Operator’s Manual PEIG (,E)

Operator’s Manual

POWER MIG ®(140, 180 MODELS)

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IM890-A | Issue D ate Nov- 13

© Lincoln Global, Inc. All Rights Reserved.

For use with machines having Code Numbers:

11254, 11255, 11256, 11257 and

11444

LINCOLN

ELECTRIC

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 FORDAMAGE IMMEDIATELY

When this equipment is shipped, title passes to the purchaser uponreceipt by the carrier. Consequently, Claims for material damaged inshipment must be made by the purchaser against the transportationcompany at the time the shipment is received.

SAFETY DEPENDS ON YOU

Lincoln arc welding and cutting equipment is designed and built withsafety in mind. However, your overall safety can be increased byproper installation ... and thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONSCONTAINED THROUGHOUT. And, most importantly, think before youact and be careful.

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

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

KEEP YOUR HEAD OUT OF THE FUMES.

DON’T get too close to the arc. Usecorrective lenses if necessary tostay a reasonable distance awayfrom the arc.

READ and obey the Material SafetyData Sheet (MSDS) and the warninglabel that appears on all containersof welding materials.

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

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

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

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

WEAR CORRECT EYE, EAR & BODY PROTECTION

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

PROTECT your body from welding spatter and arcflash with protective clothing including woolenclothing, flame-proof apron and gloves, leatherleggings, and high boots.

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

IN SOME AREAS, protection from noise may beappropriate.

BE SURE protective equipment is in good condition.

Also, wear safety glasses in work area AT ALLTIMES.

SPECIAL SITUATIONS

DO NOT WELD OR CUT containers or materials which previously hadbeen in contact with hazardous substances unless they are properlycleaned. This is extremely dangerous.

DO NOT WELD OR CUT painted or plated parts unless specialprecautions with ventilation have been taken. They can release highlytoxic fumes or gases.

Additional precautionary measures

PROTECT compressed gas cylinders from excessive heat, mechanicalshocks, 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 FORIMMEDIATE USE AND KNOW HOW TO USE IT.

WARNING

CAUTION

SECTION A:WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel Engines

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and otherreproductive harm.

Gasoline Engines

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or otherreproductive harm.

ARC WELDING CAN BE HAZARDOUS. PROTECTYOURSELF AND OTHERS FROM POSSIBLE SERIOUSINJURY OR DEATH. KEEP CHILDREN AWAY. PACE-MAKER WEARERS SHOULD CONSULT WITH THEIRDOCTOR BEFORE OPERATING.

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

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

FOR ENGINE POWEREDEQUIPMENT.

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 ANDMAGNETIC FIELDS MAYBE 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 pos-

sible to the area being welded.

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

ii

SAFETY

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 GASESCAN 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

with electrodes which require special ventilation

such as stainless or hard facing (see instructions

on container or MSDS) 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. In confined spaces or in

some circumstances, outdoors, a respirator may

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

material safety data sheet (MSDS) and follow your employer’s

safety practices. MSDS forms are available from your welding

distributor or from the manufacturer.

5.f. Also see item 1.b.

iii

SAFETY

WELDING AND CUTTINGSPARKS CAN CAUSEFIRE 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 IFDAMAGED.

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 1235 Jefferson Davis

Highway, Arlington, VA 22202.

FOR ELECTRICALLYPOWERED 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.

iv

SAFETY

Welding SafetyInteractive Web Guidefor mobile devices

ELECTROMAGNETICCOMPATIBILITY (EMC)

CONFORMANCE

Products displaying the CE mark are in conformity with EuropeanCommunity Council Directive of 3 May 1989 on the approximation ofthe laws of the Member States relating to electromagnetic compat-ibility (89/336/EEC). It was manufactured in conformity with a nationalstandard that implements a harmonized standard: EN 60974-10Electromagnetic Compatibility (EMC) Product Standard for Arc WeldingEquipment. It is for use with other Lincoln Electric equipment. It isdesigned for industrial and professional use.

