8193724_manual

LINCOLN

ELECTRIC

• Sales and Service through Subsidiaries and Distributors Worldwide •Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

• World's Leader in Welding and Cutting Products •

POWER MIG (140, 180 MODELS)

OPERATOR’S MANUAL

IM890-AMay, 2007

Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However, youroverall safety can be increased byproper installation ... and thought-ful operation on your part. DONOT INSTALL, OPERATE ORREPAIR THIS EQUIPMENTWITHOUT READING THISMANUAL AND THE SAFETYPRECAUTIONS CONTAINEDTHROUGHOUT. And, mostimportantly, think before you actand be careful.

For use with machines having Code Numbers: 11254, 11255, 11256, 11257 and11444

Copyright © 2007 Lincoln Global Inc.

FOR ENGINEpowered equipment.

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

____________________________________________________1.b. Operate engines in open, well-ventilated

areas or vent the engine exhaust fumesoutdoors.

____________________________________________________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 beforerefueling to prevent spilled fuel from vaporiz-ing on contact with hot engine parts andigniting. Do not spill fuel when filling tank. Iffuel is spilled, wipe it up and do not startengine 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 andtools away from V-belts, gears, fans and all other movingparts when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requiring their removal is complete.Always use the greatest care when working near movingparts.

___________________________________________________1.f. Do not put your hands near the engine fan.

Do not attempt to override the governor oridler by pushing on the throttle control rodswhile the engine is running.

___________________________________________________1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto wire as appropriate.

iSAFETYi

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 youpurchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is availablefrom the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

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

WARNING

Mar ʻ95

ELECTRIC ANDMAGNETIC FIELDSmay be dangerous

2.a. Electric current flowing through any conductor causeslocalized Electric and Magnetic Fields (EMF). Weldingcurrent creates EMF fields around welding cables andwelding machines

2.b. EMF fields may interfere with some pacemakers, andwelders having a pacemaker should consult their physicianbefore welding.

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

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

2.d.1. Route the electrode and work cables together - Securethem 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 andwork cables. If the electrode cable is on your rightside, the work cable should also be on your right side.

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

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

1.h. To avoid scalding, do not remove theradiator pressure cap when the engine ishot.

CALIFORNIA PROPOSITION 65 WARNINGSDiesel engine exhaust and some of its constituentsare known to the State of California to cause can-cer, birth defects, and other reproductive harm.

The engine exhaust from this product containschemicals known to the State of California to causecancer, birth defects, or other reproductive harm.

The Above For Diesel Engines The Above For Gasoline Engines

ARC RAYS can burn.4.a. Use a shield with the proper filter and cover

plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards.

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

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

ELECTRIC SHOCK cankill.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 bareskin 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 fullarea of physical contact with work and ground.

In addition to the normal safety precautions, if weldingmust be performed under electrically hazardousconditions (in damp locations or while wearing wetclothing; on metal structures such as floors, gratings orscaffolds; when in cramped positions such as sitting,kneeling or lying, if there is a high risk of unavoidable oraccidental contact with the workpiece or ground) usethe 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 semiautomaticwelding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connectionshould 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 andwelding machine in good, safe operating condition. Replacedamaged insulation.

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

3.h. Never simultaneously touch electrically “hot” parts ofelectrode holders connected to two welders because voltagebetween the two can be the total of the open circuit voltageof both welders.

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

3.j. Also see Items 6.c. and 8.

FUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing thesefumes and gases. When welding, keepyour head out of the fume. Use enoughventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. Whenwelding with electrodes which require specialventilation such as stainless or hard facing (seeinstructions on container or MSDS) or on lead orcadmium plated steel and other metals or coatingswhich produce highly toxic fumes, keep exposure aslow as possible and below Threshold Limit Values (TLV)using local exhaust or mechanical ventilation. Inconfined spaces or in some circumstances, outdoors, arespirator may be required. Additional precautions arealso required when welding on galvanized steel.

5. b. The operation of welding fume control equipment is affectedby various factors including proper use and positioning ofthe equipment, maintenance of the equipment and the spe-cific welding procedure and application involved. Workerexposure level should be checked upon installation andperiodically thereafter to be certain it is within applicableOSHA PEL and ACGIH TLV limits.

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

5.d. Shielding gases used for arc welding can displace air andcause injury or death. Always use enough ventilation,especially in confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturerʼs instructions for thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow youremployerʼs safety practices. MSDS forms are available fromyour welding distributor or from the manufacturer.

5.f. Also see item 1.b.

AUG 06

iiSAFETYii

FOR ELECTRICALLYpowered equipment.

8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.

8.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturerʼsrecommendations.

8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturerʼs recommendations.

CYLINDER may explodeif damaged.7.a. Use only compressed gas cylinders

containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition.

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

7.c. Cylinders should be located:• Away from areas where they may be struck or subjected tophysical damage.

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

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

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

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

7.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,“Precautions for Safe Handling of Compressed Gases inCylinders,” available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.

Jan, 07

WELDING and CUTTINGSPARKS cancause fire or explosion.6.a. Remove fire hazards from the welding area.

If this is not possible, cover them to preventthe welding sparks from starting a fire.

Remember that welding sparks and hotmaterials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic 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 hazardoussituations. Refer to “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operating information for theequipment being used.

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

6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen “cleaned”. For information, purchase “RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances”, AWS F4.1 from the American Welding Society(see address above).

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

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

6.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passingthrough lifting chains, crane cables or other alternate cir-cuits. This can create fire hazards or overheat lifting chainsor cables until they fail.

6.h. Also see item 1.c.

6.I. Read and follow NFPA 51B “ Standard for Fire PreventionDuring Welding, Cutting and Other Hot Work”, availablefrom NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma022690-9101.

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

iiiSAFETYiii

PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes:

Sûreté Pour Soudage A LʼArc1. Protegez-vous contre la secousse électrique:

a. Les circuits à lʼélectrode et à la piéce sont sous tensionquand la machine à souder est en marche. Eviter toujourstout contact entre les parties sous tension et la peau nueou les vétements mouillés. Porter des gants secs et sanstrous pour isoler les mains.

b. Faire trés attention de bien sʼisoler de la masse quand onsoude dans des endroits humides, ou sur un planchermetallique ou des grilles metalliques, principalement dansles positions assis ou couché pour lesquelles une grandepartie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câblede soudage et la machine à souder en bon et sûr étatdefonctionnement.

d.Ne jamais plonger le porte-électrode dans lʼeau pour lerefroidir.

e. Ne jamais toucher simultanément les parties sous tensiondes porte-électrodes connectés à deux machines à souderparce que la tension entre les deux pinces peut être letotal de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source decourant pour soudage semi-automatique, ces precautionspour le porte-électrode sʼapplicuent aussi au pistolet desoudage.

