Owner’s Manual & Safety Instructions
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.
Email our technical support at: [email protected]
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.
©
®
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.
Read this material before using this product.
Failure to do so can result in serious injury.
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Fume and Gas Safety
FUMES AND GASES can be hazardous to your health.
1. Exposure to welding or cutting
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.
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:
5. Work in a confined area only if it
is well-ventilated, or while wearing
an air-supplied respirator.
• Early onset of Parkinson’s Disease
• Heart disease
• Ulcers
6. Have a recognized specialist in
Industrial Hygiene or Environmental Services
check the operation and air quality
and make recommendations
• Damage to the reproductive organs
• Inflammation of the small intestine or
stomach
• Kidney damage
• Respiratory diseases such as
emphysema, bronchitis, or pneumonia
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.
2. Do not use near degreasing or
painting operations.
3. Keep head out of fumes.
Do not breathe exhaust fumes.
Arc Ray Safety
ARC RAYS can injure eyes and burn skin.
1. Wear ANSI-approved welding eye protection
4. Wear an approved head covering to protect
the head and neck. Use aprons, cape, sleeves,
shoulder covers, and bibs designed and
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.
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.
3. Keep clothing free of grease, oil,
solvents, or any flammable substances.
Wear dry, insulating gloves and protective clothing.
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Electrical Safety
ELECTRIC SHOCK can KILL.
1. Turn off, disconnect power, and
6. Do not expose welders to rain or wet conditions.
Water entering a welder will increase
the risk of electric shock.
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.
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.
3. Connect to grounded, GFCI-protected
power supply only.
8. Do not use outdoors.
4. Do not use near water or damp objects.
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.
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.
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.
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.
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.
6. Do not weld or cut on materials having
a combustible coating or combustible
Make sure there is adequate surrounding workspace.
Keep the work area free of obstructions,
grease, oil, trash, and other debris.
internal structure, as in walls or ceilings, without
an approved method for eliminating the hazard.
7. Do not dispose of hot slag in containers
4. Do not operate welders in atmospheres
containing dangerously reactive or
holding combustible materials.
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.
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.
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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.
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.
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.
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.
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.
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.
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.
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.
Gas Shielded Welding - Cylinder safety
Cylinders can explode when damaged.
1. Never weld on a pressurized or a closed cylinder.
5. Use only correct gas shielding equipment
designed specifically for the type of welding
you will do. Maintain this equipment properly.
2. Never allow an electrode holder,
electrode, welding torch, or welding
wire to touch the cylinder.
6. Protect gas cylinders from heat, being struck,
physical damage, slag, flames, sparks, and arcs.
3. Keep cylinders away from any electrical circuits,
including welding circuits.
7. Always use proper procedures to move cylinders.
4. Keep protective cap in place over the valve
except when the cylinder is in use.
SAVE THESE INSTRUCTIONS.
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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.
DO NOT USE
125 V~ PLUG.
NOTE SIZE
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.
DIFFERENCE.
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.
250 V~ 3-Prong Plug (6-50p) and Outlet (6-50r)
(for up to 250 V~ and up to 50 A)
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.
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:
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.
12 AWG up to 6 feet long,
10 AWG up to 75 feet long, or
6 AWG up to 175 feet long.
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Symbology
Wire Feed (Speed)
Workpiece Ground Cable
Torch Cable
Volts Alternating Current
Amperes
V~
A
OCV
KVA
IPM
AWG
Open Circuit Voltage
Kilovolt Amperes
(Volts / 1000 * Amperes)
Overheat Shutdown Indicator
Cooling Fan
Inches Per Minute
Housing Ground Point
American Wire Gauge
Specifications
Power Input
240 V~, 24 A
DCEN/DCEP
30-180 A
Welding Output
18 gauge (0.048″) to 1/4″ (0.25″) mild or stainless steel
Not for welding aluminum
20% at 140A
Capacity
Rated Duty Cycle
(See explanation on page 16)
Open Circuit Voltage
KVA
34
5.75
Wire Speed
30 – 700 IPM
Ground: 6′, 7 AWG
Torch: 6′, 7 AWG
Power: 3-wire, 6′ 5″, 12 AWG
6-50P NEMA plug type
Cable Sizes
up to 10 lb. spool
Wire Spool Capacity
Accessories
(one 1 lb. spool of flux-core wire included)
Spare Welder Tips (one each for .023″ and .030″– .035″ wire)
Welding Face Shield
Combination Wire Brush / Chipping Hammer
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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
Round
Tab
B
B
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
A
A. press the tabs through the holes and then
B. slide the tabs forward from the back,
locking the round tab in place.
