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Operator’s Manual

POWER MIG 

®

(140, 180 MODELS)

Register your machine:  

www.lincolnelectric.com/register

Authorized Service and Distributor Locator:  

www.lincolnelectric.com/locator

IM890-A

|   Issue D ate Nov- 13

© Lincoln Global, Inc.  All Rights Reserved.

For use with machines having Code Numbers:

11254, 11255, 11256, 11257 and
11444

LINCOLN

   

ELECTRIC

Save for future reference  

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

Summary of Contents for POWER MIG 140

Page 1: ...rized Service and Distributor Locator www lincolnelectric com locator IM890 A Issue Date Nov 13 Lincoln Global Inc All Rights Reserved For use with machines having Code Numbers 11254 11255 11256 11257 and 11444 LINCOLN ELECTRIC Save for future reference Date Purchased Code ex 10859 Serial ex U1060512345 ...

Page 2: ...the general area IN A LARGE ROOM OR OUTDOORS natural ventilation may be adequate if you keep your head out of the fumes See below USE NATURAL DRAFTS or fans to keep the fumes away from your face If you develop unusual symptoms see your supervisor Perhaps the welding atmosphere and ventilation system should be checked WEAR CORRECT EYE EAR BODY PROTECTION PROTECT your eyes and face with welding helm...

Page 3: ...y 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 A...

Page 4: ... ANSI Z87 I standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 4 c Protect other nearby personnel with suitable non flammable screening and or warn them not to watch 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 ga...

Page 5: ... lifting chains crane cables or other alternate circuits This can create fire hazards 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 During Welding Cutting and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 6 j Do not use a welding power source for pipe thawing CYLINDER M...

Page 6: ...s compatible This may require additional protection measures h the time of day that welding or other activities are to be carried out 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 equipme...

Page 7: ..._____ Accessories Section C Optional Accessories C 1 Utility Carts C 2 C 3 ________________________________________________________________________ Maintenance Section D Safety 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 3 __________________________________________________________...

Page 8: ...6 in 66 Ibs 357 mm 258 mm 472 mm 30 kg PHYSICAL DIMENSIONS 1 If 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 RATED OUTPUT OUTPUT Standard Voltage Frequency Input Current 120 V 60 Hz 20 Amps rated output Duty Cycle Current Voltage at Rated Amperes 20 Duty Cycle 90 Amps 19 5 Welding Current Range Open Circuit V...

Page 9: ... Hz I1 max 20 Amps I1 eff 10 7 Amps Voltage Duty Cycle Current Voltage at Rated Amperes 240 V 25 131 Amps 20 Welding Current Range Open Circuit Voltage Wire Speed Range 30 180 Amps 34 V 50 500 in min 1 3 12 7 m min Input Voltage Frequency Fuse or Breaker Size1 Input Amps Power Cord 240 V 50 Hz 40 Amp Super Lag 20 15 Amp 240 V Three Pin Plug RECOMMENDED INPUT CABLE AND FUSE SIZES Height Width Depth...

Page 10: ...d on a secure level sur face directly or on recommended cart The machine may topple over if this procedure is not followed Read entire installation section before starting installation SAFETY PRECAUTIONS ELECTRIC SHOCK can kill Only qualified personnel should perform this installation Only personnel that have read and under stood the POWER MIG Operating Manual should install and operate this equip...

Page 11: ...035 NR 211 MP WIRE L 56 MIG 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 Black Flux cored Gasless Gun Nozzle Installed on Welding Gun Brass MIG Gas Gun Nozzle 2 51mm Spindle Adapter For 8 203mm Reel of wire Regulator Gas Hose Learn to Weld LTW1 Manual DVD OU...

Page 12: ...eal 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 ...

Page 13: ... See Figure B 2 4 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 welding 5 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 w...

Page 14: ...See Figure B 5 11 WIRE DRIVE 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 Outer Wire Guide Guides the wire between the Top and Bottom Drive Roll and ...