2. Dans le cas de travail au dessus du niveau du sol, se protégercontre les chutes dans le cas ou on recoit un choc. Ne jamaisenrouler le câble-électrode autour de nʼimporte quelle partiedu corps.

3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,donc:

a. Utiliser un bon masque avec un verre filtrant appropriéainsi quʼun verre blanc afin de se protéger les yeux du ray-onnement de lʼarc et des projections quand on soude ouquand on regarde lʼarc.

b. Porter des vêtements convenables afin de protéger lapeau de soudeur et des aides contre le rayonnement delʻarc.

c. Protéger lʼautre personnel travaillant à proximité ausoudage à lʼaide dʼécrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de lʼarc desoudage. Se protéger avec des vêtements de protection libresde lʼhuile, tels que les gants en cuir, chemise épaisse, pan-talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone desoudage. Utiliser des lunettes avec écrans lateraux dans leszones où lʼon pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin deprévenir tout risque dʼincendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé dela masse. Un court-circuit accidental peut provoquer unéchauffement et un risque dʼincendie.

8. Sʼassurer que la masse est connectée le plus prés possiblede la zone de travail quʼil est pratique de le faire. Si on placela masse sur la charpente de la construction ou dʼautresendroits éloignés de la zone de travail, on augmente le risquede voir passer le courant de soudage par les chaines de lev-age, câbles de grue, ou autres circuits. Cela peut provoquerdes risques dʼincendie ou dʼechauffement des chaines et descâbles jusquʼà ce quʼils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.Ceci est particuliérement important pour le soudage de tôlesgalvanisées plombées, ou cadmiées ou tout autre métal quiproduit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenantdʼopérations de dégraissage, nettoyage ou pistolage. Lachaleur ou les rayons de lʼarc peuvent réagir avec les vapeursdu solvant pour produire du phosgéne (gas fortement toxique)ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,voir le code “Code for safety in welding and cutting” CSAStandard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR

1. Relier à la terre le chassis du poste conformement au code delʼélectricité et aux recommendations du fabricant. Le dispositifde montage ou la piece à souder doit être branché à unebonne mise à la terre.

2. Autant que possible, Iʼinstallation et lʼentretien du poste seronteffectués par un électricien qualifié.

3. Avant de faires des travaux à lʼinterieur de poste, la debranch-er à lʼinterrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leurplace.

Mar. ʻ93

ivSAFETYiv

vINSTALLATION


v

EN 60974-10

viINSTALLATION


vi

EN 60974-10:

viivii

TThhaannkk YYoouu for selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you!

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep ithandy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.The level of seriousness to be applied to each is explained below:

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

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

Please Examine Carton and Equipment For Damage ImmediatelyWhen this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claimsfor material damaged in shipment must be made by the purchaser against the transportation company at thetime the shipment is received.

Please record your equipment identification information below for future reference. This information can befound on your machine nameplate.

Product _________________________________________________________________________________Model Number ___________________________________________________________________________Code Number or Date Code_________________________________________________________________Serial Number____________________________________________________________________________Date Purchased___________________________________________________________________________Where Purchased_________________________________________________________________________Whenever you request replacement parts or information on this equipment, always supply the information youhave recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packetaccompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then“Product Registration”. Please complete the form and submit your registration.

CUSTOMER ASSISTANCE POLICYThe business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask LincolnElectric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs particular purpose,with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating orcorrecting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter anywarranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the controlof, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained inapplying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.comfor any updated information.

viii viii TABLE OF CONTENTSPage

––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––

Installation .......................................................................................................Section ATechnical Specifications.................................................................................A-1, A-2Safety Precautions.................................................................................................A-3

Location...........................................................................................................A-3Stacking ..........................................................................................................A-3Tilting...............................................................................................................A-3

Identify and Locate Components ...........................................................................A-4________________________________________________________________________________

Operation .........................................................................................................Section BSafety and Product Description .............................................................................B-1Controls and Settings.....................................................................................B-2, B-3Drive Roll and Wire Guides Table .........................................................................B-4Setting Up and Making a Flux-Cored Weld.............................................B-5 thru B-7Setting Up and Making a MIG Weld and Install Shielding Gas..............B-8 thru B-11Setting Up and Making a Aluminum Weld ...........................................................B-12

________________________________________________________________________

Accessories .....................................................................................................Section COptional Accessories.............................................................................................C-1Utility Carts ....................................................................................................C-2, C-3

________________________________________________________________________

Maintenance..............................................................................................Section DSafety Precautions ................................................................................................D-1Wire Feed Compartment, Fan Motor, Wire Reel Maintenance .............................D-1Gun And Cable Maintenance ................................................................................D-2Overload Protection...............................................................................................D-2Component Replacement Procedures ..................................................................D-3

________________________________________________________________________

Troubleshooting ..............................................................................................Section ESafety Precautions.................................................................................................E-1How to Use Troubleshooting Guide.......................................................................E-1Troubleshooting Guide.............................................................................E-2 thru E-4

________________________________________________________________________

Wiring Diagram and Dimension Print ............................................................Section F________________________________________________________________________

Parts Lists................................................................................................P-533, P-202-E________________________________________________________________________

A-1INSTALLATION


A-1TECHNICAL SPECIFICATIONS 180 Amp units (K2472-1 180T, K2473-1 180C)

INPUT – SINGLE PHASE ONLY

RATED OUTPUT

OUTPUT

Standard Voltage/Frequency Input Current230 V 60 Hz 20 Amps @ rated output208 V 60 Hz 20 Amps @ rated output

Voltage/Duty Cycle Current Voltage at Rated Amperes230 V 30% 130 Amps 20 208 V 30% 130 Amps 17

Welding Current Range Open Circuit Voltage Wire Speed Range30-180 Amps 34 V 50 - 500 in/min.

(1.3 - 12.7 m/min.)

Input Voltage/Frequency Fuse or Breaker Size1 Input Amps Power Cord

230 V 60 Hz 40 Amp Super Lag 20 50 Amp, 250 V,Three Prong Plug

(NEMA Type 6-50P)

RECOMMENDED INPUT CABLE AND FUSE SIZES

Height Width Depth Weight14.0 in 10.15 in 18.6 in 66 Ibs357 mm 258 mm 472 mm 30 kg

PHYSICAL DIMENSIONS

1 If connected to a circuit protected by fuses use Time Delay Fuse marked “D”.

140 Amp units (K2470-1 140T, K2471-1 140C)INPUT – SINGLE PHASE ONLY

RATED OUTPUT

OUTPUT

Standard Voltage/Frequency Input Current120 V / 60 Hz 20 Amps @ rated output

Duty Cycle Current Voltage at Rated Amperes20% Duty Cycle 90 Amps 19.5

Welding Current Range Open Circuit Voltage Wire Speed Range30-140 Amps 33 V 50 - 500 in/min.

