Lincoln Electric POWER MIGTM 200 IM693 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.

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

areas or vent the engine exhaust fumes 
outdoors.

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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.

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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.

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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.

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SAFETY

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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
purchase 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 ‘95

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 200

Summary of Contents for POWER MIGTM 200 IM693

Page 1: ...OUT 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 10564 For use with machine Code Numbe...

Page 2: ...S 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...

Page 3: ...th ground 3 f Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3 g Never dip the electrode in water for cooling 3...

Page 4: ...e welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines H...

Page 5: ...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 chemise paisse pan talons s...

Page 6: ...e information must be followed to avoid minor personal injury or damage to this equipment CAUTION Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes...

Page 7: ...2 Procedure for Changing 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 Making a Weld B 4 Avoidin...

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

Page 9: ...INGLE PHASE ONLY RATED OUTPUT OUTPUT RECOMMENDED INPUT WIRE AND FUSE SIZES Height Width Depth Weight 31 79 in 18 88 in 38 78 in 210 Ibs 808 mm 480 mm 985 mm 95 kg PHYSICAL DIMENSIONS Wire Speed 50 700...

Page 10: ...y qualified personnel should perform this installation Only personnel that have read and under stood the POWER MIG 200 Operating Manual should install and operate this equipment Machine must be ground...

Page 11: ...lt 50 60 Hz model POWER MIG is shipped with a 7 ft input cable and plug connected to the welder 4 Using the instructions in Figure A 3 have a quali fied electrician connect a receptacle Customer Suppl...

Page 12: ...ATTACH THE REGULATOR IF OIL GREASE OR DAMAGE 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...

Page 13: ...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 e...

Page 14: ...shielding gas WELDING CAPABILITY The POWER MIG 200 is rated at 200 amps 22 volts at a 30 duty cycle based on a ten minute cycle time It is capable of higher duty cycles at lower output currents The ta...

Page 15: ...he Readi Reel so that it will rotate in a direction when feed ing 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 retain ing spring tab 8 Lo...

Page 16: ...gh gun and repeat above steps 3 If the only result was drive roll slippage loosen the adjustment knob on the conductor plate and pull the gun cable forward about 6 15 cm There should be a slight wavin...

Page 17: ...higher voltage tap than given on the recom mended procedure chart WIRE FEED OVERLOAD PROTECTION The POWER MIG has solid state overload protection of the wire drive motor If the motor becomes over loa...

Page 18: ...le and is equipped with the integrated connector twist lock trigger connector fixed nozzle and insulator and includes a liner diffuser and contact tips for the wire sizes specified MAGNUM GUN CONNECTI...

Page 19: ...eeder gun operation 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 electrical...

Page 20: ...or as required GUN CABLE CLEANING To help prevent feeding problems clean cable liner after using approximately 300 pounds 136 kg of electrode Remove the cable from the wire feeder and lay it out stra...

Page 21: ...D REPLACE MENT NOTE Changing the liner for a different wire size requires replacement of the gas diffuser per Table D 1 to properly secure the different liner LINER REMOVAL INSTALLATION AND TRIMMING I...

Page 22: ...2 mm Alum wire Alum wire CONTACT TIPS Standard Duty S19391 6 025 0 6 mm S19391 7 030 0 8 mm S19391 1 035 0 9 mm S19391 2 045 1 2 mm Heavy Duty S19392 1 035 0 9 mm S19292 2 045 1 2 mm Tapered S19393 5...

Page 23: ...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 24: ...ssociated 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 g...

Page 25: ...s 1 No control of wire feed speed Other machine functions are nor mal POSSIBLE AREAS OF MISADJUSTMENT S 1 The gun cable may be kinked or twisted 2 The wire may be jammed in the gun cable or gun cable...

Page 26: ...the problem is within the POWER MIG 200 5 Make sure the gun is pushed all the way into gun mount and is properly seated RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustment...

Page 27: ...TIFIER MOUNTED BAFFLE TRANSFORMER THERMOSTAT RECTIFIER ASSEMBLY THERMOSTAT G F E D C B A X10 X9 B W CONTACTOR H5 FAN MOTOR X5 X7 X8 27 8V X6 SINGLE PHASE BRIDGE RECTIFIER 2 1 4 3 2 TRIGGER GUN CONTROL...

Page 28: ...F 2 F 2 DIMENSION PRINT 3 00F M19231 POWER MIG 200...

Page 29: ...383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 700 00 5 weeks of fundamentals There is a 10 discount on all orders of 50 00 or more for shipment at one time to...

Page 30: ...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 31: ...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 32: ...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...

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