Page 15: ...ooth Drive Roll 030 045 0 8mm 1 1mm Knurled Drive Roll 030 045 0 8mm 1 1mm Knurled Drive Roll Inner Wire Guide 025 035 0 6mm 0 9mm Steel Wire Guide 045 1 1mm Steel Wire Guide Inner Wire Guide Part Number KP2531 1 KP2531 2 Drive Roll Part Number KP2529 1 KP2529 2 KP2529 3 KP2529 3 See Figure B 6 12 CIRCUIT BREAKER If the rated input current of the machine is exceeded this circuit breaker will trip ...

Page 16: ... 0 9mm Contact Tip 2 025 035 0 6mm 0 9mm wire guide 3 Knurled Drive Roll 4 035 0 9mm NR 211MP Flux Cored Wire 5 Black Flux Cored gun nozzle 6 Welding Gun INNER WIRE GUIDE 025 035 6 9mm 035 035 NR 211 MP FLUX CORE WIRE 7 Work Cable Clamp 0 3 0 0 4 5 SETTING UP AND MAKING A FLUX CORED WELD ...

Page 17: ...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 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 I...

Page 18: ...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 tact tip 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 dia...

Page 19: ...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 shielding gas note this requires a CO2 regulator adapter which is sold separately INNER WIRE GUIDE 025 035 025 035 75 25 FEMALE END MIXES MALE END CO 100 2 REQUIRES ADAPTER SOLD SEPARATELY SETTING UP AND MAKING A MIG WELD ...

Page 20: ... 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 FIGURE B 13 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 ...

Page 21: ...ightening 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 ...

Page 22: ...t 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 diame...

Page 23: ...agnum 100L Gun 4 Install optional K2532 1 Magnum 100SG spool gun per instructions included with gun 5 Set Gun selector toggle switch to Spool Gun posi tion See Figure B 20 FIGURE B 20 6 Turn machine on and make weld per recommended settings on Procedure Decal inside machine door POWER MIG 140 180 MODELS SETTING UP AND MAKING A ALUMINUM WELD USING SPOOL GUN ...

Page 24: ...p gasless nozzle knurled drive roll 045 1 1mm inner wire guide and a 10 lb 4 5kg spool of 045 1 1mm Innershield NR 212 wire K2532 1 Magnum 100SG Spool Gun Designed to easily feed small 4 102mm0 diameter 1lb 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 i...

Page 25: ...ng 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 204 8mm 93 7mm 96 8mm 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 p...

Page 26: ...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 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 tra...

Page 27: ...ke 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 COMPA...

Page 28: ... should screw onto the diffuser 5 To remove gun tube from 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 ...

Page 29: ...hs 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 tu...

Page 30: ...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 A...

Page 31: ... or gas flow when gun trigger is pulled Fan operates normally POSSIBLE CAUSE Do not Plug in machine or turn it on Contact your local Authorized Field Service Facility 1 Make sure correct voltage is applied to the machine 2 Make certain that power switch is in the ON position 3 Make sure circuit breaker is reset 1 The thermostat may be tripped due to overheating Let machine cool Weld at lower duty ...

Page 32: ...rolls are installed in the machine 2 Check for clogged cable liner or contact tip 3 Check for proper size cable liner and contact tip 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 FEEDING PROBLEMS PROBLEMS SYMPTOMS Low or no gas flow when gun trigger is pulled W...

Page 33: ...SSIBLE CAUSE 1 Check for correct input voltage to machine 2 Check for proper electrode polarity for process 3 Check gun tip for wear or dam age and proper size Replace 4 Check for proper gas and flow rate for process For MIG only 5 Check work cable for loose or faulty connections 6 Check gun for damage or breaks 7 Check for proper drive roll orien tation and alignment 8 Check liner for proper size...

Page 34: ... 11255 11256 11257 FOR CODES 11254 11255 11256 11257 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 ...

Page 35: ...R MIG 180 MODELS 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 ...

Page 36: ...F 3 DIMENSION PRINT F 3 POWER MIG 140 180 MODELS M21111 2 A 18 78 14 08 10 37 12 00 6 00 5 50 3 08 2 46 ...

Page 37: ...stomer 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 manufactur...

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