(1.3 - 12.7 m/min.)

Input Voltage/Frequency Fuse or Breaker Size1,2 Input Amps Power Cord Extension Cord

120 V 60 Hz 20 Amp 20 15 Amp, 125 V, 3 Conductor # 12 AWGThree Prong Plug (4mm2) or Larger(NEMA Type 5-15P) up to 50 ft.(15.2m)


Height Width Depth Weight14.0 in 10.15 in 18.6 in 58 Ibs357 mm 258 mm 472 mm 26.3 kg

PHYSICAL DIMENSIONS

1If connected to a circuit protected by fuses use Time Delay Fuse marked “D”.

2 Requirements For Maximum OutputIn order to utilize the maximum output capability ofthe machine, a branch circuit capable of 25 amps at120 volts, 60 Hertz is required.

A-2INSTALLATION


A-2

TECHNICAL SPECIFICATIONS 180 Amp units (K2668-1 180C)INPUT – SINGLE PHASE ONLY

RATED OUTPUT

OUTPUT

Standard Voltage/Frequency Input Current240 V 50 Hz I1 max 20 Amps

I1 eff 10.7 Amps

Voltage/Duty Cycle Current Voltage at Rated Amperes240 V 25% 130 Amps 20

Welding Current Range Open Circuit Voltage Wire Speed Range30 - 180 Amps 34 V 50 - 500 in/min.

1.3 - 12.7 ( m/min.)

Input Voltage/Frequency Fuse or Breaker Size1 Input Amps Power Cord

240 V 50 Hz 40 Amp Super Lag 20 15 Amp, 240 V,Three Pin Plug


Height Width Depth Weight14.0 in 10.15 in 18.6 in 66 Ibs357 mm 258 mm 472 mm 30 kg

PHYSICAL DIMENSIONS

1 If connected to a circuit protected by fuses use Time Delay Fuse marked “D”.

A-3INSTALLATION


A-3

SELECT SUITABLE LOCATIONLocate the welder in a dry location where there is freecirculation of clean air into the louvers in the back andout the front of the unit. A location that minimizes theamount of smoke and dirt drawn into the rear louversreduces the chance of dirt accumulation that canblock air passages and cause overheating.

STACKINGPOWER MIG (140, 180 MODELS) cannot be stacked.

TILTINGEach machine must be placed on a secure, level sur-face, directly or on recommended cart. The machinemay topple over if this procedure is not followed.

Read entire installation section before startinginstallation.

SAFETY PRECAUTIONS

ELECTRIC SHOCK can kill.• Only qualified personnel should perform

this installation.• Only personnel that have read and under-

stood the POWER MIG Operating Manualshould install and operate this equipment.

• Machine must be plugged into a receptaclewhich is grounded per any national, localor other applicable electrical codes.

• The POWER MIG power switch is to be inthe OFF (“O”) position when installingwork cable and gun and when connectingpower cord to input power.

WARNING

A-4INSTALLATION


A-4

INCLUDED COMPONENTS• Wire Feeder Welder.

• Work Cable & Clamp.

• Magnum 100L Welding Gun.

• 3 .035” (0.9mm) Contact Tips(1 installed on the welding gun).

• 3 .025” (0.6mm) Contact Tips.

• Spool of .035” (0.9 mm) diameter NR-211MPInnershield Flux-cored Wire.

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

• .025”-.030” (0.6 - 0.8mm) • .035” (0.9mm)Smooth Drive Roll Smooth Drive Roll

.025

.025

.025.035

.035

NR-211 MP

WIRE

L-56 MIG

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

• .025” -.035” (0.6 - 0.9mm) Inner Wire guide• .035” -.045” (0.9 - 1.1mm) Inner Wire Guide

(Installed on Machine)• Outer Wire Guide (Installed on Machine)

• Black Flux-cored Gasless Gun Nozzle (Installed onWelding Gun)

• Brass MIG Gas Gun Nozzle

• 2”(51mm) Spindle Adapter (For 8”(203mm) Reel of wire)

• Regulator• Gas Hose• Learn to Weld (LTW1 Manual)• DVD

OUTER WIRE GUIDEINNER WIRE GUIDE.025-.035 (.6-.9mm)

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

.030

.045

LTW1"LEARN TO WELD"

DVD

GAS HOSE

REGULATOR2" SPINDLE ADAPTER (FOR 8" REEL OF WIRE)

IDENTIFY AND LOCATE COMPONENTS

B-1OPERATIONB-1


COMMON WELDING ABBREVIATIONSGMAW (MIG)• Gas Metal Arc Welding

FCAW (Innershield or Outershield)• Flux Core Arc Welding

PRODUCT DESCRIPTION (PRODUCTCAPABILITIES)

These small portable wire feed welders are capable ofMIG welding on steel, stainless steel, and aluminum.They are also capable of flux-cored welding on mildsteel.

MIG welding stands for Metal Inert Gas welding andrequires a separate bottle of shielding gas to protectthe weld until it cools. Appropriate shielding gasbased on the type of material you are welding can bepurchased separately from your local welding gas dis-tributor. MIG welding is ideal for welding on thinnerand clean materials when a very clean excellent cos-metic looking weld is required. An example would beautomotive body panels.

Flux-cored Welding does not require separate shield-ing gas to protect the weld since the welding wire hasspecial additives known as flux to protect the welduntil it cools. Flux-cored welding is ideal for mediumto thicker material and if welding on painted or rustysteel. Flux-cored welding is also ideal in outdoorapplications where windy conditions might blow theMIG shielding gas away from the weld. Flux-coredwelding produces a good looking weld but does notproduce an excellent weld appearance as MIG weld-ing does.

Your machine includes the necessary items to weldwith either the MIG or the flux-cored welding processon steel. To weld on stainless steel optional stainlesssteel welding wire can be purchased separately. Thismachine can weld aluminum using .035”(0.9mm)diameter 4043 aluminum welding wire. Since alu-minum welding wire is soft an optional aluminumspool gun is recommended for best results. A weldingProcedure Decal is located inside machine door tohelp provide suggested settings for welding.

Read entire operation section beforeoperating the POWER MIG.

ELECTRIC SHOCK can kill.• Do not touch electrically live

parts or electrode with skin orwet clothing. Insulate yourselffrom work and ground.

• Always wear dry insulatinggloves.

FUMES AND GASES can bedangerous.• Keep your head out of fumes.• Use ventilation or exhaust to

remove fumes from breathingzone.

WELDING SPARKS cancause fire or explosion.• Keep flammable material away.• Do not weld on closed contain-

ers.

ARC RAYS can burn eyesand skin.• Wear eye, ear and body protec-

tion.

Observe all safety information throughoutthis manual.------------------------------------------------------------

WARNING

B-2OPERATIONB-2


CONTROLS AND SETTINGSThis machine has the following controls:

See Figure B.1

1. POWER SWITCH – Turns power on and off to themachine.

2. ARC VOLTAGE CONTROL – This knob sets theoutput voltage of the machine. Along with wire feedspeed (WFS) this control sets a weld procedure.Refer to the procedure decal on the inside wiredrive compartment door to set a correct weldingprocedure based on type of material and thicknessbeing welded.

3. WIRE FEED SPEED CONTROL (WFS) – The knobsets the speed that the machine feeds wire. Alongwith arc voltage this control sets a weld procedure.Refer to the procedure decal on the inside wiredrive compartment door to set a correct weldingprocedure based on type of material and thicknessbeing welded.

See Figure B.2

4. GUN TRIGGER – Depress the trigger to activatesthe wire drive to feed wire and energizes the outputof the machine. Depress the trigger to weld andrelease the trigger to stop welding.

5. WELDING GUN – Delivers wire and welding cur-rent to the weld.a. Gun Liner – wire travels through the liner from

the wire drive. The gun liner will feed .025” to.035” (0.6mm to 0.9mm) wire. The 180A machinecan 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 thewire.

c. Nozzle – When flux-cored welding the black noz-zle protects the mounting threads on the gun.When MIG welding the brass nozzle funnels theshielding gas to the weld.

6. WORK CLAMP & CABLE – Clamps to the workpiece being welded and completes the electricalwelding circuit.

7. GUN TRIGGER CONNECTOR RECEPTACLE –Plug the 4 pin gun trigger connector into this recep-tacle.

1

3

2

FIGURE B.1

FIGURE B.2

.035"(0.9mm) NR-211-MP

WIRE SPOOL

4

5a

5b

5

5c

6 7

B-3OPERATIONB-3


See Figure B.3

8. WELDING GUN CONNECTOR BUSHING &THUMBSCREW – Provides electrical power to thewelding gun. The thumbscrew holds the weldinggun into the connector block. (Front of Machine,Side Door and Wire Drive Cover have beenremoved for clarity of Items 8 and 9).

9. OUTPUT TERMINALS –These connections allowto change the welding polarity of the machinedepending on whether you are MIG welding or flux-cored welding.

See Figure B.4

10. WIRE SPOOL SPINDLE AND BRAKE – Holds a4”(102mm) diameter spool. Use the 2”(51mm)spindle adapter included with the machine to use8”(203mm) diameter spools. The thumbscrewsets the brake friction to prevent the spool fromover rotating when the trigger is released.

See Figure B.5

11. WIRE DRIVE & COMPONENTS – Feeds wirefrom the wire spool through the drive and throughthe welding gun to the weld.

a. Top and Bottom Drive Roll – Drives the wirethrough the drive system. The drive roll has agroove to match the specific wire type and diam-eter. Refer to Table B.1 for available drive rolls.

b. Inner & Outer Wire Guide – Guides the wirebetween the Top and Bottom Drive Roll andthrough the wire drive. The inner guide has agroove to match a particular wire diameter.Refer to Table B.1 for available wire guides.

c. Drive Roll Tension Thumbscrew – Turningclockwise increases the force on the drive rollsand turning counterclockwise decreases theforce.

8

9

FIGURE B.3

2"(51mm) SPINDLE ADAPTER (FOR 8"(20mm) REEL OF WIRE)

( 4"(102mm) REEL OF WIRE)

FIGURE B.4

FIGURE B.5

WIRE SPOOL.035" (0.9mm)

NR-211-MP

INNER WIRE GUIDE REMOVED

LOWER DRIVE ROLL REMOVED

OUTER WIRE GUIDE REMOVED

TOP DRIVE ROLL PRESSURE ARM

TENSION ADJUSTOR DOWN

B-4OPERATIONB-4


TABLE B.1DRIVE ROLL AND WIRE GUIDES

Wire Diameter &Type

.025”(0.6mm) MIG wire



.030”(0.8mm) flux-cored



Drive Roll

.025”/.030” (0.6mm/0.8mm)Smooth Drive Roll

.035”(0.9mm) Smooth Drive Roll

.030”/.045” (0.8mm/1.1mm)Knurled Drive Roll

.030”/.045” (0.8mm/1.1mm)Knurled Drive Roll

Inner Wire Guide

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

.045”(1.1mm) Steel Wire Guide

Inner Wire GuidePart Number

KP2531-1

KP2531-2

Drive Roll PartNumber

KP2529-1

KP2529-2

KP2529-3

KP2529-3

See Figure B.6

12. CIRCUIT BREAKER – If the rated input current ofthe machine is exceeded this circuit breaker willtrip. Press to reset.

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

12 13

FIGURE B.6

B-5OPERATIONB-5


A. ITEMS NEEDED FOR FLUX COREDWELDING

1. 035”(0.9mm) Contact Tip

2. .025”-.035”(0.6mm-0.9mm) wire guide

3. Knurled Drive Roll

4. .035”(0.9mm) NR-211MP Flux-Cored Wire

5. Black Flux Cored gun nozzle

6. Welding Gun

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

.035

.035 NR-211 MP

FLUX-CORE WIRE

7. Work Cable & Clamp

.030

.045

SETTING UP AND MAKING A FLUX-CORED WELD

B-6OPERATIONB-6


B. CONNECT LEADS AND CABLES ONTHE MACHINE

(See Figure B.7)1. Open the case side door

2. Slide the connector end of the gun and cablethrough the hole in the machine front and into thegun connector bushing on the wire drive.

3. Make sure the gun connector end is seated fullyinto the wire drive and tighten the thumbscrew tosecure the gun connector.

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

5. Wire Drive Polarity. Flux cored welding requiresnegative (-) polarity. Connect the short powercable from the wire drive to the negative (-) outputterminal and tighten the thumbscrew.

6. Work Lead Connection. Slide the lugged end ofthe work cable through the hole in the machinefront and place on the positive (+) output terminaland tighten thumbscrew.

C. LOAD WIRE SPOOL(See Figure B.8)

1. Locate the blue labeled 4"(102mm) diameterspool of .035”(0.9mm) NR-211MP flux-cored wireand place onto wire spool spindle. Orient thespool so that the wire feeds off the top of thespool.

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

3. Open the top drive roll pressure arm by rotatingthe tension adjustor arm down and pivoting thedrive 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 ofwelding wire from the spool. Do not let the end of thewire go to prevent the wire from unspooling.

GUN AND CABLE

WORK CLAMP

(4 PIN)LEAD CONNECTOR

TERMINAL END (FITS ON STUD INSIDESEE FIGURE BELOW)

SLIDECONNECTOREND HERE

CASE SIDE DOOR

OPEN LATCH DOOR

WORK CLAMP

(4 PIN)TRIGGER RECEPTACLEPLUGGED IN

CONNECTOREND ATTACH

ALL COMPONENTS SHOWN CONNECTED(FRONT AND SIDE DOOR IS REMOVED FOR CLARITY)

SHORT POWERCABLE NEGATIVE "-"OUTPUT TERMINAL

WORK LEAD CONNECTIONPOSITIVE "+"OUTPUT TERMINAL

THUMB SCREW TOTIGHTEN CONNECTOR BUSHING

LOCATE COMPONENTSTO CONNECT TO THEFRONT OF MACHINE

FIGURE B.7


NR-211-MP






FIGURE B.8

B-7OPERATIONB-7


(See Figure B.9)9. Feed the wire through the wire drive inlet along the

inner wire guide groove and into the wire drive outleton the gun side.

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

11. Re-install the outer wire guide.

(See Figure B.10)12. Remove the nozzle from the gun and contact tip

and straighten the gun out flat.

13. Turn the machine power to on and depress the guntrigger to feed the wire through the gun liner untilthe wire comes out of the threaded end of the gunseveral inches. (See figure B.11)

14. When trigger is released spool of wire should notunwind. Adjust wire spool brake accordingly.

MOVING PARTS AND ELECTRICALCONTACT CAN CAUSE INJURY OR BEFATAL.•When the gun trigger is depressed driverolls, spool of wire and electrode areELECTRICALLY LIVE (HOT).

• Keep away from moving parts andpinch points.

• Keep all Doors, Covers, panels andguards securely in place.

DO NOT REMOVE OR CONCEAL WARN-ING LABELS.

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

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

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

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

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

20. Based on the thickness of the material you aregoing to weld and the type and diameter of thewelding wire set the voltage and the wire feedspeed per the procedure decal attached to theinside of the wire drive compartment door.

.035"(0.9mm) NR-211-MP

WIRE SPOOL

REMOVED NOZZLE

REMOVED CONTACT TIP

LAY CABLE AND GUN STRAIGHTENIN THIS POSITION

.035"(0.9mm) NR-211-MP

WIRE SPOOL

DEPRESS TRIGGER TO ACTIVATE WIRE,WHICH FEEDS THE WIRETHRU THE LINER.

FEED WIREAPPROXIMATELY 4.00"FROM THE GUN TUBE END

ROTATION

PLUG IN POWER INPUT CORD

ON/OFFSWITCH

WORK CLAMP AND CABLE

TENSION ADJUSTORLOCKED IN POSITION

LOWER DRIVE ROLLBE SURE WIREIS IN GROOVE


SLIDE WIRE INTO GUN CONNECTORSIDE

TOP DRIVE ROLL PRESSED AGAINSTLOWER DRIVE ROLL

DIRECTIONOF WIRE

NR-211-MP

FIGURE B.10

FIGURE B.11

WARNING

INSTALL .035 CONTACT TIP

INSTALL BLACK FLUX-CORED NOZZLE

TRIM WIRE STICKOUT3/8"(9.5mm)from the Contact Tip

FIGURE B.9

FIGURE B.12

B-8OPERATIONB-8


A. ITEMS NEEDED FOR MIG WELDING1. 025”(0.6mm) Contact Tip

2. 025”-035”(0.6mm-0.9mm) Inner wire guide

3. .025”(0.6mm) Drive Roll

4. .025”(0.6mm) SuperArc L-56 Solid MIG Wire

5. Brass gun nozzle

.025

WIRE

L-56 MIG

6. Welding Gun

7. Work Cable & Clamp

8. Gas Regulator & Gas Line

9. Bottle of 75/25 Ar/CO2 shielding gas (or 100% CO2shielding gas) (note this requires a CO2 regulatoradapter which is sold separately.

INNER WIRE GUIDE.025-.035

.025-.035

75/25

FEMALE END

MIXES

MALE END

CO100%

2

(REQUIRES ADAPTER SOLD SEPARATELY)

SETTING UP AND MAKING A MIG WELD

B-9OPERATIONB-9


B. INSTALL SHIELDING GAS

MIG welding requires an appropriate bottle of shieldinggas. For mild steel either a cylinder bottle of Ar/CO2 or100% CO2 can be used refer to the following instruc-tions to properly connect shielding gas to the machine.

CYLINDER may explode if dam-aged. Keep cylinder upright andchained 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.-----------------------------------------------------------------------

WARNING 75/25

FEMALE END

MALE END

CO

S19298

REGULATORADAPTER

PLASTIC WASHER

MIXES

100%2

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

NOTE: If connecting to 100% CO2 cylinder, a CO2regulator adapter is required. Purchase separatelyS19298 CO2 adapter be sure to install plastic washerincluded in the fitting on the bottle side.(See FigureB.13 )

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

FIGURE B.13

BUILDUP OF SHIELDING GAS mayharm health or kill.• Shut off shielding gas supply

when not in use.

1. Secure the cylinder to a wall or other stationarysupport to prevent the cylinder from falling over.Insulate the cylinder from the work circuit and earthground. Refer to Figure B.13.

2. With the cylinder securely installed, remove thecylinder cap. Stand to one side away from the out-let and open the cylinder valve very slightly for aninstant. This blows away any dust or dirt which mayhave accumulated in the valve outlet.

BE SURE TO KEEP YOUR FACE AWAY FROMTHE VALVE OUTLET WHEN “CRACKING” THEVALVE. Never stand directly in front of or behindthe flow regulator when opening the cylindervalve. Always stand to one side.------------------------------------------------------------------------

WARNING

WARNING

SHIELDING GAS1. For CO2, open the cylinder very slowly. For argon-

mixed gas, open cylinder valve slowly a fraction of aturn. When the cylinder pressure gauge pointer stopsmoving, open the valve fully.

