Lincoln Electric POWER MIG 180 User manual

LINCOLN
ELECTRIC
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] AX: 216.486.1751 WEB SITE: www.lincolnelectric.com
• World's Leader in Welding and Cutting Products •
POWER MIG (140, 180 MODELS)
OPERATOR’S MANUAL
IM890-A
May, 2007
Safety Depends on You
Lincoln arc welding and cu ing
equipmen is designed and buil
wi h safe y in mind. However, your
overall safe y can be increased by
proper ins alla ion ... and hough -
ful opera ion on your par . DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, mos
impor an ly, hink before you ac
and be careful.
or use with machines having Code Numbers: 11254, 11255, 11256, 11257 and
11444
Copyrigh © 2007 Lincoln Global Inc.

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 vaporiz-
ing 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.
i
SAFETY
i
ARC WE DING CAN BE HAZARDOUS. PROTECT YOURSE F AND OTHERS FROM POSSIB E SERIOUS INJURY OR DEATH.
KEEP CHI DREN AWAY. PACEMAKER WEARERS SHOU D CONSU T WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. or 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, lorida 33135 or CSA Standard W117.2-1974. A ree 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 A INSTA ATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ON Y BY QUA IFIED INDIVIDUA S.
WARNING
Mar ʻ95
E ECTRIC AND
MAGNETIC FIE DS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic ields (EM ). Welding
current creates EM fields around welding cables and
welding machines
2.b. EM fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EM 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 EM 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
possible to the area being welded.
2.d.5. Do not work next to welding power source.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
CA IFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause can-
cer, birth defects, and other reproductive harm.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above or Diesel Engines The Above or Gasoline Engines

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.
E ECTRIC 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.
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 with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold imit Values (T V)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may 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 spe-
cific 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 prod-
ucts.
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 manufacturerʼs instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employerʼs safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
AUG 06
ii
SAFETY
ii

FOR E ECTRICA Y
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 manufacturerʼs
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturerʼs recommendations.
CY INDER 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
1235 Jefferson Davis Highway, Arlington, VA 22202.
Jan, 07
WE DING 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”. or information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS 4.1 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 cir-
cuits. 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 N PA 51B “ Standard for ire Prevention
During Welding, Cutting and Other Hot Work”, available
from N PA,1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
iii
SAFETY
iii

PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
antes:
Sûreté Pour Soudage A ʼArc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à lʼélectrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. aire trés attention de bien sʼisoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans lʼeau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode sʼapplicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de nʼimporte quelle partie
du corps.
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi quʼun verre blanc afin de se protéger les yeux du ray-
onnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
lʻarc.
c. Protéger lʼautre personnel travaillant à proximité au
soudage à lʼaide dʼécrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où lʼon pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque dʼincendie.
8. Sʼassurer que la masse est connectée le plus prés possible
de la zone de travail quʼil est pratique de le faire. Si on place
la masse sur la charpente de la construction ou dʼautres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev-
age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR
ES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
lʼélectricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à lʼinterieur de poste, la debranch-
er à lʼinterrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. ʻ93
iv
SAFETY
iv

v
INSTA ATION
POWER MIG (140, 180 MODE S)
v
EN 60974-10

vi
INSTA ATION
POWER MIG (140, 180 MODE S)
vi
EN 60974-10:

viivii
TThhaannkk YYoouufor selecting a QUA ITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
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.
CAUTION
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.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On- ine Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• or faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
• or On-Line Registration: Go to our
WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
“Product Registration”. Please complete the form and submit your registration.
CUSTOMER ASSISTANCE PO ICY
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-
ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-
sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-
mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.

viii
viii TAB E OF CONTENTS
Page
––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
Installation .......................................................................................................Section A
Technical Specifications.................................................................................A-1, A-2
Safety Precautions.................................................................................................A-3
Location...........................................................................................................A-3
Stacking ..........................................................................................................A-3
Tilting...............................................................................................................A-3
Identify and Locate Components...........................................................................A-4
________________________________________________________________________________
Operation .........................................................................................................Section B
Safety and Product Description .............................................................................B-1
Controls and Settings.....................................................................................B-2, B-3
Drive Roll and Wire Guides Table .........................................................................B-4
Setting Up and Making a lux-Cored Weld.............................................B-5 thru B-7
Setting Up and Making a MIG Weld and Install Shielding Gas..............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 eed Compartment, an Motor, Wire Reel Maintenance .............................D-1
Gun And Cable Maintenance ................................................................................D-2
Overload Protection...............................................................................................D-2
Component Replacement Procedures ..................................................................D-3
________________________________________________________________________
Troubleshooting..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide.............................................................................E-2 thru E-4
________________________________________________________________________
Wiring Diagram and Dimension Print............................................................Section F
________________________________________________________________________
Parts ists................................................................................................P-533, P-202-E
________________________________________________________________________

