Lincoln Electric POWER MIG 180 DUAL Operator's Manual

OPERATOR’S MANUAL

MANUAL DE OPERACIÓN

MANUEL DE L’OPÉRATEUR

Operator’s Manual

POWER MIG®180 DUAL

Register your machine:

www.lincolnelectric.com/register

Authorized Service and Distributor Locator:

www.lincolnelectric.com/locator

IMT10106-A | Issue D ate Aug-16

For use with machines having Code Numbers:

11828, 12631

Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

THANK YOU FOR SELECTING A QUALITY PRODUCT BY LINCOLN ELEC TRIC.

PLEASE EXAMINE CARTON AND EQUIPMENT FOR DAMAGE IMMEDIATELY

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.

SAFETY DEPENDS ON YOU

Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part.

DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly,

think before you act and be careful.

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

KEEP YOUR HEAD OUT OF THE FUMES.

DON’T get too close to the arc. Use corrective lenses if necessary to stay a reasonable distance away from the arc.

READ and obey the Safety Data Sheet (SDS) and the warning label that appears on all containers of welding materials.

USE ENOUGH VENTILATION or exhaust at the arc, or both, to keep the fumes and gases from your breathing zone and the general area.

IN A LARGE ROOM OR OUTDOORS, natural ventilation may be adequate if you keep your head out of the fumes (See below).

USE NATURAL DRAFTS or fans to keep the fumes away from your face.

If you de velop unusual symptoms, see your supervisor. Perhaps the welding atmosphere and ventilation system should be checked.

WEAR CORRECT EYE, EAR & BODY PROTECTION

PROTECT your eyes and face with welding helmet properly fitted and with proper grade of filter plate (See ANSI Z49.1).

PROTECT your body from welding spatter and arc flash with protective clothing including woolen clothing, flame-proof apron and gloves, leather leggings, and high boots.

PROTECT others from splatter, flash, and glare with protective screens or barriers.

IN SOME AREAS, protection from noise may be appropriate.

BE SURE protective equipment is in good condition.

Also, wear safety glasses in work area

AT ALL TIMES.

SPECIAL SITUATIONS

DO NOT WELD OR CUT containers or materials which previously had been in contact with hazardous substances unless they are properly cleaned. This is extremely dangerous.

DO NOT WELD OR CUT painted or plated parts unless special precautions with ventilation have been taken. They can release highly toxic fumes or gases.

Additional precautionary measures

PROTECT compressed gas cylinders from excessive heat, mechanical shocks, and arcs; fasten cylinders so they cannot fall.

BE SURE cylinders are never grounded or part of an electrical circuit.

REMOVE all potential fire hazards from welding area.

ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR IMMEDIATE USE AND KNOW HOW TO USE IT.

WARNING

CAUTION

Safety 01 of 04 - 5/16/2018

SECTION A:

WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

WARNING: Breathing diesel engine exhaust

exposes you to chemicals known to the State of California to cause cancer and birth defects,

or other reproductive harm.

• Always start and operate the engine in a well-ventilated area.

• If in an exposed area, vent the exhaust to the outside.

• Do not modify or tamper with the exhaust system.

• Do not idle the engine except as necessary.

For more information go to www.P65 warnings.ca.gov/diesel

WARNING: This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code § 25249.5 et seq.)

WARNING: Cancer and Reproductive Harm www.P65warnings.ca.gov

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

FOR ENGINE POWERED EQUIPMENT.

1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.

1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.

1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact

with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.

1.d. Keep all equipment safety guards, covers and devices in position and in good repair. Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.

1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.

1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.

1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is

hot.

ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.

2.c. Exposure to EMF fields in welding may have other health effects which are now not known.

2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Secure them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.

2.d.5. Do not work next to welding power source.

SAFETY

Safety 02 of 04 - 5/16/2018

ELECTRIC SHOCK CAN KILL.

3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.

In addition to the normal safety precautions, if

welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical (earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage

between the two can be the total of the open circuit voltage of both welders.

3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.

3.j. Also see It ems 6.c. and 8.

ARC RAYS CAN BURN.

4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES CAN BE DANGEROUS.

5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases. When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the breathing zone. When welding

hardfacing (see instructions on container or SDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation unless exposure assessments indicate otherwise. In confined spaces or in some circumstances, outdoors, a respirator may also be required. Additional precautions are also required when welding on galvanized steel.

5. b. The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits.

5.c. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating products.

5.d. Shielding gases used for arc welding can displace air and

cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the Safety Data Sheet (SDS) and follow your employer’s safety practices. SDS forms are available from your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

SAFETY

Safety 03 of 04 - 5/16/2018

WELDING AND CUTTING SPARKS CAN CAUSE FIRE OR EXPLOSION.

6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1) and the operating information for the equipment being used.

6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been “cleaned”. For information, purchase “Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society (see address above).

6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area.

6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

6.I. Read and follow NFPA 51B “Standard for Fire Prevention During Welding, Cutting and Other Hot Work”, available from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, MA 022690-9101.

6.j. Do not use a welding power source for pipe thawing.

CYLINDER MAY EXPLODE IF DAMAGED.

7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to physical damage.

• A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,” available from the Compressed Gas Association, 14501 George Carter Way Chantilly, VA 20151.

FOR ELECTRICALLY POWERED EQUIPMENT.

8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.

8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations.

8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.

Refer to

http://www.lincolnelectric.com/safety

for additional safety information.