Handle
Face Shield
(viewed from front)
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.
Filter Lens
Face Shield
(viewed from back)
Plug Attachment
1. A 250 V~ plug will need to be installed
DO NOT USE
125 V~ PLUG.
NOTE SIZE
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.
DIFFERENCE.
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)
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Wire Spool Installation
I
1. Turn the welder OFF and unplug
it before proceeding.
LDER
2. Pull up on the door latch,
then open the Door.
Door
door
latch
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.
Spool Knob
Spool Spring
Upper
Spool Plate
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.
Wire Spool
Lower
Spool Plate
Spool Spindle
5. Secure Spool in place with the upper Spool Plate
(narrower end against the Spool),
wire must
unwind this
direction
then the Spool Spring and Spool Knob.
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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.
Flux Core (Gas-less) Polarity Setup
DCEN
Knobs
Torch Polarity: –
Connect the Red Torch Cable to the front, black,
negative Terminal using the other Knob.
This is the initial setup, called
–
+
Torch
(Red)
Direct Current Electrode Negative (DCEN).
Ground
(Black)
Ground Polarity: +
6b. Solid Core (Gas Shielded) Wire Setup:
Solid Core (Gas Shielded) Polarity Setup
DCEP
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).
Knobs
Torch Polarity: +
–
+
Ground
(Black)
Torch
Ground Polarity: –
(Red)
b. Determine which type of shielding gas
would be appropriate for the welding
you will do - see chart on welder.
c
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).
Briefly open valve
to clean,
d
then close
valve.
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.
f
e. Obtain an appropriate Regulator/Flowmeter
(not included) and close its valve completely.
Thread its inlet connector onto the
e
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).
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Feed
Tensioner
Feed Swing
Arm
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.
Feed
Roller
Knob
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.
A
B. Pull the Feed Roller Knob straight
Feed
Roller
off to expose the Feed Roller.
B
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")
C
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.
D
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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.
HOLD WIRE
SECURELY
Wire
Liner
welding
wire
10. Keep tension on the wire and guide at least
12 inches of wire into the Wire Liners.
Wire
Spool
leader
wire liner
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,
feed
swing arm
feed
tensioner
you may release it.
Feed Roller
Torch
12. Pull the Nozzle to remove it.
13. Using the third oval hole on the Multi-wrench, turn
the Contact Tip counterclockwise and remove.
Nozzle
Contact
Tip
hole for
Contact Tip
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.
Multi-wrench
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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.
I
Plug the Power Cord into its electrical
outlet and turn the welder ON.
O
180
WELDER
8886
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
Torch
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.
Welding
Wire
IMPORTANT
Stainless steel wire is less flexible than
other welding wire. Therefore, it is more
difficult to feed through the liner and torch.
It is especially important to keep the torch cable
straight while feeding stainless steel wire.
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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.
Incrementally
increase tension
until
wire bends.
I
18. TURN THE WELDER OFF.
80
WELDER
886
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
Torch
and thread it clockwise into the Torch.
Tighten the Contact Tip using the Multi-wrench.
Nozzle
20. Replace the Nozzle and cut the wire
1
1
off at / ″ from tip ( / ″ stickout).
2
2
Contact
Tip
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.
Door
door
latch
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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:
Practice your welding
technique on scrap
pieces before welding
anything of value.
•
•
•
•
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.
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Control Panel Layout
Overload
Indicator
Torch
Cable
I
O
Current
Switch
Power
Switch
MIG 180
WIRE FEED WELDER
ITEM 68886
Wire
Speed
Dial
WIRE FEED SPEED
240V~
Ground
Cable
Power
Cord
Overload Indicator:
Wire Speed Dial:
This lights up if duty cycle work period is exceeded,
resulting in overheating the welder.
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.
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 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.
Power Switch:
Torch Cable:
This turns on power to the welding Torch and
internal cooling fan. The welding Torch is
energized whenever the Power Switch is on.
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.
Current Switch:
This controls the output amperage of the welder.
Adjust this according to the weld settings
chart to achieve a good weld.
