Operator’s Manual WIRE FEEDER WELDERS OPERATOR’S …

Operator’s Manual

WIRE FEEDER WELDERS (125, 140 MODELS)

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IM10049-A | Issue D ate Mar- 14

© Lincoln Global, Inc. All Rights Reserved.

For use with machines having Code Numbers:

11631, 11632, 11633, 11634,11635, 11636, 11637, 11638,11639, 12100, 12101, 12102,12103, 12104, 12105, 12106,12107

Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

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THANK YOU FOR SELECTING A QUALITY PRODUCT BY LINCOLN ELEC TRIC.

Please examine Carton and equiPment Fordamage immediately

When this equipment is shipped, title passes to the purchaser uponreceipt by the carrier. Consequently, Claims for material damaged inshipment must be made by the purchaser against the transportationcompany at the time the shipment is received.

saFety dePends on you

Lincoln arc welding and cutting equipment is designed and built withsafety in mind. However, your overall safety can be increased byproper installation ... and thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONSCONTAINED THROUGHOUT. And, most importantly, think before youact and be careful.

This statement appears where the information must be followedexactly to avoid serious personal injury or loss of life.

This statement appears where the information must be followed toavoid minor personal injury or damage to this equipment.

KeeP your head out oF the Fumes.

DON’T get too close to the arc. Usecorrective lenses if necessary tostay a reasonable distance awayfrom the arc.

READ and obey the Material SafetyData Sheet (MSDS) and the warninglabel that appears on all containersof welding materials.

USE ENOUGH VENTILATION orexhaust at the arc, or both, to keepthe fumes and gases from your breathing zone and the general area.

IN A LARGE ROOM OR OUTDOORS, natural ventilation may beadequate if you keep your head out of the fumes (See below).

USE NATURAL DRAFTS or fans to keep the fumes away from yourface.

If you de velop unusual symptoms, see your supervisor. Perhaps thewelding atmosphere and ventilation system should be checked.

wear CorreCt eye, ear & body ProteCtion

PROTECT your eyes and face with welding helmetproperly fitted and with proper grade of filter plate(See ANSI Z49.1).

PROTECT your body from welding spatter and arcflash with protective clothing including woolenclothing, flame-proof apron and gloves, leatherleggings, and high boots.

PROTECT others from splatter, flash, and glare withprotective screens or barriers.

IN SOME AREAS, protection from noise may beappropriate.

BE SURE protective equipment is in good condition.

Also, wear safety glasses in work area AT ALLTIMES.

SPECIAL SITUATIONSDO NOT WELD OR CUT containers or materials which previously hadbeen in contact with hazardous substances unless they are properlycleaned. This is extremely dangerous.

DO NOT WELD OR CUT painted or plated parts unless specialprecautions with ventilation have been taken. They can release highlytoxic fumes or gases.

Additional precautionary measuresPROTECT compressed gas cylinders from excessive heat, mechanicalshocks, and arcs; fasten cylinders so they cannot fall.

BE SURE cylinders are never grounded or part of an electrical circuit.

REMOVE all potential fire hazards from welding area.

ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR

IMMEDIATE USE AND KNOW HOW TO USE IT.

WARNING

CAUTION

SECTION A:WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel EnginesDiesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and otherreproductive harm.

Gasoline EnginesThe engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or otherreproductive harm.

arC welding Can be hazardous. ProteCtyourselF and others From Possible seriousinJury or death. KeeP Children away. PaCe-maKer wearers should Consult with theirdoCtor beFore oPerating.

Read and understand the following safety highlights. For additionalsafety information, it is strongly recommended that you purchase acopy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from theAmerican Welding Society, P.O. Box 351040, Miami, Florida 33135 orCSA Standard W117.2-1974. A Free copy of “Arc Welding Safety”booklet E205 is available from the Lincoln Electric Company, 22801St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION,MAINTENANCE AND REPAIR PROCEDURES AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.

FOR ENGINE POWEREDEQUIPMENT.

1.a. Turn the engine off before troubleshootingand maintenance work unless themaintenance work requires it to be running.

1.b. Operate engines in open, well-ventilatedareas or vent the engine exhaust fumes outdoors.

1.c. Do not add the fuel near an open flamewelding arc or when the engine is running.Stop the engine and allow it to cool beforerefueling to prevent spilled fuel fromvaporizing on contact with hot engine partsand igniting. Do not spill fuel when fillingtank. If fuel is spilled, wipe it up and do not start engine untilfumes have been eliminated.

1.d. Keep all equipment safety guards, covers anddevices in position and in good repair.Keephands, hair, clothing and tools away from V-belts, gears, fans and all other moving partswhen starting, operating or repairingequipment.

1.e. In some cases it may be necessary to remove safety guards toperform required maintenance. Remove guards only whennecessary and replace them when the maintenance requiringtheir removal is complete. Always use the greatest care whenworking near moving parts.

1.f. Do not put your hands near the engine fan. Do not attempt tooverride the governor or idler by pushing on the throttle controlrods while the engine is running.

1.g. To prevent accidentally starting gasoline engines while turningthe engine or welding generator during maintenance work,disconnect the spark plug wires, distributor cap or magneto wireas appropriate.

1.h. To avoid scalding, do not remove the radiatorpressure cap when the engine is hot.

ELECTRIC ANDMAGNETIC FIELDS MAYBE DANGEROUS

2.a. Electric current flowing through any conductorcauses localized Electric and Magnetic Fields (EMF). Weldingcurrent creates EMF fields around welding cables and weldingmachines

2.b. EMF fields may interfere with some pacemakers, and weldershaving a pacemaker should consult their physician beforewelding.

2.c. Exposure to EMF fields in welding may have other health effectswhich are now not known.

2.d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Securethem with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and workcables. If the electrode cable is on your right side, thework cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as pos-sible to the area being welded.

2.d.5. Do not work next to welding power source.

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SAFETY

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ELECTRIC SHOCK CAN KILL.

3.a. The electrode and work (or ground) circuits areelectrically “hot” when the welder is on. Donot touch these “hot” parts with your bare skinor 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 areaof 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.

3.c. In semiautomatic or automatic wire welding, the electrode,electrode reel, welding head, nozzle or semiautomatic weldinggun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connection shouldbe as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical (earth)ground.

3.f. Maintain the electrode holder, work clamp, welding cable andwelding machine in good, safe operating condition. Replacedamaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of electrodeholders connected to two welders because voltage between thetwo can be the total of the open circuit voltage of bothwelders.

3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.

3.j. Also see It ems 6.c. and 8.

ARC RAYS CAN BURN.

4.a. Use a shield with the proper filter and cover plates to protect youreyes from sparks and the rays of the arc when welding orobserving open arc welding. Headshield and filter lens shouldconform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant materialto protect your skin and that of your helpers from the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.

FUMES AND GASESCAN BE DANGEROUS.

5.a. Welding may produce fumes and gaseshazardous to health. Avoid breathing thesefumes 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 within applicable osha Pel and

aCgih tlV limits 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.

5. b. The operation of welding fume control equipment is affected byvarious factors including proper use and positioning of theequipment, maintenance of the equipment and the specificwelding procedure and application involved. Worker exposurelevel should be checked upon installation and periodicallythereafter to be certain it is within applicable OSHA PEL andACGIH TLV limits.

5.c. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations. Theheat and rays of the arc can react with solvent vapors to formphosgene, a highly toxic gas, and other irritating products.

5.d. Shielding gases used for arc welding can displace air and causeinjury or death. Always use enough ventilation, especially inconfined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturer’s instructions for thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow your employer’ssafety practices. MSDS forms are available from your weldingdistributor or from the manufacturer.

5.f. Also see item 1.b.

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SAFETY

WELDING AND CUTTINGSPARKS CAN CAUSEFIRE OR EXPLOSION.

6.a. Remove fire hazards from the welding area. Ifthis is not possible, cover them to prevent thewelding sparks from starting a fire. Remember that weldingsparks and hot materials from welding can easily go throughsmall cracks and openings to adjacent areas. Avoid welding nearhydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site, specialprecautions 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.

6.c. When not welding, make certain no part of the electrode circuit istouching the work or ground. Accidental contact can causeoverheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedures willnot cause flammable or toxic vapors from substances inside.They can cause an explosion even though they have been“cleaned”. For information, purchase “Recommended SafePractices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held Hazardous Substances”,AWS F4.1 from the American Welding Society (see addressabove).

6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oil freeprotective garments such as leather gloves, heavy shirt, cufflesstrousers, high shoes and a cap over your hair. Wear ear plugswhen welding out of position or in confined places. Always wearsafety glasses with side shields when in a welding area.

6.g. Connect the work cable to the work as close to the welding areaas practical. Work cables connected to the building framework orother locations away from the welding area increase thepossibility of the welding current passing through lifting chains,crane cables or other alternate circuits. This can create firehazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention DuringWelding, Cutting and Other Hot Work”, available from NFPA, 1Batterymarch Park, PO box 9101, Quincy, Ma 022690-9101.

6.j. Do not use a welding power source for pipe thawing.

CYLINDER MAY EXPLODE IFDAMAGED.

7.a. Use only compressed gas cylinders containingthe correct shielding gas for the process usedand properly operating regulators designed forthe gas and pressure used. All hoses, fittings,etc. should be suitable for the application andmaintained in good condition.

7.b. Always keep cylinders in an upright position securely chained toan undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjectedto physical damage.

• A safe distance from arc welding or cutting operationsand any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tightexcept when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders,associated equipment, and CGA publication P-l, “Precautions forSafe Handling of Compressed Gases in Cylinders,” availablefrom the Compressed Gas Association 1235 Jefferson DavisHighway, Arlington, VA 22202.

FOR ELECTRICALLYPOWERED EQUIPMENT.

8.a. Turn off input power using the disconnectswitch at the fuse box before working on theequipment.

8.b. Install equipment in accordance with the U.S. National ElectricalCode, all local codes and the manufacturer’s recommendations.

8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturer’s recommendations.

refer to

http://www.lincolnelectric.com/safety

for additional safety information.

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SAFETY

Welding SafetyInteractive Web Guidefor mobile devices

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TABLE OF CONTENTS

TABLE OF CONTENTS

General Decription. . . . . . . . . . . . . . . . . . . . . . Page 7Installation . . . . . . . . . . . . . . . . . . . . . . . . .Section ATechnical Specifications . . . . . . . . . . . . . . . . . . . . .A-1

Identify and Locate Components for 125 Amp Unit .A-2

Identify and Locate Components for 140 Amp Unit .A-3

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .Section BSafety and Product Description . . . . . . . . . . . . . . . .B-1

Controls and Settings . . . . . . . . . . . . . . . . . . .B-2, B-3

Dual Track Drive Roll and Wire Guide Table . . . . . .B-4

Setting Up and Making a Flux-Cored Weld with a 125Amp

or 140Amp machines . . . . . . . . . . . . . . . . .B-4 thru B-6

Setting Up and Making a MIG Weld and Install Shielding

Gas for a 140Amp machine . . . . . . . . . .B-7 thru B-10

Setting Up and Making a Aluminum Weld . . . . . . .B-11

Accessories . . . . . . . . . . . . . . . . . . . . . . . . .Section COptional Accessories . . . . . . . . . . . . . . . . . . . . . . .C-1

Utility Carts . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2, C-3

Maintenance . . . . . . . . . . . . . . . . . . . . . . . .Section DSafety Precautions . . . . . . . . . . . . . . . . . . . . . . . . .D-1

Wire Feed Compartment, Fan Motor, Wire Reel

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1

Gun And Cable Maintenance . . . . . . . . . . . . . . . . . .D-2

Overload Protection . . . . . . . . . . . . . . . . . . . . . . . .D-2

Component Replacement Procedures . . . . . . . . . . .D-2

Troubleshooting . . . . . . . . . . . . . . . . . . . . .Section ESafety Precautions . . . . . . . . . . . . . . . . . . . . . . . . .E-1

How to Use Troubleshooting Guide . . . . . . . . . . . . .E-1

Troubleshooting Guide . . . . . . . . . . . . . . .E-2 thru E-3

Wiring Diagram and Dimension Print . . . . . . . . . Section FParts Pages . . . . . . . . . . . . . . . . . . . .P-653, P-202-E

7

PRODUCT DESCRIPTION

PRODUCT DESCRIPTION (PRODUCT CAPABILITIES)

The portable 125Amp Wire Feeder Model is capable of flux-coredwelding on mild steel. The portable 140Amp Wire Feeder Model iscapable of MIG welding on steel, stainless steel, and aluminum, inaddition to flux-core welding on mild steel.

MIG welding stands for Metal Inert Gas welding and requires aseparate bottle of shielding gas to protect the weld. The Shieldinggas used is determined by the type of material you are welding on.Shielding gases can be purchased separately from your localwelding gas distributor. MIG welding is ideal for welding on thinand clean materials when an excellent cosmetic weld is required.An example is automotive body panels.

FCAW-S stands for Self shielding Flux-cored Arc Welding and doesnot require a shielding gas to protect the weld since the weldingwire has special additives known as flux to protect the weld fromimpurities. Flux-cored welding is ideal for medium to thickermaterial and for welding on painted or rusty steel. Flux-coredwelding is also ideal for outdoor applications where windy condi-tions might blow the MIG shielding gas away from the weld. Flux-cored welding produces a good looking weld but does not producean excellent weld appearance as MIG welding does.

Your 140Amp machine includes the necessary items to weld witheither the flux-cored welding or MIG welding process on steel. Toweld on stainless steel, an optional stainless steel welding wirecan be purchased separately. The 140Amp machine is spool gunready and the machine can weld aluminum using .035”(0.9mm)diameter 4043 aluminum welding wire. Since aluminum weldingwire is soft, an optional spool gun is recommended for bestresults. A welding Procedure Decal on the wire drive compartmentdoor provides suggested settings for welding.

COMMON WELDING ABBREVIATIONS

GMAW (MIG)• Gas Metal Arc Welding

FCAW (Innershield or Outershield)• Flux Core Arc Welding

WIRE FEEDER WELDERS (125, 140)

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A-1

INSTALLATIONWIRE FEEDER WELDERS (125, 140)

TECHNICAL SPECIFICATIONS

125 Amp units (K2479-1, K2513-1, K2696-1, K2699-1, K2785-1)

140 Amp units (K2480-1, K2514-1, K2658-1, K2697-1)

1 If 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.

INPUT – SINGLE PHASE ONLY

RATED OUTPUT

OUTPUT

Standard Voltage/Frequency120 V / 60 Hz

Duty Cycle20% Duty Cycle

Current90 Amps

Voltage at Rated Amperes19

Welding Current Range30-125 Amps

Input Voltage / Frequence120V 60Hz

Height13.7 in.347 mm

Width10.15 in.258 mm

Depth17.9 in.454 mm

Weight49.5 lbs.22.5 kg.