SAFETY

Safety 04 of 04 - 5/16/2018

NOTES

OPERATOR’S MANUAL

3

TABLE OF CONTENTS

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A-1

INSTALLATIONPOWER MIG®180 DUAL

 

1 If connected to a circuit protected by fuses use Time Delay Fuse

marked “D”.

2 Requirements for maximum output: In order to utilize the maximum output

capability of the machine, a branch circuit capable of 30 amps @ 120 volts, 60Hz is required.

Read this entire installation section before you s

tart installation.

INSTALLATION

ELECTRIC SHOCK CAN KILL.

• Only qualified personnel should perform this installation.

• Only personnel that have read and understood the POWER MIG

®

180 DUAL

O

perator’s 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

®

180 DUAL power switch is to be in the OFF (“O”) position when installing work cable and gun and when connecting power cord to input power.



Locate the POWER MIG®180 Dual in a dry location where there is free circulation of clean air into the louvers in the back and out the front of the unit. A location that minimizes the amount of smoke and dirt drawn into the rear louvers reduces the chance of dirt accumulation that can block air passages and cause overheating.



POWER MIG®180 DUAL cannot be stacked.



Each machine must be placed on a secure, level surface, directly or on recommended cart. The machine may topple over if this procedure is not followed.

WARNING

INPUT – SINGLE PHASE ONLY

Standard Voltage/Frequency Input Current

230 V 60 Hz 208 V 60 Hz 1

20 V 60 Hz

20 Amps @ rated output

RATED OUTPUT

Voltage/Duty Cycle Current Voltage at Rated Amperes

230 V 30% 208 V 30% 120 V 20%

130 Amps 130 Amps

90 Amps

20

17.6

19.5

OUTPUT

Welding Current Range

Open Circuit

Voltage

Wire Speed Range

(208 V / 230 V) 30-180 Amps (120 V) 30-140 Amps

34 V 33 V

50 - 500 in/min.

(1.3 - 12.7 m/min.)

PHYSICAL DIMENSIONS

Height Width Depth Weight

14.08 in.

(357.6 mm)

10.37 in.

(263.4 mm)

18.78 in.

(477.6 mm)

66 lbs.

(30 kg.)

RECOMMENDED INPUT CABLE AND FUSE SIZES

Input Voltage /

Frequence

Fuse or

Breaker

Size

1

Input

Amps

(Power Cord) Lincoln

Electric Part Number

230 V / 208 V 60 Hz

120 V 60 Hz

40 Amp

20 Amp

2

20 20

M22590 M22589

A-2

INSTALLATIONPOWER MIG®180 DUAL



1. Wire Feeder Welder.

2. Work Cable & Clamp.

3. Magnum PRO 100L Welding Gun.

4. 3 (qty) .035(0.9mm) Contact Tips (1 installed on the welding gun) & 3 (qty) .025(0.6mm) Contact Tips.

5. Spool of .035(0.9mm) diameter NR-211MP Innershield Flux-cored Wire.

6. Spool of .025(0.6mm) diameter L-56 MIG Wire.

7. .025-.030(0.6-0.9mm) Smooth Drive Roll.

8. .035(0.9mm) Smooth Drive Roll.

9. .030 -.045(0.8-1.1mm) Knurled Drive Roll (Installed on Machine).

10. .025” -.035” (0.6 - 0.9mm) Inner Wire guide.

11. .035” -.045” (0.9 - 1.1mm) Inner Wire Guide.

(Installed on Machine).

12. Outer Wire Guide (Installed on Machine).

13. Black Flux-cored Gasless Gun Nozzle.

14. Copper MIG Gas Gun Nozzle. (Installed on welding gun).

15. Regulator

16. Gas Hose

17. 230V Input Cord

18. 120V Input Cord

19. Learn to Weld (LTW1 Manual)

20. How to Weld DVD

21. 2” Spindle Adapter (For 8” Reel of wire)

22. Accessory Bag

OPERATOR’S MANUAL

Welding Guide

LEARNING TO WELD

L

TW1

31/70 eta D eussI |

Welding Safety Interactive Web Guide f

or mobile devices

OUTER WIRE GUIDE

INNER WIRE GUIDE .025-.035 (.6-.9mm)

INNER WIRE GUIDE .035-.045 (.9-1.1mm)

1

5

7 8 9 10 11 12

13

14

15

19

18

17

21

20

22

16

6

2

3

4

.035 .035 .025 .025 .025

B-1

OPERATION

SAFETY PRECAUTIONS

Read entire operation section before operating the WIRE FEEDER WELDER.

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or e

lectrode 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.

WELDING SPARKS can cause fire or explosion.

• Keep flammable material away.

• Do not weld on closed containers.

ARC RAYS can burn eyes and skin.

• Wear eye, ear and body protection.

Observe all safety information

throughout this manual.



This small portable wire feed welder is capable of MIG welding on s

teel, stainless steel, and aluminum. The wire feed welder is also

capable of flux-cored welding on mild steel.

MIG welding stands for Metal Inert Gas welding and requires a shielding gas to protect the weld until it cools. Appropriate shielding gas based on the type of material you are welding can be purchased separately from your local welding gas distributor. MIG welding is ideal for welding on thinner and clean materials when a very clean excellent cosmetic looking weld is required. An example would be automotive body panels.

Self Shielding Flux-cored Welding does not require a separate shielding gas to protect the weld since the welding wire has special additives known as flux to protect the weld until it cools. Flux-cored welding is ideal for medium to thicker material and if welding on painted or rusty steel. Flux-cored welding is also ideal in outdoor applications where windy conditions might blow the MIG shielding gas away from the weld. Flux-cored welding produces a good looking weld but does not produce an excellent weld appearance as MIG welding 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 aluminum welding wire is soft an optional aluminum spool gun is recommended for best results. A welding Procedure Decal is located inside machine door to help provide suggested settings for welding.



GMAW (MIG)

• Gas Metal Arc Welding

FCAW (INNERSHIELD OR OUTERSHIELD)

• Flux Core Arc Welding

WARNING

POWER MIG®180 DUAL

B-2

OPERATION



This machine has the following controls:

(See Figure B.1)

1. POWER SWITCH – Turns power on and off to the machine.

2. ARC VOLTAGE CONTROL – This knob sets the output voltage

o

f the machine. Along with wire feed speed (WFS) this control sets a weld procedure. Refer to the procedure decal on the inside wire drive compartment door to set a correct welding procedure based on type of material and thickness being welded.

3. WIRE FEED SPEED CONTROL (WFS) – The knob sets the

speed that the machine feeds wire. Along with arc voltage this control sets a weld procedure. Refer to the procedure decal on the inside wire drive compartment door to set a correct welding procedure based on type of material and thickness being welded.

FIGURE B.1

(

See Figure B.2)

4

. GUN TRIGGER – Pressing the trigger activates the wire drive

to feed wire and energizes the output of the machine. Press the trigger to weld and release the trigger to stop welding.

5. WELDING GUN – Delivers wire and welding current 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 nozzle protects

the mounting threads on the gun. When MIG welding the copper nozzle funnels the shielding gas to the weld.

6. WORK CLAMP & CABLE – Clamps to the work piece being

welded and completes the electrical welding circuit.

7. GUN TRIGGER CONNECTOR RECEPTACLE – Plug the 4 pin

gun trigger connector into this receptacle.

FIGURE B.2

2

1

3

5C 5B

5A

4

5

7

6

POWER MIG®180 DUAL

OPERATOR’S MANUAL

B-3

OPERATION

(See Figure B.3)

8. WELDING GUN CONNECTOR BUSHING & THUMBSCREW –

Provides electrical power to the welding gun. The thumbscrew holds the welding gun into the connector block. (Front of Machine, Side Door and Wire Drive Cover have been removed for clarity of Items 8 and 9).

9. OUTPUT TERMINALS –These connections allow for changing

t

he welding polarity of the machine depending on whether

you are MIG welding or flux-cored welding.

FIGURE B.3

(See Figure B.4)

10. WIRE SPOOL SPINDLE AND BRAKE – Holds a 4 inch

diameter spool. Use the 2 inch I.D. spindle adapter included with the machine to use 8 inch diameter spools. The Wing Nut sets the brake friction to prevent the spool from over rotating when the trigger is released.

FIGURE B.4

(See Figure B.5)

11. WIRE DRIVE & COMPONENTS – Feeds wire from the wire

spool through the drive and through the welding gun to the weld.

a. Top and Bottom Drive Roll – Drives the wire through the

drive system. The drive roll has a groove to match the specific wire type and diameter. Refer to Table B.1 for a

vailable 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.

12. SPOOL GUN SWITCH - Pre-Installed switch permits either

spool gun welding with the Magnum 100SG or standard welding with the Magnum PRO 100L.

FIGURE B.5

8

9

2” Spindle Adaptor (For 8” Reel of Wire)

4” Reel of Wire

12

INNER WIRE GUIDE REMOVED

LOWER DRIVE ROLL REMOVED

OUTER WIRE GUIDE REMOVED

TOP DRIVE ROLL PRESSURE ARM

TENSION ADJUSTOR DOWN

POWER MIG®180 DUAL

B-4

OPERATION

TABLE B.1

(See Figure B.6 for the following Items.)

13. CIRCUIT BREAKER – If the rated input current of the machine

is exceeded this circuit breaker will trip. Press to reset.

14. GAS INLET – Shielding gas connects to this inlet.

15. POWER CORD CONNECTION - Ensure power cord is

disconnected from input voltage supply prior to connecting or removing the cord from the machine. Connect the circular connector present on either input cord (120V or 230V) to the receptacle on the back of the machine. The power cord connector is secured to the receptacle by rotating the connector’s coupling ring clockwise, until the coupling ring latches on to the receptacle. Use only the appropriate (120V or 230V) power cords supplied by the Lincoln Electric Company.

FIGURE B.6

13 14 15

POWER MIG®180 DUAL

OPERATOR’S MANUAL

DRIVE ROLL AND WIRE GUIDES

Wire Diameter & Type Drive Roll

Drive Roll Part

Number

Inner Wire Guide

Part Number

.025”(0.6mm) MIG wire

.

025”/.030” (0.6mm/0.8mm)

Smooth Drive Roll

KP2529-1

.025”-.035” (0.6mm-0.9mm) Steel Wire Guide

KP2531-1

.030”(0.8mm) MIG wire

.035”(0.9mm) MIG wire

.035”(0.9mm)

Smooth Drive Roll

KP2529-2

.030”(0.8mm) flux-cored .035”(0.9mm) flux-cored

.030”/.045” (0.8mm/1.1mm)

Knurled Drive Roll

KP2529-3

.045”(1.1mm) flux-cored

.030”/.045” (0.8mm/1.1mm)

Knurled Drive Roll

KP2529-3

.045” (1.1mm)

Steel Wire Guide

KP2531-2

B-5

OPERATION



A

. Items needed for flux cored welding

1. 035”(0.9mm) Contact Tip

2.Black Flux Cored gun nozzle

3. Knurled Drive Roll

4. .025”-.035”(0.6mm-0.9mm) wire guide

5. .035”(0.9mm) NR-211MP Flux-Cored Wire

6. Welding Gun

7. Work Cable & Clamp





(See Figure B.7)

1. Open the case side door

2. Slide the connector end of the gun and cable through the hole i

n the machine front and into the gun connector bushing on

the wire drive.

