Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
FOR ENGINEpowered 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
ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable...
Page 4 - iii; WELDING and CUTTING; Refer to
iii SAFETY iii FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturerʼsrecommendations. 8.c. Ground the ...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
iv SAFETY 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 seco...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately; On-Line Product Registration
v v Thank You 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...
Page 7 - TABLE OF CONTENTS
vi vi TABLE OF CONTENTS Page ________________________________________________________________________ Installation .......................................................................................................Section A Technical Specifications ..................................................
Page 9 - INSTALLATION; TECHNICAL SPECIFICATIONS – POWER MIG
A-1 A-1 INSTALLATION Input Ampere Input Voltage Fuse or Breaker Rating On Frequency (Hz) Size (Super Lag) Nameplate 208/60 60 56A 8 230/60 60 52A 10 230/60 60 47A 10 460/60 30 24A 14 575/60 25 19A 14 TECHNICAL SPECIFICATIONS – POWER MIG ® 256 INPUT – SINGLE PHASE ONLY RATED OUTPUT OUTPUT RECOMMENDED...
Page 10 - SAFETY PRECAUTIONS; UNCRATING THE POWER MIG
FIGURE A.1 — Dual Voltage Machine Input Connections A-2 A-2 INSTALLATION Read entire installation section before startinginstallation. SAFETY PRECAUTIONS INPUT POWER, GROUNDING ANDCONNECTION DIAGRAM 1. Before starting the installation, check with the local p o w e r c o m p a n y i f t h e r e i s a...
Page 11 - OUTPUT POLARITY CONNECTIONS
Hand Screw Male End Gun and Cable Gun Adapter Receptacle Gun Trigger Connector 3. The 208/230 volt 60 Hz model POWER MIG is shipped with a 10 ft. input cable and plug connect-ed to the welder. Obtain a receptacle and mount itin a suitable location. Be sure it can be reached bythe plug on the input c...
Page 12 - SHIELDING GAS
SHIELDING GAS [For Gas Metal Arc Welding ( GMAW ) Processes] Customer must provide cylinder of appropriate type shield-ing gas for the process being used. A gas flow regulator, for Argon blend gas, an inlet gas hose,a n d a r e g u l a t o r a d a p t e r a r e f a c t o r y p r o v i d e d w i t h ...
Page 13 - OPERATION; ELECTRIC SHOCK can kill.
B-1 B-1 OPERATION R e a d e n t i r e O p e r a t i o n s e c t i o n b e f o r eoperating the POWER MIG ® 256. ELECTRIC SHOCK can kill. • D o n o t t o u c h e l e c t r i c a l l y l i v e p a r t s o r e l e c t r o d e w i t h s k i n o rw e t c l o t h i n g . I n s u l a t e y o u r s e l ffro...
Page 14 - PRODUCT DESCRIPTION; NEMA; WELDING CAPABILITY; WILL NOT operate; DESCRIPTION OF CONTROLS; -Step Trigger interlock mode
B-2 B-2 OPERATION PRODUCT DESCRIPTION The POWER MIG ® 256 is a complete semiautomatic constant voltage DC arc welding machine built to meet NEMA specifications. It combines a constant voltage power source and a constant speed wire feeder with amicrocomputer-based controller to form a reliable high-p...
Page 15 - Spool Gun Gas Connection; WIRE SIZE CONVERSION PARTS; POWER MIG
3 2 1 4 5 6 7 8 B-3 B-3 OPERATION To make spot plug welds, punch 3/16" (5 mm) holesin the top sheet. Set the Spot Time control toapproximately 1.2 seconds and set the procedure forthe metal thickness to be welded. Install spot weldnozzle (if available) on gun and press it against thetop sheet so...
Page 16 - CAUTION
B-4 B-4 OPERATION FIGURE B.3 POWER MIG ® 256 WIRE REEL LOADING - READIREELS, SPOOLS OR COILS To Mount a 30 Lb. (14 kg) Readi-Reel Package(Using the Molded Plastic K363-P Readi-ReelAdapter:) (See Figure B.3) 1. Open the Wire Drive Compartment Door. 2. Depress the Release Bar on the Retaining Collar a...
Page 17 - FEEDING WIRE ELECTRODE
The pressure arm controls the amount of force thedrive rolls exert on the wire. Proper adjustment of bothpressure arm gives the best welding performance. Forbest results, set both pressure arms to the samevalue. Set the pressure arm as follows (See Figure B.4): Aluminum wires between 1 and 3 Cored w...
Page 18 - WIRE DRIVE CONFIGURATION
B-6 B-6 OPERATION GUN RECEIVER BUSHING LOOSEN TIGHTEN THUMB SCREW OUTER WIRE GUIDE SOCKET HEADCAP SCREW CONNECTOR BLOCK WIRE DRIVE CONFIGURATION (See Figure B.5) Changing the Gun Receiver Bushing ELECTRIC SHOCK can kill. • Turn the input power OFF at the weld- ing power source before installationor ...
Page 19 - MAKING A WELD; FAN CONTROL; (See Welding Thermal Overload Protection); INPUT LINE VOLTAGE PROTECTION; High Line Voltage; WIRE FEED OVERLOAD PROTECTION
B-7 B-7 OPERATION MAKING A WELD 1. Check that the electrode polarity is correct for the process being used, then turn the power switch ON. 2. Set desired arc voltage and wire speed for the particular electrode wire, material type and thickness, and gas (forGMAW) being used. Use the Application Chart...
Page 20 - OVERCURRENT PROTECTION
B-8 B-8 OPERATION WELDING THERMAL OVERLOADPROTECTION The POWER MIG ® 256 has built-in protective thermostats that respond to excessive temperature.They open the wire feed and welder output circuits ifthe machine exceeds the maximum safe operatingtemperature because of a frequent overload, or highamb...
Page 21 - ACCESSORIES; DRIVE ROLL KITS; Bold; K363P READI-REELTM ADAPTER; SPOOL GUN; Remove all input power to the POWER MIG
C-1 C-1 ACCESSORIES DRIVE ROLL KITS Refer to Table C.1 for various drive roll kits that areavailable for the POWER MIG ® 256.The item in Bold is supplied standard with the POWER MIG ® 256. TABLE C.1 K2378-1 Canvas CoverK468 Spindle Adapter - for 8” (203.2mm) O.D. spool. K363P READI-REEL™ ADAPTER The...
Page 24 - MAINTENANCE; GUN TUBES AND NOZZLES; • Have an electrician install and; GENERAL MAINTENANCE
D-1 D-1 MAINTENANCE 3. If using optional adjustable slip-on nozzles. (Refer to www.lincolnelectric.com ) • Be sure the nozzle insulator is fully screwedonto the gun tube and does not block the gasholes in the diffuser. • Slip the appropriate gas nozzle onto the nozzleinsulator. Either a standard .50...
Page 25 - n o t
D-2 D-2 MAINTENANCE 5. Fully seat the liner bushing into the connector. tighten the set screw on the brass cable connector.T h e g a s d i f f u s e r , a t t h i s t i m e , s h o u l d n o t b e installed onto the end of the gun tube. 6. With the gas diffuser still removed from the gun tube, be su...
Page 26 - GUN HANDLE DISASSEMBLY
D-3 D-3 MAINTENANCE GUN HANDLE DISASSEMBLY The internal parts of the gun handle may beinspected or serviced if necessary. The gun handle consists of two halves that areheld together with a collar on each end. Toopen up the handle, turn the collars approxi-mately 60 degrees counterclockwise (the same...
Page 27 - TROUBLESHOOTING; Local Lincoln Authorized Field Service Facility; HOW TO USE TROUBLESHOOTING GUIDE
E-1 E-1 TROUBLESHOOTING If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshooting Guide is provi...
Page 28 - OUTPUT PROBLEMS; Observe all Safety Guidelines detailed throughout this manual
E-2 E-2 TROUBLESHOOTING PROBLEMS(SYMPTOMS) Major Physical or ElectricalDamage is Evident There is no wire feed or open cir-cuit voltage when the gun trigger ispulled. Input power is applied toPOWER MIG ® 256. Output voltage and wire feed is pre-sent when gun trigger is not pulled(not activated). Mac...
Page 29 - FEEDING PROBLEMS
E-3 E-3 TROUBLESHOOTING PROBLEMS(SYMPTOMS) Poor arc striking with electrodesticking or blasting off. Rough wire feeding or wire will notfeed but drive rolls are turning. POSSIBLE CAUSE 1. Make sure settings for wire feed speed and voltage are correctfor process being used. 2. T h e g a s s h i e l d...
Page 30 - GAS FLOW PROBLEMS
E-4 E-4 TROUBLESHOOTING PROBLEMS(SYMPTOMS) The wire feed stops while welding.When trigger is released andpulled again the wire feed starts. No control of wire feed speed.Other machine functions are nor-mal. Gas does not flow when gun triggeris pulled. POSSIBLE CAUSE 1. Check the wire feed drive roll...
Page 31 - WIRING DIAGRAMS; POW
F-1 F-1 WIRING DIAGRAMS L124 64-2 A. 0 1 COLOR CODE : ELECT RI CA L SYM BOLS PER E153 7 GENERA L I NFOR M A T IO N 26 5 26 3 26 0 26 1 U - BLUE R - RED W - W H IT E B - BLA C K INDI CA T ES CONNECT O R CA V IT Y NO. 26 2 26 7 26 4 OU T P U T CH O K E P O W E R F A CT O R EN H A N C EMEN T CH O K E 2...
Page 33 - DIMENSION PRINT
F-3 F-3 DIMENSION PRINT M1 92 31 -1 A. 0 2 19. 15 39. 92 12. 00 38. 58 32. 56 29. 73 30. 43 20. 12 POWER MIG ® 256
Page 34 - NOTES
