Chicago Electric MIG 180 Assembly instructions

Visit our website at: http://www.harborfreight.com

Email our technical support at: [email protected]

Read this material before using this product.

Failure to do so can result in serious injury.

SAVE THIS MANUAL.

this manual or any artwork contained herein may be reproduced in any shape

or form without the express written consent of Harbor Freight Tools. Diagrams

within this manual may not be drawn proportionally. Due to continuing

improvements, actual product may differ slightly from the product described

herein. Tools required for assembly and service may not be included.

When unpacking, make sure that the product is intact

and undamaged. If any parts are missing or broken,

please call 1-800-444-3353 as soon as possible.

Save This Manual Keep this manual for the safety warnings and precautions, assembly, operating,

inspection, maintenance and cleaning procedures. Write the product’s serial number in the back of the manual

near the assembly diagram (or month and year of purchase if product has no number). Keep this manual and

the receipt in a safe and dry place for future reference.

Owner’s Manual & Safety Instructions

Page 2 For technical questions, please call 1-800-444-3353. SKU 68886

Table of Contents

Safety ......................................................... 2

Setup .......................................................... 7

Specifications ............................................. 7

Basic Welding............................................ 15

Welding Tips .............................................. 23

Maintenance.............................................. 27

Parts List and Diagrams ............................ 30

Warranty .................................................... 32

WARNING SYMBOLS AND DEFINITIONS

This is the safety alert symbol. It is used to alert you to potential personal injury hazards.

Obey all safety messages that follow this symbol to avoid possible injury or death.

Indicates a hazardous situation which, if not avoided,

will result in death or serious injury.

Indicates a hazardous situation which, if not avoided,

could result in death or serious injury.

Indicates a hazardous situation which, if not avoided,

could result in minor or moderate injury.

Addresses practices not related to personal injury.

IMPORTANT SAFETY INFORMATION

Read all safety warnings and instructions.

Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.

Save all warnings and instructions for future reference.

General Safety

PROTECT yourself and others. Read and understand this information.

1. Before use, read and understand

manufacturer′s instructions,

Material Safety Data Sheets (MSDS′s),

employer′s safety practices, and ANSI Z49.1.

2. Keep out of reach of children.

Keep children and bystanders away while operating.

3. Place the welder on a stable location before use.

If it falls while plugged in, severe injury,

electric shock, or fire may result.

4. Do not overreach.

Keep proper footing and balance at all times.

5. Stay alert, watch what you are doing and use

common sense when operating a welder.

Do not use a welder while you are tired or under

the influence of drugs, alcohol or medication.

A moment of inattention while operating welders

may result in serious personal injury.

6. Avoid unintentional starting. Make sure you are

prepared to begin work before turning on the Welder.

7. Never leave the Welder unattended while

energized. Turn power off if you have to leave.

8. The warnings, precautions, and instructions

discussed in this instruction manual cannot

cover all possible conditions and situations

that may occur. It must be understood by the

operator that common sense and caution are

factors which cannot be built into this product,

but must be supplied by the operator.

9. This product, when used for welding and similar

applications, contains or produces a chemical

known to the State of California to cause cancer

and birth defects (or other reproductive harm).

(California Health & Safety Code § 25249.5, et seq.)

10. Handling the cord on this product will expose

you to lead, a chemical known to the State of

California to cause cancer, and birth defects or

other reproductive harm.

Wash hands after handling.

(California Health & Safety Code § 25249.5, et seq.)

SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP

Page 3For technical questions, please call 1-800-444-3353.SKU 68886

Fume and Gas Safety

FUMES AND GASES can be hazardous to your health.

1. Exposure to welding or cutting

exhaust fumes can increase the risk

of developing certain cancers, such as

cancer of the larynx and lung cancer.

Also, some diseases that may be linked to exposure

to welding or cutting exhaust fumes are:

• Early onset of Parkinson’s Disease

• Heart disease • Ulcers

• Damage to the reproductive organs

• Inflammation of the small intestine or

stomach • Kidney damage

• Respiratory diseases such as

emphysema, bronchitis, or pneumonia

2. Do not use near degreasing or

painting operations.

3. Keep head out of fumes.

Do not breathe exhaust fumes.

4. Use enough ventilation, exhaust at arc, or

both, to keep fumes and gases from breathing

zone and general area. If engineering controls

are not feasible, use an approved respirator.

5. Work in a confined area only if it

is well-ventilated, or while wearing

an air-supplied respirator.

6. Have a recognized specialist in

Industrial Hygiene or Environmental Services

check the operation and air quality

and make recommendations

for the specific welding situation.