3. Make sure the gun connector end is seated fully into the wire drive and tighten the thumbscrew to secure the gun connector.

4. Plug the gun trigger lead connector into the 4 pin gun trigger receptacle on the machine front.

5. Wire Drive Polarity. Flux cored welding requires negative (-) polarity. Connect the short power cable from the wire drive to the negative (-) output terminal and tighten the Wing Nut.

6. Work Lead Connection. Slide the lugged end of the work cable through the hole in the machine front and place on the positive (+) output terminal and tighten Wing Nut.

FIGURE B.7

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OCATE COMPONENTS

T

O CONNECT

TO THE

FRONT OF MACHINE

5

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1

NR-211-MP

.035

(

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BUSHING

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WORK LEAD CONNECTION POSITIVE "+" OUTPUT TERMINAL

THUMB SCREW TO TIGHTEN CONNECTOR

SHORT POWER CABLE NEGATIVE “–” OUTPUT TERMINAL

POWER MIG®180 DUAL

B-6

OPERATION





(See Figure B.8)

1. Locate the 4"(102mm) diameter spool of .035”(0.9mm) N

R-211MP flux-cored wire and place onto wire spool spindle.

Orient the spool so that the wire feeds off the top of the spool.

2. Secure spool in place by tightening the wing nut against the against the spacer that holds the wire spool on the spindle.

3. Open the top drive roll pressure arm by rotating the tension adjustor arm down and pivoting the drive roll pressure arm up.

4. Remove the outer wire guide.

4a. Slide gun out of drive slightly.

5. Remove the lower drive roll and inner wire guide.

6. Install the .025”-.035”(0.6mm-0.9mm) inner wire guide.

7. Install the .030”/.045”(0.8mm/1.1mm) knurled lower drive roll.

8. Carefully unwind and straighten the first six inches of welding wire from the spool. Do not let the end of the wire go to prevent the wire from unspooling.

FIGURE B.8

(See Figure B.9)

9. Feed the wire through the wire drive inlet along the inner wire guide groove and into the wire drive outlet on the gun side.

10. Close the top drive roll pressure arm and secure by pivoting the tension adjustor back to the up position.

11. Re-install the outer wire guide.

FIGURE B.9

TENSION ADJUSTOR LOCKED IN POSITION

LOWER DRIVE ROLL BE SURE WIRE IS IN GROOVE

W

IRE SPOOL

.

035" (0.9mm)

SLIDE WIRE INTO GUN CONNECTOR SIDE

TOP DRIVE ROLL PRESSED AGAINST L

OWER DRIVE ROLL

DIRECTION O

F WIRE

N

R-211-MP

WIRE SPOOL .035" (0.9mm)

NR-211-MP

INNER WIRE GUIDE REMOVED

LOWER DRIVE ROLL REMOVED

OUTER WIRE GUIDE REMOVED

TENSION ADJUSTOR DOWN

TOP DRIVE ROLL PRESSURE ARM

POWER MIG®180 DUAL

OPERATOR’S MANUAL

B-7

OPERATION

(See Figure B.10)

12. Remove the nozzle from the gun and contact tip and straighten the gun out flat.

FIGURE B.10

(See Figure B.11)

13. Turn the machine power to on and depress the gun trigger to feed the wire through the gun liner until the wire comes out of the threaded end of the gun several inches.

14. When trigger is released spool of wire should not unwind. Adjust wire spool brake accordingly.

MOVING PARTS AND ELECTRICAL

CONTACT CAN CAUSE INJURY OR

BE FATAL.

• When the gun trigger is depressed drive rolls, spool of wire and electrode are ELECTRICALLY LIVE (HOT).

• Keep away from moving parts and pinch points.

• Keep all Doors, Covers, panels and guards securely in place.

DO NOT REMOVE OR CONCEAL

WARNING LABELS.

------------------------------------------------------------------------

FIGURE B.11

15. Install the .035”(0.9mm) contact tip

16. Install the black flux cored welding nozzle to the gun.

17. Trim the wire stickout to 3/8”(9.5mm) from the contact tip. (See Figure B.12)

FIGURE B.12

18. Close the case side door. The machine is now ready to weld.

19. Read "Learn to Weld" (LTW1) that is included with the machine or watch the "How to Weld" DVD included with the machine.

20. Based on the thickness of the material you are going to weld and the type and diameter of the welding wire set the voltage and the wire feed speed per the procedure decal attached to the inside of the wire drive compartment door.