Ground Cable:
This connects to the base metal to provide a good
connection for the current to travel back to the welder.
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Duty Cycle (Duration of Use)
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.
20% Rated Duty Cycle
at 140A output
2 minutes welding
followed by
at least 8 minutes
of rest
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
Torch
I
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.
O
concrete slab
(or other heat-proof,
non-conductive
surface)
MIG 180
WIRE FEED WELDER
ITEM 68886
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.
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Flux Weld Settings
NO
GAS
DCEN
Polarity
Metal Thickness
Wire
Diameter
Material
Being
Wire
Type
Shielding
Gas
Suggested 22 Ga
18 Ga
.048″
16 Ga
.060″
14 Ga
.075″
Settings
.030″
1/8″
3/16″
1/4″
Welded
0.8mm
1.2mm
1.5mm
2.0mm
3.2mm
4.8mm
6.4mm
Current
Wire Feed
Current
B
2.5
C
3
C
4
C
4
C
5
D
5
D
6
NO .030″
Mild
Flux-core
GAS
Steel (E71T-GS)
D
7
E
9
Required .035″
Wire Feed
MIG Weld Settings
GAS
DCEP
Polarity
Metal Thickness
Material
Being
Wire
Type
Wire
Diameter
Shielding Suggested 22 Ga
18 Ga
.048″
16 Ga
.060″
14 Ga
.075″
Gas
Settings
.030″
1/8″
3/16″
1/4″
Welded
0.8mm
1.2mm
1.5mm
2.0mm
3.2mm
4.8mm
6.4mm
75% CO
+25% Argon
6-8L / MIN
2
Current
Wire Feed
Current
Wire Feed
Current
Wire Feed
A
4.5
A
B
5
.023″
.030″
.035″
75% CO
+25% Argon
8-10L / MIN
2
B
4
B
6
C
6
C
7
Mild
Steel
Solid
(E70S-6)
3.5
75% CO
+25% Argon
8-10L / MIN
2
A
3
B
5
B
6
C
8
D
F
9
10
Page 18
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Setting Up The Weld
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
clamps
workpieces
(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.
Clean
surfaces to
bare metal.
Chamfer thick workpieces.
Workpiece
I
3. Clamp Ground Cable to bare metal on the
workpiece near the weld area, or to metal work
bench where the workpiece is clamped.
O
MIG 180
Clean
surface to
bare metal.
WIRE FEED WELDER
ITEM 68886
Ground
Clamp
WIRE FEED SPEED
240V~
LDER
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.
WIRE FEED SPEED
I
DO NOT SWITCH THE CURRENT
WHILE WELDING.
+
O
240V~
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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.
I
The circuit must be equipped with delayed
action type circuit breaker or fuses.
180
WELDER
8886
HOLD
TORCH
CLEAR
7. Hold the Torch, without touching the Trigger, with the
wire and tip clearly out of the way of any grounded
objects.
I
O
Then, turn the Power Switch ON.
80
WELDER
886
Page 20
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Basic Welding Technique
1. Press (and hold) Trigger and contact area to
be welded with electrode wire to ignite arc.
2. For a narrow weld, you can usually draw the wire in
a steady straight line,
stringer bead
weave bead
this is called a stringer bead.
For a wider weld, draw the wire back and forth
across the joint,
this is called a weave bead and takes
practice to perform properly.
3. Hold Torch in one hand and the face shield in
the other. If a hands-free welding shield (not
included, see #6, page 4 for guidelines) is used,
then both hands can be used to control Torch.
Weld Torch angles,
viewed from front of weld joint.
4. Direct the welding wire straight into the joint.
This gives an angle of 90° (straight up and
down) for butt (end to end) welds, and an
angle of 45° for fillet (T-shaped) welds.
90°
butt weld joint
45°
fillet weld joint
5. The end of torch should be tilted so that wire
is angled anywhere in-between straight on
and 15° in the direction you are welding. The
amount of tilt is called the drag angle.
Drag Angle
0-15°
1
6. The welding wire should extend no more than / ″
2
past the tip.
This distance is called stickout or CTWD
- Contact Tip to Work Distance.
Stickout
1
(up to / ″)
2
Weld
Direction
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Page 21
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Note: If Welder is used too long, the amber Overload
Indicator will light and the Welder Torch will shut off
until the welder cools. If this happens, rest the Torch
on an electrically non-conductive, heat-resistant
surface, such as a concrete slab, well clear of the
ground clamp. Wait about 8-10 minutes with the Power
Switch ON for the welder to cool. When the welder
can be used again, use shorter welding periods and
longer rest periods to help prevent needless wear.
Torch
I
O
concrete slab
(or other heat-proof,
non-conductive
surface)
MIG 180
WIRE FEED WELDER
ITEM 68886
After practice welding for a few
seconds, STOP and examine
your weld using the guidelines
starting on the next page.
7. After welding the test weld on a piece of scrap
for a few seconds, stop, and check your progress.
Clean, then compare your weld’s appearance with
the diagrams and descriptions in the Welding Tips
section starting on the next page. After making
any necessary adjustments, continue to weld
while carefully following the DUTY CYCLE
guidelines as explained on page 20.
FOLLOW DUTY CYCLE!
CAUTION! Weld will be hot, do not touch.
up to 2 minutes
welding at rated output
HOLD
TORCH
CLEAR
8. When the weld is complete, lift the Torch and
welding wire clearly away from any grounded
object, and turn the Power Switch off.
I
180
WELDER
8886
9. Set the Torch down on a heat-proof, electrically
Torch
non-conductive surface. Unplug the Power Cord.
concrete slab
(or other heat-proof,
non-conductive
surface)
10. MIG ONLY:
Close shielding gas tank valve completely.
Page 22
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Welding Tips
A typical flux-core wire (FCAW) weld
before cleaning.
A good way to test welding technique is to examine
a weld’s appearance after it has cooled and the slag
has been removed. Then, better welding can be
learned by adjusting your weld technique
to remedy any problems found.
weld bead
slag
spatter
spatter
base metal
A typical solid wire (GMAW) weld
before cleaning.
weld bead
base metal
Cleaning the Weld
Chipping
Hammer
TO PREVENT SERIOUS INJURY:
Continue to wear ANSI-approved safety
goggles and protective wear when
cleaning a weld.
Sparks or chips may fly when cleaning.
1. A weld from flux core wire will be covered by slag, use
the Chipping Hammer to knock this off. Be careful
not to damage the weld or base material.
Wire Brush
2. Then, use the Wire Brush to further
clean the weld or use an angle grinder
(sold separately) to shape the weld.
Strike Test
A test weld on a PIECE OF SCRAP can be tested by
using the following procedure.
WEAR ANSI GOGGLES DURING THIS PROCEDURE.
clamp
dead-blow hammer
SCRAP
workpiece
WARNING! This test WILL damage the weld it is
performed on. This test is ONLY an indicator of weld
technique and is not intended to test working welds.
1. After two scraps have been welded together and the
weld has cooled, clamp one scrap in a sturdy vise.
GOOD WELD
bends and is not brittle
2. Stay clear from underneath while you strike
the opposite scrap with a heavy hammer,
preferably a dead-blow hammer.
clamp
dead-blow hammer
SCRAP
workpiece
3. A GOOD WELD will deform but not break,
as shown on top.
A POOR WELD will be brittle and snap at the weld,
as shown on bottom.
POOR WELD
snaps or cracks
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Weld Diagnosis
Workpiece Heat Control / Weld Penetration
EXCESS PENETRATION OR
BURN-THROUGH
INADEQUATE PENETRATION
PROPER PENETRATION
Not hot enough
Ideal heat
Too hot
How to increase workpiece heat
How to reduce workpiece heat
and increase penetration:
(to weld THICKER workpieces properly)
and limit penetration:
(to weld THINNER workpieces properly)
a.Increase weld current c.Use faster wire feed
a.Decrease weld current c.Use slower wire feed
b.Weld more slowly
d.Use shorter stickout
b.Weld more quickly
d.Use longer stickout
Example Weld Diagrams
Good
Weld
Current
Too Low or
Wire Feed
Too Slow
Current
Too High or
Wire Feed
Too Fast
Weld Speed
Too Fast
Weld Speed
Too Slow
Stickout
Too Long
or Wrong
Polarity
TO CORRECT:
TO CORRECT:
TO CORRECT:
TO CORRECT:
TO CORRECT:
Check Polarity
and
I
I
O
O
maintain
less
1
than / ″
2
weld
slower
weld
faster
or
or
stickout
Page 24
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Weld Problems
Penetration (Workpiece Heat Control)
EXCESS PENETRATION OR
BURN-THROUGH
Weld droops on top and
underneath, or falls through
entirely, making a hole.
