Lincoln POWER MIG 140 Operator's Manual
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Lincoln POWER MIG 140 Operator's Manual

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Operator's Manual

POWER MIG

Register your machine:
www.lincolnelectric.com/register
Authorized Service and Distributor Locator:
www.lincolnelectric.com/locator
Save for future reference
Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM890-A
| Issue D ate Nov- 13
© Lincoln Global, Inc. All Rights Reserved.
®
(140, 180 MODELS)
For use with machines having Code Numbers:
11254, 11255, 11256, 11257 and
11444

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Summary of Contents for Lincoln POWER MIG 140

  • Page 1: Power Mig

    11254, 11255, 11256, 11257 and 11444 Register your machine: www.lincolnelectric.com/register Authorized Service and Distributor Locator: www.lincolnelectric.com/locator Save for future reference Date Purchased Code: (ex: 10859) Serial: (ex: U1060512345) IM890-A | Issue D ate Nov- 13 © Lincoln Global, Inc. All Rights Reserved.

  • Page 2: Safety Precautions

    USE NATURAL DRAFTS or fans to keep the fumes away from your face. Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by If you de velop unusual symptoms, see your supervisor. Perhaps the proper installation ...

  • Page 3: California Proposition 65 Warnings

    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 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE DANGEROUS 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 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding shielding the supply cable of permanently installed welding Equipment. It is for use with other Lincoln Electric equipment. It is equipment, in metallic conduit or equivalent. Shielding should be designed for industrial and professional use.

  • Page 7: Table Of Contents

    viii viii TABLE OF CONTENTS Page –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– Installation .......................Section A Technical Specifications.................A-1, A-2 Safety Precautions....................A-3 Location......................A-3 Stacking ......................A-3 Tilting.......................A-3 Identify and Locate Components ................A-4 ________________________________________________________________________________ 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 INSTALLATION TECHNICAL SPECIFICATIONS 180 Amp units (K2668-1 180C) INPUT – SINGLE PHASE ONLY Standard Voltage/Frequency Input Current 20 Amps 240 V 50 Hz 1 max 10.7 Amps 1 eff RATED OUTPUT Voltage/Duty Cycle Current Voltage at Rated Amperes 240 V 131 Amps OUTPUT Welding Current Range...

  • Page 10: 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 11: Identify And Locate Components

    INSTALLATION IDENTIFY AND LOCATE COMPONENTS • .030” -.045” (0.8 - 1.1mm) Knurled Drive Roll (Installed on Machine) INCLUDED COMPONENTS • Wire Feeder Welder. • .025” -.035” (0.6 - 0.9mm) Inner Wire guide • .035” -.045” (0.9 - 1.1mm) Inner Wire Guide (Installed on Machine) •...

  • Page 12: 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 13: 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 14 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).

  • Page 15: 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”(0.6mm) MIG wire .025”/.030” (0.6mm/0.8mm) Smooth Drive Roll KP2529-1 .030”(0.8mm) MIG wire .025”-.035” .035”(0.9mm) MIG wire .035”(0.9mm) Smooth Drive Roll KP2529-2 (0.6mm-0.9mm)

  • Page 16: 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”(0.9mm) Contact Tip 2. .025”-.035”(0.6mm-0.9mm) wire guide INNER WIRE GUIDE .025-.035 (.6-.9mm) 3. Knurled Drive Roll 4. .035”(0.9mm) NR-211MP Flux-Cored Wire 5.
  • Page 17 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 18 OPERATION FIGURE B.9 (See 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 19 OPERATION SETTING UP AND MAKING A MIG WELD A. ITEMS NEEDED FOR MIG WELDING 1. 025”(0.6mm) Contact Tip 7. Work Cable & Clamp 2. 025”-035”(0.6mm-0.9mm) Inner wire guide INNER WIRE GUIDE .025-.035 8. Gas Regulator & Gas Line 3. .025”(0.6mm) Drive Roll 9.
  • Page 20 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 21 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 22 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.

  • Page 23: 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 24 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.

  • Page 25: 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 26 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.

  • Page 27: Maintenance

    No user serviceable parts inside! Do not attempt to perform service in the power source (fixed) side of the POWER MIG (140, 180 MODELS). Take the unit to an authorized Lincoln Service Center if you experience problems. NO maintenance is required.

  • Page 28: 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 29: Changing Liner

    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.

  • Page 30: 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 31 CAUTION 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. POWER MIG (140, 180 MODELS)
  • Page 32 CAUTION 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. POWER MIG (140, 180 MODELS)
  • Page 33 CAUTION 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. POWER MIG (140, 180 MODELS)
  • Page 34 DIAGRAMS Enhanced Diagram 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 35 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 (180 MODELS)
  • Page 36 DIMENSION PRINT POWER MIG (140, 180 MODELS)
  • Page 37 Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice.

This manual is also suitable for:

Power mig 180

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