WARNING

NR-211-MP

REMOVED NOZZLE

REMOVED CONTACT TIP

L

AY CABLE AND GUN

S

TRAIGHTEN IN

THIS POSITION

NR-211-MP

DEPRESS TRIGGER T

O ACTIVATE WIRE,

W

HICH FEEDS THE WIRE

THRU THE LINER

FEED WIRE APPROXIMATELY 4.00” FROM GUN TUBE END

PLUG IN POWER I

NPUT CORD

ON/OFF SWITCH

IN

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POWER MIG®180 DUAL

OPERATOR’S MANUAL

B-8

OPERATION



A. Items needed for MIG welding

1. 025”(0.6mm) Contact Tip

2. Copper gun nozzle

3. .025”(0.6mm) Drive Roll

4. 025”-035”(0.6mm-0.9mm) Inner wire guide

5. .025”(0.6mm) SuperArc L-56 Solid MIG Wire

6. Welding Gun

7. Work Cable & Clamp

8. Gas Line

9. Gas Regulator

Bottle of 75/25 Ar/CO2shielding gas (or 100% CO2shielding gas) (note this requires a CO2regulator adapter which is sold separately.

5

3

4

2

7

6

1

8

9

75/25

FEMALE END

MIXES

MALE END

.025

L-56 MIG WIRE

CO

100%

2

(

REQU IRES AD APTER

SOLD SEPARATELY)

POWER MIG®180 DUAL

B-9

OPERATION

B. Install shielding gas

MIG welding requires an appropriate bottle of shielding gas. For mild steel either a cylinder bottle of Ar/CO

2

or 100% CO2can be used. Refer to the following instructions to properly connect shielding gas to the machine.

CYLINDER may explode if damaged. Keep cylinder upright and

chained to support

• Keep cylinder away from areas where it

may be damaged.

• Never lift welder with cylinder attached.

• Never allow welding electrode to touch cylinder.

• Keep cylinder away from welding or other live electrical

circuits.

BUILDUP OF SHIELDING GAS

may harm health or kill.

Shut off shielding gas supply when not in use.

1. Secure the cylinder to a wall or other stationary support to prevent the cylinder from falling over. Insulate the cylinder from the work circuit and earth ground. Refer to Figure B.13.

2. With the cylinder securely installed, remove the cylinder cap. Stand to one side away from the outlet and open the cylinder valve very slightly for an instant. This blows away any dust or dirt which may have accumulated in the valve outlet.

BE SURE TO KEEP YOUR FACE AWAY

FROM THE VALVE OUTLET WHEN

“CRACKING” THE VALVE.

Never stand directly in front of or behind the flow regulator when opening the cylinder valve. Always stand to one side.

FIGURE B.13

3. Attach the flow regulator to the cylinder valve and tighten the union nut securely with a wrench.

NOTE: If connecting to 100% CO2cylinder, a CO2regulator

adapter is required. Purchase separately S19298 CO2adapter be sure to install plastic washer included in the fitting on the bottle side.(See Figure B.13 )

4. Refer to Figure B.13. Attach one end of inlet gas hose to the outlet fitting of the flow regulator and tighten the union nut securely with a wrench. Connect the other end to the machine Solenoid Inlet Fitting (5/8-18 female threads — for CGA — 032 fitting). Make certain the gas hose is not kinked or twisted.

Shielding Gas

1. For CO2, open the cylinder very slowly. For argon-mixed gas, open cylinder valve slowly a fraction of a turn. When the cylinder pressure gauge pointer stops moving, open the valve fully.

2. Set gas flow rate for 30 to 40 cubic feet per hour (14 to 18

I/min.) under normal conditions, increase to as high as 40 to 50 CFH (18 to 23.5 I/min.) for out of position welding.

3. Keep the cylinder valve closed, except when using the

machine.

WARNING

75/25

F

EMALE END

MALE END

CO

S19298

REGULATOR ADAPTER

PLASTIC WASHER

MIXES

100%

2

POWER MIG®180 DUAL

OPERATOR’S MANUAL

B-10

OPERATION

C. Connect leads and cables on the machine

(See Figure B.14)

1. Open the case side door.

2. Slide the connector end of the gun and cable through the hole o

f the machine front and into the gun connector bushing on

the wire drive.

3. Make sure the gun connector end is seated fully into the wire drive and tighten the thumbscrew to secure the gun.

4. Plug the gun trigger lead connector into the 4 pin gun trigger receptacle on the machine front.

5. Wire Drive Polarity. MIG welding requires Positive (+) polarity. Connect the short power cable from the wire drive to the positive (+) output terminal and tighten the thumbscrew.

6. Work Lead Connection. Slide the lugged end of the work cable through the hole in the machine front and place on the negative (-) output terminal and tighten thumbscrew.

FIGURE B.14

D. Load Wire Spool

(See Figure B.15)

1. Locate the 4"(102mm) diameter spool of .025”(0.6mm) L-56 s

olid MIG wire and place onto wire spool spindle. Orient the

spool so that the wire feeds off the top of the spool.

2. Secure spool in place by tightening the wing nut against the against the spacer that holds the wire spool on the spindle.

3. Open the top drive roll pressure arm by rotating the tension adjustor arm down and pivoting the idle roll pressure arm up.

4. Remove the outer wire guide.

4a. Slide gun out of drive slightly.

5. Remove the lower drive roll and inner wire guide.

6. Install the .025”-.035”(0.6mm-0.9mm) inner wire guide.

7. Install the .025”(0.6mm) smooth grooved lower drive roll.

8. Carefully unwind and straighten the first six inches of welding wire from the spool. Do not let the end of the wire go to prevent the wire from unspooling.

FIGURE B.15

(See Figure B.16)

9. Feed the wire through the wire drive inlet along the inner wire

guide groove and into the wire drive outlet on the gun side.

10. Close the top drive roll pressure arm and secure by pivoting

the tension adjustor back to the up position.