2. Set gas flow rate for 30 to 40 cubic feet per hour (14to 18 I/min.) under normal conditions, increase to ashigh as 40 to 50 CFH (18 to 23.5 I/min.) under drafty(slightly windy) conditions.

3. Keep the cylinder valve closed, except when usingthe machine.

B-10OPERATIONB-10


C. CONNECT LEADS AND CABLES ONTHE MACHINE

(See Figure B.14)1. Open the case side door.

2. Slide the connector end of the gun and cablethrough the hole of the machine front and into thegun connector bushing on the wire drive.

3. Make sure the gun connector end is seated fullyinto the wire drive and tighten the thumbscrew tosecure the gun.

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

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

6. Work Lead Connection. Slide the lugged end of thework cable through the hole in the machine frontand place on the negative (-) output terminal andtighten thumbscrew.

D. LOAD WIRE SPOOL(See Figure B.15)1. Locate the green labeled 4"(102mm) diameter

spool of .025”(0.6mm) L-56 solid MIG wire andplace onto wire spool spindle. Orient the spool sothat the wire feeds off the top of the spool.

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

3. Open the top drive roll pressure arm by rotating thetension adjustor arm down and pivoting the idle rollpressure 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 inchesof welding wire from the spool. Do not let the endof the wire go to prevent the wire from unspooling.

GUN AND CABLE

WORK CLAMP

(4 PIN)LEAD CONNECTOR

TERMINAL END (FITS ON STUD INSIDESEE FIGURE BELOW)

SLIDECONNECTOREND HERE

CASE SIDE DOOR

OPEN LATCH DOOR

WORK CLAMP

(4 PIN)TRIGGER RECEPTACLEPLUGGED IN

CONNECTOREND ATTACH

ALL COMPONENTS SHOWN CONNECTED(FRONT AND SIDE DOOR IS REMOVED FOR CLARITY)

SHORT POWERCABLE POSITIVE "+"OUTPUT TERMINAL

WORK LEAD CONNECTIONNEGATIVE "-"OUTPUT TERMINAL

THUMB SCREW TOTIGHTEN CONNECTOR BUSHING

LOCATE COMPONENTSTO CONNECT TO THEFRONT OF MACHINE

FIGURE B.15

FIGURE B.14







L-56 SOLID MIG

B-11OPERATIONB-11


(See Figure B.16)9. Feed the wire through the wire drive inlet along the

inner wire guide groove and into the wire drive out-let on the gun side.

10. Close the top drive roll pressure arm and secureby pivoting the tension adjustor back to the upposition.

11. Re-install the outer wire guide.

(See Figure B.17)12. Remove the nozzle from the gun and contact tip

and straighten the gun out flat.

13. Turn the machine power to on and depress thegun trigger to feed the wire through the gun lineruntil the wire comes out of the threaded end of thegun several inches. (See Figure B.18)

14. When trigger is released spool of wire should notunwind. Adjust wire spool brake accordingly.

MOVING PARTS AND ELECTRICALCONTACT CAN CAUSE INJURY OR BEFATAL.•When the gun trigger is depresseddrive rolls, spool of wire and elec-trode are ELECTRICALLY LIVE (HOT).

• Keep away from moving parts andpinch points.

• Keep all Doors, Covers, panels andguards securely in place.

DO NOT REMOVE OR CONCEALWARNING LABELS.

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

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

17. Trim the wire stickout to 3/8”(9.5mm) from the nozzle end. (See Figure B.19)

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

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

20. Based on the thickness of the material you are goingto weld and the type and diameter of the weldingwire set the voltage and the wire feed speed per theprocedure decal attached to the inside of the wiredrive compartment door.

TENSION ADJUSTORLOCKED IN POSITION

DRIVE ROLLBE SURE WIREIS IN GROOVE


SLIDE WIRE INTO GUN CONNECTORSIDE

TOP IDLER ROLL PRESSED AGAINSTLOWER DRIVE ROLL

DIRECTIONOF WIRE

L-56 SOLID MIG

REMOVED NOZZLE

REMOVED CONTACT TIP

LAY CABLE AND GUN STRAIGHTENIN THIS POSITION


L-56 SOLID MIG

DEPRESS TRIGGERTO ACTIVATE WIRE,WHICH FEEDS THE WIRETHRU THE LINER.

FEED WIREAPPROXIMATELY 4.00"FROM THE GUN TUBE END

ROTATION

PLUG IN POWER INPUT CORD

ON/OFFSWITCH

WORK CLAMP AND CABLE


L-56 SOLID MIG

INSTALL .025 CONTACT TIP

INSTALL BRASS NOZZLE

TRIM WIRE STICKOUT3/8"(9.5mm)from the Brass Nozzle

FIGURE B.17

FIGURE B.18

FIGURE B.19

FIGURE B.16

WARNING

B-12OPERATIONB-12

1. Follow the MIG welding steps in the previous sec-tion.

2. Connect a bottle of 100% Argon shielding Gas perprevious section.

3. Disconnect Magnum 100L Gun.

4. Install optional K2532-1 Magnum 100SG spool gunper instructions included with gun.

5. Set Gun selector toggle switch to Spool Gun posi-tion. (See Figure B.20)

FIGURE B.20

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


SETTING UP AND MAKING A ALUMINUM WELD USING SPOOL GUN

C-1ACCESSORIESC-1


K2525-1 - Spot Timer Kit Timer kit, when turned on, allows you to set a fixedweld time so that when the gun trigger is pulled themachine will weld for a fixed time period up to 10 sec-onds. Ideal for making consistent spot welds whenwelding on thin sheet metal

K2528-1 - 045 Innershield Kit (For 230V models) Includes everything needed to weld with .045”(1.1mm)diameter Innershield wire. Includes an.035”/.045”(0.9mm/1.1mm) Magnum™ 100L gun liner,.045”(1.1mm) Contact Tip, gasless nozzle, knurleddrive roll, .045”(1.1mm) inner wire guide, and a 10 lb.(4.5kg) spool of .045"(1.1mm) Innershield® NR®-212wire.

K2532-1 - Magnum 100SG Spool Gun Designed to easily feed small 4"(102mm) diameter(1lb.-.5kg spools of) .030”(0.8mm) or .035”(0.9mm)aluminum wire. Includes gun, adapter kit, three extra.035”(0.9mm) contact tips, gas nozzle, and spool ofSuperglaze 4043 .035"(0.9mm) diameter welding wire.Packaged in a convenient carry case.

K2377-1 - Small Canvas Cover Protect your machine when not in use. Made fromattractive red canvas that is flame retardant, mildewresistant and water repellent. Includes a convenientside pocket to hold welding gun.

For additional Optional and Miscellaneous Parts(See Parts Pages)

C-2ACCESSORIESC-2


3-3/4" (95.3mm)

4"(102mm)16"(406.4mm)

3-11/16"

8-1/16"

3-13/32"

9/32"(7.1mm) 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)


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 cartwith the proper hardware shown.

(204.8mm)

(93.7mm) (96.8mm)

K520—Utility CartHeavy duty cart stores and transports welder, 150

cubic foot shielding gas cylinder, welding cables andaccessories. Includes stable platforms for welder andgas bottle platform, lower tray for added storagecapacity and adjustable height handle.

C-3ACCESSORIESC-3


2-15/16"(74.6mm)3-3/16"(81mm)

7-9/16"(192.1mm)

1-1/2"(38.1mm)

13-1/2"(342.9mm)

1-1/4"(31.8mm)9/32"(7.1mm) DRILL 3 PLACES

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

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


For mounting welding machines to K2275 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 cartwith the proper hardware shown.

K2275-1 - Welding CartLightweight cart stores and transports welder, 80cubic foot shielding gas cylinder, welding cables andaccessories. Includes an angled top shelf for easyaccess to controls, lower tray for added storagecapacity, a sturdy fixed handle and convenient cablewrap hanger.

D-1MAINTENANCED-1


MAINTENANCESAFETY PRECAUTIONS

ELECTRIC SHOCK can kill.

• Disconnect input power by removingplug from receptacle before workinginside POWER MIG (140, 180 MODELS).Use only grounded receptacle. Do nottouch electrically “hot” parts insidePOWER MIG (140, 180 MODELS).

• Have qualified personnel do the mainte-nance and trouble shooting work.

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

ROUTINE MAINTENANCEPOWER SOURCE COMPARTMENTNo user serviceable parts inside! Do not attempt to performservice in the power source (fixed) side of the POWER MIG(140, 180 MODELS). Take the unit to an authorized LincolnService Center if you experience problems. NO maintenanceis required.

In extremely dusty locations, dirt may clog the air passagescausing the welder to run hot with premature tripping of ther-mal protection. If so, blow dirt out of the welder with low pres-sure air at regular intervals to eliminate excessive dirt and dustbuild-up on internal parts.

WIRE FEED COMPARTMENT1. When necessary, vacuum accumulated dirt from gearbox

and wire feed section.

2. Occasionally inspect the wire guides and keep groovesclean.

3. Motor and gearbox have lifetime lubrication and require nomaintenance.

FAN MOTORHas lifetime lubrication — requires no maintenance.

WIRE REEL SPINDLERequires no maintenance. Do not lubricate shaft.

WARNING

D-2MAINTENANCED-2


GUN AND CABLE MAINTENANCEFOR MAGNUM™ 100L GUNGun Cable CleaningClean cable liner after using approximately 300 lbs(136 kg) of solid wire or 50 lbs (23 kg) of flux-coredwire. Remove the cable from the wire feeder and lay itout straight on the floor. Remove the contact tip fromthe gun. Using low pressure air, gently blow out thecable liner from the gas diffuser end.

Excessive pressure at the start may cause the dirtto form a plug.

Flex the cable over its entire length and again blowout the cable. Repeat this procedure until no furtherdirt comes out.

Contact Tips, Nozzles, and Gun Tubes1. Dirt can accumulate in the contact tip hole and

restrict wire feeding. After each spool of wire isused, remove the contact tip and clean it by push-ing a short piece of wire through the tip repeatedly.Use the wire as a reamer to remove dirt that maybe adhering to the wall of the hole through the tip.

2. Replace worn contact tips as required. A variableor “hunting” arc is a typical symptom of a worn con-tact tip. To install a new tip, choose the correct sizecontact tip for the electrode being used (wire size isstenciled on the side of the contact tip) and screw itsnugly into the gas diffuser.

3. Remove spatter from inside of gas nozzle and fromtip after each 10 minutes of arc time or as required.

4. Be sure the gas nozzle is fully screwed onto thediffuser for gas shielded processes. For theInnershield® process, the gasless nozzle shouldscrew onto the diffuser.

5. To remove gun tube from gun, remove gas nozzleor gasless nozzle and remove diffuser from guntube. Remove both collars from each end of thegun handle and separate the handle halves.Loosen the locking nut holding the gun tube inplace against the gun end cable connector.Unscrew gun tube from cable connector. To installgun tube, screw the locking nut on the gun tube asfar as possible. Then screw the gun tube into thecable connector until it bottoms. Then unscrew (nomore than one turn) the gun tube until its axis isperpendicular to the flat sides of the cable connec-tor and pointed in the direction of the trigger.Tighten the locking nut so as to maintain the properrelationship between the gun tube and the cableconnector. Replace the gun handle, trigger and dif-fuser. Replace the gas nozzle or gasless nozzle.

OVERLOAD PROTECTIONOutput OverloadThe POWER MIG (140, 180 MODELS) is equippedwith a circuit breaker and a thermostat which protectsthe machine from damage if maximum output isexceeded. The circuit breaker button will extend outwhen tripped. The circuit breaker must be manuallyreset.

Thermal ProtectionThe POWER MIG (140, 180 MODELS) has a ratedoutput duty cycle as defined in the TechnicalSpecification page. If the duty cycle is exceeded, athermal protector will shut off the output until themachine cools to a reasonable operating temperature.This is an automatic function of the POWER MIG(140, 180 MODELS) and does not require user inter-vention. The fan continues to run during cooling.

Electronic Wire Drive Motor ProtectionThe POWER MIG (140, 180 MODELS) has built-inprotection for wire drive motor overload.

CAUTION

D-3MAINTENANCED-3


GUN HANDLE PARTSThe gun handle consists of two halves that are heldtogether with a collar on each end. To open up thehandle, turn the collars approximately 60 degreescounter-clockwise until the collar reaches a stop. Thenpull the collar off the gun handle. If the collars are diffi-cult to turn, position the gun handle against a corner,place a screwdriver against the tab on the collar andgive the screwdriver a sharp blow to turn the collarpast an internal locking rib. See Figure D-3.

FIGURE D.3

�

Counter-clockwise

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

9. Replace the contact tip and nozzle.

1-1/4”(31.8 mm)Liner Trim Length

Gas Diffuser

Gas Nozzle orGasless NozzleSet Screw Brass Cable

Connector

Liner Assembly (Liner bushing to be sealed tightagainst brass cable connector)

FIGURE D.2Liner trim length

CHANGING LINERNOTICE: The variation in cable lengths prevents theinterchangeability of liners. Once a liner has been cutfor a particular gun, it should not be installed in anoth-er gun unless it can meet the liner cutoff lengthrequirement. Refer to Figure D.2.

1. Remove the gas nozzle from the gun by unscrew-ing counter-clockwise.

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

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

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

5. Insert a new untrimmed liner into the connector endof the cable. Be sure the liner bushing is stenciledappropriately 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 installedonto the end of the gun tube.

7. With the gas nozzle and diffuser removed from thegun tube, be sure the cable is straight, and thentrim the liner to the length shown in the Figure D.2.Remove any burrs from the end of the liner.

E-1TROUBLESHOOTINGE-1


If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourCAUTION

This Troubleshooting Guide is provided to help youlocate and repair possible machine malfunctions.Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).Look under the column labeled “PROBLEM (SYMP-TOMS)”. This column describes possible symptomsthat the machine may exhibit. Find the listing thatbest describes the symptom that the machine isexhibiting.

Step 2. POSSIBLE CAUSE.The second column labeled “POSSIBLE CAUSE” liststhe obvious external possibilities that may contributeto the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTIONThis column provides a course of action for thePossible Cause, generally it states to contact yourlocal Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform theRecommended Course of Action safely, contact yourlocal Lincoln Authorized Field Service Facility.

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 andmachine operator and will invalidate your factory warranty. For your safety and to avoid ElectricalShock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

WARNING



Observe all Safety Guidelines detailed throughout this manual


PROBLEMS(SYMPTOMS)

Major physical or electrical damageis evident.

No wire feed, weld output or gasflow when gun trigger is pulled. Fandoes NOT operate.

No wire feed, weld output or gasflow when gun trigger is pulled.Fan operates normally.

POSSIBLE CAUSE

“Do not Plug in machine or turn it on”.Contact your local Authorized FieldService Facility.

1. Make sure correct voltage isapplied to the machine.

2. Make certain that power switchis in the ON position.

3. Make sure circuit breaker isreset.

1. The thermostat may be trippeddue to overheating. Let machinecool. Weld at lower duty cycle.

2. Check for obstructions in airflow. Check Gun Trigger connec-tions. See Installation section.

3. Gun trigger may be faulty.

RECOMMENDEDCOURSE OF ACTION

If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local LincolnAuthorized Field ServiceFacility.

OUTPUT PROBLEMS





PROBLEMS(SYMPTOMS)

No wire feed when gun trigger ispulled. Fan runs, gas flows andmachine has correct open circuitvoltage (33V) – weld output.

POSSIBLECAUSE

1. If the wire drive motor is runningmake sure that the correct driverolls are installed in the machine.

2. Check for clogged cable liner orcontact tip.

3. Check for proper size cable linerand contact tip.



FEEDING PROBLEMS

PROBLEMS(SYMPTOMS)

Low or no gas flow when guntrigger is pulled. Wire feed, weldoutput and fan operate normally.

POSSIBLECAUSE

1. Check gas supply, flow regulatorand gas hoses.

2. Check gun connection tomachine for obstruction or leakyseals.



GAS FLOW PROBLEMS





PROBLEMS(SYMPTOMS)

Arc is unstable – Poor starting

POSSIBLECAUSE

1. Check for correct input voltageto machine.

2. Check for proper electrodepolarity for process.

3. Check gun tip for wear or dam-age and proper size – Replace.

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

5. Check work cable for loose orfaulty connections.

6. Check gun for damage orbreaks.

7. Check for proper drive roll orien-tation and alignment.

8. Check liner for proper size.



WELDING PROBLEMS

F-1DIAGRAMSF-1


WIR

ING

DIAG

RAM

FOR

CODE

S 11

254,

1125

5, 11

256 A

ND 11

257

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. Thespecific diagram for a particular code is pasted inside the machine on one of the enclosure panels.

F-2DIAGRAMSF-2

POWER MIG (180 MODELS)

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. Thespecific diagram for a particular code is pasted inside the machine on one of the enclosure panels.

F-3DIMENSION PRINTF-3


10.3

5”(2

62.9

mm

)

18.7

8”(4

77m

m)

14.0

8”(3

57.6

mm

)

NOTES


WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOSCONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS AETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

� Do not touch electrically live parts orelectrode with skin or wet clothing.

� Insulate yourself from work andground.

� No toque las partes o los electrodosbajo carga con la piel o ropa moja-da.

� Aislese del trabajo y de la tierra.

� Ne laissez ni la peau ni des vête-ments mouillés entrer en contactavec des pièces sous tension.

� Isolez-vous du travail et de la terre.

� Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!

� Isolieren Sie sich von denElektroden und dem Erdboden!

� Não toque partes elétricas e elec-trodos com a pele ou roupa molha-da.

� Isole-se da peça e terra.

� Keep flammable materials away.

� Mantenga el material combustiblefuera del área de trabajo.

� Gardez à l’écart de tout matérielinflammable.

� Entfernen Sie brennbarres Material!

� Mantenha inflamáveis bem guarda-dos.

� Wear eye, ear and body protection.

� Protéjase los ojos, los oídos y elcuerpo.

� Protégez vos yeux, vos oreilles etvotre corps.

� Tragen Sie Augen-, Ohren- und Kör-perschutz!

� Use proteção para a vista, ouvido ecorpo.

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA ASPRÁTICAS DE SEGURANÇA DO EMPREGADOR.

� Keep your head out of fumes.� Use ventilation or exhaust to

remove fumes from breathing zone.

� Los humos fuera de la zona de res-piración.

� Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.

� Gardez la tête à l’écart des fumées.� Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zonesde travail.

� Vermeiden Sie das Einatmen vonSchweibrauch!

� Sorgen Sie für gute Be- undEntlüftung des Arbeitsplatzes!

� Mantenha seu rosto da fumaça.� Use ventilação e exhaustão para

remover fumo da zona respiratória.

� Turn power off before servicing.

� Desconectar el cable de ali-mentación de poder de la máquinaantes de iniciar cualquier servicio.

� Débranchez le courant avant l’entre-tien.

� Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öff-nen; Maschine anhalten!)

� Não opere com as tampas removidas.� Desligue a corrente antes de fazer

serviço.� Não toque as partes elétricas nuas.

� Do not operate with panel open orguards off.

� No operar con panel abierto oguardas quitadas.

� N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.

� Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!

� Mantenha-se afastado das partesmoventes.

� Não opere com os paineis abertosou guardas removidas.

• Sales and Service through Subsidiaries and Distributors Worldwide •Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

• World's Leader in Welding and Cutting Products •

8193724_manual

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