PROPER PENETRATION
Weld is visible underneath and
bulges slightly on top.
INADEQUATE PENETRATION
Weld does not contact the joint
fully, just on the surface.
PROFILE VIEWS
POSSIBLE CAUSES AND SOLUTIONS
1. Workpiece overheating:
POSSIBLE CAUSES AND SOLUTIONS
1. Incorrect welding technique:
1
Reduce wire feed speed.
Maintain / ″ or less stickout.
2
Decrease weld current.
Keep arc on leading edge of weld puddle.
Hold torch at proper angles.
2. Welding speed too slow:
Increase welding speed and ensure
that welding speed is kept steady.
2. Insufficient weld heat:
Reduce welding speed.
Increase weld current.
3. Excessive material at weld:
Reduce wire feed speed.
3. Workpieces too thick/close:
Bevel thick workpieces, allow slight
gap, and weld in several passes.
Bend at Joint
4. Insufficient weld material:
Increase wire feed speed.
PROFILE
VIEW
POSSIBLE CAUSES AND SOLUTIONS
1. Improper clamping:
Weld Not Adhering Properly
Gaps present between weld and previous bead or
between weld and workpiece. See areas below.
Clamp workpieces securely.
Make tack welds to hold workpieces.
2. Excessive heat:
Weld a small portion and allow to cool before
proceeding.
Increase weld speed.
PROFILE
VIEW
Reduce wire feed speed.
Coat of Slag Over Weld
POSSIBLE CAUSES AND SOLUTIONS
1. Incorrect welding technique:
Place stringer bead at correct place in joint.
Adjust workpiece position or weld angle to permit
proper welding to bottom of piece.
TOP
VIEW
Pause briefly at sides during weave bead.
Keep arc on leading edge of weld puddle.
Hold torch at proper angles.
PARTIALLY CHIPPED AWAY TO SHOW WELD
2. Insufficient weld heat:
Increase current.
Slag is a necessary part of a flux-core wire
weld. It shields the weld from impurities.
Clean off the slag with the Chipping
Increase wire feed speed.
3. Dirty workpiece:
Hammer and Wire Brush after welding.
Clean workpiece down to bare metal.
Gas-shielded MIG welds are protected by the
4. Insufficient weld material:
shielding gas and do not need slag to protect them.
Increase wire feed speed.
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Excessive Spatter
Porosity
Fine spatter is normal.
Spatter that is grainy and large is a problem.
Small cavities or holes in the bead.
TOP
VIEW
TOP
VIEW
POSSIBLE CAUSES AND SOLUTIONS
POSSIBLE CAUSES AND SOLUTIONS
1. Incorrect polarity:
Check that polarity is set correctly
for type of welding.
1. Dirty workpiece or welding wire:
Clean workpiece down to bare metal.
Make certain that wire is clean and free
from oil, coatings, and other residues.
2. Insufficient shielding gas (MIG only):
Increase flow of gas.
2. Incorrect polarity:
Check that polarity is set correctly
for type of welding.
Clean nozzle.
Maintain proper stickout.
3. Incorrect shielding gas (MIG only):
3. Insufficient shielding gas (MIG only):
Increase flow of gas.
Use shielding gas recommended by wire supplier.
4. Dirty workpiece or welding wire:
Clean workpiece down to bare metal.
Make certain that wire is clean and free
from oil, coatings, and other residues.
Clean nozzle.
Maintain proper stickout.
4. Wire feeding too fast:
Reduce wire feed speed.
5. Inconsistent welding speed:
5. Stickout too long:
Maintain steady weld speed.
Reduce stickout.
6. Stickout too long:
Reduce stickout.
Crooked/Wavy Bead
Burn-Through
Base material melts away,
leaving a hole in the weld.
TOP
VIEW
TOP
VIEW
POSSIBLE CAUSES AND SOLUTIONS
POSSIBLE CAUSES AND SOLUTIONS
1. Inaccurate welding:
1. Workpiece overheating:
Use two hands or rest hand on steady surface.
Reduce current and/or wire feed speed.
2. Inconsistent welding speed:
Maintain steady weld speed.
2. Welding speed too slow:
Increase welding speed and ensure
that welding speed is kept steady.