Follow OSHA guidelines for

Permissible Exposure Limits (PEL’s) and

the American Conference of Governmental

Industrial Hygienists recommendations for

Threshold Limit Values (TLV’s) for fumes and gases.

Arc Ray Safety

ARC RAYS can injure eyes and burn skin.

1. Wear ANSI-approved welding eye protection

featuring at least a number 10 shade lens rating.

2. Wear leather leggings, fire resistant shoes

or boots during use. Do not wear pants with

cuffs, shirts with open pockets, or any clothing

that can catch and hold molten metal or sparks.

3. Keep clothing free of grease, oil,

solvents, or any flammable substances.

Wear dry, insulating gloves and protective clothing.

4. Wear an approved head covering to protect

the head and neck. Use aprons, cape, sleeves,

shoulder covers, and bibs designed and

approved for welding and cutting procedures.

5. When welding/cutting overhead or in confined

spaces, wear flame resistant ear plugs or

ear muffs to keep sparks out of ears.

SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP

Page 4 For technical questions, please call 1-800-444-3353. SKU 68886

Electrical Safety

ELECTRIC SHOCK can KILL.

1. Turn off, disconnect power, and

discharge electrode to ground before setting

down torch/electrode holder and before service.

2. Do not touch energized electrical parts.

Wear dry, insulating gloves. Do not touch electrode

holder, electrode, welding torch, or welding wire with

bare hand. Do not wear wet or damaged gloves.

3. Connect to grounded, GFCI-protected

power supply only.

4. Do not use near water or damp objects.

5. People with pacemakers should consult their

physician(s) before use. Electromagnetic fields

in close proximity to heart pacemaker could cause

pacemaker interference or pacemaker failure.

6. Do not expose welders to rain or wet conditions.

Water entering a welder will increase

the risk of electric shock.

7. Do not abuse the cord. Never use the cord

for carrying, pulling or unplugging the welder.

Keep cord away from heat, oil, sharp edges

or moving parts. Damaged or entangled

cords increase the risk of electric shock.

8. Do not use outdoors.

9. Insulate yourself from the workpiece and ground.

Use nonflammable, dry insulating material if possible,

or use dry rubber mats, dry wood or plywood, or

other dry insulating material large enough to cover

your full area of contact with the work or ground.

Fire Safety

ARC AND HOT SLAG can cause fire.

1. Clear away or protect flammable objects.

Remove or make safe all combustible materials for a

radius of 35 feet (10 meters) around the work area.

Use a fire resistant material to cover or block all open

doorways, windows, cracks, and other openings.

2. Keep ABC-type fire extinguisher near

work area and know how to use it.

3. Maintain a safe working environment.

Keep the work area well lit.

Make sure there is adequate surrounding workspace.

Keep the work area free of obstructions,

grease, oil, trash, and other debris.

4. Do not operate welders in atmospheres

containing dangerously reactive or

flammable liquids, gases, vapors, or dust.

Provide adequate ventilation in work areas

to prevent accumulation of such substances.

Welders create sparks which may ignite flammable

substances or make reactive fumes toxic.

5. If working on a metal wall, ceiling, etc.,

prevent ignition of combustibles on the

other side by moving the combustibles to a

safe location. If relocation of combustibles is

not possible, designate someone to serve as

a fire watch, equipped with a fire extinguisher,

during the cutting process and for at least one

half hour after the cutting is completed.

6. Do not weld or cut on materials having

a combustible coating or combustible

internal structure, as in walls or ceilings, without

an approved method for eliminating the hazard.

7. Do not dispose of hot slag in containers

holding combustible materials.

8. After welding, make a thorough examination

for evidence of fire. Be aware that easily

visible smoke or flame may not be present

for some time after the fire has started.

9. Do not apply heat to a container that has held

an unknown substance or a combustible

material whose contents, when heated,

can produce flammable or explosive vapors.

Clean and purge containers before applying heat.

Vent closed containers, including castings,

before preheating, welding, or cutting.

SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP

Page 5For technical questions, please call 1-800-444-3353.SKU 68886

Welder use and care

1. Do not use the welder if the switch does not turn

it on and off. Any welder that cannot be controlled

with the switch is dangerous and must be repaired.

2. Disconnect the plug from the power

source before making any adjustments,

changing accessories, or storing welders.

Such preventive safety measures reduce the

risk of starting the welder accidentally.

3. Prevent unintentional starting.

Ensure the switch is in the off-position before

connecting to power source or moving the welder.

Carrying or energizing welders that have

the switch on invites accidents.

4. Store idle welders out of the reach of children and

do not allow persons unfamiliar with the welder or

these instructions to operate the welder. Welders

are dangerous in the hands of untrained users.