A-1
INSTA ATION
POWER MIG (140, 180 MODE S)
A-1
TECHNICA SPECIFICATIONS 180 Amp units (K2472-1 180T, K2473-1 180C)
INPUT – SING E PHASE ON Y
RATED OUTPUT
OUTPUT
Standard Voltage/Frequency Input Current
230 V 60 Hz 20 Amps @ rated output
208 V 60 Hz 20 Amps @ rated output
Voltage/Duty Cycle Current Voltage at Rated Amperes
230 V 30% 130 Amps 20
208 V 30% 130 Amps 17
Welding Current Range Open Circuit Voltage Wire Speed Range
30-180 Amps 34 V 50 - 500 in/min.
(1.3 - 12.7 m/min.)
Input Voltage/Frequency Fuse or Breaker Size1Input Amps Power Cord
230 V 60 Hz 40 Amp Super Lag 20 50 Amp, 250 V,
Three Prong Plug
(NEMA Type 6-50P)
RECOMMENDED INPUT CAB E AND FUSE SIZES
Height Width Depth Weight
14.0 in 10.15 in 18.6 in 66 Ibs
357 mm 258 mm 472 mm 30 kg
PHYSICA DIMENSIONS
1 If connected to a circuit protected by fuses use Time Delay use marked “D”.
140 Amp units (K2470-1 140T, K2471-1 140C)
INPUT – SING E PHASE ON Y
RATED OUTPUT
OUTPUT
Standard Voltage/Frequency Input Current
120 V / 60 Hz 20 Amps @ rated output
Duty Cycle Current Voltage at Rated Amperes
20% Duty Cycle 90 Amps 19.5
Welding Current Range Open Circuit Voltage Wire Speed Range
30-140 Amps 33 V 50 - 500 in/min.
(1.3 - 12.7 m/min.)
Input Voltage/Frequency Fuse or Breaker Size1,2 Input Amps Power Cord Extension Cord
120 V 60 Hz 20 Amp 20 15 Amp, 125 V, 3 Conductor # 12 AWG
Three Prong Plug (4mm2) or Larger
(NEMA Type 5-15P) up to 50 ft.(15.2m)
RECOMMENDED INPUT CAB E AND FUSE SIZES
Height Width Depth Weight
14.0 in 10.15 in 18.6 in 58 Ibs
357 mm 258 mm 472 mm 26.3 kg
PHYSICA DIMENSIONS
1If connected to a circuit protected by fuses use Time Delay use marked “D”.

2 Requirements For Maximum Output
In order to utilize the maximum output capability of
the machine, a branch circuit capable of 25 amps at
120 volts, 60 Hertz is required.
A-2
INSTA ATION
POWER MIG (140, 180 MODE S)
A-2
TECHNICA SPECIFICATIONS 180 Amp units (K2668-1 180C)
INPUT – SING E PHASE ON Y
RATED OUTPUT
OUTPUT
Standard Voltage/Frequency Input Current
240 V 50 Hz I1 max 20 Amps
I1 eff 10.7 Amps
Voltage/Duty Cycle Current Voltage at Rated Amperes
240 V 25% 130 Amps 20
Welding Current Range Open Circuit Voltage Wire Speed Range
30 - 180 Amps 34 V 50 - 500 in/min.
1.3 - 12.7 ( m/min.)
Input Voltage/Frequency Fuse or Breaker Size1Input Amps Power Cord
240 V 50 Hz 40 Amp Super Lag 20 15 Amp, 240 V,
Three Pin Plug
RECOMMENDED INPUT CAB E AND FUSE SIZES
Height Width Depth Weight
14.0 in 10.15 in 18.6 in 66 Ibs
357 mm 258 mm 472 mm 30 kg
PHYSICA DIMENSIONS
1If connected to a circuit protected by fuses use Time Delay use marked “D”.

A-3
INSTA ATION
POWER MIG (140, 180 MODE S)
A-3
SE ECT SUITAB E OCATION
Locate the welder 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.
STACKING
POWER MIG (140, 180 MODELS) cannot be stacked.
TI TING
Each machine must be placed on a secure, level sur-
face, directly or on recommended cart. The machine
may topple over if this procedure is not followed.
Read entire installation section before starting
installation.
SAFETY PRECAUTIONS
E ECTRIC SHOCK can kill.
• Only qualified personnel should perform
this installation.
• Only personnel that have read and under-
stood the POWER MIG Operating Manual
should install and operate this equipment.
• Machine must be plugged into a receptacle
which is grounded per any national, local
or other applicable electrical codes.
• The POWER MIG power switch is to be in
the OFF (“O”) position when installing
work cable and gun and when connecting
power cord to input power.
WARNING

A-4
INSTA ATION
POWER MIG (140, 180 MODE S)
A-4
INC UDED COMPONENTS
• Wire eeder Welder.
• Work Cable & Clamp.
• Magnum 100L Welding Gun.
• 3 .035” (0.9mm) Contact Tips
(1 installed on the welding gun).
• 3 .025” (0.6mm) Contact Tips.
• Spool of .035” (0.9 mm) diameter NR-211MP
Innershield lux-cored Wire.
• Spool of .025” (0.6 mm) diameter L-56 MIG Wire.
• .025”-.030” (0.6 - 0.8mm) • .035” (0.9mm)
Smooth Drive Roll Smooth Drive Roll
.025
.025 .025
.035
.035
NR-211 MP
WIRE
L-56 MIG
• .030” -.045” (0.8 - 1.1mm) Knurled Drive Roll
(Installed on Machine)
• .025” -.035” (0.6 - 0.9mm) Inner Wire guide
• .035” -.045” (0.9 - 1.1mm) Inner Wire Guide
(Installed on Machine)
• Outer Wire Guide (Installed on Machine)
• Black lux-cored Gasless Gun Nozzle (Installed on
Welding Gun)
• Brass MIG Gas Gun Nozzle
• 2”(51mm) Spindle Adapter ( or 8”(203mm) Reel of
wire)
• Regulator
• Gas Hose
• Learn to Weld (LTW1 Manual)
• DVD
OUTER WIRE GUIDE
INNER WIRE GUIDE
.025-.035 (.6-.9mm)
INNER WIRE GUIDE
.035-.045 (.9-1.1mm)
.030
.045
LTW1
"LEARNTOWELD"
DVD
GAS HOSE
REGULATOR 2" SPINDLE ADAPTER (FOR 8" REEL OF WIRE)
IDENTIFY AND OCATE COMPONENTS

B-1
OPERATION
B-1
POWER MIG (140, 180 MODE S)
COMMON WE DING ABBREVIATIONS
GMAW (MIG)
• Gas Metal Arc Welding
FCAW (Innershield or Outershield)
• lux Core Arc Welding
PRODUCT DESCRIPTION (PRODUCT
CAPABI ITIES)
These small portable wire feed welders are capable of
MIG welding on steel, stainless steel, and aluminum.
They are also capable of flux-cored welding on mild
steel.
MIG welding stands for Metal Inert Gas welding and
requires a separate bottle of 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 dis-
tributor. MIG welding is ideal for welding on thinner
and clean materials when a very clean excellent cos-
metic looking weld is required. An example would be
automotive body panels.
lux-cored Welding does not require separate shield-
ing gas to protect the weld since the welding wire has
special additives known as flux to protect the weld
until it cools. lux-cored welding is ideal for medium
to thicker material and if welding on painted or rusty
steel. lux-cored welding is also ideal in outdoor
applications where windy conditions might blow the
MIG shielding gas away from the weld. lux-cored
welding produces a good looking weld but does not
produce an excellent weld appearance as MIG weld-
ing does.
Your machine includes the necessary items to weld
with either the MIG 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 alu-
minum 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.
Read entire operation section before
operating the POWER MIG.
E ECTRIC 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.
FUMES AND GASES can be
dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to
remove fumes from breathing
zone.
WE DING SPARKS can
cause fire or explosion.
• Keep flammable material away.
• Do not weld on closed contain-
ers.
ARC RAYS can burn eyes
and skin.
• Wear eye, ear and body protec-
tion.
Observe all safety information throughout
this manual.
------------------------------------------------------------
WARNING

B-2
OPERATION
B-2
POWER MIG (140, 180 MODE S)
CONTRO S AND SETTINGS
This machine has the following controls:
See Figure B.1
1. POWER SWITCH – Turns power on and off to the
machine.
2. ARC VO TAGE CONTRO – This knob sets the
output voltage of the machine. Along with wire feed
speed (W S) 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 CONTRO (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.
See Figure B.2
4. GUN TRIGGER – Depress the trigger to activates
the wire drive to feed wire and energizes the output
of the machine. Depress the trigger to weld and
release the trigger to stop welding.
5. WE DING GUN – Delivers wire and welding cur-
rent to the weld.
a. Gun 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 noz-
zle protects the mounting threads on the gun.
When MIG welding the brass nozzle funnels the
shielding gas to the weld.
6. WORK C AMP & CAB E – Clamps to the work
piece being welded and completes the electrical
welding circuit.
7. GUN TRIGGER CONNECTOR RECEPTAC E –
Plug the 4 pin gun trigger connector into this recep-
tacle.
1
3
2
FIGURE B.1
FIGURE B.2
.035"(0.9mm)
NR-211-MP
WIRE SPOOL
4
5a
5b
5
5c
67

B-3
OPERATION
B-3
POWER MIG (140, 180 MODE S)
See igure B.3
8. WE DING GUN CONNECTOR BUSHING &
THUMBSCREW – Provides electrical power to the
welding gun. The thumbscrew holds the welding
gun into the connector block. ( ront of Machine,
Side Door and Wire Drive Cover have been
removed for clarity of Items 8 and 9).
9. OUTPUT TERMINA S –These connections allow
to change the welding polarity of the machine
depending on whether you are MIG welding or flux-
cored welding.
See igure B.4
10. WIRE SPOO SPIND E AND BRAKE – Holds a
4”(102mm) diameter spool. Use the 2”(51mm)
spindle adapter included with the machine to use
8”(203mm) diameter spools. The thumbscrew
sets the brake friction to prevent the spool from
over rotating when the trigger is released.
See igure B.5
11. WIRE DRIVE & COMPONENTS – eeds 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 diam-
eter. Refer to Table B.1 for available drive rolls.
b. Inner & Outer Wire Guide – Guides 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 counterclockwise decreases the
force.
8
9
FIGURE B.3
2"(51mm) SPINDLE ADAPTER (FOR 8"(20mm) REEL OF WIRE)
( 4"(102mm) REEL OF WIRE)
FIGURE B.4
FIGURE B.5
WIRE SPOOL
.035" (0.9mm)
NR-211-MP
INNER WIRE GUIDE REMOVED
LOWER DRIVE ROLL REMOVED
OUTER WIRE GUIDE REMOVED
TOP DRIVE ROLL PRESSURE ARM
TENSION ADJUSTOR DOWN

B-4
OPERATION
B-4
POWER MIG (140, 180 MODE S)
TAB E B.1
DRIVE RO AND WIRE GUIDES
Wire Diameter &
Type
.025”(0.6mm) MIG wire
.030”(0.8mm) MIG wire
.035”(0.9mm) MIG wire
.030”(0.8mm) flux-cored
.035”(0.9mm) flux-cored
.045”(1.1mm) flux-cored
Drive Roll
.025”/.030” (0.6mm/0.8mm)
Smooth Drive Roll
.035”(0.9mm) Smooth Drive Roll
.030”/.045” (0.8mm/1.1mm)
Knurled Drive Roll
.030”/.045” (0.8mm/1.1mm)
Knurled Drive Roll
Inner Wire Guide
.025”-.035”
(0.6mm-0.9mm)
Steel Wire Guide
.045”(1.1mm) Steel
Wire Guide
Inner Wire Guide
Part Number
KP2531-1
KP2531-2
Drive Roll Part
Number
KP2529-1
KP2529-2
KP2529-3
KP2529-3
See igure B.6
12. CIRCUIT BREAKER – If the rated input current of
the machine is exceeded this circuit breaker will
trip. Press to reset.
13. GAS IN ET – Shielding gas connects to this inlet.
12 13
FIGURE B.6

B-5
OPERATION
B-5
POWER MIG (140, 180 MODE S)
A. ITEMS NEEDED FOR F UX CORED
WE DING
1. 035”(0.9mm) Contact Tip
2. .025”-.035”(0.6mm-0.9mm) wire guide
3. Knurled Drive Roll
4. .035”(0.9mm) NR-211MP lux-Cored Wire
5. Black lux Cored gun nozzle
6. Welding Gun
INNER WIRE GUIDE
.025-.035 (.6-.9mm)
.035
.035 NR-211 MP
F
L
U
X
-
C
O
R
E
W
I
R
E
7. Work Cable & Clamp
.030
.045
SETTING UP AND MAKING A F UX-CORED WE D

B-6
OPERATION
B-6
POWER MIG (140, 180 MODE S)
B. CONNECT EADS AND CAB ES ON
THE MACHINE
(See igure 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. lux cored welding requires
negative (-) polarity. Connect the short power
cable from the wire drive to the negative (-) 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 positive (+) output terminal
and tighten thumbscrew.
C. OAD WIRE SPOO
(See igure B.8)
1. Locate the blue labeled 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.
GUN AND CABLE
WORK CLAMP
(4 PIN)
LEAD CONNECTOR
TERMINAL END
(FITS ON STUD INSIDE
SEE FIGURE BELOW)
SLIDE
CONNECTOR
END HERE
CASE SIDE DOOR
OPEN LATCH DOOR
WORK CLAMP
(4 PIN)
TRIGGER RECEPTACLE
PLUGGED IN
CONNECTOR
END ATTACH
ALL COMPONENTS SHOWN CONNECTED
(FRONT AND SIDE DOOR IS REMOVED
FOR CLARITY)
SHORT POWER
CABLE NEGATIVE "-"
OUTPUT TERMINAL
WORK LEAD
CONNECTION
POSITIVE "+"
OUTPUT TERMINAL
THUMB SCREW TO
TIGHTEN CONNECTOR
BUSHING
LOCATE COMPONENTS
TO CONNECT TO THE
FRONT OF MACHINE
FIGURE B.7
WIRE SPOOL
.035" (0.9mm)
NR-211-MP
INNER WIRE GUIDE REMOVED
LOWER DRIVE ROLL REMOVED
OUTER WIRE
GUIDE REMOVED
TOP DRIVE ROLL PRESSURE ARM
TENSION ADJUSTOR DOWN
FIGURE B.8

B-7
OPERATION
B-7
POWER MIG (140, 180 MODE S)
( See igure B.9)
9. eed 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.
(See igure B.10)
12. Remove the nozzle from the gun and contact tip
and straighten the gun out flat.
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.11)
14. When trigger is released spool of wire should not
unwind. Adjust wire spool brake accordingly.
MOVING PARTS AND E ECTRICA
CONTACT CAN CAUSE INJURY OR BE
FATA .
•When the gun trigger is depressed drive
rolls, spool of wire and electrode are
E ECTRICA Y IVE (HOT).
• Keep away from moving parts and
pinch points.
• Keep all Doors, Covers, panels and
guards securely in place.
DO NOT REMOVE OR CONCEA WARN-
ING ABE S.
----------------------------------------------------------------------------
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 con-
tact tip. (See igure 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.
.035"(0.9mm)
NR-211-MP
WIRE SPOOL
REMOVED NOZZLE
REMOVED CONTACT TIP
LAY CABLE AND GUN STRAIGHTEN
IN THIS POSITION
.035"(0.9mm)
NR-211-MP
WIRE SPOOL
DEPRESS TRIGGER
TO ACTIVATE WIRE,
WHICH FEEDS THE WIRE
THRU THE LINER.
FEED WIRE
APPROXIMATELY 4.00"
FROM THE GUN TUBE END
ROTATION
PLUG IN POWER
INPUT CORD
ON/OFF
SWITCH
WORK CLAMP AND CABLE
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
FIGURE B.10
FIGURE B.11
WARNING
INSTALL .035 CONTACT TIP
INSTALL BLACK FLUX-CORED NOZZLE
TRIM WIRE
STICKOUT
3/8"(9.5mm)
from the Contact Tip
FIGURE B.9
FIGURE B.12