INTRODUCTION

All electrical equipment generates small amounts of electromagneticemission. Electrical emission may be transmitted through power linesor radiated through space, similar to a radio transmitter. Whenemissions are received by other equipment, electrical interferencemay result. Electrical emissions may affect many kinds of electricalequipment; other nearby welding equipment, radio and TV reception,numerical controlled machines, telephone systems, computers, etc.Be aware that interference may result and extra precautions may berequired when a welding power source is used in a domestic estab-lishment.

INSTALLATION AND USE

The user is responsible for installing and using the welding equipmentaccording to the manufacturer’s instructions. If electromagneticdisturbances are detected then it shall be the responsibility of theuser of the welding equipment to resolve the situation with thetechnical assistance of the manufacturer. In some cases this remedialaction may be as simple as earthing (grounding) the welding circuit,see Note. In other cases it could involve construction of an electro-magnetic screen enclosing the power source and the work completewith associated input filters. In all cases electromagnetic disturbancesmust be reduced to the point where they are no longer troublesome.Note: The welding circuit may or may not be earthed for safety reasons

according to national codes. Changing the earthing arrangements shouldonly be authorized by a person who is competent to access whether thechanges will increase the risk of injury, e.g., by allowing parallel weldingcurrent return paths which may damage the earth circuits of other equip-ment.

ASSESSMENT OF AREA

Before installing welding equipment the user shall make anassessment of potential electromagnetic problems in the surroundingarea. The following shall be taken into account:

a. other supply cables, control cables, signaling and telephone cables;

above, below and adjacent to the welding equipment;

b. radio and television transmitters and receivers;

c. computer and other control equipment;

d. safety critical equipment, e.g., guarding of industrial equipment;

e. the health of the people around, e.g., the use of pacemakers and

hearing aids;

f. equipment used for calibration or measurement

g. the immunity of other equipment in the environment. The user shall

ensure that other equipment being used in the environment is

compatible. This may require additional protection measures;

h. the time of day that welding or other activities are to be carried out.

The size of the surrounding area to be considered will depend on thestructure of the building and other activities that are taking place. Thesurrounding area may extend beyond the boundaries of the premises.

METHODS OF REDUCING EMISSIONS

Mains Supply

Welding equipment should be connected to the mains supplyaccording to the manufacturer’s recommendations. If interferenceoccurs, it may be necessary to take additional precautions such asfiltering of the mains supply. Consideration should be given toshielding the supply cable of permanently installed weldingequipment, in metallic conduit or equivalent. Shielding should beelectrically continuous throughout its length. The shielding should beconnected to the welding power source so that good electrical contactis maintained between the conduit and the welding power sourceenclosure.

Maintenance of the Welding Equipment

The welding equipment should be routinely maintained according tothe manufacturer’s recommendations. All access and service doorsand covers should be closed and properly fastened when the weldingequipment is in operation. The welding equipment should not bemodified in any way except for those changes and adjustmentscovered in the manufacturers instructio ns. In particular, the sparkgaps of arc striking and stabilizing devices should be adjusted andmaintained according to the manufacturer’s recommendations.

Welding Cables

The welding cables should be kept as short as possible and should bepositioned close together, running at or close to floor level.

Equipotential Bonding

Bonding of all metallic components in the welding installation andadjacent to it should be considered. However, metallic componentsbonded to the work piece will increase the risk that the operator couldreceive a shock by touching these metallic components and theelectrode at the same time. The operator should be insulated from allsuch bonded metallic components.

Earthing of the Workpiece

Where the workpiece is not bonded to earth for electrical safety, notconnected to earth because of its size and position, e.g., ships hull orbuilding steelwork, a connection bonding the workpiece to earth mayreduce emissions in some, but not all instances. Care should be takento prevent the earthing of the work piece increasing the risk of injuryto users, or damage to other electrical equipment. Where necessary,the connection of the workpiece to earth should be made by a directconnection to the work piece, but in some countries where directconnection is not permitted, the bonding should be achieved bysuitable capacitance, selected according to national regulations.

Screening and Shielding

Selective screening and shielding of other cables and equipment inthe surrounding area may alleviate problems of interference.Screening of the entire welding installation may be considered forspecial applications.

1 Portions of the preceding text are contained in EN 60974-10: “Electromagnetic

Compatibility (EMC) product standard for arc welding equipment.”