3. Stickout too long:
Reduce stickout.
3. Excessive material at weld:
Reduce wire feed speed.
Page 26
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Maintenance
TO PREVENT SERIOUS INJURY,
FIRE AND BURNS:
Torch
Unplug the welder, rest the Torch on a
heat-proof, electrically non-conductive
surface, and allow all parts of the Welder
to cool thoroughly before service.
concrete slab
+
1. Periodically remove the Side Panel, and using
compressed air, blow out all dust from the interior.
(or other heat-proof,
non-conductive
surface)
2. Store in a clean and dry location.
3. For optimal weld quality, clean and
inspect the Contact Tip and Nozzle
before each use, as explained below:
Nozzle and Contact Tip Inspection and Cleaning
1. Make sure that the entire Torch is completely
cool and that the Power Cord is unplugged
from the electrical outlet before proceeding.
2. Turn the Nozzle counterclockwise
while pulling to remove.
3. Scrub the interior of the Nozzle
clean with a wire brush.
4. Examine the end of the Nozzle. The end should be
flat and even. If the end is uneven, chipped, melted,
cracked, or otherwise damaged, the Nozzle will
adversely effect the weld and should be replaced.
Torch
5. Using the third oval hole on the Multi-wrench,
turn the Contact Tip counterclockwise
and slide it off the welding wire.
6. Scrub the outside of the Tip clean with a wire brush.
Nozzle
Clean out the inside of the tip with a tip
cleaner (sold separately). Check that the Tip
is the proper type for the wire size used.
Contact
7. Examine the shape of the hole at the end of
the Contact Tip. It should be an even circle, it
should not be oblong or have any bulges in it.
Tip
hole for
Contact Tip
8. If any problems are noted, Contact Tip replacement
would be advisable. Select a new Tip that is
the correct size for the welding wire used.
9. Reinstall the Tip and securely
Multi-wrench
reinstall the Nozzle as well.
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Troubleshooting
IMPORTANT!
Be CERTAIN to shut off the Welder, disconnect it from power, and discharge the Torch to ground
before adjusting, cleaning, or repairing the unit.
Wire feed motor runs but wire does not feed properly
POSSIBLE CAUSES AND SOLUTIONS
1. Insufficient wire feed pressure:
Increase wire feed pressure properly - follow step 17 on page 17.
2. Incorrect wire feed roll size:
Flip roll to correct size, follow the Wire Spool Installation instructions, starting on page 12.
3. Damaged Torch, cable, or liner assembly:
Have a qualified technician inspect these parts and replace as necessary.
Wire creates a bird’s nest during operation
POSSIBLE CAUSES AND SOLUTIONS
1. Excess wire feed pressure:
Adjust wire feed pressure properly - follow step 17 on page 17.
2. Incorrect contact tip size:
Replace with the proper tip for wire used.
3. Torch end not inserted into drive housing properly:
Loosen torch securing bolt and push torch end into housing just enough
so that it does not touch wire feed mechanism.
4. Damaged liner:
Have a qualified technician inspect and repair/replace as necessary.
Welding arc not stable
POSSIBLE CAUSES AND SOLUTIONS
1. Wire not feeding properly:
See first Troubleshooting section above.
2. Incorrect contact tip size:
Replace with the proper tip for wire used.
3. Incorrect wire feed speed:
Adjust wire feed speed to achieve a more stable arc.
4. Loose Torch cable or ground cable:
Check to ensure that all connections are tight.
5. Damaged Torch or loose connection within Torch:
Have a qualified technician inspect and repair/replace as necessary.
Weak Arc strength
POSSIBLE CAUSES AND SOLUTIONS
1. Incorrect line voltage:
Check the line voltage and, if insufficient, have a licensed electrician remedy the situation.
2. Improper gauge or length of cord:
Extension cords are not recommended. If possible, eliminate the use of an extension cord.
If a longer cord is needed, refer to the replacement cord guidelines on page 7.
3. Not enough current:
Switch current to proper setting for metal thickness.
Page 28
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SKU 68886
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Troubleshooting (continued)
IMPORTANT!
Be CERTAIN to shut off the Welder, disconnect it from power, and discharge the Torch to ground
before adjusting, cleaning, or repairing the unit.
Power switch lights,
but welder does not function when switched on
POSSIBLE CAUSES AND SOLUTIONS
1. Tripped thermal protection device:
Stop welding and allow welder to cool for at least 20 minutes.