5. Use the welder and accessories in accordance

with these instructions, taking into account the

working conditions and the work to be performed.

Use of the welder for operations different from those

intended could result in a hazardous situation.

Maintenance

1. Maintain welders. Check for misalignment or

binding of moving parts, breakage of parts

and any other condition that may affect the

welder’s operation. If damaged, have the

welder repaired before use. Many accidents

are caused by poorly maintained welders.

2. Have your welder serviced by a qualified

repair person using only identical

replacement parts. This will ensure that

the safety of the welder is maintained.

3. Maintain labels and nameplates on the Welder.

These carry important information.

If unreadable or missing, contact

Harbor Freight Tools for a replacement.

4. Unplug before maintenance. Unplug the Welder

from its electrical outlet before any inspection,

maintenance, or cleaning procedures.

Gas Shielded Welding - Cylinder safety

Cylinders can explode when damaged.

1. Never weld on a pressurized or a closed cylinder.

2. Never allow an electrode holder,

electrode, welding torch, or welding

wire to touch the cylinder.

3. Keep cylinders away from any electrical circuits,

including welding circuits.

4. Keep protective cap in place over the valve

except when the cylinder is in use.

5. Use only correct gas shielding equipment

designed specifically for the type of welding

you will do. Maintain this equipment properly.

6. Protect gas cylinders from heat, being struck,

physical damage, slag, flames, sparks, and arcs.

7. Always use proper procedures to move cylinders.

SAVE THESE INSTRUCTIONS.

SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP

Page 6 For technical questions, please call 1-800-444-3353. SKU 68886

Grounding

TO PREVENT ELECTRIC SHOCK AND DEATH

FROM INCORRECT GROUNDING WIRE CONNECTION:

Check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded.

Have a plug installed by a certified electrician.

Do not use the welder if the power cord or plug is damaged. If damaged, have it repaired by a service facility

before use. If the plug will not fit the outlet, have a proper outlet installed by a qualified electrician,

do not use adapter plugs.

1. The green wire inside the cord is connected to

the grounding system in the welder. The green

wire in the cord must be the only wire connected

to the welder’s grounding system and must never

be attached to an electrically “live” terminal.

Never leave the grounding wire disconnected

or modify the Power Cord Plug in any way.

2. Make sure the tool is connected to an outlet having

the same configuration as the plug. If the tool must

be reconnected for use on a different type of electric

circuit, the reconnection should be made by qualified

service personnel; and after reconnection, the tool

should comply with all local codes and ordinances.

3. A 250 V~ plug will need to be installed

by a certified electrician before use.

4. The plug shown (NEMA 6-50p) is for use on a

50 A circuit. A different 250 V~ plug and outlet

combination may be used, provided it is rated

to handle the electrical requirements of the tool

and is installed by a certified electrician.

250 V~ 3-Prong Plug (6-50p) and Outlet (6-50r)

(for up to 250 V~ and up to 50 A)

DO NOT USE

125 V~ PLUG.

NOTE SIZE

DIFFERENCE.

Extension Cords

Do not use an extension cord on this welder.

Replacement Cords

1. A qualified electrician can install either of the

following UL-listed, 3 wire cords as a replacement

cord for this welder:

12 AWG up to 6 feet long,

10 AWG up to 75 feet long, or

6 AWG up to 175 feet long.

2. Do not install a thinner or longer

cord on this welder.

3. Do not patch cords of any length together for this

item, patches may allow moisture to penetrate

the insulation, resulting in electric shock.

SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP

Page 7For technical questions, please call 1-800-444-3353.SKU 68886

Symbology

Wire Feed (Speed)

Workpiece Ground Cable

Torch Cable

Overheat Shutdown Indicator

Cooling Fan

Housing Ground Point

V~ Volts Alternating Current

AAmperes

OCV Open Circuit Voltage

KVA Kilovolt Amperes

(Volts / 1000 * Amperes)

IPM Inches Per Minute

AWG American Wire Gauge

Specifications

Power Input 240 V~, 24 A

Welding Output DCEN/DCEP

30-180 A

Capacity 18 gauge (0.048″) to 1/4″ (0.25″) mild or stainless steel

Not for welding aluminum

Rated Duty Cycle 20% at 140A

(See explanation on page 16)

Open Circuit Voltage 34

KVA 5.75

Wire Speed 30 – 700 IPM

Cable Sizes

Ground: 6′, 7 AWG

Torch: 6′, 7 AWG

Power: 3-wire, 6′ 5″, 12 AWG

6-50P NEMA plug type

Wire Spool Capacity up to 10 lb. spool

(one 1 lb. spool of flux-core wire included)

Accessories

Spare Welder Tips (one each for .023″ and .030″– .035″ wire)

Welding Face Shield

Combination Wire Brush / Chipping Hammer

SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP

Page 8 For technical questions, please call 1-800-444-3353. SKU 68886

1. Attach the handle to the Face Shield by lining

up the two rectangular tabs on the handle with

the corresponding holes in the face shield and

A. press the tabs through the holes and then

B. slide the tabs forward from the back,

locking the round tab in place.

2. Wear heavy-duty work gloves, the edges of the

filter lens may be sharp. Remove any protective

film from both sides of the filter lens. Slide the

filter lens into the helmet behind the holding tabs.

Make sure that the filter lens fits securely and

that light cannot leak around its edges.

Handle

Face Shield

(viewed from front)

Round

Tab

Face Shield

(viewed from back)

Filter Lens

Setup

Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual

including all text under subheadings therein before set up or use of this product.

TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION:

Turn the Power Switch off and unplug the welder before assembly.

Note: Remove the protective foam and cardboard from the welder before setup.

Face Shield Assembly

Plug Attachment

1. A 250 V~ plug will need to be installed

by a certified electrician before use.

2. The plug shown is for use on a 50 A circuit. A

different 250 V~ plug and outlet combination

may be used, provided it is rated to handle

the electrical requirements of the tool and

is installed by a certified electrician.

Note: Although 125 V~ plugs may look similar,

the required plug is much larger, see illustration.

250 V~ 3-Prong Plug (6-50p) and Outlet (6-50r)

(for up to 250 V~ and up to 50 A)

DO NOT USE

125 V~ PLUG.

NOTE SIZE

DIFFERENCE.

SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP

Page 9For technical questions, please call 1-800-444-3353.SKU 68886

Wire Spool Installation

1. Turn the welder OFF and unplug

it before proceeding.

2. Pull up on the door latch,

then open the Door.

3. Remove the Spool Knob, Spool Spring, and upper

Spool Plate. If replacing a Spool, remove the old

Spool and all remaining wire from the liners.

4. Place the new Wire Spool over the Spool Spindle

and on top of the lower Spool Plate as illustrated.

To prevent wire feed problems, set the

Spool so that it will unwind clockwise.

5. Secure Spool in place with the upper Spool Plate

(narrower end against the Spool),

then the Spool Spring and Spool Knob.

MIG 180

WIRE FEED WELDER

ITEM 68886

WIRE FEED SPEED

240V~

door

latch

Door

Spool Knob

Wire Spool

Lower

Spool Plate

Upper

Spool Plate

Spool Spring

Spool Spindle

wire must

unwind this

direction

SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP

Page 10 For technical questions, please call 1-800-444-3353. SKU 68886

6a. Flux Core (Gas-less) Wire Setup:

Remove the two Knobs securing the cables.

Connect the Black Ground Cable to the rear, red,

positive Terminal using the Knob.

Connect the Red Torch Cable to the front, black,

negative Terminal using the other Knob.

This is the initial setup, called

Direct Current Electrode Negative (DCEN).

6b. Solid Core (Gas Shielded) Wire Setup:

a. Remove the two Knobs securing the cables.

Connect the Black Ground Cable to the front,

black, negative Terminal using the Knob.

Connect the Red Torch Cable to the rear, red,

positive Terminal using the other Knob.

This is called Direct Current Electrode Positive

(DCEP).

b. Determine which type of shielding gas

would be appropriate for the welding

you will do - see chart on welder.

c. With assistance, set the cylinder

(not included) onto a shelf or cart near

the welder and secure the cylinder in

place with two straps (not included).

d. Remove the protective cap from the cylinder (if

present). Stand to the side of the valve opening,

and open the valve briefly to blow dust and dirt

from the valve opening. Close the cylinder valve.

e. Obtain an appropriate Regulator/Flowmeter

(not included) and close its valve completely.

Thread its inlet connector onto the

cylinder and wrench tighten.

Note: If the threads do not match, then the Regulator/

Flowmeter is likely for a different type of cylinder/gas.

f. Attach the Gas Hose securely to the

outlet of the Regulator/Flowmeter

using a hose clamp (sold separately).

–+

Ground Polarity: +

Ground

(Black)

Flux Core (Gas-less) Polarity Setup

DCEN

Torch Polarity: –

Knobs

Torch

(Red)

–+

Ground Polarity: –

Torch

(Red)

Solid Core (Gas Shielded) Polarity Setup

DCEP

Torch Polarity: +

Knobs

Ground

(Black)

Briefly open valve

to clean,

then close

valve.

SAFETY MAINTENANCEBASIC WELDING WELDING TIPSSETUP

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