SAFETY

viii viii TABLE OF CONTENTS

Page

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

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 C

Optional Accessories.............................................................................................C-1Utility Carts ....................................................................................................C-2, C-3

________________________________________________________________________

Maintenance..............................................................................................Section D

Safety 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 E

Safety 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

POWER MIG (140, 180 MODELS)

A-1

TECHNICAL 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 Amperes

230 V 30% 130 Amps 20 208 V 30% 130 Amps 17

Welding Current Range Open Circuit Voltage Wire Speed Range

30-180 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 Weight

14.0 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)


RATED OUTPUT

OUTPUT

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

Duty Cycle Current Voltage at Rated Amperes

20% 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)


RATED OUTPUT

OUTPUT

Standard Voltage/Frequency Input Current

240 V 50 Hz I1 max 20 AmpsI1 eff 10.7 Amps

Voltage/Duty Cycle Current Voltage at Rated Amperes240 V 25% 131 Amps 20

Welding Current Range Open Circuit Voltage Wire Speed Range

30 - 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 Weight

14.0 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 LOCATION

Locate 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.

STACKING

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

TILTING

Each 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 performthis 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

.02

5

.02

5

.02

5

.03

5

.03

5

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 ABBREVIATIONS

GMAW (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.


• Do not touch electrically liveparts or electrode with skin orwet clothing. Insulate yourselffrom work and ground.

• Always wear dry insulating

gloves.

FUMES AND GASES can bedangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to

remove fumes from breathing

zone.

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 SETTINGS

This 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.1

DRIVE 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 Guide

Part Number

KP2531-1

KP2531-2

Drive Roll Part

Number

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)

.03

5

.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) diameter

spool 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 POWER

CABLE NEGATIVE "-"

OUTPUT TERMINAL

WORK LEAD

CONNECTION

POSITIVE "+"

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 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 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 POWERINPUT 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 WELDING

1. 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

6. Welding Gun

.02

5

WIRE

L-56 MIG

7. Work Cable & Clamp

8. Gas Regulator & Gas Line

9. Bottle of 75/25 Ar/CO2 shielding gas (or 100% CO2

shielding gas) (note this requires a CO2 regulator

adapter 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 or

100% 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 and

chained to support

• Keep cylinder away from areaswhere it may be damaged.

• Never lift welder with cylinderattached.

• 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

REGULATOR

ADAPTER

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 may

harm 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 behind

the flow regulator when opening the cylindervalve. Always stand to one side.------------------------------------------------------------------------

WARNING

WARNING

SHIELDING GAS

1. 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 POWER

CABLE POSITIVE "+"

OUTPUT TERMINAL

WORK LEAD

CONNECTION

NEGATIVE "-"

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 ELECTRICAL

CONTACT CAN CAUSE INJURY OR BE

FATAL.

•When the gun trigger is depressed

drive rolls, spool of wire and elec-

trode 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.

-----------------------------------------------------------------------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 SOL ID MIG

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

FEED WIREAPPROXIMATELY 4.00"FROM THE GUN TUBE END

ROTATION

PLUG IN POWERINPUT 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"(102mm0 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 cart

with the proper hardware shown.

(204.8mm)

(93.7mm)(96.8mm)

K520—Utility Cart

Heavy duty cart stores and transports welder, 150cubic 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 cart

with 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


MAINTENANCE

SAFETY PRECAUTIONS


• Disconnect input power by removing

plug 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 MAINTENANCE

POWER 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 COMPARTMENT

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

2. Occasionally inspect the wire guides and keep groovesclean.

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

FAN MOTOR

Has lifetime lubrication — requires no maintenance.

WIRE REEL SPINDLE

Requires no maintenance. Do not lubricate shaft.

WARNING

D-2MAINTENANCED-2


GUN AND CABLE MAINTENANCE

FOR MAGNUM™ 100L GUN

Gun Cable Cleaning

Clean 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 Tubes

1. Dirt can accumulate in the contact tip hole andrestrict 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 PROTECTION

Output Overload

The 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 Protection

The 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 PARTS

The 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 LINER

NOTICE: 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 yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

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 ACTION

This 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


CAUTION

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 Lincoln

Authorized Field Service

Facility.

OUTPUT PROBLEMS





CAUTION

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.


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

Facility.

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.


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

GAS FLOW PROBLEMS





CAUTION

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.


If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local Lincoln

Authorized Field Service

Facility.

WELDING PROBLEMS

F-1DIAGRAMSF-1


FO

R C

OD

ES

11254, 11255, 11256, 11257

FO

R C

OD

ES

11254, 11255, 11256, 11257

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


M21111-2

A

18.7

8

14.0

8

10.3

7

12.0

0

6.0

05.5

0

3.0

8

2.4

6

POWER MIG® (140, 180 MODELS)

P-533P-533

PARTS LIST FOR

POWER MIG®

(140 & 180 Models)

This parts list is provided as an informative guide only.

It was accurate at the time of printing. These pages are only updated on the

Service Navigator DVD and in Lincoln Electricʼs official Parts Book (BK-34).

When ordering parts, always refer to Lincoln Electricʼs official Parts Book

(BK-34) for the latest pages.

02-04-2010POWER MIG® (140, 180 MODELS)

P-533-AP-533-A

ILLUSTRATION OF SUB-ASSEMBLIES

5

3

2

1

4

01-30-2012POWER MIG® (140, 180 MODELS)

Do Not use this Parts List for a machine if its code number is not listed. Contact the Service Department for any

code numbers not listed.

Use the Illustration of Sub-Assemblies page and the table below to determine which sub assembly page and

column the desired part is located on for your particular code machine.

P-533-A.1 P-533-A.1

POWER MIG® (140, 180 Models)

For Codes: 11254, 11255, 11256, 11257, 11444, 11804, 11819 & 11820

CODE NO.

11254 (140 Amp) 1 1 1 1 1 1 1 �

11255 (140 Amp) 1 5 1 1 1 2 1 �

11256 (180 Amp) 2 1 2 1 1 1 1 �

11257 (180 Amp) 2 1 2 1 1 2 1 �

11444 (180 Amp) 3 1 2 2 1 3 1 �

11804 (140 Amp) 4 4 3 3 1 2 � 1

11819 (140 Amp) 4 2 1 3 1 2 � 1

11820 (180 Amp) 5 3 2 3 1 2 � 1

Ma

gn

um

Pro

10

0 L

Gu

n &

Ca

ble

(K

30

80

-1)

P-202-AJ

Ma

gn

um

10

0 L

Gu

n &

Ca

ble

(K5

30

-6)

P-202-E2

Wra

pa

rou

nd

& D

oo

r A

sse

mb

ly

P-533-G

5

Wire

Drive

Asse

mb

ly

P-533-F

4

Ce

nte

r P

an

el A

sse

mb

lyP-533-E

3

Po

we

r M

od

ule

Asse

mb

ly

P-533-D

2

Ge

ne

ral A

sse

mb

ly

P-533-C

1

Mis

ce

llan

eo

us I

tem

s

P-533-B.2

Op

tio

na

l E

qu

ipm

en

t L

istin

g

P-533-B.1

SUB ASSEMBLY

PAGE NAME

PAGE NO.

Sub Assembly Item

No.

#

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PART NUMBER

Spot Timer Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K2525-1

.045 Innershield Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K2528-1

Deluxe Adjustable Gas Regulator & Hose Kit (Codes 11254,11255,11256 & 11257) . . . . . . .Order K586-1

Welding Cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K2275-1

Utility Cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K520-1

Spool Gun Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K2532-1

.025 Smooth Drive Roll Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order KP2529-1

.035 Smooth Drive Roll Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order KP2529-2

.030/.045 Knurled Drive Roll Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order KP2529-3

.025/.035 Steel Wire Guide Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order KP2531-1

.045 Steel Wire Guide Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order KP2531-2

02-04-2010POWER MIG® (140, 180 MODELS)

Miscellaneous Options Available for your machine are listed below:

# Indicates a change this printing.

P-533-B.1P-533-B.1OPTIONAL EQUIPMENT LISTING

MISCELLANEOUS ITEMS (THESE ITEMS ARE NOT ILLUSTRATED)