11. Re-install the outer wire guide.

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OCATE COMPONENTS

T

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TO THE

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(

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BUSHING

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SHORT POWER CONNECTION POSITIVE "+" OUTPUT TERMINAL

THUMB SCREW TO TIGHTEN CONNECTOR

WORK LEAD CABLE NEGATIVE “–” OUTPUT TERMINAL

L-56 SOLID WIRE

INNER WIRE GUIDE REMOVED

LOWER DRIVE ROLL REMOVED

OUTER WIRE GUIDE REMOVED

TENSION ADJUSTOR DOWN

T

OP DRIVE ROLL PRESSURE ARM

WIRE SPOOL .025" (0.6mm)

POWER MIG®180 DUAL

B-11

OPERATION

FIGURE B.16

(See Figure B.17)

12. Remove the nozzle from the gun and contact tip and straighten the gun out flat.

FIGURE B.17

MOVING PARTS AND ELECTRICAL CONTACT CAN CAUSE INJURY OR

BE FATAL.

• When the gun trigger is depressed drive rolls, spool of wire and electrode are ELECTRICALLY LIVE (HOT).

• Keep away from moving parts and pinch p

oints.

• Keep all Doors, Covers, panels and guards securely in place.

DO NOT REMOVE OR CONCEAL

WARNING LABELS.

------------------------------------------------------------------------

13. Turn the machine power to on and depress the gun trigger to

feed the wire through the gun liner until the wire comes out of the threaded end of the gun several inches. (See Figure B.18)

14. When trigger is released spool of wire should not unwind.

Adjust wire spool brake accordingly.

FIGURE B.18

15. Install the .025”(0.6mm) contact tip.

16. Install the Copper gas MIG welding nozzle to the gun.

TENSION ADJUSTOR LOCKED IN POSITION

LOWER DRIVE ROLL BE SURE WIRE IS IN GROOVE

SLIDE WIRE INTO GUN CONNECTOR SIDE

TOP DRIVE ROLL P

RESSED AGAINST

LOWER DRIVE ROLL

DIRECTION OF WIRE

L-56 SOLID WIRE

R

EMOVED NOZZLE

REMOVED CONTACT TIP

LAY CABLE AND GUN STRAIGHTEN IN THIS POSITION

L-56 SOLID WIRE

DEPRESS TRIGGER TO ACTIVATE WIRE, WHICH FEEDS THE WIRE THRU THE LINER

FEED WIRE APPROXIMATELY 4.00” FROM GUN TUBE END

PLUG IN POWER INPUT CORD

ON/OFF SWITCH

L-56 SOLID WIRE

WARNING

POWER MIG®180 DUAL

B-12

OPERATION

17. Trim the wire stickout to 3/8”(9.5mm) from the nozzle

end. (See Figure B.19)

FIGURE B.19

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.

 



1

. Disconnect Magnum Pro 100L Gun.

2

. Install optional K3269-1 Magnum PRO 100SG spool gun per

instructions included with gun.

3. Set Gun selector toggle switch to Spool Gun position. (See Figure B.20)

4. Connect a bottle of 100% Argon shielding Gas per previous section.

5. Follow the MIG welding steps in the previous section.

6. Turn machine on and make weld per recommended settings on Procedure Decal inside machine door.

FIGURE B.20

INSTALL .025 CONTACT TIP

INSTALL COPPER NOZZLE

TRIM WIRE STICKOUT 3/8"(9.5mm) from the Copper Nozzle

Set Gun selector toggle switch to Spool Gun position.

Load Aluminum Spool

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I

N

SHORT POWER CONNECTION POSITIVE "+" OUTPUT TERMINAL

WORK LEAD CABLE NEGATIVE “–” OUTPUT TERMINAL

Connect Gas

POWER MIG®180 DUAL

OPERATOR’S MANUAL

ACCESSORIES

K2525-1 - Spot Timer Kit

Timer kit, when turned on, allows you to set a fixed weld time so t

hat when the gun trigger is pulled the machine will weld for a fixed time period up to 10 seconds. Ideal for making consistent spot welds when welding on thin sheet metal.

K2528-1 - 045 Innershield Kit (For 230V models)

Includes everything needed to weld with .045 diameter Innershield wire. Includes an .035/.045 Magnum™ 100L gun liner, .045 Contact Tip, gasless nozzle, knurled drive roll, .035-.045 inner wire guide, and a 10 lb. (4.5kg) spool of .045"(0.9mm) Innershield

®NR®

-212 wire.

K3269-1 - Magnum PRO 100SG Spool Gun

Designed to easily feed small 4" diameter (1lb. spools of) .030 or .035 aluminum wire. Includes gun, adapter kit, three extra .035 contact tips, gas nozzle, and spool of Superglaze 4043 .035" diameter welding wire. Packaged in a convenient carry case.

K2377-1 - Small Canvas Cover

Protect your machine when not in use. Made from attractive red canvas that is flame retardant, mildew resistant and water repellent. Includes a convenient side pocket to hold welding gun.

For additional Optional and Miscellaneous Parts (See Parts Pages)

POWER MIG®180 DUAL

C-1

ACCESSORIES

C-2

ACCESSORIES

POWER MIG®180 DUAL

3-3/4"

4"

16"

3-11/16"

8-1/16"

3-13/32"

9/32" DRILL 3 PLACES

1/4"-20 X 1/2" Hex Head Cap Screw (2 Required)

1/4"-20 X 1" Thread Forming Screw (1 Required)

1/4"-20 Flanged Nut (2 Required)

For mounting welding machines to K520 carts that do not have slotted mounting holes. Drill 9/32” holes (3 places) into the cart top as shown and attach the welding machine to the cart with the proper hardware shown.