Fuse or Breaker Size1,220 Amp

Input Amps20

Power Cord15 Amp, 125 V,Three Prong Plug(NEMA Type 5-15P)

Extension Cord3 Conductor # 12 AWG(4mm2) or Largerup to 50 ft.(15.2m)

Maximum-Open Circuit Voltage33 V

Wire Speed Range50 - 500 in/min.

(1.3 - 12.7 m/min.)

Input Current20 Amps @ rated output

RECOMMENDED INPUT CABLE AND FUSE SIZES

PHYSICAL DIMENSIONS

INPUT – SINGLE PHASE ONLY

RATED OUTPUT

OUTPUT

Standard Voltage/Frequency120 V / 60 Hz

Duty Cycle20% Duty Cycle

Current90 Amps

Voltage at Rated Amperes19.5

Welding Current Range30-140 Amps

Input Voltage / Frequence120V 60Hz

Height13.7 in.347 mm

Width10.15 in.258 mm

Depth17.9 in.454 mm

Weight49.5 lbs.22.5 kg.

Fuse or Breaker Size1,220 Amp

Input Amps20

Power Cord15 Amp, 125 V,Three Prong Plug(NEMA Type 5-15P)

Extension Cord3 Conductor # 12 AWG(4mm2) or Largerup to 50 ft.(15.2m)

Maximum-Open Circuit Voltage33 V

Wire Speed Range50 - 500 in/min.

(1.3 - 12.7 m/min.)

Input Current20 Amps @ rated output

RECOMMENDED INPUT CABLE AND FUSE SIZES

PHYSICAL DIMENSIONS

A-2


• .025” -.035”(0.6mm-0.8mm) Dual Groove Drive Roll(Factory installed .035”(0.9mm) groove ready for flux-cored process)

• Black Gun Nozzle (Installed on Welding Gun)

• 2”(51mm) Spindle Adapter (For 8”(203mm) reel of wire)

• Instruction Manual

• How to Weld “DVD”

• Wire Feeder Welder

• Work Cable & Clamp

• Magnum 100L Welding Gun

• (3) .035”(0.9mm) Contact Tips (1 installed on the welding gun)

• Spool of .035”(0.9mm) diameter NR-211MP Innershield Flux-cored Wire

IDENTIFY AND LOCATE COMPONENTS for 125 AMP UNIT

.03

5

.03

5

.035 NR-211 MP

FLUX-CORED WIRE

.0

25

.025 GROOVE

.035 GROOVE

IM"INSTRUCTION MANUAL"

DVD

2" SPINDLE ADAPTER (FOR 8" REEL OF WIRE)

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A-3


• Wire Feeder Welder

• Work Cable & Clamp

• Magnum 100L Welding Gun

• (3) .035”(0.9mm) Contact Tips (1 installed on the welding gun).• (3) .025”(0.6mm) Contact Tips

• Spool of .035”(0.9mm) diameter NR-211MP Innershield Flux-cored Wire

• Spool of .025”(0.6mm) diameter Super Arc L-56 MIG Wire

• .025” -.035”(0.6mm-0.8mm) Dual Groove Drive Roll(Factory installed .035”(0.9mm) groove ready forflux-cored process).

• Black Gun Nozzle (Installed on Welding Gun)

• Brass MIG Gun Nozzle for MIG welding

• 2”(51mm) Spindle Adapter for 8”(203mm) reel ofwire.

• Regulator• Gas Hose• Instruction Manual• How to Weld “DVD”

.025

.025

.025

.035

.035

NR-211 MP

WIRE

L-56 MIGNR-211 MP

WIRE

L-56 MIG

IM10049"INSTRUCTION MANUAL"

DVD

GAS HOSE

REGULATOR2" SPINDLE ADAPTER (FOR 8" REEL OF WIRE)

IDENTIFY AND LOCATE COMPONENTS for 140 AMP UNIT

.0

25

.025 GROOVE

.035 GROOVE

B-1

OPERATIONWIRE FEEDER WELDERS (125, 140)

Read entire operation section before operating theWIRE FEEDER WELDERS.

ELECTRIC SHOCK can kill.• Do not touch electrically live parts orelectrode with skin or wet clothing.Insulate yourself from work and ground.

• Always wear dry insulating gloves.

FUMES AND GASES can be danger-ous.• Keep your head out of fumes.

• Use ventilation or exhaust to removefumes from breathing zone.

WELDING SPARKS can cause fire orexplosion.• Keep flammable material away.

• Do not weld on closed containers.

ARC RAYS can burn eyes and skin.• Wear eye, ear and body protection.

Observe all safety information throughout thismanual.------------------------------------------------------

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WARNING

B-2


CONTROLS AND SETTINGS

This machine has the following controls:

See Figure B.11. POWER SWITCH – Turns power on and off to the machine.

2. ARC VOLTAGE CONTROL – This knob sets the output voltageof the machine. Along with wire feed speed (WFS), this con-trol sets a weld procedure. Refer to the procedure decal onthe wire drive compartment door to set a welding procedurebased on the type of material and thickness being welded.

3. WIRE FEED SPEED CONTROL (WFS) – This knob sets thespeed that the machine feeds wire. Along with arc voltage,this control sets a weld procedure. Refer to the proceduredecal on the wire drive compartment door to set a weldingprocedure based on the type of material and thickness beingwelded.

See Figure B.24. GUN TRIGGER – Pressing the trigger activates the wire drive

and energizes the output of the machine. Press the trigger toweld and release the trigger to stop welding.

5. WELDING GUN – Delivers wire and welding current to thework piece.a. Gun Liner – wire travels through the liner from the wire

drive. The gun liner will feed .025” to .035”(0.6mm to0.9mm) wire.

b. Contact Tip – provides electrical contact to the wire.

c. Nozzle – When flux-cored welding, the black nozzle pro-tects the mounting threads on the gun. When MIG welding,the brass nozzle funnels the shielding gas to the weld.

6. WORK CLAMP & CABLE – Clamps to the work piece beingwelded and completes the electrical welding circuit.

7. GUN TRIGGER CONNECTOR RECEPTACLE – Plug the 4 pingun trigger connector into this receptacle.

1

3

2

FIGURE B.1

FIGURE B.2

5

5b

5a

5c

67

4

B-3


See Figure B.38. WELDING GUN CONNECTOR BUSHING & THUMBSCREW –

Provides electrical power to the welding gun. The thumbscrewholds the welding gun into the connector block. (Front Coverand Side Door have been removed for clarity of Items 8 and9).

9. OUTPUT TERMINALS - Connections to these terminals deter-mines the welding polarity, depending on whether the processbeing used is flux-cored welding or MIG welding.

See Figure B.410. WIRE SPOOL SPINDLE AND BRAKE – Holds a 4”(102mm)

diameter spool. Use the 2”(51mm) spindle adapter includedwith the machine for 8” (203mm) diameter spools. The wingnut sets the brake friction to prevent the spool from overrotating when the trigger is released. Tightening the wing nutwill prevent the spool from rotating when the trigger isreleased.

See Figure B.511. WIRE DRIVE & COMPONENTS – Feeds wire from the wire

spool through the drive and through the welding gun to thework piece.

a. Drive Roll – Drives the wire through the drive system. Thedrive roll has grooves to match the specific wire type anddiameter. Refer to Table B.1 for available drive rolls.

b. Incoming & Outgoing Guide – The wire is fed throughboth guides. The Pivot Arm Assembly, Tension ArmAssembly and Drive Roll keep pressure on the wire in thegroove.

c. Tension Arm Assembly – Turning clockwise increases theforward force on the wire and turning counterclockwisedecreases the force.

89

FIGURE B.3

FIGURE B.4

FIGURE B.5

FIGURE B.5a

WIRE SPOOL.035" (0.9mm)

NR-211-MP

DRIVE ROLL

PIVOT ARM ASSEMBLY

TENSION ARM ASSEMBLY

OUTGOING GUIDE

INCOMING GUIDE

BEARING

See Figure B.5aMagnum 100SG / Magnum 100L Switch - The spool gunswitch is available on 140 Amp machines only. The Magnum100SG Spool Gun can be purchased at authorized retailers. Thepart number is K2532-1.

MAGNUM 100SG

SWITCH

MAGNUM 100L

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B-4


A. ITEMS NEEDED FOR FLUXCORED WELDING

1. .035”(0.9mm) Contact Tip

2. Dual Groove Drive Roll.

3. .035”(0.9mm) NR-211MP Flux-CoredWire

4. Black Flux Cored gun nozzle

5. Welding Gun

7. Work Cable & Clamp

.035

.035 NR-211 MP

FLUX-CORED WIRE

SETTING UP AND MAKING A FLUX-CORED WELD WITH 125AMP OR 140AMP MACHINES

TABLE B.1DRIVE ROLLS

See Figure B.612. 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(This is not available on 125 Amp Unit.)

12 13

FIGURE B.6

125/140 Amp

.025

.025 GROOVE

.035 GROOVE*

Wire Diameter & Type

.025”(0.6mm) MIG wire



.030”(0.8mm) flux-cored

.035”(0.9mm) flux-cored

Smooth Drive Roll (Dual Grooves)

Use .025”(0.6mm) Drive Roll Groove

Use .035”(0.9mm) Drive Roll Groove

Drive Roll PartNumber

KP2948-1

B-5


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 through thehole in the machine front and into the gun connector bush-ing. Tighten thumb screw to connector bushing.

3. Make sure the gun connector end is seated fully into thewire drive.

4. Plug the gun trigger lead connector into the 4 pin gun triggerreceptacle on the machine front.

5. Wire Drive Polarity. NR-211 MP requires negative (-) polarity.Connect the short power cable from the wire drive to thenegative (-) output terminal and tighten wing nut.

6. Work Lead Connection. Slide the lugged end of the workcable through the hole in the machine front and route cablethrough strain relief as shown in figure B.7. Place lug on thepositive (+) output terminal and tighten wing nut.

C. LOAD WIRE SPOOL

(See Figure B.8)1. Locate the sample spool of .035”(0.9mm) NR-211MP flux-

cored wire and place onto wire spool spindle. Orient thespool so that the wire feeds off the top of the spool.

2. Secure spool by tightening the wing nut against the spacerthat holds the wire spool on the spindle. Do not over tightenthe spool.

3. Open the pivot arm assembly by rotating the tension armassembly down and lift pivot arm assembly up.

4. Remove drive roll by un-screwing the black knob that holds thedrive roll on. Install the Dual Groove drive roll with the.035”(0.9mm) mark facing outward which will allow feeding of.035”(0.9mm) NR-211MP flux-cored wire.

5. Carefully unwind and straighten the first six inches of weldingwire from the spool. Do not let the end of the wire go to preventthe wire from unspooling.

WORK CLAMP

(4 PIN)TRIGGER RECEPTACLEPLUGGED IN

ALL COMPONENTS SHOWN CONNECTED(FRONT AND SIDE DOOR IS REMOVED FOR CLARITY)

SHORT POWERCABLE NEGATIVE "-"OUTPUT TERMINAL

WORK LEAD

STRAIN RELIEF

CONNECTIONPOSITIVE "+"OUTPUT TERMINAL

TIGHTEN THUMB SCREW TOCONNECTOR BUSHING

GUN AND CABLE

WORK CLAMP

(4 PIN)LEAD CONNECTOR

TERMINAL END (FITS ON STUD INSIDESEE FIGURE BELOW)

SLIDECONNECTOREND HERE

OPEN LATCH DOOR

FIGURE B.7


NR-211-MP

DRIVE ROLL

PIVOT ARM ASSEMBLY


OUTGOING GUIDE

BEARING

INCOMING GUIDE

FIGURE B.8

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(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 onthe gun side.

7. Close the Pivot Arm Assembly and secure by rotating theTension Arm Assembly back to the up position. (See Tensioninformation on decal.)

(See Figure B.10)8. Remove the nozzle from the gun and contact tip and

straighten the gun out flat.

9. Turn the machine power to on and depress the gun triggerto feed the wire through the gun liner until the wire comesout of the threaded end of the gun several inches. (See fig-ure B.11)

10. When trigger is released spool of wire should not unwind.Adjust wire spool brake accordingly.

MOVING PARTS AND ELECTRICAL CONTACTCAN CAUSE INJURY OR BE FATAL.•When the gun trigger is depressed, driverolls, spool of wire and electrode are ELEC-TRICALLY LIVE (HOT).

• Keep away from moving parts and pinch points.• Keep all doors, covers, panels and guardssecurely in place.

DO NOT REMOVE OR CONCEAL WARNINGLABELS.

-------------------------------------------------------------------

11. Install the .035”(0.9mm) contact tip.

12. Install the black welding nozzle to the gun.

13. Trim the wire stickout to 3/8”(9.5mm) from the contact tip.(See Figure B.12)

14. Close the case side door. The machine is now ready toweld.

15. "Learn to Weld" Video is on the DVD.

16. Based on the thickness of the material you are going toweld and the type and diameter of the welding wire, set thevoltage and the wire feed speed per the procedure decalattached to the inside of the wire drive compartment door.

REMOVED NOZZLE

REMOVED CONTACT TIP

LAY CABLE AND GUN STRAIGHTENIN THIS POSITION

.035"(0.9mm) NR-211-MP

WIRE SPOOL

PLUG IN POWER INPUT CORD

DEPRESS TRIGGER TO ACTIVATE WIRE,WHICH FEEDS THE WIRETHRU THE LINER.

FEED WIREAPPROXIMATELY 4.00"FROM THE GUN TUBE END

ON/OFFSWITCH

WORK CLAMP AND CABLE

ROTATION

.035"(0.9mm) NR-211-MP

WIRE SPOOL

WIRE SPOOL BRAKE

TENSION ARM ASSEMBLYLOCKED IN UP POSITION

PIVOT ARM ASSEMBLYWITH BEARING PRESSINGAGAINST DRIVE ROLL

DIRECTIONOF WIRE


NR-211-MPDRIVE ROLL

INCOMINGGUIDE

OUTGOING GUIDE

BEARING

SLIDE WIRE INTO GUN CONNECTORSIDE

FIGURE B.10

FIGURE B.11

INSTALL .035 CONTACT TIP

INSTALL BLACK NOZZLE

TRIM WIRE STICKOUT3/8"(9.5mm)from the Contact Tip

FIGURE B.9

FIGURE B.12

WARNING

B-7


A. ITEMS NEEDED FOR MIG WELDING

1. .025”(0.6mm) Contact Tip

3. .025”(0.6mm) Dual Groove drive roll is used with L-56 SolidMig wire.

4. .025”(0.6mm) SuperArc L-56 Solid MIG Wire

5. Brass gun nozzle

6. Welding Gun

.025

WIRE

L-56 MIG

7. Work Cable & Clamp

8. Gas Regulator & Gas Line

9. Bottle of 75/25 Ar/CO2 shielding gas (or 100% CO2 shieldinggas) (note this requires a CO2 regulator adapter which is soldseparately).

75/25

FEMALE END

MIXES

MALE END

CO100%

2

(REQUIRES ADAPTER

SOLD SEPARATELY)

SETTING UP AND MAKING A MIG WELD 140AMP MACHINE*

* 125 Amp Units can not be upgraded for MIG welding.

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B-8


B. INSTALL SHIELDING GAS

MIG welding requires an appropriate bottle of shielding gas. Formild steel a cylinder of Ar/CO2 or 100% CO2 can be used; refer to

the following instructions to properly connect shielding gas to themachine.

CYLINDER may explode if damaged. Keepcylinder upright and chained to support

• Keep cylinder away from areas where itmay be damaged.

• Never lift welder with cylinder attached.

• Never allow welding electrode to touchcylinder.

• Keep cylinder away from welding orother live electrical circuits.

75/25

FEMALE END

MALE END

CO

S19298

REGULATORADAPTER

PLASTIC WASHER

MIXES

100%2

3. Attach the flow regulator to the cylinder valve and tighten theunion nut securely with a wrench.

NOTE: If connecting to 100% CO2 cylinder, a CO2 regulatoradapter is required. Purchase separately S19298 CO2 adapter,be sure to install plastic washer included in the fitting on thebottle side.(See Figure B.13 )

4. Refer to Figure B.13. Attach one end of inlet gas hose to theoutlet fitting of the flow regulator and tighten the union nutsecurely with a wrench. Connect the other end to the machineSolenoid Inlet Fitting (5/8-18 female threads — for CGA — 032fitting). Make certain the gas hose is not kinked or twisted.

FIGURE B.13

BUILDUP OF SHIELDING GAS may harmhealth or kill.

• Shut off shielding gas supply when notin use.

1. Secure the cylinder to a wall or other stationary supportto prevent the cylinder from falling over. Insulate thecylinder from the work circuit and earth ground. Refer toFigure B.13.

2. With the cylinder securely installed, remove the cylindercap. Stand to one side away from the outlet and open thecylinder valve very slightly for an instant. This blowsaway any dust or dirt which may have accumulated inthe valve outlet.

BE SURE TO KEEP YOUR FACE AWAY FROM THE VALVE OUT-LET WHEN “CRACKING” THE VALVE. Never stand directly infront of or behind the flow regulator when opening the cylin-der valve. Always stand to one side.

SHIELDING GAS

1. For CO2, open the cylinder very slowly. For argon-mixed gas,open cylinder valve slowly a fraction of a turn. When the cylin-der pressure gauge pointer stops moving, open the valve fully.

2. Set gas flow rate for 30 to 40 cubic feet per hour (14 to 18L/min) under normal conditions. Increase to as high as 40 to 50CFH (18 to 23.5 L/min) for out of position welding.

3. Keep the cylinder valve closed, except when using themachine.

WARNING

WARNING

WARNING

B-9


C. CONNECT LEADS AND CABLES ON THE MACHINE

(See Figure B.14)1. Open the case side door.

2. Slide the connector end of the gun and cable through the holeof the machine front and into the gun connector bushing onthe wire drive. Tighten thumbscrew to connector bushing.

3. Make sure the gun connector end is seated fully into the wiredrive.

4. Plug the gun trigger lead connector into the 4 pin gun triggerreceptacle on the machine front.

5. Wire Drive Polarity. MIG welding requires Positive (+) polarity.Connect the short power cable from the wire drive to the posi-tive (+) output terminal and tighten wingnut.

6. Work Lead Connection. Slide the lugged end of the workcable through the hole in the machine front and route cablethrough the strain relief as shown in figure B.14. Place lug onthe negative (-) output terminal and tighten wing nut.

D. LOAD WIRE SPOOL

(See Figure B.15)1. Locate the sample spool of .025”(0.6mm) L-56 solid MIG wire

and place onto wire spool spindle. Orient the spool so that thewire feeds off the top of the spool.

2. Secure spool in place by tightening the wing nut against thespacer that holds the wire spool on the spindle.

3. Open the pivot arm assembly by rotating the tension armassembly down and lift pivot arm assembly up.

4. Remove drive roll by un-screwing the black knob that holds thedrive roll on. Install the Dual Track drive roll with the.025”(0.6mm) mark facing outward which will allow feeding of.025”(0.6mm) L-56 Solid MIG wire.

5. Carefully unwind and straighten the first six inches of weldingwire from the spool. Hold onto the wire until the the Pivot Armassembly and Tension Arm are locked in place. This will pre-vent the wire from unspooling.

GUN AND CABLE

WORK CLAMP

(4 PIN)LEAD CONNECTOR

TERMINAL END (FITS ON STUD INSIDESEE FIGURE BELOW)

SLIDECONNECTOREND HERE

OPEN LATCH DOOR

LOCATE COMPONENTSTO CONNECT TO THEFRONT OF MACHINE

WORK CLAMP

(4 PIN)TRIGGER RECEPTACLE

PLUGGED IN

ALL COMPONENTS SHOWN CONNECTED(FRONT AND SIDE DOOR IS REMOVED FOR CLARITY)

SHORT POWERCABLE POSITIVE "+"OUTPUT TERMINAL

WORK LEAD CONNECTIONNEGATIVE "-"OUTPUT TERMINAL

GAS LINE

TIGHTEN THUMB SCREW TOCONNECTOR BUSHING STRAIN

RELIEF

FIGURE B.15

FIGURE B.14


L-56 SOLID MIG WIRE

DRIVE ROLL

PIVOT ARM ASSEMBLY


OUTGOING GUIDE

BEARING

INCOMING GUIDE

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B-10


(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 thegun side.

7. Close the Pivot Arm Assembly and secure by rotating theTension Arm Assembly back to the up position. (See Tensioninformation on decal.)

(See Figure B.17)8. Remove the nozzle from the gun and contact tip and

straighten the gun out flat.

9. Turn the machine power switch to on and press the gun trig-ger to feed wire through the gun liner until the wire comesout of the threaded end of the gun several inches. (SeeFigure B.18)

10. When trigger is released, the spool of wire should notunwind. Adjust wire spool brake accordingly.

MOVING PARTS AND ELECTRICAL CONTACTCAN CAUSE INJURY OR BE FATAL.•When the gun trigger is depressed drive rolls,spool of wire and electrode are ELECTRICALLYLIVE (HOT).

• Keep away from moving parts and pinchpoints.

• Keep all doors, covers, panels and guardssecurely in place.

DO NOT REMOVE OR CONCEAL WARNINGLABELS.

--------------------------------------------------------------------

11. Install the .025”(0.6mm) contact tip.

12. Install the brass MIG welding nozzle to the gun.

13. Trim the wire stickout to 3/8”(9.5mm) from the nozzle end.(See Figure B.19)

14. Close the wire drive compartment door. The machine is nowready to weld.

15. "Learn to Weld" Video is on the DVD.

16. Based on the thickness of the material you are going to weldand the type and diameter of the welding wire, set the volt-age and the wire feed speed per the procedure decalattached to the inside of the wire drive compartment door.

TENSION ARM ASSEMBLYLOCKED IN UP POSITION

PIVOT ARM ASSEMBLYWITH BEARING PRESSING AGAINST DRIVE ROLL

DIRECTIONOF WIRE


L-56 Solid MIG WIRE

DRIVE ROLL

INCOMINGGUIDE

OUTGOING GUIDE

BEARING

SLIDE WIRE INTO GUN CONNECTORSIDE


L-56 SOLID MIG

REMOVED NOZZLE

REMOVED CONTACT TIP

LAY CABLE AND GUN STRAIGHTENIN THIS POSITION

PLUG IN POWER INPUT CORD

DEPRESS TRIGGER TO ACTIVATE WIRE,WHICH FEEDS THE WIRETHRU THE LINER.

FEED WIREAPPROXIMATELY 4.00"FROM THE GUN TUBE END

ON/OFFSWITCH

WORK CLAMP AND CABLEROTATION

WIRE SPOOL

WIRE SPOOL BRAKE

.025" (0.6mm)

L-56 SOLID MIG

INSTALL .025 (0.6mm) CONTACT TIP

INSTALL BRASS NOZZLE

TRIM WIRE STICKOUT3/8"(9.5mm)from the Brass Nozzle

FIGURE B.17

FIGURE B.18

FIGURE B.19

FIGURE B.16

WARNING

B-11


1. Loosen the THUMB SCREW and disconnect Magnum 100LGun.

2. Insert K2532-1 Magnum 100SG spool gun into the brass blockand tighten the THUMB SCREW.

3. Depress Gun selector SWITCH to Spool Gun position. (SeeFigure B.20 and B.21)

4. Connect a bottle of 100% Argon shielding Gas per previoussection.

5. Follow the MIG welding steps in the previous section.

FIGURE B.20

6. Turn machine on and make weld per recommended settingson Procedure Decal inside machine door.

SETTING UP AND MAKING A ALUMINUM WELD USING SPOOL GUN(Aluminum Welding can only be used on 140 Amp machines.)

FIGURE B.21(Location of Selector Switch and Thumb Screw)

MAGNUM 100SG

SWITCH

THUMB SCREW FORCONNECTING THE MAGNUM 100L GUN OR MAGNUM 100SG SPOOL GUN.

MAGNUM 100L

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C-1

ACCESSORIESWIRE FEEDER WELDERS (125, 140)

K2532-1 - Magnum 100SG Spool Gun (Only available on 140 Models K2480-1, K2514-1, K2658-1 andK2697-1).Designed to easily feed small 4" diameter (1lb. spools of) .030 or.035 aluminum wire. Includes gun, adapter kit, three extra .035contact tips, gas nozzle, and spool of Superglaze 4043 .035"diameter welding wire. Packaged in a convenient carry case.

K2377-1 - Small Canvas Cover Protect your machine when not in use. Made from attractive redcanvas that is flame retardant, mildew resistant and water repel-lent. Includes a convenient side pocket to hold welding gun.

For additional Optional and Miscellaneous Parts(See Parts Pages)

C-2


K520—Utility Cart

Heavy duty cart stores and transports welder, 150 cubic footshielding gas cylinder, welding cables and accessories. Includesstable platforms for welder and gas bottle platform, lower trayfor added storage capacity and adjustable height handle.

4"

16"

3-11/16" 3-13/32"

9/32" DRILL 2 PLACES

1/4"-20 X 1/2" Hex Head Cap Screw (2 Required)

1/4"-20 X 1" Thread Forming Screw (1 Required)


For mounting welding machines to K520 carts that do not have slotted mounting holes.Drill 9/32” holes (2 places) into the cart top as shown and attach the welding machine to the cart with the proper hardware shown.

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1/4"-20 Flange Nut (2 Required)


K2275-3 - Welding Cart

Lightweight cart stores and transports welder, 80 cubic footshielding gas cylinder, welding cables and accessories. Includesan angled top shelf for easy access to controls, lower tray foradded storage capacity, a sturdy fixed handle and convenientcable wrap hanger.

D-1

MAINTENANCEWIRE FEEDER WELDERS (125, 140)

SAFETY PRECAUTIONS

ELECTRIC SHOCK can kill.

• Disconnect input power by removing plugfrom receptacle before working insideWIRE FEEDER WELDERS (125 and 140MODELS).

Use only grounded receptacle. Do nottouch electrically “hot” parts inside WIREFEEDER WELDERS (125 and 140 MODELS).

• Have qualified personnel do the maintenance and troubleshooting work.

-----------------------------------------------------------------

ROUTINE MAINTENANCE

POWER SOURCE COMPARTMENTNo user serviceable parts inside! Do not attempt to perform ser-vice in the power source (fixed) side of the WIRE FEEDERWELDERS (125 and 140 MODELS). Take the unit to an authorizedLincoln Service Center if you experience problems. NO mainte-nance is required.

In extremely dusty locations, dirt may clog the air passagescausing the welder to run hot with premature tripping of thermalprotection. If so, blow dirt out of the welder with low pressure airat regular intervals to eliminate excessive dirt and dust build-upon internal parts.

WIRE FEED COMPARTMENT

1. When necessary, vacuum accumulated dirt from gearbox andwire feed section.

2. Occasionally inspect the incoming guide tube and cleaninside diameter if necessary.

3. Motor and gearbox have lifetime lubrication and require nomaintenance.

FAN MOTOR

Has lifetime lubrication — requires no maintenance.

WIRE REEL SPINDLE

Requires no maintenance. Do not lubricate shaft.

GUN AND CABLE MAINTENANCE

FOR MAGNUM™ 100L GUNGun Cable CleaningClean cable liner after using approximately 300 lbs (136 kg) ofsolid wire or 50 lbs (23 kg) of flux-cored wire. Remove the cablefrom the wire feeder and lay it out straight on the floor. Removethe contact tip from the gun. Using low pressure air, gently blowout the cable liner from the gas diffuser end.

Excessive pressure at the start may cause the dirt to form aplug.-----------------------------------------------------------------

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 Tubes1. Dirt can accumulate in the contact tip hole and restrict wire

feeding. After each spool of wire is used, remove the contacttip and clean it by pushing a short piece of wire through thetip repeatedly. Use the wire as a reamer to remove dirt thatmay be adhering to the wall of the hole through the tip.

2. Replace worn contact tips as required. A variable or “hunt-ing” arc is a typical symptom of a worn contact tip. To installa new tip, choose the correct size contact tip for the elec-trode being used (wire size is stenciled on the side of thecontact tip) and screw it snugly into the gas diffuser.

3. Remove spatter from inside of gas nozzle and from tip aftereach 10 minutes of arc time or as required.

4. Be sure the gas nozzle is fully screwed onto the diffuser forgas shielded processes. For the Innershield® process, thegasless nozzle should be screwed onto the diffuser.

5. To remove gun tube from gun, remove gas nozzle or gaslessnozzle and remove diffuser from gun tube. Remove both col-lars from each end of the gun handle and separate the han-dle halves. Loosen the locking nut holding the gun tube inplace against the gun end cable connector. Unscrew guntube from cable connector. To install gun tube, screw thelocking nut on the gun tube as far as possible. Then screwthe gun tube into the cable connector until it bottoms. Thenunscrew (no more than one turn) the gun tube until its axis isperpendicular to the flat sides of the cable connector andpointed in the direction of the trigger. Tighten the locking nutso as to maintain the proper relationship between the guntube and the cable connector. Replace the gun handle, trig-ger and diffuser. Replace the gas nozzle or gasless nozzle.

CAUTION

WARNING

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D-2

MAINTENANCEWIRE FEEDER WELDERS (125, 140)

1-1/4”(31.8 mm)Liner Trim Length

Gas Diffuser

Gas Nozzle orGasless Nozzle

OVERLOAD PROTECTION

Output OverloadThe WIRE FEEDER WELDERS (125 and 140 MODELS) areequipped with a circuit breaker and a thermostat which protectsthe machine from damage if maximum output is exceeded. Thecircuit breaker button will extend out when tripped. The circuitbreaker must be manually reset.

Thermal ProtectionThe WIRE FEEDER WELDERS (125 and 140 MODELS) have arated output duty cycle as defined in the Technical Specificationpage. If the duty cycle is exceeded, a thermal protector will shutoff the output until the machine cools to a reasonable operatingtemperature. This is an automatic function of the WIRE FEEDERWELDERS (125 and 140 MODELS) and does not require userintervention. The fan continues to run during cooling.

Electronic Wire Drive Motor ProtectionThe WIRE FEEDER WELDERS (125 and 140 MODELS) have built-inprotection for wire drive motor overload.

Set Screw Brass Cable

Connector

Liner Assembly (Liner bushing to be sealed tight againstbrass cable connector)

FIGURE D.2Liner trim length

CHANGING LINER

NOTICE: The variation in cable lengths prevents the interchange-ability of liners. Once a liner has been cut for a particular gun, itshould not be installed in another gun unless it can meet theliner cutoff length requirement. Refer to Figure D.2.

1. Remove the gas nozzle from the gun by unscrewing counter-clockwise.

2. Remove the existing contact tip from the gun by unscrewingcounter-clockwise.

3. Remove the gas diffuser from the gun tube by unscrewingcounter-clockwise.

4. Lay the gun and cable out straight on a flat surface. Loosenthe set screw located in the brass connector at the wire feed-er end of the cable. Pull the liner out of the cable.

5. Insert a new untrimmed liner into the connector end of thecable. Be sure the liner bushing is stenciled appropriately forthe wire size being used.

6. Fully seat the liner bushing into the connector. Tighten the setscrew on the brass cable connector. At this time, the gas dif-fuser should not be installed onto the end of the gun tube.

7. With the gas nozzle and diffuser removed from the gun tube,be sure the cable is straight, and then trim the liner to thelength shown in the Figure D.2. Remove any burrs from theend of the liner.

8. Screw the gas diffuser onto the end of the gun tube andsecurely tighten.

9. Replace the contact tip and nozzle.

GUN HANDLE PARTS

The gun handle consists of two halves that are held togetherwith a collar on each end. To open up the handle, turn the collarsapproximately 60 degrees counter-clockwise until the collarsreach a stop. Then pull the collars off the gun handle. If the col-lars are difficult to turn, position the gun handle against a corner,place a screwdriver against the tab on the collar and give thescrewdriver a sharp blow to turn the collar past an internal lock-ing rib. See Figure D.3.

„

Counter-clockwise

FIGURE D.3

CAUTION

E-1

TROUBLE SHOOTINGWIRE FEEDER WELDERS (125, 140)

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln AuthorizedField Service Facility for technical troubleshooting assistance before you proceed.

This Troubleshooting Guide is provided to help you locate andrepair possible machine malfunctions. Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMPTOMS)”. Thiscolumn describes possible symptoms that the machine mayexhibit. Find the listing that best describes the symptom that themachine is exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists the obviousexternal possibilities that may contribute to the machine symp-tom.

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 FieldService Facility.

If you do not understand or are unable to perform theRecommended Course of Action safely, contact your localLincoln Authorized Field Service Facility.

HOW TO USE TROUBLESHOOTING GUIDE

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 factorywarranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed through-out this manual.

__________________________________________________________________________

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WARNING

Observe all Safety Guidelines detailed throughout this manual

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

E-2


PROBLEMS(SYMPTOMS)

Major physical or electrical damage is evi-dent.

No wire feed, weld output or gas flowwhen gun trigger is pulled. Fan does NOToperate.

No wire feed, weld output or gas flowwhen gun trigger is pulled.Fan operates normally.

POSSIBLE CAUSE

“Do not Plug in machine or turn it on”.Contact your local Authorized Field ServiceFacility.

1. Make sure correct voltage is applied tothe machine.

2. Make certain that power switch is inthe ON position.

3. Make sure circuit breaker is reset.

1. The thermostat may be tripped due tooverheating. Let machine cool. Weld atlower duty cycle.

2. Check for obstructions in air flow.Check Gun Trigger connections. SeeInstallation section.

3. Gun trigger may be faulty.

RECOMMENDEDCOURSE OF ACTION

If all recommended possible areas ofmisadjustment have been checked andthe problem persists, Contact your localLincoln Authorized Field ServiceFacility.

OUTPUT PROBLEMS

PROBLEMS(SYMPTOMS)

No wire feed when gun trigger is pulled.Fan runs, gas flows and machine has cor-rect open circuit voltage (33V) – weld out-put.

POSSIBLECAUSE

1. If the wire drive motor is running makesure that the correct drive rolls areinstalled in the machine.

2. Check for clogged cable liner or con-tact tip.

3. Check for proper size cable liner andcontact tip.

4. For 140Amp machine only:• Check Magnum 100SG/Magnum 100Lswitch is properly switched to activateproper gun.



FEEDING PROBLEMS

Observe all Safety Guidelines detailed throughout this manual

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

E-3


PROBLEMS(SYMPTOMS)

Low or no gas flow when gun trigger ispulled. Wire feed, weld output and fanoperate normally.

POSSIBLECAUSE

1. Check gas supply, flow regulator andgas hoses.

2. Check gun connection to machine forobstruction or leaky seals.



GAS FLOW PROBLEMS

PROBLEMS(SYMPTOMS)

Arc is unstable – Poor starting

POSSIBLECAUSE

1. Check for correct input voltage tomachine.

2. Check for proper electrode polarity forprocess.

3. Check gun tip for wear or damage andproper size – Replace.

4. Check for proper gas and flow rate forprocess. (For MIG only.)

5. Check work cable for loose or faultyconnections.

6. Check gun for damage or breaks.

7. Check for proper drive roll orientationand alignment.

8. Check liner for proper size.



WELDING PROBLEMS

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WIR

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DIAG

RAM

FOR

COD

E 11

631,

116

32, 1

1633

, 116

38, 1

1639

N.C.

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for aparticular code is pasted inside the machine on one of the enclosure panels.

F-1

DIAGRAMSWIRE FEEDER WELDERS (125, 140)

F-2



WIR

ING

DIAG

RAM

FOR

COD

E 11

634,

116

35, 1

1636

, 116

37

N.C.

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F-3


M249

69

WIR

ING

DIAG

RAM

FOR

COD

E 12

101,

121

03, 1

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OPER

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F-5

DIMENSION PRINTWIRE FEEDER WELDERS (125, 140)

F-6

NOTES

OPER

ATOR

’S M

ANUA

L

Shown K2697-1

Publication E7.44 | Issue D ate 08/13© Lincoln Global, Inc. All Rights Reserved.

Easy-MIG ® 140WIRE FEEDER/WELDERS

Processes MIG, Flux-Cored

Product Number K2697-1 See back for complete specs

ISO 9001:200014001:2004

THE LINCOLN ELECTRIC COMPANY22801 St. Clair Avenue • Cleveland, OH • 44117-1199 • U.S.A.

PH: +1.216-481-8100 • www.lincolnelectric.com

INPUT OUTPUT

LINCOLN ELECTRIC

Two Year Extended Warranty Available in

the U.S.A. and Canada.

APPLICATIONS Shop Farm Home

Input Power 120/1/60Input Current at Rated Output 20ARated Output Current/Voltage/Duty Cycle 90A/19.5V @ 20%

Output Range

30-140 A 50-500 WFS (1.3-12.7 m/min) Max. OCV: 33Weight/Dimensions (H x W x D) 50 lbs. (22.7 kg) 13.7 x 10.15 x 17.9 in. (357 x 258 x 472 mm)

120 Volt AC Input Compact Wire Feeder/WelderRequiring common 120 volt input power, the Easy-MIG® 140 can be used almost anywhere. With simple two knob control, the machine is easy to set up for gasless flux-cored welding for deep penetration on thicker steel or gas-shielded MIG welding on thin gauge steel, stainless or aluminum. Compare the precise drive, rugged construction and full list of standard accessories. . . the Lincoln Electric Easy-MIG® 140 is an excellent choice!

FEATURES Heavy Duty Wire Drive – Fully adjustable drive system reduces

the chance of wire tangling and crushing.

– Brass-to-brass gun connection enhances conductivity.

– Durable cast aluminum gear box delivers added drive torque and quiet operation.

– Easy-turn numeric drive tension indicator identifies optimized ranges for different wire diameters.

Capable Performance – Forgiving arc makes dialing in your

application easy. – Smooth arc starts with minimal

spatter. – Wide 30-140 amp welding

output range. – MIG weld 24 gauge up to 3/16 in.

(4.8 mm) sheet metal in a single pass. Weld up to 5/16 in. (7.9 mm) steel using self-shielded Lincoln Electric Innershield® (FCAW-S) wires.

WHAT’S INCLUDEDGun Magnum® 100L gun and 10 ft. (3.0 m)

cable assembly with brass connection and 4-pin MS-Type connection for trigger control (K530-6)

.025 in (0.6 mm) contact tips (Qty 3) (KH710)

.035 in. (0.9 mm) contact tips (Qty. 3) (KH712)

Gasless nozzle for Innershield® welding (KH726)

Gas nozzle for MIG welding (KH725) Spindle adapter for 8 in. (203 mm)

diameter spools (KH720) .025 - .035 in. (0.6 - 0.9 mm) wire

diameter dual track drive roll for MIG and flux-cored welding (KP2948-1)

Shielding Gas Apparatus Harris® 3000290 Gas Regulator

(S25805) and 52 in. (1.3 m) hose (S19303) for use with Ar/CO2 or CO2 gases. For use with CO2 shielding gas, order a Lincoln Electric S19298 CO2 shielding gas bottle adapter.

Welding Wire Sample spool of .025 in. (0.6 mm)

diameter SuperArc® L-56® premium MIG wire

Sample spool of .035 in. (0.9 mm) diameter Innershield® NR®-211-MP flux-cored wire

Other Work clamp and 10 ft. (3.0 m)

cable How TO MIG Weld DVD Instruction manual

S

POOL G

UN

C U S T O M E R A S S I S T A N C E P O L I C Y 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. Our employees, however, are not in a position to verify the information provided or to evaluate the engineering requirements for the particular weldment. Accordingly, Lincoln Electric does not warrant or guarantee or assume any liability with respect to such information or advice. Moreover, the provision of such information or advice does not create, expand, or alter any warranty on our products. Any express or implied warranty that might arise from the information or advice, including any implied warranty of merchantability or any warranty of fitness for any customers’ particular purpose is specifically disclaimed.

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.

For best welding results with Lincoln Electric equipment, always use Lincoln Electric consumables. Visit www.lincolnelectric.com for more details.

Product Name

Product Number

Input Power

Rated Output

Current/Voltage/Duty Cycle

Input Current

@ Rated Output

Output Range

H x W x D

inches (mm)

Net Weight

lbs. (kg)Easy-MIG® 140 K2697-1 120/1/60 90/19.5V/20% 20A 30-140 Amps DC

50-500 ipm WFS(1.3-12.7 m/min)

Max. OCV: 33

13.7 x 10.15 x 17.9(357 x 258 x 472)

50(22.7)

PRODUCT SPECIFICATIONS

HEAVY DUTY WIRE DRIVE

Enhanced Quality

1. Brass-to-brass gun connection enhances conductivity.

2. Rigid drive aids wire alignment. The cast aluminum body with an enclosed multi-stage gear box delivers improved torque and quiet operation.

Easy to Use

3. Easy-turn drive tension adjustment with numeric tension indicators.

4. Fast tool-less drive roll changeovers. The dual track drive roll ensures positive flux-cored wire feeding with common wire diameters.

5. Easy tool-less polarity changes for MIG or flux-cored welding.

6. Spool gun ready switch allows user to select spool gun or standard push gun drive operation.

PERFORMANCE PLUS

GENERAL OPTIONS

Welding Cart Full-featured cart is designed to store and transport a welder, 80 cubic foot gas cylinder, welding cables and accessories. Includes an angled top shelf for easy access to welder controls, a lower tray for added storage space, a sturdy handle also used as a convenient cable wrap hanger. Order K2275-1

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. Order K520

Small Canvas Cover Protect your welder 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 your welding torch or gun. Order KH495

WIRE FEEDER OPTIONS

Magnum® 100SG Spool Gun Designed to easily feed 4 in. (102 mm) diameter 1 lb. (0.45 kg) spools of .030 in. (0.8 mm) or .035 in. (0.9 mm) diameter SuperGlaze® aluminum MIG wire. Includes gun, adapter kit, .035 in. (0.9 mm) contact tips (qty. 3), gas nozzle, and a 1 lb. (0.45 kg) spool of SuperGlaze® 4043 .035 in. (0.9 mm) MIG wire. Packaged in a convenient carrying case. Order K2532-1

RECOMMENDED ACCESSORIES

3

4

21

5

6

L12603-10

SP - Single PassMP - Multiple Pass

DRIVE ROLLS

Product Number

Wire Diameter in. (mm)

Process

KP2948-1KP3285-1

.025 - .035 (0.6 - 0.9)

.035 - .045 (0.9 - 1.1) MIG/Flux-Cored(1) Aluminum welding requires optional K2532-1 Magnum® spool gun.

(1)

Operator’s Manual WIRE FEEDER WELDERS OPERATOR’S …

Documents