Lincoln Electric POWER MIG 140 Operator's Manual
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IM890
January, 2007
POWER MIG (140, 180 MODELS)
11254, 11255, 11256 and 11257
For use with machines having Code Numbers:
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT
READING
THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
OPERATOR'S MANUAL
Copyright © 2007 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• 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
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Related Manuals for Lincoln Electric POWER MIG 140
Summary of Contents for Lincoln Electric POWER MIG 140
- Page 1 IM890 January, 2007 POWER MIG (140, 180 MODELS) 11254, 11255, 11256 and 11257 For use with machines having Code Numbers: Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ...
- Page 2 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
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Page 3: Electric Shock Can Kill
SAFETY ARC RAYS can burn. ELECTRIC SHOCK can 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot”... - Page 4 SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can if damaged. cause fire or explosion. 7.a. Use only compressed gas cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used and properly operating the welding sparks from starting a fire.
- Page 5 SAFETY 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté...
- Page 6 Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses- sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor- mation or advice.
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Page 7: Table Of Contents
TABLE OF CONTENTS Page –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– Installation .......................Section A Technical Specifications ..................A-1 Safety Precautions....................A-2 Location......................A-2 Stacking ......................A-2 Tilting.......................A-2 Identify and Locate Components ................A-3 ________________________________________________________________________________ Operation ......................Section B Safety and Product Description ................B-1 Controls and Settings..................B-2, B-3 Drive Roll and Wire Guides Table .................B-4 Setting Up and Making a Flux-Cored Weld..........B-5 thru B-7 Setting Up and Making a MIG Weld and Install Shielding Gas....B-8 thru B-11 Setting Up and Making a Aluminum Weld ............B-12... -
Page 8: Installation
INSTALLATION TECHNICAL SPECIFICATIONS 180 Amp units (K2472-1 180T, K2473-1 180C) INPUT – SINGLE PHASE ONLY Standard Voltage/Frequency Input Current 230 V 60 Hz 20 Amps @ rated output 208 V 60 Hz 20 Amps @ rated output RATED OUTPUT Voltage/Duty Cycle Current Voltage at Rated Amperes 230 V... -
Page 9: Safety Precautions
INSTALLATION Read entire installation section before starting installation. SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Only qualified personnel should perform this installation. • Only personnel that have read and under- stood the POWER MIG Operating Manual should install and operate this equipment. •... -
Page 10: Identify And Locate Components
INSTALLATION IDENTIFY AND LOCATE COMPONENTS • .030 -.045 Knurled Drive Roll (Installed on Machine) INCLUDED COMPONENTS • Wire Feeder Welder. • .025 -.035 Inner Wire guide • .035 -.045 Inner Wire Guide (Installed on Machine) • Outer Wire Guide (Installed on Machine) INNER WIRE GUIDE INNER WIRE GUIDE OUTER WIRE GUIDE... -
Page 11: Operation
OPERATION PRODUCT DESCRIPTION (PRODUCT Read entire operation section before CAPABILITIES) operating the POWER MIG. These small portable wire feed welders are capable of WARNING MIG welding on steel, stainless steel, and aluminum. They are also capable of flux-cored welding on mild steel. -
Page 12: Controls And Settings
OPERATION CONTROLS AND SETTINGS This machine has the following controls: FIGURE B.1 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 control sets a weld procedure. - Page 13 OPERATION See Figure B.3 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).
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Page 14: Drive Roll And Wire Guides Table
OPERATION TABLE B.1 DRIVE ROLL AND WIRE GUIDES Wire Diameter & Drive Roll Drive Roll Part Inner Wire Guide Inner Wire Guide Type Number Part Number .025 MIG wire .025/.030 Smooth Drive Roll KP2529-1 .030 MIG wire .035 MIG wire .035 Smooth Drive Roll KP2529-2 .025-.035 Steel... -
Page 15: Setting Up And Making A Flux-Cored Weld
OPERATION SETTING UP AND MAKING A FLUX-CORED WELD A. ITEMS NEEDED FOR FLUX CORED WELDING 7. Work Cable & Clamp 1. 035 Contact Tip 2. .025-.035 wire guide INNER WIRE GUIDE .025-.035 3. Knurled Drive Roll 4. .035 NR-211MP Flux-Cored Wire 5. - Page 16 OPERATION B. CONNECT LEADS AND CABLES ON FIGURE B.7 LOCATE COMPONENTS TO CONNECT TO THE THE MACHINE FRONT OF 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.
- Page 17 OPERATION (See Figure B.9) FIGURE B.9 TOP DRIVE ROLL 9. Feed the wire through the wire drive inlet along the PRESSED AGAINST LOWER DRIVE ROLL TENSION ADJUSTOR inner wire guide groove and into the wire drive outlet LOCKED IN POSITION on the gun side.
- Page 18 OPERATION SETTING UP AND MAKING A MIG WELD 6. Welding Gun A. ITEMS NEEDED FOR MIG WELDING 1. 025 Contact Tip 7. Work Cable & Clamp 2. 025-035 Inner wire guide 8. Gas Regulator & Gas Line 3. .025 Drive Roll 9.
- Page 19 OPERATION FIGURE B.13 B. INSTALL SHIELDING GAS MIG welding requires an appropriate bottle of shielding MALE END REGULATOR ADAPTER gas. For mild steel either a cylinder bottle of Ar/CO S19298 PLASTIC 100% CO can be used refer to the following instruc- WASHER 100% tions to properly connect shielding gas to the machine.
- Page 20 B-10 B-10 OPERATION FIGURE B.14 C. CONNECT LEADS AND CABLES ON THE MACHINE LOCATE COMPONENTS TO CONNECT TO THE FRONT OF 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.
- Page 21 B-11 B-11 OPERATION (See Figure B.16) FIGURE B.16 TOP IDLER ROLL 9. Feed the wire through the wire drive inlet along the PRESSED AGAINST LOWER DRIVE ROLL TENSION ADJUSTOR inner wire guide groove and into the wire drive out- LOCKED IN POSITION let on the gun side.
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Page 22: Setting Up And Making A Aluminum Weld
B-12 B-12 OPERATION SETTING UP AND MAKING A ALUMINUM WELD USING SPOOL GUN 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. - Page 23 ACCESSORIES 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.
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Page 24: Accessories
ACCESSORIES K520—Utility Cart Heavy duty cart stores and transports welder, 150 cubic foot shielding gas cylinder, welding cables and accessories. Includes stable platforms for welder and gas bottle platform, lower tray for added storage capacity and adjustable height handle. For mounting welding machines to K520 carts that do not have slotted mounting holes. Drill 9/32”... - Page 25 ACCESSORIES K2275-1 - Welding Cart Lightweight cart stores and transports welder, 80 cubic foot shielding gas cylinder, welding cables and accessories. Includes an angled top shelf for easy access to controls, lower tray for added storage capacity, a sturdy fixed handle and convenient cable wrap hanger.
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Page 26: Maintenance
MAINTENANCE MAINTENANCE SAFETY PRECAUTIONS WARNING 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). •... -
Page 27: Gun And Cable Maintenance
MAINTENANCE GUN AND CABLE 5. To remove gun tube from gun, remove gas nozzle MAINTENANCE or gasless nozzle and remove diffuser from gun tube. Remove both collars from each end of the FOR MAGNUM™ 100L GUN gun handle and separate the handle halves. Loosen the locking nut holding the gun tube in Gun Cable Cleaning place against the gun end cable connector. - Page 28 MAINTENANCE 1-1/4”(31.8 mm) Liner Trim Length Gas Diffuser Gas Nozzle or Gasless Nozzle Set Screw Brass Cable Connector Liner Assembly (Liner bushing to be sealed tight against brass cable connector) FIGURE D.2 8. Screw the gas diffuser onto the end of the gun tube Liner trim length and securely tighten.
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Page 29: Troubleshooting
HOW TO USE TROUBLESHOOTING GUIDE WARNING 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 and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual. - Page 30 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual RECOMMENDED PROBLEMS POSSIBLE COURSE OF ACTION (SYMPTOMS) CAUSE OUTPUT PROBLEMS Major physical or electrical damage “Do not Plug in machine or turn it on”. is evident. Contact your local Authorized Field Service Facility.
- Page 31 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual POSSIBLE PROBLEMS RECOMMENDED CAUSE (SYMPTOMS) COURSE OF ACTION FEEDING PROBLEMS 1. If the wire drive motor is running No wire feed when gun trigger is make sure that the correct drive pulled.
- Page 32 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION WELDING PROBLEMS Arc is unstable – Poor starting 1. Check for correct input voltage to machine. 2. Check for proper electrode polarity for process. 3.
- Page 33 DIAGRAMS 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. POWER MIG (140, 180 MODELS)
- Page 34 DIMENSION PRINT POWER MIG (140, 180 MODELS)
- Page 35 NOTES POWER MIG (140, 180 MODELS)
- Page 36 NOTES POWER MIG (140, 180 MODELS)
- Page 37 Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. Insulate yourself from work and ground. Spanish No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE bajo carga con la piel o ropa moja-...
- Page 38 Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or Use ventilation or exhaust to guards off. WARNING remove fumes from breathing zone. Spanish Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o AVISO DE...
- Page 39 • World's Leader in Welding and Cutting Products • • 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...