Lincoln Electric POWER MIG 180 DUAL User manual

OPERATOR’S MA UAL
MA UAL DE OPERACIÓ
MA UEL DE L’OPÉRATEUR
Operator’s Ma ual
POWER MIG ®180 DUAL
Register your machi e:
www.lin olnele tri . om/register
Authorized Service a d Distributor Locator:
www.lin olnele tri . om/lo ator
IMT10106-A | Issue D ate Aug-16
© Lin oln Global, In . All Rights Reserved.
For use with ma hines having Code Numbers:
11828, 12631
Save for future refere ce
Date Pur hased
Code: (ex: 10859)
Serial: (ex: U1060512345)

THANK YOU FOR SELECTING
A QUALITY PRODUCT BY
LINCOLN ELECTRIC.
PLEASE EXAMINE CARTON AND EQUIPMENT FOR
DAMAGE IMMEDIATELY
When this equipment is shipped, title passes to the purchaser
upon receipt by the carrier. Consequently, claims for material
damaged in shipment must be made by the purchaser against the
transportation company at the time the shipment is received.
SAFETY DEPENDS ON YOU
Lincoln arc welding and cutting equipment is designed and built
with safety in mind. However, your overall safety can be increased
by proper installation ... and thoughtful operation on your part.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT
WITHOUT READING THIS MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly,
think before you act and be careful.
This statement appears where the information must be followed
exactly to avoid serious personal injury or loss of life.
This statement appears where the information must be followed
to avoid minor personal injury or damage to this equipment.
KEEP YOUR HEAD OUT OF THE FUMES.
DON’T get too close to the arc.
Use corrective lenses if necessary
to stay a reasonable distance
away from the arc.
READ and obey the Safety Data
Sheet (SDS) and the warning label
that appears on all containers of
welding materials.
USE ENOUGH VENTILATION or
exhaust at the arc, or both, to
keep the fumes and gases from
your breathing zone and the general area.
IN A LARGE ROOM OR OUTDOORS, natural ventilation may be
adequate if you keep your head out of the fumes (See below).
USE NATURAL DRAFTS or fans to keep the fumes away
from your face.
If you develop unusual symptoms, see your supervisor.
Perhaps the welding atmosphere and ventilation system
should be checked.
WEAR CORRECT EYE, EAR &
BODY PROTECTION
PROTECT your eyes and face with welding helmet
properly fitted and with proper grade of filter plate
(See ANSI Z49.1).
PROTECT your body from welding spatter and arc
flash with protective clothing including woolen
clothing, flame-proof apron and gloves, leather
leggings, and high boots.
PROTECT others from splatter, flash, and glare
with protective screens or barriers.
IN SOME AREAS, protection from noise may be appropriate.
BE SURE protective equipment is in good condition.
Also, wear safety glasses in work area
AT ALL TIMES.
SPECIAL SITUATIONS
DO NOT WELD OR CUT containers or materials which previously
had been in contact with hazardous substances unless they are
properly cleaned. This is extremely dangerous.
DO NOT WELD OR CUT painted or plated parts unless special
precautions with ventilation have been taken. They can release
highly toxic fumes or gases.
Additional precautionary measures
PROTECT compressed gas cylinders from excessive heat,
mechanical shocks, and arcs; fasten cylinders so they cannot fall.
BE SURE cylinders are never grounded or part of an
electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR
IMMEDIATE USE AND KNOW HOW TO USE IT.
WARNING
CAUTION
Safety 01 of 04 - 5/16/2018

