Lincoln Electric 12101 Operator's Manual
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Lincoln Electric 12101 Operator's Manual

Wire feeder welders
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Operator's Manual
WIRE FEEDER WELDERS
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10049-A
| Issue Date Mar- 14
© Lincoln Global, Inc. All Rights Reserved.
(125, 140 MODELS)
For use with machines having Code Numbers:
11631, 11632, 11633, 11634,
11635, 11636, 11637, 11638,
11639, 12100, 12101, 12102,
12103, 12104, 12105, 12106,
12107

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  • Page 1 Operator’s Manual WIRE FEEDER WELDERS (125, 140 MODELS) For use with machines having Code Numbers: 11631, 11632, 11633, 11634, 11635, 11636, 11637, 11638, 11639, 12100, 12101, 12102, 12103, 12104, 12105, 12106, 12107 Register your machine: www.lincolnelectric.com/register Authorized Service and Distributor Locator: www.lincolnelectric.com/locator...
  • Page 2 THANK YOU FOR SELECTING KeeP your head out oF the Fumes. A QUALITY PRODUCT BY LINCOLN ELECTRIC. DON’T get too close to the arc. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Material Safety...
  • Page 3 American Welding Society, P.O. Box 351040, Miami, Florida 33135 or ELECTRIC AND CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” MAGNETIC FIELDS MAY booklet E205 is available from the Lincoln Electric Company, 22801 BE DANGEROUS St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, 2.a.

  • Page 4: Electric Shock Can Kill

    SAFETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot”...
  • Page 5 SAFETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the the gas and pressure used.

  • Page 6: Table Of Contents

    Technical Specifications .....A-1 Identify and Locate Components for 125 Amp Unit .A-2 Identify and Locate Components for 140 Amp Unit .A-3 Operation .
  • Page 7 WIRE FEEDER WELDERS (125, 140) PRODUCT DESCRIPTION PRODUCT DESCRIPTION (PRODUCT CAPABILITIES) The portable 125Amp Wire Feeder Model is capable of flux-cored welding on mild steel. The portable 140Amp Wire Feeder Model is capable of MIG welding on steel, stainless steel, and aluminum, in addition to flux-core welding on mild steel.

  • Page 8: Installation

    WIRE FEEDER WELDERS (125, 140) INSTALLATION TECHNICAL SPECIFICATIONS 125 Amp units (K2479-1, K2513-1, K2696-1, K2699-1, K2785-1) INPUT – SINGLE PHASE ONLY Input Current Standard Voltage/Frequency 120 V / 60 Hz 20 Amps @ rated output RATED OUTPUT Duty Cycle Current...

  • Page 9: Identify And Locate Components For 125 Amp Unit

    WIRE FEEDER WELDERS (125, 140) INSTALLATION IDENTIFY AND LOCATE COMPONENTS for 125 AMP UNIT • .025” -.035”(0.6mm-0.8mm) Dual Groove Drive Roll • Wire Feeder Welder (Factory installed .035”(0.9mm) groove ready for flux- cored process) .025 GROOVE .035 GROOVE • Black Gun Nozzle (Installed on Welding Gun) •...

  • Page 10: Identify And Locate Components For 140 Amp Unit

    WIRE FEEDER WELDERS (125, 140) INSTALLATION IDENTIFY AND LOCATE COMPONENTS for 140 AMP UNIT • Wire Feeder Welder • .025” -.035”(0.6mm-0.8mm) Dual Groove Drive Roll (Factory installed .035”(0.9mm) groove ready for flux-cored process). .025 GROOVE .035 GROOVE • Work Cable & Clamp •...

  • Page 11: Operation

    WIRE FEEDER WELDERS (125, 140) OPERATION Read entire operation section before operating the WIRE FEEDER WELDERS WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. Insulate yourself from work and ground.

  • Page 12: Controls And Settings

    WIRE FEEDER WELDERS (125, 140) 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.
  • Page 13 WIRE FEEDER WELDERS (125, 140) OPERATION FIGURE B.3 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 Cover and Side Door have been removed for clarity of Items 8 and 9.
  • Page 14 Press to reset. 13. GAS INLET –Shielding gas connects to this inlet (This is not available on 125 Amp Unit.) SETTING UP AND MAKING A FLUX-CORED WELD WITH 125AMP OR 140AMP MACHINES A. ITEMS NEEDED FOR FLUX CORED WELDING 3.
  • Page 15 WIRE FEEDER WELDERS (125, 140) OPERATION B. CONNECT LEADS AND CABLES ON THE MACHINE FIGURE B.7 (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 bush- ing.
  • Page 16 WIRE FEEDER WELDERS (125, 140) OPERATION FIGURE B.9 (See Figure B.9) 6. Feed the wire through the incoming guide, over the drive roll groove, thru the outgoing guide and wire drive outlet on PIVOT ARM ASSEMBL Y the gun side.
  • Page 17 (note this requires a CO regulator adapter which is sold separately). FEMALE END MALE END 75/25 100% MIXES 5. Brass gun nozzle (REQUIRES ADAPTER SOLD SEPARATELY) 6. Welding Gun * 125 Amp Units can not be upgraded for MIG welding.
  • Page 18 WIRE FEEDER WELDERS (125, 140) OPERATION B. INSTALL SHIELDING GAS FIGURE B.13 MIG welding requires an appropriate bottle of shielding gas. For MALE END mild steel a cylinder of Ar/CO or 100% CO can be used; refer to REGULATOR ADAPTER...
  • Page 19 WIRE FEEDER WELDERS (125, 140) 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 20 WIRE FEEDER WELDERS (125, 140) OPERATION FIGURE B.16 (See Figure B.16) 6. Feed the wire through the incoming guide, over the drive roll groove, thru the outgoing guide and wire drive outlet on the gun side. PIVOT ARM ASSEMBL Y...

  • Page 21: Setting Up And Making A Aluminum Weld

    WIRE FEEDER WELDERS (125, 140) OPERATION SETTING UP AND MAKING A ALUMINUM WELD USING SPOOL GUN (Aluminum Welding can only be used on 140 Amp machines.) 1. Loosen the THUMB SCREW and disconnect Magnum 100L Gun. FIGURE B.21 2. Insert K2532-1 Magnum 100SG spool gun into the brass block (Location of Selector Switch and Thumb Screw) and tighten the THUMB SCREW.

  • Page 22: Accessories

    WIRE FEEDER WELDERS (125, 140) ACCESSORIES K2532-1 - Magnum 100SG Spool Gun (Only available on 140 Models K2480-1, K2514-1, K2658-1 and K2697-1). Designed to easily feed small 4" diameter (1lb. spools of) .030 or .035 aluminum wire. Includes gun, adapter kit, three extra .035 contact tips, gas nozzle, and spool of Superglaze 4043 .035"...
  • Page 23 WIRE FEEDER WELDERS (125, 140) 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.
  • Page 24 WIRE FEEDER WELDERS (125, 140) ACCESSORIES K2275-3 - 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.

  • Page 25: Maintenance

    (fixed) side of the WIRE FEEDER tip repeatedly. Use the wire as a reamer to remove dirt that WELDERS (125 and 140 MODELS). Take the unit to an authorized may be adhering to the wall of the hole through the tip.

  • Page 26: Overload Protection

    Gas Diffuser Thermal Protection The WIRE FEEDER WELDERS (125 and 140 MODELS) have a rated output duty cycle as defined in the Technical Specification Gas Nozzle or page. If the duty cycle is exceeded, a thermal protector will shut...

  • Page 27: Troubleshooting

    HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs per- formed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty.
  • Page 28 WIRE FEEDER WELDERS (125, 140) TROUBLE SHOOTING Observe all Safety Guidelines detailed throughout this manual RECOMMENDED PROBLEMS POSSIBLE COURSE OF ACTION (SYMPTOMS) CAUSE OUTPUT PROBLEMS Major physical or electrical damage is evi- “Do not Plug in machine or turn it on”.
  • Page 29 WIRE FEEDER WELDERS (125, 140) TROUBLE SHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION GAS FLOW PROBLEMS Low or no gas flow when gun trigger is 1. Check gas supply, flow regulator and pulled.
  • Page 30 WIRE FEEDER WELDERS (125, 140) 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.
  • Page 31 WIRE FEEDER WELDERS (125, 140) 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.
  • Page 32 WIRE FEEDER WELDERS (125, 140) DIAGRAMS 1 2 3 4 1 2 3 4 5 6 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a...
  • Page 33 WIRE FEEDER WELDERS (125, 140) 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.
  • Page 34 WIRE FEEDER WELDERS (125, 140) DIMENSION PRINT...
  • Page 35 NOTES...
  • Page 36 MIG welding on thin gauge steel, stainless or aluminum. Compare the precise drive, WHAT’S INCLUDED rugged construction and full list of standard accessories. . . the Lincoln Electric Easy-MIG 140 is an excellent choice! ® ...
  • Page 37 The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for information or advice about their use of our products. Our employees respond to inquiries to the best of their ability based on information provided to them by the customers and the knowledge they may have concerning the application.

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