Lincoln Electric 140 Welder User Manual
Contents
1. 1 4 20 X 1 Thread Forming Screw 1 Required 1 4 20 X 1 2 Hex Head Cap Screw 2 Required 3 3 4 95 3mm 9 32 7 1mm DRILL 3 PLACES 7 j 8 1 16 204 8mm 1 3 11 16 93 7mm o o 3 13 32 96 8mm pg 4 102mm 16 406 4mm POWER MIG 140 180 MODELS LINCOLN 3 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 For mounting welding machines to K2275 carts that do not have slotted mounting holes Drill 9 32 holes 3 places into the cart top as shown and attach the welding machine to the cart with the proper hardware shown 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 Flange Nut 2 Required 9 32 7 1mm DRILL 3 PLACES 1 1 4 31 8 7 9 16 192 1mm T i 3 3 16 81mm 2 15 16 74 6mm 1 A3 1 1 2 38 1mm 13 1 2 342 9mm POWER MIG 140 180 MODELS LINCOLN MAINTENANCE MAINTENANCE SAFETY PRECAUTIONS WARNING2. SH7IAE SUAS MAS AH PARAH MBH Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten opere com as tampas removidas Desligue a corrente antes de fazer servico e N o toque as partes el tricas nuas e X7TTLA 9 UACRU PRE EFBRAL FE DF e HE BIS ER Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s e Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes N o opere com os paineis abertos ou guardas removidas CB EHTEUSXVCREU SER HGTBI BUSUR ERE e 430 Yel Me z Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO it ie BIR Chinese oe lue chal TU Gal 3 Ar ggill iti Adu oe Quad Aie hy pha al juil ail e AREY cuts Pb tha Y e Ale Ll gli LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPA
3. syed jeouosje jou og o p109 Jamod 51 02 JIM 9jeJedo JOU 00 e lt LSZLL 99511 SSZLL 6 53 00 WVH5VIG ONIHIM 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 LINCOLN E 2 c OLVOCIN LOV ALILNIAI NOEZ AOCL ZES LA 43 S TOHWAS 1V2IH12313 H21V1 01 6 8 a oe Sv C Ed WV49VIQ NND 10045 401 L OLVOCW 335 WWVd5VIG ONIHIM H3WLL LOdS 99 9 5 33S d 5 SNONNILNOD ONY SANIHDWW Q3dd7 L 401 15 51 LNJNOdWOO SIHL 35 VL 1OA LNdNI SANIHDVW G3NIIWH3L3Q SI vf SHOLD3NNOO 10 AGIS NOLLH3SNI WOHA JDNANOAS SNIB38IWAN ONIGTIJM MVIND NMOHS SNOLLD3NNOO ANY AYOM ONIHOV LLV3H N3HM 07 ONINHOD ANNOdWOD ANIOF Z 8 LL SNOLLD3NNOO Q3L108 vf vf DIAGRAMS LOW LOW YOLOW Q33H F 2 68S LI PEZI M0139 11V A NOILVHNOIANOD ALLLN3GI 33S GN Sf YOLOW IVNOLLdO NND 10045 wt YAWYOASNVUL NI
4. 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 Have qualified personnel do the mainte nance and trouble shooting work ROUTINE MAINTENANCE POWER SOURCE COMPARTMENT 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 In extremely dusty locations dirt may clog the air passages causing the welder to run hot with premature tripping of ther mal protection If so blow dirt out of the welder with low pres sure air at regular intervals to eliminate excessive dirt and dust build up on internal parts WIRE FEED COMPARTMENT 1 When necessary vacuum accumulated dirt from gearbox and wire feed section 2 Occasionally inspect the wire guides and keep grooves clean 3 Motor and gearbox have lifetime lubrication and require no maintenance FAN MOTOR Has lifetime lubrication requires no maintenance WIRE REEL SPINDLE Requires no maintenance Do not lubricate shaft POWER MIG 140 180 MODELS LINCOLN D 1 2 GUN AND CABLE MAINTENANCE FOR MAGNUM 100L GUN Gun Cable Cleaning Clean cable liner after using a
5. 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 Machine must be plugged into a receptacle which is grounded per any national local or other applicable electrical codes The POWER MIG power switch is to be in the OFF position when installing work cable and gun and when connecting power cord to input power 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 reduces the chance of dirt accumulation that can block air passages and cause overheating STACKING POWER MIG 140 180 MODELS cannot be stacked TILTING Each machine must be placed on a secure level sur face directly or on recommended cart The machine may topple over if this procedure is not followed POWER MIG 140 180 MODELS LINCOLN idi INSTALLATION A IDENTIFY AND LOCATE COMPONENTS INCLUDED COMPONENTS Wire Feeder Welder 3 035 0 9mm Contact Tips 1 installed on the welding gun E 025 pr ue Contact Tips lo N e e Spool of 035 0 9 mm diameter NR 211MP Innershield Flux cored Wire gt of 025 0 6 mm diameter L 56 MIG Wire 035 0 9mm ha D
6. deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pou
7. ez 119 Bo Soave de vues al ad 4 aun y READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n e Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases e Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona respirat ria E1 APSMERTLIICLT 9 fsPBHEICTAESUCFEU e RED BEBE
8. MIG wire 030 0 8mm flux cored 035 0 9mm flux cored 045 1 1mm flux cored OPERATION TABLE B 1 DRIVE ROLL AND WIRE GUIDES Drive Roll 025 030 0 6mm 0 8mm Smooth Drive Roll 035 0 9mm Smooth Drive Roll 030 045 0 8mm 1 1mm Knurled Drive Roll 030 045 0 8mm 1 1mm Knurled Drive Roll See Figure B 6 12 CIRCUIT BREAKER If the rated input current of the machine is exceeded this circuit breaker will trip Press to reset 13 GAS INLET Shielding gas connects to this inlet 12 Inner Wire Guide Part Number 025 035 0 6mm 0 9mm Steel Wire Guide 045 1 1mm Steel KP2531 FIGURE B 6 KP2531 1 13 POWER MIG 140 180 MODELS LINCOLN 5 OPERATION SETTING UP AND MAKING A FLUX CORED WELD A ITEMS NEEDED FOR FLUX CORED WELDING 7 Work Cable amp Clamp 1 035 0 9mm Contact Tip 9 e e 7 y 2 025 035 0 6mm 0 9mm wire guide INNER WIRE GUIDE 025 035 6 9mm 4 035 0 9mm NR 211MP Flux Cored Wire 5 Black Flux Cored gun nozzle 6 Welding Gun POWER MIG 140 180 MODELS LINCOLN 6 OPERATION 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 su ron X through the hol
9. control cables signaling and telephone cables above below and adjacent to the welding equipment radio and television transmitters and receivers computer and other control equipment safety critical equipment e g guarding of industrial equipment the health of the people around e g the use of pacemakers and hearing aids equipment used for calibration or measurement the immunity of other equipment in the environment The user shall ensure that other equipment being used in the environment is compatible This may require additional protection measures the time of day that welding or other activities are to be carried out L10093 POWER MIG 140 180 MODELS LINCOLN 8 vi INSTALLATION i ELECTROMAGNETIC COMPATIBILITY EMC The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surrounding area may extend beyond the boundaries of the premises Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer s recommendations If interference occurs it may be necessary to take additional precautions such as filtering of the mains supply Consideration should be given to shielding the supply cable of permanently installed welding equipment in metallic conduit or equivalent Shielding should be electrically continuous throughout its length The shielding should be
10. In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 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 287 standards 4 b Use suitable clothing made from durable flame resistant 54 06 LINCOLN material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch
11. WARNING CYLINDER may explode if dam aged Keep cylinder upright and chained to support Keep cylinder away from areas where it may be damaged Never lift welder with cylinder attached Never allow welding electrode to touch cylinder Keep cylinder away from welding or other live electrical circuits WARNING BUILDUP OF SHIELDING GAS may harm health or kill Shut off shielding gas supply when not in use 1 Secure the cylinder to a wall or other stationary support to prevent the cylinder from falling over Insulate the cylinder from the work circuit and earth ground Refer to Figure B 13 2 With the cylinder securely installed remove the cylinder cap Stand to one side away from the out let and open the cylinder valve very slightly for an instant This blows away any dust or dirt which may have accumulated in the valve outlet WARNING BE SURE TO KEEP YOUR FACE AWAY FROM THE VALVE OUTLET WHEN CRACKING THE VALVE Never stand directly in front of or behind the flow regulator when opening the cylinder valve Always stand to one side FIGURE B 13 PLASTIC WASHER 7 ADAPTER uh 519298 3 Attach the flow regulator to the cylinder valve and tighten the union nut securely with a wrench NOTE If connecting to 10096 cylinder a regulator adapter is required Purchase separately 519298 CO adapter
12. be sure to install plastic washer included in the fitting on the bottle side See Figure B 13 4 Refer to Figure B 13 Attach one end of inlet gas hose to the outlet fitting of the flow regulator and tighten the union nut securely with a wrench Connect the other end to the machine Solenoid Inlet Fitting 5 8 18 female threads for CGA 032 fitting Make cer tain the gas hose is not kinked or twisted SHIELDING GAS 1 For open the cylinder very slowly For argon mixed gas open cylinder valve slowly a fraction of a turn When the cylinder pressure gauge pointer stops moving open the valve fully 2 Set gas flow rate for 30 to 40 cubic feet per hour 14 to 18 l min under normal conditions increase to as high as 40 to 50 CFH 18 to 23 5 l min under drafty slightly windy conditions 3 Keep the cylinder valve closed except when using the machine POWER MIG 140 180 MODELS LINCOLN 10 C CONNECT LEADS AND CABLES 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 connector end is seated fully into the wire drive and tighten the thumbscrew to secure the gun 4 Plug the gun trigger lead connector into the 4 pin gun trigger receptacle on the machine front 5 Wire Drive Polarity MIG welding requires Positive po
13. connected to the welding power source so that good electrical contact is maintained between the conduit and the welding power source enclosure Maintenance of the Welding Equipment The welding equipment should be routinely maintained according to the manufacturer s recommendations All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturers instructions In particular the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer s recommendations Welding Cables The welding cables should be kept as short as possible and should be positioned close together running at or close to the floor level Equipotential Bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered However metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time The operator should be insulated from all such bonded metallic components Earthing of the Workpiece Where the workpiece is not bonded to earth for electrical safety not connected to earth because of its size and position e g ships hull or building steelwork a connection bonding the workpiece to e
14. d31V2O1 dWL LVLSOWYSHL cH H3W4O1 SNVHL LH LX 34OHD LNdLNO NA a dVO qv5 SALON GION31OS SYD 105 NV4 1D HOLIDDVdVO 3009 N 212973 VN VN IVNOLLVN GNNOYD OL avi HLOOWS 182 0341415 1 80d 431114 sp esu pjnous e py ued JOVLIOAHSIH syed oq Aq jovodind 1519 05 YUM 1 jou 3000 401 IWNVH9VIG ONIHIM V 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 NOTE This diagram is for reference only POWER MIG 180 MODELS LINCOLN E F 3 DIMENSION PRINT F 3 M21111 2 E a y Lo e o POWER MIG 140 180 MODELS LINCOLN E NOTES POWER MIG 140 180 MODELS LINCOLN Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO Japanese ER BIR Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes los electrodos bajo carga con la piel o ropa moja a Aisle
15. gun remove gas nozzle or gasless nozzle and remove diffuser from gun tube Remove both collars from each end of the gun handle and separate the handle halves Loosen the locking nut holding the gun tube in place against the gun end cable connector Unscrew gun tube from cable connector To install gun tube screw the locking nut on the gun tube as far as possible Then screw the gun tube into the cable connector until it bottoms Then unscrew no more than one turn the gun tube until its axis is perpendicular to the flat sides of the cable connec tor and pointed in the direction of the trigger Tighten the locking nut so as to maintain the proper relationship between the gun tube and the cable connector Replace the gun handle trigger and dif fuser Replace the gas nozzle or gasless nozzle OVERLOAD PROTECTION Output Overload The POWER MIG 140 180 MODELS is equipped with a circuit breaker and a thermostat which protects the machine from damage if maximum output is exceeded The circuit breaker button will extend out when tripped The circuit breaker must be manually reset Thermal Protection The POWER MIG 140 180 MODELS has a rated output duty cycle as defined in the Technical Specification page If the duty cycle is exceeded a thermal protector will shut off the output until the machine cools to a reasonable operating temperature This is an automatic function of the POWER MIG 140 180 MODELS and does not require user in
16. the arc nor expose themselves to the arc rays or to hot spatter or metal FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 3 The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the spe cific welding procedure and application involved Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene
17. 0 9mm 1 1mm Magnum 100L gun liner 045 1 1mm Contact Tip gasless nozzle knurled drive roll 045 1 1mm inner wire guide and a 10 Ib 4 5kg spool of 045 1 1mm Innershield NR 212 wire K2532 1 Magnum 100SG Spool Gun Designed to easily feed small 4 102mm diameter 11b 5kg spools of 030 0 8mm or 035 0 9mm aluminum wire Includes gun adapter kit three extra 035 0 9mm contact tips gas nozzle and spool of Superglaze 4043 035 0 9mm diameter welding wire Packaged in a convenient carry case K2377 1 Small Canvas Cover Protect your machine when not in use Made from attractive red canvas that is flame retardant mildew resistant and water repellent Includes a convenient side pocket to hold welding gun For additional Optional and Miscellaneous Parts See Parts Pages POWER MIG 140 180 MODELS LINCOLN amp c2 ACCESSORIES c2 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 holes 3 places into the cart top as shown and attach the welding machine to the cart with the proper hardware shown 1 4 20 X 1 2 Hex Head Cap Screw 2 Required
18. G CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 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 FOR ENGINE D A 1 h To avoid scalding do not remove the radiator pressure cap when the engine is powered equipment AES oo 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 SX 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND MAGNETIC FIELDS ae 1 c Do not add the fuel near an open flame may be dangerous welding arc or when the engine is running Stop the engine and allow it to cool before 2 a Electric current flowing through any conductor causes refueling to prevent spilled fuel from vaporiz localized Electric and Magnetic Fields EMF Welding ing on
19. G PARTS AND ELECTRICAL CONTACT CAN CAUSE INJURY OR BE FATAL When the gun trigger is depressed drive rolls spool of wire and electrode are ELECTRICALLY LIVE HOT Keep away from moving parts and pinch points LS Keep all Doors Covers panels and guards securely in place DO NOT REMOVE OR CONCEAL WARN ING LABELS 15 Install the 035 0 9mm contact tip 16 Install the black flux cored welding nozzle to the gun 17 Trim the wire stickout to 3 8 9 5mm from the con tacttip See Figure B 12 18 Close the case side door The machine is now ready to weld 19 Read Learn to Weld LTW1 that is included with the machine or watch the How to Weld DVD included with the machine 20 Based on the thickness of the material you are going to weld and the type and diameter of the welding wire set the voltage and the wire feed speed per the procedure decal attached to the inside of the wire drive compartment door OPERATION B 7 FIGURE B 9 TOP DRIVE ROLL PRESSED AGAINST LOWER DRIVE ROLL TENSION ADJUSTOR LOCKED IN POSITION DIRECTION OF WIRE WIRE SPOOL 035 0 9mm LOWER DRIVE ROLL BE SURE WIRE IS IN GROOVE SLIDE WIRE INTO GUN CONNECTOR SIDE FIGURE B 10 035 0 9mm N amp 2n MP 9 ji 4 REMOVED NOZZLE REMOVED CONTACT TIP 5 v LAY CABLE AND GUN STRAIGH
20. INCOLN 8 CYLINDER may explode gt if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage A safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication P I Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect Switch at the fuse box before working on the equipment Install equipment in accordance with th
21. LE AND FUSE SIZES Input Voltage Frequency Fuse or Breaker Size Input Amps Power Cord Extension Cord 120 V 60 Hz 20 Amp 20 15 Amp 125 V 3 Conductor 12 AWG Three Prong Plug 4mm or Larger NEMA Type 5 15P up to 50 ft 15 2m PHYSICAL DIMENSIONS Height Width Depth 14 0 in 10 15 in 18 6 in 357 mm 258 mm 472 mm 11f connected to a circuit protected by fuses use Time Delay Fuse marked D POWER MIG 140 180 MODELS LINCOLN 2 INSTALLATION A 2 TECHNICAL SPECIFICATIONS 180 Amp units K2668 1 180C INPUT SINGLE PHASE ONLY Standard Voltage Frequency Input Current 240 V 50 Hz li max 20 Amps 10 7 Amps RATED OUTPUT Voltage Duty Cycle Current Voltage at Rated Amperes 240 V 25 130 Amps 20 OUTPUT Welding Current Range Open Circuit Voltage Wire Speed Range 30 180 Amps 34 V 50 500 in min 1 3 12 7 m min RECOMMENDED INPUT CABLE AND FUSE SIZES 240 V 50 Hz 40 Amp Super Lag 15 Amp 240 V Three Pin Plug PHYSICAL DIMENSIONS connected to a circuit protected by fuses use Time Delay Fuse marked D 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 POWER MIG 140 180 MODELS LINCOLN INSTALLATION Read entire installation section before starting installation SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill
22. MENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR SRM amp lt MA CUCRITEOSSXSUEL HS CF eU Rie OE D RRR BU 0 HAY AIA HAS SHSM HECH palal gl aui Qui al gll Gail guet i LINCOLN 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
23. ND CABLE WORK LEAD CONNECTION NEGATIVE OUTPUT TERMINAL THUMB SCREW TO TIGHTEN CONNECTOR BUSHING CONNECTOR END ATTACH SHORT POWER CABLE POSITIVE PIN TRIGGER RECEPTACLE OUTPUT TERMINAL PLUGGED IN FIGURE B 15 Oc TOP DRIVE ROLL PRESSURE ARM TENSION ADJUSTOR DOWN WIRE SPOOL 025 0 6mm Sd 96 sou INNER WIRE GUIDE REMOVED 6 LOWER DRIVE ROLL REMOVED OUTER WIRE GUIDE REMOVED POWER MIG 140 180 MODELS LINCOLN 11 See Figure B 16 9 Feed the wire through the wire drive inlet along the inner wire guide groove and into the wire drive out let on the gun side 10 Close the top drive roll pressure arm and secure by pivoting the tension adjustor back to the up position 11 Re install the outer wire guide See Figure B 17 12 Remove the nozzle from the gun and contact tip and straighten the gun out flat 13 Turn the machine power to on and depress the gun trigger to feed the wire through the gun liner until the wire comes out of the threaded end of the gun several inches See Figure B 18 14 When trigger is released spool of wire should not unwind Adjust wire spool brake accordingly A WARNING e MOVING PARTS AND ELECTRICAL CONTACT CAN CAUSE INJURY OR BE FATAL When the gun trigger is depressed drive rolls spool of wire and elec trode are ELECTRICALLY LIVE HOT Keep away from moving parts and pinch points Ke
24. RE WHICH FEEDS THE WIRE THRU THE LINER ROTATION WORK CLAMP AND CABLE FIGURE B 19 TRIM WIRE STICKOUT 3 8 9 5mm from the Brass Nozzle INSTALL 025 CONTACT TIP POWER MIG 140 180 MODELS LINCOLN 12 OPERATION SETTING UP AND MAKING A ALUMINUM WELD USING SPOOL GUN Follow the MIG welding steps in the previous sec tion Connect a bottle of 10096 Argon shielding Gas per previous section Disconnect Magnum 100L Gun Install optional K2532 1 Magnum 100SG spool gun per instructions included with gun Set Gun selector toggle switch to Spool Gun posi tion See Figure B 20 FIGURE B 20 TI11006 2008 2292 OPTIONAL SPOOL GUN K2532 1 Supplement Pistolet d vidoir K2532 1 PAATS AND ELECTRICAL CONTACT CAN CAUSE 6 Turn machine on and make weld per recommended settings on Procedure Decal inside machine door POWER MIG 140 180 MODELS LINCOLN B 12 C1 ACCESSORIES 1 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 sheet metal K2528 1 045 Innershield Kit For 230V models Includes everything needed to weld with 045 1 1mm diameter Innershield wire Includes 035 045
25. RETURN TO MAIN MENU B IM890 A POWER MIG 140 180 MODELS For use with machines having Code Numbers 11254 11255 11256 11257 and 11444 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 1509001 o LL I nK DU ie j as A Desi Under a d by LINCOLNE Copyright 2007 Lincoin Global Inc World s Leader in Welding and Cutting Products e 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 CERTIFICATE NUMBER 30273 SAFETY A WARNING CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDIN
26. Section E Safety Precautions ssis nter sans tra erste ee E 1 How to Use Troubleshooting Guide E 1 Troubleshooting Guide E 2 thru E 4 Wiring Diagram and Dimension Print Section F Parts Licm TE P 533 P 202 E 1 INSTALLATION 1 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 3096 130 Amps 208 V 3096 130 Amps OUTPUT Welding Current Range Open Circuit Voltage Wire Speed Range 30 180 Amps 34 V 50 500 in min 1 3 12 7 m min RECOMMENDED INPUT CABLE AND FUSE SIZES Input Voltage Frequency Fuse or Breaker Size Input Amps PowerCord 230 V 60 Hz 40 Amp Super Lag 20 50 Amp 250 V Three Prong Plug NEMA Type 6 50P PHYSICAL DIMENSIONS Width 10 15 in 258 mm connected to a circuit protected by fuses use Time Delay Fuse marked D 140 Amp units K2470 1 140T K2471 1 140C INPUT SINGLE PHASE ONLY Standard Voltage Frequency Input Current 120 V 60 Hz 20 Amps rated output RATED OUTPUT Duty Cycle Current Voltage at Rated Amperes 20 Duty Cycle 90 Amps 19 5 OUTPUT Welding Current Range Open Circuit Voltage Wire Speed Range 30 140 Amps 33 V 50 500 in min 1 3 12 7 m min RECOMMENDED INPUT CAB
27. TEN IN THIS POSITION x PLUG IN POWER INPUT CORD ON OFF SWITCH FEED WIRE APPROXIMATELY 4 00 FROM THE GUN TUBE END 035 0 9 211 3 Vm E L i ROTATION DEPRESS TRIGGER ACTIVATE WIRE WHICH FEEDS THE WIRE THRU THE LINER WORK CLAMP AND CABLE FIGURE B 12 TRIM WIRE STICKOUT 3 8 9 5mm from the Contact Tip INSTALL 035 CONTACT TIP INSTALL BLACK FLUX CORED NOZZLE POWER MIG 140 180 MODELS LINCOLN 8 OPERATION B 8 SETTING UP AND MAKING A MIG WELD 6 Welding Gun A ITEMS NEEDED FOR MIG WELDING 1 025 0 6mm Contact 7 Work Cable amp Clamp 2 025 035 0 6mm 0 9mm Inner wire guide INNER WIRE GUIDE 3 025 0 6mm Drive Roll 2 9 Bottle of 75 25 Ar CO shielding gas or 100 CO shielding gas note this requires a CO regulator adapter which is sold separately 4 025 0 6mm SuperArc L 56 Solid MIG Wire FEMALE END REQUIRES ADAPTER SOLD SEPARATELY POWER MIG 140 180 MODELS LINCOLN B 9 OPERATION B 9 B INSTALL SHIELDING GAS MIG welding requires an appropriate bottle of shielding gas For mild steel either a cylinder bottle of Ar CO or 100 can be used refer to the following instruc tions to properly connect shielding gas to the machine
28. a highly toxic gas and other irritating prod ucts Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b SAFETY 7 WELDING and CUTTING SPARKS can cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper step
29. arth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users or damage to other electrical equipment Where necessary the connection of the workpiece to earth should be made by a direct connection to the workpiece but in some countries where direct connection is not permitted the bonding should be achieved by suitable capacitance selected according to national regulations Screening and Shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference Screening of the entire welding installation may be considered for special applications 1 Portions of the preceding text are contained in EN 60974 10 Electromagnetic Compatibility EMC product standard for arc welding equipment L10093 POWER MIG 140 180 MODELS LINCOLN 8 vii vii for selecting a QUALITY product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln Electric Company product much pride as we have in bringing this product to you CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting equip ment Our challenge is to meet the needs of our customers and to exceed their expectations On occasion purchasers may ask Lincoln Electric for advice or informatio
30. chine depending on whether you are MIG welding or flux cored welding See Figure B 4 FIGURE B 4 2 51mm SPINDLE ADAPTER FOR 8 20mm REEL OF WIRE 4 102mm REEL OF WIRE 10 WIRE SPOOL SPINDLE AND BRAKE Holds a 4 102mm diameter spool Use the 2 51mm spindle adapter included with the machine to use 8 203mm diameter spools The thumbscrew sets the brake friction to prevent the spool from over rotating when the trigger is released See Figure B 5 FIGURE B 5 1 WIRE DRIVE 8 COMPONENTS Feeds wire from the wire spool through the drive and through the welding gun to the weld a Top and Bottom Drive Roll Drives the wire through the drive system The drive roll has a groove to match the specific wire type and diam eter Refer to Table B 1 for available drive rolls b Inner amp Outer Wire Guide Guides the wire between the Top and Bottom Drive Roll and through the wire drive The inner guide has a groove to match a particular wire diameter Refer to Table B 1 for available wire guides c Drive Roll Tension Thumbscrew Turning clockwise increases the force on the drive rolls and turning counterclockwise decreases the HOMER force OUTER WIRE GUIDE REMOVED WIRE SPOOL 035 0 9mm INNER WIRE GUIDE REMOVED POWER MIG 140 180 MODELS LINCOLN Wire Diameter amp Type 025 0 6mm MIG wire 030 0 8mm MIG wire 035 0 9mm
31. contact with hot engine parts and current creates EMF fields around welding cables and igniting Do not spill fuel when filling tank If welding machines fuel is spilled wipe it up and do not start engine until fumes have been eliminated EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician 1 d Keep all equipment safety guards covers and devices in before welding position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving y Exposure to EMF fields in welding may have other health parts when starting operating or repairing equipment effects which are now not known All welders should use the following procedures in order to 1 e In some cases it may be necessary to remove safety od i mud minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete 2 d 1 Route the electrode and work cables together Secure Always use the greatest care when working near moving them with tape when possible arts 2 4 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan m Do not attempt to override the governor or 2 d 3 Do not place your body between the electrode and idler by pushing on the throttle control rods work cables I
32. ding WELDING GUN Delivers wire and welding cur rent to the weld a Gun Liner wire travels through the liner from the wire drive The gun liner will feed 025 to 035 0 6mm to 0 9mm wire The 180A machine can weld with 045 1 1mm wire if an optional 045 1 1mm liner is installed in the gun b Contact Tip provides electrical contact to the wire c Nozzle When flux cored welding the black noz zle protects the mounting threads on the gun When MIG welding the brass nozzle funnels the shielding gas to the weld WORK CLAMP amp CABLE Clamps to the work piece being welded and completes the electrical welding circuit GUN TRIGGER CONNECTOR RECEPTACLE Plug the 4 pin gun trigger connector into this recep tacle OPERATION FIGURE B 1 FIGURE B 2 035 0 9mm 211 Nine SPOOL Eu a POWER MIG 140 180 MODELS LINCOLN 3 3 See Figure FIGURE B 3 8 WELDING GUN CONNECTOR BUSHING amp 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 y A i CE J Ke ce 9 OUTPUT TERMINALS These connections allow to change the welding polarity of the ma
33. dy protec tion 12 Observe all safety information throughout this manual PRODUCT DESCRIPTION PRODUCT CAPABILITIES These small portable wire feed welders are capable of MIG welding on steel stainless steel and aluminum They are also capable of flux cored welding on mild steel MIG welding stands for Metal Inert Gas welding and requires a separate bottle of shielding gas to protect the weld until it cools Appropriate shielding gas based on the type of material you are welding can be purchased separately from your local welding gas dis tributor MIG welding is ideal for welding on thinner and clean materials when a very clean excellent cos metic looking weld is required An example would be automotive body panels Flux cored Welding does not require separate shield ing gas to protect the weld since the welding wire has special additives known as flux to protect the weld until it cools Flux cored welding is ideal for medium to thicker material and if welding on painted or rusty steel Flux cored welding is also ideal in outdoor applications where windy conditions might blow the MIG shielding gas away from the weld Flux cored welding produces a good looking weld but does not produce an excellent weld appearance as MIG weld ing does Your machine includes the necessary items to weld with either the MIG or the flux cored welding process on steel To weld on stainless steel optional stainless steel welding wire can be purc
34. e does NOT operate Make certain that power switch is in the ON position Make sure circuit breaker is reset If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility No wire feed weld output or gas The thermostat may be tripped flow when gun trigger is pulled due to overheating Let machine Fan operates normally cool Weld at lower duty cycle Check for obstructions in air flow Check Gun Trigger connec tions See Installation section Gun trigger may be faulty CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your POWER MIG 140 180 MODELS LINCOLN E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual PROBLEMS SYMPTOMS No wire feed when gun trigger is pulled Fan runs gas flows and machine has correct open circuit voltage 33V weld output PROBLEMS SYMPTOMS Low or no gas flow when gun trigger is pulled Wire feed weld output and fan operate normally POSSIBLE CAUSE FEEDING PROBLEMS If the wire drive motor is running make sure that the correct drive rolls are installed in the machine Check for clogged cable liner or contact tip Check for proper size cable liner and contact tip POSSIBLE CAUSE GAS FLOW PROBLEMS Check gas sup
35. e U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations i SAFETY i PRECAUTIONS DE S RET 5 Toujours porter des lunettes de s curit dans la zone de Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s
36. e in the machine front and into the vene gun connector bushing on the wire drive 3 Make sure the gun connector end is seated fully into the wire drive and tighten the thumbscrew to secure the gun connector GUN AND CABLE 4 Plug the gun trigger lead connector into the 4 pin gun trigger receptacle on the machine front B 6 FIGURE B 7 CASE SIDE DOOR TERMINAL END FITS ON STUD INSIDE SEE FIGURE BELOW WORK CLAMP ALL COMPONENTS SHOWN CONNECTED FRONT AND SIDE DOOR IS REMOVED FOR CLARITY 5 Wire Drive Polarity Flux cored welding requires THUMB SCREW TO Ea PN negative polarity Connect the short power BM T OUTPUT TERMINAL cable from the wire drive to the negative output terminal and tighten the thumbscrew 6 Work Lead Connection Slide the lugged end of the work cable through the hole in the machine front and place on the positive output terminal and tighten thumbscrew C LOAD WIRE SPOOL See Figure B 8 1 Locate the blue labeled 4 102mm diameter spool of 035 0 9mm NR 211MP flux cored wire and place onto wire spool spindle Orient the spool so that the wire feeds off the top of the spool gt 2 Secure spool in place by tightening the wing nut against the against the spacer that holds the wire spool on the spindle 3 Open the top drive roll pressure arm by rotating the tension adjustor arm down and pivoting the drive roll pressure arm up 4 Remove the outer wire
37. ep all Doors Covers panels and guards securely in place DO NOT REMOVE OR CONCEAL WARNING LABELS 15 Install the 025 0 6mm contact tip 16 Install the brass gas MIG welding nozzle to the gun 17 Trim the wire stickout to 3 8 9 5mm from the nozzle end See Figure B 19 18 Close the case side door The machine is now ready to weld 19 Read Learn to Weld LTW1 that is included with the machine or watch the How to Weld DVD includ ed with the machine 20 Based on the thickness of the material you are going to weld and the type and diameter of the welding wire set the voltage and the wire feed speed per the procedure decal attached to the inside of the wire drive compartment door OPERATION FIGURE B 16 TOP IDLER ROLL PRESSED AGAINST LOWER DRIVE ROLL TENSION ADJUSTOR LOCKED IN POSITION DIRECTION ud WIRE WIRE SPOOL 025 0 6mm e soup we SLIDE WIRE INTO GUN CONNECTOR SIDE DRIVE ROLL BE SURE WIRE IS INGROOVE FIGURE B 17 WIRE 025 pod IN THIS POSITION REMOVED NOZZLE i REMOVED CONTACT TIP a CABLE AND GUN STRAIGHTEN FIGURE B 18 PLUG IN POWEF INPUT CORD FEED WIRE APPROXIMATELY 4 00 FROM THE GUN TUBE END WIRE SPOOL 025 0 6mm 9 5 4 d DEPRESS TRIGGER TO ACTIVATE WI
38. f life A CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment viii TABLE OF CONTENTS viii Page Installation Section Technical Specifications 1 2 Safety Precautions m A 3 ISOC ATOM ru A 3 nae ean A 3 dili DN A 3 Identify and Locate Components A 4 srl Section B Safety and Product Description ss B 1 Controls and Settings cocta nera Ta E e RETE B 2 B 3 Drive Roll and Wire Guides B 4 Setting Up and Making Flux Cored 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 B 12 ACCOSSOLFIGS 2 Section C Optional AOGCeSSOTL GS a dre Gade e has Ed ugue C 1 Utility C 2 Section D Safety Precautioris itenim cipes D 1 Wire Feed Compartment Fan Motor Wire Reel Maintenance D 1 Gun And Cable Maintenance D 2 Overload Protectioun m D 2 Component Replacement Procedures sse D 3 Troubleshooting ss eene
39. f the electrode cable is on your right while the engine is running side the work cable should also be on your right side Connect the work cable to the workpiece as close as possible to the area being welded 1 g To prevent accidentally starting gasoline engines while d 5 Do not work next to welding power source turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate LINCOLN SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control
40. guide 4a Slide gun out of drive slightly 5 Remove the lower drive roll and inner wire guide 6 Install the 025 035 0 6mm 0 9mm inner wire guide 7 Install the 030 045 0 8mm 1 1mm knurled lower drive roll 8 Carefully unwind and straighten the first six inches of welding wire from the spool Do not let the end of the wire go to prevent the wire from unspooling POWER MIG 140 180 MODELS LINCOLN CONNECTOR END ATTACH 4 PIN TRIGGER RECEPTACLE PLUGGED IN DRIVE ROLL PRESSURE ARM WORK LEAD CONNECTION POSITIVE OUTPUT TERMINAL FIGURE B 8 Qe TENSION ADJUSTOR DOWN WIRE SPOOL 035 0 9mm NR 211 MP OUTER WIRE GUIDE REMOVED 7 See Figure 9 9 Feed the wire through the wire drive inlet along the inner wire guide groove and into the wire drive outlet on the gun side 10 Close the top drive roll pressure arm and secure by pivoting the tension adjustor back to the up position 11 Re install the outer wire guide See Figure B 10 12 Remove the nozzle from the gun and contact tip and straighten the gun out flat 13 Turn the machine power to on and depress the gun trigger to feed the wire through the gun liner until the wire comes out of the threaded end of the gun several inches See figure B 11 14 When trigger is released spool of wire should not unwind Adjust wire spool brake accordingly A WARNING MOVIN
41. hased separately This machine can weld aluminum using 035 0 9mm diameter 4043 aluminum welding wire Since alu minum welding wire is soft an optional aluminum spool gun is recommended for best results A welding Procedure Decal is located inside machine door to help provide suggested settings for welding COMMON WELDING ABBREVIATIONS GMAW MIG Gas Metal Arc Welding FCAW Innershield or Outershield Flux Core Arc Welding POWER MIG 140 180 MODELS LINCOLN 2 CONTROLS AND SETTINGS This machine has the following controls 1 2 3 9 See Figure B 1 POWER SWITCH Turns power on and off to the machine ARC VOLTAGE CONTROL This knob sets the output voltage of the machine Along with wire feed speed WFS this control sets a weld procedure Refer to the procedure decal on the inside wire drive compartment door to set a correct welding procedure based on type of material and thickness being welded WIRE FEED SPEED CONTROL WFS The knob sets the speed that the machine feeds wire Along with arc voltage this control sets a weld procedure Refer to the procedure decal on the inside wire drive compartment door to set a correct welding procedure based on type of material and thickness being welded See Figure B 2 GUN TRIGGER Depress the trigger to activates the wire drive to feed wire and energizes the output of the machine Depress the trigger to weld and release the trigger to stop wel
42. ize A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your POWER MIG 140 180 MODELS LINCOLN OLVOCIN gt 18813 Hd STOSWAS 1 F 1 9 ONIMIM LIM NNS 100dS HOS 335 ONIMIM LIM 104 403 99 905 335 S3NIHOVIN SNONNILNOD 303 S3NIHOVIN 5 SI LNANOdNO9 SIHL 39 V LIOA LNdNI SI vf H0 103NNOO JO 3916 NOLLHASNI NOHA SNISSIADN ALIAVO MYNS 03 NMOHS SNOLLO3NNOO 9 ONIHOWLIWSY 075 ONINHO9 GNNOdNOD 268011 SNOLLOANNOO Iv 031109 Enhanced Diagram W3INHOJSNVMLI NI 9319907 4 LVLSOWYSHL MOT38 TIVL3Q NOILVSROIJNOO ALLLN3GI 33S cH SNVUL DIAGRAMS GION31OS Sv9 Tos of o 10s 3009 19119573 WNOLLVN 93 OL YOLOW 9333 IVNOILdO 100dS F 1 Gv 0341415 939814 UES SIY Jo 39VL1OA HOIH Iesu suos d
43. larity Connect the short power cable from the wire drive to the positive output terminal and tighten the thumbscrew 6 Work Lead Connection Slide the lugged end of the work cable through the hole in the machine front and place on the negative output terminal and tighten thumbscrew D LOAD WIRE SPOOL See Figure B 15 1 Locate the green labeled 4 102mm diameter spool of 025 0 6mm L 56 solid MIG wire and place onto wire spool spindle Orient the spool so that the wire feeds off the top of the spool 2 Secure spool in place by tightening the wing nut against the against the spacer that holds the wire spool on the spindle 3 Open the top drive roll pressure arm by rotating the tension adjustor arm down and pivoting the idle roll pressure arm up 4 Remove the outer wire guide 4a Slide gun out of drive slightly 5 Remove the lower drive roll and inner wire guide 6 Install the 025 035 0 6mm 0 9mm inner wire guide 7 Install the 025 0 6mm smooth grooved lower drive roll 8 Carefully unwind and straighten the first six inches of welding wire from the spool Do not let the end of the wire go to prevent the wire from unspooling OPERATION B 10 FIGURE B 14 CASE SIDE DOOR 222 OPEN LATCH DOOR LY SLIDE CONNECTOR END HERE FITS ON STUD INSIDE SEE FIGURE BELOW WORK CLAMP ALL COMPONENTS SHOWN CONNECTED FRONT AND SIDE DOOR IS REMOVED FOR CLARITY GUN A
44. n 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 liability with respect to such infor mation or advice We expressly disclaim any warranty of any kind including any warranty of fitness for any customer s particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given nor does the provision of information or advice create expand or alter any warranty with respect to the sale of our products Lincoln Electric is a responsive manufacturer but the selection and use of specific products sold by Lincoln Electric is solely within the control of and remains the sole responsibility of the customer Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements Subject to Change This information is accurate to the best of our knowledge at the time of printing Please refer to www lincolnelectric com for any updated information Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made b
45. nd repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your POWER MIG 140 180 MODELS LINCOLN 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION 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 No wire feed weld output or gas Make sure correct voltage is flow when gun trigger is pulled Fan applied to the machin
46. ply flow regulator and gas hoses Check gun connection to machine for obstruction or leaky seals RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your POWER MIG 140 180 MODELS LINCOLN 4 TROUBLESHOOTING E 4 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION WELDING PROBLEMS Arc is unstable Poor starting Check for correct input voltage to machine Check for proper electrode polarity for process Check gun tip for wear or dam age and proper size Replace If all recommended possible areas Check for proper gas and flow of misadjustment have been rate for process For MIG only checked and the problem persists Contact your local Lincoln Check work cable for loose or Authorized Field Service faulty connections Facility Check gun for damage or breaks Check for proper drive roll orien tation and alignment Check liner for proper s
47. pproximately 300 165 136 kg of solid wire or 50 Ibs 23 kg of flux cored wire Remove the cable from the wire feeder and lay it out straight on the floor Remove the contact tip from the gun Using low pressure air gently blow out the cable liner from the gas diffuser end CAUTION Excessive pressure at the start may cause the dirt to form a plug Flex the cable over its entire length and again blow out the cable Repeat this procedure until no further dirt comes out Contact Tips Nozzles and Gun Tubes 1 Dirt can accumulate in the contact tip hole and restrict wire feeding After each spool of wire is used remove the contact tip and clean it by push ing a short piece of wire through the tip repeatedly Use the wire as a reamer to remove dirt that may be adhering to the wall of the hole through the tip 2 Replace worn contact tips as required A variable or hunting arc is a typical symptom of a worn con tact tip To install a new tip choose the correct size contact tip for the electrode being used wire size is stenciled on the side of the contact tip and screw it snugly into the gas diffuser 3 Remove spatter from inside of gas nozzle and from tip after each 10 minutes of arc time or as required 4 Be sure the gas nozzle is fully screwed onto the diffuser for gas shielded processes For the Innershield process the gasless nozzle should screw onto the diffuser MAINTENANCE D 2 5 To remove gun tube from
48. r le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 du corps PR CAUTIONS DE S RET POUR Un coup d arc peut tre plus s v re qu un coup de soliel LES MACHINES SOUDER dad TRANSFORMATEUR ET Utiliser un bon masque avec un verre filtrant appropri REDRESSEUR ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc 1 Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes LINCOLN Relier la terre le chassis du poste conformement au code de l lect
49. ricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 INSTALLATION ELECTROMAGNETIC COMPATIBILITY EMC Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 3 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility 89 336 EEC It was manufactured in conformity with a national standard that implements a harmonized standard EN 60974 10 Electromagnetic Compatibility EMC Product Standard for Arc Welding Equipment It is for use with other Lincoln Electric equipment It is designed for industrial and professional use Introduction All electrical equipment generates small amounts of electromagnetic emission Electrical emission may be transmitted through power lines or radiated through space similar to a radio transmitter When emissions are received by other equipment electrical interference may result Electrical emissions may affect many kinds of electrical equipment other nearby welding equipment radio and TV reception numerical cont
50. rive Roll 02 025 030 0 6 0 8mm Smooth Drive Roll 030 045 0 8 1 1mm Knurled Drive Roll Installed on Machine 025 035 0 6 0 9mm Inner Wire guide 035 045 0 9 1 1mm Inner Wire Guide Installed on Machine Outer Wire Guide Installed on Machine INNER WIRE GUIDE 025 035 6 9mm INNER WIRE GUIDE 035 045 9 1 1mm OUTER WIRE GUIDE Black Gasless Gun Nozzle Installed on Welding Gun Brass MIG Gas Nozzle 2 51mm Spindle Adapter For 8 203mm Reel of M Regulator Gas Hose Learn to Weld LTW1 Manual DVD REGULATOR 2 SPINDLE ADAPTER FOR 8 REEL OF WIRE Ce LEARNTO WELD GAS HOSE Q DVD POWER MIG 140 180 MODELS LINCOLN 1 OPERATION B 1 Read entire operation section before operating the POWER MIG WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground Always wear dry insulating gloves FUMES AND GASES can be dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or explosion Keep flammable material away Do not weld on closed contain ers ARC RAYS can burn eyes and skin Wear eye ear and bo
51. rolled machines telephone systems computers etc Be aware that interference may result and extra precautions may be required when a welding power source is used in a domestic establishment Installation and Use The user is responsible for installing and using the welding equipment according to the manufacturer s instructions If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing grounding the welding circuit see Note In other cases it could involve constructing an electromagnetic screen enclosing the power source and the work complete with associated input filters In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome Note The welding circuit may or may not be earthed for safety reasons according to national codes Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will increase the risk of injury e g by allowing parallel welding current return paths which may damage the earth circuits of other equipment Assessment of Area Before installing welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area The following shall be taken into account other supply cables
52. s have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate cir cuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c Read and follow NFPA 51B Standard for Fire Prevention During Welding Cutting and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 Do not use a welding power source for pipe thawing L
53. se del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e N o toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da pega e terra OMLMPT APSSAPREBS NTUSHILT FSU E GUB DERNIERE Oa CRM ER ecu Xe uc s e 2x9 Weal AMI d uil el jad Quali Y O pall ay ast slt DA daas wae Keep flammable materials away e Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos ORAPTUSOOM COREE CIE REA 9 5 YA SEL IF eis A Jo ALD al gll pis Ac AI Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido corpo A EROS SCRHBREUCF HEBSSSSRSSR
54. ter vention The fan continues to run during cooling Electronic Wire Drive Motor Protection The POWER MIG 140 180 MODELS has built in protection for wire drive motor overload POWER MIG 140 180 MODELS LINCOLN D 3 MAINTENANCE D 3 1 1 4 81 8 mm Brass Cable Set Screw Liner Assembly Liner bushing to be sealed tight against brass cable connector FIGURE D 2 Liner trim length CHANGING LINER NOTICE The variation in cable lengths prevents the interchangeability of liners Once a liner has been cut for a particular gun it should not be installed in anoth er gun unless it can meet the liner cutoff length requirement Refer to Figure D 2 1 Remove the gas nozzle from the gun by unscrew ing counter clockwise 2 Remove the existing contact tip from the gun by unscrewing counter clockwise 3 Remove the gas diffuser from the gun tube by unscrewing counter clockwise 4 Lay the gun and cable out straight on a flat surface Loosen the set screw located in the brass connec tor at the wire feeder end of the cable Pull the liner out of the cable 5 Insert a new untrimmed liner into the connector end of the cable Be sure the liner bushing is stenciled appropriately for the wire size being used 6 Fully seat the liner bushing into the connector Tighten the set screw on the brass cable connector At this time the gas diffuser should not be installed onto the end of the gun t
55. ube 7 With the gas nozzle and diffuser removed from the gun tube be sure the cable is straight and then trim the liner to the length shown in the Figure D 2 Remove any burrs from the end of the liner Liner Trim Length Gas Nozzle or Gasless Nozzle 3 8 Screw the gas diffuser onto the end of the gun tube and securely tighten 9 Replace the contact tip and nozzle 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 gun handle If the collars are diffi cult to turn position the gun handle against a corner place a screwdriver against the tab on the collar and give the screwdriver a sharp blow to turn the collar past an internal locking rib See Figure D 3 E odes FIGURE D 3 POWER MIG 140 180 MODELS LINCOLN 1 TROUBLESHOOTING 1 HOW TO USE TROUBLESHOOTING GUIDE A 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 This Troubleshooting Guide is provided to help you locate a
56. y the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment always supply the information you have recorded above The code number is especially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss o
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