Page 2 - FOR ENGINE; SAFETY; PERFORMED ONLY BY QUALIFIED INDIVIDUALS.; WARNING; ELECTRIC AND; CALIFORNIA PROPOSITION 65 WARNINGS
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...
Page 3 - ii
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-res...
Page 4 - iii
FOR ELECTRICALLY powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturerʼs recommendations. 8.c. Ground the equipment in...
Page 5 - PRÉCAUTIONS DE SÛRETÉ; PRÉCAUTIONS DE SÛRETÉ POUR; iv
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 électriq...
Page 6 - INSTALLATION
v INSTALLATION POWER MIG (140, 180 MODELS) v EN 60974-10
Page 8 - TThhaannkk Y; Please Examine Carton and Equipment For Damage Immediately
vii vii TThhaannkk Y Yoouu 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. Sa...
Page 9 - TABLE OF CONTENTS
viii viii TABLE OF CONTENTS Page –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– Installation .......................................................................................................Section A Technical Specifications.......................................
Page 10 - TECHNICAL SPECIFICATIONS 180 Amp units
A-1 INSTALLATION 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 Current 230 V 60 Hz 20 Amps @ rated output 208 V 60 Hz 20 Amps @ rated output Voltage/Duty Cycle Current...
Page 11 - Requirements For Maximum Output; In order to utilize the maximum output capability of; INPUT – SINGLE PHASE ONLY; 0 Amp Super Lag; RECOMMENDED INPUT CABLE AND FUSE SIZES
2 Requirements For Maximum Output In order to utilize the maximum output capability of the machine, a branch circuit capable of 25 amps at 120 volts, 60 Hertz is required. A-2 INSTALLATION POWER MIG (140, 180 MODELS) A-2 TECHNICAL SPECIFICATIONS 180 Amp units (K2668-1 180C) INPUT – SINGLE PHASE ONLY...
Page 12 - SELECT SUITABLE LOCATION; STACKING; Read entire installation section before starting; SAFETY PRECAUTIONS; ELECTRIC SHOCK can kill.
A-3 INSTALLATION POWER MIG (140, 180 MODELS) A-3 SELECT SUITABLE LOCATION 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 re...
Page 13 - INCLUDED COMPONENTS; IDENTIFY AND LOCATE COMPONENTS
A-4 INSTALLATION 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 Flu...
Page 14 - OPERATION
B-1 OPERATION B-1 POWER MIG (140, 180 MODELS) COMMON WELDING ABBREVIATIONS GMAW (MIG) • Gas Metal Arc Welding FCAW (Innershield or Outershield) • Flux Core Arc Welding PRODUCT DESCRIPTION (PRODUCT CAPABILITIES) These small portable wire feed welders are capable of MIG welding on steel, stainless ste...
Page 15 - CONTROLS AND SETTINGS; This machine has the following controls:
B-2 OPERATION 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 VOLTAGE CONTROL – This knob sets the output voltage of the machine. Along with wire feed speed (WFS) this contro...
Page 18 - A. ITEMS NEEDED FOR FLUX CORED; Knurled Drive Roll; SETTING UP AND MAKING A FLUX-CORED WELD
B-5 OPERATION 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...
Page 19 - B. CONNECT LEADS AND CABLES ON
B-6 OPERATION 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 connec...
Page 21 - A. ITEMS NEEDED FOR MIG WELDING; shielding gas) (note this requires a CO; SETTING UP AND MAKING A MIG WELD
B-8 OPERATION 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 ...
Page 22 - B. INSTALL SHIELDING GAS; SHIELDING GAS
B-9 OPERATION B-9 POWER MIG (140, 180 MODELS) B. INSTALL SHIELDING GAS MIG welding requires an appropriate bottle of shielding gas. For mild steel either a cylinder bottle of Ar/CO 2 or 100% CO 2 can be used refer to the following instruc- tions to properly connect shielding gas to the machine. CYLI...
Page 23 - C. CONNECT LEADS AND CABLES ON
B-10 OPERATION 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 co...
Page 25 - SETTING UP AND MAKING A ALUMINUM WELD USING SPOOL GUN
B-12 OPERATION 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...
Page 26 - ACCESSORIES
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...
Page 27 - Utility Cart; Heavy duty cart stores and transports welder, 150
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 Forming Screw (1 Required) 1/4"-20 X 1/2"...
Page 28 - Lightweight cart stores and transports welder, 80
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) DRILL 3 PLACES 1/4"-20 Flange Nut (2 Required) 1/4"-20 X 1" Thread Forming Screw (1 Required) 1/4"-2...
Page 29 - MAINTENANCE; ROUTINE MAINTENANCE; POWER SOURCE COMPARTMENT
D-1 MAINTENANCE D-1 POWER MIG (140, 180 MODELS) MAINTENANCESAFETY 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 (14...
Page 30 - GUN AND CABLE; Gun Cable Cleaning; OVERLOAD PROTECTION; Output Overload; CAUTION
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 flux-cored wire. Remove the cable from the wire feeder and lay it out straight on the floo...
Page 31 - GUN HANDLE PARTS; Liner trim length; CHANGING LINER
D-3 MAINTENANCE D-3 POWER MIG (140, 180 MODELS) GUN HANDLE PARTS The gun handle consists of two halves that are held together with a collar on each end. To open up the handle, turn the collars approximately 60 degrees counter-clockwise until the collar reaches a stop. Then pull the collar off the gu...
Page 32 - TROUBLESHOOTING; Step 3. RECOMMENDED COURSE OF ACTION; HOW TO USE TROUBLESHOOTING GUIDE
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 th...
Page 33 - PROBLEMS; C o n t a c t y o u r l o c a l L i n c o l n; OUTPUT PROBLEMS
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 damag...
Page 34 - FEEDING PROBLEMS; GAS FLOW PROBLEMS
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 p...
Page 35 - WELDING PROBLEMS
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 PO...
Page 36 - DIAGRAMS; WIRING DIAGRAM FOR CODES 1; Enhanced Diagram
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 encl...
Page 38 - DIMENSION PRINT
F-3 DIMENSION PRINT F-3 POWER MIG (140, 180 MODELS) 10.35”(262.9mm) 18.78”(477mm) 14.08”(357.6mm)
Page 39 - NOTES
