust, paint, oil, or other materials
on the weld surfaces, only bare metal.
2. Use clamps (not included) to hold the workpieces
in position so that you can concentrate on
proper welding technique. The distance
(if any) between the two workpieces must be
controlled properly to allow the weld to hold
both sides securely while allowing the weld
to penetrate fully into the joint. The edges of
thicker workpieces may need to be chamfered
(or beveled) to allow proper weld penetration.
3. Clamp Ground Cable to bare metal on the
workpiece near the weld area, or to metal work
bench where the workpiece is clamped.
4. Set the Wire Speed Dial and the Current Switch to
the desired settings.
Refer to the chart on the welder or the chart on the
previous page.
DO NOT SWITCH THE CURRENT
WHILE WELDING.
clamps
workpieces
Chamfer thick workpieces.
Clean
surfaces to
bare metal.
MIG 180
WIRE FEED WELDER
ITEM 68886
WIRE FEED SPEED
240V~
I
O
Workpiece
Ground
Clamp
Clean
surface to
bare metal.
+
MIG 180
WIRE FEED WELDER
ITEM 68886
WIRE FEED SPEED
240V~
I
O
MIG 180
WIRE FEED WELDER
ITEM 68886
WIRE FEED SPEED
240V~
I
O
Setting Up The Weld
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP

Page 20 For technical questions, please call 1-800-444-3353. SKU 68886
DANGER! TO PREVENT DEATH
FROM ASPHYXIATION:
Do not open gas without proper ventilation. Fix gas
leaks immediately.
Shielding gas can displace air and cause rapid loss of
consciousness and death.
Shielding gas without carbon dioxide can be even
more hazardous,
because asphyxiation can start
without feeling shortness of breath.
5. Gas shielded, solid-core wire only:
Open gas tank valve and adjust regulator/
flowmeter to flow rate indicated on chart.
6. Flip the Power Switch to the OFF position, then plug
the Welder into a dedicated, 240 V~ receptacle that
matches the plug.
The circuit must be equipped with delayed
action type circuit breaker or fuses.
7. Hold the Torch, without touching the Trigger, with the
wire and tip clearly out of the way of any grounded
objects.
Then, turn the Power Switch ON.
MIG 180
WIRE FEED WELDER
ITEM 68886
WIRE FEED SPEED
240V~
I
O
MIG 180
WIRE FEED WELDER
ITEM 68886
WIRE FEED SPEED
240V~
I
O
HOLD
TORCH
CLEAR
SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP