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. Visit our website at: http://www.harborfreight.com Email our technical support at: tech@harborfreight.
Table of Contents SAFETY Safety.......................................................... 2 Setup........................................................... 7 Specifications.............................................. 7 Basic Welding............................................. 15 Welding Tips............................................... 23 Maintenance............................................... 27 Parts List and Diagrams............................. 30 Warranty....................................
SAFETY Fume and Gas Safety FUMES AND GASES can be hazardous to your health. 2. Do not use near degreasing or painting operations. 3. Keep head out of fumes. Do not breathe exhaust fumes. 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.
Electrical Safety ELECTRIC SHOCK can KILL. SAFETY 1. Turn off, disconnect power, and discharge electrode to ground before setting down torch/electrode holder and before service. 6. Do not expose welders to rain or wet conditions. Water entering a welder will increase the risk of electric shock. 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.
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. 5. Use the welder and accessories in accordance with these instructions, taking into account the working conditions and the work to be performed.
Grounding SAFETY 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.
Symbology Cooling Fan Housing Ground Point SAFETY Open Circuit Voltage Kilovolt Amperes (Volts / 1000 * Amperes) Inches Per Minute American Wire Gauge SETUP Overheat Shutdown Indicator Amperes Specifications Power Input Welding Output Capacity Rated Duty Cycle Open Circuit Voltage KVA Wire Speed Cable Sizes Wire Spool Capacity Accessories SKU 68886 240 V~, 24 A DCEN/DCEP 30-180 A 18 gauge (0.048″) to 1/4″ (0.
Setup SAFETY 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 SETUP 1.
Wire Spool Installation I 1. Turn the welder OFF and unplug it before proceeding. SAFETY O MIG 180 WIRE FEED WELDER ITEM 68886 WIRE FEED SPEED 240V~ 2. Pull up on the door latch, then open the Door. SETUP 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 Spring Upper Spool Plate 4. Place the new Wire Spool over the Spool Spindle and on top of the lower Spool Plate as illustrated.
Flux Core (Gas-less) Polarity Setup SAFETY 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). DCEN Knobs Torch Polarity: – + – Torch (Red) Ground (Black) Ground Polarity: + 6b.
Feed Tensioner Feed Swing Arm SETUP Feed Roller Knob A. Twist the Feed Roller Knob about 1/3 of a turn counterclockwise until it stops. 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") B Feed Roller .023 groove and stamp .030/.035 groove and stamp B. Pull the Feed Roller Knob straight off to expose the Feed Roller. BASIC WELDING A D MAINTENANCE D.
IMPORTANT: SAFETY 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. SETUP 9. Cut off all bent and crimped wire. The cut end must have no burrs or sharp edges; cut again if needed. welding wire HOLD WIRE SECURELY Wire Liner 10. Keep tension on the wire and guide at least 12 inches of wire into the Wire Liners. BASIC WELDING Wire Spool 11.
WARNING 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. SETUP 2. Do not touch internal welder components while it is plugged in. SAFETY The following steps require applying power to the welder with the cover open. 15. Do not touch the Torch’s Trigger. Plug the Power Cord into its electrical outlet and turn the welder ON.
Incrementally increase tension until wire bends. ″ SETUP 18. TURN THE WELDER OFF. 2-3 SAFETY 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. I O MIG 180 WIRE FEED WELDER ITEM 68886 WIRE FEED SPEED 240V~ BASIC WELDING 19.
Basic Welding SAFETY Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before welding. SETUP 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.
Control Panel Layout SAFETY Overload Indicator Torch Cable I SETUP O Power Switch Current Switch MIG 180 WIRE FEED WELDER Wire Speed Dial ITEM 68886 BASIC WELDING WIRE FEED SPEED 240V~ Ground Cable WELDING TIPS Overload Indicator: This lights up if duty cycle work period is exceeded, resulting in overheating the welder.
SETUP This welder has an internal thermal protection system to help prevent this sort of over-stress. When the unit overheats, it automatically shuts down and the Overload Indicator lights, then the welder automatically returns to service after cooling off. Rest the Torch on an electrically non-conductive, heat‑proof surface, such as a concrete slab, well clear of the ground clamp while allowing the welder to cool with the Power Switch on, so that the internal Fan will help cool the welder.
Flux Weld Settings NO GAS SAFETY DCEN Polarity Metal Thickness Material Being Welded Mild Steel Wire Type Shielding Gas Flux-core (E71T-GS) NO GAS Required Wire Suggested Diameter Settings Current .030″ Wire Feed .035″ Wire Feed 22 Ga .030″ 0.8mm 18 Ga .048″ 1.2mm 16 Ga .060″ 1.5mm 14 Ga .075″ 2.0mm 1/8″ 3.2mm 3/16″ 4.8mm B 2.5 C 3 C 4 C 4 C 5 D 5 D 6 D 7 E 9 Current 1/4″ 6.
Setting Up The Weld SAFETY 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.
SAFETY 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. SETUP 5. Gas shielded, solid-core wire only: Open gas tank valve and adjust regulator/ flowmeter to flow rate indicated on chart. BASIC WELDING 6.
Basic Welding Technique stringer bead weave bead 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. Weld Torch angles, viewed from front of weld joint. 90° 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.
SAFETY 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.
A typical flux-core wire (FCAW) weld before cleaning. weld bead slag spatter base metal A typical solid wire (GMAW) weld before cleaning. spatter weld bead SETUP base metal Cleaning the Weld 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. Chipping Hammer 1. A weld from flux core wire will be covered by slag, use the Chipping Hammer to knock this off.
Weld Diagnosis Workpiece Heat Control / Weld Penetration SAFETY SETUP INADEQUATE PENETRATION PROPER PENETRATION EXCESS PENETRATION OR BURN-THROUGH Not hot enough Ideal heat Too hot How to increase workpiece heat and increase penetration: How to reduce workpiece heat and limit penetration: (to weld THICKER workpieces properly) (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 b.
Weld Problems 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. SAFETY Penetration (Workpiece Heat Control) 2. 3. 4. PROFILE VIEW POSSIBLE CAUSES AND SOLUTIONS 1. Improper clamping: Clamp workpieces securely. Make tack welds to hold workpieces. 2.
Excessive Spatter SAFETY Porosity Small cavities or holes in the bead. TOP VIEW 1. SETUP 2. 3. 4. TOP VIEW BASIC WELDING WELDING TIPS POSSIBLE CAUSES AND SOLUTIONS Incorrect polarity: Check that polarity is set correctly for type of welding. Insufficient shielding gas (MIG only): Increase flow of gas. Clean nozzle. Maintain proper stickout. Incorrect shielding gas (MIG only): Use shielding gas recommended by wire supplier. Dirty workpiece or welding wire: Clean workpiece down to bare metal.
TO PREVENT SERIOUS INJURY, FIRE AND BURNS: 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. + 1. Periodically remove the Side Panel, and using compressed air, blow out all dust from the interior. SAFETY Maintenance Torch concrete slab (or other heat-proof, non-conductive surface) 2. Store in a clean and dry location. SETUP 3.
Troubleshooting IMPORTANT! SAFETY 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 SETUP 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.
Troubleshooting (continued) 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 SETUP 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.
Parts List and Diagrams SAFETY Wiring Diagram Welding Torch Switch Thermal Relay SETUP Gas Gasless Welding Torch Ground Clamp Gas/Gasless Wire Feed Motor BASIC WELDING Parts List Part WELDING TIPS MAINTENANCE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 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 Rectifier Bracket Rec
Assembly Diagram 35 36 37 31 SAFETY 32 1 30 28 34 29 2 27 3 26 25 24 33 5 23 SETUP 4 6 22 21 8 20 9 19 10 BASIC WELDING 7 17 12 16 13 15 MAINTENANCE 14 WELDING TIPS 18 11 SKU 68886 For technical questions, please call 1-800-444-3353.
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.