Plug & Lead Assembly S18250-908 1 X � � X �

Plug & Lead Assembly S18250-909 1 � X X � X

Plug & Lead Assembly (P301) S18250-916 1 X X � X �

Plug & Lead Assembly S18250-944 1 � � X � �

Plug & Lead Assembly (P1005) S18250-917 1 X X X � X

Work Cable S11609-29 1 X � � X �

Work Cable S11609-30 1 � X X � X

Work Clamp M12033 1 X X X X X

DVD (Arc Welding) S26375 1 X X X X X

Wire Reel Spindle Adapter M15445-1 1 X X X X X

Gas Regulator (Argon Mixed) S25805 * 1 X X � � �

Gas Regulator S25183 1 � � X � �

Gas Regulator 3000290 1 � � � X X

Gas Hose Assembly S19303 1 X X � X X

Gas Hose Assembly S19303-3 1 � � X � �

05-25-2011POWER MIG® (140, 180 MODELS)

Use only the parts marked “x” in the column under the

heading number called for in the model index page.


P-533-B.2

DESCRIPTION PART NO. QTY. 1 2 3 4 5 6 7 8 9

P-533-B.2

* Deluxe version available as K586-1.

Includes S19303 Gas Hose Asbly

02-04-2010POWER MIG® (140, 180 MODELS)

P-533-CP-533-C

General Assembly

1A1A

1313

1B1B

7A7A

7B7B

4

6

1B1B

12A12A

11B11B

9A9A

8

1010

9B9B 9C9C

5A5A

5B5B

3A3A

2

1414

1A Case Front G4812-1 1 X X X X X

1B Thread Forming Screw S9225-63 4 X X X X X

2 Nameplate (Code 11254) L12398-2 1 X � � � �

2 Nameplate (Code 11255) L12398-4 1 � � � � X

2 Nameplate (Code 11256) L12398-3 1 X � � � �

2 Nameplate (Codes 11257 & 11444) L12398-5 1 X � � � �

2 Nameplate (Codes 11804 & 11819) L13921-1 1 � X � X �

2 Nameplate (Code 11820) L13921-2 1 � � X � �

3A Knob S18425-1 2 X X X X X

3B Nut (Not Shown) T10940-10 As Req X X X X X

3C Self Tapping Screw (Not Shown) S8025-96 2 X X X X X

3D Lock Washer (Not Shown) T9695-5 2 � X X X �

4 Switch T10800-59 1 X X X X X

5A Square Flange Female Receptacle (Part of Plug & Lead Asbly) S18657 1 X X X X X

5B Self Tapping Screw S8025-96 2 X X X X X

6 Control P.C. Board (Code 11254 & 11256) L12450-[ ] 1 X � � � X

6 Cntrl P.C. Bd (Codes 11255,11257,11444,11804,11819 &11820) L12230-[ ] 1 X X X X X

7A Handle M20483 1 X X X X X

7B Thread Forming Screw S9225-63 2 X X X X X

8 Case Back & Bottom G4718 1 X X X X X

9A Solenoid Assembly M17294-8 1 X X X X X

9B Plain Washer S9262-10 1 X X X X X

9C Lock Nut T14370-1 1 X X X X X

10 Circuit Breaker T12287-21 1 X � X � �

10 Circuit Breaker T12287-40 1 � X � X X

11A Power Cord (Not Shown) (Codes 11254, 11255 & 11819) S25563-3 1 X X � � X

11A Power Cord (Not Shown) (Codes 11256, 11257 & 11820) S15599-2 1 X � X � X

11A Power Cord (Not Shown) (Code 11444) S19836-7 1 X � � � X

11A Power Cord (Not Shown) (Code 11804) S25563-1 1 � � � X �

11B Lead Grommet (Codes 11254,11255,11256,11257,11804,11819 & 11820) T9274-11 1 X X X X X

11B Lead Grommet (Code 11444) S19999-2 1 X � � � X

12A Case Back (Codes 11254,11255,11256,11257,11804,11819&11820) G4813 1 X X X X X

12A Case Back Panel (Code 11444) G4813-1 1 X � � � X

12B Self Tapping Screw (Not Shown) S8025-101 4 X X X X X

13 Gas Hose T10642-217 1 X X X X X

14 Rating Decal (Codes 11254, 11255, 11804 & 11819) S26499-2 1 X X � X X

14 Rating Decal (Codes 11256, 11257 & 11820) S26499-3 1 X � X � �

14 Rating Decal (Code 11444) S26499-5 1 X � � � �

Grounding Screw Mounting Hardware:

16A Thread Forming Screw (Not Shown) S9225-63 1 X � � � X

16A Thread Forming Screw (Not Shown) S9225-76 1 � X X X �

16B #10-24 HN (Not Shown) CF000010 2 X X X X X

16C Lock Washer (Not Shown) T9695-1 1 X X X X X

Hardware to Secure Leads to Ground Screw:

17A #10-24 HN (Not Shown) CF000010 1 X X X X X

17B Lock Washer (Not Shown) E106A-1 1 X X X X X

17C Plain Washer (Not Shown) S9262-27 1 X X X X X

07-24-2012POWER MIG® (140, 180 MODELS)




P-533-C.1

ITEM DESCRIPTION PART NO. QTY. 1 2 3 4 5 6 7 8 9

P-533-C.1

Note: When ordering new printed circuit boards indicate the dash number [ ] of the “Old” board

that is to be replaced. This will aid Lincoln in supplying the correct and latest board along

with any necessary jumpers or adapters. The dash number brackets [ ] have purposely

been left blank so as to eliminate errors, confusion and updates.

#

02-04-2010POWER MIG® (140, 180 MODELS)

P-533-DP-533-D

Power Module Assembly

4

1

62

3

5

Power Module Assembly, Includes: G4716-2 1 X � �

Power Module Assembly, Includes: G4716-3 1 � X �

Power Module Assembly, Includes: G4716-7 1 � � X

1 Chassis G4715 2 X X X

2 Rectifier L12306 1 X � �

2 Rectifier L12307 1 � X �

2 Rectifier L12306-1 1 � � X

3 Capacitor S13490-218 1 X � �

3 Capacitor S13490-220 1 � X �

3 Capacitor S13490-109 1 � � X

4 Transformer & Choke Assembly G4808-2 1 X � X

4 Transformer & Choke Assembly G4808-3 1 � X �

5 Fan S18977-4 1 X � X

5 Fan S18977-5 1 � X �

6 Flange Bolt S9225-8 2 X X X

Hardware for Mounting Rectifier & Choke Leads to Capacitor:

10A 1/4-28 HN (Not Shown) CF000198 2 X X X

10B Plain Washer (Not Shown) S9262-98 2 X X X

10C Lock Washer (Not Shown) E106A-2 2 X X X

Oct-13POWER MIG® (140, 180 MODELS)




P-533-D.1


P-533-D.1

#

05-25-2011POWER MIG® (140, 180 MODELS)

P-533-EP-533-E

Center Panel Assembly

1

1010

1010

23

45

6

11D11D

11B11B

15C15C15G15G

16A16A16B16B

17A17A

17A17A

1212

1313

7

89

11C11C 11A11A

Center Panel Assembly, Includes: L12322 1 X � X

Center Panel Assembly, Includes: L12322-2 1 � X �

1 Center Panel L12321 1 X � X

1 Center Panel L12321-1 1 � X �

2 Bow Washer T10781-10 1 X X X

3 Wear Plate S18423-1 1 X X X

4 Spindle Shaft S24227 1 X X X

5 Spindle Spacer S24226 1 X X X

6 Wing Nut T9968-5 1 X X X

7 Plain Washer S9262-120 1 X X X

8 Lock Washer E106A-16 1 X X X

9 3/8-16 x .625 HHCS CF000018 1 X X X

10 Self Tapping Screw (Secures Center Panel to Chassis) S8025-101 6 X X X

11A Polarity Panel L12555-1 1 X X X

11B Output Stud S25937 2 X X X

11C 1/4-20 x .50 HHCS CF000012 2 X X X

Plain Washer (Not Shown) S9262-23 2 X X X

Lock Washer (Not Shown) E106A-2 2 X X X

11D Wing Nut T9968-6 2 X X X

12 Plug Button T10397-3 1 X X X


15A By-Pass Assembly (Refer to Wiring Diagram) S22969-4 1 � X �

15B Ground Screw Asbly, Includes: S18922-8 1 � X �

15C Thread Forming Screw S9225-63 1 � X �

15D Plain Washer (Not Shown) S9262-27 2 � X �

15E #10-24 HN (Not Shown) CF000010 2 � X �

15F Lock Washer (Not Shown) E106A-1 1 � X �

15G Lock Washer T9695-1 1 � X �

16A By-Pass P.C. Board L10882-[ ] 1 � X �

16B Sems Screw T10082-27 2 � X �

17A Spot Timer & Spool Gun Decal (Not Shown) (Includes -A & -B) T13086-200 1 X X �

17A Spot Timer & Spool Gun Decal (Not Shown) (Includes -A & -B) T13086-213 1 � � X

05-25-2011POWER MIG® (140, 180 MODELS)




P-533-E.1


P-533-E.1

Note: When ordering new printed circuit boards indicate the dash number [ ] of the “Old” board

that is to be replaced. This will aid Lincoln in supplying the correct and latest board along

with any necessary jumpers or adapters. The dash number brackets [ ] have purposely

been left blank so as to eliminate errors, confusion and updates.


P-533-FP-533-F

Wire Drive Assembly

1A1A 7

1010

21A21A

2020

22221717

65

4B4B

1111

1212

8

1919

13131414

1616

15A15A15B15B 15C15C 18A18A

01-07-2011

Wire Drive Assembly, Includes: L12379-3 1 X

1A Motor Parts Order Sub Assembly, Includes: L13556 1 X

Motor NSS 1 X

Metric Screw (Not Shown) NSS 2 X

Base NSS 1 X

Hose Nipple NSS 1 X

Pinion NSS 1 X

Bearing NSS 1 X

4B Bearing M9300-141 1 X

5 Shaft S26311 1 X

6 Gear S26298 1 X

7 Pivot Arm Assembly S26296 1 X

8 Conductor Block S25931 1 X

9 Dowel Pin (Not Shown) T13942-15 1 X

10 Tension Arm Assembly M20593-2 1 X

11 Cover L12390 1 X

12 Inner Wire Guide S25932-2 1 X

13 Gear S26234-1 1 X

14 Hub M20860 1 X

15A Twist Lock S26238 1 X

15B Screw T14731-63 1 X

15C Lock Washer T9695-3 1 X

16 Drive Roll (Knurled) S26236-3 1 X

17 Molded Hand Screw T13858-4 1 X

18A Outer Wire Guide Assembly, Includes: S26899 1 X

Wire Guide Knob NSS 2 X

19 Hose Nipple T13776-5 1 X

20 Insulating Washer S26452 3 X

21A 1/4-20 x .625 HHCS CF000013 1 X

21B Lock Washer (Not Shown) E106A-2 1 X

21C Plain Washer (Not Shown) S9262-98 1 X

22 Self Tapping Screw S8025-116 3 X

01-07-2011POWER MIG® (140, 180 MODELS)




P-533-F.1


P-533-F.1

NSS - Not Sold Separately

#

#

05-25-2011POWER MIG® (140, 180 MODELS)

P-533-GP-533-G

Wraparound & Door Assembly

1

4

1515

62

8

9

7

1616

1111

1414

1313

3A3A

3B3B

7A7A

1212

Wraparound & Door Asbly, (M20452-3) Includes: NSS 1 X X X

1 Door L12320-1 1 X X X

2 Case Side G4719-1 1 X X X

3A Hinge (Includes S25898-2) S25898-1 2 X X X

3B Self Tapping Screw S8025-92 4 X X X

4 Door Latch S21033 1 X X X

6 Warranty Decal S22127-1 1 X X X

7 Side Decal T13086-172 2 X � �

7A Logo Decal S27368-2 2 � X X

8 Wiring Diagram M20410 1 X X �

8 Wiring Diagram M20410-2 1 � � X

9 Warning Decal M16196 1 X X �

9 Warning Decal M16196-3 1 � � X


12 Procedure Decal (Code 11254) L12603-2 1 X � �

12 Procedure Decal (Code 11255, 11804 & 11819) L12603-4 1 � X �

12 Procedure Decal (Code 11256) L12603-3 1 X � �

12 Procedure Decal (Codes 11257, 11444 & 11820) L12603-5 1 � X X

13 Self Tapping Screw S8025-92 8 X X X

14 Self Tapping Screw S8025-101 2 X X X

15 Family Name Decal S27369-1 2 � X X

16 Nascar Decal S27370-2 2 � X X

09-26-2011POWER MIG® (140, 180 MODELS)




P-533-G.1


P-533-G.1

NSS - Not Sold Separately

#

Item Description Part Number Qty.

New Complete Gun & Cable Assemblies:Magnum® 100L K530-6

Replacement Parts:

1 Cable Assembly M16318-2 1

2 Trigger Assembly S19725 1

3 Locking Nut S19580 1

4A Gun Tube Assembly KP2038-1 1

4B Gun Tube Assembly Cover T10642-162 1

5 Collar S19701 2

6A Gun Handle (Right & Left) G2209 1

7 O Ring T13483-8 2

8 Control Wire Cord S26388 1

Gun Consumable Parts:

Liners:

.025-.035” Liner KP1937-3

.030-.035” Liner (Aluminum) KP1959-1

.035-.045ʼ Liner KP45-40-15

Diffuser:

Gas Diffuser KP35-50

Item Description Part Number Qty.Item Description Part Number Qty

Item Description Part Number Qty.

Contact Tips:

.025” (0.5 mm) KP11-25

.030” (0.8 mm) KP11-30

.035” (0.9 mm) KP11-35

.045” (1.2 mm) KP11-45

Tapered Contact Tips:

.025” (0.6 mm) KP11T-25

.030” (0.8 mm) KP11T-30

.035” (0.9 mm) KP11T-35

.045” (1.2 mm) KP11T-45

Nozzles:

Gas Nozzle 0.5 ID, Tip Flush KP21-50-F

Gas Nozzles, Tip Recessed

0.37” I.D. KP21T-37

0.50” I.D. KP21T-50

0.62” I.D. KP21T-62

Gasless Flux Cored Nozzle KP1939-1

Spot Welding Nozzle .625 ID KP21-62-FAS

MAGNUM® 100L Parts

MAGNUM® 100L 01-20-2012

GASGASDIFFUSERDIFFUSER

CONTACTCONTACTTIPTIP

NOZZLENOZZLE

LINERLINER

5

3

2 7

6A6A

6A6A

4A4A

4B4B

5

8

1

MA

GN

UM

®100L

MA

GN

UM

®100L

P-202-E.2 P-202-E.2

#

#

MAGNUM® 100L

NOTES


NOTES

CUSTOMER ASSISTANCE POLICY

The business of The Lincoln Electric Company is manufacturing andselling high quality welding equipment, consumables, and cuttingequipment. Our challenge is to meet the needs of our customers andto exceed their expectations. On occasion, purchasers may askLincoln Electric for advice or information about their use of ourproducts. We respond to our customers based on the best informationin our possession at that time. Lincoln Electric is not in a position towarrant or guarantee such advice, and assumes no liability, withrespect to such information or advice. We expressly disclaim anywarranty of any kind, including any warranty of fitness for anycustomer’s particular purpose, with respect to such information oradvice. As a matter of practical consideration, we also cannot assumeany responsibility for updating or correcting any such information oradvice once it has been given, nor does the provision of informationor advice create, expand or alter any warranty with respect to the saleof our products.

Lincoln Electric is a responsive manufacturer, but the selection anduse of specific products sold by Lincoln Electric is solely within thecontrol of, and remains the sole responsibility of the customer. Manyvariables beyond the control of Lincoln Electric affect the resultsobtained in applying these types of fabrication methods and servicerequirements.

Subject to Change – This information is accurate to the best of ourknowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.

Operator’s Manual PEIG (,E)

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Transcript of Operator’s Manual PEIG (,E)