SECTION A:
WARNINGS
CALIFORNIA PROPOSITION 65 WARNINGS
WARNING: Breathing diesel engine exhaust
exposes you to chemicals known to the State
of California to cause cancer and birth defects,
or other reproductive harm.
• Always start and operate the engine in a
well-ventilated area.
• If in an exposed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system.
• Do not idle the engine except as necessary.
For more information go to
www.P65 warnings.ca.gov/diesel
WARNING: This product, when used for welding or
cutting, produces fumes or gases which contain
chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California
Health & Safety Code § 25249.5 et seq.)
WARNING: Cancer and Reproductive Harm
www.P65warnings.ca.gov
ARC WELDING CAN BE HAZARDOUS. PROTECT
YOURSELF AND OTHERS FROM POSSIBLE SERIOUS
INJURY OR DEATH. KEEP CHILDREN AWAY.
PACEMAKER WEARERS SHOULD CONSULT WITH
THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For
additional safety information, it is strongly recommended
that you purchase a copy of “Safety in Welding & Cutting -
ANSI Standard Z49.1” from the American Welding Society,
P.O. Box 351040, Miami, Florida 33135 or CSA Standard
W117.2-1974. A Free copy of “Arc Welding Safety” booklet
E205 is available from the Lincoln Electric Company,
22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION,
MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE POWERED
EQUIPMENT.
1.a. Turn the engine off before troubleshooting
and maintenance work unless the
maintenance work requires it to be running.
1.b. Operate engines in open, well-ventilated areas or vent the engine
exhaust fumes outdoors.
1.c. Do not add the fuel near an open flame welding
arc or when the engine is running. Stop the
engine and allow it to cool before refueling to
prevent spilled fuel from vaporizing on contact
with hot engine parts and igniting. Do not spill fuel when filling
tank. If fuel is spilled, wipe it up and do not start engine until
fumes have been eliminated.
1.d. Keep all equipment safety guards, covers
and devices in position and in good repair.
Keep hands, hair, clothing and tools away
from V-belts, gears, fans and all other
moving parts when starting, operating or
repairing equipment.
1.e. In some cases it may be necessary to remove safety guards to
perform required maintenance. Remove guards only when
necessary and replace them when the maintenance requiring
their removal is complete. Always use the greatest care when
working near moving parts.
1.f. Do not put your hands near the engine fan. Do not attempt to
override the governor or idler by pushing on the throttle control
rods while the engine is running.
1.g. To prevent accidentally starting gasoline engines while turning
the engine or welding generator during maintenance work,
disconnect the spark plug wires, distributor cap or magneto wire
as appropriate.
1.h. To avoid scalding, do not remove the radiator
pressure cap when the engine is hot.
ELECTRIC AND
MAGNETIC FIELDS MAY
BE DANGEROUS
2.a. Electric current flowing through any conductor
causes localized Electric and Magnetic Fields (EMF).
Welding current creates EMF fields around welding cables
and welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health effects
which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and work
cables. If the electrode cable is on your right side, the
work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as pos-
sible to the area being welded.
2.d.5. Do not work next to welding power source.
SAFETY
Safety 02 of 04 - 5/16/2018

ELECTRIC SHOCK
CAN KILL.
3.a. The electrode and work (or ground) circuits are
electrically “hot” when the welder is on. Do
not touch these “hot” parts with your bare skin or wet clothing.
Wear dry, hole-free gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full area
of physical contact with work and ground.
In addition to the normal safety precautions, if
welding must be performed under electrically
hazardous conditions (in damp locations or while
wearing wet clothing; on metal structures such as
floors, gratings or scaffolds; when in cramped
positions such as sitting, kneeling or lying, if there
is a high risk of unavoidable or accidental contact
with the workpiece or ground) use the following
equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic welding
gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection should
be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical (earth)
ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of electrode
holders connected to two welders because voltage
between the
two can be the total of the open circuit voltage of both
welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
ARC RAYS CAN BURN.
4.a. Use a shield with the proper filter and cover plates to protect your
eyes from sparks and the rays of the arc when welding or
observing open arc welding. Headshield and filter lens should
conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant material
to protect your skin and that of your helpers from the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
CAN BE DANGEROUS.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases. When welding, keep your head out of the fume.
Use enough ventilation and/or exhaust at the arc to keep fumes
and gases away from the breathing zone. When welding
hardfacing (see instructions on container or SDS)
or on lead or cadmium plated steel and other
metals or coatings which produce highly toxic
fumes, keep exposure as low as possible and
within applicable OSHA PEL and ACGIH TLV limits
using local exhaust or mechanical ventilation
unless exposure assessments indicate otherwise.
In confined spaces or in some circumstances,
outdoors, a respirator may also be required.
Additional precautions are also required when
welding
on galvanized steel.
5. b. The operation of welding fume control equipment is affected by
various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker exposure
level should be checked upon installation and periodically
thereafter to be certain it is within applicable OSHA PEL and
ACGIH TLV limits.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations. The
heat and rays of the arc can react with solvent vapors to form
phosgene, a highly toxic gas, and other irritating products.
5.d. Shielding gases used for arc welding can displace air and
cause
injury or death. Always use enough ventilation, especially in
confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
Safety Data Sheet (SDS) and follow your employer’s safety
practices. SDS forms are available from your welding
distributor or from the manufacturer.
5.f. Also see item 1.b.
SAFETY
Safety 03 of 04 - 5/16/2018

WELDING AND CUTTING
SPARKS CAN CAUSE
FIRE OR EXPLOSION.
6.a. Remove fire hazards from the welding area. If
this is not possible, cover them to prevent the welding sparks
from starting a fire. Remember that welding sparks and hot
materials from welding can easily go through small cracks and
openings to adjacent areas. Avoid welding near hydraulic lines.
Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site, special
precautions should be used to prevent hazardous situations.
Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1)
and the operating information for the equipment being used.
6.c. When not welding, make certain no part of the electrode circuit is
touching the work or ground. Accidental contact can cause
overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances inside.
They can cause an explosion even though they have been
“cleaned”. For information, purchase “Recommended Safe
Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous Substances”,
AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil free
protective garments such as leather gloves, heavy shirt, cuffless
trousers, high shoes and a cap over your hair. Wear ear plugs
when welding out of position or in confined places. Always wear
safety glasses with side shields when in a welding area.
6.g. Connect the work cable to the work as close to the welding area
as practical. Work cables connected to the building framework or
other locations away from the welding area increase the
possibility of the welding current passing through lifting chains,
crane cables or other alternate circuits. This can create fire
hazards or overheat lifting chains or cables until they fail.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B “Standard for Fire Prevention During
Welding, Cutting and Other Hot Work”, available from NFPA, 1
Batterymarch Park, PO box 9101, Quincy, MA 022690-9101.
6.j. Do not use a welding power source for pipe thawing.
CYLINDER MAY EXPLODE IF
DAMAGED.
7.a. Use only compressed gas cylinders containing
the correct shielding gas for the process used
and properly operating regulators designed for
the gas and pressure used. All hoses, fittings,
etc. should be suitable for the application and
maintained in good condition.
7.b. Always keep cylinders in an upright position securely chained to
an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected
to physical damage.
• A safe distance from arc welding or cutting operations
and any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tight
except when the cylinder is in use or connected for use.
7.g. Read and follow the instructions on compressed gas cylinders,
associated equipment, and CGA publication P-l, “Precautions for
Safe Handling of Compressed Gases in Cylinders,” available from
the Compressed Gas Association, 14501 George Carter Way
Chantilly, VA 20151.
FOR ELECTRICALLY
POWERED EQUIPMENT.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National Electrical
Code, all local codes and the manufacturer’s recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Refer to
http://www.lincolnelectric.com/safety
for additional safety information.
SAFETY
Safety 04 of 04 - 5/16/2018

NOTES

OPERATOR’S MA UAL
3
TABLE OF CONTENTS
Installation ..................................................................................................................................................Section A
Technical Specifications........................................................................................................................................A-1
Safety Precautions................................................................................................................................................A-1
Location............................................................................................................................................................A-1
Stacking.......................................................................................................................................................A-1
Tilting...........................................................................................................................................................A-1
Identify and Locate Components ...........................................................................................................................A-2
Operation ..................................................................................................................................................Section B
Safety and Product Description..............................................................................................................................B-1
Controls and Settings.....................................................................................................................................B-2, B-3
Drive Roll and Wire uides Table...........................................................................................................................B-4
Setting Up and Making a Flux-Cored Weld .............................................................................................B-5 thru B-7
Setting Up and Making a MI Weld and Install Shielding as.................................................................B-8 thru B-11
Setting Up and Making a Aluminum Weld ............................................................................................................B-12
Accessories..................................................................................................................................................Section C
Optional Accessories.............................................................................................................................................C-1
Utility Carts....................................................................................................................................................C-2, C-3
Maintenance..................................................................................................................................................Section D
Safety Precautions................................................................................................................................................D-1
Wire Feed Compartment, Fan Motor, Wire Reel Maintenance ................................................................................D-1
un And Cable Maintenance .................................................................................................................................D-1
Overload Protection...............................................................................................................................................D-2
Component Replacement Procedures....................................................................................................................D-2
Troubleshooting.............................................................................................................................................Section E
Safety Precautions.................................................................................................................................................E-1
How to Use Troubleshooting uide........................................................................................................................E-1
Troubleshooting uide.............................................................................................................................E-2 thru E-3
Wiring Diagram and Dimension Print .......................................................................................................... Section F
Parts List .........................................................................................................................parts.lincolnelectric.com
Content/details may be changed or updated without notice. For most current Instruction Manuals,
go to Parts.lincolnelectric.com.

A-1
INSTALLATIONPOWER MIG®180 DUAL


1 If connected to a c rcu t protected by fuses use T me Delay Fuse
marked “D”.
2 Requ rements for max mum output: In order to ut l ze the max mum output
capab l ty of the mach ne, a branch c rcu t capable of 30 amps @ 120
volts, 60Hz s requ red.
Read this entire installation section before you
start installation.
INSTALLATION
ELECTRIC SHOCK CAN KILL.
• Only qualified personnel should perform
this installation.
• Only personnel that have read and
understood the POWER IG
®
180 DUAL
Operator’s anual should install and
operate this equipment.
• achine must be plugged into a receptacle which is
grounded per any national, local or other applicable
electrical codes.
• The POWER IG
®
180 DUAL power switch is to be in the
OFF (“O”) position when installing work cable and gun and
when connecting power cord to input power.

Locate the POWER MI ®180 Dual in a dry location where there is
free circulation of clean air into the louvers in the back and out the
front of the unit. A location that minimizes the amount of smoke
and dirt drawn into the rear louvers reduces the chance of dirt
accumulation that can block air passages and cause overheating.

POWER MI ®180 DUAL cannot be stacked.

Each machine must be placed on a secure, level surface, directly
or on recommended cart. The machine may topple over if this
procedure is not followed.
WAR I G
INPUT – SINGLE PHASE ONLY
Standard Voltage/Frequency Input Current
230 V 60 Hz
208 V 60 Hz
120 V 60 Hz
20 Amps @ rated output
RATED OUTPUT
Voltage/Duty Cycle Current Voltage at Rated Amperes
230 V 30%
208 V 30%
120 V 20%
130 Amps
130 Amps
90 Amps
20
17.6
19.5
OUTPUT
Welding Current Range Open Circuit
Voltage Wire Speed Range
(208 V / 230 V) 30-180 Amps
(120 V) 30-140 Amps
34 V
33 V
50 - 500 in/min.
(1.3 - 12.7 m/min.)
PHYSICAL DI ENSIONS
Heig t Widt Dept Weig t
14.08 in.
(357.6 mm)
10.37 in.
(263.4 mm)
18.78 in.
(477.6 mm)
66 lbs.
(30 kg.)
RECO ENDED INPUT CABLE AND FUSE SIZES
Input Voltage /
Frequence
Fuse or
Breaker
Size1
Input
Amps
(Power Cord) Lincoln
Electric Part Number
230 V / 208 V 60 Hz
120 V 60 Hz
40 Amp
20 Amp2
20
20
M22590
M22589

A-2
INSTALLATIONPOWER MIG®180 DUAL

1. Wire Feeder Welder.
2. Work Cable & Clamp.
3. agnum PRO 100L Welding Gun.
4. 3 (qty) .035(0.9mm) Contact Tips (1 installed on the
welding gun) & 3 (qty) .025(0.6mm) Contact Tips.
5. Spool of .035(0.9mm) diameter NR-211 P Innershield
Flux-cored Wire.
6. Spool of .025(0.6mm) diameter L-56 IG Wire.
7. .025-.030(0.6-0.9mm) Smooth Drive Roll.
8. .035(0.9mm) Smooth Drive Roll.
9. .030 -.045(0.8-1.1mm) Knurled Drive Roll
(Installed on achine).
10. .025” -.035” (0.6 - 0.9mm) Inner Wire guide.
11. .035” -.045” (0.9 - 1.1mm) Inner Wire Guide.
(Installed on achine).
12. Outer Wire Guide (Installed on achine).
13. Black Flux-cored Gasless Gun Nozzle.
14. Copper IG Gas Gun Nozzle.
(Installed on welding gun).
15. Regulator
16. Gas Hose
17. 230V Input Cord
18. 120V Input Cord
19. Learn to Weld (LTW1 anual)
20. How to Weld DVD
21. 2” Spindle Adapter (For 8” Reel of wire)
22. Accessory Bag
OPERATOR’S MA UAL
Welding Guide
LEARNING TO WELD
L
TW1 31/70etaDeussI|
© Lincoln Global, Inc. All Rights Reserved.
Welding Safety
Interactive Web Guide
for mobile devices
OUTER WIRE GUIDE
INNER WIRE GUIDE
.025-.035 (.6-.9mm)
INNER WIRE GUIDE
.035-.045 (.9-1.1mm)
1
5
7 8 9 10 11 12
13
14
15
19
18
17
21
20
22
16
6
2
3
4
.035 .035 .025 .025 .025

B-1
OPERATION
OPERATION
SAFETY PRECAUTIONS
Read entire operation section before operating
the WIRE FEEDER WELDER.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
•Insulate yourself from work and ground.
• Always wear dry insulating gloves.
FU ES AND GASES can be
dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove
fumes from breathing zone.
WELDING SPARKS can cause fire or
explosion.
• Keep flammable material away.
• Do not weld on closed containers.
ARC RAYS can burn eyes and skin.
• Wear eye, ear and body protection.
Observe all safety information
throughout this manual.

This small portable wire feed welder is capable of MI welding on
steel, stainless steel, and aluminum. The wire feed welder is also
capable of flux-cored welding on mild steel.
MI welding stands for Metal Inert as welding and requires a
shielding gas to protect the weld until it cools. Appropriate
shielding gas based on the type of material you are welding can
be purchased separately from your local welding gas distributor.
MI welding is ideal for welding on thinner and clean materials
when a very clean excellent cosmetic looking weld is required. An
example would be automotive body panels.
Self Shielding Flux-cored Welding does not require a separate
shielding gas to protect the weld since the welding wire has
special additives known as flux to protect the weld until it cools.
Flux-cored welding is ideal for medium to thicker material and if
welding on painted or rusty steel. Flux-cored welding is also ideal
in outdoor applications where windy conditions might blow the
MI shielding gas away from the weld. Flux-cored welding
produces a good looking weld but does not produce an excellent
weld appearance as MI welding does.
Your machine includes the necessary items to weld with either the
MI or the flux-cored welding process on steel. To weld on
stainless steel optional stainless steel welding wire can be
purchased separately. This machine can weld aluminum using
.035”(0.9mm) diameter 4043 aluminum welding wire. Since
aluminum welding wire is soft an optional aluminum spool gun is
recommended for best results. A welding Procedure Decal is
located inside machine door to help provide suggested settings for
welding.

GMAW (MIG)
• as Metal Arc Welding
FCAW (I ERSHIELD OR OUTERSHIELD)
• Flux Core Arc Welding
WAR I G
POWER MIG®180 DUAL

B-2
OPERATION

This machine has the following controls:
(See Figure B.1)
1. POWER SWITCH – Turns power on and off to the machine.
2. ARC VOLTAGE CO TROL – This knob sets the output voltage
of the machine. Along with wire feed speed (WFS) this
control sets a weld procedure. Refer to the procedure decal
on the inside wire drive compartment door to set a correct
welding procedure based on type of material and thickness
being welded.
3. WIRE FEED SPEED CO TROL (WFS) – The knob sets the
speed that the machine feeds wire. Along with arc voltage
this control sets a weld procedure. Refer to the procedure
decal on the inside wire drive compartment door to set a
correct welding procedure based on type of material and
thickness being welded.
FIGURE B.1
(See Figure B.2)
4. GU TRIGGER – Pressing the trigger activates the wire drive
to feed wire and energizes the output of the machine. Press
the trigger to weld and release the trigger to stop welding.
5. WELDI G GU – Delivers wire and welding current to the
weld.
a. un Liner – wire travels through the liner from the wire drive.
The gun liner will feed .025” to .035” (0.6mm to 0.9mm)
wire. The 180A machine can weld with .045”(1.1mm) wire if
an optional .045”(1.1mm) liner is installed in the gun.
b. Contact Tip – provides electrical contact to the wire.
c. Nozzle – When flux-cored welding the black nozzle protects
the mounting threads on the gun. When MI welding the
copper nozzle funnels the shielding gas to the weld.
6. WORK CLAMP & CABLE – Clamps to the work piece being
welded and completes the electrical welding circuit.
7. GU TRIGGER CO ECTOR RECEPTACLE – Plug the 4 pin
gun trigger connector into this receptacle.
FIGURE B.2
2
1
3
5C 5B
5A 4
5
7
6
POWER MIG®180 DUAL
OPERATOR’S MA UAL

B-3
OPERATION
(See Figure B.3)
8. WELDI G GU CO ECTOR BUSHI G & THUMBSCREW –
Provides electrical power to the welding gun. The
thumbscrew holds the welding gun into the connector block.
(Front of Machine, Side Door and Wire Drive Cover have been
removed for clarity of Items 8 and 9).
9. OUTPUT TERMI ALS –These connections allow for changing
the welding polarity of the machine depending on whether
you are MI welding or flux-cored welding.
FIGURE B.3
(See Figure B.4)
10. WIRE SPOOL SPI DLE A D BRAKE – Holds a 4 inch
diameter spool. Use the 2 inch I.D. spindle adapter included
with the machine to use 8 inch diameter spools. The Wing
Nut sets the brake friction to prevent the spool from over
rotating when the trigger is released.
FIGURE B.4
(See Figure B.5)
11. WIRE DRIVE & COMPO E TS – Feeds wire from the wire
spool through the drive and through the welding gun to the
weld.
a. Top and Bottom Drive Roll – Drives the wire through the
drive system. The drive roll has a groove to match the
specific wire type and diameter. Refer to Table B.1 for
available drive rolls.
b. Inner & Outer Wire uide – uides the wire between the Top
and Bottom Drive Roll and through the wire drive. The inner
guide has a groove to match a particular wire diameter.
Refer to Table B.1 for available wire guides.
c. Drive Roll Tension Thumbscrew – Turning clockwise
increases the force on the drive rolls and turning counter-
clockwise decreases the force.
12. SPOOL GU SWITCH - Pre-Installed switch permits either
spool gun welding with the Magnum 100S or standard
welding with the Magnum PRO 100L.
FIGURE B.5
8
9
2” Spindle Adaptor
(For 8” Reel of Wire)
4” Reel of Wire
12
INNER WIRE GUIDE REMOVED
LOWER DRIVE ROLL REMOVED
OUTER WIRE GUIDE REMOVED
TOP DRIVE ROLL
PRESSURE ARM
TENSION
ADJUSTOR DOWN
POWER MIG®180 DUAL

B-4
OPERATION
TABLE B.1
(See Figure B.6 for the following Items.)
13. CIRCUIT BREAKER – If the rated input current of the machine
is exceeded this circuit breaker will trip. Press to reset.
14. GAS I LET – Shielding gas connects to this inlet.
15. POWER CORD CO ECTIO - Ensure power cord is
disconnected from input voltage supply prior to connecting or
removing the cord from the machine. Connect the circular
connector present on either input cord (120V or 230V) to the
receptacle on the back of the machine. The power cord
connector is secured to the receptacle by rotating the
connector’s coupling ring clockwise, until the coupling ring
latches on to the receptacle. Use only the appropriate (120V
or 230V) power cords supplied by the Lincoln Electric
Company.
FIGURE B.6
13 14 15
POWER MIG®180 DUAL
OPERATOR’S MA UAL
DRIVE ROLL AND WIRE GUIDES
Wire Diameter & Type Drive Roll Drive Roll Part
Number Inner Wire Guide Inner Wire Guide Part Number
.025”(0.6mm) MI wire .025”/.030” (0.6mm/0.8mm)
Smooth Drive Roll KP2529-1
.025”-.035”
(0.6mm-0.9mm)
Steel Wire uide
KP2531-1
.030”(0.8mm) MI wire
.035”(0.9mm) MI wire .035”(0.9mm)
Smooth Drive Roll KP2529-2
.030”(0.8mm) flux-cored
.035”(0.9mm) flux-cored
.030”/.045” (0.8mm/1.1mm)
Knurled Drive Roll KP2529-3
.045”(1.1mm) flux-cored .030”/.045” (0.8mm/1.1mm)
Knurled Drive Roll KP2529-3 .045” (1.1mm) Steel Wire uide KP2531-2

B-5
OPERATION

A. Items needed for flux cored welding
1. 035”(0.9mm) Contact Tip
2.Black Flux Cored gun nozzle
3. Knurled Drive Roll
4. .025”-.035”(0.6mm-0.9mm) wire guide
5. .035”(0.9mm) NR-211MP Flux-Cored Wire
6. Welding un
7. Work Cable & Clamp

(See Figure B.7)
1. Open the case side door
2. Slide the connector end of the gun and cable through the hole
in the machine front and into the gun connector bushing on
the wire drive.
3. Make sure the gun connector end is seated fully into the wire
drive and tighten the thumbscrew to secure the gun
connector.
4. Plug the gun trigger lead connector into the 4 pin gun trigger
receptacle on the machine front.
5. Wire Drive Polarity. Flux cored welding requires negative (-)
polarity. Connect the short power cable from the wire drive to
the negative (-) output terminal and tighten the Wing Nut.
6. Work Lead Connection. Slide the lugged end of the work cable
through the hole in the machine front and place on the
positive (+) output terminal and tighten Wing Nut.
FIGURE B.7
GUNANDCABLE
WORKCLAMP
(4PIN)
LEADCONNECTOR
SLIDE
CONNECTOR
ENDHERE
CASE SIDE DOOR
TERMINALEND
(FITS ONSTUDINSIDE
SEE FIGURE BELOW)
OPEN LATCH DOOR
LOCATE COMPONENTS
TO CONNECT
TO THE
FRONTOF MACHINE
5
34
2
7
6
1
NR-211-MP
.035
(4PIN)
BUSHING
WORKCLAMP
TRIGGERRECEPTACLE
PLUGGEDIN
CONNECTOR
ENDATTACH
WORK LEAD CONNECTION
POSITIVE "+" OUTPUT TERMINAL
THUMB SCREW TO
TIGHTEN CONNECTOR
SHORT POWER
CABLE NEGATIVE “–”
OUTPUT TERMINAL
POWER MIG®180 DUAL

B-6
OPERATION

(See Figure B.8)
1. Locate the 4"(102mm) diameter spool of .035”(0.9mm)
NR-211MP flux-cored wire and place onto wire spool spindle.
Orient the spool so that the wire feeds off the top of the spool.
2. Secure spool in place by tightening the wing nut against the
against the spacer that holds the wire spool on the spindle.
3. Open the top drive roll pressure arm by rotating the tension
adjustor arm down and pivoting the drive roll pressure arm
up.
4. Remove the outer wire guide.
4a. Slide gun out of drive slightly.
5. Remove the lower drive roll and inner wire guide.
6. Install the .025”-.035”(0.6mm-0.9mm) inner wire guide.
7. Install the .030”/.045”(0.8mm/1.1mm) knurled lower drive
roll.
8. Carefully unwind and straighten the first six inches of welding
wire from the spool. Do not let the end of the wire go to
prevent the wire from unspooling.
FIGURE B.8
(See Figure B.9)
9. Feed the wire through the wire drive inlet along the inner wire
guide groove and into the wire drive outlet on the gun side.
10. Close the top drive roll pressure arm and secure by pivoting
the tension adjustor back to the up position.
11. Re-install the outer wire guide.
FIGURE B.9
TENSION ADJUSTOR
LOCKED IN POSITION
LOWER DRIVE ROLL
BE SURE WIRE
IS IN GROOVE
WIRE SPOOL
.035" (0.9mm)
SLIDE WIRE
INTO GUN
CONNECTOR
SIDE
TOP DRIVE ROLL
PRESSED AGAINST
LOWER DRIVE ROLL
DIRECTION
OF WIRE
NR-211-MP
WIRE SPOOL
.035" (0.9mm)
NR-211-MP
INNER WIRE GUIDE REMOVED
LOWER DRIVE ROLL REMOVED
OUTER WIRE GUIDE REMOVED
TENSION ADJUSTOR DOWN
TOP DRIVE ROLL PRESSURE ARM
POWER MIG®180 DUAL
OPERATOR’S MA UAL

B-7
OPERATION
(See Figure B.10)
12. Remove the nozzle from the gun and contact tip and
straighten the gun out flat.
FIGURE B.10
(See Figure B.11)
13. Turn the machine power to on and depress the gun trigger to
feed the wire through the gun liner until the wire comes out
of the threaded end of the gun several inches.
14. When trigger is released spool of wire should not unwind.
Adjust wire spool brake accordingly.
OVING PARTS AND ELECTRICAL
CONTACT CAN CAUSE INJURY OR
BE FATAL.
• When the gun trigger is depressed drive
rolls, spool of wire and electrode are
ELECTRICALLY LIVE (HOT).
• Keep away from moving parts and pinch
points.
• Keep all Doors, Covers, panels and
guards securely in place.
DO NOT RE OVE OR CONCEAL
WARNING LABELS.
------------------------------------------------------------------------
FIGURE B.11
15. Install the .035”(0.9mm) contact tip
16. Install the black flux cored welding nozzle to the gun.
17. Trim the wire stickout to 3/8”(9.5mm) from the contact tip.
(See Figure B.12)
FIGURE B.12
18. Close the case side door. The machine is now ready to weld.
19. Read "Learn to Weld" (LTW1) that is included with the
machine or watch the "How to Weld" DVD included with the
machine.
20. Based on the thickness of the material you are going to weld
and the type and diameter of the welding wire set the
voltage and the wire feed speed per the procedure decal
attached to the inside of the wire drive compartment door.
WAR I G
NR-211-MP
REMOVED NOZZLE
REMOVED CONTACT TIP
LAY CABLE AND GUN
STRAIGHTEN IN
THIS POSITION
NR-211-MP
DEPRESS TRIGGER
TO ACTIVATE WIRE,
WHICH FEEDS THE WIRE
THRU THE LINER
FEED WIRE
APPROXIMATELY 4.00”
FROM GUN TUBE END
PLUG IN POWER
INPUT CORD
ON/OFF
SWITCH
INSTALL .035CONTACTTIP
INSTALL BLACKFLUX-COREDNOZZLE
TRIM WIRE
STICKOUT
3/8"(9.5mm)
fromtheContact Tip
POWER MIG®180 DUAL

OPERATOR’S MA UAL
B-8
OPERATION

A. Items needed for IG welding
1. 025”(0.6mm) Contact Tip
2. Copper gun nozzle
3. .025”(0.6mm) Drive Roll
4. 025”-035”(0.6mm-0.9mm) Inner wire guide
5. .025”(0.6mm) SuperArc L-56 Solid MI Wire
6. Welding un
7. Work Cable & Clamp
8. as Line
9. as Regulator
Bottle of 75/25 Ar/CO2shielding gas (or 100% CO2shielding
gas) (note this requires a CO2regulator adapter which is sold
separately.
5
34
2
7
6
1
8
9
75/25
FEMALE
END
MIXES
MALE
END
.025
L-56 MIG WIRE
CO
100%
2
(REQUIRES ADAPTER
SOLD SEPARATELY)
POWER MIG®180 DUAL

B-9
OPERATION
B. Install shielding gas
MI welding requires an appropriate bottle of shielding gas. For
mild steel either a cylinder bottle of Ar/CO2or 100% CO2can be
used. Refer to the following instructions to properly connect
shielding gas to the machine.
CYLINDER may explode if dam-
aged. Keep cylinder upright and
chained to support
• Keep cylinder away from areas where it
may be damaged.
• Never lift welder with cylinder attached.
• Never allow welding electrode to touch cylinder.
• Keep cylinder away from welding or other live electrical
circuits.
BUILDUP OF SHIELDING GAS
may harm health or kill.
Shut off shielding gas supply when not in
use.
1. Secure the cylinder to a wall or other stationary support to
prevent the cylinder from falling over. Insulate the cylinder
from the work circuit and earth ground. Refer to Figure B.13.
2. With the cylinder securely installed, remove the cylinder cap.
Stand to one side away from the outlet and open the cylinder
valve very slightly for an instant. This blows away any dust or
dirt which may have accumulated in the valve outlet.
BE SURE TO KEEP YOUR FACE AWAY
FRO THE VALVE OUTLET WHEN
“CRACKING” THE VALVE.
Never stand directly in front of or behind the flow regulator
when opening the cylinder valve. Always stand to one side.
FIGURE B.13
3. Attach the flow regulator to the cylinder valve and tighten the
union nut securely with a wrench.
OTE: If connecting to 100% CO2cylinder, a CO2regulator
adapter is required. Purchase separately S19298 CO2adapter
be sure to install plastic washer included in the fitting on the
bottle side.(See Figure B.13 )
4. Refer to Figure B.13. Attach one end of inlet gas hose to the
outlet fitting of the flow regulator and tighten the union nut
securely with a wrench. Connect the other end to the machine
Solenoid Inlet Fitting (5/8-18 female threads — for C A —
032 fitting). Make certain the gas hose is not kinked or
twisted.
Shielding Gas
1. For CO2, open the cylinder very slowly. For argon-mixed gas,
open cylinder valve slowly a fraction of a turn. When the
cylinder pressure gauge pointer stops moving, open the valve
fully.
2. Set gas flow rate for 30 to 40 cubic feet per hour (14 to 18
I/min.) under normal conditions, increase to as high as 40 to
50 CFH (18 to 23.5 I/min.) for out of position welding.
3. Keep the cylinder valve closed, except when using the
machine.
WAR I G
WAR I G
WAR I G
75/25
FEMALE END
MALE END
CO
S19298
REGULATOR
ADAPTER
PLASTIC
WASHER
MIXES
100%
2
POWER MIG®180 DUAL

OPERATOR’S MA UAL
B-10
OPERATION
C. Connect leads and cables on the machine
(See Figure B.14)
1. Open the case side door.
2. Slide the connector end of the gun and cable through the hole
of the machine front and into the gun connector bushing on
the wire drive.
3. Make sure the gun connector end is seated fully into the wire
drive and tighten the thumbscrew to secure the gun.
4. Plug the gun trigger lead connector into the 4 pin gun trigger
receptacle on the machine front.
5. Wire Drive Polarity. MI welding requires Positive (+) polarity.
Connect the short power cable from the wire drive to the
positive (+) output terminal and tighten the thumbscrew.
6. Work Lead Connection. Slide the lugged end of the work
cable through the hole in the machine front and place on the
negative (-) output terminal and tighten thumbscrew.
FIGURE B.14
D. Load Wire Spool
(See Figure B.15)
1. Locate the 4"(102mm) diameter spool of .025”(0.6mm) L-56
solid MI wire and place onto wire spool spindle. Orient the
spool so that the wire feeds off the top of the spool.
2. Secure spool in place by tightening the wing nut against the
against the spacer that holds the wire spool on the spindle.
3. Open the top drive roll pressure arm by rotating the tension
adjustor arm down and pivoting the idle roll pressure arm up.
4. Remove the outer wire guide.
4a. Slide gun out of drive slightly.
5. Remove the lower drive roll and inner wire guide.
6. Install the .025”-.035”(0.6mm-0.9mm) inner wire guide.
7. Install the .025”(0.6mm) smooth grooved lower drive roll.
8. Carefully unwind and straighten the first six inches of welding
wire from the spool. Do not let the end of the wire go to
prevent the wire from unspooling.
FIGURE B.15
(See Figure B.16)
9. Feed the wire through the wire drive inlet along the inner wire
guide groove and into the wire drive outlet on the gun side.
10. Close the top drive roll pressure arm and secure by pivoting
the tension adjustor back to the up position.
11. Re-install the outer wire guide.
GUNANDCABLE
WORKCLAMP
(4PIN)
LEADCONNECTOR
SLIDE
CONNECTOR
ENDHERE
CASE SIDE DOOR
TERMINALEND
(FITS ONSTUDINSIDE
SEE FIGURE BELOW)
OPEN LATCH DOOR
LOCATE COMPONENTS
TO CONNECT
TO THE
FRONTOF MACHINE
(4PIN)
BUSHING
WORKCLAMP
TRIGGERRECEPTACLE
PLUGGEDIN
CONNECTOR
ENDATTACH
SHORT POWER CONNECTION
POSITIVE "+" OUTPUT TERMINAL
THUMB SCREW TO
TIGHTEN CONNECTOR
WORK LEAD
CABLE NEGATIVE “–”
OUTPUT TERMINAL
L-56 SOLID WIRE
INNER WIRE GUIDE REMOVED
LOWER DRIVE ROLL REMOVED
OUTER WIRE GUIDE REMOVED
TENSION ADJUSTOR DOWN
TOP DRIVE ROLL PRESSURE ARM
WIRE SPOOL
.025" (0.6mm)
POWER MIG®180 DUAL

B-11
OPERATION
FIGURE B.16
(See Figure B.17)
12. Remove the nozzle from the gun and contact tip and
straighten the gun out flat.
FIGURE B.17
OVING PARTS AND ELECTRICAL
CONTACT CAN CAUSE INJURY OR
BE FATAL.
• When the gun trigger is depressed drive
rolls, spool of wire and electrode are
ELECTRICALLY LIVE (HOT).
• Keep away from moving parts and pinch
points.
• Keep all Doors, Covers, panels and
guards securely in place.
DO NOT RE OVE OR CONCEAL
WARNING LABELS.
------------------------------------------------------------------------
13. Turn the machine power to on and depress the gun trigger to
feed the wire through the gun liner until the wire comes out of
the threaded end of the gun several inches. (See Figure B.18)
14. When trigger is released spool of wire should not unwind.
Adjust wire spool brake accordingly.
FIGURE B.18
15. Install the .025”(0.6mm) contact tip.
16. Install the Copper gas MI welding nozzle to the gun.
TENSION ADJUSTOR
LOCKED IN POSITION
LOWER DRIVE ROLL
BE SURE WIRE
IS IN GROOVE
SLIDE WIRE
INTO GUN
CONNECTOR
SIDE
TOP DRIVE ROLL
PRESSED AGAINST
LOWER DRIVE ROLL
DIRECTION
OF WIRE
L-56 SOLID WIRE
REMOVED NOZZLE
REMOVED CONTACT TIP
LAY CABLE AND GUN
STRAIGHTEN IN
THIS POSITION
L-56 SOLID WIRE
DEPRESS TRIGGER
TO ACTIVATE WIRE,
WHICH FEEDS THE WIRE
THRU THE LINER
FEED WIRE
APPROXIMATELY 4.00”
FROM GUN TUBE END
PLUG IN POWER
INPUT CORD
ON/OFF
SWITCH
L-56 SOLID WIRE
WAR I G
POWER MIG®180 DUAL