K520—Utility Cart Heavy duty cart stores and transports welder, 150 cubic foot s

hielding gas cylinder, welding cables and accessories. Includes stable platforms for welder and gas bottle platform, lower tray for added storage capacity and adjustable height handle.

OPERATOR’S MANUAL

C-3

ACCESSORIES

POWER MIG®180 DUAL

2-15/16"

3-3/16"

7-9/16"

1-1/2"

13-1/2"

1-1/4"

9/32" DRILL 3 PLACES

1/4"-20 Flange Nut (2 Required)

1/4"-20 X 1" Thread Forming Screw (1 Required)

1/4"-20 X 1/2" Hex Head Cap Screw (2 Required)

For mounting welding machines to K2275-1 carts that do not have slotted mounting holes. Drill 9/32” holes (3 places) into the cart top as shown and attach the welding machine to the cart with the proper hardware shown.

K

2275-1 - Welding Cart

Lightweight cart stores and transports welder, 80 cubic foot shielding gas cylinder, welding cables and accessories. Includes an angled top shelf for easy access to controls, lower tray for added storage capacity, a sturdy fixed handle and convenient cable wrap hanger.

D-1

MAINTENANCE

SAFETY PRECAUTIONS

ELECTRIC SHOCK can kill.

•

Disconnect input power by removing

plug from receptacle before working inside POWER MIG® 180 DUAL.

• Use only grounded receptacle. Do not

touch electrically “hot” parts inside POWER MIG® 180 DUAL.

• Have qualified personnel do the

maintenance and trouble shooting work.





No user serviceable parts inside! Do not attempt to perform service in the power source (fixed) side of the POWER MIG® 180 DUAL. Take the unit to an authorized Lincoln Service Center if you experience problems. NO maintenance is required.

In extremely dusty locations, dirt may clog the air passages causing the welder to run hot with premature tripping of thermal protection. If so, blow dirt out of the welder with low pressure air at regular intervals to eliminate excessive dirt and dust build-up on internal parts.



1. When necessary, vacuum accumulated dirt from gearbox and wire feed section.

2. Occasionally inspect the incoming guide tube and clean inside diameter if necessary.

3. Motor and gearbox have lifetime lubrication and require no maintenance.



Has lifetime lubrication — requires no maintenance.



Requires no maintenance. Do not lubricate shaft.





GUN CABLE CLEANING

Clean cable liner after using approximately 300 lbs (136 kg) of solid wire or 50 lbs (23 kg) of flux-cored wire. Remove the cable f

rom the wire feeder and lay it out straight on the floor. Remove the contact tip from the gun. Using low pressure air, gently blow out the cable liner from the gas diffuser end.

E

xcessive pressure at the start may cause the dirt

to form a plug.

Flex the cable over its entire length and again blow out the cable. Repeat this procedure until no further dirt comes out.

Contact Tips, Nozzles, and Gun Tubes

1. Dirt can accumulate in the contact tip hole and restrict wire

feeding. After each spool of wire is used, remove the contact tip and clean it by pushing a short piece of wire through the tip repeatedly. Use the wire as a reamer to remove dirt that may be adhering to the wall of the hole through the tip.

2. Replace worn contact tips as required. A variable or “hunting”

arc is a typical symptom of a worn contact tip. To install a new tip, choose the correct size contact tip for the electrode being used (wire size is stenciled on the side of the contact tip) and screw it snugly into the gas diffuser.

3. Remove spatter from inside of gas nozzle and from tip after

each 10 minutes of arc time or as required.

4. Be sure the gas nozzle is fully screwed onto the diffuser for

gas shielded processes. For the Innershield® process, the gasless nozzle should screw onto the diffuser.

5. To remove gun tube from gun, remove gas nozzle or gasless

nozzle and remove diffuser from gun tube. Remove both collars from each end of the gun handle and separate the handle halves. Loosen the locking nut holding the gun tube in place against the gun end cable connector. Unscrew gun tube from cable connector. To install gun tube, screw the locking nut on the gun tube as far as possible. Then screw the gun tube into the cable connector until it bottoms. Then unscrew (no more than one turn) the gun tube until its axis is perpendicular to the flat sides of the cable connector and pointed in the direction of the trigger. Tighten the locking nut so as to maintain the proper relationship between the gun tube and the cable connector. Replace the gun handle, trigger and diffuser. Replace the gas nozzle or gasless nozzle.

WARNING

CAUTION

POWER MIG®180 DUAL

OPERATOR’S MANUAL

D-2

MAINTENANCE





The POWER MIG® 180 DUAL is equipped with a circuit breaker and a thermostat which protects the machine from damage if maximum output is exceeded. The circuit breaker button will e

xtend out when tripped. The circuit breaker must be manually

reset.



The POWER MIG® 180 DUAL has a rated output duty cycle as defined in the Technical Specification page. If the duty cycle is exceeded, a thermal protector will shut off the output until the machine cools to a reasonable operating temperature. This is an automatic function of the POWER MIG® 180 DUAL and does not require user intervention. The fan continues to run during cooling.



The POWER MIG® 180 DUAL has built-in protection for wire drive motor overload.



NOTICE: The variation in cable lengths prevents the interchangeability of liners. Once a liner has been cut for a particular gun, it should not be installed in another gun unless it can meet the liner cutoff length requirement. Refer to Figure D.1.

