Lincoln Electric POWER MIG 140 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 • PO WER MIG (140, 180 MODELS) OPERA TOR’S MANUAL IM890-A May, 2007 Safety Depends on You Linco[...]

FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ________________________________________________[...]

ARC RA YS 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[...]

FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8 .b . Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturerʼs recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical [...]

PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A LʼArc 1. Protegez-vous contre la secousse électrique: a. Les circuits à lʼélectrod[...]

v INST ALLA TION POWER MIG (140, 180 MODELS) v EN 60974-10[...]

vi INST ALLA TION POWER MIG (140, 180 MODELS) vi EN 60974-10:[...]

vii vii T T h h a a n n k k Y Y o o u u for selecting a QUALITY product by Lincoln Electric. We want you to 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 it hand[...]

viii viii T ABLE OF CONTENTS Page –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– Installation ..............................................................[...]

A-1 INST ALLA TION POWER MIG (140, 180 MODELS) A-1 TECHNICAL SPECIFICA TIONS 180 Amp units (K2472-1 180T , K2473-1 180C) INPUT – SINGLE PHASE ONL Y RA TED OUTPUT OUTPUT Standard Voltage/Frequency Input Current 230 V 60 Hz 20 Amps @ rated output 208 V 60 Hz 20 Amps @ rated output Voltage/Duty Cycle Current Voltage at Rated Amperes 230 V 30% 130 Am[...]

2 Requirements For Maximum Output In order to u tilize th e maximum output capabi lity of the machine, a branch circuit capable of 25 amps at 120 volts, 60 Hertz is required. A-2 INST ALLA TION POWER MIG (140, 180 MODELS) A-2 TECHNICAL SPECIFICA TIONS 180 Amp units (K2668-1 180C) INPUT – SINGLE PHASE ONL Y RA TED OUTPUT OUTPUT Standard Voltage/Fr[...]

A-3 INST ALLA TION POWER MIG (140, 180 MODELS) A-3 SELECT SUIT ABLE LOCA TION Locate the welder in a dry location where there is free circulation of clean air into the louvers in the back and out the front of the unit. A location that minimizes the amount of smoke and dirt drawn into the rear louvers reduces the chance of dirt accumulation that can[...]

A-4 INST ALLA TION POWER MIG (140, 180 MODELS) 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-211MP Innershield Flux-cored Wire. • Spool of .02[...]

B-1 OPERA TION B-1 POWER MIG (140, 180 MODELS) COMMON WELDING ABBREVIA TIONS GMAW (MIG) • Gas Metal Arc Welding FCAW (Innershield or Outershield) • Flux Core Arc Welding PRODUCT DESCRIPTION (PRODUCT CAP ABILITIES) These small portable wire feed welders are capable of MIG welding on steel, stainless steel, and aluminum. They are also capable of [...]

B-2 OPERA TION B-2 POWER MIG (140, 180 MODELS) CONTROLS AND SETTINGS This machine has the following controls: See Figure B.1 1. POWER SWITCH – Turns power on and off to the machine. 2. ARC VOL TAGE CON TROL – This knob s ets the output voltage of the machine. Along with wire feed speed (WFS) this control sets a weld procedure. Refer to the proc[...]

B-3 OPERA TION B-3 POWER MIG (140, 180 MODELS) See Figure B.3 8 . WELDING GUN CONNECTOR BUSHING & THUMBSCREW – Provides electrical power to the welding gun. The thumbscrew holds the welding gun into the connector block. (Front of Machine, Side Door and Wire Drive Cover have been removed for clarity of Items 8 and 9). 9. OUTPUT TERMINALS – T[...]

B-4 OPERA TION B-4 POWER MIG (140, 180 MODELS) TABLE B.1 DRIVE ROLL AND WIRE GUIDES Wire Diameter & Type .025”(0.6mm) MIG wire .030”(0.8mm) MIG wire .035”(0.9mm) MIG wire .030”(0.8mm) flux-cored .035”(0.9mm) flux-cored .045”(1.1mm) flux-cored Drive Roll .025”/.030” (0.6mm/0.8mm) Smooth Drive Roll .035”(0.9mm) Smooth Drive Roll[...]

B-5 OPERA TION B-5 POWER MIG (140, 180 MODELS) A. ITEMS NEEDED FOR FLUX CORED WELDING 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-21 1 MP F L U X - C O R E W I R[...]

B-6 OPERA TION B-6 POWER MIG (140, 180 MODELS) B. CONNECT LEADS AND CABLES ON THE MACHINE (See Figure B.7) 1. Open the case side door 2 . Slide the connector end of the gun and cable through the hole in the machine front and into the gun connector bushing on the wire drive. 3. Make sure the gun connector end is seated fully into the wire drive and [...]

B-7 OPERA TION B-7 POWER MIG (140, 180 MODELS) ( See Figure B.9) 9. Feed the wire through the wire drive inlet along the inner wire guide groove and into the wire drive outlet on the gun side. 10. Close the top drive roll pressure arm and secure by pivoting the tension adjustor back to the up position. 11. Re-install the outer wire guide. (See Figu[...]

B-8 OPERA TION B-8 POWER MIG (140, 180 MODELS) 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 .025 WIRE L-56 MIG 6. Welding Gun 7. Work Cable & Clamp 8. Gas Regulator & Gas Line 9. Bott[...]

B-9 OPERA TION B-9 POWER MIG (140, 180 MODELS) B. INST ALL SHIELDING GAS MIG welding requires an appropriate bottle of shielding gas. For mild steel either a cylinder bottle of Ar/CO 2 or 100% CO 2 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 upr[...]

B-10 OPERA TION B-10 POWER MIG (140, 180 MODELS) C . CONNECT LEADS AND CABLES ON THE MACHINE (See Figure B.14) 1. Open the case side door. 2 . Slide the connector end of the gun and cable through the hole of the machine front and into the gun connector bushing on the wire drive. 3. Make sure the gun connector end is seated fully int o th e wi re d [...]

B-11 OPERA TION B-11 POWER MIG (140, 180 MODELS) (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 secure by pivoting the tension adjustor back to the up position. 11. Re-install the outer wire guide. (See [...]

B-12 OPERA TION B-12 1. Follow the MIG welding steps in the previous sec- tion. 2. Connect a bottle of 100% Argon shielding Gas per previous section. 3. Disconnect Magnum 100L Gun. 4. Install optional K2532-1 Magnum 100SG spool gun per instructions included with gun. 5. Set Gun selector toggle switch to Spool Gun posi- tion. (See Figure B.20) FIGUR[...]

C-1 ACCESSORIES C-1 POWER MIG (140, 180 MODELS) K2525-1 - Spot Timer Kit Timer kit, when turned on, allows you to set a fixed weld time so that when the gun trigger is pulled the machine will weld for a fixed time period up to 10 sec- onds. Ideal for making consistent spot welds when welding on thin sheet metal K2528-1 - 045 Innershield Kit (For 23[...]

C-2 ACCESSORIES C-2 POWER MIG (140, 180 MODELS) 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 For mi ng Screw (1 Required) 1/4"-20 X 1/ 2" Hex Head Cap Screw (2 Required) [...]

C-3 ACCESSORIES C-3 POWER MIG (140, 180 MODELS) 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) DR ILL 3 PLACES 1/4"-20 Flange Nut (2 Required) 1/4"-20 X 1" Thread For min g Screw (1 Required) 1/4"-20 X 1/ 2" Hex Head Cap Screw (2[...]

D-1 MAINTENANCE D-1 POWER MIG (140, 180 MODELS) MAINTENANCE SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Disconnect input power by removing plug from receptacle before working inside POWER MIG (140, 180 MODELS). Use only grounded receptacle. Do not touch electrically “hot” parts inside POWER MIG (140, 180 MODELS). • Have qualified personne[...]

D-2 MAINTENANCE D-2 POWER MIG (140, 180 MODELS) 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 fl ux-cored wire. Remove the cable from the wire feeder and lay it out straight on the floor. Remove the contact tip from the gun. Using [...]

D-3 MAINTENANCE D-3 POWER MIG (140, 180 MODELS) GUN HANDLE P ARTS The gu n handle consists of two halves that are held together with a collar on each end. To open up the handle, turn the collars approximately 60 degrees counter-clockwise until the collar reaches a stop. Then pull the collar off the gun handle. If the collars are diffi- cult to turn[...]

E-1 TROUBLESHOOTING E-1 POWER MIG (140, 180 MODELS) If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your CAUTION This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below. Step 1. LOCAT[...]

E-2 TROUBLESHOOTING E-2 POWER MIG (140, 180 MODELS) Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your CAUTION PROBLEMS (SYMPTOMS) Major physical or electrical damage is evident. No wire feed, weld output or gas flo[...]

E-3 TROUBLESHOOTING E-3 POWER MIG (140, 180 MODELS) Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your CAUTION PROBLEMS (SYMPTOMS) No wire feed when gun trigger is pulled. Fan runs, gas flows and machine has correct[...]

E-4 TROUBLESHOOTING E-4 POWER MIG (140, 180 MODELS) Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your CAUTION PROBLEMS (SYMPTOMS) Arc is unstable – Poor starting POSSIBLE CAUSE 1. Check for correct input voltage [...]

F-1 DIAGRAMS F-1 POWER MIG (140, 180 MODELS) WIRING DIAGRAM FOR CODES 1 1254, 1 1255, 1 1256 AND 1 1257 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.[...]

F-2 DIAGRAMS F-2 POWER MIG (180 MODELS) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.[...]

F-3 DIMENSION PRINT F-3 POWER MIG (140, 180 MODELS) 10.35”(262.9mm) 18.78”(477mm) 14.08”(357.6mm)[...]

NOTES POWER MIG (140, 180 MODELS)[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUFACTURER’S INSTRUCTIO N FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE P ARA EL [...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIP AMENTO E AS PAR TES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head o ut of f umes. ● Use ventil ation or exha ust to remo ve fum[...]

• 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 •[...]