Reduce duration or frequency of welding periods to help reduce wear on the welder.
Refer to Duty Cycle section on page 20.
2. Faulty or improperly connected Trigger:
Qualified technician must check and secure/replace Trigger.
Power switch does not light when switched on
POSSIBLE CAUSES AND SOLUTIONS
Unit is not connected to outlet properly or outlet is unpowered:
Verify the voltage at the outlet and the connection to the outlet.
If voltage is not present at outlet, check circuit breaker/GFCI devices; if any are tripped, determine and remedy
cause before resetting.
Verify that the circuit is designed to supply the required input voltage and amperage as detailed on the
Specifications table.
Make sure installed plug is correct rating (250 V~, 50 A recommended) - see page 7.
Wire Feeds, but arc does not ignite
POSSIBLE CAUSES AND SOLUTIONS
1. Improper ground connection:
Make certain that the workpiece is contacted properly by the Ground Clamp and that the
workpiece is properly cleaned near the ground clamp and the welding location.
2. Improperly sized or excessively worn Contact Tip:
Verify that Contact Tip is the proper size for welding wire.
Check that the hole in the tip is not deformed or enlarged.
Also, check that the tip is not dirty; this would prevent a good connection.
If needed, replace Contact Tip with proper size and type.
PLEASE READ THE FOLLOWING CAREFULLY
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM
IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER OR DISTRIBUTOR
MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS
QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT, OR THAT HE OR SHE IS QUALIFIED TO REPLACE
ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER AND/OR DISTRIBUTOR EXPRESSLY
STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND
LICENSED TECHNICIANS, AND NOT BY THE BUYER. THE BUYER ASSUMES ALL RISK AND LIABILITY
ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS
THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO.
SKU 68886
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Page 29
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Parts List and Diagrams
Wiring Diagram
Parts List
Part
1
2
3
4
5
6
7
8
Description
Ground Clamp (and Cable)
Power Cord
Grommet
Current Knob
Wire Speed Knob
Front Panel
PCB Bracket
PCB
Divider
Control Transformer
Foot
Thermal Protector
Transformer
Right Panel
Gas Connector
Back Panel
Fan
Qty
1
1
2
1
1
1
1
1
1
1
4
1
1
1
1
1
Part
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
Description
Qty
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
Handle
Spool Holder
Hinge
Wire Feed Mechanism
Left Panel
Red Terminal
Latch
Black Terminal
Rubber Tube
Indicator
Torch Cable Grommet
Power Switch
Torch (and Cable)
Face Shield Handle
Face Shield Shell
Filter Lens
9
10
11
12
13
14
15
16
17
18
19
1
1
1
Wire Brush / Chipping Hammer
Wrench
1
1
Rectifier Bracket
Rectifier
Record Serial Number Here:
Note: Some parts are listed and shown for
illustration purposes only, and are not available
individually as replacement parts.
Note: If product has no serial number, record
month and year of purchase instead.
Page 30
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Assembly Diagram
SKU 68886
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Limited 90 Day Warranty
Harbor Freight Tools Co. makes every effort to assure that its products meet high quality and durability
standards, and warrants to the original purchaser that this product is free from defects in materials and
workmanship for the period of 90 days from the date of purchase. This warranty does not apply to damage
due directly or indirectly, to misuse, abuse, negligence or accidents, repairs or alterations outside our
facilities, criminal activity, improper installation, normal wear and tear, or to lack of maintenance. We shall
in no event be liable for death, injuries to persons or property, or for incidental, contingent, special or
consequential damages arising from the use of our product. Some states do not allow the exclusion or
limitation of incidental or consequential damages, so the above limitation of exclusion may not apply to you.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED,
INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS.
To take advantage of this warranty, the product or part must be returned to us with transportation charges
prepaid. Proof of purchase date and an explanation of the complaint must accompany the merchandise.
If our inspection verifies the defect, we will either repair or replace the product at our election or we may elect
to refund the purchase price if we cannot readily and quickly provide you with a replacement. We will return
repaired products at our expense, but if we determine there is no defect, or that the defect resulted from
causes not within the scope of our warranty, then you must bear the cost of returning the product.
This warranty gives you specific legal rights and you may also have other rights which vary from state to state.
3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-3353
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