1. Remove the gas nozzle from the gun by unscrewing counterclockwise.

2. Remove the existing contact tip from the gun by unscrewing counter-clockwise.

3. Remove the gas diffuser from the gun tube by unscrewing counter-clockwise.

4. Lay the gun and cable out straight on a flat surface. Loosen the set screw located in the brass connector at the wire feeder end of the cable. Pull the liner out of the cable.

5. Insert a new untrimmed liner into the connector end of the cable. Be sure the liner bushing is stenciled appropriately for the wire size being used.

6. Fully seat the liner bushing into the connector. Tighten the set screw on the brass cable connector. At this time, the gas diffuser should not be installed onto the end of the gun tube.

7. With the gas nozzle and diffuser removed from the gun tube, be sure the cable is straight, and then trim the liner to the length shown in the Figure D.1. Remove any burrs from the end of the liner.

8. Screw the gas diffuser onto the end of the gun tube and securely tighten.

9. Replace the contact tip and nozzle.

FIGURE D.1



The gun handle consists of two halves that are held together with a collar on each end. To open up the handle, turn the collars approximately 60 degrees counter-clockwise until the collar reaches a stop. Then pull the collar off the gun handle. If the collars are difficult to turn, position the gun handle against a corner, place a screwdriver against the tab on the collar and give the screwdriver a sharp blow to turn the collar past an internal locking rib. See Figure D.2.

FIGURE D.2

S

et Screw

G

as Diffuser

1-1/4”(31.8 mm) Liner Trim Length

G

as Nozzle or

G

asless Nozzle

B

rass Cable Connector

L

iner Assembly (liner bushing to be sealed tight a

gainst brass cable connector)

POWER MIG®180 DUAL

„

Counter-clockwise

E-1

TROUBLESHOOTING

How to Use troUblesHooting gUide

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions d

etailed throughout this manual.

This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the threestep procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists the obvious external possibilities that may contribute to the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for the Possible Cause, generally it states to contact your local Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform the Recommended Course of Action safely, contact your local Lincoln Authorized Field Service Facility.

WARNING

POWER MIG®180 DUAL

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Lincoln Authorized Service Facility for technical troubleshooting assistance before you proceed.

WWW.LINCOLNELECTRIC.COM/LOCATOR

OPERATOR’S MANUAL

E-2

TROUBLESHOOTING

POWER MIG®180 DUAL

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Lincoln Authorized Service Facility for technical troubleshooting assistance before you proceed.

WWW.LINCOLNELECTRIC.COM/LOCATOR

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

OUTPUT PROBLEMS

Major physical or electrical damage is evident.

“Do not Plug in machine or turn it on”.

Contact your local Authorized Field Service Facility.

If all recommended possible areas of misadjustment have been checked and the problem persists, CONTACT YOUR LOCAL

LINCOLN AUTHORIZED FIELD SERVICE FACILITY.

No wire feed, weld output or gas flow when gun trigger is pulled. Fan does NOT operate.

1. Make sure correct voltage is applied to the machine.

2. Make certain that power switch is in the ON position.

3. Make sure circuit breaker is reset.

No wire feed, weld output or gas flow when gun trigger is pulled.

Fan operates normally.

1. The thermostat may be tripped due to overheating. Let machine cool. Weld at lower duty cycle.

2. Check for obstructions in air flow. Check Gun Trigger connections. See Installation section.

3. Gun trigger may be faulty.

FEEDING PROBLEMS

No wire feed when gun trigger is pulled. Fan runs, gas flows and machine has correct open circuit voltage (33V) – weld output.

1. If the wire drive motor is running make sure that the correct drive rolls are installed in the machine.

If all recommended possible areas of misadjustment have been checked and the problem persists, CONTACT YOUR LOCAL

LINCOLN AUTHORIZED FIELD SERVICE FACILITY

2. Check for clogged cable liner or contact tip.

3. Check for proper size cable liner and contact tip.

4. Check if the spool gun switch, located in

the wire drive compartment, is set to the desired location.

E-3

TROUBLESHOOTING

POWER MIG®180 DUAL

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

GAS FLOW PROBLEMS

Low or no gas flow when gun trigger is p

ulled. Wire feed, weld output and fan

operate normally.

1. Check gas supply, flow regulator and g

as hoses.

If all recommended possible areas of misadjustment have been checked and the p

roblem persists, CONTACT YOUR LOCAL

LINCOLN AUTHORIZED FIELD SERVICE FACILITY.

2. Check gun connection to machine for obstruction or leaky seals.

WELDING PROBLEMS

Arc is unstable – Poor starting. 1. Check for correct input voltage to

machine.

If all recommended possible areas of misadjustment have been checked and the problem persists, CONTACT YOUR LOCAL

LINCOLN AUTHORIZED FIELD SERVICE FACILITY

2. Check for proper electrode polarity for process.

3. Check gun tip for wear or damage and proper size – Replace.

4. Check for proper gas and flow rate for process. (For MIG only.)

5. Check work cable for loose or faulty connections.

6. Check gun for damage or breaks.

7. Check for proper drive roll orientation and alignment.

8. Check liner for proper size.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Lincoln Authorized Service Facility for technical troubleshooting assistance before you proceed.

WWW.LINCOLNELECTRIC.COM/LOCATOR

OPERATOR’S MANUAL

F-1

DIAGRAMS

POWER MIG®180 DUAL

WARNING

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a

particular code is pasted inside the machine on one of the enclosure panels.

Lincoln Electric POWER MIG 180 DUAL Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual