Lincoln Electric Power MIG 215 Operator'S Manual Download Page 2

FOR ENGINE

powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance

work unless the maintenance work requires it to be running.

____________________________________________________

1.b. Operate engines in open, well-ventilated

areas or vent the engine exhaust fumes 
outdoors.

____________________________________________________

1.c. Do  not  add  the  fuel  near  an  open  flame

welding  arc  or  when  the  engine  is  running.
Stop  the  engine  and  allow  it  to  cool  before
refueling to prevent spilled fuel from vaporiz-
ing  on  contact  with  hot  engine  parts  and
igniting.  Do  not  spill  fuel  when  filling  tank.  If
fuel  is  spilled,  wipe  it  up  and  do  not  start
engine until fumes have been eliminated.

____________________________________________________

1.d. Keep  all  equipment  safety  guards,  covers  and  devices  in

position  and  in  good  repair.Keep  hands,  hair,  clothing  and
tools  away  from  V-belts,  gears,  fans  and  all  other  moving
parts when starting, operating or repairing equipment.

____________________________________________________

1.e. In  some  cases  it  may  be  necessary  to  remove  safety

guards  to  perform  required  maintenance.  Remove
guards  only  when  necessary  and  replace  them  when  the
maintenance  requiring  their  removal  is  complete.
Always  use  the  greatest  care  when  working  near  moving
parts.

___________________________________________________

1.f. Do  not  put  your  hands  near  the  engine  fan.

Do  not  attempt  to  override  the  governor  or
idler  by  pushing  on  the  throttle  control  rods
while the engine is running.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenance
work,  disconnect  the  spark  plug  wires,  distributor  cap  or
magneto wire as appropriate.

i

SAFETY

i

ARC WELDING 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 pur-
chase a copy of “Safety in Welding & 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.

WARNING

Mar ʻ95

ELECTRIC AND 

MAGNETIC FIELDS

may be dangerous

2.a.  Electric  current  flowing  through  any  conductor  causes 

localized  Electric  and  Magnetic  Fields  (EMF).  Welding 
current  creates  EMF  fields  around  welding  cables  and 
welding machines

2.b. EMF  fields  may  interfere  with  some  pacemakers,  and

welders  having  a  pacemaker  should  consult  their  physician
before welding.

2.c. Exposure  to  EMF  fields  in  welding  may  have  other  health

effects which are now not known.

2.d. All  welders  should  use  the  following  procedures  in  order  to

minimize  exposure  to  EMF  fields  from  the  welding  circuit:

2.d.1. Route the electrode and work cables together - Secure

them 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

work cables. If the electrode cable is on your right 
side, the work cable should also be on your right side.

2.d.4. Connect  the  work  cable  to  the  workpiece  as  close  as

possible to the area being welded.

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

1.h. To  avoid  scalding,  do  not  remove  the

radiator pressure cap when the engine is
hot.

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents
are known to the State of California to cause can-
cer, birth defects, and other reproductive harm.

The  engine  exhaust  from  this  product  contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

The Above For Diesel Engines

The Above For Gasoline Engines

POWER MIG 215

Summary of Contents for Power MIG 215

Page 1: ...MENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful For use with machine Code Numbers 1 11 10 07 70 0 1 11 10 09 9...

Page 2: ...SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you pur chase a copy of Safety...

Page 3: ...cooling 3 h 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...

Page 4: ...ng can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 6 b Where compressed gases are to be used at the job...

Page 5: ...crans appropri s et non inflammables 4 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 chemis...

Page 6: ...cially 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 for...

Page 7: ...hanging Drive Roll B 3 Wire Reel Loading B 3 Mounting of 10 to 30 lbs Spools B 3 To Start the Welder B 3 Feeding Electrode B 4 Idle Roll Pressure Setting B 4 Wire Drive Configuration B 4 B 5 Making a...

Page 8: ...ip and Gas Nozzle Installation D 1 Gun Tubes and Nozzles D 1 Gun Cable Cleaning D 1 Liner Removal and Replacement D 2 Gun Handle Disassembly D 3 Troubleshooting Section E How to Use Troubleshooting Gu...

Page 9: ...79 in 18 88 in 38 78 in 210 Ibs 808 mm 480 mm 985 mm 95 kg PHYSICAL DIMENSIONS Wire Speed 50 700 IPM 1 27 17 8 m minute WIRE SPEED RANGE Standard Voltage Phase Frequency Input Current 170 Amp Rated O...

Page 10: ...ding and lift off cardboard carton Cut banding holding the machine to the skid Remove foam and corrugated packing material Untape accessories from Gas Bottle Platform Unscrew the two wood screws at th...

Page 11: ...es proper grounding of the welder frame when the welder plug is inserted into a grounded receptacle FIGURE A 2 Receptacle Diagram CONNECT TO A SYSTEM GROUNDING WIRE SEE THE UNITED STATES NATIONAL ELEC...

Page 12: ...IS PRESENT Inform your gas supplier of this condition Oil or grease in the presence of high pressure oxygen is explosive 3 Stand to one side away from the outlet and open the cylinder valve for an ins...

Page 13: ...d 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...

Page 14: ...es Use of GMAW processes requires a supply of shielding gas WELDING CAPABILITY The POWER MIG 215 is rated at 215 amps 22 volts at a 30 duty cycle based on a ten minute cycle time It is capable of high...

Page 15: ...tion 6 Position the Readi Reel so that it will rotate in a direction when feeding so as to be de reeled from top of the coil 7 Set one of the Readi Reel inside cage wires on the slot in the retaining...

Page 16: ...or changing drive rolls and or guides Do not touch electrically live parts When inching with the gun trigger electrode and drive mechanism are hot to work and ground and could remain energized severa...

Page 17: ...ET HEAD CAP SCREW CONNECTOR BLOCK WARNING 5 Loosen the socket head cap screw that holds the connector bar against the gun bushing Important Do not attempt to completely remove the socket head cap scre...

Page 18: ...the line voltage is less than rated input The unit will continue to weld but the output may be less than normal for a given tap setting If your input line is low you may want to select a higher voltag...

Page 19: ...for use with the POWER MIG 215 Each is rated 250 amps 40 duty cycle and is equipped with the integrated connector twist lock trigger connector fixed nozzle and insulator and includes a liner diffuser...

Page 20: ...and machine gas solenoid valve Enables spool gun operation and spool gun gas solenoid valve Closing spool gun trigger starts spool gun weld ing and makes both electrodes electrically HOT 3 Operation w...

Page 21: ...le shooting section on rough wire feeding SAFETY PRECAUTIONS ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the input power off at the fuse box before working on e...

Page 22: ...Loosen the set screw with a 5 64 2 0 mm Allen wrench 2 Remove the gas diffuser from the gun tube 3 Lay the gun and cable out straight on a flat surface Loosen the set screw located in the brass connec...

Page 23: ...re Alum wire CONTACT TIPS Standard Duty KP2020 6B1 025 0 6 mm KP2020 7B1 030 0 8 mm KP2020 1B1 035 0 9 mm KP2020 2B1 045 1 2 mm Heavy Duty KP2021 1B1 035 0 9 mm KP2020 2B1 045 1 2 mm Tapered KP2022 5B...

Page 24: ...LE 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 generall...

Page 25: ...with built in feed er and Spool Gun if pulling spool gun trigger 1 Remove gun assembly from machine If problem is solved gun assembly is faulty Repair or replace 2 If problem persists when gun assemb...

Page 26: ...e or gun cable may be dirty 3 Check drive roll tension and position of grooves 4 Check for worn or loose drive rolls 5 The electrode may be rusty or dirty 6 Check for damaged or incorrect contact tip...

Page 27: ...y is con nected properly and turned on 2 If the gas solenoid does actuate click when the gun trigger is pulled there may be a restriction in the gas supply line 3 The gun cable assembly may be faulty...

Page 28: ...e 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 If the diagram is illegible write to the Servi...

Page 29: ...e 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 If the diagram is illegible write to the Servi...

Page 30: ...F 3 F 3 DIMENSION PRINT 3 00F M19231 POWER MIG 215...

Page 31: ...NOTES POWER MIG 215...

Page 32: ...NOTES POWER MIG 215...

Page 33: ...electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y...

Page 34: ...e Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fuma a Use ventila o e exhaust o para remover fumo da zona respirat ria Turn power off before servicing Desconectar el cable de ali mentaci...

Page 35: ...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 World s Leader in Welding and Cutting Pr...

Reviews: